Buch80107en PDF

NMF

Instruction Manual
Board crane

Type: Crane 1 DK II 45027,5/35032,2

Crane 2 DK II 45027,5/35031,5
Order-No.: 80107
Hull-No.: 2027
Buildingyard: Zhoushan Shipyard
Name of Ship:
Year of Construction: 2006
Edition: 2006
Neuenfelder Maschinenfabrik GmbH

Neuenfelder Fährdeich
21129 Hamburg
Phone: 040 / 7451102
Fax: 040 / 74511867
e-mail: [email protected]
Internet:www.nmf-crane.com
Instruction manual
Board crane type DK II NMF
Index
9. Mai2005
1 What is worth knowing about this operating manual

1.1 Manufacturer ..........................................................................................................1
1.2 The operator´s duty of care ....................................................................................1
1.3 Terms, short cuts and symbols ..............................................................................1
1.4 Technical Amendments..........................................................................................2
1.5 Guarantee ..............................................................................................................2
1.6 Copyright ................................................................................................................3
2 Description of the Crane

2.1 Technical Data .......................................................................................................1
2.2 Construction ...........................................................................................................3
2.3 General Aspects.....................................................................................................4
2.4 Pump unit ...............................................................................................................4
2.5 Lifting gear..............................................................................................................4
2.6 Luffing gear ............................................................................................................4
2.7 Turning gear ...........................................................................................................4
2.8 Gear oil cooler ........................................................................................................4
2.9 Hydraulic oil cooler .................................................................................................5
2.10 Heating ...................................................................................................................5
2.11 Slake rope switch ...................................................................................................5
2.12 Gear limit switch .....................................................................................................5
2.13 Slip ring assembly ..................................................................................................5
2.14 Load measuring bolt...............................................................................................6
2.15 Description of the electrical components............................................................. )7
2.15.1 Electronic regulator print card ................................................................................7
3 Safety
3.1 Use for the designed purpose ................................................................................1
3.2 General safety instructions.....................................................................................1
3.3 Requirement of personnel ......................................................................................1
3.4 Symbols on the crane.............................................................................................1

3.5 Warning signals during the crane operation 2
3.6 Safety devices on the crane and their functional test.............................................2
3.6.1 Control lever ...........................................................................................................2
3.6.2 Pressure switch ......................................................................................................2
3.6.3 Hydraulic overload safety .......................................................................................2
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NMF Board crane type DK II
3.6.4 Limit switch ........................................................................................................... 3

3.6.5 Anticollision............................................................................................................ 3
3.7 Dangers and behaviour in case of danger............................................................. 3
3.7.1 Danger from noise ................................................................................................. 3
3.7.2 Danger from „residual energy“:.............................................................................. 3
3.7.3 Behavious in case of danger ................................................................................. 4
3.7.4 Behaviour in critical situations .............................................................................. 4
3.7.5 Emergency exit ..................................................................................................... 4
4 Operation
4.1 Safety instructions ................................................................................................. 1
4.2 Requirement of personnel ..................................................................................... 1
4.3 Working range of the crane ................................................................................... 2
4.4 Operation ............................................................................................................... 3
4.4.1 Operator´s cabin .................................................................................................... 3
4.4.2 Control panels........................................................................................................ 4
4.5 Inspection prior starting/operating the crane ......................................................... 6
4.5.1 Before starting ....................................................................................................... 6
4.5.2 Switching on .......................................................................................................... 6
4.5.3 During operation 7
4.5.4 Switching the load stage on................................................................................... 7
4.5.5 Switching the half-load stage on............................................................................ 7
4.6 Switch off 8
4.7 Emergency shutdown of the crane ........................................................................ 8
5 Monitoring, Failure, Troubleshooting and Elimination

5.3 Monitoring, Failure, troubleshooting and elimination ............................................. 1
5.4 Brake relay monitoring........................................................................................... 1
5.4.1 „TEST OPERATION“ switch .................................................................................. 1
5.4.2 „RESET“ button ..................................................................................................... 2
5.5 Fault notification card............................................................................................. 2
5.6 Fault Search Diagram............................................................................................ 3
6 Maintenance and Repair

6.3 Maintenance schedule........................................................................................... 2
6.4 Maintenance and repair 4
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Instruction manual
Board crane type DK II NMF
6.4.1 Cleaning the crane .................................................................................................4

9. Mai2005
6.4.2 Greasing.................................................................................................................4
6.4.3 Gear .......................................................................................................................4
6.4.4 Oil change ..............................................................................................................4
6.4.5 Gear box inspection ...............................................................................................4
6.4.6 Pump distribution gear ...........................................................................................5
6.4.7 Gear oil cooler filter 6
6.4.8 Changing the hydraulic oil ......................................................................................6
6.4.9 Changing the hydraulic oil filter ..............................................................................6
6.4.10 Bottom hook block..................................................................................................9
6.4.11 Roller Revolving Joint 10
6.4.12 Function and safety inspection.............................................................................11
6.4.13 Lamellar brakes....................................................................................................11
6.4.14 Changing the lamellars.........................................................................................11
6.4.15 Slack rope switch gear 13
6.4.16 Slip ring assembly ................................................................................................14
6.4.17 Load measuring bolts ...........................................................................................15
6.5 Maintenance, service and discard criteria for wire rope .......................................17
6.5.1 Cleaning and greasing the wire rope....................................................................17
6.5.2 Monitoring.............................................................................................................17
6.5.3 Wire changing ......................................................................................................19
6.5.4 Replacement state of wear...................................................................................19
6.6 Gear cam limit switch ...........................................................................................23
6.6.1 Setting of the limit switch......................................................................................24
6.6.2 Perform the following work ...................................................................................24
6.7 How do I exchange a Memory-Programmable Control (MPC)?...........................29
6.7.1 Changing the battery. ...........................................................................................29
6.8 List of lubricants ...................................................................................................35
7 Functional description of hydraulic

7.1 General aspects .....................................................................................................1
7.2 Starting the pump unit ............................................................................................1
7.3 Venting ...................................................................................................................1

7.4 Heating/Cooling system .........................................................................................1
7.5 Function of the electro-hydraulic control ................................................................2
7.6 Hoisting gear ..........................................................................................................3
7.6.1 Hoisting of the nominal load ...................................................................................3
7.6.2 Function of half load (Set load range selector to 16 tons)......................................4
7.6.3 Hydraulic overload cut-off.......................................................................................6
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7.7 Luffing gear 7

7.7.1 „Luffing up“............................................................................................................ 7
7.7.2 „Luffing down“ ....................................................................................................... 7
7.8 Turning gear 8
7.8.1 Turning „RIGHT-LEFT“ .......................................................................................... 8
8 Hoisting of brakes in case of emergency

8.1 Hoisting gear.......................................................................................................... 1
8.1.1 Connect the hand pump for opening the brakes as follows................................... 1
8.2 Jib 2
8.3 Slewing gear .......................................................................................................... 2
9 Illustration
10 Spare parts
10.1 Ordering spare parts.............................................................................................. 1
11 Subcontractor documentation
12 Drawings
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Board crane type DK II
Illustration
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Chapter 2; Illustr.1 Overview 3

Chapter 4; Illustr.2 Working range of the crane 2
Chapter 4; Illustr.3 Operator´s cabin 3
Chapter 4; Illustr.4 Control panel left 4
Chapter 4; Illustr.5 Control panel right 5
Chapter 5; Illustr.6 Electrical fault 3
Chapter 5; Illustr.7 Pump unit fault 5
Chapter 5; Illustr.8 Lifting gear fault (electr.) 5
Chapter 5; Illustr.9 Lifting gear fault 6
Chapter 5; Illustr.10 Lifting gear fault 7
Chapter 5; Illustr.11 Luffing gear fault (electr.) 8
Chapter 5; Illustr.12 Luffing gear fault 9
Chapter 5; Illustr.13 Luffing gear fault 10
Chapter 5; Illustr.14 Turning gear fault (electr.) 11
Chapter 5; Illustr.15 Turning gear fault 12
Chapter 6; Illustr.16 Filter 8
Chapter 6; Illustr.17 Lamellar brake 12
Chapter 6; Illustr.18 Slack rope switch 13
Chapter 6; Illustr.19 Load measuring bolts 15
Chapter 6; Illustr.20 Gear cam limit switch 23
Chapter 6; Illustr.21 Limit switch adjustment hoisting gear 26
Chapter 6; Illustr.22 Limit switch adjustment luffing gear 27
Chapter 6; Illustr.23 imit switch adjustment jib 28
Chapter 7; Illustr.24 Pump diagram 3
Chapter 7; Illustr.25 Half load function 5
Chapter 8; Illustr.30 Ball vlave „By-pass“ 3
Chapter 8; Illustr.31 Connections for the solenoid valve block 4
Chapter 8; Illustr.32 Brake lifting pump 5
Chapter 8; Illustr.33 6
Chapter 9; Illustr.34 Pump unit 1
Chapter 9; Illustr.35 Load measuring system 2
Chapter 9; Illustr.36 current pilot print card 3
Chapter 9; Illustr.37 Emergency exit 4
Chapter 9; Illustr.38 Interfrence pilot print card 5
Chapter 9; Illustr.39 Gear oil cooler 6
Chapter 9; Illustr.40 Reset-Switch 7
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Instruction manual
6
Instruction manual
Board Crane type DK II NMF
1 What is worth knowing about this operating manual
May, 2005
1.1 Manufacturer
The crane manufacturer is NMF Neuenfelder Maschinenfabrik GmbH
The address is:
NMF Neuenfelder Maschinenfabrik GmbH
Neuenfelder Fährdeich
21129 Hamburg
You can contact us under
Telephone 040 / 74511-02
Fax 040 / 74511-867
1.2 The operator´s duty of care

The operator must ensure that
• the crane is only to be used in accordance with the designed purpose (see Chapter 3.1,
page 1, ).
• the crane is only used in a fault-free, operational condition,
• the safety devices are regularly checked in order to ensure that they function as stipu-
lated,
• personal protective clothing and equipments is provided for the operating, maintenance
and repair personnel and that this is worn or used.
• the instruction manual is always complete and legible and situated at the crane´s loca-
tion,
• only sufficiently qualified and authorised personnel operate, maintain and repair the
crane,
• this personnel is regularly instructed in all pertinent aspects of works safety and environ-
mental protection and are familiar with the instruction manual and in particular the safety
instructions enclosed in it
• all safety and warning instructions on the crane are legible and are not removed.
Operating instructions in the sense of industrial safety legislation and regulations for the use
of the work materials are also to be provided.
1.3 Terms, short cuts and symbols

The terms used in the instruction manual are explained in Table 1, Seite 1, .
Terms / short cuts Meaning
NMF Neuenfelder Maschinenfabrik GmbH

Operator Company or person responsible for using the crane
Table 1: Terms and short cuts
Copyright © 2005 What is worth knowing about this operating manual 1

Instruction manual
NMF Board Crane type DK II
Together with the text in the safety instructions, the safety symbols draw attention to rest
hazards when handling the crane. These rest hazards are related to
• people
• the crane
• other objects and items
• the environment
The safety symbols included in Table 2, Seite 2, are used in this instruction manual
Symbols Explanation
NOTE
Information which is important for operating the product
CAUTION
Hazards which can result in the device and / or other plant compo-
nents suffering damage, but which do not pose a threat to life and
limb
DANGER
Hazards which pose a threat to life and limb or additional hazards
which can result in the device and / or other plant components suf-
fering damage
Table 2: Symbols
Please note that a safety symbol can never replace the text of a safety instruction. For this
reason, always completely read the text of a safety instruction!
1.4 Technical Amendments

For safety reasons, no unauthorised changes are to be made to the crane - this also applies
to the welding work on bearing parts. All planned changes must be approved by Neuenfelder
Maschinenfabrik GmbH in writing.
We reserve the right to implement technical amendments for product improvement pur-
poses. The illustrations in this instruction manual can slightly deviate from the actual design.
1.5 Guarantee
Unless otherwise stipulated in the contract, any warranty claims shall be dealt with in
accordance with the Neuenfelder Maschinenfabrik GmbH „General Terms and Conditions
of Supplies and Services“ applicable at the time the contract has been concluded.
The Neuenfelder Maschinenfabrik GmbH
guarantee will become void if:
2 What is worth knowing about this operating manual Copyright © 2005

Instruction manual
• the product is modified without our consent,
• this instruction manual is not observed,
• spare parts and additional devices have been fitted and removed which have not been
May, 2005
supplied or approved by us
• the crane is overloaded, e. g. the carrying force is exceeded,
• the crane is not used in accordance with the designed purpose, e. g. by oblique pull,
• the technical data stipulated in Chapter 2.1, Technical Data, page 1 are exceeded or not
reached,
• the product is improperly handled.
1.6 Copyright
The copyright in this instruction manual and the drawings remains with Neuenfelder
Maschinenfabrik GmbH. The instruction manual and the drawings are only to be used for
the purpose it was transferred to the recipient. The documents are no to be handed over or
disclosed to third parties without our express consent in writing. Any reproduction (including
details) is prohibited. Any contraventions will be subjected to prosecution.
Copyright © 2005 What is worth knowing about this operating manual 3

Instruction manual
4 What is worth knowing about this operating manual Copyright © 2005

Instruction manual
2 Description of the Crane
May, 2005
2.1 Technical Data

The DK II board crane is a loading device. The technical data is complied in Table 3, page
1, .
Feature Value
Crane Crane 1 Crane 2

Crane type DK II DK II
Capacity (SWL) follow 45t; 35t; 16t 45t; 35t; 16t
load step eligible over key
switch
Outreach
SWL 45 t 4,5 - 27,5m 4,5 - 27,5m
SWL 35 t 2,6 - 32,2m 2,6 - 31,5m
SWL 16 t 2,6 - 32,2 2,6 - 31,5
Lifting height ca. 40m ca. 40m
Luffing 70 70s
Hoisting speed
SWL 45 t 0 - 20,0 m/min 0 - 20,0 m/min
SWL 35 t 0 - 25,0 m/min 0 - 25,0 m/min
SWL 16 t 0 - 32,0 m/min 0 - 32,0 m/min
Turning speed 0 - 0,8 U/min 0 - 0,8 U/min
Slewing range 360° 360°
Specification 45 t load and 27,5 m out- 45 t load and 27,5 m out-
reach at +/- 5° heeling and reach at +/- 5° heeling and
simultaneous trim of +/- 2° simultaneous trim of +/- 2°
Half load stage 0 - 16 t load with double 0 - 16 t load with double
hoisting speed hoisting speed
(0 - 32 m/min) (0 - 32 m/min)
Voltage
Nominal Voltage (U) 440 V / 60 Hz 440 V / 60 Hz
Motor speed (n) 1.775 r/min 1.775 r/min
Mounting power 160 kW 160 kW
Max. input, temporarily 270 kW 270 kW

Auxiliary supply 230 V / 60 Hz 230 V / 60 Hz
Heating ___ kW ___ kW
Total lighting ___ kW ___ kW
Main pump motor
Type 280 S4 280 S4
Table 3: Technical Data
Copyright © 2005 Description of the Crane 1

Instruction manual
Feature Value
Manufacturer ___ ___

Performance 160 kW 160 kW
System of protection, IP 23 IP 23
insulation class
Structural shape Standstill heating with three Standstill heating with three
posistors posistors
Miscellaneous Star-delta start-up Star-delta start-up
Fan motors
Maximum input 2.5 kW 2.5 kW
Table 3: Technical Data
2 Description of the Crane Copyright © 2005

Instruction manual
2.2 Construction
May, 2005
Illustration1: Overview

Instruction manual
2.3 General Aspects

All of the working motions can be regulated infinitely from zero to max. speed: all operations
can take place simultaneously. With a nominal load on the hook, an electric capacity gover-
nor reduces the control current to the pump adjustment of the lifting, turning and luffing gear,
depending on the power input to the electric motor. These speeds are reduced and the
power input to the electric motor is kept at the same level.
2.4 Pump unit

A pump unit is installed in the crane housing. It comprises an electric motor, a pump distri-
bution gear and an hydraulic pumps.
The pump is driven by the electric motor through the distribution gear. The pump unit pro-
vides the lifting gear, turning gear and luffing gear with pressure oil.
The hydraulic pump is variable, reversible high-pressure, axial piston pump which is con-
nected to the hydraulic motors by high-pressure hoses.
2.5 Lifting gear

The lifting gear is mounted in the crane casing, consisting of the winch drum, the winch gear
and an hydraulic motor. The winch gear is installed in the winch drum, the hydraulic motor
being flanged onto the latter.
The hydraulic motor is a axial piston-bent axis motor with spherical pistons. The motors start
at a maximum displacement volume and therefore at a maximum starting moment
2.6 Luffing gear

The setup of the luffing gear is the same as that of the lifting gear.
2.7 Turning gear

The turning gear consists of two turning gears which are mounted on the floor of the crane.
Each turning gear engages via a gear wheel into a gear rim of the spherical turning connec-
tion, hereby transmitting the turning motion to the crane. A constant bent axis motor is fitted
to each of the turning gears.
2.8 Gear oil cooler

The gear oil cooler is an oil-air cooler which cools the gear oil in the pump distribution gear
(see Chapter 11, Subcontractor documentation, page 1).
This starts at an oil temperature of 20 °C.
The gear oil cooler has an oil filter which must be replaced at regular maintenance intervals
(see Table 4, page 2, ).

Instruction manual
2.9 Hydraulic oil cooler
The hydraulic oil coolers are oil-air cooler which are mounted in the return line of the hydrau-
lic system.
May, 2005
The spring-loaded vent flap [2.7] is automatically hydraulically opened when the pump unit
is started. The oil-air cooler is switched on at an oil temperature of 40 °C. The heated air is
fed-off through the opened vent flap. All functions are switched off when the oil temperature
exceeds 85 °C. The pump unit and the oil-air coolers continue to run.
2.10 Heating
Electrical heating elements are installed in the hydraulic oil tank and the crane housing. The
ambient temperature is controlled by a room thermostat. The oil temperature in the oil tank
is controlled by a thermo sensor. The tank heating is continuously switched in at an oil tem-
perature under 20 °C. At ca. 22 °C the tank heating is switched off.
2.11 Slake rope switch

As soon as the rope of the lifting gear within the crane column tends to slacken so that the
rope threatens to jump out of the grooves, the inductive proximity switch is actuated by the
rocker. This immediately switches the lifting gear off in „lowering“ mode. However, a lifting
operation is possible.
The correct positioning of the rope must be checked (see Chapter 6.5, Maintenance, service
and discard criteria for wire rope, page 17).
2.12 Gear limit switch

A gear limit switch is fitted to each of the winch gears.
The limit switches are provided with a variable number of cams which are actuated as
required by the various crane-operating conditions.
(see Chapter 11, Subcontractor documentation, page 1).
CAUTION!
The limit switches are only to be operated, serviced and repaired by authorized,
skilled and instructed personnel.
This personnel must have read and understood the complete instruction manual and
it must also have received instruction in the ensuing hazards (see Chapter 6,
Maintenance and Repair, page 1.
2.13 Slip ring assembly

The slip ring assembly guides the tension from the fixed part of the crown (foundation) to the
turning crane and can therefore be turned without restriction.
Due to its enclosed design, the slip ring assembly is splashwater-proof and fitted to the
rotary transmission leadthrough, it can be accessed after the cover has been opened.

Instruction manual
CAUTION
Prior to opening the slip ring assembly cover
• switch off the voltage
• protect the power supply against unauthorised activation.
2.14 Load measuring bolt

The load measurement is electrically carried out via load measuring bolts in the rope end
fixing point. The load is shown on a display in the cabin.
Under no circumstances should the load measuring bolts be driven into the bore hole with
a hammer or other tool. A non-adherence to this warning can result in the load measuring
bolts suffering mechanical damage and incorrect measuring results being produced.
Should such a non-observance be determined, the warranty rights are deleted.
The load measuring system can be switched off with a key switch in the switch cabinet. (see
page 2) The load bolts are therefore electrically bypassed and the electrical load measure-
ment deactivated. This has no effect on the hydraulic load measurement.
CAUTION:
If the load measuring system is deactivated, the loadmaster is unable to initiate a
deactivation by overload.

Instruction manual
2.15 Description of the electrical components )
May, 2005
2.15.1 Electronic regulator print card
2.15.1.1 4-Channel current regulator print card
see (Chapter Abbildung 36:, Seite 3, )

Short description
Magnet current regulator print cards for triggering proportional valves.
The card is equipped with a total of four PWM-outlets, from which max. two can be simul-
taneously active. The set value triggering is carried out via a driving lever potentiometer.
Functions:
• Individual operation for pump 1, pump 2 or both pumps
• Normal operation, creep speed 1. Creep speed 2.
• Synchronous drive as Master for a second crane.
• Synchronous drive as Master for a second crane.
• Parametrizing operation, operated via buttons the front plate.
• Extended parametriting operation via RS232 from laptop
• Power limitation
Technical Data:
• Supply voltage: 24VDC(1 -32V) residual ripple max. 5%
• Range of output current: 10 -999mA (PWM 122 Hz)
• Five ramp generators, durations up to 10sec. from IminÞ Imax, or Imax Þ Imin
• Supply voltage for driving lever: ± 15VDC
• Incremental transducer (24 VDC) for Gemini-operation
• RS485- interface for Gemini operation
• Ten inpits (24VDC) for the function selection
• Two AC-inlets for convertor (10 VAC)
• Status information via display (2x 16 characters)
Mechanical:
• Europe card(100x160 mm)Front:12TE,3 HE
Operating instructions
If the enable signal has not been applied, one can enter the parameter mode by pressing
the ENTER button The parameter number and the abbreviation for the turning direction
appear in the top line of the display. In the bottom line, one can see the abbreviation for the
value which is to be edited left, the current value with the abbreviation of the dimensioning
being right. If one now wishes to amend a value, the ENTER button is to be pushed. EDIT
appears in the top line. The value can now be increased or reduced using the arrow keys.
The Autorepeat function enables a setting to be made even with large changes. The new
value is stored by the ENTER being pushed once more. EDIT disappears again and one can
change to a different parameter number by pressing the arrow keys (also Autorepeat here).
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Instruction manual
If one only wishes to store the old value instead of the new value, only the ESC button needs
to be pressed. The parameter menu is terminated with ESC
2.15.1.2 Description of the request for the start release
The start request/start release signals are blocked with the crane control system. The crane
cannot be started without the release signal. This is an active system.
The system works as follows:
A "Permission to start request" button is situated on the control console. A relay is activated
with this button. The relay goes into self-locking and a floating contact closes. The relay
remains in self-locking until the motor is started. The signal voltage for this contact is pro-
vided from the ship, max. 230V.
After the "Permission to start reques" button has been pushed, the "Wait for permission to
start" lamp illuminates.
A floating "Permission to start" contact is provided from the ship. The contact closes if there
is enough power for the start. In the cabin a "Permission to start" signal lamp illuminates.
The signal voltage for this contact comes from the crane control and amounts to 230VAC.
The crane can be subsequently restarted.
8 Copyright © 2005
Instruction manual
3 Safety
May, 2005
3.1 Use for the designed purpose

The board crane type DK II is designed for use as a loading device for the loading and
unloading of small consignments and containers off ships.
3.2 General safety instructions

The products manufactured by Neuenfelder Maschinenfabrik GmbH are designed and con-
structed on the basis of a risk analysis and subject to additional national standards and tech-
nical specification. They therefore meet the latest state of the art and guarantee the highest
possible degree of safety.
This safety level can only be achieved if all of the necessary measures have been taken. It
is therefore a part of the crane operator´s duty of care to plan these measures and ensure
that they are correctly executed (see Kapitel 1.2, The operator´s duty of care, Seite 1).
3.3 Requirement of personnel

The crane is only to be operated by persons who
• are trained, instructed and authorised,
• are familiar with the instruction manual and act in accordance with it,
• confirm with their signature that they have understood the instruction manual.
In addition, the personnel must be especially instructed in the following activities and know
them:
• Emergency shutdown of the crane (see Kapitel 4.7, Emergency shutdown of the crane,
Seite 8),
• escape hatch if the operator´s cabin via a ladder or a descending device (see Emer-
gency exit, Seite 4),
• emergency lowering of the load and the jib (see Kapitel 8, Hoisting of brakes in case of
emergency, Seite 1),
• behaviour in critical situations, e. g. heeling and trimming (see Behaviour in critical situ-
ations, Seite 4).
The respective areas of authority of the operating personnel must be clearly defined.
3.4 Symbols on the crane

Always keep all safety instruction plate and operating instruction plates on the crane in a leg-
ible state. Replace any damaged or illegible plates without delay.
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Instruction manual
3.5 Warning signals during the crane operation

Acoustic warning signals
• horn
Optical warning signals
• Warning lamps on the left control panel
3.6 Safety devices on the crane and their functional test
3.6.1 Control lever
The control levers are spring loaded and automatically return to the neutral position when
released. The brakes for hoisting, luffing and turning gears are spring loaded and always
closed. They are only opened when the corresponding control lever is shifted.
The brakes close automatically
• when the control levers are at neutral position,
• there is a pressure loss in the system (in this case the pump unit is immediately
switched off),
• power failure
• in case of overload
• when the limits of the outreach are reached in the individual load ranges,
• when the slack rope is at „lower“ in the lifting gear.
3.6.2 Pressure switch
A pressure switch for monitoring the feed pressure is installed in each of the high-pressure
lines.
• 3.4 luff down
• 4.4 luff down
• 5.4 turning
In the case of a pressure loss, this pressure switch switches the pump unit off immediately.
A level switch in the hydraulic oil tank also switches the pump unit off if there is a lack of oil.
The pumps are then protected against running dry.
If the crane is switched off due to a pressure switch opening or a failure of the gear oil cooler:
• the crane operator is unable to re-start the crane.
• It is possible that a hose has burst.
• before, restarting subject the hydraulic system to a visual inspection. Should you not find
any defects, press the „Reset“ button in the switch cabinet. Then restart the crane.
3.6.3 Hydraulic overload safety
The complete hydraulic oil system is protected again excess pressure by pressure limitation
valves. A load pressure switch is fitted in the lifting gear hoisting pipe.
[3.5] 45t hoist/lower
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Instruction manual
[3.6] 0-35t hoist /lower
In case of overload
• the load pressure switch cuts the activated function off,
May, 2005
• the pump unit continues to run,

• the lifting winch brake is applied immediately,
• the lifting gear pump returns to the neutral position.
3.6.4 Limit switch
The lifting and luffing gears are limited in the working range of the individual load range by
limit switches (see Kapitel 6.6, Gear cam limit switch, Seite 23). When this final position is
reached, the corresponding function is deactivated and the brakes are applied. However, a
reverse operation is possible. All limit switches only work concerning the triggering of the
pumps, e. g. the electric motor continues to run at a constant speed, whereby only the idling
speed is applied.
When crane operations are recommenced, no current peaks are achieved due to the cen-
trifugal masses produced by the electric motor and the smoothly operating hydraulics.
3.6.5 Anticollision
Crane 2 is equipped with an anti-collision system. This prevents the crane from coming into
content with the superstructure during operation.
3.7 Dangers and behaviour in case of danger
3.7.1 Danger from noise
Depending on the local conditions, higher sound levels can occur outside the crane opera-
tor´s cabin which can result in deafness, a loss of balance or diminished alertness.
Always use the personal protective equipment and clothing.
Please note that if the crane is in operation, the communication of speech and the discern-
ment of acoustic signals e. g. warning signals et c.
3.7.2 Danger from „residual energy“:

Please not that various forms of energy can still exist after the crane has been switched off
or at a standstill - examples of these are:
• raised jibs or loads
• hydraulic pressure hoses
• live power cables
Please advise the personnel accordingly when instructing them.
Copyright © 2005 Safety 3

Instruction manual
3.7.3 Behavious in case of danger
In case of danger, press the emergency-stop button immediately, see Kapitel 4.7, Emer-
gency shutdown of the crane, Seite 8.
In case of fire, switch the crane off at the main switch immediately.
Take the special action with regard to fire fighting in the following areas:
• with operational materials (hydraulic oil, lubricants),
• electric cables
3.7.4 Behaviour in critical situations
A critical situation is given if the heeling exceeds 3° is exceeded.

Warning of this critical situation is provided in the form of both optical and acoustic signals.
Take the following action.
• luff the jib up
• turn the crane across the shortest path to the centre of the ship.
• place the load on the ground.
• determine the cause of the heavy heeling.
3.7.5 Emergency exit
In case of emergency, leave the crane via the emergency exit in the crane operator´s cabin.
• or via an external ladder placed against the crane (should one exist)
• or via the emergency descending device in the crane operator´s cabin (see Subcontrac-
tor documentation, Seite 1
4 Safety Copyright © 2005

Instruction manual
4 Operation
May, 2005
4.1 Safety instructions

Before operation, make yourself familiar with
• the instruction manual,
• the crane´s operating and controlling elements,
• the immediate environment of the crane
• the crane´s safety equipment,
• action top be taken in case of danger.

The crane is only to be operated by persons who are trained, instructed and authorised.
These persons must be familiar with the instruction manual and are to act in accordance with
it. The respective areas of authority of the operating personnel must be clearly defined.
Operating personnel who are in training are only to initially work on the crane under super-
vision of an experienced person. The successful completion of the training period should be
confirmed in writing.
All control and safety devices are only to be operated by persons who have been suitably
instructed.
All persons working on the crane are to read the instruction manual and confirm with their
signature that they have understood it.
Copyright © 2005 Operation 1

Instruction manual
4.3 Working range of the crane
Illustration2: Working range of the crane
2 Operation Copyright © 2005

Instruction manual
4.4 Operation
May, 2005
4.4.1 Operator´s cabin
The crane operating elements are situated in the operator´s cabin.

Illustration3: Operator´s cabin

Betriebsanleitung
Bordkran Typ DK II NMF
4.4.2 Control panels
The control levers are delicate and are to be actuated continuously.

1
3
5
2
7
1 NO FUNCTION 9
2 CONTROL LEVER 11 4 2
3 PUSH BUTTON „EMERGENCY STOP“
4 LAMP „FAILURE“ 6
13
5 LAMP „HEEL 3°“ 8
6 LAMP „HEEL 5°“
7 LAMP „ OVERLOAD“
10
8 LAMP „WARNING OVERLOAD“
9 LAMP „OIL COOLER OPERATION”
12
10 LAMP „READY FOR OPERATION“
14
11 PUSH BUTTON „MOTOR OFF“ 16
12 PUSH BUTTON „MOTOR ON“
13 LAMP „WAIT FOR PERMISSION TOSTART“ 15
14 LAMP „PERMISSION TO START“
15 PUSH BUTTON „PERMISSION TO START
16 SOCKET 220V
Illustration4: Control panel left
Operation 4
Betriebsanleitung
Bordkran Typ DK II NMF
3
5
7
9
2 11
13
4
1) PUSH BUTTON „BY-PASS 16t STEP“
6
2) CONTROL LEVER 8
3) LAMP „LOAD STEP 35t“
4) LAMP „FAST SPEED 16t“ 10
5) KEY SWITCH LOAD STEP „0= 45t; 1=35t“
6) LAMP „LOAD STEP 45t“ 12
7) KEY SWITCH „FAST SPEED“
8) KEY SWITCH „JIB IN PARKPOSITON“ 14
9) KEY SWITCH „ANTICOLLISION“
10) SWITCH „WINDOWS SCREEN WIPER“
11) PUSH BUTTON „HORN“
12) SWITCH „LIGHT CABIN“
13) SWITCH „WARNING LIGHT JIB“
14) LAMP „FLOOD LIGHT“
Illustration5: Control panel right
Operation 5
Instruction manual
4.5 Inspection prior starting/operating the crane
4.5.1 Before starting
Before every start

• Ensure that all of the safety devices have been fitted and that they are functioning.
• Inspect the crane for visible damage; remedy any defects found immediately and report
this to your supervisors or the crane user.
• Ensure that only authorised persons are in the crane operating area and that no other
persons can be endangered when the crane is started up.
• Remove all objects and other material which is not required for the crane operation from
the crane operating area out of the crane working area.
• Check the oil level in the hydraulic oil tank. Oil must be visible in the lower inspection
glass.
• Check whether all shut-off valves and if necessary open the valves
• Check whether the oil drain valve.
• Only use the crane if it is free from faults.
4.5.2 Switching on
1. Switch on the main switch in the machine room.

2. Operate push button (9) „PERMISSION TO START REQUEST“, this activates the
white pilot light (15) „WAIT FOR PERMISSION TO START“. see (Chapter 2.15.1.2,
page 8, )
3. Wait until green pilot lamp (3) „READY FOR START“ illuminates, than start crane.
4. Start the pump unit. After ca. 10 seconds, the green pilot lamp on the left control
panel illuminates
5. Check whether the vent flap is open.
6. Luff the jib down completely and check whether the luffing jib stops without difficulty
when the max. position is reached.
7. Move the lifting gear in „Lift“. The bottom hook block must stop ca. 1 m below the jib
head.
8. Luff the jib up completely and check whether the jib stops without difficulty when the
min. position is reached.
NOTE
When the 70° jib positions is passed, the luffing up speed is automatically reduced
by half.
9. Remove the key from the „lay resting jib down“ key switch so as to avoid misuse by
the crane operator during normal cargo handling.

Instruction manual
4.5.3 During operation
• Do not remove any safety devices and do not taken them out of operation.
• You and other operating personnel are only to be in the stipulated work places.
May, 2005
• Ensure that no unauthorised persons are within the crane operating area.
• Never suspend accepted loads above peoples´ head.
• The load shift is only to be activated with an empty load hook and for the corresponding
load.
• An angular pulling with the load rope is not permitted.
Activate the warning signal
• Only activate the „lay resting jib down“ key switch if the jib is situated in the rest parking
support.
• Caution: All other limit switches do not function.
• It is imperative that a slack rope is avoided.
4.5.4 Switching the load stage on
The load stages are switched on at the right panel (see Control panels, Seite 4)
NOTE:
The load steps are only to be changed when the hook is not subjected to a load. If the
load on the hook is greater than the set load step, the crane switches off „hoisting“.
„Lowering“ is posible.
4.5.5 Switching the half-load stage on
The half-load stage is only to be activated for loads of 0 -16 t. The lifting speed in the half-
load stage amounts to 0 - 32 m/min.
The half-load stage is switched on with a key switch on the right control panel and activated
via the white push button on the lifting gear control lever. (see Control panels, Seite 4).
Press the white push button and start up within a period of 5 seconds, otherwise the system
automatically returned to nominal load. When the half-load stage is switched on, the white
push button must be pushed in once more by every „0“ advanced control. If the load to be
handled is heavier than 16 t, the cargo winch brake nevertheless opens but it is then imme-
diately applied. Immediately return the control lever to neutral. Set the key switch to nominal
load.

Instruction manual
4.6 Switch off
Shutting down.
1. Extend the jib to the maximum outreach. Actuate the „rest jib“ key switch and hold the
key switch in position. Place the jib in the resting position and relieve the topping lift a
little.
2. Fasten the jib in the resting support.
3. Place the bottom hook block under the jib head, DO NOT lift the jib head.
4. Switch the pump unit off.
5. Check whether the vent flap is closed
6. Close the cabin window and the cabin vent.
7. Switch the main switch in the machine room off. Do not switch off the auxiliary supply.
4.7 Emergency shutdown of the crane

3 emergency-off buttons are installed in the crane and the crane housing.
• in the crane exit on the ladder
• in the switch cabinet
• on the right control panel

Instruction manual
5 Monitoring, Failure, Troubleshooting and Elimination
May, 2005

• All work on the crane´s electrical equipment must be carried out by trained electrical
specialists only.
• Any interventions in the crane´s control programme are only to be carried by Neuen-
felder Maschinenfabrik GmbH or with its approval.
• Repairs and inspections are only to be carried out when there is no load on the hook.
Place the load on the ground first. (see Chapter 8, Hoisting of brakes in case of emer-
gency, page 1).

Only remedy a fault if you are qualified to do so.
Please also read Chapter 3.2, General safety instructions, page 1.
5.3 Monitoring, Failure, troubleshooting and elimination

The troubleshooting list is provided in order to assist you with the remedying of any faults on
the turning crane more easily. It is always important that a hydraulic diagram be taken to
hand.
Every dismantled and cleaned hydraulic component must be carefully replaced after being
lightly lubricated. Seals are to be replaced.
Never apply force and use any fluffy cleaning cloths or similar.
5.4 Brake relay monitoring

For safety reasons, the solenoid valves for the lifting gear, turning gear and jib brakes are
triggered by 2 relays situated in a row. This switching guarantees the greatest possible secu-
rity. Should a relay bond and the contact no longer open, the second relay is still able to
switch the brake off safely. The relays are always monitored by the SPC. The relay is
checked 0.5 sec. after the brake has been released. Should a relay still have a closed con-
tact, an error message is transmitted to the crane operator. In the switch cabinet at the inter-
ference pilot print card, it is possible to determine which brake control is defect.
Lifting gear brake: Relay 1K17, 1K30 error message lamp 10 on the interference pilot print
card.
Jib brake: Relay 1K19, 1K31 error message lamp 11 on the interference pilot print card.
5.4.1 „TEST OPERATION“ switch
(see Reset-Switch, Seite 7).

In „Test Operation“, the control can be driven to all areas electrically. The E-motor or the
hydraulic pumps respectively do not also run. The „Test Operation“ mainly serves for trou-
bleshooting.
Copyright © 2005 Monitoring, Failure, Troubleshooting and Elimination 1

Instruction manual
5.4.2 „RESET“ button
(see Reset-Switch, Seite 7).
„HOSE RUPTURE“
Should the crane switch off by the opening of a pressure control device or a breakdown in
the gear oil cooler, the crane operator is unable to restart the crane.
It is possible that a hose has ruptured. Before restarting, the hydraulic system should be
subjected to a visual inspection. If this is carried out and no defects are determined, the
„Reset button“ in the switch cabinet must be activated. The crane can then be restarted.
5.5 Fault notification card

See Interfrence pilot print card, Seite 5.
Any crane faults are shown acoustically and optically.
• acoustic with a horn,
the horn is switched off using the „Acknowledge Alarm“ button on the interference pilot
print card.
• optical with the signal lamp at the left control panel „Fault Lamp“ and
• the signal lamp on the interference pilot print card
FAULT 1 OIL COOLER 1
FAULT 2 OIL COOLER 2
FAULT 3 GEAR OIL COOLER
FAULT 4 E- MOTOR
FAULT 5 OIL TEMPERATUR TO HIGH
FAULT 6 OIL LEVEL TO LOW
FAULT 7 HOSE RUPTURE
FAULT 8
FAULT 9 GEAR OIL TEMPERATUR TO HIGH
Should the crane have a fault, the corresponding lamp on the fault message card is
illuminated. After acknowledgement (press button) the lamp continues to illuminate
until the fault is cleared.
2 Monitoring, Failure, Troubleshooting and Elimination Copyright © 2005

Neuenfelder Maschinenfabrik GmbH May, 2005
Copyright © 2005
5.6
Board Crane type DK II

Instruction manual
F a ilu re o f e le c tric
F a u lt P ro b a b le c a u s e R em edy
Illustration6:
Fault Search Diagram

E m e rg e n c y O ff p u s h b u tto n s in c o n tro l
E l. m o to r d o e s n o t s ta rt U n lo c k e m e r g e n c y o ff p u s h b u tto n s b y
c o n s o le a t a c c e s s o r in s w itc h c a b in e t o r
p u llin g o r tu rn in g .
c ra n e fo u n d a tio n a re a c tu a te d .
M a in s w itc h is c u t – o ff. S w itc h o n m a in s w itc h in e n e r g iz e r o o m

Electrical fault
C h e c k o il le v e l. R e p le n is h if re q u ire d . If o il
L a c k o f o il. S e e fa ilu re p u m p u n it le v e l is c o rre c t, th e a u x . c o n ta c to r m u s t
re s p o n d
C h e c k a u to m . c irc u it b re a k e r lo c a te s h o rt
N o 2 3 0 V c o n tro l v o lta g e a v a ila b le .
c irc u it.
N o v o lta g e a t 4 4 0 /4 0 0 V c o n tro l
Monitoring, Failure, Troubleshooting and Elimination
A s y m m e t ric re la y h a s trip p e d , th e r e d a n d C h e c k fu s e s . M e a s u re m a in fe e d e r.
g re e n L E D d o n o t li g h t.
T rip p in g d e v ic e h a s trip p e d o w in g to A m b ie n t te m p e ra tu r e to o h ig h . C ra n e is
w in d in g te m p e ra tu r e , L E D ’s a re a lig h t. p e rm a n e n tly o p e ra te d a t its lo a d p e a k .
C o o l d o w n e l. m o to r.
C o n t ro l o f m a in fu s e s b lo w n . R e p la s e s fu s e s . In c a s e o f re p re a te d
d e fe c t lo o k fo r p o s s ib le s h o r t c irc u it in m a in
c a b le a n d s lip rin g u n it.
F a ilu re la m p in th e c o n tro l c o n s o l lig h ts u p . S e e in te r fre n c e p ilo t p rin t c a rd .

(s w itc h b o a r d )
E l. m o to r s ta rts in S ta r/ D e lta , b u t
S e e fa ilu r e o f p u m p u n it.
s to p s a g a in im m e d ia te l y .
C h e c k th e h y d r . s y s te m ( h y d r. h o s e
R e s e t – S w itc h is a c tu a te d . d a m a g e ) R e s e t – s w itc h s w itc h in g o ff.
C o n t ro l lig h t 'r e a d y fo r o p e ra tio n '

T h e s w itc h fo r te s t o p e r a tio n is T h e s w itc h fo r te s t o p e r a tio n
a lig h t, b u t e l. m o to r d o e s n o t
s w itc h in g o n . s w itc h o ff.
s ta rt.
NMF
P o w e r L E D d o e s n o t lig h ts u p ,
o r R U N L E D fla s h e s . N o 2 4 V D C in p u t ; S P S – 4 d e fe c tiv e C h e c k 2 4 V D C in p u t ; c h a n g e S P S - 4
3
4
NMF
Fault of power pack
Fault Probable cause Remedy
Power pack start- up

Trace source of leakage, remedy leakage and
and close down again. Leak of oil. Failure lamp lights up.
refill oil (for oil types see table of lubricant).
Control pressure bypass valve does not Meter current supply. Examine valve for being
switch or is mechanically blocked. clogged. Exchange solenoid.
Repeat start procedure and watch LED's in

switch cabinet for proper function of feed
pressure switches. The pilot lamp will not
One or more feed pressure switches not show for defective feed pressure (to be 25
working. bar) to find whether pump or hydraulic piping
is defective. Remedy fault. Do not bridge over
defective feed pressure switch!
Pump defect. Change the pump.(see check the pump)
Hydr. Hose damage. Change the hydr. hose. Reset – switch

switching off.

Instruction manual
Repeat start procedure and watch LED's in
Gear oil cooler is no starting. switch cabinet for proper function of gear
Copyright © 2005
Oil cooler. Check the motor circuit breaker.

Copyright © 2005

Instruction manual
Illustration8:
Illustration7:
Failure of Lifting Gear (el.)

Lifting gear fault (electr.)
Pump unit fault

Lifting winch does not turn. Current Regulator print card are not contacted. Input LED Memory-Programmable Control (MPC) do
not light up.
Check potentiometer on control lever, whether it is
maladjusted or defective.
Current Regulator print card are defective and/or the Check Current Regulator print card. Depending on
32 V AC power supply has failed. operation direction one LED must be alight, and the
ammeter must indicate.
Alternative set in and check Current Regulator print

Card into the other crane.
Input LED for the control lever do not light up. Check aux. contacts on control lever.
Crosspoint relay does not tighten up, brake do not

Check crosspoint relay and output LED of MPC.
ventilate. Output LED do not light up.
Lifting winch turns only in

"Lifting" mode. Slack wire rope switch has switched. Input LED light Solenoid valve defective.
up. LED of the solenoid valve light up.
Check, whether over load system has turned off.

Find cause for overload (perhaps reduce load).
(if available).
Lifting winch turns only at Current Regulator print card are defective; one or
Check Current Regulator print card, the red current
half speed. both proportional solenoids on one lifting gear is/are
instrument must be alight. Depending on operation
defective.
direction one LED must be alight, and the ammeter
must indicate. Alternative set in and check Current
Regulator print Card into the other crane.
Check proportional solenoid valve.
NMF
5
6
NMF
Failure Lifting Gear
Illustration9:
Lifting winch does not lift; Pressure relief valve on one lifting
nominal load at half speed gear pump is defective or fouled. One
resp., but the brake remains pressure cut-off is maladjusted or This repair must only be carried out by an expert,
open. defective.
Lifting gear fault
The lifting gear pumps, one pump

See list of el. Failures
resp, are not actuated electrically.
Leak oil portion of lifting winch motor The pump pressure should be measured. If the pressure
is too excessive. drops, the motor or the pump are defective.
Remove alternatingly the pump control solenoid plugs to

locate the defective pump. Separate all pressure connections
One lifting gear pump is defective. of the defective pump from the system and all connections to
be blanked off.
Lifting winch starts to lift the

Incorrect load stage selected or the Select corresponding load stage, reduce load resp.
load, but the brake responds load is too heavy.
again.
Lifting gear has reached its highest The jib to be topped up or the load to be attached shorter.
hook position at maximum outreach.
Adjust the load pressure switch as follows Connect gauge

and take up nominal load Loosen safety catch of pressure
adjustment screw, Lift up the load and turn pressure
Load pressure switch maladjusted. adjustment screw clockwise until the nominal load can be
lifted properly from its suspended position. Rescue
pressure adjustment screw, It should now not be able to lift
nominal load + 5 per cent. The brake must close.
The lifting gear motor is still switched

Check half-load solenoid for proper operation and fouling.
to half-load.
Instruction manual
The lifting winch should be checked by an " expert”. Prior to
Copyright © 2005
The two-speed valve on lifting winch

dismounting the lifting winch motor, if required, the load
motor jams.
should be lowered first.
Copyright © 2005

Instruction manual
Failure of Lifting Gear
Illustration10:
Lifting winch does not turn. Defective or fouled brake solenoid valve. No
Brake does not vent. No control pressure.
power supply to solenoid valve.
Lifting gear pump is not contacted/does not

respond. Pump control solenoids are Actuate pump control solenoids manually,
defective. whether the pump supplies pressure.
Lifting gear fault
Current Regulator print card defective.

Potentiometer on lifting gear control lever See list of el. failures
defective.
Oil-air cooler has failed; perhaps the fuses or

Operating and oil temperatures too high motor protective device are defective. V-belt for
thus switching off the pump contact for gear oil cooler slips or is defective. Excessive
crane functions all; heat will occur in pump distr. gear, pump and
hydraulic oil.
Actuate by hand alternatingly the pump control

Hydraulic motor is defective. solenoids. The system pressure required must
be achieved, as the brake is closed.
Limit switches are jamming; supply line Check limit switch for proper working and
is defective resp. adjustment Check whether supply line is clear.
Lifting winch turns only in Check limit switches and readjust if required.
"Lifting" mode and for a short Slack wire rope switch or " Lowering" limit The 'Lowering` limit switch must be so adjusted
time; not in "Lowering" mode switch have switched/responded. that three safety wire rope turns remain on
resp. winch drum at lowest hook position.
Pump control solenoid "Lowering" is Actuate by hand the pump control solenoid and
defective, fouled or is not contacted/does check to assure maximum working condition.
not respond electrically. See list of el. failures.
The pressure relief valve on one lifting gear

The lifting winch does not hold Check pump pressure with the brake being
pump or packing are defective. Leak oil
the load with the brake being closed. In case of a pressure drop stop crane
portion too excessive i.w.o. lifting winch
NMF
open. operation and request Suppliers .Service.
motor.
7
8
NMF
Failure of Luffing Gear(el.)
Illustration11:
Fault Probable cause Remed y
Current Regulator print Card does not Input LED (MPC) do not light up.
Topping winch does not turn
Luffing gear fault (electr.)
respond. Check potentiometer on control lever whether it

is maladjusted or defective.
The LED for "Topping Up" and/or Aux. contacts on control lever to be checked.
"Lowering" do not alight.
On the Capacity Regulating Card the Check Capacity Regulating Card.

luffing gear control part is maladjusted or Exchange defective Capacity Regulating Card.
defective.
Current Regulator print card. Depending on

direction of operation the red must be alight
Current Regulator print card the 32 A AC LCD and the ammeter must indicate a value.
su pp ly has defective or failed. Alternative, set in and check Current Regulator
print Card into the other crane.
Crosspoint relay does not tighten up, brake do

not ventilate. Output LED do not light up. Check crosspoint relay and output LED of MPC
Instruction manual
Copyright © 2005
Copyright © 2005

Instruction manual
Failure of Luffing Gear
Illustration12:
Foult Probable cause Remedy
Brake solenoid valve defective or fouled. Actuate

Luffing gear winch does not turn, The brake does not vent. No control pressure on
solenoid valve by hand, to check whether it works
but pump pressure is available. brake.
properly. Clean or renew solenoid if required.
Luffing gear fault
Pump control solenoid valves to be actuated by hand

The luffing gear winch does not respond. Pump
and check whether they are working correctly. Check
control solenoids are defective or fouled.
solenoids and clean, renew resp, if required.
Current Regulator print card is defective.

Potentiometer on luffing gear control lever is See list of el. failures
defective, Limit switches jam or supply is defective.
Capacity Regulating Card is defective.

Luffing gear winch turns only very Potentiometer on luffing gear control lever is
maladjusted. Automatic creeping speed is See list of el. failures
slowly.
permanently switched.
Under full load and actuating all functions the

capacity regulating is activated. The crane jib has No fault; normal operation.
reached its creeping speed range.
Luffing gear winch does not keep Pressure relief valve "Topping Up" is defective or Check pump pressure at closed brake. In case of a
the crane jib, with the brake being packing is defective. Too large leak oil portion pressure drop the crane to be put out of order and
open. occurs in luffing gear winch motor.. request Supplier's service .
With load on the hook the luffing The spring in the pressure relief valve "Topping Up"
gear winch does not lift the crane is weak. The pressure cut-off on the pump is This repair should only be carried out by an expert.
jib very slowly resp. maladjusted. Control pressure too low.
Current Regulator print card maladjusted or

defective. Potentiometer on luffing gear control See List of el. failures.
lever is maladjusted.
NMF
Blank off pressure pipe lines and actuate pump control
Defective luffing gear pump; no or little pressure
solenoid valves by hand. In case of a pressure drop or
only available.
no pressure at all, the pump should be renewed.
9
10
NMF
Failure of Luffing Gear
Illustration13:

Luffing gear fault
Luffing gear winch does

The crane jib has reached its maximum
not turn in direction of No fault; normal operation.
outreach at the individual load stages.
"lowering.
Lifting gear to be operated approx. 1 m

Lifting gear is at its uppermost hook position. in "Lowering
Check limit switch, readjust if required;

Luffing gear limit switch maladjusted or is
by no means to be bridged. For
jamming, wire rupture.
adjustment see el. Circuit Diagram.
Luffing gear pump does not respond. Power Check pump control solenoid valve
control p.c.b. defective. Potentiometer at Lowering" for easy working; exchange
luffing gear control lever defective. solenoid if required. See list of el.
failures.

Luffing gear winch stop at no Key-type switch "Put Down Jib" is defective or Check key-type switch and limit switch
Instruction manual
maximum outreach. jams. Limit switch for jib 0° position is for correct working. Defective switches
defective must be renewed.
Copyright © 2005
Copyright © 2005

Instruction manual
Failure of Slewing Gear (el.)
Illustration14:

Turning gear fault (electr.)
Check potentiometer on control lever, whether

Crane does not slew Power control is not contacted.
maladjusted or defective.
Input LED does not light up. aux. contactors on control lever.
Slewing gear control part on Capacity

Regulating Card is maladjusted or Check Capacity Regulating Card. Defective card to
defective. be renewed
Check Current Regulator print card, the red current

instrument must be alight. Depending on operating
Current Regulator print card is defective or direction the red LED must light and the ammeter
the 32 V AC supply has failed. must indicate value.
Alternative set in and check Current Regulator print
into the other crane.
The brakes do not close with

"zero-position" of the control Contacts on the control lever do not open. Check contacts, perhaps exchange.
lever.
NMF
11
12
NMF
Failure of Slewing Gear
Illustration15:
Crane does not slew, but pump Slewing gear brakes do not vent, no control Brake solenoid valve defective or fouled. Actuate solenoid by hand to check
pressure is available. pressure. whether it works freely. Clean or renew solenoid, if required.
Turning gear fault
Slewing gear pump is not contacted electrically.

Current Regulator print card is defective.
See list of el. failures.
Potentiometer on slewing gear control lever is
defective.
Crane does not slew; but brakes Slewing gear pump is not contacted. Pump control Actuate pump control solenoid valves manually and check whether they
open. solenoid valves are defective or fouled. work freely. Check solenoids, and clean or renew if required.
Blank off individually the pressure lines, but not the brake lines and slew.
Dismantle when defective motor is located. The crane may only be
subjected to a half load moment. The control lever may only be moved one
Slewing gear motor(s) may be defective.
half of its full distance/deflection. In case that two motors are defective, the
crane may only be slewed slowly with the jib topped up and without any load
being applied.
Crane slews very slowly or comes At full load and actuating all functions, the power
No fault; is normal operation.
to a standstill. limit is activated.
The pressure cut-off on pump is maladjusted. The

pressure springs in pressure relief valves are weak. This repair must only be carried out by an expert.
Current Regulator print card is maladjusted or

defective. Potentiometer on slewing gear control See list of el. failures.

lever is maladjusted.
Instruction manual
Slewing gear pump is defective; and does not Blank off pressure lines and actuate pump control solenoid valves manually.
Copyright © 2005
produce any pressure or only little pressure. In case of a pressure drop or no pressure at all, renew pump.
Instruction manual
6 Maintenance and Repair
May, 2005

Before maintenance and repair
1. Take the crane out of operation
2. Switch the central power supply off with the master switch.
3. Lock the master switch and put up a warning sign prohibiting it being switched on
again.
4. Block the access to the crane´s working area and ensure that no unauthorised per-
sons are within the crane´s working area.
5. Ensure that suitable lifting gear and weight-carrying equipment is available for replac-
ing large crane parts
6. Replace all defective crane parts immediately.
7. Only use original NMF-parts.
Working on electrical equipment
Electrical equipment must be checked regularly: Loose connections must be made secure,
damaged wires or cables must be replaced immediately.
The switch cabinet and all electrical supply units must always be kept locked. Access is only
permitted for authorised persons with a key or a special tool.
Never clean electrical equipment with water or similar liquids.
Working on hydraulic installations and equipment:
Before starting work depressurise all hydraulic installations / installation parts.
During preventive servicing during work, the hoses pipes should always be replaced - even
if no damage is discernible.
Environmental protection
During all work on and with the crane, the regulations for waste avoidance and proper waste
disposal or recycling respectively must be observed.
In particular, when carrying out erection and servicing work and taking the crane out of oper-
ation, ensure that substances which can contaminate ground water such as grease, oil,
coolants, solvent-based cleaning fluids, et c. are unable to contaminate the environment.
These substances are to be collected, stored, transported and disposed of in suitable recep-
tacles.
After maintenance and repair
Before starting the crane, observe the following,

• Double-check all previously loosened screws in order to ensure that they are tightly
secured
• Check that all previously removed protective devices, covers, filters, pressure switches
and limit switches have been replaced correctly
• Make sure that all previously used tools, materials and other equipment have been
removed from the working area.
• Clean the working area and remove any spilled liquids or similar substances.
• Make sure that all of the crane´s safety devices are functioning properly again
• Check all of the functions and the limit switches for the individual load steps without
load.
Copyright © 2005 Maintenance and Repair 1

Instruction manual

Working on electrical equipment
All work on the crane´s electrical equipment must be carried out by trained electrical spe-
cialists only.
When working on all live crane parts or cables, a second person must be present who can
deactivate the master switch in an emergency.
Working on hydraulic installations and equipment:
All work on the crane´s hydraulic equipment must be carried out by persons especially
trained for such work.
6.3 Maintenance schedule

Maintenance is deemed to be the regular inspection of and caring for the crane in order to
ensure a trouble-free operation
The maintenance intervals are stated in (Table 4, page 2.)
The lubricating schedule stipulates the maintenance schedule (see Maintenanca plan 840-
0500-17(1).).)
Interval Parts Work
Prior to any operation or Crane visual inspection

after any sea journey check oil level
weekly Gear: (winch gear, turning gear, check oil level

pump distribution gear)
Gear rim and pinions, revolving greasing
bearing
every three months Crane cleaning
Crane rope greasing
Rope sheave greasing
every six months Slip ring assembly visual inspection
screw connection retighten the bolts with the
specified tightening torque
yearly Crane function and safety inspec-
tion
lamellar brakes Brake inspection
Hydraulic system testing of a hydraulic oil
sample
for the first time after 50 Hydraulic oil filter change filter
hours of operation gear oil filter
for the first time after Slewing bearing retighten the bolts with the
100 hours of operation specified tightening torque
Table 4: Maintenance Intervals
2 Maintenance and Repair Copyright © 2005

Instruction manual
Interval Parts Work
for the first time after Gear: (winch gear, turning gear, oil change
May, 2005
200 hours of operation,

every 500 hours of oper- Hydraulic oil filter change filter
ation gear oil filter
for the first time after Hydraulic system oil change

800 hours of operation,
every 1000 hours of Gear: (winch gear, turning gear, oil change
operation pump distribution gear)
every 1500 hours of Hydraulic system oil change

operation
min. once a year Gear: (winch gear, turning gear, oil change
Hydraulic oil filter change filter
gear oil filter
Table 4: Maintenance Intervals
NOTE
Please also observe the subsupplier´s documents (see Chapter 11, page 1, ).

Instruction manual
6.4 Maintenance and repair
6.4.1 Cleaning the crane
• Grease all bright parts in order to avoid corrosion.

• Please check the tight fit of all screwed connections and leaks in the line system.
• Do not repair damaged pipes and hoses, replace them.
6.4.2 Greasing
Use the lubricants stipulated in (Chapter 6.8, List of lubricants, page 35).
6.4.3 Gear
The Zollern planetary gear is provided with splash lubrication. The antifriction bearing on the
main drive pinion is filled with grease. As it is a lifetime lubrication it is not necessary to
renew or refill it.
6.4.4 Oil change
CAUTION
Only change the oil when
• the gear is at a standstill
• in a warm operating state.
1. Remove the ventilation filter

2. Only at a low ambient temperature:
rinse out with a pre-heated part of the new oil so as to remove abrasion and soiling.
3. Fill with the amount of oil stated on the rating plate.
6.4.5 Gear box inspection
Checking for oil discolouration

The used oil is of a dark, black colour
• This indicates that temperatures over 100 °C have occurred during operation. This
results in the oil ageing faster with a reduced lubricity.
• The oil change must be carried out at more frequent intervals.
The used oil has a cloudy colouring:
• It is possible that water penetration has taken place.
• Change the oil immediately flushing the gearbox out thoroughly several times with new
oil.
• It is recommended that the gearbox be disassembled and the parts examined for corro-
sion.

Instruction manual
Checking the oil level
Compare the amount of oil drained off with the stipulated amount of oil.
Checking for solid foreign matter
May, 2005
We recommend that a check be carried out for foreign matter in accordance with DIN 51592.
The samples is dissolved in pure benzol. If necessary, it should be heated up a little, this
then be filtered through a benzol-resistant, fine-pored membrane filter. The rest is washed,
dried, weighed and stated as an amount of solid foreign matter.
The maximum permissible weight of foreign matter is approx. 0.15 % of the total weight of
the oil in the gearbox. However, the foreign matter particles is only to consist of fine abrasion
up to max. 25 my.
If the permitted value is not exceeded, the gearbox can continue to be used after the oil
change.
If coarse abrasion (above 25 my) or flakes of materials from the profiles of the gear teeth are
discovered, the gearbox must be disassembled, irrespective of the amount of foreign matter.
The profiles of the gear wheels, in particular the large sun wheel of the output planetary gear
set, should be subjected to a visual inspection
6.4.6 Pump distribution gear
Cleaning
• Clean the gear externally.
• Pay attention to leakage or loose screwed connections.
• Oil samples should be taken. Considerable signs of metal abrasion in the oil or on the
drain plug indicate increased wear or the occurrence of a fault and in such cases the
gear should be examined carefully.
Oil change
• When changing the oil for the first time, clean the gear with flushing oil.
• The air breather filter and the magnetic plug on the drain plug must be cleaned each
time the oil is changed.

Instruction manual
6.4.7 Gear oil cooler filter
(See Chapter 11, Subcontractor documentation, page 1).

Cleaning and changing the oil filter cartridge
1. Screw off the filter casing.
1. Take out the dirt collector vessel together with the cartridge.
2. The separate dirt sump is to be disposed of in the used oil container.
3. Pull the element out of the dirt collector vessel.
4. Clean the collector vessel.
CAUTION
Only clean wire gauze elements (type 25W) in cleaning fluid.
5. Insert a new cartridge with collector vessel into the filter casing.
6.4.8 Changing the hydraulic oil
We recommend that oil samples be examined by the oil supplier. The supplier then provides
you with information concerning the oil condition and suggests a date for the oil change.
6.4.9 Changing the hydraulic oil filter
Indicator
The filters are equipped with an optical dirt indicator (see Chapter 11, Subcontractor docu-
mentation, page 1).
Changing filter elements.
Generally speaking, the element is to be changed when the dirt indicator is triggered under
normal operating conditions. If the dirt indicator is only triggered by a cold start, the filter ele-
ment need not be changed.
When taking the crane into operation, repairing, changing the oil, etc in the hydraulic system,
shorter change intervals are to be expected.
1. Switch the crane off.
2. Depressurise the filter.
CAUTION
If the filter is not depressurised prior to any work being carried out, this may result in
a sudden, violent evacuation resulting in a risk of injuries or material damage.
3. Screw off the casing (2).

4. Dispose of the liquid in a suitable container. Do not reuse the liquid in the system.
5. Remove the element (3).
6. Examine the surface of the elements for any remaining dirt and larger particles. This
may indicate damage caused to components.
7. Clean or replace the element (3) respectively.

Instruction manual
CAUTION:
Only clean elements with wire gauze (W) and metal fleece (V). Elements containing
filter material such as BETAMICRONe-2 (BH/HC, BN/HC, BH and BN) cannot be
May, 2005
cleaned.
8. Clean the inside of the casing (2). Ensure that no dirt is deposited on the clean side.
9. Examine the filter, in particular the sealing surfaces and threads for signs of mechan-
ical damage. If necessary, replace the parts.
10. Inspect the O-ring (4) on the casing (2). In case of damage replace the O-ring.
11. Wet the thread and sealing surfaces on the filter and the O-ring of the element (3)
with a clean medium.
A non-depressurised filter and dirt particles in the screw-in thread of the casing (2) can
jam.
12. Check whether the designation of the new element corresponds with that of the
removed element.
NOTE
Replace disposable filter elements, soiled Betamicton`N-2 (BN, BN/HC) or
Betamicron 9H-2 (BH, BH/HC) elements with new elements.
13. Mount the element on the centring pivot. Screw the casing (2) in as far as it will go.
14. Check the seal for leakage.

Instruction manual
Illustration16: Filter

Instruction manual
6.4.10 Bottom hook block
1. Maintenance
May, 2005
The inspection and lubrication intervals depend on the number of operating hours, the con-
ditions of use, the operating conditions and the user assessing the situation correctly. The
following guidelines are valid for normal use:
2. Inspection
Each of the bottom hook blocks are to be inspected at intervals of max. 1 year by a special-
ist. The following must be inspected at regular intervals:
• Wear to the side plates, rope sheave surfaces, axes, bushes and bearings,
• Any deformations on the bottom hook block;
• Seating and play of the rope sheaves;
• Securing devices on nuts, bolts and other fixing elements,
• Corrosion
• Welding seams for cracks.
For repair work, the user or owner should contact NMF.
3. Lubrication
Grease specification: see Chapter 6.8, List of lubricants, page 35.
• Rope sheave bearing:
Roller bearing: Daily during continuous use or every 14 days with periodic use,
• Thrust bearing on the hooks:
Roller bearing: 14 days during continuous use or monthly with periodic use,
4. Permissible Load
It is to be ensured that the permissible load, Save Working Load (SWL) or Working Load
Limit (WLL) stated on the bottom hook block are not exceeded.
5. Warning
• Do not pull diagonally.
• Apply load gradually without jerking.
• A double hook is not to be loaded from one side.
• Max. force applied to the rope lug = 1/3 SWL
• Do not carry out any welding work on bottom hook block parts.
• Keep your hands out of the way of the rope sheaves and other moving parts.
• In those areas in which loads are transported or in which loads are moved using a bot-
tom hook block, employees must where personal protective clothing.
also see Chapter 11, Subcontractor documentation, page 1.

Instruction manual
6.4.11 Roller Revolving Joint
Lubrication and Maintenance

The first relubrication of the raceway and lubrication of the gear must be carried out imme-
diately after installation. For this and each subsequent lubrication, the lubricants named in
Table of lubricant (see Chapter 6.8, List of lubricants, page 35) are to be used. These race-
way greases are solely KP 2 K greases, i.e. lithium-saponified mineral oils of NLGI Grade 2
with EP additives. The raceway lubricants listed in Table of lubricant can be mixed together.
The lubricants are listed in random order and not according to quality. The grease filling is
there to reduce friction, seal the bearing and provide protection against corrosion. There-
fore, the bearing must always be greased liberally so that a collar of fresh grease forms
around the whole circumference of the bearing gaps and seals. The bearing should be
rotated during relubrication.
Lubricants
The appropriate manufacturer should answer queries concerning lubricants. The greases
listed in Table of lubricant are approved for our large diameter antifriction bearings and
tested for compatibility with the materials stipulated by us for spacers and seals.
It is the responsibility of the maintenance personnel to ensure individual consumption rates
by accurate checking of the lubricated condition of bath the raceway and gear.
Lubrication intervals
are to be selected according to the operating condi-
tions; generally every 100 operating hours, roller
bearings every 50 operating hours.
Shorter greasing intervals must be used:
• in tropical regions in the presence of high
humidity, dust or dirt strong temperature fluctua-
tions, and for continuous rotation,
• If there are standstill times between bearing
installation and equipment start-up, respective
maintenance procedures will be required, e.g.
relubrication under rotation no later than after 3
months and every 3 months thereafter.
• Before and after prolonged stoppage of the
equipment relubrication is absolutely necessary.
This is especially important after a winter shutdown. When cleaning the equipment~
care must be taken to prevent cleaning agents from damaging the seals or penetrating
into the raceways. The seals must be checked every 6 months.
Lubrication intervals far the gear
Pinion and gear are to be greased sufficiently with grease recommended in table of lubri-
cant. Weekly gear lubrication is recommended. The gear should always have sufficient
grease.
Checking of bolts
To compensate for settling phenomena, it is necessary to retighten the bolts with the spec-
ified tightening torque. During this operation the bolted connection must be relieved of all
tensile stresses coming from external loads. This should be checked after approximately
100 operating hours at the latest Thereafter, checking should be repeated about every 600
operating hours or every 3 months.

Instruction manual
Under special operating conditions, or if specific test instructions so require, the interval
between checks should be changed accordingly.
Checking of the raceway system
May, 2005
In their delivered condition large diameter antifriction bearings have clearances which war-
rant good operating conditions and functional safety. When the bearing is put into operation,
we recommend to perform a base measurement. After a prolonged operating time, bearing
clearances will increase. It is, therefore, necessary to check the axial movement or settling
at regular intervals.
6.4.12 Function and safety inspection
The function and safety inspection of the crane is to be carried out according to guideline
issued by the responsible classification society. If necessary, request that the manufacturer
send a specialist.
Carry out the following inspections:
1. Visual inspection of the steel structures for any damage
2. Inspect the main welding seams of the foundation and the crane for cracks.
3. Inspect the rope for wire ruptures.
4. Inspect the sheaves for damages, easy run and wear at the bottom of the grooves.
5. Inspect the swivel of the load hook for easy turn.
6. Check the setting of the limit switch.
7. Check the nominal speed of the various functions when the crane is idling.
8. Test the system with nominal load.
9. Determination of the system pressures and comparison with the figures stated in the
circuit diagram, if necessary amend.
10. Practise brake manoeuvres with all movements and activation of the emergency-off
switch. The brakes should apply immediately and the load should be held perfectly.
11. If necessary, secure maladjusted relief valves, pressure switches, etc., mark their
position with marking paint.
6.4.13 Lamellar brakes
The hydraulically ventilated disc brake has to be filled with 0,2 ltr. oil when fitting the energin.
Suitable are above all hydraulic oil customary in commerce relatively to friction, coking of
the oil, foam formation, a. s. o. Especially.
Automatic-Transmission-Fluid.
The lamellar brakes are mounted as a compact unit between the propulsion motor and the
gear. They are laid out for two components:
• as a run-dry brake with a greater brake moment with the same springs and lamellars.
• as a wet-run brake which achieve the required brake moment even when subjected to
oil.
6.4.14 Changing the lamellars
The lamellars have to be changed when subjected to wear. The wear makes itself known
when the brake moment is not longer achieved ( see Chapter 6.4.13, Lamellar brakes,

Instruction manual
page 11). The metallised lamellars are then worn down to the base of the oil and dust sep-
aration grooves. As a result, the main drive pinion or the oil stick between the lamellars,
thereby reducing the brake moment. Fit the lamellars in the correct sequence.
Illustration17: Lamellar brake

Instruction manual
6.4.15 Slack rope switch gear
Adjustment of switch 2
May, 2005
1. Loosen the clamp bolt (1.1).

2. Lower the load hook onto the deck and run out some slack rope.
3. turn the cam disc 1 by 1 cm clearance past switch 2 until the red pilot lamp is extin-
guished. Tighten clamp bolt 1.1
4. Repeat the lowering process.
The „lowering“ lift gear must be perfectly deactivated when the load hook is resting.
No rope layers are to jump over each other.
Illustration18: Slack rope switch

Instruction manual
6.4.16 Slip ring assembly
CAUTION
Prior to opening the slip ring assembly cover
• switch off the voltage
• protect the voltage against unauthorised activation.
1. The complete slip ring assembly including the brush holder and the insulating mate-
rial must be dry, dustless and free from grease.
The abrasion is to be carefully removed from the contact carbons.
Smoothen oxidised parts of the running surfaces with a fine emery cloth.
2. Inspect the jointed arms of the brush holders for well running and force of pressure
by lifting them.
Replace tight jointed arms and brush holders which have a too low force of pressure.
Check whether all of the brush holders are positioned centrally to the slip rings.
CAUTION
Under no circumstances are the joints of the brush holder or the ring surfaces to be
greased or oiled!
3. Replace heavily worn contact carbons and carbons with burnt spots with new ones.
The contact carbons are only to be worn down to max. 1/3 of the original length.
If new contact carbons are necessary, it is important that both carbons in the brush
holder are replaced and that only contact carbons from the same manufacturer are
used.
The life time of the carbons depends on the operating time and the speed of the slip
ring assembly so it is impossible to state exact changing intervals.
New contact carbons have to be ground into the ring radius in order to achieve a large
contact surface. This is achieved by placing the emery cloth on the ring surface and
pushing it back and forth underneath the new carbons several times in order to grind
the ring radius into the carbon. The resulting dust is to be removed.
4. Check the tight fit of the connection cable at the ring and the brush holders. If neces-
sary, re-tighten the bolts.
5. Check the shaft blind flange, the cable screwed connection and the profile rubber
sealing of the slip ring assembly housing for impermeability. defective parts have to
be replaced immediately in order to avoid moisture penetration.
6. Screw on the housing cover and check that it is tightly fitted.

Instruction manual
6.4.17 Load measuring bolts
May, 2005
Illustration19: Load measuring bolts

Instruction manual

Instruction manual
6.5 Maintenance, service and discard criteria for wire rope
May, 2005
NOTE
Maintenance at regular intervals ensures a safe crane operation and considerably
increase the rope life. When exposed to the same test condition, a well-greased rope
has produced four times as many working cycles than an ungreased rope.
6.5.1 Cleaning and greasing the wire rope
A crane rope is a moving and slightly twisting part, producing friction on the rope sheaves
and drums during operation.
1. Clean heavily soiled wire ropes with a brush. Should there be heavy soiling or rope
grease become resinous, clean the rope, rope pulleys and the rope drum with a non-
caustic cold cleaning agent and dry it afterwards.
2. Especially grease the rope at the bending zones (drums and pulleys). The lubricants
to be used are stipulated in Kapitel 6.8, List of lubricants, Seite 35. The re-greasing
agents are to be the same as those used for the original greasing of the rope.
CAUTION
Ensure that 3 safety windings remain on the drum when the rope is unwound. Grease
the ropes again with a suitable lubricant and operate the crane for some load cycles
without load in order to distribute the lubricant properly.
If the lower layers on the drum are seldom used or not at all, they are to be unwound and
replaced under pre-tension. A rope works most economically if the complete length is
always used. Therefore, it is recommended that the appropriate rope length be used fur
crane operations lasting longer periods of time.
Should parts of a rope be unequally loaded, one can turn the rope around after a certain
operation period. The end which was formerly free is fixed in the drum, so that the part of
the rope which was nor formerly used is positioned in the zone previously occupied by the
part exposed to wear, the part exposed to wear now being positioned where there is less
wear, this then resulting a noticeably longer useful life.
if the wear mainly occurs in the multiple-layer coiling on the lebus drum, the rope life can be
increased by cutting a length corresponding to 1/3 of the drum circumference. This can be
repeated max. twice.
6.5.2 Monitoring
If necessary, the wire rope and the fastenings of the rope end should be inspected for dam-
age on a daily basis. Any irregularities discerned are to be reported to the decision-making
party.
Wire ropes are to be inspected by trained specialists at regular intervals in order to ascertain
that they are in a safe operational condition. The inspection intervals are to be so deter-
mined that damage can be detected at an early stage. Therefore, the intervals during the
Copyright © 2005 17
Instruction manual
first few weeks of a new wire rope being laid on and after the first wire breaks are to be
shorter than during the remaining laying on duration. After being subjected to extraordinary
loads or if there is a suspicion of non-visible damage, the intervals are to be shortened
accordingly. Such an inspection is also to be carried after the crane is taken into operation
after it has been at a standstill for longer periods and after an accident or damaging event
which has occurred in connection with the use of the rope drive.
During this monitoring, special attention is to be paid to those parts of the rope which move
over the rope pulleys or which are close to differential pulley, rope suspensions or rope fas-
tenings.
Crane ropes are so designed that should an initial wire breakage take place, there is still
sufficient room for a safe laying on.
The operational safety of the rope can be determined on the basis of this criteria
• type and number of wire breakages,
• position and temporal succession of the wire breakages,
• reduction of the rope diameter during the period of operation,
• Corrosion,
• Abrasion,
• Rope deformations,
• Heat effects,
• Lay-on duration
Special attention should be paid to changes in the rope behaviour which are just discernible.
CAUTION
As soon as the rope lines strike together above the crane block, there is a risk of
serious rope damage. This twisting is always caused by an additional torsion in the
rotation-resistant hoisting rope originating from a number of adverse effects but it
may also be due to an overstitching of the hoisting rope during heavy duty operation.
The compensation of such a torsion requires extreme care and profound know-how.
Untwisting of the crane pulley block with rotation-stable rope fixed point:
1. Set the pulley block down.
2. Determine the direction of twist.
3. Detach the rope at the fixed point.
4. Carefully turn the rope at the free end by approx. 180-360 degrees to compensate
the pulley block twist. If necessary, determine the direction of the twist by means of a
string.
5. Reattach the rope at the fixed point.
6. Carefully lift the pulley block and operate the crane unloaded with a pulley block and
a crane trolley if one exists.
7. Repeat if necessary.
Ensure that the twist is distributed to a long free rope end. By operating the crane in an
unloaded condition, the twist is to be distributed along the entire rope length
18 Copyright © 2005
Instruction manual
CAUTION
Under no circumstances should a short length of rope be forcefully twisted; this may
permanently damage the rope structure.
May, 2005
If the hoisting rope was operated with an open swivel, an untwisting can be achieved by
operating the trolley several times under no load. If not successful, follow the same proce-
dure given for ropes with a fixed point, e. g. if no swivel exists or the rope is already dam-
aged or the reason for the twisting cannot be remedied otherwise.
The rope end connections and suspensions are also to be inspected in order to ensure that
they function correctly. The individual components of the rope drive unit, drums and pulleys
must turn freely in their bearings, grooves should not show any rope marks.
6.5.3 Wire changing
To avoid readjustments of the limit switches, please follow this procedure when changing a
wire.
Please note that the life of a rope depends on many influences. The ropes are mainly sub-
jected to internal friction and corrosion. However, a rope is to be changed after 5-6 years of
service.
1. Put the crane in its resting position
2. Slightly pull the luffing and hoisting wire.
3. Count the reels on the hoisting / luffing drum.
4. Make a note of the number of reels.
5. Remove the limit switch from the drum and secure it. Do not touch the shaft of the
switch.
6. Now change the rope.
7. When the new rope has been installed, count the reels. The number of reels must
agree with Pos. 4. Reinstall the limit switch.
8. For safety reasons, check the adjustments. Also refer to the assembly instructions for
the crane
6.5.4 Replacement state of wear
In the interest of safety in hoist operations, the wire rope must be replaced in good time. On
the basis of the criteria included in Kapitel 6.5.2, Seite 17, , the following information stipu-
lates when the wire cable is to be replaced depending on the scope of the damage. A con-
tinued use can result in the operation of the hoist posing a risk.
1. Type and number of wire breakages
Rope drives are so designed that the wire ropes are not durable. For this reason, wire break-
ages occur during operation.
A wire rope is to be replaced if one of the number of visible wire breakages stipulated in the
table on page 3 are determined.
2. Position of the wire breakages
The wire rope is to be replaced upon occurrence of wire breakage clusters. The wire rope
is to be replaced immediately should a strand break.
Instruction manual
Temporal sequence of the occurrence of wire breakages. In importance cases it may be

advisable to determine the number of wire breakages in relation to the time. From this, a
further increase in the number of wire breakages and the expected time of replacement can
be concluded.
In doing so, it should be taken into account that the initial wire breakages occur after a cer-
tain operational period and subsequently increase at a faster rate.
3. Reduction of the rope diameter during the period of operation
The wire rope must be replaced if the rope diameter is reduced by structural changes by
15% or more along longer lengths, when compared with the nominal size.
The requirement for this is that the tolerances of the new wire rope are also adhered to in
accordance with DIN 3055 - DIN 3070 even if the wire rope is not of a standard design.
4. Corrosion
Corrosion especially occurs when subjected to a saltwater atmosphere, with operation in a
corrosive atmosphere and with wire ropes which are laid on outside for longer periods. A
corrosion of the external rope can be determined by examination. Corrosion on wires which
cannot be perceived from the outside is difficult to determine.
Corrosion can reduce both the static breaking force of the wire rope due to a reduction of
the metallic cable cross section and the operational capacity due to corrosion pit.
If the rope diameter is reduced by 10% or more when compared with the nominal size, the
wire rope is also to be replaced if no wire breakages are determined.
5. Abrasion
Abrasion on the rope wires as „internal abrasion“ resulting in the movement of the strands
and wires against each other when bending the wire rope and as „external abrasion“ result-
ing from movements between the wire rope and the rope groove (e.g. due to the wire rope
slipping in the groove when starting and braking) or as a result of the wire rope trailing along
the floor or the items to be hoisted. Abrasion is encouraged by insufficient or no lubrication
and the effects of dust.
Abrasion can reduce both the static breaking force of the wire rope due to a reduction of the
metallic cable cross section and the operational capacity due to wear chamfer.
If the rope diameter is reduced by 10% or more when compared with the nominal size, the
wire rope is also to be replaced if no wire breakages are determined.
6. Rope deformations
Deformation of the wire cable and visible changes in the rope bond. On the basis of their
appearance, differences are made between the following deformations:
Deformations in corkscrew form, contractions,
Basket formation, flattening,
Looping of wires, curl-shaped deformations,
Loosening of individual wires or strands, kinks and knots, buckling.
Deformations normally result in a loosening of the rope structure, at least close to the defor-
mation location. If the deformations are in a corkscrew form (see figure), the axis of the non-
loaded wire rope is helical.
Instruction manual
May, 2005
Number of visible wire breakages when wire rope is to be replaced

driving gear groups driving gear groups
Number of bearing wires
1E m , 1D m, 1C m , 1B m 1A m 2 m, 3 m , 4 m , 5 m
in the external strands of
3 crosslay long lay crosslay long lay
the wire rope )
along a length of along a length of along a length of along a length of
6d 30d 6d 30d 6d 30d 6d 30d
Bis 50 2 4 1 2 4 5
51 bis 75 3 6 2 3 6 12 3 6
76 bis 100 4 8 2 4 5 16 4 ~8
101 bis 120 6 10 2 6 10 19 ~ 10
121 bis 140 6 11 3 6 11 22 6 11
141 bis 160 6 13 3 6 13 26 6 13
161 bis 180 7 14 4 7 14 29 7 14
181 bis 200 8 16 4 8 16 12 8 16
201 bis 220 9 18 4 9 18 35 9 18
221 bis 240 10 19 5 10 19 38 10 19
241 bis 260 10 21 5 10 21 42 10 21
261 bis 280 11 22 6 11 22 45 11 22
281hi.300 12 24 6 13 24 48 12 24
4
über 300 ) 0.04 n 0.08*rn 0,01*n 0.04*n 0.08*n 0,16*n 0.04*n 0.08*n
With rope designs with specially thick wires in the external layer of the external strands, e.g. 6 x 19 Seale-
type round stand rope in accordance with DIN 3058 or 8 x 19 round strand rope in accordance with DIN
3062, the number of visible wire breakages are to be seen as being 2 lines less than the table values.
Driving gear groups in accordance with sheet 1 of DIN 15 020.
d wire rope diameter

3) Filler wire is not seen as being bearing
If wire ropes have numerous strand layers only the strands in the exterior strand layers are "external
strands".
If steel ropes have a steel reinforcement, only the reinforcement us is to be seen as being an interior
strand.
4) The calculated figures are to be rounded up.

Instruction manual
Instruction manual
6.6 Gear cam limit switch
Every person involved in operation, maintaining and repairing the limit switch must
May, 2005
be authorized, adequately trained and instructed.
MAINTENANCE
When carry-out maintenance and inspection works, pay attention to chapter „Safety instruc-
tion“
Generally no maintenance or inspection works at the geared limit switch are necessary. Do
not remove dust deposits on the contacts or in the contact space by means of compressed
air. The dust would penetrate into the contacts and would affect the switching capacity.
Do no use benzine for cleaning of the limit switch. #the cap sealing has to be replaced
after having opened the cap after a longer period of operation.
CONTACT ADJUSTMENT
Each contact is co-ordinated by an adjustable pack of cam discs consisting of the cam discs
(6) and (7). The cam disc packet and the selector shaft are held in the selector shaft groove
by means of a ring (2) and the toothing of the disc.
The cam disc part (7) is infinitely adjustable in a radial direction by slewing the self-locking
screw (8) in a ratio of 74 : 1. An extremely fine adjustment is possible with the turn of a
screwdriver.
In order to reach the screw (8) with a screwdriver, the nut (3) must be loosened somewhat.
The corresponding cam disc pack can then be radially adjusted without the other cam disc
packs being adjusted.
The cam disc (7) is designed in such a way that the effective path and an overrun path are
provided. No damage is caused by an exceeding of the overrun path but there is once more
an opening or closing of the contact.
(see Kapitel 12.2, Spare Parts Catalog, Seite 127).
Adjustment of crane cam discs (see Kapitel 6.6.1, Setting of the limit switch, Seite 24)
Illustration20: Gear cam limit switch
Instruction manual
6.6.1 Setting of the limit switch
Home position :
Jib is in the park position
All LED´s 0-13 on module 1A5 of the PLC in the electric cabinet are on, i.e. all contacts for
the limit switch are closed.
Cam controllers for luffing gear WW0 and WW1 and WW2 switch during lowering.
Cam controllers luffing gear WW4, WW5 and WW6 switch during hoisting.
Cam controllers hoisting gear HW1,HW2, HW3 switch during hoisting.
Cam controller hoisting gear HW6 switches during lowering.
Direction of rotation A on the gear side = lower
Direction of rotation B on the gear side = hoist
The direction of rotation is opposite on the cam controller side
(see illustration 21, page 26)
6.6.2 Perform the following work
1 Jib is in the park position, turn cam WW0 on luffing gear limit switch
towards "B" until the LED 6 on the 1A5 goes out. (see illustration 22,
page 27)
2 Measure maximum length from the middle of the crane's pivot to the
middle of the hook.
Luff up the jib - up to the measured point (maximum length of jib)
Turn cam WW1 on the luffing gear limit switch (see Fig. 2) in the direc-
tion "B" until LED 7 on the 1A5 goes out.
3 Move bottom hook block to around 1m below the jib head.

Turn cam HW1 on the hoisting gear limit switch in the direction A until
the LED 0 on the 1A5 goes out.
4 Turn cam HW2 on the hoisting gear limit switch (see illustration 21,
page 26) in the direction A until LED 1 on the 1A5 goes out, then back
again in the direction B so that the LED1 only just comes on again.
5 Run-on stage for bottom hook block.

Measure 27,5m length of jib from the middle of the crane pivot to the
middle of the hook.-Luff up jib to the measured point.
Turn cam WW2 on the luffing gear limit switch in the direction A until
the LED 8 on the 1A5 lights.
Move bottom hook block again to around 1m below the jib head.
The rope from the hoisting gear can be wound twice around the
drum.
Turn cam HW3 on the hoisting gear limit switch in the direction A until
6 Measure 6m length of jib from the middle of the crane pivot to the mid-
dle of the hook.
Instruction manual
Luff up jib to the measured point (6m).
(This is where the speed reduction range 6.0m -3.5m begins for the
jib.)
May, 2005
7 Measure 4.5m length of jib from the middle of the crane pivot to the
middle of the hook.
Luff up jib to the measured point.
8 Turn cam WW7 on the luffing gear limit switch in the direction A until
9 Move the bottom hook block down until the hook is approx. 1m above
the double bottom. There must be at least 3 safety windings left on
the hoisting drum.
Turn cam HW6 in the direction B until LED 5 on the 1A5 goes out.
10 After adjusting the end-of-travel switch, run through the luffing and
hoisting gear.
When luffing down the jib and switching off the hoisting gear the jib
may not touch the bottom hook block.
When lowering the jib from the upper position the jib switches of at a
length of 27,5m. Only when the bottom hook block is lowered can the
jib be extended to the max. length.
11 Slew the crane into the park position.

Press the key switch „Park position“ and hold down, the jib moves to
the park position.
Instruction manual
Illustration21: Limit switch adjustment hoisting gear
Instruction manual
May, 2005
Illustration22: Limit switch adjustment luffing gear
Instruction manual
Illustration23: imit switch adjustment jib
Instruction manual
6.7 How do I exchange a Memory-Programmable Control (MPC)?
Designation of the instruments
May, 2005
PS 4--201-MM1
EM 4-201-DX2
LE 4-116-DX1
LE 4-116-DX1
One of these instruments must be changed if 24 VDC is at the input but the input LED is not
illuminated
If an output LED is illuminated but no 24 VDC has been applied Check in advance whether
the power supply for the outputs are working
The PS4 is also to be replaced if the POWER LED is no longer illuminated but the power
supply has been applied
If the RUN LED flash, the PS4 or a EM4/LE4 could be defect.
Before replacing an instrument, disconnect the power supply.
PS4:
Disconnect wiring of the power supply (see Figure 1).
Open the cover of the input and output terminals (see Figure 2 Do not disconnect the
wiring
Pull the cover to disconnect the plug (see Figure 3)
After the new PS4 has been installed, the memory is to be inserted. (see Figure 5-6).
EM4:
Disconnect the wiring of the power supply lines (see Figure 7
Open the cover of the input terminal (see Figure 8). Do not disconnect the wiring of the cable
Pull the cover to disconnect the plug (see Figure 9) Open the cover in the middle and
release the data lines to the next LE (see Figure 10 Now release the plug of the data line of
socket 1 (see Figure 12). This data line connects the PS4 with the EM4.
The EM4 can be removed from the top hat rail after all wires have been released.
Before the new EM4 can be switched on, all codification switches are to be adjusted
following the instructions given in the electric diagram (see Figure 13).
LE4:
Open the cover of the input or output terminals (see Figure 14).
Do not disconnect the wiring
Pull the cover to disconnect the plug (see Figure 15) Then open the cover in the middle and
release the data lines to the other LE4 (see Figure 16).
The instrument can now be removed from the top-hat rail.
6.7.1 Changing the battery.
(see Fig. 16)

Only change the battery when switched on as there could otherwise be a loss of data.
when changing the battery
Instruction manual
Only disconnect the plug when switched on!

Caution:
Change the battery every year!!!
Prove that the battery has been changed with date and signature
Instruction manual
PS4.
Fig.1 Fig.2
May, 2005
Fig.3 Fig.4
memory card switch to position 3
Fig.1 Fig.2
Fig.5 Fig.6
insert memory card break button

Instruction manual
Fig.7 Fig.8
Fig.9 Fig.10
Fig.11 Fig.12
1
Codierschalter
Instruction manual
Fig.13 Fig.14
May, 2005
Fig.15 Fig.16
Battery
Instruction manual
Instruction Manual
Board crane type: DK II NMF
6.8
Neuenfelder Schmierstofftabelle für Schiffshilfsmaschinen
NMF Maschinenfabrik GmbH
21129 Hamburg Table of Lubricant for Hull Auxiliaries
BEDINGUNGEN / CONDITIONS 2003
List of lubricants
Außentemp. x)
Viskosität Hydraulikanlagen in:
Outdoor Pourpoint ELF BP Castrol Exxonmobil SHELL FAMM Füllmenge
Viscosity Hydr. Equipm. Installed in:
temp. Oil Quantity
Tief -20°C Bordkran/Deck Crane 1200 l
Low Lastdrehvorrichtung
l
Univis Rando oil Load Turning Devise
Visga Bartran Hyspin N 46 Tellus oil HDZ 46 Spannwinde
l
46cST/40°C <-15° 46 HV46 AWH-M 46 Nuto T 46 HD46 Span winch
ISO VG 46 Vitam H 46 Rudermaschine
l
HF 46 Mobil DTE Steering Gear
Normal 45°C 15 M Sonstige hydr. Anlagen
l
Normal Other hydr. Drives
Tief -30°C Hubwindengetriebe x ) 18,0 l
1
Low Cargo Winch Gear
Hangerwindengetriebe x ) 15,5 l
1
Spartan Omala Topping Winch Gear
SEP HD Drehwerksgetriebe x ) 2x25,0 l
1
220 Turning Gear
. Hilfswindengetriebe l
220cST/40°C <-25° C Syntherma Enersyn Alphasyn Mobil Tivela Pinnacle Auxiliary Winch Gear
ISO VG 220 P 270 HTX HG SHC 630 WB Marine Bootswindengetriebe l
Synthetical 220 220 GEL Boat Winch Gear
PAO Oil Kabeltrommelgetriebe l
Cable drum gear
Sonstige Getriebe l
Other Gears
Normal 45°C Pumpenverteilergetriebe x ) 7,5 l
1
Normal Pump Distribution Gear
Achtung: Synthetisches Getriebeöl auf PAO- Energrease Spheerol MobilTac Alvania Offene Zahnradgetriebe 30 kg
Basis darf nicht mit synthetischen Getriebeöl auf MP-MG2 SX2 375 NC EP2 OpenToothed Gearings
Polyglykolbasis gemischt werden. Cardrexa Energrease Spheerol Mobilarma Novatex
Ölwechsel und Fettschmierintervalle siehe DC1 MP-MG 2 SX2 798 EP2 Seile
Wartungsanleitung 50 kg
Mobil Grease Novatex Rope
XHP 222 FK10
Attention: Synthetically gear oil on PAO-base EPEXA 2 Energrease Spheerol Mobil Grease Alvania
may not be mixed with synthetically gear oil on MP-MG 2 SX2 XHP 222 G2 Lager(Fettschmierung)
polyglycol base Mobilith Bearings (Grease Lubrication) 30 kg
Oil change and greasing intervals see SHC 460
maintenance instruction.
x) für einen Kran/for one crane
x1)Werksfüllung/filling in the factory Erzeugnis/Produkt
Auftrag/Order NB/Hull No.
R 06/03
35
Instruction manual
Instruction manual
7 Functional description of hydraulic
The numbers in brackets refer to the circuit diagram with the drawing no. 845-4900-05(1)
May, 2005
7.1 General aspects

The crane drives work electro-hydraulically and in a closed circuit. The electric motor [1.0]
drives the reversible axial piston pumps [3.0-5.0] via a distributor gear [1.1]. The power pack
[1] is flexibly supported and connected to the consumers with high pressure hoses.
Each of the axial piston pumps [3.0-5.0] is fitted with an integrated, externally control and
lighting pumps [2.0]
The oil flow hoisting device of the axial piston pumps [3.0-5.0] are reversed by electro-
hydraulic proportional valves and current regulator print cards.
Both the complete systems and the individual functions are protected against overload by
means of pressure limitation valves.
Electro-hydraulic manometric switches for the monitoring of the feed pressure are also
installed in the pressure lines. These manometric switches immediately interrupt the control
voltage by a pressure loss or line breakage, the electric motor [1.0] is cut-off.
The niveau switch [2.5] in the hydraulic oil tank [2.8] also cut off the system in should there
be an oil loss. This protects the pumps [3.0, 4.0 and 5.0] from running dry and avoids heavy
hydraulic oil losses.
7.2 Starting the pump unit

The electric motor [1.0] runs in star/delta connection. The gear oil cooler [1.2] starts at an oil
temperature of 20 °C. The 4/2 way valve [2.2] valve is energized and interrupts the pres-
sureless circulation of the control and feed oil for the control and feed pumps [2.0].
When all of the pressure switches [3.4], [4.4], [5.3] and [5.4] in the system lines have been
actuated by accumulated pressure, the green pilot lamp is illuminated. The vent flaps [2.7]
are automatically opened by the control pressure. During the crane operation, the heated
hydraulic oil is fed to the hydraulic oil tank [2.8] through the feed-out valves [2.1] at a rate
of 20 l/min. Cooled hydraulic oil is redelivered by the control and feed pumps [2.0] through
the combined pressure limitation valves with delivery valves [3.1], [4.1] and [5.2]. Excess
overpressure oil from the pressure control valves [2.1] of the control and feed pumps [2.0]
flows back into the hydraulic oil tank [2.8].
7.3 Venting
The spring-loaded vent flap [2.7] is automatically hydraulically opened when the power pack
is started.
Air and oil warmed during the crane operation to a temperature exceeding 40°C is drawn-
off through the open vent flap [2.7] by automatically starting oil-oil coolers [2.6].
7.4 Heating/Cooling system

Electrical heating elements are installed in the hydraulic oil tank [2.8] and the crane housing.
The room heaters are controlled by thermostats and cut-off at an ambient temperature of
20°.
Copyright © 2005 Functional description of hydraulic 1

Instruction manual
A thermic sensor controls the oil temperature in the hydraulic oil tank. The tank heater [2.4]
is actuated when the oil temperature is below 20°. When the oil temperature reaches ca.
22°, the tank heater [2.4] is switched off and the air-oil coolers [2.6] started at 40°C.
At ca. 85°oil temperature, all of the controls are interrupted, no functions work. The pump
unit and the air-oil coolers [2.6] continue to run, the vent flap [2.7] remain closed.
7.5 Function of the electro-hydraulic control

The servo valve [2.1.2] uses an external, electrical input signal at the pressure control pilot
valve [2.1.1] of the solenoid. The pressure control pilot valve [2.1.1] works on the basis of
a nozzle-swashplate principle and creates a hydraulic differential pressure which is propor-
tional to the electrical input signal.
The servo valve [2.1.2] converts the electrical input signal to a position controlling output sig-
nal. This position controlling signal determines the angular rotation of the displacement
pump.
The displacement volume of the displacement pump is proportional to the electrical input
signal. A mechanical feedback to the swashplate retains the pre-selected swashplate posi-
tion and stabilises the displacement volume which has already been selected. This makes
the handling of the working functions fast, exact and safe.
2 Functional description of hydraulic Copyright © 2005

Instruction manual
May, 2005
Illustration24: Pump diagram
7.6 Hoisting gear

7.6.1 Hoisting of the nominal load
By shifting the hoisting gear control lever, the electrical pump control solenoid „a“ and the
way valve [3.8] are provided with voltage. The cargo winch brake [3.9] opens. The hoisting
gear pump [3.0] moves out of the „0“ position proportional to the position of the control lever.
The variable cargo winch motor [3.11] is kept at Qmax. by the load pressure and controls
itself automatically in accordance with the corresponding load pressure.

Instruction manual
In case of overload, the load pressure switch [3.5],0-45 t; [3.6] 0-16-40t is actuated by the
load pressure. The solenoid „a“ at the electrical pump control [3.1.2] and the way valve [3.8]
are without voltage.
The hoisting gear pump [3.0] is pressed against the „0“ position by springs and the cargo
winch brake [3.9] immediately applies. In case of overburden, the pressure relief valve [3.1.]
responds.
In the upper hook position, the hoisting function is cut-off by a limit switch, the cargo winch
brake [3.9] immediately applies
However, a lowering operation is possible.
7.6.2 Function of half load (Set load range selector to 16 tons)
The way valve [3.10] is provided with voltage. The cargo winch motor [3.11] swivels to. and
is held in position by the load pressure.
Changing the swivel angle of the variable cargo winch motor [3.11] reduces the displace-
ment and increases the output speed. Simultaneously however, the torque related to the
operating pressure and the swivel angle also change.
If the load to be handled is heavier than 16t, the cargo winch brake [3.9] nevertheless opens
but it is then immediately applied. The increasing pressure in the hoisting line actuates the
load pressure switch [3.5]. The way valve [3.8] and the electrical pump control [3.1.1] are
without voltage. Shift control lever immediately into „0“ position, otherwise the hoisting gear
jerks. Set the load range selector to nominal load.

Instruction manual
May, 2005
Illustration25: Half load function

Instruction manual
7.6.3 Hydraulic overload cut-off
Each of the axial piston pumps 3.0 - 5.0 disposes of its hydraulically actuated pressure cutter
3.1.1+4.1.1+5.1.1. These are connected to the high pressure lines. In comparison with the
electro/hydraulic load pressure switches their setting is somewhat higher.
The pressure cutters 4.1.1+5.1.1 of luffing gear pump 4.0 and turning gear pump 5.0 are set
somewhat lower than the pressure relief valves 4.1- 5.2.
In case of overload the relating pressure cutter comes out of the centre position by means
of the system pressure. The control pressure oil for pump adjustment flows through the pres-
sure cutter in the hydraulic oil tank. The cervo control valve is pressed against neutral posi-
tion by springs. It now delivers just so much pressure oil to hold the load, as the still open
brake will not yet apply.
Return control lever to zero position an select appropriate load range.

Instruction manual
7.7 Luffing gear
May, 2005
7.7.1 „Luffing up“
When the luffing control lever is shifted the way valve [4.6] is provided with voltage. The
released control pressure now opens the luffing winch brake [4.7].
When the jib passes the ca. 70° position, the luffing up speed is reduced and completely
stopped with a minimum outreach. The way valve [4.6] is without voltage and the luffing
winch brake [4.7] applies, luffing down is possible. In case of overburden, the pressure cut-
off valve [4.1] is actuated at the luffing gear pump [4.0]. (see , page 6).
7.7.2 „Luffing down“
The function of the luffing down is the same as with the luffing up. It is restricted by a limit
switch and the max. outreach position.
Important Note:
The key switch „rest jib“ is only to be used when the jib is to be lowered down into the resting
position. When the key switch is actuated, all limit switches are not activated, only the limit
switch for the 0° jib position still functions, this stops the luffing down function. A minimum
of three safety windings of the rope remain on the luffing winch drum. Luffing up is possible.

Instruction manual
7.8 Turning gear
7.8.1 Turning „RIGHT-LEFT“
When the turning control lever is shifted the way valve [5.5] is provided with voltage and the
turning gear brakes [5.7] When the control lever is returned to the neutral position, the turn-
ing gear pumps [5.0] turns to the „0“ position. Due to an electrical time relay, the turning gear
brakes [5.7] close slowly. This results in the crane slowing down smoothly. By overburden-
ing, this being a turning against the heel with load and a large outreach, the pressure cut-off
valve [5.1] at the turning gear pump [5.0] is triggered. (see , page 6). Shift the control lever
into a neutral position and luff up the jib to reduce heel.

Instruction manual
8 Hoisting of brakes in case of emergency
Should there be a total power failure, the crane can be slewed to its resting position and the
May, 2005
load be lowered if necessary.

The working steps are described on the following pages.
Important Note:
Under no circumstances are the working lines A and B between the pump and the winch
motor to be disconnected or connected to each other as if the lamella brake is opened using
the brake hoisting pump, the load is immediately dropped. Life is placed at a risk and exten-
sive material damage is caused.
8.1 Hoisting gear

For this, the following is necessary:
1. open the ball valve „by-pass“ (6.0) (see illustration 30, page 3),
2. small wheel at the throttle valve (6.1) turn a one turn outwards. (see illustration 30,
page 3),
3. with the brake lifting pump lift the gear brake. (see illustration 32, page 5).
8.1.1 Connect the hand pump for opening the brakes as follows.
1. Find the solenoid valve block (see illustration 31, page 4) and the marking for the
hoisting gear brake.
2. Disconnect the brake hose 5 of the hoisting gear brake to the solenoid valve (see
illustration 31, page 4).
3. Connect the hose 2 of the hand pump (see (see illustration 32, page 5)) to the brake
hose 5.
4. Plug the connection to the solenoid valve of the hoisting gear using a screwed plug.
5. Connect the pressure release valve 5 to the hand pump for hoisting the brake and
check the oil level in the pump tank (see illustration 32, page 5).
6. Carefully increase the pressure at the hand pump (max. brake opening pressure ca.
20 bar) until the winch drum starts to rotate slowly (max. 2-3 rpm). If the winch drum
rotates faster immediately open the pressure release valve 5 for the hand brake
hoisting pump.
CAUTION:
If the hook is under load, the jib already lowers the load at a braking air pressure of
3-4 bar. When the hook is under load, the braking torque is reduced by 30%.
7. After the load is lowered, restore the original situation.

• close and secure the ball valve „by-pass“ (6.0)
• small wheel at the throttle valve (6.1) turn again screwing in.
Copyright © 2005 Hoisting of brakes in case of emergency 1

Instruction manual
8.2 Jib
luffing gear brake.
2. Disconnect the brake hose 4 of the luffing gear brake to the solenoid valve (see illus-
tration 31, page 4).
3. Connect the hose 2 of the hand pump (see illustration 32, page 5) to the brake hose
4 of the luffing gear brake.
4. Plug the connection to the solenoid valve of the luffing gear using a screwed plug.
5. Connect the pressure release valve 5 to the hand pump and check the oil level in the
pump tank (see illustration 32, page 5).
6. Open the corresponding bypass valves 4.1 und 4.2 on the luffing gear hydraulic
pump. (see illustration 33, page 6)
7. Carefully increase the pressure at the hand pump until the winch drum starts to rotate
slowly (max. 2-3 rpm). If the winch drum rotates faster immediately open the pres-
sure release valve 5 for the hand brake hoisting pump.
8. After lowering the jib, restore the original situation.
CAUTION:
Due to the tare weight of the jib, this already lowers at a hand brake air pressure of 3-
4 bar. This reduces the braking torque by 30%.
8.3 Slewing gear

slewing gear brake.
2. Close the ball valve (1).
3. Remove the screwed plug underneath the ball valve.
4. Connect the hand pump hose to the screwed connection.
5. Connect the pressure release valve 5 to the hand pump and check the oil level in the
pump tank (see illustration 32, page 5).
6. Open the corresponding bypass valves 4.1 und 4.2 on the luffing gear hydraulic
pump. (see illustration 33, page 6)
7. Increase the pressure at the hand pump. The brakes are now fully open at 20 bar, the
slewing gears are free. The crane can be turned with the assistance of an external
winch.
8. To close the brakes, open the pressure release valve 5 at the hand pump for hoisting
the brake.
9. After completing the work, restore the original situation.
CAUTION:
When releasing the brake, take care of the heel/trimming of the ship.
2 Hoisting of brakes in case of emergency Copyright © 2005

Instruction manual
May, 2005
6.0
„ON“
6.1
Illustration 30: Ball vlave „By-pass“

Instruction manual
Illustration 31: Connections for the solenoid valve block
1. =ball stop valve

2. =close fitting /connection for hand pump
3. =Brake hose slewing gear
4. =Brake hose luffing gear
5. =Brake hose hoisting gear
6. measuring connection
y=measuring connection
3.8 Solenoid valve for the hoisting gear break
4.6 Solenoid valve for the luffing gear break
5.5 Solenoid valve for the slewing gear brake
2.2 Solenoid valve for the bypass

Instruction manual
May, 2005
Illustration32: Brake lifting pump

Instruction manual
Illustration33:

Instruction manual
9 Illustration
May, 2005
Illustration34: Pump unit
Copyright © 2005 Illustration 1

Instruction manual
Illustration35: Load measuring system
2 Illustration Copyright © 2005

Instruction manual
May, 2005
Illustration36: current pilot print card


Instruction manual
Illustration37: Emergency exit

Instruction manual
May, 2005
Illustration38: Interfrence pilot print card

Instruction manual
Illustration39: Gear oil cooler

Instruction manual
May, 2005
Illustration40: Reset-Switch

Instruction manual

Instruction manual
10 Spare parts
May, 2005
10.1 Ordering spare parts

Use only original NMF-spare parts because these parts are designed specially for the crane.
It is not ensured that externally produced parts are designed and manufactured to meet the
wear and safety demands.
The drawings of the spare parts are our possession and are copyrighted according to legal
requirements. They may be used and utilised as well as made available to third parties only
with our written consent. Objects manufactured due to these drawings may be photo-
graphed only with our written consent. Unauthorised use or utilisation has consequences
according to civil - and criminal law.
Copyright © 2005 Spare parts 1

Instruction manual
Ersatzteilbestellanleitung/How to order spare parts

Für die Bestellung von Ersatzteilen sind folgende Angaben erforderlich:
When ordering spare parts the following data are necessary:
Auftrags-Nr./Order -No.
Erzeugnis/Product Siehe Typenschild/See type plate
Typ/Type
Zeichnungs-Nr. Teil Benennung Menge

Drawing -No. Part Denomination Quantity
879-4900-01(0) 20 4/2 Wegeventil 1 Stück
4/2 Way solenoid valve 1 piece
P10P
Diese Darstellung(Zeichnung, Skizze, Fotografie, Plan ,Liste u.a.) ist unser Eigentum
und nach Maßgabe der gesetzlichen Bestimmungen urheberrechtlich geschützt. Sie darf
ohne unsere schriftliche Einwilligung weder benutzt noch verwertet, insbesondere nicht
Dritten zugänglich gemacht werden. Aufgrund dieser Darstellung hergestellte
Gegenstände dürfen ohne unsere schriftliche Einwilligung nicht fotografiert werden . Die
unbefugte Benutzung oder Verwertung hat zivil- und gegebenenfalls auch strafrechtliche
Folgen.
We have the proprietary right in this presentation (drawing, sketch, photo, plan,
statement etc.) which is copyrighted according to provision of law. Without written
consent it must neither be used or exploited nor made available to third parties. Photos
from the goods manufactured according to this presentation must not be taken without
our written consent. The unauthorised use or exploitation is liable to civil or - should the
case occur- penal prosecution.
2 Spare parts Copyright © 2005

NMF-Auftragsbezogene Stückliste
NMF-partlist
Zeichnungsnummer Benennung Auftragsnummer Auftragsmenge Artikelnummer/Item-No.
Drawing-No. Designation Order No.: Quantity
840-9900-02(o.Z.) Reserveteilliste 80107/000 1,00 840-9900-02
Pos Zeichnungsnummer Stk. Benennung DIN-Nummer/DIN-No. Artikelnummer Strukturmenge Gewicht Beistellung

Item Drawing-No. Qty. Designation Werkstoff/Material Item-No. qry of structure Weight Supply
01 1,00 1 0,00
Handhebelfettpresse
besteht aus Pos.02-04
Manual grease gun
consists of items 02-04
02 1,00 HANDHEBEL-FETTPRESSE PK 56 1250ft010 1 0,00
OHNE SCHLAUCH
grease gun PK 56
03 1,00 SCHLAUCH 160L 300 MM LANG 1250ft011 1 0,00

FÜR HANDHEBELFETTPRESSE
04 1,00 KUPPLUNG 521A F.FLACHKOPFNIPP. 1250ft005 1 0,00

M10x1 u.R¼""),m.DREHGELENK 140
coupling
05 1,00 GLYCERIN-MANOMETER 1680mn003 1 0,00

63 MM, 60 BAR
pressure manometer
06 1,00 GLYCERIN-MANOMETER 1680mn005 1 0,00

63 MM, 400 BAR
pressure manometer
1 = NMF-Beistelllung Rohmaterial / NMF scope of supply raw material Gesamtgewicht: ca. 0,00 Kg
2 = NMF-Beistellung Fertigteil / NMF scope of supply finished part
3 = NMF-Fertigung und Einbau / NMF production and mounting Seite 1 von 10
NMF-partlist

07 2,00 MANOMETERMESSSCHLAUCH DN2 1681mn202 1 0,00

BMT 50.80.XX 400mm LANG
monometer hose
08 1,00 1 0,00
Bremslüfthandpumpe
manual pump for brake
Entnahmeschein
09 1,00 SEILEINZIEHSTRUMPF 1980sl001 1 0,00
TYP 30 - 39
wire rigging socks
10 10,00 SHELL ALVANIA FETT RL 2 3000ft004 1 0,00

IN KARTUSCHEN ZU 400 GRAMM
grease SHELL RL 2
11 10,00 FLACHKOPFSCHMIERNIPPEL M 1, 3000sn004 1 0,00

M10x1,DIN3404,MESSING
flat grease nippel
12 1,00 4/2 W.-VENTIL, ELEKTR.BETÄTIGT 2600vt039 1 0,00

4D01-3111-0101-B1-GOQ S. ZU
4/2 way valve
13 10,00 O-Ring/o-ring für 4D01 2423or011 1 0,00

691-000-12
o-ring for HD-hose
NMF-partlist

14 3,00 FILTERERSATZELEMENT 1262fi321 1 0,00

E 2.460 H 20 SL-AOO-O-P
filter element
15 3,00 ERSATZPATRONE 0160 MG 010 P 1262fi200 1 0,00

NO. 249005 F.FILTER MF160 G10-
filter element
16 5,00 O-Ring 9x2 NBR 70 2423or002 1 0,00
o-ring for HD-hose
17 5,00 O-Ring 13x2 DN 12 2423or003 1 0,00

für HD-Schlauch
o-ring for HD-hose
18 5,00 O-Ring 17x2,5; NBR 70 2423or004 1 0,00
o-ring for HD-hose
19 5,00 O-Ring 22x2,5 2423or005 1 0,00

NBR 70
o-ring for HD-hose
20 5,00 O-Ring 27x2,5 DN 25 2423or006 1 0,00

für HD-Schlauch
o-ring for HD-hose
NMF-partlist

21 5,00 O-Ring 35x2,5 DN 32 2423or007 1 0,00

für HD-Schlauch
o-ring for HD-hose
22 5,00 O-Ring 48x3; NBR 70 2423or008 1 0,00
o-ring for Hd-hose
23 5,00 O-Ring 32,92x3,53 (SAE 1") 2423or009 1 0,00

NBR 70
o-ring for HD-hose
24 5,00 O-Ring 37,69x3,53 SAE 1 1/4" 2423or010 1 0,00

NBR 70
o-ring for HD-hose
25 4,00 Ermeto-Verschraubung g08sa3cx 1 0,00

G16-S
NMF-partlist

33 4,00 Ermeto-Verschraubung g35la3cx 1 0,00
NMF-partlist

36 2,00 SAE-VERSCHLUßFLANSCH AFC-404M 1343fl330 1 0,00

1 1/4"" 6000 PSI
37 2,00 SAE-VERSCHLUß-GEGENFLANSCH 1343fl350 1 0,00

GFC-404 1 1/4"" 6000 PSI
38 4,00 Ermeto-Verschraubung vka08bpa3c 1 0,00
NMF-partlist

NMF-partlist

49 E558-04(4) 1,00 OELAUFFUELLAGGREGAT 230V/60Hz 1020ag101 1 0,00

AUS WERKAUFTRAG 2393/...
50 625-5000-02(1) 1,00 TRANSPORTABLES PUMPENAGGREGAT 625-5000-02 1 0,00
51 1,00 1 0,00
Hubseil; Ø36 mm; 235 m

cargo runner
840-0900-65(0)
52 1,00 1 0,00
Hangerseil; Ø36 mm; 196 m

span runner
840-0900-65(0)
58 1,00 HD-Schlauch DN6-2SN dn06-001-gl 900 0,00
DKO-8S-DKO-8L
840-4900-05 (1) Pos.62

DKOS-DKOS90°
840-4900-05(1) Pos.58
NMF-partlist


DKOS-DKOS
840-4900-05(1) Pos.75
61 1,00 HD-Schlauch DN20-4SP dn20-012-gl 1000 0,00

DKOS-SFS 90° ¾"-6000Psi
840-4900-05(1) Pos.93
62 1,00 HD-Schlauch DN32-4SH dn32-011-gl 3900 0,00

DKOS-SFS 90° 1¼"-6000Psi
840-4900-05(1) Pos.84

DKOL-DKOL90°
840-4900-05 (1) Pos.89
64 1,00 HD-Schlauch DN40-4SH dn40-008-gl 4300 0,00

SFS 90° 1¼-SFS 90° 1½"-6000Psi
840-4900-05(1) Pos.109
71 1,00 STROMREGELKARTE SRK 04 1810pr017 1 0,00

STROMBEREICH 0-1000 mA
73 1,00 KOMPAKTSTEUERUNG PS4-201-MM1 1170es010 1 0,00

KLÖ-MOE NR 051296
NMF-partlist

74 2,00 SPEICHERMODUL ZB4-128-SF1 1170es012 1 0,00

KLÖ-MOE NR. 050 189
75 1,00 GLEICHRICHTER B 250-25 1420gr001 1 0,00

CONRAD NO. 501158-66
76 1,00 NAV - LAMPE HD 1650le901 1 0,00

250 W E 40
77 2,00 POTENTIOMETER B5 MIT PLATINE 1800pt008 1 0,00

ESS084
78 2,00 SCHALTKONTAKTE 3RT1956-6A 2364su724 1 0,00

wird ersetzt durch 2364su730
79 2,00 Schaltkontakte 3RT1965-6A 2364su729 1 0,00

für Siemens Schütz 3RT1065-6AP
80 10,00 GLÜHLAMPE 30 V BA 9S 1055bt003 1 0,00

3SB 1902-2AF
Instruction manual
11 Subcontractor documentation
May, 2005
Item.no Denotation Typ Manufacturer

.
1 Regulating Axial Piston Pump A4VG 125 Drehwerk 1831PA290

A4VG 125 Wippwerk 1831PA291
A4VG 180 Hubwerk 1831PA295
2 Regulating Axial Piston Motor A6VM 250 Hubwerk 1702MH154
3 Axial Piston Constant Motor A2FM 56 Drehwerk 1702MH020
4 Axial Piston Constant Motor A2FM 107 Wippwerk 1702MH027
5 Winch unit ZHP 4.29 04.29 1014798 1390GT103
6 Turning Gear ZHP 3.25 03.25 10310 1391GT335
7 Oil cooler 2000 001 00 1587KU001
8 Gear oil cooler OKAF-EL2S... 1588KU005
9 Pump Distributor Gear i=0,73 4387.24 1392GT113
10 Solenoid Valve 4D01 2600VT038
2600VT039
11 In-Line Filter 160 LEN 0400 - 09 A0,6 1262FI320
14 Cabine NMF Type "NG" Miller
15 Control Lever NMF 1210FH108/109
16 Lifting Block 50 t 1610LD702
Table 5: List of the subcontractor documentation

Copyright © 2005 Subcontractor documentation 1

Instruction manual
2 Subcontractor documentation Copyright © 2005

Spare parts list Brueninghaus Hydromatik
Order No.: 02059970 Elchingen Plant
Denomination: A4VG180EP2DM1/32R-NZD02F00XDH-S
Type: 252.25.03.29
Drawing no.: 09719210

Info:
Item Order No. Denomination Quantity

1 09607946 ROTARY GROUP 1 ST L
NZ
2 02022131 CONTROL, HYDRAULIC 1 ST L
3 09609002 PORT PLATE WITH VALVES 1 ST L
4 09606233 INTERNAL GEAR PUMP ASSEMBLY 1 ST L
5 02056868 CONTROL MODULE 1 ST L
10 02025660 HOUSING 1 ST
13 09426653 JOINT PIN 2 ST
14 09405732 DOWEL PIN 1 ST
20 09153862 LOCKING SCREW 1 ST D
N 02.009-M42X2 -NBR #240NM
N 02.009-M18X1,5-NBR #40NM
N 02.009-M16X1,5-NBR #35NM
DIN 908-M42X2 -5.8PHR-N 02.017
25 09085545 O-RING 1 ST D
N 02.079- 39,34 X 2,62-S-NBR90
DIN 906-M 8X1 -5.8PHR #3NM
28 09426703 ORIFICE 2 ST
N 02.105-M10-1,2 #12NM
31 09153512 CLAMPING PIN 2 ST
DIN 7344- 4 X14
N 02.009-M12X1,5-NBR #20NM
N 02.009-M33X2 -NBR #140NM
N 02.009-M10X1 -NBR #10NM
37 09156570 LOCKING SCREW 1 ST
DIN 906-M20X1,5-5.8PHR #26NM
L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 1 Following page: 2 Date: 17.08.2001
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.
Status of version: 02/2001

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen
Denomination: A4VG180EP2DM1/32R-NZD02F00XDH-S
Type: 252.25.03.29

46 09157393 THREADED PIN 1 ST
DIN 913-M14X1,5X30-10.9N02.033
47 09152975 SEAL LOCK NUT 1 ST D
N02.100-M14X1,5#120NM
N 02.009-M22X1,5-NBR #60NM
49 09426708 ORIFICE 1 ST
N 02.105-M10-2,2 #12NM


Denomination: ROTARY GROUP
Type: 215.25.23.12

Info: NZ

1 02040803 CYLINDER WITH CONTROL PLATE 1 ST
2 09429499 PISTON-SLIPPER PAD 9 ST
11 09445400 CUP-SPRING STACK 1 ST
21525.2121
12 09445149 CRADLE 1 ST
'KC'
13 09449034 SLIDE RING 1 ST
21522.2102
14 09449874 DRIVE SHAFT 1 ST
17 09403549 WIRE 2 ST
23031.0320
20 09432995 SHIM 1 ST
20 09432996 SHIM 1 ST
20 09432997 SHIM 1 ST
20 09432998 SHIM 1 ST
24 09445277 RETAINING PLATE 1 ST
25 09440135 RETAINING BALL 1 ST
26 09650056 BEARING LINER (PAIR) 1 ST
21525.2121
27 09449875 WASHER 2 ST
29 09435429 PRESSURE SPRING 1 ST
' 8,00/ 52,00/ 55,10'
31 09157194 PLAIN ROLLER BEARING 1 ST
NUP 52 X106 X35
32 09830146 CRADLE BEARING ASSEMBLY ( SET) 1 ST
F-208174.6
36 09150122 RETAINING RING 1 ST
DIN 471- 52X2
DIN 472-105X4
38 09830979 SHAFT SEAL RING 1 ST D
BAFSL1SF 60X106X 7/5-FKM
39 02600142 SICHERUNGSRING DIN 984-106X4 1 ST
DIN 984-106X4


Type: 215.25.23.12

DIN 472- 62X2


Denomination: CONTROL, HYDRAULIC
Type: 452.25.72.16

Info:

1 02025599 POSITIONING PISTON COMPLETE 1 ST L
3 02019658 COVER 1 ST
4 02019659 COVER 1 ST
16 09157477 HEXAGON NUT 1 ST
DIN 439-B-M16X1,5-04-N 02.018
17 09083040 SOCKET-HEAD SCREW 8 ST D
DIN 912-M 8X 30-8.8 #25NM
20 09083824 O-RING 2 ST D
N 02.079- 88,49 X 3,53-S-NBR70
N 02.100-M12 #69NM
30 02600840 GUIDE RING 2 ST
GRYD000873C380/TL61
31 02600274 TURCON-GLYD-RING + O-RING F. DURCHM. 83 2 ST
+ O-RING F. DURCHM. 83


Type: 452.25.72.16


Denomination: POSITIONING PISTON COMPLETE
Type: 452.25.72.12

Info:

1 02015673 POSITIONING PISTON 1 ST
2 09449242 ROD 1 ST
5 02020493 RING 2 ST
'8.00'
5 02020494 RING 2 ST
'7.85'
5 02020495 RING 2 ST
'7.90'
5 02020496 RING 2 ST
'7.95'
5 02020497 RING 2 ST
'8.05'
5 02020498 RING 2 ST
'8.10'
5 02029756 RING 2 ST
'7.75'
5 02029757 RING 2 ST
'7.8'
5 02043149 RING 2 ST
'8.20'
6 02600767 ASSEMBLY RING 2 ST
20 ZEICHN.-NR. 11.44638
7 09449253 SPRING COLLAR 2 ST
8 09436960 SPACER BUSH 2 ST
'17,45'
'17,55'
'17,35'
'17,75'
'17,65'


Type: 452.25.72.12

'17,25'
' 7,00/ 40,70/ 84,20'
' 8,00/ 60,30/ 72,00'
DIN 472- 72X2,5
19 09086333 O-RING 1 ST D
N 02.079- 12,42 X 1,78-S-NBR90


Denomination: PORT PLATE WITH VALVES
Type: 231.25.32.06

Info:

1 02600467 MHDBN32K2-20/420VHN #200NM*Z* 1 ST L
#200NM*Z*
2 09437151 PRESSURE RELIEF VALVE 1 ST L
3 09433834 PRESSURE OVERRIDE VALVE 1 ST L
5 09651033 PORT PLATE 1 ST
6 09449063 BEARING BUSHING 1 ST
7 09830008 SOCKET-HEAD SCREW 4 ST
DIN 912-M20X100-10.9 #620NM
9 09086427 O-RING 1 ST D
N 02.079-158,34 X 3,53-S-NBR90
11 09831320 DOUBLE BREAK-OFF PIN 2 ST D
N 02.023-M10
N 02.009-M 8X1 -NBR #5NM
26 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
N 02.009-M12X1,5-NBR #20NM
43 09445670 BUSH 1 ST


Type: 231.25.32.06


Denomination: MHDBN32K2-20/420VHN #200NM*Z*
Type:
Drawing no.:
Info: #200NM*Z*

1 02600124 SEAL KIT 1 ST D
BEST-NR 312 718
2 09157895 CAP 1 ST D
BN 168 151


Denomination: PRESSURE RELIEF VALVE
Type: 521.20.10.12

Info:

2 09449641 ADJUSTING SCREW 1 ST
3 09436363 VALVE PISTON 1 ST
' 3,20/ 18,00/ 38,50'
8 09083763 O-RING 1 ST D
N 02.079- 25,07 X 2,62-S-NBR90
N 02.100-M10X1#44NM


Type: 521.20.10.12


Denomination: PRESSURE OVERRIDE VALVE
Type: 525.10.04.02

Info:

2 09426552 VALVE BUSHING 1 ST
3 09432301 CONTROL PISTON 1 ST
4 09432163 PISTON 1 ST
6 09432775 POPPET SEAT 1 ST
' 1,80/ 7,30/ 24,85'
10 09083757 O-RING 1 ST D
N 02.079- 17,12 X 2,62-S-NBR90
N 02.100-M 8 #22NM
15 09086380 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR90


Type: 525.10.04.02


Type: 521.20.05.04

Info:

2 09409929 PISTON 1 ST
4 09409819 GUIDE BUSHING 1 ST
5 09002455 PLUG 1 ST
8 09409822 LOCKING BOLT 1 ST
11 09150369 SHIM 1 ST
DIN 988- 10X 16X1
11 09153402 SHIM 1 ST
DIN 988- 10X 16X0,3
' 2,80/ 13,20/ 35,50'
' 2,00/ 25,00/ 41,00'
17 09084890 O-RING 1 ST D
N 02.079- 36,09 X 3,53-S-NBR90
18 09084890 O-RING 1 ST D
N 02.079- 36,09 X 3,53-S-NBR90


Type: 521.20.05.04


Denomination: INTERNAL GEAR PUMP ASSEMBLY
Type: 296.25.70.00

Info:

2 09650693 WEAR PLATE 1 ST L


Type: 296.25.20.00

Info:

1 09439967 PUMP COVER 1 ST
5 09921571 STUB SHAFT 1 ST
7 02006264 WHEEL SET 1 ST
8 02025642 SHAFT KEY 1 ST
9 09154019 SNAP RING 1 ST
DIN 7993-A 50
DIN 912-M10X 35-10.9 #75NM
12 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70
14 09157315 SNAP RING 1 ST
DIN 7993-B 40


Denomination: WEAR PLATE
Type: 296.25.70.00

Info:

1 09650692 WEAR PLATE 1 ST
3 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70


Type: 296.25.70.00


Denomination: CONTROL MODULE
Type: 428.25.42.07

Info:

3 09443201 COVER 1 ST
4 02063327 ZUGFEDER 42825.4200 1 ST
42825.4200
5 09651478 GASKET 1 ST D
42722.3116
6 02046037 ASSEMBLY PIECE 2 ST
DIN 6912-M 5X 10-8.8 #6,1NM
DIN 912-M 6X 65-8.8 #10,4NM
10 02600641 O-RING 1 ST D
N 02.079- 29,87 X 1,78-S-NBR90
12 09086178 O-RING 3 ST D
N 02.079- 10,82 X 1,78-S-NBR70
13 02601860 PROPORTIONAL SOLENOID 2 ST
GRCY037N54E14-002-24V #19NM/5NM
15 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
16 09083724 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR70
17 09157273 O-RING 2 ST D
N 02.079- 26,64 X 2,62-S-FKM90
18 02601640 CUP SPRING 2 ST D
18 X 6,2X0,8
19 09085290 PLUG BOX 1 ST
GDM 2009 933 988-100, SW
20 09152503 PLUG BOX 1 ST
GDM 2009-933 988-106, GRAU
30 09087338 CYLINDER PIN 1 ST D
DIN 6325- 6 M6X 14


Type: 428.25.42.07


Type: 428.25.42.20

Info:

1 02046895 CONTROL HOUSING WITH ACCESSOR. 1 ST L
5 02031190 FEEDBACK LEVER 1 ST
6 02051223 SHIM 1 ST
22 09087453 NEEDLE ROLLER 1 ST
DIN 5402-A3 X15,8 G2


Denomination: CONTROL HOUSING WITH ACCESSOR.
Type: 428.00.42.01

Info:

1 02056224 HOUSING 1 ST
'KC'
3 02056210 CONTROL PISTON WITH CYL.PIN 1 ST
'KC'
4 09426573 LEVER 2 ST
6 02056212 ECCENTRIC PIN 1 ST
8 02044854 SHIM 1 ST
DIN 912-M 6X 20-8.8 #10,4NM
DIN 912-M 5X 8-8.8 #6,1NM
N 02.023-M10
29 09153668 O-RING 1 ST
N 02.079- 5,28 X 1,78-S-NBR70*Z*


Type: 428.00.42.01

->In order to assure a correct processing of spare parts orders, Page: 26 Following page: - Date: 17.08.2001

Denomination: A4VG125EP2DM1/32R-NZF02F00XDH-S
Type: 252.22.03.36

Info:

NZ
10 02025545 HOUSING 1 ST
13 09435016 JOINT PIN 2 ST
14 09405732 DOWEL PIN 1 ST
N 02.009-M33X2 -NBR #140NM
N 02.009-M18X1,5-NBR #40NM
N 02.009-M16X1,5-NBR #35NM
DIN 908-M42X2 -5.8PHR-N 02.017
25 09085545 O-RING 1 ST D
N 02.079- 39,34 X 2,62-S-NBR90
DIN 906-M 8X1 -5.8PHR #3NM
28 09426700 ORIFICE 2 ST D
N 02.105-M10-1,0 #12NM
DIN 7344- 3 X12
N 02.009-M12X1,5-NBR #20NM
N 02.009-M33X2 -NBR #140NM
N 02.009-M10X1 -NBR #10NM
DIN 906-M20X1,5-5.8PHR #26NM


Denomination: A4VG125EP2DM1/32R-NZF02F00XDH-S
Type: 252.22.03.36

46 09154982 THREADED PIN 1 ST D
DIN 913-M12X1,5X30-10.9N02.033
N02.100-M12X1,5 #72NM
N 02.009-M22X1,5-NBR #60NM
49 09426707 ORIFICE 1 ST
N 02.105-M10-2,0 #12NM


Type: 215.22.23.11

Info: NZ

21522.2121
12 09445122 CRADLE 1 ST
'KC'
21522.2102
17 09421418 WIRE 2 ST
21522.2101
20 09432505 SHIM 1 ST
20 09432506 SHIM 1 ST
20 09432507 SHIM 1 ST
20 09432508 SHIM 1 ST
21522.2121
27 09921717 WASHER 2 ST
' 6,50/ 44,50/ 49,74'
NUP 50 X90 X23
F-208142.6
DIN 471- 50X2
37 02600002 SICHERUNGSRING DIN 984- 90X3 2 ST
DIN 984- 90X3
BAFSL1SF 55X 90X 7/5-FKM
DIN 472- 55X2


Type: 215.22.23.11


Type: 452.22.72.16

Info:

3 02010745 COVER 1 ST
4 02010746 COVER 1 ST
DIN 439-B-M16X1,5-04-N 02.018
DIN 912-M 8X 25-8.8 #25NM
20 09085360 O-RING 2 ST D
N 02.079- 82,22 X 2,62-S-NBR70
N 02.100-M12 #69NM
GRYD000872C380/TL61
31 02600272 TURCON-GLYD-RING 2 ST D


Type: 452.22.72.16


Type: 452.22.72.12

Info:

2 09449241 ROD 1 ST
5 02020493 RING 2 ST
'8.00'
5 02020494 RING 2 ST
'7.85'
5 02020495 RING 2 ST
'7.90'
5 02020496 RING 2 ST
'7.95'
5 02020497 RING 2 ST
'8.05'
5 02020498 RING 2 ST
'8.10'
5 02029756 RING 2 ST
'7.75'
5 02029757 RING 2 ST
'7.8'
5 02043149 RING 2 ST
'8.20'
20 ZEICHN.-NR. 11.44638
' 4,50/ 28,64/ 57,58'
' 8,00/ 43,50/ 60,60'
DIN 472- 72X2,5
19 09086333 O-RING 1 ST D
N 02.079- 12,42 X 1,78-S-NBR90


Type: 452.22.72.12


Type: 231.22.32.12

Info:

#200NM*Z*
DIN 912-M16X100-10.9 #310NM
9 09830217 O-RING 1 ST D
N 02.079-158,42 X 2,62-S-NBR90
N 02.023-M10
N 02.009-M 8X1 -NBR #5NM
26 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
N 02.009-M12X1,5-NBR #20NM
43 09432774 BUSH 1 ST
N 02.023-M 8


Type: 231.22.32.12


Type:
Drawing no.:
Info: #200NM*Z*

1 02600124 SEAL KIT 1 ST D
BEST-NR 312 718
2 09157895 CAP 1 ST D
BN 168 151


Type: 521.15.10.12

Info:

' 2,50/ 13,00/ 35,00'
8 09083761 O-RING 1 ST D
N 02.079- 23,47 X 2,62-S-NBR90
N 02.100-M10X1#44NM


Type: 521.15.10.12


Type: 525.10.04.02

Info:

4 09432163 PISTON 1 ST
' 1,80/ 7,30/ 24,85'
10 09083757 O-RING 1 ST D
N 02.079- 17,12 X 2,62-S-NBR90
N 02.100-M 8 #22NM
15 09086380 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR90


Type: 525.10.04.02


Type: 521.20.05.04

Info:

2 09409929 PISTON 1 ST
4 09409819 GUIDE BUSHING 1 ST
5 09002455 PLUG 1 ST
8 09409822 LOCKING BOLT 1 ST
11 09150369 SHIM 1 ST
DIN 988- 10X 16X1
11 09153402 SHIM 1 ST
DIN 988- 10X 16X0,3
' 2,80/ 13,20/ 35,50'
' 2,00/ 25,00/ 41,00'
17 09084890 O-RING 1 ST D
N 02.079- 36,09 X 3,53-S-NBR90
18 09084890 O-RING 1 ST D
N 02.079- 36,09 X 3,53-S-NBR90


Type: 521.20.05.04


Type: 296.22.70.00

Info:



Type: 296.22.50.00

Info:

DIN 7993-A 50
DIN 912-M12X 35-10.9 #130NM
12 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70


Type: 296.25.70.00

Info:

3 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70


Type: 296.25.70.00


Type: 428.22.42.07

Info:

3 09443201 COVER 1 ST
4 02063327 ZUGFEDER 42825.4200 1 ST
42825.4200
5 09651478 GASKET 1 ST D
42722.3116
DIN 6912-M 5X 10-8.8 #6,1NM
DIN 912-M 6X 65-8.8 #10,4NM
10 02600641 O-RING 1 ST D
N 02.079- 29,87 X 1,78-S-NBR90
12 09086178 O-RING 3 ST D
N 02.079- 10,82 X 1,78-S-NBR70
GRCY037N54E14-002-24V #19NM/5NM
15 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
16 09083724 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR70
17 09157273 O-RING 2 ST D
N 02.079- 26,64 X 2,62-S-FKM90
18 X 6,2X0,8
19 09085290 PLUG BOX 1 ST
GDM 2009 933 988-100, SW
20 09152503 PLUG BOX 1 ST
GDM 2009-933 988-106, GRAU
DIN 6325- 6 M6X 14


Type: 428.22.42.07


Type: 428.22.42.20

Info:

6 02051223 SHIM 1 ST
DIN 5402-A3 X15,8 G2


Type: 428.00.42.01

Info:

1 02056224 HOUSING 1 ST
'KC'
3 02056210 CONTROL PISTON WITH CYL.PIN 1 ST
'KC'
4 09426573 LEVER 2 ST
6 02056212 ECCENTRIC PIN 1 ST
8 02044854 SHIM 1 ST
DIN 912-M 6X 20-8.8 #10,4NM
DIN 912-M 5X 8-8.8 #6,1NM
N 02.023-M10
29 09153668 O-RING 1 ST
N 02.079- 5,28 X 1,78-S-NBR70*Z*


Type: 428.00.42.01


Denomination: A4VG125EP2DM1/32R-NZF02F001DH-S
Type: 252.22.03.39

Info:

NZ
10 02025545 HOUSING 1 ST
13 09435016 JOINT PIN 2 ST
14 09405732 DOWEL PIN 1 ST
N 02.009-M33X2 -NBR #140NM
N 02.009-M18X1,5-NBR #40NM
N 02.009-M16X1,5-NBR #35NM
DIN 908-M42X2 -5.8PHR-N 02.017
25 09085545 O-RING 1 ST D
N 02.079- 39,34 X 2,62-S-NBR90
DIN 906-M 8X1 -5.8PHR #3NM
28 09426700 ORIFICE 2 ST D
N 02.105-M10-1,0 #12NM
DIN 7344- 3 X12
N 02.009-M12X1,5-NBR #20NM
N 02.009-M33X2 -NBR #140NM
N 02.009-M10X1 -NBR #10NM
DIN 906-M20X1,5-5.8PHR #26NM


Denomination: A4VG125EP2DM1/32R-NZF02F001DH-S
Type: 252.22.03.39

46 09154982 THREADED PIN 1 ST D
DIN 913-M12X1,5X30-10.9N02.033
N02.100-M12X1,5 #72NM
N 02.009-M22X1,5-NBR #60NM
49 09426707 ORIFICE 1 ST
N 02.105-M10-2,0 #12NM


Type: 215.22.23.11

Info: NZ

21522.2121
12 09445122 CRADLE 1 ST
'KC'
21522.2102
17 09421418 WIRE 2 ST
21522.2101
20 09432505 SHIM 1 ST
20 09432506 SHIM 1 ST
20 09432507 SHIM 1 ST
20 09432508 SHIM 1 ST
21522.2121
27 09921717 WASHER 2 ST
' 6,50/ 44,50/ 49,74'
NUP 50 X90 X23
F-208142.6
DIN 471- 50X2
37 02600002 SICHERUNGSRING DIN 984- 90X3 2 ST
DIN 984- 90X3
DIN 472- 55X2


Type: 215.22.23.11


Type: 452.22.72.16

Info:

3 02010745 COVER 1 ST
4 02010746 COVER 1 ST
DIN 439-B-M16X1,5-04-N 02.018
DIN 912-M 8X 25-8.8 #25NM
20 09085360 O-RING 2 ST D
N 02.079- 82,22 X 2,62-S-NBR70
N 02.100-M12 #69NM
GRYD000872C380/TL61
31 02600272 TURCON-GLYD-RING 2 ST D


Type: 452.22.72.16


Type: 452.22.72.12

Info:

2 09449241 ROD 1 ST
5 02020493 RING 2 ST
'8.00'
5 02020494 RING 2 ST
'7.85'
5 02020495 RING 2 ST
'7.90'
5 02020496 RING 2 ST
'7.95'
5 02020497 RING 2 ST
'8.05'
5 02020498 RING 2 ST
'8.10'
5 02029756 RING 2 ST
'7.75'
5 02029757 RING 2 ST
'7.8'
5 02043149 RING 2 ST
'8.20'
20 ZEICHN.-NR. 11.44638
' 4,50/ 28,64/ 57,58'
' 8,00/ 43,50/ 60,60'
DIN 472- 72X2,5
19 09086333 O-RING 1 ST D
N 02.079- 12,42 X 1,78-S-NBR90


Type: 452.22.72.12


Type: 231.22.32.00

Info:

#200NM*Z*
DIN 912-M16X100-10.9 #310NM
9 09830217 O-RING 1 ST D
N 02.079-158,42 X 2,62-S-NBR90
N 02.023-M10
N 02.009-M 8X1 -NBR #5NM
26 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
N 02.009-M12X1,5-NBR #20NM
43 09432774 BUSH 1 ST
N 02.023-M 8


Type: 231.22.32.00


Type:
Drawing no.:
Info: #200NM*Z*

1 02600124 SEAL KIT 1 ST D
BEST-NR 312 718
2 09157895 CAP 1 ST D
BN 168 151


Type: 521.15.10.12

Info:

' 2,50/ 13,00/ 35,00'
8 09083761 O-RING 1 ST D
N 02.079- 23,47 X 2,62-S-NBR90
N 02.100-M10X1#44NM


Type: 521.15.10.12


Type: 525.10.04.02

Info:

4 09432163 PISTON 1 ST
' 1,80/ 7,30/ 24,85'
10 09083757 O-RING 1 ST D
N 02.079- 17,12 X 2,62-S-NBR90
N 02.100-M 8 #22NM
15 09086380 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR90


Type: 525.10.04.02


Type: 296.22.70.00

Info:



Type: 296.22.50.00

Info:

DIN 7993-A 50
DIN 912-M12X 35-10.9 #130NM
12 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70


Type: 296.25.70.00

Info:

3 09157881 O-RING 1 ST D
N 02.079-120,37 X 1,78-S-NBR70


Type: 296.25.70.00


Type: 428.22.42.07

Info:

3 09443201 COVER 1 ST
4 02063327 ZUGFEDER 42825.4200 1 ST
42825.4200
5 09651478 GASKET 1 ST D
42722.3116
DIN 6912-M 5X 10-8.8 #6,1NM
DIN 912-M 6X 65-8.8 #10,4NM
10 02600641 O-RING 1 ST D
N 02.079- 29,87 X 1,78-S-NBR90
12 09086178 O-RING 3 ST D
N 02.079- 10,82 X 1,78-S-NBR70
GRCY037N54E14-002-24V #19NM/5NM
15 09086333 O-RING 2 ST D
N 02.079- 12,42 X 1,78-S-NBR90
16 09083724 O-RING 1 ST D
N 02.079- 6,07 X 1,78-S-NBR70
17 09157273 O-RING 2 ST D
N 02.079- 26,64 X 2,62-S-FKM90
18 X 6,2X0,8
19 09085290 PLUG BOX 1 ST
GDM 2009 933 988-100, SW
20 09152503 PLUG BOX 1 ST
GDM 2009-933 988-106, GRAU
DIN 6325- 6 M6X 14


Type: 428.22.42.07


Type: 428.22.42.20

Info:

6 02051223 SHIM 1 ST
DIN 5402-A3 X15,8 G2


Rexroth
Bosch Group
Mobile Hydraulics
Spare parts list Product Unit

Axial Piston Units
Part No.: R902438709

Designation: A A6V M 250 EP2D /63W2-VZB157 B
Drawing no.: R910939288
L = Assembly group D = Sealing element Page: 1 Date: 10.05.2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910935504

Designation: G A6V M 250 /63W2-VZB

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910906477

Designation: TW A6V M 250 /63W-VZ

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910933596

Designation: EINSTELLTEIL M16X130-V

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910933592

Designation: EINSTELLTEIL M16X 90-V

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R902433405

Designation: V A6V M 250 EP2D /63-V157

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910936728

Designation: VERSTELLTEIL A6VM 250/63-V157

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910934354

Designation: STEUERTEIL A6VM 250 EP2/63-V

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R902408868

Designation: DRE4K-3X/30G24-10Z4 V

Rexroth
Bosch Group
Mobile Hydraulics

Axial Piston Units
Part No.: R910974659

Designation: EINST.RUECKSCHL.V. A6,A7 250,355/63

Denomination: A2FM56/61W-VAB020
Type: 211.17.25.62

Info:

3 02040495 HOUSING 1 ST
5 09084150 CYLINDER PIN 1 ST
DIN 7- 5 M6X 12-ST-S
6 09085571 O-RING 1 ST D
N 02.079- 78,97 X 3,53-S-FKM70
DIN 912-M10X 25-8.8 #51NM
DIN 912-M10X 60-8.8 #51NM
N 02.009-M18X1,5-FKM #40NM


Type: 201.17.33.61

Info:

1 02028933 ROTARY GROUP, HYDR. SECTION 1 ST L
2 02030594 DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 09408442 COVER 1 ST D
DIN 472-105X4
15 09154986 O-RING 1 ST D
N 02.079- 98,02 X 3,53-S-FKM70
17 09152831 SHIM 2 ST
DIN 988- 85X105X0,1
18 09084592 SHIM 1 ST
DIN 988- 85X105X0,3


Denomination: ROTARY GROUP, HYDR. SECTION
Type: 201.17.33.90

Info:

1 09421305 CYLINDER 1 ST
2 09650831 CONTROL PLATE 1 ST
3 02028565 CENTER PIN 1 ST
4 02031674 PISTON WITH PISTON RINGS 7 ST L
5 09409994 WASHER 1 ST
20118.0710
6 02028559 ADJUSTMENT SHIM 1 ST
' 2,80/ 9,80/ 32,20'
12 09831106 PAN HEAD SCREW W. TORX 7 ST
N 02.119-M 5X16-10.9-MK#9,1NM


Denomination: ROTARY GROUP, HYDR. SECTION
Type: 201.17.33.90


Denomination: PISTON WITH PISTON RINGS
Type: 201.17.33.90

Info:

1 02028620 PISTON 1 ST
2 09831887 STEEL SEALING RING 2 ST
15 X16,8X2,3


Type: 201.17.33.90


Denomination: DRIVE SHAFT WITH BEARING ASSY
Type: 201.18.33.10

Info:

3 09430338 BEARING RING 1 ST
6 02030518 BACK-UP PLATE 1 ST L
DIN 471- 45X1,75
10 09156194 TAPERED-ROLLER BEARING 1 ST
T 7FC 050
DIN 720-32009 X


Type: 201.18.33.10


Denomination: BACK-UP PLATE
Type: 201.18.33.10
Drawing no.:
Info:

1 02028800 BACK-UP PLATE 1 ST
12 09084737 BACK-UP PLATE 1 ST D
DIN 988-S 45X 55


Mobile Hydraulics

Denomination: A2FM107/61W-VAB106
Type: 211.21.75.60

Info:

3 02038551 HOUSING 1 ST
5 09084163 CYLINDER PIN 1 ST
DIN 7- 6 M6X 12-ST-S
6 09154986 O-RING 1 ST D
N 02.079- 98,02 X 3,53-S-FKM70
DIN 912-M12X 30-8.8 #87NM
N 02.009-M18X1,5-FKM #40NM


Mobile Hydraulics

Type: 201.21.34.61

Info:

1 02036545 TRIEBWERK, HYDR. TEIL 20121.3490 1 ST L
2 02027404 DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 09409482 COVER 1 ST D
DIN 472-125X4
15 09086636 O-RING 1 ST D
N 02.079-117,07 X 3,53-S-FKM70
17 09154359 SHIM 2 ST
N 02.085-2 PS100 X125 X0,1
18 09154360 SHIM 1 ST
N 02.085-2-PS100 X125 X0,3


Mobile Hydraulics

Denomination: TRIEBWERK, HYDR. TEIL 20121.3490
Type: 201.21.34.90

Info:

1 09421309 CYLINDER 1 ST
2 09428533 CONTROL PLATE 1 ST
3 02027352 CENTER PIN 1 ST
4 02031678 PISTON WITH PISTON RINGS 7 ST L
5 09409612 WASHER 1 ST
20122.0710
' 3,60/ 13,00/ 47,90'
12 09831108 PAN HEAD SCREW W. TORX 7 ST
N 02.119-M 6X20-10.9-MK #15,8NM
13 09419096 WASHER 1 ST


Mobile Hydraulics

Denomination: TRIEBWERK, HYDR. TEIL 20121.3490
Type: 201.21.34.90


Mobile Hydraulics

Type: 201.21.33.90

Info:

1 02028624 PISTON 1 ST
2 09831891 STEEL SEALING RING 2 ST
18,4X20,6X2,8


Mobile Hydraulics

Type: 201.21.33.90


Mobile Hydraulics

Type: 201.22.33.10

Info:

3 09430091 BEARING RING 1 ST
6 02027403 BACK-UP PLATE 1 ST L
DIN 471- 55X2
T7FC060.T51EF
A 42794


Mobile Hydraulics

Denomination: BACK-UP PLATE
Type: 201.22.33.10
Drawing no.:
Info:

DIN 988-S 55X 68


SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE
Getriebe – Typ: ZHP 4.29

Gear Type:
Réducteur Type:
Geräte – Nr.: 1014798

Aggregate No:
Appareil No:
Serien – Nr.: 101 - 102

Serial No:
Série No:
Auftrags – Nr.: 1413004482 vom 24.03.2005

Order No:
Commande No:
Firma : Neuenfelder Maschinenfabrik GmbH

Company:
Société:
Anschrift : Neuenfelder Faehrdeich 120
Address:
Adresse: D - 21129 Hamburg
Abteilung : zu Hd. Hr. B. Holler
Department:
Service:
Bestell – Nr.: EK 402189 vom 11.03.2005 Sach – Nr.: ---

Order No: Ident. No:
Commande No Produit No:
Geräte – Typ: --- Pos – Nr.: ---
Aggregate Type: Pos. No:
Appareil Type: Pos. No:
Bau / Komm – Nr. --- Projekt – Nr.: ---
Constr. No: Project No:
Constr. Spéc. No: Projet No:
Lieferumfang: 1-fach deutsch/englisch per e-mail 04.04.2005 MA/KD

ZOLLERN Vertriebs-GmbH & Co.KG Telefon: 07586 / 959 - 0
Heustrasse 1 Telefax: 07586 / 959 - 710
E-Mail: [email protected]
D-88518 Herbertingen Homepage: www.zollern.de
1000000004494.doc Seite 1
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ZOLLERN GmbH & Co. KG
SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 06.04.2005
When ordering spares parts, please indicated type, material number, serial number and part number !
Type: Winch unit ZHP 4_29

Materialno.: 1014798
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.:
Oil filling quantity: 33,500 L Weight: 4.970,000 KG
POS-NO. QUANTITY PART NO. DESCRIPTION TECHNICAL DESCRIPTION.
1 1,0 PC 60042900615 Rope winch ZHP 4_29

2 1,0 PC 60042900495 Rope winch ZHP 4_29
40 1,0 PC 1016016 Winch support
5 von 68
6 von 68
7 von 68

Date: 06.04.2005
Type: Rope winch ZHP 4_29

Parts list 1 / Z001
Cust.-ident-No.: 1391GT874
1 1,0 PC 60193008185 Gear

21 1,0 PC 60193006232 Rope drum
22 1,0 PC 60193006169 Flange bearing
24 1,0 PC 60193008187 Drive
60 1,0 PC 60193006188 Oil line
9 von 68
10 von 68

Date: 06.04.2005

Parts list 1 / Z001
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.
1 1,0 PC 60193008185 Gear

1/1 1,0 PC 60193008186 Output
1/1/1 1,0 PC 60242901900 Planet carrier
1/1/3 1,0 PC 60242901834 Bearing ring
1/1/6 1,0 PC 60232900716 Intermediate housing
1/1/14 1,0 PC 60242901835 Disc A114_I86_L6
1/1/21 18,0 PC 60411200023 Cylindrical bolt DIN912_M24_L150_10.9
1/1/25 4,0 PC 60403900049 Retaining ring DIN7980_A18_I12,2
1/1/27 18,0 PC 60240700320 Disc A37_I25_L4
1/1/31 1,0 PC 60441100070 Shaft sealing ring DIN3760_B2_NM460_A500_B20_FPM
1/1/41 1,6 M 60442000005 Profiled cord DIN7715_10,0*36
1/1/42 1,7 M 60542000010 Holding strap
1/1/43 1,0 PC 60542100010 Belt lock S0,4_L8_BEFESTIGUNGSBAND_V2A
1/1/51 1,0 PC 60453300171 Cylindrical roller bearing NM375_A444,82_B48_RN
1/1/53 1,0 PC 60453000212 Grooved ball bearing DIN625_/ 6044_NM220_A340_B56
1/1/60 1,0 PC 60403100082 Circlip / locking ring DIN471_NM260_S5_A
1/1/62 1,0 PC 60403200212 Circlip / locking ring DIN472_NM340_S6_J
1/1/201 1,0 PC 60242901838 Intermediate flange
1/1/203 24,0 PC 60240700320 Disc A37_I25_L4
1/1/444 1,0 PC 60403200045 Circlip / locking ring DIN472_NM75_S2,5_J
1/1/473 14,0 PC 60404300241 Adjusting ring DIN988_A75_I60_S1
1/1/491 1,0 PC 60242400492 Disc A75_I46_L2
1/1/951 2,0 PC 60414030001 Screw plug DIN908_M10_P1_ZYL.+BUND
1/1/952 2,0 PC 60441000207 Flat sealing ring DIN7603_NM10_A13,5_S1_A_ST
1/11 1,0 PC 60100100712 BG planetary stage
1/11/1 1,0 PC 60233900001 Inner wheel
1/11/3 1,0 PC 60242901904 Sun wheel
1/21/1 1,0 PC 60233705109 Inner wheel
1/21/3 1,0 PC 60242600412 Sun wheel
1/24 1,0 PC 60100010560 BG planet carrier
13 von 68

Date: 06.04.2005

Parts list 1 / Z001
1/24/4 1,0 PC 60503100059 Circlip / snap ring NM130

1/27 1,0 PC 60100020401 BG intermediate housing
1/27/2 24,0 PC 60411130103 Hexagon bolt DIN931_M16_L120_8.8
1/31/1 1,0 PC 60232200001 Inner wheel
1/31/3 1,0 PC 60242901255 Sun wheel
1/34/3 1,0 PC 60403100050 Circlip / locking ring DIN471_NM80_S2,5_A
1/39 1,0 PC 60100020407 BG cover
1/39/1 1,0 PC 60242400349 Cover
1/39/21 1,0 PC 60453000252 Grooved ball bearing DIN625_6304_NM20_A52_B15
14 von 68
15 von 68

Date: 06.04.2005

Parts list 1 / Z001
21 1,0 PC 60193006232 Rope drum

21/1 1,0 PC 60242901643 Rope drum
21/5 1,0 PC 60243100481 Rope plate
21/20 24,0 PC 60411130573 Hexagon bolt DIN933_M24_L55_8.8
21/21 24,0 PC 60411230424 Cylindrical bolt DIN912_M24_L55_8.8
21/23 6,0 PC 60412300013 Threaded pin DIN915_M20_L45_I6KT_45H
17 von 68
18 von 68

Date: 06.04.2005

Parts list 1 / Z001

22/1 1,0 PC 60242900831 Flange
22/2 1,0 PC 60242901160 Flange plate
22/3 1,0 PC 60234705440 Disc A199,9_I111_L4
22/4 1,0 PC 60403200078 Circlip / locking ring DIN472_NM200_S4_J
22/5 0,4 M 60688100003 Felt sealing strip DIN5419_L5_B4
22/6 1,0 PC 60453400072 Self-aligning roller bearing DIN635_NM110_A200_B53_22222
22/8 1,0 PC 60242900950 Cover
22/9 1,0 PC 60242200389 Driver
22/12 1,0 PC 60417000094 Slotted pin DIN1481_NM4_L16
22/401 1,0 PC 60449900003 Lubricating nipple DIN71412_KEGEL_M10
22/421 1,0 PC 60230001181 Cover
20 von 68
21 von 68
22 von 68

Date: 06.04.2005

Parts list 1 / Z001
24 1,0 PC 60193008187 Drive

24/1 1,0 PC 60242901839 Brake flange
24/4 1,0 PC 60193000259 Drive sleeve
24/7 1,0 PC 60230000021 Motor flange
24/18 1,0 PC 60242400086 Cover
24/30 1,0 PC 60453000039 Grooved ball bearing DIN625_/ 6018_NM90_A140_B24
24/41 1,0 PC 60403100054 Circlip / locking ring DIN471_NM90_S3_A
24/42 1,0 PC 60403200029 Circlip / locking ring DIN472_NM42_S1,75_J
24/50 1,0 PC 60441100573 Shaft sealing ring DIN3760_BA_NM100_A130_B12_FPM
24/53 1,0 PC 60441100666 Shaft sealing ring DIN3760_B1_NM130_A160_B8_FPM
24/59 1,0 PC 60541000070 O-ring I200_SD3_NBR-70_-35/120
24/60 3,0 PC 60414030023 Screw plug DIN910_M10_P1_ZYL.+BUND
24/61 3,0 PC 60441000207 Flat sealing ring DIN7603_NM10_A13,5_S1_A_ST
24/64 1,0 PC 60414030005 Screw plug DIN908_M18_P1,5_ZYL.+BUND
24/65 1,0 PC 60441000213 Flat sealing ring DIN7603_NM18_A22_S1,5_A_ST
24/66 1,0 PC 60242400144 Cover
24/67 4,0 PC 60541800007 Stopper 14_D10,7_H5,5
24/69 1,0 PC 60543400075 Air filter VENTIL M 12*1,5 /LÜFT_0,02B 0,07B /EL L
24/70 15,0 PC 60404300224 Adjusting ring DIN988_A40_I28_S1
24/75 18,0 PC 60402100312 Pressure spring
24/77 12,0 PC 60242901220 Disc A19_I13_L5
24/79 4,0 PC 60404130015 Disc DIN125_A37_I21_L3
24/95 1,0 PC 60506701104 Oil pressure unit
24/96 1,0 PC 60506700230 Disc housing
24/97 9,0 PC 60506700192 Outer disc
24/98 7,0 PC 60506700193 Inner disc
24/611 1,0 PC 60540100869 Swivel screw connection WH_8_PLM_M12_P1,5
24/612 0,3 M 60620100005 VM Precision steel pipe
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Date: 06.04.2005

Parts list 1 / Z001
24/613 1,0 PC 60540100073 Straight screw connection G_8_S

24/614 1,0 PC 60541800005 Stopper 14_D8,4_H6
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27 von 68

Date: 06.04.2005

Parts list 1 / Z001
60 1,0 PC 60193006188 Oil line
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30 von 68
31 von 68

Date: 06.04.2005

Parts list 1 / Z001
1 1,0 PC 60193005430 Gear

21 1,0 PC 60193000425 Rope drum
24 1,0 PC 60193003794 Drive
60 1,0 PC 60193003795 Oil line
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34 von 68

Date: 06.04.2005

Parts list 1 / Z001
1 1,0 PC 60193005430 Gear

1/1 1,0 PC 60193004044 Output
1/1/3 1,0 PC 60242901701 Bearing ring
1/1/31 1,0 PC 60441100700 Shaft sealing ring DIN3760_B2_NM440_A470_B20_FPM
1/1/41 1,6 M 60442000001 Profiled cord WZ.NR 6/2823_6,0*20
1/1/42 1,7 M 60542000010 Holding strap
1/1/43 1,0 PC 60542100010 Belt lock S0,4_L8_BEFESTIGUNGSBAND_V2A
1/1/51 1,0 PC 60453300171 Cylindrical roller bearing NM375_A444,82_B48_RN
1/1/62 1,0 PC 60403200212 Circlip / locking ring DIN472_NM340_S6_J
1/1/201 1,0 PC 60242901300 Output housing EG
1/1/203 22,0 PC 60404130524 Disc DIN6916_A44_I25_L4
1/1/454 1,0 PC 60441100687 Shaft sealing ring DIN3760_BA_NM45_A75_B8_NBR
1/1/462 4,0 PC 60414030111 Screw plug DIN908_M30_P1,5_ZYL.+BUND
1/1/463 4,0 PC 60441000223 Flat sealing ring DIN7603_NM30_A36_S2_A_ST
1/1/491 1,0 PC 60242400492 Disc A75_I46_L2
1/1/520 2,0 PC 60524100009 Oil valve M18_P1,5_SW22_HUB3,5_HUNGER
1/1/521 2,0 PC 60441000213 Flat sealing ring DIN7603_NM18_A22_S1,5_A_ST
1/11/1 1,0 PC 60233900001 Inner wheel
1/11/3 1,0 PC 60242901904 Sun wheel
1/21/1 1,0 PC 60233705109 Inner wheel
1/21/3 1,0 PC 60242600412 Sun wheel
1/24/4 1,0 PC 60503100059 Circlip / snap ring NM130
1/27 1,0 PC 60100020406 BG intermediate housing
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Date: 06.04.2005

Parts list 1 / Z001

1/31/1 1,0 PC 60232400264 Inner wheel
1/31/3 1,0 PC 60242901314 Sun wheel
1/34/3 1,0 PC 60403100050 Circlip / locking ring DIN471_NM80_S2,5_A
1/39 1,0 PC 60100020557 BG cover
1/39/1 1,0 PC 60242901244 Cover
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Date: 06.04.2005

Parts list 1 / Z001
21 1,0 PC 60193000425 Rope drum

21/1 1,0 PC 60242901319 Rope drum
21/5 1,0 PC 60234705567 Rope plate
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Date: 06.04.2005

Parts list 1 / Z001

22/1 1,0 PC 60242900831 Flange
22/2 1,0 PC 60242901160 Flange plate
22/3 1,0 PC 60234705440 Disc A199,9_I111_L4
22/5 0,4 M 60688100003 Felt sealing strip DIN5419_L5_B4
22/6 1,0 PC 60453400072 Self-aligning roller bearing DIN635_NM110_A200_B53_22222
22/8 1,0 PC 60242900950 Cover
22/9 1,0 PC 60242200389 Driver
22/401 1,0 PC 60449900003 Lubricating nipple DIN71412_KEGEL_M10
22/421 1,0 PC 60230001181 Cover
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Date: 06.04.2005

Parts list 1 / Z001
24 1,0 PC 60193003794 Drive

24/1 1,0 PC 60242400491 Brake flange
24/4 1,0 PC 60193000633 Drive sleeve
24/7 1,0 PC 60230000014 Motor flange
24/18 1,0 PC 60242400085 Cover
24/30 1,0 PC 60453000039 Grooved ball bearing DIN625_/ 6018_NM90_A140_B24
24/41 1,0 PC 60403100054 Circlip / locking ring DIN471_NM90_S3_A
24/50 1,0 PC 60441100573 Shaft sealing ring DIN3760_BA_NM100_A130_B12_FPM
24/53 1,0 PC 60441100665 Shaft sealing ring DIN3760_B1_NM110_A130_B8_FPM
24/58 1,0 PC 60541000314 O-ring I285_SD3_NBR-70_-35/120
24/59 1,0 PC 60541000447 O-ring I160_SD3_NBR-70_-35/120
24/60 2,0 PC 60414030023 Screw plug DIN910_M10_P1_ZYL.+BUND
24/61 2,0 PC 60441000207 Flat sealing ring DIN7603_NM10_A13,5_S1_A_ST
24/66 1,0 PC 60242400142 Cover
24/70 3,0 PC 60404300224 Adjusting ring DIN988_A40_I28_S1
24/79 4,0 PC 60404130013 Disc DIN125_A30_I17_L3
24/95 1,0 PC 1002700 Oil pressure unit
24/96 1,0 PC 60506700224 Disc housing
24/97 8,0 PC 60506700162 Outer disc
24/98 7,0 PC 60506700163 Inner disc
24/201 1,0 PC 60540100814 Straight screw-in screw connection GE_PLM_M10_P1_6
24/202 1,0 PC 60540900004 Pipe clip
24/203 1,0 PC 60540100831 Pocketing connection BE_A6_L_4
24/205 0,2 M 60622500001 VM plastic pipe
24/211 1,0 PC 60540100024 Straight screw-in screw connection GE_PLM_M12_P1,5_8
24/212 1,0 PC 60540100100 Straight bulkhead stuffing box SV_8_L
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Date: 06.04.2005

Parts list 1 / Z001
24/213 1,0 PC 60234200034 Haltewinkel

24/215 1,0 PC 60540500167 Hydraulic parts
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51 von 68

Date: 06.04.2005

Parts list 1 / Z001
60 1,0 PC 60193003795 Oil line
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Date: 06.04.2005
Type: Winch unit ZHP 4_29

Parts list 1 / Z001
Cust.-ident-No.:
40 1,0 PC 1016016 Winch support

40/1 1,0 PC 1003071 Windenbock Windeneinheit
40/5 24,0 PC 60404130524 Disc DIN6916_A44_I25_L4
40/9 24,0 PC 60404130524 Disc DIN6916_A44_I25_L4
40/11 4,0 PC 60242200312 Distance
40/31 16,0 PC 60404130520 Disc DIN6916_A37_I21_L4
40/120 2,0 PC 1009505 Cover
40/122 16,0 PC 60241500466 Disc A27_I9_L5
40/128 1,0 PC 60242902001 Haltewinkel
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INSTALLATION INSTRUCTION
General
Please also note the indications in our installation drawings:
installation drawing -winch unit- and installation drawing -rope winch-
The ZOLLERN winch unit with support is supplied completely assembled.
Before assembling the winch unit, verify your steel construction according to our installation drawing.
Please note installation position of winch according to our installation drawing -winch unit- !
Strength classes and torque moments for screws see installation drawing.
Assembly
Put winch unit with winch support into steel frame.
Fix winch support.
Carry out following assembly steps for each winch:
Remove transport cover off the motor flange.
Connect brake line (see installation drawing -rope winch-).
Release hydraulically holding brake.
The drive sleeve in the drive unit must turn easy.
Remove plug off the drive sleeve of the drive unit.
For protection against corrosion the drive sleeve is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before montage of the motor.
Attention: Motor shaft grease-free!
Centre motor in the motor flange.
Seal connecting surfaces.
Fix motor with screws.
Before test-running, fill motor flange completely with gear oil.
Check oil level with oil dipstick.
Refill oil if necessary.
If the rope winch is supplied without oil, this is indicated on a corresponding label.
Oil type see name plate resp. maintenance instruction.
Oil quantity see name plate resp. spare parts list.
Check rope winch with running motor as to function.
Check above all the control and function of the holding brake and the drive motor.
After test-running check oil level once more with oil dipstick.
During the test-running, the oil level in the gear and motor flange is adjusting itself and so fills the space
to the motor shaft slowly with gear oil. Therefore the oil level may be reduced.
If necessary, refill oil.
Insert rope and fix it.
Secure screws accordingly.
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MAINTENANCE INSTRUCTION
Lubrication
The Zollern planetary gear of rope winch has splashed lubrication.
Oil filling ex factory :MOBIL SHC 630
Description :synthetically PAO-oil
The oil quantity is marked on the name plate. If the gear is delivered without oil, we point out to that with a
sticker.
The bearing of the second journal bearing is filled with grease.

Grease filling ex factory :AVIA AVIALITH 2 EP
Choice according to DIN :DIN 51502
Description according to DIN :Grease, DIN 51825-KP2K
Before taking into operation grease again second journal bearing till grease emerges at the sealing profile.
Further oil and grease types see recommendations for lubricants.
Recommendation for maintenance intervals

Oil-control : Weekly.
Control oil level only with non-running gear.
First oil change after 200, then after each 3000 service hours, but at least every 3 years.
The intervals refer to the service temperatures indicated in the installation drawing.
Oil change only with temperature condition.
We recommend to clean with a pre-heated part of new oil when ambient temperature is low, so that abrasion
and contaminations can flow away.
Greasing intervals : Once a week or before taking rope winch into operation.
190000751.gb.doc
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RECOMMENDED LUBRICANTS
Selection table
LUBRICATING OIL LUBRICATING GREASE

SELECTION SELECTION
DIN 51 502 DIN 51502

LUBRICATING OIL, LUBRICATING GREASE,
NAME
CLP PAO 220 DIN 51825 KP 2 K
ARAL ARAL DEGOL PAS 220 ARAL GREASE HLP 2
AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP
BP ENERSYN HTX 220 BP ENERGR. LS EP 2
CASTROL SPHEEROL EPL 2

CASTROL ---
GREASE
DEA DEA UBTOR HCLP 220
ESSO --- ESSO BEACON 2 EP
FUCHS --- FUCHS RENOLIT FEP 2
GULF --- GULF CROWN GREASE NO.2
KLÜBER KLÜBERSYNTH GEM 4-220 N CENTOPLEX 2 EP
MOBIL MOBIL SHC 630 MOBILUX 2 EP
SHELL OMALA HD 220 SHELL ALVANIA EP 2
TOTAL CARTER SH 220 MULTIS EP 2
Attention: Synthetically gear oil on PAO-base may not be mixed with synthetically gear oil on
polyglycol base.
Greases with different soap bases are not to be mixed.
Oil change and greasing intervals see maintenance instruction.
190000752.gb.doc
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GEAR INSPECTION
Gear oil analysis - preventive maintenance
Monitoring mechanisms for machines and gears are becoming increasingly important, because the
requirements and operating conditions often differ from those envisaged by the design engineer.
Systematic oil inspections carried out at regular intervals allow a reliable diagnosis to be made of wear
development and incipient damage. The decisive factor is whether the oil specified in the recommended
lubricants table is always actually used.
Why oil analyses?
Early diagnosis of damage:

Worn particles "float“ in oil. They can be detected by analysis and provide an indication of the wear of the
component from which they came.
Condition-dependent maintenance:
Damage detected early by oil analysis means lower repair and downtime costs.
Low-cost damage analysis:

Low -cost oil inspection allows a statement to be made on the possible cause of damage. Traces of
contamination due to dust and water, mixing with other oils, portions of worn metals and changes in oil level
allow specific, early detection of damage.
Easy monitoring:
In order to make a specific statement on the condition of the gear, partial or complete disassembly is no
longer necessary if oil analyses are carried out regularly.
Influential disruptive factors of the lubricating oil:

Worn metals, contamination, changes in oil level and in additives can have a substantial negative influence
on the effect of the oil used. Oil analyses carried out by an authorised laboratory record the levels of worn
metals, contamination etc.
The analysis is reported on according to the data and information provided.
The more precise the information is about the oil used, the duration and conditions of use, the more
indicative and specific preventive measures are possible.
There are no comparative or limit levels for worn metals and contamination. A decisive factor is always the
oil quantity from which the oil sample was taken.
A reliable diagnosis is only possible from a qualified laboratory. Resulting levels which appear to be
extremely high are not necessarily an indication of incipient damage.
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The laboratory technician includes all levels determined in the overall assessment in the correct relation
according to experience. Oil analyses carried out at regular intervals allow a reliable diagnosis to be made of
wear and incipient damage of a certain component.
Every gear has its own wear behaviour according to its operating conditions.
If magnetic particles larger than 5 µm are detected in an analysis, it is very probable that there is incipient
pitting formation of a component.
Particles of 40 µm can be detected by the naked eye in clear oil. If this is the case, it can be assumed with
certainty that there is advanced damage in the gear.
Taking oil samples:

A decisive factor for a certain, indicative diagnosis of an oil sample is the way in which the sample is taken.
The oil sample must always be taken in the same way. The oil should always be at least lukewarm when the
sample is taken. If possible, the oil to be analysed should be taken from the middle of the oil level.
With winch gears where access to the oil level is not possible, the oil to be analysed is taken from the oil
drainage pipe. Approximately 1-2 l of oil are to be discharged into a collecting vessel and a sample quantity
to be taken from the oil being drained.
With slewing gears, access to the optimum oil level is also difficult. Here we also recommend taking a
sample quantity from the oil being drained by removing an accessible oil drain plug.
190000781.gb.doc
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TIGHTENING TORQUES
Tightening torques for fixing bolts from M 4 to M 36 and for property classes 8.8
and 10.9 with friction coefficient 0.125.
8.8 10.9
M4 = 2.7 Nm 3.8 Nm
M5 = 5.5 Nm 8.0 Nm
M6 = 9.5 Nm 13.0 Nm
M8 = 23.0 Nm 32.0 Nm
M 10 = 46.0 Nm 64.0 Nm
M 12 = 80.0 Nm 110.0 Nm
M 14 = 125.0 Nm 180.0 Nm
M 16 = 195.0 Nm 275.0 Nm
M 18 = 270.0 Nm 390.0 Nm
M 20 = 385.0 Nm 540.0 Nm
M 22 = 510.0 Nm 720.0 Nm
M 24 = 660.0 Nm 930.0 Nm
M 27 = 980.0 Nm 1400.0 Nm
M 30 = 1350.0 Nm 1850.0 Nm
M 36 = 2350.0 Nm 3300.0 Nm
• The specified tightening torques are maximum values.

• Bolts secured with Loctite no. 242.
• Connecting surfaces on gear parts sealed with Loctite no. 640.
• Flat surfaces on the holding brake sealed with Loctite Type 573 (see illustration).
• Screw connection thread of the pipelines and connecting surface of the drive motor to the gear sealed
with Loctite no. 572.
• Observe Loctite user instructions!
Loctite Type 573
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_________________________________________________________________________
ZOLLERN SERVICE BLATT

SERVICE FORM
FEUILLE DE SERVICE
_________________________________________________________________________
Getriebe Typ ZHP 3.25

Gear Type
Reducteur Type
Geräte Nr. 0 3.25 10310

Aggregat No.
Appareil No.
Serien Nr. 101 - 125

Serial No.
Serie No.
Auftrags Nr. 6/63330 vom 21.07.98

Order No. 6/64190 19.08.98
Commande No.
_________________________________________________________________________
Firma : Neuenfelder Maschinenfabrik GmbH

Company :
Societe :
Anschrift : Neuenfelder Fährdeich 120

Adress : 21129 Hamburg
Adresse :
Abteilung :
Department :
Service :
_________________________________________________________________________
Bestell- Nr.: 807186 vom 17.07.98 Firmen Nr.: ---

Order- No.: 808089 vom 11.08.98 Company No.:
Commande- No.: Societe No.:
Geräte Type: --- Sach Nr.: ---

Aggregat Type: Ident. No.:
Appareil Type: Produit No.:
Bau/Komm. Nr.: 30008 0001 Pos. Nr.: ---

Constr. No.: Pos. No.:
Constr.Spec. No.: Rep. No.:
Projekt Nr.: ---

Project No.:
Projet No.:
ZOLLERN VERTRIEBS-GmbH + Co.

Heustraße 1
Telefon 07586-959-0, Telefax-Service-Dep. 07586-959-710, Telex 732 218
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für Getriebeinspektion GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
1. Inspektionsintervalle
Alle 1000 Betriebsstunden, mindestens 1 mal jährlich sollte das

abgelassene Getriebeöl geprüft werden. Für ein repräsentatives Ölmuster
ist es zweckmäßig, das Öl in betriebswarmem Zustand abzulassen.
2. Prüfung
Zur Überprüfung, ob im Getriebe eine ausreichende Ölmenge vorhanden war,

soll die Menge des abgelassenen Öles mit der vorgeschriebenen Ölmenge
verglichen werden. Die vorgeschriebene Ölmenge ist aus dem Typenschild
des Getriebes oder der Wartungsanleitung zu entnehmen.
3. Prüfung auf Ölfärbung
Wenn das Gebrauchtöl eine dunkle, schwarze Färbung aufweist, sind im

Betrieb Temperaturen von über 100 Grad C. aufgetreten. Als Folge tritt
verstärkte Alterung des Öles auf, dies bedeutet verminderte
Schmierfähigkeit. Der Ölwechsel muß dann in kürzeren Intervallen
durchgeführt werden.
Hat die Ölprobe eine trübe Färbung, kann dies auf eingedrungenes Wasser
hinweisen.Ein sofortiger Ölwechsel mit mehrmaliger gründlicher Spülung
durch Frischöl muß vorgenommen werden. Es ist zu empfehlen, das Getriebe
zu demontieren und die Teile auf Korrosionsschäden zu überprüfen.
4. Prüfung auf feste Fremdstoffe
Wir empfehlen eine Prüfung der Fremdstoffe nach DIN 51592.
Die Probe wird, gegebenenfalls unter geringem Erwärmen, in Reinbenzol

gelöst und über ein benzolbeständiges feinporiges Membranfilter
filtriert. Der Rückstand wird gewaschen, getrocknet, gewogen und als
Gehalt an festen Fremdstoffen angegeben.
Gesamtbeurteilung:
Max. zulässiger Fremdstoff-Massenanteil ist ca. 0,15 % von der

Gesamtölmasse der Getriebefüllung. Die Fremdstoffteile dürfen jedoch nur
aus feinem Abrieb bestehen (bis max. 25 ym). Wird der zulässige Wert
nicht überschritten kann nach Ölwechsel der Betrieb des Getriebes
fortgeführt werden.
Wenn grobkörniger Abrieb (über 25 ym) oder Abblätterungen von Material

der Zahnflanken festgestellt werden, ist unabhängig vom Massenanteil, das
Getriebe zu demontieren. Die Zahnflanken der Zahnräder, insbesondere das
große Sonnenrad der Abtriebsplanetenstufe ist durch Sichtprobe zu
überprüfen.
-------------------------------------------------------------------------
Heustraße 1
Telefon 07586-959-0, Telefax-Kundendienst 07586-959-710, Telex 732 218
-------------------------------------------------------------------------
Dok.-Nr.: ANWEISD1/TXTKD Seite 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung für Getriebeinspektion GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Bei normalem Verschleiss und nach der Einlaufperiode sind die

Rauhigkeitsspitzen vom Zahnflanken schleifen geglättet und die
Zahnflanken haben eine glatte, helle, glänzende Oberfläche.
Bei allen anderen Merkmalen, wie Schleifverschleiß, Riefen, Fressen,

Grübchen, Abblätterungen, Risse und plastische Verformung müssen die
Zahnräder getauscht werden, bzw. ist es dann zweckmäßig, eine
Generalüberholung des Getriebes durchzuführen.
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Instruction for Gearbox Inspection GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
1. Inspection Intervals
The drained gearbox oil should be checked every 1.000 operating hours,
but at least once per year. In order to obtain a representative oil
sample, the oil should be drained with the gear box at operating
temperature.
2. Checking the Drained Oil
In order to check whether there was a sufficient quantity of oil in the

gearbox, the quantity of oil drained has to be compared with the quantity
prescribed. The prescribed oil quantity is indicated on the gearbox
rating plate or specified in the maintenance instructions.
3. Checking for Oil Discolouration
If the used oil displays a dark, black colouring, this indicates that
temperatures of over 100 degrees C. have occurred during operation. As a
consequence, more rapid ageing of the oil occurs, causing reduced
lubricating properties. The oil change must then be carried out at more
frequent intervals.
If the oil sample has a cloudy colouring, this can indicate the
penetration of water.
An immediate oil change must be performed and the gearbox flushed out
thoroughly several times with fresh oil. It is to be recommended that
the gearbox is disassembled and the parts examined for corrosion.
4. Checking for Solid Foreign Matter
We recommend to check for foreign substances regarding DIN 51592.
The sample will be dissolved in pure benzol, if necessary warm up a

little, and then filter it through a benzol resistant, fine-pored
membrane filter. The rest will be washed, dried, weighed and inicated as
amount of solid foreign substances.
Overall Assessment:
The max. permissible weight of foreign matter is approx. 0.15 % of the

total weight of oil in the gearbox. However, the foreign matter must
consist only of fine abrasion (up to max. 25 ym). If the permitted value
is not exceeded, the gearbox can continue to be operated after the oil
change.
If coarse abrasion (above 25 ym) or flakes of material from the profiles

of the gear teeth are discovered, the gearbox must be disassembled,
irrespective of the amount of foreign matter. The profiles of the gear
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Heustraße 1
-------------------------------------------------------------------------
Doc.-No.: ANWEISE1/TXTKD Page 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Instruction for Gearbox Inspection GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
wheels, in particular the large sun wheel of the output planetary gear
set, should be inspected visually. With normal wear and after the
running-in period, the rough peaks should have been smoothed by the
friction between the tooth profiles and the profiles should have a
smooth, bright, shiny surface.
If any other characteristics are detected, such as wear due to grinding,

scores, scuffs, pits, flaking, cracks or plastic distortion, the gear
wheels should be replaced and/or a general overhaul of the gearbox
carried out.
ZOLLERN Schmierstoffempfehlung ZOLLERN
VERTRIEBS- für ZOLLERN - Getriebe Getriebe
GmbH + Co. Abt. KD
! ! !
! Schmieröl-Auswahl ! Schmierölauswahl ! Schmierfett Auswahl
! nach API GL5 ! nach DIN 51502 ! nach DIN 51502
_________!___________________!___________________!
! ! !
! Schmieröl ! Schmieröl ! Schmierfett
! SAE 90 ! DIN 51517-CLP 220 ! DIN 51825-KP2K
_________!___________________!___________________!
! ! !
ARAL ! Aral Getriebeöl ! BG 220 ! Aral Fett HLP 2
! HYP 90 ! !
_________!___________________!___________________!
! ! !
AVIA ! Avia Getriebeöl ! RSX 220 ! Avia Avialith 2 EP
! Hypoid 90 EP ! !
_________!___________________!___________________!
! ! !
BP ! BP Hypogear EP 90 ! GR-XP 220 ! BP Energr. LS EP 2
_________!___________________!___________________!
! ! !
CASTROL ! Castrol EPX 90 ! Alpha SP 220 ! Castrol Spheerol EPL 2
! ! ! Grease
_________!___________________!___________________!
! ! !
ELF ! Tranself Typ B ! Reductelf SP 220 ! ELF Epexa 2
! SAE 90 ! !
_________!___________________!___________________!
! ! !
ESSO ! Esso Getriebeöl ! Spartan EP 220 ! Esso Beacon 2 EP
! GX-D90 ! !
_________!___________________!___________________!
! ! !
FUCHS ! Fuchs Getriebeöl ! Compound 106 ! Fuchs Renolit FEP 2
! Renogear Hypoid 90! VG 220 !
_________!___________________!___________________!
! ! !
GULF ! Gulf Multi-Purpose! EP Lubricant ! Gulf Crown Grease No.2
! Gear Lubricant ! HD 220 !
! SAE 90 ! !
_________!___________________!___________________!
! ! !
MOBIL ! Mobilube HD-A 90 ! Mobilgear 630 ! Mobilux 2 EP
_________!___________________!___________________!
! ! !
SHELL ! Shell Spirax MB 90! Omala 220 ! Shell Alvania EP 2
_________!___________________!___________________!
Ölwechsel- und Fettschmierintervalle siehe Wartungsanleitung.

-------------------------------------------------------------------------
ZOLLERN Anzugsmoment für Befestigungsschrauben. ZOLLERN
VERTRIEBS- Tightening torques for screws. GETRIEBE
GmbH + Co. Moment de serrage pour vis de fixation (mN). Abt. KD
Pares de apriete para tornillos de fijacion.
------------------------------------------------------------------------
Festigkeitsklassen (Reibungszahl 0,125)

strength-class (frictioncoefficient)
Classe de resistance (coefficient de frict.)
Clases de resistencia (coeficciente de fric.)
8.8 10.9 12.9
M 4 = 2,7 Nm 3,8 Nm 4,6 Nm

M 5 = 5,5 Nm 8,O Nm 9,5 Nm
M 6 = 9,5 Nm 13,O Nm 16,O Nm
M 8 = 23,O Nm 32,O Nm 39,O Nm
M 10 = 46,O Nm 64,O Nm 77,O Nm
M 12 = 8O,O Nm 11O,O Nm 135,O Nm
M 14 = 125,O Nm 18O,O Nm 215,O Nm
M 16 = 195,O Nm 275,O Nm 33O,O Nm
M 18 = 27O,O Nm 39O,O Nm 455,O Nm
M 20 = 385,O Nm 54O,O Nm 650,O Nm
M 22 = 510,O Nm 72O,O Nm 870,O Nm
M 24 = 660,O Nm 93O,O Nm 11OO,O Nm
M 27 = 98O,O Nm 1400,O Nm 165O,O Nm
M 30 = 135O,O Nm 185O,O Nm 225O,O Nm
-------------------------------------------------------------------------
Schrauben gesichert mit Loctite Typ 242.

Secured by Loctite Type 242.
Frein de vis par Loctite Type 242.
Tornillos asegurados con Loctite Tipo 242.
Verbindungsflächen an den Getriebeteilen mit Loctite Typ 640 abgedichtet

Fitting surfaces sealed by Loctite Type 640.
Les surfaces des elements de fixation sont assurees par Loctite Type 640.
Superficies de union hermetizadas con Loctite Tipo 640.
Planflächen an der Haltebremse mit Loctite Type 573 abgedichtet.

Surfacing on brake sealed by Loctite Type 573.
Les surfaces du frein de retenue sont etanches par Loctite Type 573.
Superficies planas en el freno de retencion hermetizadas con Loctite
Tipo 573.
Verschraubungsgewinde der Rohrleitungen und die Verbindungsfläche des

Antriebsmotors zum Getriebe mit Loctite Typ 572 abgedichtet.
Screwing of the tubing and the connection surfaces of the driving motor
to the gear are sealed with Loctite type 572.
Raccord a vis des conduites et la surface du moteur d'entrainement au
reducteur ont ete etanches par Loctite type 572.
Rosca del racor de los tubos y la superficie de union del motor de
accionamiento con el engranaje estan estanqueizadas con Loctite
Tipo 572.
Anwendervorschriften der Firma Loctite beachten.

Note application instructions of Loctite.
Faites attention aux instructions d'utilisation de Loctite.
Tenganse en cuenta las instrucciones de utilizacion dadas por Loctite.
-------------------------------------------------------------------------
Heustraße 1
-------------------------------------------------------------------------
Doc.-No.: ANZUGSM5/TXTKD Page 1
ZOLLERN ANZUGSMOMENTE
TIGHTENING TORQUES
MOMENT DE SERRAGE
____________________________________________________________________________________
D - Anzugsmomente für Befestigungsschrauben von M 4 bis M 36 und für

Festigkeitsklassen 8.8, 10.9 und 12.9 bei Reibungszahl 0,125.
GB - Tightering torques for fixing screws M 4 to M 36 and for strength classes

8.8, 10.9 and 12.9 ata coefficient of friction 0,125.
F - Moment de serrage pour vis de fixation de M 4 … M 36 et pour degres de

resistances 8.8. 10.9 et 12.9 … un nombre de friction 0,125.
8.8 10.9 12.9
M 4 = 2,7 Nm 3,8 Nm 4,6 Nm

M 5 = 5,5 Nm 8,O Nm 9,5 Nm
M 6 = 9,5 Nm 13,O Nm 16,O Nm
M 8 = 23,O Nm 32,O Nm 39,O Nm
M 10 = 46,O Nm 64,O Nm 77,O Nm
M 12 = 8O,O Nm 11O,O Nm 135,O Nm
M 14 = 125,O Nm 18O,O Nm 215,O Nm
M 16 = 195,O Nm 275,O Nm 33O,O Nm
M 18 = 27O,O Nm 39O,O Nm 455,O Nm
M 20 = 385,O Nm 54O,O Nm 650,O Nm
M 22 = 510,O Nm 72O,O Nm 870,O Nm
M 24 = 660,O Nm 93O,O Nm 11OO,O Nm
M 27 = 98O,O Nm 1400,O Nm 165O,O Nm
M 30 = 135O,O Nm 185O,O Nm 225O,O Nm
M 36 = 2350,0 Nm 3300,0 Nm
____________________________________________________________________________________
D - Schrauben gesichert mit Loctite Typ 242.

- Verbindungsflächen an den Getriebeteilen mit Loctite Typ 640 abgedichtet.
- Planflächen an der Haltebremse mit Loctite Type 573 abgedichtet.
- Verschraubungsgewinde der Rohrleitungen und die Verbindungsfläche des
Antriebsmotors zum Getriebe mit Loctite Typ 572 abgedichtet.
Anwendervorschriften der Firma Loctite beachten!
GB - Secured by Loctite Type 242.

- Fitting surfaces sealed by Loctite Type 640.
- Surfacing on brake sealed by Loctite Type 573.
- Screwing of the tubing and the connection surfaces of the driving motor
to the gear are sealed with Loctite type 572.
Note application instructions of Loctite!
F - Frein de vis par Loctite Type 242.

- Les surfaces des elements de fixation sont assurees par Loctite Type 640.
- Les surfaces du frein de retenue sont etanches par Loctite Type 573.
- Raccord a vis des conduites et la surface du moteur d'entrainement au
reducteur ont ete etanches par Loctite type 572.
Faites attention aux instructions d'utilisation de Loctite!
____________________________________________________________________________________
Dok-Nr: 19OOOO159.DEF/OO
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- DREHWERKSGETRIEBE GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Wartungsanleitung
Schmierung:
Das Zollern-Drehwerksgetriebe hat Tauchschmierung.
Ölfüllung ab Werk : AVIA Getriebeöl Hypoid 90 EP.

Auswahl nach DIN : DIN 51502.
Bezeichnung nach DIN: Schmieröl, DIN 51517-CLP 220.
Die Öleinfüllmenge ist auf dem Typenschild vermerkt. Wird das Getriebe
ohne Öl ausgeliefert, ist mit einem Aufkleber darauf hingewiesen.
Die hydraulisch gelüftete Federdrucklamellenbremse ist beim Anbau des

Motors mit 0,1 Ltr. Öl zu füllen. Geeignet sind grundsätzlich
handelsübliche Hydrauliköle, bezüglich Reibwertverhalten, Ölkohlebildung,
Schaumbildung usw. Besonders geeignet:
AUTOMATIC-TRANSMISSIONS-FLUID (ATF Dexron oder Suffix A, Donax TM,

HLP 22, 32, 68, 100.)
Das Wälzlager am Getriebeabtrieb ist mit Schmierfett gefüllt.
Fettfüllung ab Werk : AVIA Avialith 2 EP

Auswahl nach DIN : DIN 51502.
Bezeichnung nach DIN: Schmierfett, DIN 51825-KP2K.
Da Lebensdauerschmierung, braucht diese Fettfüllung nicht ergänzt oder

ausgetauscht zu werden.
Weitere verwendbare Öl- und Fettsorten von anderen Herstellern siehe

Schmierstoffempfehlung.
-------------------------------------------------------------------------
Empfehlung für Wartungstermine:
Öl-Kontrolle: wöchentlich.
Ölwechsel nach 200-1000-2000 Betriebsstunden, mindestens jedoch

1 x jährlich.
Achtung: Ölstand darf nur bei stillstehendem Getriebe geprüft werden.
Ölwechsel möglichst in betriebswarmen Zustand vornehmen, dazu müssen die

Entlüftungsfilter entfernt werden.
Bei niedriger Umgebungstemperatur sollte mit einer erwärmten Teilmenge

Neuöl gespült werden, damit möglicher Abrieb bzw. Verunreinigungen
abfließen können.
-------------------------------------------------------------------------
Heustraße 1
-------------------------------------------------------------------------
Dok.-Nr.: D3001006/TXTKD Seite 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- SLEWING GEAR GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Maintenance Instruction
Lubrication:
The Zollern-Slewing gear has splashed lubrication.
Oil filled in ex factory : AVIA gear oil Hypoid 90 EP.

Choosen according to DIN : DIN 51502.
Description according to DIN: Oil, DIN 51517-CLP 220.
Oil quantity is marked on the name plate. If the gear is delivered

without oil, we point out to that with a sticker.
The hydraulically ventilated disc brake has to be filled with 0,1 ltr.
oil when fitting the engine. Suitable are above all hydraulic oil
scustomary in commerce relatively to friction, coking of the oil, foam
formation, a. s. o. Especially qualified:
AUTOMATIC-TRANSMISSIONS-FLUID (ATF Dexron or Suffix A, Donax TM,

HLP 22, 32, 68, 100.)
The roller bearing of the gear output is filled with grease.
Grease filled in ex factory : AVIA Avialith 2 EP

Choosen according to DIN : DIN 51502.
Description according to DIN: Grease, DIN 51825-KP2K.
This is life-time lubrication and it is not necessary to renewal or to

refill it.
Further oil and grease types see recommendations for lubricants.
-------------------------------------------------------------------------
Recommendation for maintenance intervals:
Weekly inspection of oil.
Oil change after 200-1000-2000 operation hours, but at least once a year.
Attention: oil level can only be inspected with non-running gear.
If possible, oil change only with service temperature condition,

therefore remove the ventilating filters.
It is highly recommendable to clean with a pre-heated part of new oil

if the ambient temperatures are low in order to allow the flowing off
wearness and contaminations.
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- DREHWERKSGETRIEBE GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Einbau- und Montageanweisung
- Drehwerksgetriebe ohne Gewaltanwendung in die Aufnahmebohrung des

Gerätes einsetzen.
- Haltebremse (Lamellenbremse) mit Handpumpe hydraulisch lüften,

Antriebshülse muss sich leicht durchdrehen lassen.
- Zahnflankenspiel zwischen Ritzel und Zahnkranz der Kugeldreh-

verbindung entsprechend den Angaben des Kranherstellers messen bzw.
einstellen (z. B. Spiel = 0,03 bis 0,04 x Modul). Hierzu zweck-
mäßigerweise Meßuhr an Zahn des Ritzels anordnen. Durch Drehen von
Hand am Getriebeantrieb kann das Ritzel in beide Drehrichtungen bis
zum Anliegen der Zähne bewegt und damit das Zahnflankenspiel an der
Meßuhr genau abgelesen werden.
- Bei Exzentrität des Getriebe-Gehäuses kann das Flankenspiel durch

Verdrehen des gesamten Drehwerksgetriebes um eine oder mehrere
Schraubenteilungen verändert werden.
- Getriebe durch Anziehen der Schrauben auf vorgeschriebenes Anzugs-

moment befestigen. Es wird empfohlen, zur Schraubensicherung z. B.
Loctite Typ 242 zu verwenden. Der Reibschluß bzw. die Scherfestig-
keit kann durch Verwendung von z. B. Loctite Typ 640 an der
Flanschfläche erhöht werden.
- Verschlußschraube oben entfernen (war nur für Transport) und

beigefügte Lüftfilter einschrauben.
- Wenn erforderlich, Getriebeöl (Sorte siehe Wartungsanleitung)

einfüllen. Ca. Einfüllmenge ist auf dem Typenschild vermerkt.
- Lamellenraum der Haltebremse mit Hydrauliköl füllen.

(Ölsorte und Ölmenge siehe Wartungsanleitung)
- Vor Montage des Motors, Welle und Steckprofil mit geeignetem Fett
gegen Passungsrost schützen. Empfohlen wird Optimoly Paste White T.
- Drehwerksgetriebe mit laufendem Motor auf Funktion überprüfen,

insbesondere Funktion der Haltebremse und die Steuerung des
Antriebsmotors.
- Im übrigen verweisen wir auf die technischen Angaben unserer

Einbauzeichnung.
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- SLEWING GEAR GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Instructions for design and assembly
- Install slewing gear forcelessly into the holding fixture of the unit.
- Release brake (disc brake) hydraulically with manual pump.

Drive sleeve must be slightly turnable.
- Tooth flank clearance between pinion and wheel rim of the bearing
slewing ring to be adjusted acc. to the indications of the crane
manufacturer (for ex. clearance = 0,03 - 0,04 x module). For this
it is necessary to put the dial gauge on the tooth of
the pinion. By manual turning at the input, the pinion can be moved
in both directions up to contact with the teeth. Now, the tooth
flank clearance can be exactly read on the dial gauge.
- With excentricity of the gear-housing the flank clearance can be

changed by means of turning by one or more screw holes of the whole
slewing gear.
- Fix the gear by tightening the screws up to the recommended torque.

We recommend add. to use Loctite Type 242 for screw security.
The tensile shear, i.e. the shear tension can be increased
by means of e.g. Loctite Type 640 on the surface of the
flange.
- Screw plug removed on the surface (for transport only) and added
air vents screwed in.
- If necessary fill in gear oil (type see maintenance instructions).

Approx. oil quantity is marked on the type plate.
- Fill disc space of the holding brake with hydraulic oil. .

(Oil type and quantity, see maintenance instructions)
- Before assembly of the hydr. motor, the shaft and the tooth profile
has to be protected with appropriate grease against corrosion. We
recommend Optimoly Paste White T.
- Check function of slewing gear when motor is running,

esp. function of brake and control of input motor.
- Furthermore we point out to the technical data in our installation

drawing.
DATUM E R S A T Z T E I L - L I S T E
ZOLLERN VERTRIEBS-GMBH + CO
-------- -------------------------------
HEUSTRASSE 1
9.03.01 S P A R E - P A R T - L I S T
D-88518 HERBERTINGEN/WÜRTT.
DREHWERKSGETRIEBE ZHP 3.25 032510310 PLANETARY GEAR

GEWICHT ÖLEINFÜLLMENGE
WEIGHT OIL QTY

SERIEN - NR. 101 - 125 SERIAL - NO. 101 - 125
319,0 KG 13,5 LITER
*************************************************************************************************
SEITE - 1
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************
Pos-Nr. Stück Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
______________________________________________________________________________________________________________________
1 1,0 132513034 PLANETENSTUFE PLANETARY STAGE
-----------------------------------------------------------------------------------------------------------
1/ 11 1,0 100100315 PLANETENSTUFE PLANETARY STAGE
1/ 11/ 1 1,0 233700002 INNENRAD INTERNAL-WHEEL

1/ 11/ 2 3,0 232500827 PLANETENRAD PLANETARY WHEEL
1/ 11/ 3 1,0 232500533 SONNENRAD SUN WHEEL
1/ 11/ 4 6,0 453300216 ZYL.ROLLENLAGER CYLINDER ROLLER BEARING
30X 68,15X31/L31,5
1/ 11/ 5 3,0 403200042 SICHERUNGSRING CIR CLIP
---,--X 68,00X 2,50 DIN 472
1/ 11/ 6 6,0 503400034 SCHEIBE WASHER
61,00X 68,00X 3,25
-----------------------------------------------------------------------------------------------------------

1/ 21/ 4 6,0 453300213 ZYL.ROLLENLAGER CYLINDER ROLLER BEARING
25X 46,52X22/
---,--X 47,00X 1,75 DIN 472
1/ 21/ 6 6,0 503400031 SCHEIBE WASHER
41,50X 46,00X 1,85
-----------------------------------------------------------------------------------------------------------
1/ 24 1,0 100010375 PLANETENTRÄGER PLANETARY CARRIER
1/ 24/ 1 1,0 232000267 PLANETENTRÄGER PLANETARY CARRIER

1/ 24/ 2 3,0 234502512 PLANETENACHSE PLANETARY AXLE
70,00X---,--X 2,50 DIN 471
1/ 24/ 4 1,0 503100045 SPRENGRING CIR CLIP
70,00X---,--X 2,00
-----------------------------------------------------------------------------------------------------------
1/ 27 1,0 100020251 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING
1/ 27/ 1 1,0 232000040 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING

1/ 27/ 2 18,0 411130083 SECHSKANTSCHRAUBE HEXAGON BOLT
M 12X 80 ZN 8.8 DIN 931
-----------------------------------------------------------------------------------------------------------

1/ 31/ 4 96,0 453900089 NADELN NEEDLE ROLLER
5,0X15,3 G2 TYP LRB
1/ 31/ 5 3,0 231500303 SCHEIBE WASHER
1/ 31/ 6 6,0 231500302 SCHEIBE WASHER
-------- -------------------------------
HEUSTRASSE 1
9.03.01 S P A R E - P A R T - L I S T

WEIGHT OIL QTY

319,0 KG 13,5 LITER
*************************************************************************************************
SEITE - 2
**********************************************************************************************************************
Technische - Daten
TECHNICAL - DATA
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
1/ 34/ 1 1,0 231500313 PLANETENTRÄGER PLANETARY CARRIER

1/ 34/ 2 3,0 231500301 PLANETENACHSE PLANETARY AXLE
45,00X---,--X 1,75 DIN 471
1/ 34/ 4 1,0 503100036 SPRENGRING CIR CLIP
45,00X---,--X 1,50
-----------------------------------------------------------------------------------------------------------
29 1,0 132541069 TRIEBSTOCK LANG LONG OUTPUT HOUSING
29/ 1 1,0 232500787 SCHAFTRITZEL PINION SHAFT

29/ 3 1,0 232500790 ABTRIEBSGEHÄUSE OUTPUT HOUSING
29/ 5 3,0 232500419 PLANETENACHSE PLANETARY AXLE
29/ 6 1,0 232500393 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING
29/ 7 1,0 232500792 SCHEIBE WASHER
29/ 9 1,0 232500791 HALTESCHEIBE HOLDING DISC
29/ 20 3,0 411200005 ZYLINDERSCHRAUBE CYLINDRICAL SCREW
M 20X 70 10.9 DIN 912
M 16X110 10.9 DIN 912
29/ 30 1,0 453400050 KEGEL-ROLLENLAGER TAPER ROLLER BEARING
130X230X 67,75 DIN 720
29/ 31 1,0 453400110 KEGEL-ROLLENLAGER TAPER ROLLER BEARING
120X215X 43,50 A DIN 720
29/ 50 1,0 441300013 V-RING V-RING
D1= 210- 233/B1= 8
29/ 51 2,0 441100386 WELLENDICHTRING SHAFT SEALING RING
125X150X12 BA NBR DIN3760
29/ 52 1,0 541000013 O-RING SEALING RING
130,00X3 NBR-70
29/ 60 1,0 414430007 VERSCHLUSS-SCHRAUBE PLUG
M 22X 1,5 ZN MAGN. DIN 908
M 22X 1,5 ZN DIN 908
29/ 63 4,0 441000216 FLACH-DICHTRING SEALING RING
A 22X 27X1,5 DIN7603
29/ 70 3,0 404300792 PASS-SCHEIBE WASHER
120,00X150,00X 1,00 DIN 988
120,00X150,00X 0,20 DIN 988
-----------------------------------------------------------------------------------------------------------
40 1,0 113125014 ANTRIEB DRIVE IN
40/ 1 1,0 231500347 BREMSFLANSCH BRAKE FLANGE

40/ 4 1,0 242400952 ANTRIEBSHÜLSE DRIVING SLEEVE
40/ 6 1,0 242400052 HÜLSE SLEEVE
40/ 7 1,0 230000022 MOTORFLANSCH MOTOR FLANGE
40/ 12 1,0 242400038 SCHEIBE WASHER
M 10X 90 ZN 8.8 DIN 912
M 10X120 ZN 8.8 DIN 912
40/ 30 1,0 453000037 RILLENKUGELLAGER BALL BEARING
45X 75X16 DIN 625
40/ 40 1,0 403200045 SICHERUNGSRING CIR CLIP
---,--X 75,00X 2,50 DIN 472
45,00X---,--X 1,75 DIN 471
---,--X 26,00X 1,20 DIN 472
40/ 50 1,0 441600005 WELLENDICHTRING SHAFT SEALING RING
50X 68X 8 BA NBR DUO
47,00X2 NBR-72
-------- -------------------------------
HEUSTRASSE 1
9.03.01 S P A R E - P A R T - L I S T

WEIGHT OIL QTY

319,0 KG 13,5 LITER
*************************************************************************************************
SEITE - 3
**********************************************************************************************************************
Technische - Daten
TECHNICAL - DATA
______________________________________________________________________________________________________________________

126,00X3 NBR-72
M 18X 1,5 ZN DIN 908
A 18X 22X1,5 DIN7603
19,00X 26,00X 1,00 DIN 988
40/ 95 1,0 506701002 ÖLDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE
40/ 96 1,0 506700218 LAMELLENTRÄGER CLUTCH PLATE CARRIER
40/ 97 9,0 506700146 AUSSENLAMELLE MULTIPLE DISK
DIN5480RAD-NUT-L2,30
40/ 98 7,0 506700147 INNENLAMELLE MULTIPLE DISK
DIN 867--------L1,45
-----------------------------------------------------------------------------------------------------------
70 1,0 130000101 ÖLKONTROLLE OIL CONTROL
70/ 11 1,0 540100828 VERSCHRAUBUNG THREADED JOINT CONNECTION

M 22X 1,5 ED-160B
70/ 13 1,0 133290007 ROHR PIPE
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 36 1,0 540100828 VERSCHRAUBUNG THREADED JOINT CONNECTION
M 22X 1,5 ED-160B
70/ 37 1,0 133290007 ROHR PIPE
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 44 1,0 543400081 LUFTFILTER VENT FILTER
V=0,1L/0,2BAR/
A 10X 13,5X1,0 DIN7603
M 10X 1,0 ZN DIN 908
70/ 58 1,0 543400014 ENTLÜFTUNGSVENTIL VENT FILTER
0,04 BAR MESSING M10*1,0
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 66 2,0 543100021 ÖLSTANDAUGE-M 22*1,5 + DR. OIL SIGHT GLASS
WEICHEISEN /-30+120
-----------------------------------------------------------------------------------------------------------
75 14,0 100003006 FEDERN SPRINGS
75/ 1 14,0 402100306 DRUCKFEDER SPRINGS
-----------------------------------------------------------------------------------------------------------
76 14,0 100003007 FEDERN SPRINGS
76/ 1 14,0 402100307 DRUCKFEDER SPRINGS
______________________________________________________________________________________________________________________
*** ENDE DER STÜCKLISTE

Spare Parts
QTY. Position DESCRIPTION SAP CODE
2 10 Feet 295x30x15 3087930

1 9 Pump FZP-1/1.1/P/71/10/RV4.5 721068
1 8 Motor M. 220/480-50/60HZ 0.37KW 1500G B14-B14 2507124
1 7 Indicator 303854
1 6 Filter MF-160 314858
1 5 Filter Support 3087899
1 4 Grid Ø294 strengthened 3087932
1 3 Fan Ø300/6-6/25LD/PPG/D/FM14 3087898
1 2 Casing 3087762
1 1 Radiator BSR-70 3078616
5 5 5 5
5
5
5
9
9
8 8
HYDAC Label
44
22 33
7
7
11
6
6
10
10
OKAF-EL2S/10/3.0/M/400-50/MF160/10/1/So61
Spare part list
Artikel gearbox Output-Ø mm Ratio Capacity kW Torque Nm Weight kg Date Sheet
44719 4387.24.09901 0,731 146,00 11.11.2002 1
Pos. Quantity Unit Spare part number Discription Dimension / DIN Weight kg Price/Unit EUR
10 2,000 STK 08320 4387 5 01-01 splin. hollow shaft D75/36x108 2,100
20 1,000 STK 08321 4387 5 02-01 splin. hollow shaft D75/46x114 1,540
50 1,000 STK 08310 4387 0 01-01 housing 665x610x120 67,000
60 1,000 STK 08315 4387 1 04 Mounting flange D660/120x97 66,000
70 1,000 STK 31090 4382 1 07-01 Mounting flange D356/108x65 18,000
80 2,000 STK 08284 4382 1 02 Mounting flange D297/107x55 16,500
110 1,000 STK 08318 4387 3 03 Cylindrical gear D241/80x63 10,900
120 3,000 STK 08319 4387 3 04-01 Cylindrical gear D179/75x32 4,600
130 1,000 STK 08325 4387 6 04 Ring D118/80x99 3,120
140 1,000 STK 08324 4387 6 02-01 Hole disk D118/21x27 1,240
160 1,000 STK 31522 4387 9 04 oil dipstick R1/2"x106 1021-14-901-00 0,080
200 3,000 STK 00043 001.006213 Ball bearing DIN625 6213 65x120x23 0,990
205 3,000 STK 00351 004.006213 Ball bearing DIN625 6213RS 65x120x23 0,990
210 1,000 STK 03172 073.110130 Radial oil seal DIN3760-FPM A110x130x12 0,070
220 1,000 STK 03250 077.080030 O-ring DIN3770-NBR 80x3 0,010
260 6,000 STK 03418 090.075250 circlip DIN471 A75x2,5 0,030
280 6,000 STK 03995 116.200032 Key DIN6885 B20x12x32 0,040
300 16,000 STK 04185 130.010025 Socketed head bolt DIN912-8.8 M10x25 gal.verz. 0,030
310 8,000 STK 04187 130.010035 Socketed head bolt DIN912-8.8 M10x35 gal.verz. 0,030
© 2002
Stiebel-Getriebebau GmbH & Co KG Tel.: +49 (0)2291 / 791 - 0
Industriestrasse 12 Fax.: +49 (0)2291 / 791 - 290
D-51545 Waldbröl E-Mail: [email protected]
Spare part list
Artikel gearbox Output-Ø mm Ratio Capacity kW Torque Nm Weight kg Date Sheet
44719 4387.24.09901 0,731 146,00 11.11.2002 2
Pos. Quantity Unit Spare part number Discription Dimension / DIN Weight kg Price/Unit EUR
320 1,000 STK 04410 137.020050 Head lap screw DIN933-8.8 M20x50 gal.verz. 0,200
340 15,000 STK 04455 191.012030 Stud DIN939-8.8 M12x30 0,030
350 15,000 STK 33195 219.000130 Disk 300HV 13 DIN EN ISO 7089 galv. verz 0,010
360 15,000 STK 04601 240.000012 Hexagon nut DIN934-8 M12 gal.verz. 0,020
370 1,000 STK 04842 290.006030 Spring pin DIN1481 6x30 0,010
380 2,000 STK 04944 301.264016 Hexagon head plug DIN910-5.8 R3/4" gal.verz. 0,130
390 1,000 STK 04941 301.209014 Hexagon head plug DIN910-5.8 R1/2" gal.verz. 0,070
410 2,000 STK 05296 400.212615 Sealing ring DIN7603-Cu A21x26x2 0,001
420 2,000 STK 05298 400.273220 Sealing ring DIN7603-Cu A27x32x2 0,010
430 1,000 STK 45959 419.000400 Cap GPN 670 DN250 D400x 35 0,260
470 7,500 L 24578 798.000001 NE Gear oil DIN51517 CLP220 0,910
© 2002
Stiebel-Getriebebau GmbH & Co KG Tel.: +49 (0)2291 / 791 - 0
Industriestrasse 12 Fax.: +49 (0)2291 / 791 - 290
D-51545 Waldbröl E-Mail: [email protected]
Type NG
Documentation
part-no..: 70853
cabin 1 to 5
Karl Miller GmbH

Industriestr. 19
D - 77933 Lahr / Schwarzwald
Tel.: (0049) (0) 7821 / 9476-0
Fax: (0049) (0) 7821 / 9476-10
www.kml-miller.de
Karl Miller GmbH
Systemlösungen im Kabinenbau
www.kml-miller.de
general drawing
4
Karl Miller GmbH
www.kml-miller.de
drawings
35/36 39
5
12
14/32
33
1
27/29-31
11
26
34
28/29-31
28/29-31
2
19
3
38
37
26
20
15
9/10
27/29-31
14/32 42
5
Karl Miller GmbH
www.kml-miller.de
43/44 25
11
16-18
40
4 21/23
22/24
7/8
41
13
6
6
spare part list
pos. name
1. ESG-glass________________________________________________
2. ESG-glass________________________________________________
3. ESG-glass________________________________________________
4. ESG-glass________________________________________________
5. VSG-glass________________________________________________
6. VSG-glass________________________________________________
7. clamping profile___________________________________________
8. filling profile _____________________________________________
9. clamping profile___________________________________________
10. filling profile _____________________________________________
11. edge protection with sealing _________________________________
12. transparent sealant ________________________________________
13. double sided scotch tape ____________________________________
14. bed _____________________________________________________
15. label „emergency exit only“ _________________________________
16. cover for windscreen wiper motor_____________________________
17. fixing for cover____________________________________________
18. windscreen wiper motor 60/70/80 degree, 24 V __________________
19. wiper arm 750 mm _________________________________________
20. wiper blade 800 mm ________________________________________
21. mortise lock, DIN right _____________________________________
22. profile cylinder____________________________________________
23. door handle ______________________________________________
24. escutcheon _______________________________________________
25. adjustable hinge___________________________________________
26. window stay ______________________________________________
Karl Miller GmbH
www.kml-miller.de
27. handle right ______________________________________________

28. handle left _______________________________________________
29. hook ____________________________________________________
30. PVC – disc hard ___________________________________________
31. PVC – disc soft____________________________________________
32. hinge plastic ______________________________________________
33. star gripp, M12____________________________________________
34. duct for wiring ____________________________________________
35. blind plug M 25 x 1,5_______________________________________
36. locknut M 25 _____________________________________________
37. drivers seat _______________________________________________
38. ashtray __________________________________________________
39. hanger __________________________________________________
40. eye______________________________________________________
41. finned plug _______________________________________________
42. rubber mat isolated ________________________________________
43. insulation with textile cover, 20 mm ___________________________
44. insulation 20 mm __________________________________________
8
Ersatzteilliste Fahrhebel - 1210 FH**
Spare Parts List Control Lever
1210FH021
1210FH025
1210FH032/
33/34
Text angeben
1210FH023
1210FH026
1210FH022
1210FH019
Instruction manual
12 Drawings
May, 2005
Item. Denotation
Drawing no. 80107
no.
1 Maintenance chart 845 -0500- 00(1)

2 Electric Wiring Diagram 824 -0700- 140(4)
3 Crane housing complete 845 -0800- 02(0)
4 General Arrangement Crane 1 845 -0900- 03(0)
5 General Arrangement Crane 2 845 -0900- 04(0)
6 Jib complete 845 -1500- 05(1)
7 Jib complete 845 -1500- 06(1)
8 Jib Foot complete 822 -2100 00(2)
9 Rope Sheave 800 -2400- 20(3)
10 Anit collision 845 -3900- 00(1)
11 Transportable pump unit 625 -5000- 02(1)
12 Bottom Hook Block SWL 50t
13 Hydraulic Circuit 845 -4900- 05(1)
14 Pump Unit 820 -5000- 18(1)
15 Hydraulic Oil Tank 845 -6100- 00(1)
16 Fan Flap 800 -7300- 03(2)
17 Rope End Connection 820 -8700- 04(3)
18 Slack Rope Connection 897 -8800- 03(2)
19 Energy Suply 845 -9000- 02(1)
20 Crane Rig crane 1
21 Crane Rig crane 2
Table 6: List of the drawings
Copyright © 2005 Drawings 1

Instruction manual
2 Drawings Copyright © 2005

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NMF

Type: Crane 1 DK II 45027,5/35032,2

Neuenfelder Maschinenfabrik GmbH

1 What is worth knowing about this operating manual

2 Description of the Crane

3.4 Symbols on the crane.............................................................................................1

3.6.4 Limit switch ........................................................................................................... 3

5 Monitoring, Failure, Troubleshooting and Elimination

6 Maintenance and Repair

6.4.1 Cleaning the crane .................................................................................................4

7 Functional description of hydraulic

7.3 Venting ...................................................................................................................1

7.7 Luffing gear 7

8 Hoisting of brakes in case of emergency

Chapter 2; Illustr.1 Overview 3

Chapter 9; Illustr.40 Reset-Switch 7

1.2 The operator´s duty of care

1.3 Terms, short cuts and symbols

Terms / short cuts Meaning

NMF Neuenfelder Maschinenfabrik GmbH

Table 1: Terms and short cuts

Copyright © 2005 What is worth knowing about this operating manual 1

1.4 Technical Amendments

2 What is worth knowing about this operating manual Copyright © 2005

Copyright © 2005 What is worth knowing about this operating manual 3

4 What is worth knowing about this operating manual Copyright © 2005

2.1 Technical Data

Crane Crane 1 Crane 2

Max. input, temporarily 270 kW 270 kW

Table 3: Technical Data

Copyright © 2005 Description of the Crane 1

Manufacturer ___ ___

Table 3: Technical Data

2 Description of the Crane Copyright © 2005

Copyright © 2005 Description of the Crane 3

2.3 General Aspects

2.4 Pump unit

2.5 Lifting gear

2.6 Luffing gear

2.7 Turning gear

2.8 Gear oil cooler

4 Description of the Crane Copyright © 2005

2.11 Slake rope switch

2.12 Gear limit switch

2.13 Slip ring assembly

Copyright © 2005 Description of the Crane 5

2.14 Load measuring bolt

6 Description of the Crane Copyright © 2005

2.15.1 Electronic regulator print card

2.15.1.1 4-Channel current regulator print card

see (Chapter Abbildung 36:, Seite 3, )

2.15.1.2 Description of the request for the start release

3.1 Use for the designed purpose

3.2 General safety instructions

3.3 Requirement of personnel

3.4 Symbols on the crane

Copyright © 2005 Safety 1

3.5 Warning signals during the crane operation

3.6 Safety devices on the crane and their functional test

Manufacturer _ _