Professional Documents
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Instruction Manual
Board crane
Typ: DK II 120016/50033
Order-No.: 80211
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Instruction Manual
NMF Board crane type DK II
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Instruction Manual
Board crane type DK II NMF
3.20.2.............Fault notification card ........................................................................ 20
6. March, 2007
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Instruction Manual
NMF Board crane type DK II
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Instruction Manual
Board crane type DK II NMF
6.9.1...............Description ....................................................................................... 15
6. March, 2007
6.9.2...............Connections ..................................................................................... 15
6.9.3...............Pressure media ................................................................................ 17
6.9.4...............Operation.......................................................................................... 17
6.9.5...............Manual emergency release .............................................................. 17
6.9.6...............Brake maintenance .......................................................................... 17
6.9.7...............Dismounting and assembly .............................................................. 17
6.9.8............... Malfunctions ..................................................................................... 19
6.10 ....................Lifting of brakes in case of emergency ............................................. 20
6.11 ....................Lifting gear........................................................................................ 21
6.11.1.............Connect the hand pump for opening the brakes as follows. ............ 21
6.12 ....................Jib..................................................................................................... 22
6.13 ....................Slewing gear..................................................................................... 23
6.14 ....................Gear cam limit switch ....................................................................... 27
6.14.1.............Maintenance..................................................................................... 27
6.14.2.............Contact adjustment .......................................................................... 27
6.14.3.............Home position : ................................................................................ 28
6.14.4.............Perform the following work ............................................................... 28
6.15 ....................How do I exchange a Memory-Programmable Control (MPC)? ....... 33
6.15.1.............Changing the battery. ........................................................................ 34
7 Spare Parts
7.1 ......................Ordering spare parts .......................................................................... 1
7.1.1...............How to order spare parts .................................................................... 2
8 Figures
9 Spare Parts Catalog
10 Drawings
Neuenfelder Maschinenfabrik GmbH
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Instruction Manual
NMF Board crane type DK II
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Instruction manual
Board crane type DK II 120016/55033 NMF
Table of figures
6. March, 2007
36................................. ....................................................................................................... 18
37................................. Connections for the solenoid valve block ..................................... 24
38................................. Brake lifting pump ........................................................................ 25
39................................. Pressure limit valves at the pump (Sauer)..................................... 26
40................................. Gear cam limit switch ................................................................... 27
41................................. Limit switch adjustment hoisting gear .......................................... 30
42................................. Limit switch adjustment luffing gear ............................................ 31
43................................. limit switch adjustment jib ............................................................ 32
44................................. Pump unit ...................................................................................... 1
45................................. Pressure Switch/solenoid valve..................................................... 2
46................................. Load Measuring Device ................................................................ 3
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Instruction manual
NMF Board crane type DK II 120016/55033
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Instruction manual
Board Crane type DK II 120016/55033 NMF
1 What is worth knowing about this operating manual
March, 2007
1.1 Manufacturer
The crane manufacturer is NMF Neuenfelder Maschinenfabrik GmbH
The address is:
NMF Neuenfelder Maschinenfabrik GmbH
Neuenfelder Fhrdeich 120
21129 Hamburg
Germany
You can contact us under
Telephone 040 / 74511-02
Fax 040 / 74511-867
e-mail: info@nmf-crane.de
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 (see table 2, page 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
A safety symbol can never replace the text in a safety instruction. For this reason, always
completely read the text of a safety instruction.
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:
the product is modified without our consent,
this instruction manual is not observed,
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 (see item 3.1, 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.
Neuenfelder Maschinenfabrik GmbH
Pumps
-with one direction of flow
Pumps
-with two directions of flow
Hydraulic motor
-with one direction of flow
Hydraulic motor
-with two directions of flow
1.7.2 Cylinders
Cylinder
-single-acting
Neuenfelder Maschinenfabrik GmbH
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Instruction manual
NMF Board Crane Type DK II 120016/55033
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Instruction manual
Board Crane Type DK II 120016/55033 NMF
1.7.4 Triggering type for way valves
March, 2007
directly working
Reel/tappet
hand lever
with spring return
electromagnetic triggering
with spring centring
electromagnetic triggering
with spring return
hydraulically triggering
with spring return
servo-controlled detailed
-hydraulically operated
electro magnetically controlled
-larger way valve are operated
hydraulically by a pilot valve.
the pilot valve operated electrically
simplified
Description:
3/4 way-valve, constantly variable
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Instruction manual
NMF Board Crane Type DK II 120016/55033
Hydraulically controlled
proportional-way valve
electro-hydraulically controlled
proportional-way valve
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Instruction manual
Board Crane Type DK II 120016/55033 NMF
1.7.6 Pressure valves
March, 2007
-Pressure switch
an electric contact switches with
reached the adjusted pressure
Neuenfelder Maschinenfabrik GmbH
-Pressure emitter
an electric contact switches with
reaching the adjusted pressure
to the PLC
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Instruction manual
NMF Board Crane Type DK II 120016/55033
-Throttle
firm resp. adjustable
-aperture
short throttle way
-non-return valve
with recoil spring
-non-return valve
with adjustable throttle
-shuttle valve
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Instruction manual
Board Crane Type DK II 120016/55033 NMF
1.7.9 Pipe connections
March, 2007
-Main pipe
-Flexible hoses
-Pipe connection
1.7.10 Others
Filter
Heating
Cooler
Manometer
Neuenfelder Maschinenfabrik GmbH
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NMF Board Crane Type DK II 120016/55033
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Instruction manual
Board Crane Type: DK II 120016/55033 NMF
2 Safety
March, 2007
Safety 1
korr So/ho2007
Instruction manual
NMF Board Crane Type: DK II 120016/55033
The control levers are spring loaded and automatically return to the neutral position when
released. The brakes for hoisting, luffing and slewing gears are spring loaded and generally
closed. They are only opened with a time-delay when the corresponding control lever is
shifted.
The brakes close automatically
if the control levers are at the neutral position,
if there is a pressure loss in the system (in this case, the pump unit is immediately
switched off),
during a power failure
in case there is an overload
when the limits of the outreach are reached in the individual load levels,
when the slack rope in the hoisting gear is set at lower.
A pressure switch for monitoring the charge pressure is installed in each of the high-pres-
sure lines.
3.4 lower
4.4 luffing down
5.4 slewing
In the case there is a pressure loss, this pressure switch turns the pump unit off immediately.
A float switch in the hydraulic oil tank also switches the pump unit off if there is insufficient
oil. The pumps are then protected against running dry.
If the crane switches off because a pressure switch opens or a gear oil cooler fails:
the crane operator is unable to restart the crane.
It is possible that a hose has burst.
Before restarting, visually inspect the hydraulic system. If you do not find any defects,
press the Reset button in the switch cabinet.
Then restart the crane.
The pressure sensor [3.15] in the hoisting line registers the last working pressure.
In the following working operation, the sensor will only open the hoisting winch brake when
this registered pressure is achieved again.
2 Safety
Instruction manual
Board Crane Type: DK II 120016/55033 NMF
2.6.4 Hydraulic overload safety
March, 2007
The complete hydraulic oil system is protected against excess pressure by pressure limita-
tion valves. A load pressure switch is fitted in the hoisting gears hoisting pipe.
[3.10] test load 132t
[3.11] nominal load 120t
[3.12] nominal load 38-55-75-95t
[3.14] 0-120t lower
In case of overload
Nominal load: Stop Hoisting gear hoist, luffing up, luffing down
It is only possible to lower.
Over speed: Stop: Hoisting gear hoist, luffing up, luffing down;
only lowering is possible, but the change over valves become current-free,
Hoisting gear works in full load level.
the load pressure switch cuts off the activated function,
the pump unit continues to run,
the hoisting winch brake is applied immediately,
the hoisting gear pump 3.0 returns to the 0 position,
the magnetic valve [14] becomes current-free,
When moving the control lever, the hoisting gear immediately rotates to the max. dis-
placement, max. torque.
Limit switches limit the hoisting and luffing gears in the operating ranges of the individual
load levels (see item 6.14, page 27). When this final position is reached, the corresponding
function is deactivated and the brakes are applied. A reverse operation is possible, though.
All limit switches only have an affect on the triggering of the pumps, i.e. the electric motor
continues to run at a constant speed although only the idling speed has been applied.
When crane operations are re-commenced, no current peaks are triggered as a result of the
centrifugal masses produced by the electric motor and the smoothly operating hydraulics.
Depending on the local conditions, higher sound levels can occur outside the crane opera-
tors cabin which can result in deafness, a loss of balance or reduced alertness.
Always use the personal protective equipment and clothing.
Neuenfelder Maschinenfabrik GmbH
Please note that when the crane is operating, oral communication and the discernment of
acoustic signals e.g. warning signals etc. are impaired.
Safety 3
korr So/ho2007
Instruction manual
NMF Board Crane Type: DK II 120016/55033
Please note that various forms of energy can still exist after the crane has been switched off
or is at a standstill - such as:
when jibs or loads are raised
in hydraulic pressure lines
in live power lines
Please advise the personnel accordingly during instruction.
In case of danger, press the emergency stop button immediately, (see item 4.4.2, page 4).
In case of fire, immediately switch off the crane using the main switch.
Follow special procedures when fighting a fire with:
working materials (hydraulic oil, lubricants),
electric lines
In case of an emergency, leave the crane through the emergency exit in the crane opera-
tors cabin.
using an external ladder mounted on the side of the crane (if present)
or using the emergency rope-down device in the crane operators cabin (see Kapitel 9,
Seite 1, )
4 Safety
Instruction manual
Board Crane type DK II 120016/55033 NMF
3 Description of the Crane
March, 2007
Feature Value
Crane
Crane type DK II
Capacity (SWL) 120 t
Length of jib
SWL 120t 4,0 - 16,0m
SWL 95t 4,0 - 19,0m
SWL 75t 4,0 - 24,0m
SWL 55t 3,3 - 33,0m
SWL 38t 3,3 - 33,0m
Lifting height approx. 46m
Luffing
SWL 0-38t at 3,3m - 33,0m - T = 50 sek
SWL 0-120t at 4,0m - 16m T = 80 sek
Hoisting speed
SWL 120t 0 - 7,5 m/min
SWL 95t 0 - 8,5 m/min
SWL 75t 0 - 10,0 m/min
SWL 55t 0 - 13,0 m/min
SWL 38t 0 - 18,0 m/min
Slewing speed>55t 0 -0.5 rpm
Slewing speed<38t 0 -0,7 rpm
Slewing range 360unlimited
Specification 120 t load and 16 m outreach at +/- 5 heeling and simultaneous
trim of +/- 2
Voltage
Nominal voltage (U) 380 V / 50 Hz
Motor speed (n) 1,475 r/min
Neuenfelder Maschinenfabrik GmbH
Feature Value
3.10 Heating
Electrical heating elements are installed in the hydraulic oil tank and in the crane housing.
The oil temperature in the oil tank is controlled by a thermo sensor. The tank heating is con-
stantly switched on at an oil temperature below 20C. At approx. 22C, the tank heating
switched off.
The room heating is controlled by a thermostat.
CAUTION
The limit switches are only to be operated, serviced and repaired by authorised,
skilled and instructed personnel.
This personnel must have read and understood the complete instruction manual and
they must also have received instructions about the ensuing hazards (see item 6.14,
page 27).
CAUTION
Prior to opening the slip ring elements cover
switch off the voltage,
protect the voltage from unauthorised activation,
820-4900-16(1)
To this purpose, the selection switch in the switch cabinet must be positioned at 0.
The pump units 1A and 1B are started with the start button at the left control panel.
The electric motor of unit 1A starts first, the gear oil cooler [1.2] is switched on from an oil
temperature of 20C. The directional control valve [2.2] is energized and interrupts the
pressureless circulation of the control and feed pressure for the control and feed pumps
[2.0], the fan flaps [2.7] open. The el.-motor of unit [1B] starts up after approx. 7-10.
When all of the pressure switches [3.4, 4.3, 5.4] in the system lines have been actuated by
feed pressure, the green lamp indicating operation is illuminated. If the el. motors [1.0] stop
and the red fault lamp does not illuminate, repeat the starting process.
Neuenfelder Maschinenfabrik GmbH
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Instruction manual
NMF Board Crane type DK II 120016/55033
The complete hydraulic system is protected against overload with pressure limitation valves.
Load pressure switches for the individual load stages are installed in the lifting line of the
lifting gear:
[3.10] Test load 132t
[3.11] Nominal load 120t
[3.12] Nominal load 38t-55t-75t-95t
[3.14] Nominal load 0 - 120t (senken)
These load pressure switches deactivate the activated function by overload but not the
pump units.
The lifting winch brakes apply immediately, the lifting gear pumps swivel to the 0 position.
The lifting and luffing gear are limited in the working area of the individual load stages by
limit switches. When the final position is reached, the corresponding function is deactivated,
the brakes apply. However, a reverse operation is possible.
All limit switches only work concerning the triggering of the pumps, e.g. the electric motors
continue 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 centrifugal masses
produced by the electric motor and the pumps together with the smoothly operating hydrau-
lics.
The pressure value transmitters [3.20], [4.20], in the lifting line store the last working pres-
sure and only open the lifting gear brake by the next working process when this is reached.
3.15.6 Ventilation
The spring-loaded vent flap [2.7] is automatically hydraulically opened when the pump units
1A and 1B are started.
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Instruction manual
Board Crane type DK II 120016/55033 NMF
Heat from the air and oil warmed during the crane operation to a temperature exceeding
March, 2007
40C is drawn-off through the open vent flap [2.7] by automatically starting oil-air coolers
[2.6].
Electrical heating elements are installed in the hydraulic oil tank [2.8] and the crane housing.
The room heaters are controlled by room thermostats and cut off at an ambient temperature
of 20.
A thermal feeler monitors the oil temperature.
The tank heater [2.4] is actuated when the oil temperature is below 20. When the oil tem-
perature reaches 40, the tank heater [2.4] is switched off and the oil-air coolers [2.6] start.
At approx. 85oil temperature, all of the controls are interrupted, no functions work. The
pump unit and the oil-air coolers 2.6 continue to run, the vent flaps [2.7] remain closed.
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
signal. This position controlling signal determines the angular rotation of the variable dis-
placement pump.
The delivery volume of the variable displacement pump is proportional to the electrical input
signal. A mechanical feedback to the swashplate retains the per-selected swashplate posi-
tion and stabilises the delivery volume which has already been selected. This makes the
handling of the working functions fast, exact and safe:
Neuenfelder Maschinenfabrik GmbH
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NMF Board Crane type DK II 120016/55033
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Instruction manual
Board Crane type DK II 120016/55033 NMF
3.16 Lifting gear
March, 2007
In this load stage the lifting winch motors [3.8 A-D] are switched to Q max.
The electro-solenoid valves [3.15-3.18] are current less.
They are held in this position with spring force and the load pressure.
If the slewing and luffing gear are moved at full speed when lifting the nominal load, a power
reduction card reduces the control current for the luffing, slewing and lifting gear pumps
depending on the power input of the el. motors [1.0]. The speed of this function is reduced.
This results in the power input of the el. motors [1.0] being kept constant.
The individual load stages are adjusted using the key switch at the right control panel in the
crane operators cabin, this activating the corresponding solenoid valves simultaneously.
Should a solenoid valve in a lifting gear motor receive current, this is switched to Qmin, i.e.
with a reduction of the absorption volume, the torque is reduced and the hook speed is
increased.
The maximum jib lengths are automatically set.
The solenoid on the way valve [3.15] receives a current. The lifting gear motor [3.8A] is
switched to Q min
The solenoids on the way valves [3.15 and 3.16] receive voltage. The lifting winch motors
3.8A and 3.8B are switched to Q min.
The solenoids on the way valves [3.15, 3.16 and 3.17] receive voltage. The lifting winch
motors [3.8A, 3.8B 3.8C und 3.8D] are switched to Q min.
The solenoids on the way valves [3.15, 3.16, 3.17 and 3.18] receive voltage. The lifting
winch motors [3.8A, 3.8B 3.8C und 3.8D] are switched to Q min.
The overload protection in these load stages is provided by the active load pressure switch
[3.12]. The load pressure switch [3.14] is activated when lowering the overload. When deac-
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NMF Board Crane type DK II 120016/55033
tivating the overload, immediately position the control lever to 0 and then select the load
stage which corresponds to the load. Observe the jib length.
3 .1 5
3 .1 6
3 .1 7
3 .1 8
Q m ax . V e n til sp a n n u n gslo s
Q m in . V e n til ge sch a lte t
Each of the axial piston pumps [3.0-5.0] is equipped with a step valve (see Pressure Regu-
lator, page 88) which successively actuates a pressure regulator and a pressure relief valve
in succession.
When the pre-adjusted pressure is reached, the pressure regulator quickly returns the
pump. The pressure relief valve is fitted for unusual pressure increases.
If the set pressure of the regulator is exceeded, operating (pressure) fluid flows through the
pressure valve (A) and through a throttle point in the control piston in port (B) thus increasing
the pressure on the servo side where at the moment low pressure exists. The low pressure
relief valve in (C) limits this pressure to an appropriate pressure level. The pressure regula-
tor overrides the signal of the supply quantity adjustment and adjusts the pressure on both
actuating cylinders to an equal level. The swing disk reset moments alter the displacement
volume until the system pressure has reached the set pressure again.
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Instruction manual
Board Crane type DK II 120016/55033 NMF
March, 2007
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Instruction manual
NMF Board Crane type DK II 120016/55033
If the luffing gear control lever is deflected, the way valves [4.6] and [4.17] receive current
and the released control pressure opens the topping winch brake [4.7]. The magnet on the
proportional valve [4.9a+b] is (only black/white) switched and receive a passage through to
the distributing valve [4.10] controlling this against the elastic force. This closes the passage
between the servo-pistons to the tank side and created the connection between the high-
pressure line and the servo-pistons of the motor. In this switching situation the hydraulic
motor can be variably adjusted by the load pressure via the servo piston. If the load pressure
exceeds 240 bar (pre-adjusted at the spring), the distributing valve [4.11] is adjusted against
the elastic force and is connected with the tank side. The motor pivoting angle is increased,
thereby resulting in an increased absorption volume and a pressure reduction which reduc-
tion which in turn results in the distributing valve [4.11] being reset. The connection with the
tank side is interrupted once more.
The proportional valve [4.17] has no voltage. The motor disk position is set at max. absorp-
tion volume, i.e. lower winch speed and large torque.
Before reaching the upper end position, the luffing up speed is reduced (crawling speed) as
from a radius of 7.0 m and it is deactivated as from a 4,0 m radius, the luffing winch brakes
[4.7] will engages automatically. Luffing down is, however, fully possible.
In case of overburden, the pressure cut-off valve [4.1] is actuated at the luffing gear pump
[4.0]. The luffing gear pumps [4.0] are swivelled in the direction of 0 and only deliver as
much pressure oil as is necessary for the jib to retain its position. The topping winch brakes
[4.7] do not fall in.
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. The max. jib length is limited by the individual load
steps.
With the highest hook position all load steps luffing down is automatically activated.
Lower the lifting gear by approx. 1 m. Luffing down is then only possible up to the max.
length of the corresponding load step.
The excess pressure protection is provided with pressure limitation valves.
4.1 luffing up
4.2. luffing down
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Instruction manual
Board Crane type DK II 120016/55033 NMF
3.19 Slewing gear
March, 2007
When the slewing control lever is shifted, the way valve [5.5] is provided with voltage and
the slewing gear brakes [5.7]open. When the control lever is returned to the neutral position,
the slewing gear pumps [5.0] turns to the 0 position. Due to an electrical time relay, the
slewing gear brakes [5.7] close slowly. This results in the crane slowing down smoothly. By
overburdening, this being a slewing against the heel with load and a large outreach, the
pressure cut-off valve [5.1] at the slewing gear pump [5.0] is triggered. (see Hydraulic over-
load cut-off, Page 86). Shift the control lever into a neutral position and luff up the jib to
reduce heel.
The excess pressure protection is hereby provided with pressure limitation valves.
5.1 Slewing right,
5.2 Slewing left
Neuenfelder Maschinenfabrik GmbH
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NMF Board Crane type DK II 120016/55033
16 Copyright 2005
Instruction manual
Board Crane type DK II NMF
3.20 Electrical Equipment
March, 2007
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 of the front plate.
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NMF Board Crane type DK II
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 pushing ENTER once more. EDIT disappears again and one can change
to a different parameter number by pressing the arrow keys (also Autorepeat here). If one
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Instruction manual
Board Crane type DK II NMF
only wishes to store the old value instead of the new value, only the ESC button needs to
March, 2007
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
Neuenfelder Maschinenfabrik GmbH
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 request 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.
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NMF Board Crane type DK II
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Instruction manual
Board Crane type DK II NMF
3.20.3 Switches in the switch board
March, 2007
If the pressure transmitter (3.15) is defective, with this switch can be bridged.
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Instruction manual
NMF Board Crane type DK II
Illustration 5: Switches
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Instruction manual
Board Crane type DK II 120016/55033 NMF
3.20.4 Load measuring unit / Loadmaster (DMSA)
March, 2007
The load measuring unit consists of the loadmaster (DMSA) in the switch cabinet (see illus-
tration 6, page 25), the display for the indication in the cabin (see illustration 7, page 26)
and the load measuring bolt.
The DMSA 04 is for load acquisition on a ship's crane, based on the values of load-meas-
uring pins and (in automatic mode) jib angles (potentiometer on the jib).
1. Parametering and calibration
Crane-specific data may be input and the measuring system may be calibrated with known
loads. Due to the arrangement of the load-measuring pins, correction values between lifting
and lowering must be determined with the system.
2. Load-level mode
The jib position is recorded in stages ( PLC). The DMSA 04 displays the maximum permis-
sible load according to the selected load level and evaluates the corresponding thresholds
(warning, deactivation). Thresholds may be entered for a maximum of 10 load levels.
3. Automatic mode
Calculation of the sliding maximum load depending on the jib position. This mode possesses
highest priority. The maximum permissible loads as well as warning and deactivation thresh-
olds are calculated on the basis of the crane data ( maximum permissible torque for the
crane column) as well as the jib sizes.
Operating mode card
The key switch for selecting operating modes is located on this card.
1. Operation ( load monitoring ON)
2. Parameter mode ( access to the operating data possible)
3. Alarm bridge (deactivates warning and alarm outputs) it is only possible to remove
the key when it is in the operating position.
Besides the key switch, this card also houses the fuses for the external components. Light-
emitting diodes indicate whether the external circuits are being supplied with 24 VDC.
3.20.4.1 At overload
The load measuring system can be switched off with a key switch in the switch cabinet.
(see illustration 6, page 25) The load bolts are therefore electrically bypassed and the
electrical load measurement deactivated.
The crane works in the biggest load stage, that means the lifting gear motor slewing on
max. displacement, max. torque, small rotation speed. It can not switched onto a
smaller load stage.
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Instruction manual
NMF Board Crane type DK II 120016/55033
CAUTION:
This has no effect on the hydraulic load measurement.
The required settings are made through a PC or laptop using the DMSA04 parameter pro-
gram. The hardware is connected via a COM interface and a null-modem cable. Settings
may only be transferred to the card if
a. the key switch is switched to PARAMETER MODE
b. the password has been entered correctly.
Note: the password is currently DMSA04.
The setting of system parameters always distinguishes between the data by the crane man-
ufacturer ( e.g. load thresholds, jib length, etc.) and measured data determined by corre-
sponding calibration methods. It is possible to overwrite all data ( even the measured
data!).The setting of system parameters is naturally easiest with the help of a computer (lap-
top) because sufficient labelling is available here. The data may, however, also be modified
without a laptop because all parameters may be accessed by the four keys on the controller
card. The password must also be entered for this process. A list with the corresponding
numbers and short names has been provided.
24 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
March, 2007
1 = Parameter running -
only for the regulation of
the Parameter. 2
2 = Operation - Switch
position at crane opera- 1 3
tion. 5
3 = Overbrigde alarm and
warning - switch off the
load master
4
4 = Fuses - in case of 6
defective fuse the LED
goes out.
5 = Display + manuall
Parameter input
6 = PC-connection
Caution:
Parameter settings and modification may be practised only
of authorize personnel.
Illustration6: Loadmaster
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 25
Instruction manual
NMF Board Crane type DK II 120016/55033
Illustration7: Indication-Display
26 Copyright 2005
Instruction manual
Board Crane type DK II NMF
3.20.7 Test operation
March, 2007
No hydraulic pressure is created up during the test operation phase and the main motor and
oil cooler are not started. The electrical connection to the actuators and sensors may be
tested as well as the activation of the current regulation boards.
1. Switch off the crane and turn on the Test operation switch in the switch panel.
2. The crane is now ready for operation (usual only when the main motor is running).
3. The DMSA load-measurement system DMSA (optional) is activated.
4. The feed pressure and pressure switches cannot be tested, as no pressure has been
created.
5. Test the PLC 's input and output:
All sensors and actuators can be tested, if they are connected to the PLC. These are
indicated by the LEDs in the PLC input/output modules.
Look at the switch diagram and find the sensors or actuators to be tested (e.g. pres-
sure switch for load steps). Disconnect the pressure switch plug, the LED on the cor-
responding PLC input module will go out (check with switch diagram) and the
overload alert LED on the PLC output module will come on (if the corresponding load
steps are selected).
The operation of the corresponding current regulation boards can be tested by using the
throttle.
When the throttle is activated (contact 1/2 shows the direction), the amount of current
displayed on the current regulation board increases to a mid-point, preset value. The
direction (Up /Down) is also indicated. (See page 2, Fig. 1)
The valve corresponding to the pump is activated
If the value in the display remains at 0, check contacts 1 / 2 on the throttle.
3.20.7.2 Potentiometer and solenoid valve test when brakes are opened:
At the Test operation switch, switch on the LG pressure sensor bridge switch for the
lifting gear or the extending arm switch. See Fig.
When the throttle is activated, the amount of current increases up to the maximum value
according to the movement of the throttle (Potentiometer 3).
If the mid-point, preset value remains, despite the movement of the throttle to the maxi-
mum and the fact that the LG pressure sensor bridge is switched on potentiometer 3 is
to be checked on the throttle
If the throttle moves, the corresponding brake valve must receive a signal. (LED indica-
tion on the solenoid valve).
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 27
Instruction manual
NMF Board Crane type DK II
After the test, the Test operation and Pressure sensor switches for the lifting gear
and extending arm are switched off and disconnected again.
28 Copyright 2005
Instruction manual
Board Crane type DK II NMF
3.21 PS4-200 Compact PLC
March, 2007
3.21.1 Setup
3.21.2 Elements
Copyright 2005 29
Instruction manual
NMF Board Crane type DK II
You can count pulses at up to 3 kHz via the digital input I 0.0, irrespective of the cycle time.
The up counter is capable of processing square-wave pulses with a pulse/pause ratio of 1.
3. Digital inputs
The PLC has 8 digital inputs. They are galvanically isolated from the CPU. The inputs are
designed for 24V DC. The input delay of normally 55 ms ensures short response times (e.g.
for direct peripheral scans and alarm evaluations). Inputs I 0.0 to I 0.7 can be addressed in
bit or byte format with peripheral I/O commands.
4. Status LEDs for digital inputs
The physical states of the inputs and the diagnostics status word are indicated by LEDs.
5. Status LEDs for outputs
The logical states of the outputs are indicated with light-emitting diodes (LEDs). Outputs Q
0.6 and Q 0.7 are only provided as LEDs.
6. Digital/analog outputs, analog inputs Digital outputs:
The PS4-200 has 6 24V/0.5 A digital outputs. They are galvanically isolated from the CPU
and protected against short-circuits and overloads. Up to four outputs can be connected in
parallel.
Outputs Q 0.0 to Q 0.5 can be addressed either in bit or byte format with peripheral
commands (see chapter 5 Slave addressing).
Analog inputs/outputs: The controller has two analog inputs and one analog output. The sig-
nal range is 0 to 10 V. The resolution of the inputs is 10 bits (1024 increments), while that of
the output is 12 bits (4096 increments).
7. Switch S1 for bus terminating resistors
You can set the bus terminating resistors for the first and last physical stations with switch S1
8. Memory modules
The PS4-200 has an internal, battery-backed, 32kByte RAM. The memory is subdivided into
a data memory and a user program memory.
9. Status LEDs for the PLC
The PLC states are indicated by means of the Ready, Run, Not Ready and Battery
LEDs
30 Copyright 2005
Instruction manual
Board Crane type DK II NMF
March, 2007
1. Back-up battery
2. Reset button
3. Plug connector for local expansion modules
4. Operating mode selector switch
to 1. Back-up battery
The battery backs up the internal RAM and the real-time clock.
Warning! The back-up battery must only be replaced with the power supply switched
on, or data will be lost.
to 2; 4 Operating mode selector switch/reset button
You can select the Halt (stop), Run and Run M-Reset modes with the operating mode
selector switch. The selected mode is activated when you press the Reset button. The oper-
ating states are described in detail in the chapter Operation.
to 3. Plug connector for local expansion module
The plug connector provides the interface for connecting the LE4-... local expansion mod-
ules
Set the bus terminating resistors on the module for the first and last physical stations on a
line. To do this, both S1 switches should be set to the ON position. Both switches must be
set to the OFF position for all other stations.
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Instruction manual
NMF Board Crane type DK II
In order for the PLC to function correctly the two S1 switches must be set to the same
position (ON or OFF).
The PLC can have the following operating states: Run, Ready, Not Ready.
Communication with the PC is possible in all three operating states. Accordingly, the
current status of the PLC and the real-time clock can always be read, for example.
Ready
The Ready status means the following:
There is a user program loaded in the PLC;
The user program is not running;
The outputs are reset and disabled.
The PLC is switched to the Ready status:
If the Reset button is pressed when the operating mode selector switch is set to
Halt;
After the power supply is switched on if the operating mode selector switch is set to
Halt;
By means of the programming software on the PC;
In slave mode, if the master switches to the Halt (stop) status and you have set in
the slave parameters the remote control function to ON in the Sucosoft Topology
Configurator;
If the tab of the memory module is pulled out.
Run
Run status means that the user program is running cyclically.
The PLC is switched to the Run status:
If the Reset button is pressed when the operating mode selector switch is set to
Run or Run M-Reset;
After the power supply is switched on if the operating mode selector switch is set to
Run or Run M-Reset;
By means of the programming software on the PC.
Not Ready
The user program does not run in Not Ready status.
The PLC is switched to the Not Ready status:
If there is no program loaded in the PLC;
As a result of a hardware error;
As a result of a serious error in the user program (e.g. cycle time violation)
Once the error has been rectified, you can cancel the Not Ready status as follows:
By pressing the Reset button; if the operating mode selector switch is set to Run M-
Reset, the PLC will be switched to the Run status;
By switching the power supply off and then on again; if the operating mode selector
switch is set to Run M-Reset the PLC will be switched to the Run status;
32 Copyright 2005
Instruction manual
Board Crane type DK II NMF
By means of the programming software on the PC.
March, 2007
Neuenfelder Maschinenfabrik GmbH
When ever the PLC is started by switching on the power supply, by pressing the
Reset button or by means of the PC, the backup program is compared with the pro-
gram in the RAM. If the programs are not the same, the program in the memory mod-
ule (backup program) is copied to the RAM.If the user program in the memory module
is defective, it is updated, providing the user program in the RAM is valid. An update
is also carried out every time the user program is transferred from the PC to the PLC.
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Instruction manual
NMF Board Crane type DK II
3.21.5 Testing/Commissioning/Diagnostics
Status LEDs
The coloured light-emitting diodes (LEDs) allow fast and simple diagnostics of the PLC func-
tions. The states of the inputs/outputs are easy to monitor.
1) CAUTION!
Data may be lost if the battery does not supply sufficient power. Always replace the
battery with the power supply switched on!
34 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
4 Operation
March, 2007
Load indicator
1
4
5 3
7
9
2
11
6
13
8
15
10
12
14
3
5
2
9
4
6
7
8
10
Neuenfelder Maschinenfabrik GmbH
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 are open and if necessary open the valves
Check whether the oil drain valve is closed.
Only use the crane if it is free from faults.
4.5.2 Switching on
NOTE
Should one pump unit not work, the crane can be operated with another unit. (Turn
the key switch on the switch cabinet to 1 or 2.)
NOTE
From a jib position of 70, the luffing up speed is automatically reduced to crawling
speed and the jib moves slowly to the top final position. From the top final position,
the jib moves faster from 70%.
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 workaholics.
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.
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.
The load steps are switched on at the right panel (see item 4.4.2, page 4). The selected
load step is only shown by pilot lamps in the display unit (see item 11, page 3)) if the jib has
moved to the working area of the load step and the control lever has subsequently been
positioned at O. The load weight is calculated by the load measurement and also shown
on the pilot lamp
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 possible.
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
Neuenfelder Maschinenfabrik GmbH
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.
3 emergency-off buttons are installed in the crane and the crane housing.
in the crane exit on the ladder (upper part of the foundation)
in the switch cabinet
on the right control panel
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.
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, etc. do not to contaminate the environment.
These substances are to be collected, stored, transported and disposed in suitable recep-
tacles.
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 cranes safety devices function properly again
Check all of the functions and the limit switches for the individual load steps without
load.
All work on the cranes 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.
All work on the cranes hydraulic equipment must be carried out by persons especially
trained for such work.
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.
Every six months Slip ring assembly -visual inspection (see item
5.6.10, page 27)
Oil cooler -visual inspection
Screw connection -to check, that screws and nuts are
firmly positioned,
-particularly rope end connection,
jib foot and bottom hook block.
Slewing rim -check seals.
Yearly Crane - function and safety inspection
(see item 5.1.7, page 2)
Multiple disc brake: - check for leakage
(winch gear, slewing gear) - check braking torque
- check brake disc
according to instruction. (see item
6.9, page 15)
Hydraulic system oil analysis (oil tank),
testing of a hydraulic oil sample
Slew ring grease sample:
- grease sample checked of the
manufacturer.
-extruded grease is to be checked
for abraded particles.
Bottom hook block examination by experts
For the first time after 50 Hydraulic system change filter (see item 5.6.7.3,
hours of operation page 21)
gear oil cooler change filter (see item 5.6.7.1,
page 20)
Slew ring (roller bearing) to grease
For the first time after 100 Slew ring to check that screws and nuts are
hours of operation firmly positioned. (see item 5.6.9,
page 24)
Pumps -check visual and leakage
Neuenfelder Maschinenfabrik GmbH
Every 500 hours of operation Hydraulic system change filter (see item 5.6.7.3,
page 21)
Hydraulic system oil analysis (oil tank),
testing of a hydraulic oil sample
Gear oil cooler change gear oil filter (see item
5.6.7.1, page 20)
Gear oil sample oil analysis,
(winch gear, slewing gear, testing of a gear oil sample
pump distribution gear)
Oil cooler visual check, clean with necessity
Wire ropes, rope end connec- rope inspect for wear, see
tion - wire ropes are inspected accord-
ing to stipulations issued by clas-
sification associations and
national bodies.
- check that wire thimbles are
safety secured.
Rope sheaves - inspect for wear
- check that shafts are safely
secured.
Bottom hook block -check that block, beam, hook,
swivel and shackle are intact.
(see item 5.6.8, page 22)
Slack rope switch (optional) check rollers for wear or damage.
Electrical equipment including
slip ring unit.
Heating elements -check
Crane house, foundation and -inspect for any sign of crack.
jib welding joints
Slewing rim -check seals.
Slewing gear and pinion -check backlash
Cable drum (optional) - v-belt, check tension
- slipring unit, check
- brake disk, check
- brush holder, check
see
for the first time after 800 Hydraulic system - oil change;
hours of operation, - oil analysis (oil tank),
testing of a hydraulic oil sample
every 1000 hours of operation Gear: (winch gear, slewing -oil change
gear, pump distribution gear)
Crane -the crane should be inspected by
competent person or returned to
NMF-Cranes for serving.
every 1500 hours of opera- Hydraulic system - oil change
tion; - oil analysis (oil tank), testing of a
or min. once a year hydraulic oil sample
Hydraulic system -change filter (see item 5.6.7.3,
page 21)
Gear oil cooler change gear oil filter (see item
5.6.7.1, page 20)
Gear brake, - disassembled motor and brake,
(winch gear, slewing gear, to check the splint shafts at the
drive side.
Every two years Hydraulic oil tank - take out the drain plug,
- drain oil and clean the reservoir,
- verify that the oil level float switch
is working properly. This inspec-
tion is verified when changing oil
or cleaning of oil tank,
- check air breather cap,
-change filter (see item 5.6.7.3,
page 21)
Every three years Gears - inspection gears
Quinquennial examinations
Slewing rim studs/screw - tighten all studs or screw with a
class renewal surveys
hydraulic crew tensioner or a
torque wrench.
( siehe Seite 24, Absatz 5.6.9)
- consult NMF-service before
replacing studs or screws with
any other specifications than rec-
ommended.
Rope - inspect wire,
Neuenfelder Maschinenfabrik GmbH
NOTE
Please also observe the subsuppliers documents (Chapter 7, Spare Parts).
5.4.1 Symbols
Grease for open spur gears c every 200 hours, every free month
Oil output
dipstick check
Indicator glass
Oil filter check; first filter change to be
done 50 hours.
Hydraulic oil change
first oil change to be done after 800
hour.
Gear oil change
first oil change to be done after 200
hour.
Air breather cab
Neuenfelder Maschinenfabrik GmbH
Pos. Bauteil a b c d e f
grease nipples
grease nipples
Oil inlet
Grease nipple
Grease nipple
oil inlet
oil dipstick
Neuenfelder Maschinenfabrik GmbH
oil outlet
5.6.2 Greasing
5.6.3 Gear
The Zollern planetary gear is provided with splash lubrication. The anti friction 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.
CAUTION
Only change the oil when
the gear is at a standstill
in a warm operating state.
Compare the amount of oil drained off with the stipulated amount of oil.
Checking for solid foreign matter
We recommend a check carried out for foreign matter in accordance with DIN 51592. The
sample 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 are only to consist of fine abra-
sion up to max. 25 ym.
If the permitted value is not exceeded, the gearbox can continue to be used after the oil
change.
If coarse abrasion (above 25 ym) 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.
For safety reasons, check the screws for tight fit before resp. after long period of con-
tinuous operation and in case of frequent maximum load. If inspections or repairs are
necessary, we recommend sending the works under all circum stances so that a max-
imum of reliability is guaranteed for safety reasons we recommend an inspection of
the gear (inside and outside) every 3 years.
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
Neuenfelder Maschinenfabrik GmbH
The markings of put-in dipsticks (not screwed execution) apply in the status put in up to
impact.
5.6.7 Filter
CAUTION
Only clean wire gauze elements (type 25W) in cleaning fluid.
We recommend to oil examine oil samples by the oil supplier. The supplier then provides
you with information concerning the oil condition and suggests a date for the oil change.
Indicator
The filters are equipped with an optical dirt indicator(Chapter 7, Spare Parts).
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 needs 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.
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
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 (5) of the element (3)
Neuenfelder Maschinenfabrik GmbH
NOTE
Replace disposable filter elements, soiled Betamicton`N-2 (BN, BN/HC) or
Betamicron 9H-2 (BH, BH/HC) elements with new elements.
Illustration22: Filter
1. Maintenance
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:
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 item 5.4, page 9) are to be used. These raceway 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 fric-
tion, seal the bearing and provide protection against corrosion. Therefore, the bearing must
always be greased liberally so that a collar of fresh grease forms around the whole circum-
ference of the bearing gaps and seals. The bearing should be rotated during relubrication.
5.6.9.2 Lubricants
The appropriate manufacturer should answer queries concerning lubricants. The greases
listed in Table of lubricant are approved for our large diameter anti friction 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 both 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 for 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
The stud bolts are tightened twice at assembly / when fitted using a clamping cylinder, which
stretches the screws with a corresponding tensile force.
The bolts connection has to keep a sufficient pre-load during the whole bearing life. For com-
pensation of settlement phenomena a refastening on regular base may be necessary.
It is necessary to check that the foundation bolts are secure. This is only possible by lightly
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.
Smooth 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.
Neuenfelder Maschinenfabrik GmbH
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.
Adjustment of switch 2
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.
Neuenfelder Maschinenfabrik GmbH
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.
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 sheaves 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 sheaves) The lubricants
to be used are stipulated in (see table 7.9, page 33). The re-greasing agents are to
be compatible with 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 work 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 from
time to time and replaced under pre-tension. A rope works most economically if the com-
plete length is always used. Therefore, it is recommended that the appropriate rope length
be used for 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 not 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 results in a noticeably longer 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
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 31
Instruction manual
NMF Board Crane type DK II 120016/55033
5.7.2 Monitoring
If necessary, the wire rope and the fastening 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
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 over expansion 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.
32 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6. Carefully lift the pulley block and operate the crane unloaded with a pulley block and
March, 2007
CAUTION
Under no circumstances should a short length of rope be forcefully twisted; this may
permanently damage the rope structure.
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.
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 item. 4. Reinstall the limit switch.
8. For safety reasons, check the adjustments. Also refer to the assembly instructions for
Neuenfelder Maschinenfabrik GmbH
the crane
Copyright 2005 33
Instruction manual
NMF Board Crane type DK II 120016/55033
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 (see item 5.7.2, page 32), the following information stip-
ulates 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.
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
34 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
Deformation of the wire cable are visible changes in the rope bond. On the basis of their
March, 2007
Copyright 2005 35
Betriebsanleitung
Bordkran Typ DK II 40025 NMF
N u m b e r o f v is ib l e w i r e b r e a k a g e s w h e n w ir e r o p e is t o b e r e p la c e d
d r iv in g g e a r g r o u p s d r iv in g g e a r g r o u p s
N u m b e r o f b e a r i n g w ir e s
1E m , 1D m, 1C m , 1B m 1A m 2 m, 3 m , 4 m , 5 m
in t h e e x t e r n a l s t r a n d s o f
3 c r o s s la y lo n g l a y c r o s s la y lo n g l a y
t h e w ir e r o p e )
a lo n g a le n g t h o f a lo n g a le n g t h o f a lo n g a l e n g t h o f a lo n g a le n g t h o f
6d 30d 6d 30d 6d 30d 6d 30d
B is 5 0 2 4 1 2 4 5
5 1 b is 7 5 3 6 2 3 6 12 3 6
7 6 b is 1 0 0 4 8 2 4 5 16 4 ~8
1 0 1 b is 1 2 0 6 10 2 6 10 19 ~ 10
1 2 1 b is 1 4 0 6 11 3 6 11 22 6 11
1 4 1 b is 1 6 0 6 13 3 6 13 26 6 13
1 6 1 b is 1 8 0 7 14 4 7 14 29 7 14
1 8 1 b is 2 0 0 8 16 4 8 16 12 8 16
2 0 1 b is 2 2 0 9 18 4 9 18 35 9 18
2 2 1 b is 2 4 0 10 19 5 10 19 38 10 19
2 4 1 b is 2 6 0 10 21 5 10 21 42 10 21
2 6 1 b is 2 8 0 11 22 6 11 22 45 11 22
2 8 1 h i. 3 0 0 12 24 6 13 24 48 12 24
4
ber 300 ) 0 .0 4 n 0 .0 8 * rn 0 ,0 1 * n 0 .0 4 * n 0 .0 8 * n 0 ,1 6 * n 0 .0 4 * n 0 .0 8 * n
W it h r o p e d e s i g n s w i t h s p e c ia l l y t h ic k w ir e s in t h e e x t e r n a l la y e r o f t h e e x t e r n a l s t r a n d s , e . g . 6 x 1 9 S e a le -
t y p e r o u n d s t a n d r o p e i n a c c o r d a n c e w it h D I N 3 0 5 8 o r 8 x 1 9 r o u n d s t r a n d r o p e in a c c o r d a n c e w it h D I N
3 0 6 2 , t h e n u m b e r o f v is i b l e w ir e b r e a k a g e s a r e t o b e s e e n a s b e i n g 2 l in e s le s s t h a n t h e t a b l e v a lu e s .
D r i v i n g g e a r g r o u p s i n a c c o r d a n c e w it h s h e e t 1 o f D I N 1 5 0 2 0 .
d w ir e r o p e d ia m e t e r
3) F i ll e r w i r e is n o t s e e n a s b e i n g b e a r in g
I f w ir e r o p e s h a v e n u m e r o u s s t r a n d la y e r s o n l y t h e s t r a n d s in t h e e x t e r io r s t r a n d la y e r s a r e " e x t e r n a l
s tra n d s ".
I f s t e e l r o p e s h a v e a s t e e l r e in f o r c e m e n t , o n l y t h e r e in f o r c e m e n t u s is t o b e s e e n a s b e i n g a n i n t e r io r
s tra n d .
4) T h e c a lc u la t e d f ig u r e s a r e t o b e r o u n d e d u p .
36
Instruction manual
Board Crane type DK II 120016/55033 NMF
6 Monitoring, Failure, Troubleshooting and Elimination
March, 2007
6.5 Speed monitoring of the jib winch and lifting gear winch
The jib and lifting gear winches are equipped with a speed monitoring. Should the maximum
speed be exceeded due to a drive fault, a forced braking is automatically activated. The
FAULT lamp on the left control panel in the cabin is illuminated, in the switch cabinet, the
lamps excess winch speed, excess jib winch speed. The crane operator is unable to
restart the winch. The fault can be eliminated with the Reset excess speed button (see
illustration 50, page 7).
Should there be a deactivation due to excess speed and there are no faults on the drive, the
excess speed monitoring can be deactivated.
NOTE:
A deactivation of the excess speed is only to be carried out with the agreement of the
manufacturer.
The switch is in the switch cabinet. (see item 48, page 5).
The switch is only to be activated if the crane is to be subjected to a loading test.
CAUTION:
The hook my collide with the jib.
Neuenfelder Maschinenfabrik GmbH
Overload
yes Display no
on the
DMSA
blinks.
L o o k fo r th e p re s s u re s w itc h in
Lifting up the load again th e e le c tric d ia g ra m ; fo r e x e m p le
o.k.
.:
C h e c k th e in p u t (f.e . in p u t 5 ) o n
th e P L C -m o d u le (f.e . 1 A 7 ).
L ig h ts n o th is p ilo t la m p a t
a c tiv a te d c o n tro l le v e r, c h e c k th e
p re s s u re s w itc h , if n e c e s s a r y
c h a n g e th is .
F a ilu r e o f e le c tr ic
F a u lt P ro b a b le c a u s e R em edy
E m e r g e n c y O ff p u s h b u tt o n s i n c o n t ro l
E l. m o to r d o e s n o t s t a rt U n lo c k e m e r g e n c y o ff p u s h b u tt o 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 t u r n in g .
c r a n e f o u n d a tio n a re a c t u a t e d .
C h e c k o il le v e l. R e p le n is h if re q u ir e 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 rr e c t, t h e a u x . c o n t a c t o r m u s t
re s p o n d
C h e c k a u to m . c i rc u it b r e a k e r lo c a te s h o rt
N o 2 3 0 V c o n tr o 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 t ro l
A s y m m e t ric r e la y h a s tri p 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 f e e d e r .
g re e n L E D d o n o t lig h t.
T r ip p in g d e v ic e h a s t r ip p e d o w i n g to A m b ie n t t e m p e ra t u r e t o o h ig h . C ra n e is
w in d in g t e m p e ra t u r e , L E D s a r e a lig h t. p e r m a n e n tly o p e ra te d a t its l o 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 i n fu s e s b lo w n . R e p la s e s fu s e s . I n c a s e o f r e p r e a t e d
d e f e c t lo o k fo r p o s s ib le s h o r t c ir c u it in m a in
c a b le a n d s lip r in g u n it.
E l. m o to r s ta rts in S t a r / D e lt a , b u t
S e e f a 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 t e ly .
C h e c k th e h y d r . s y s t e m ( h y d r . h o s e
R e s e t S w it c h is a c t u a te d . d a m a g e ) R e s e t s w itc h s w it c h in g o ff.
P o w e r L E D d o e s n o t li g 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
Control pressure by- pass valve does not Meter current supply. Examine valve for being
switch or is mechanically blocked. clogged. Exchange solenoid.
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.
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.
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.
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.
Lifting gear has reached its highest The jib to be topped up or the load to be attached shorter.
hook position at maximum outreach.
The lifting gear motor is still switched Check half-load solenoid for proper operation and fouling.
to half-load.
Lifting winch does not turn. Defective or fouled brake solenoid valve. No
Brake does not vent. No control pressure.
power supply to solenoid valve.
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.
Current Regulator print Card does not Input LED (MPC) do not light up.
Topping winch does not turn
respond. Check potentiom eter on control lever whether it
is maladjusted or defective.
The LED for "Topping Up" and/or Aux. contacts on control lever to be checked.
"Low ering" do not alight.
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.
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
maximum outreach. jams. Limit switch for jib 0 position is for correct working. Defective switches
defective must be renewed.
Input LED does not light up. aux. contactors on control lever.
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.
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.
Slewing gear pump is defective; and does not Blank off pressure lines and actuate pump control solenoid valves manually.
produce any pressure or only little pressure. In case of a pressure drop or no pressure at all, renew pump.
The multiple-plate brakes are installed as compact unit between driving motor and transmis-
sion.
6.9.1 Description
In the case of hydraulically-controlled, spring loaded brakes the disk assembly is pressed
together by a set of coil springs. The annular housing (2) with toothing for engagement with
the outer disks (5) and piston (1/1) and cylinder (1/2) are combined in a unit (see picture 7).
This brake unit is secured on the gear by anti-fatigue bolts (12). The disk ring (4) is provided
with toothing to engage with the inner disk (6) and is connected with the shaft to be braked.
Neuenfelder Maschinenfabrik GmbH
6.9.2 Connections
The brake is provided with connections for the intake of the pressure media. These have to
be connected with the hydraulic system of your installation. Dimensions and position of con-
! nections can be taken from the mounting design enclosed.
Unscrewing or removing of hydraulic pipes under pressure resp. of connections are
hazardous. Take care that -in case of works at the brake (mounting, dismounting)- the
brake and the belonging hydraulic pipes are depressurized.
Copyright 2005 15
Instruction manual
NMF Board Crane type DK II 120016/55033
16 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.9.3 Pressure media
March, 2007
Hydraulic oil is necessary to release the brake. Viscosity should not exceed 32 to 68 cSt at
40 C.
6.9.4 Operation
The brakes are designed for max. 320 bar operating pressure. The minimally needed
release pressure can be taken from the rating plate.
Never operate the brake with higher pressures than 320 bar, because there is danger
of screw breaks resp. the break of safety rings. Don`t operate the brake with low
! release pressure because it isn`t layed out to work as a dynamically brake. In such
case it will be damaged.
In case of breakdown of the hydraulic system or in case of maintenance work the brake can
be opened mechanically. For that purpose a hand operated hydraulic pump can be con-
nected to the compressed oil connection of the brake. According to with the minimum
release pressure see rating plate admit the brake.
The flange (1/3) is under spring pressure. It can suddenly come off when unscrewing the
screws(12). It is necessary to release the brake manually before dismounting. Insert two
screws of suitable length with nuts in the threaded borings of the piston (1/1) opposite each
other at 180on the face ends (see picture 7.7). Each nut must be tightened alternately with
a half turn, by that with draw the piston to the flange (1/3) - (Avoid tilting the piston!). Then
unscrew the screws(12), the closed brake can be removed from the gear.
Copyright 2005 17
Instruction manual
NMF Board Crane type DK II 120016/55033
Illustration 36:
To dismantle further, unscrew the two screws (1/7). It is now possible to pull the flange (1/
3) with piston (1/1) out of the cylinder (1/2). When replacing the outer and inner seals, pay
attention to the position of the seals to ensure that they are reinstalled in the same way.The
chromium-plated and super-finished piston tracks must not be damaged in any way. Ensure
complete cleanliness! (Do not use cleaning wool).When replacing disks, first guide the
annular housing (2) alone onto the gear centre. The disk assembly should then be fitted.
Ensure that the correct disks are fitted. Pay attention to right disk placement because it is
important for the braking torque. The correct disk placement can be taken from the technical
data sheet enclosed.If it will be necessary to pull the flange (1/3) of the piston (1/1), it will be
done by alternate unscrewing the nuts, placed on the screws for emergency release. Never
screw out the screws for emergency release before complete releasing of springs between
piston and flange (danger of accident!).
The brake is assembled in reverse order.
18 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.9.8 Malfunctions
March, 2007
Copyright 2005 19
Instruction manual
NMF Board Crane type DK II 120016/55033
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 lifting pump, the load is immediately dropped. Life is placed
at a risk and extensive material damage is caused.
20 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.11 Lifting gear
March, 2007
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%.
6.11.1 Connect the hand pump for opening the brakes as follows.
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the lift-
ing gear brake.
2. Disconnect the brake hose 5 of the lifting gear brake to the solenoid valve (see illustra-
tion 37, page 24)
3. Connect the hose 2 of the hand pump for lifting the brake (see item 38, page 25) to the
brake hose 5.
4. Plug the connection Y to the solenoid valve of the lifting gear using a screwed plug.
5. Connect the pressure release valve 5 to the hand pump for lifting the brake and check the
oil level in the pump tank (see illustration 38, page 25).
6. Open the corresponding bypass valves 3.1; 3.2 on the lifting gear hydraulic pump. (see
illustration 39, page 26).
7. Carefully increase the pressure at the hand pump (max. brake opening pressure approx.
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 lifting
pump.
8. After the load is lowered, restore the original situation.
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 21
Instruction manual
NMF Board Crane type DK II 120016/55033
6.12 Jib
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%.
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the luff-
ing gear brake.
2. Disconnect the brake hose 4 of the luffing gear brake to the solenoid valve (see illustra-
tion 37, page 24)
3. Connect the hose 2 of the hand pump for lifting the brake (see illustration 38, page 25) to
the brake hose 4.
4. Plug the connection Y to the solenoid valve of the luffing gear using a screwed plug.
5. Connect the pressure release valve 5 to the hand pump for lifting the brake and check the
oil level in the pump tank (see illustration 38, page 25).
6. Open the corresponding by-pass valves 4.1;4.2 on the luffing gear hydraulic pump. (see
illustration 39, page 26).
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 pressure
release valve 5 for the hand brake lifting pump.
8. After lowering the jib, restore the original situation.
22 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.13 Slewing gear
March, 2007
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the
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 for lifting the brake and check the
oil level in the pump tank (see illustration 38, page 25).
6. Open the corresponding bypass valves 5.1; 5.2 on the slewing gear hydraulic pump. (see
illustration 39, page 26).
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 lifting 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.
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 23
Instruction manual
NMF Board Crane type DK II 120016/55033
1
2
24 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
March, 2007
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 25
Instruction manual
NMF Board Crane type DK II 120016/55033
26 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.14 Gear cam limit switch
March, 2007
Every person involved in operation, maintaining and repairing the limit switch must
be authorized, adequately trained and instructed.
6.14.1 Maintenance
When carrying out maintenance and inspection works, pay attention to chapter Safety
instruction
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.
Each contact is coordinated 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 item 9, page 1).
Adjustment of crane cam discs (see illustration 40, page 27)
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 27
Instruction manual
NMF Board Crane type DK II 120016/55033
28 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
10. Move bottom hook block to around 1m below the jib head.
March, 2007
Turn cam HW5 on the hoisting gear limit switch in the direction A until the LED 12 on
the 1A12 goes out.
11. Measure 6,0m length of jib from the middle of the crane pivot to the middle of the
hook.
Luff up jib to the measured point.
(This is where the speed reduction range 6,0m -3.3m begins for the jib.)
Turn cam WW5 on the luffing gear limit switch in the direction A until the LED 6 on
the 1A12 goes out.
12. 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.
Turn cam WW6 on the luffing gear limit switch in the direction A until the LED 6 on
the 1A12 goes out.
13. Measure 3,3m length of jib from the middle of the crane pivot to the middle of the
hook.
Luff up jib to the measured point.
Between crane housing and stop bumper of the jib should be a distance of approx.
100 mm remain.
Turn cam WW7 on the luffing gear limit switch in the direction A until the LED 8 on
the 1A12 goes out.
NOTE:
The jib should not touch the crane housing, to turn off absolutely before.
14. The rope from the hoisting gear can be wound twice around the drum.T
Turn cam HW6 on the hoisting gear limit switch in the direction A until the LED 13 on
the 1A12 goes out.
15. Move the bottom hook block down until the hook is approx. 1m above the double bot-
tom. There must be at least 3 safety windings left on the hoisting drum.
Turn cam HW7 in the direction B until LED 14 on the 1A12 goes out.
16. If the drum full, turn cam HW8 on the hoisting gear limit switch in the direction A until
the LED 15 on the 1A12 goes out.
17. After adjusting the limit 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.
18. Slew the crane into the park position.
Press the Park jib key switch and hold down, the jib moves to the park position.
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 29
Instruction manual
NMF Board Crane type DK II 120016/55033
B
B
A
A
Modul 1A12
30 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
March, 2007
B
A
Module 1A12
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 31
Instruction manual
NMF Board Crane type DK II 120016/55033
WW7
WW6
3,3m 4,2m
WW5
6m
WW4/HW4
16m
WW3/HW3
19m
WW2/HW2
24m
WW/1HW1
33,0m
WW0
Parkposition
32 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
6.15 How do I exchange a Memory-Programmable Control (MPC)?
March, 2007
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.
Copyright 2005 33
Instruction manual
NMF Board Crane type DK II 120016/55033
34 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
PS4.
March, 2007
Fig.1 Fig.2
Fig.3 Fig.4
Fig.1 Fig.2
Fig.5 Fig.6
Copyright 2005 35
Instruction manual
NMF Board Crane type DK II 120016/55033
Fig.7 Fig.8
Fig.9 Fig.10
Fig.11 Fig.12
1
Codierschalter
36 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
March, 2007
Fig.13 Fig.14
Fig.15 Fig.16
Battery
Neuenfelder Maschinenfabrik GmbH
Copyright 2005 37
Instruction manual
NMF Board Crane type DK II 120016/55033
38 Copyright 2005
Instruction manual
Board Crane type DK II 120016/55033 NMF
7 Spare Parts
March, 2007
Auftrags-Nr./Order -No.
Product See type plate
Type
P10P
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.
050
051
052
053
054
055
056
070
Emergency exit
Filter
L8T2 L9T2
C05
Series 90R(L)100
L0T2
C13 L9TA L6TA
B80
Baureihe 90R(L)100
C14 L6T2
B80A L0TA
C15 W3CN L1T2
B70
C16 W1CN B82 B82A B70A
L9TG
B83 B90
L2TA
B83 L1TA
C80
B83A
E000 087 W32 L2TG
F20
L1TG
W2CN B71A L0TG
M14 D75 (B100)
B20 B71
D65 D70 B50
D55 D85 B10
G96
D10 D80
Original
E6
Ersatzteile
Genuine Parts
B30 E30
E20
G30 E80
D95 E8 E11
D60 E82
E50
E10
E5
Seite
E22
Page
D50 E24
1
E70A E61
W5BD
of
von
E000 001
P001 677D
F10*
F11 F010
F12
F60*
F10
F12
F303 F11
F31*
Series 90R(L)100
F020
Baureihe 90R(L)100
F40
F50 F50
F607 F35* F34* F40 F30*
F140 F22 F21 F60* F020
F705 F31*
F020 F60
F50
F120 F40
F100 F30*
F717
F090 F60
F130 F070 F40 F34*
F827 F080 F50
F110
F50
F060
F040 F40 F35*
F140 F030
F317 F308
F31B F030
F050
Ersatzteile
F100 F080
Genuine Parts
F060 F120
F40 F090 F40 F070 F130 F60*
F50 F50 F080
F070 F120
F070 F100
F130 F110
F827 F110 F080 F090
F100 F827
F060
E000 088 F110 F040 F705
F030
Seite
Page
F140
F40
of
F050
von
12
500328,Rev. L
E000 001
P001 677D
M90
M72 M90 S40 M72
M90 M90
M71 M83M M71
Series 90R(L)100
M1C*
M1M*
M1M*
E000 014
E000 012
E000 010
TA A B TB
Original
Ersatzteile
P
Genuine Parts
E000 006
T8** T6**
3
T001
of
von
T009
12
500328,Rev. L
E000 001
P001 677D
M74M
M76M
M9M* M92M
M78M M76M
M75M M78M
M75M
M77M M77M M90 M97M
Series 90R(L)100
M90 M90
M72 M95M M98M W702
S40 M72
M90 M71 M83M
Baureihe 90R(L)100
M1M*
M1D*
M11M
M11M M11M M11M
E000 018
E000 016
E000 020 M0M8
M0MC M0MD M0DC
M0MN E000 067
M0DD
W701A
T00P
P
A B
Original
Ersatzteile
Genuine Parts
TA A B TB T
E000 006
T8** T6**
T001
of
von
T009
12
500328,Rev. L
E000 001
P001 677D
M95
M96
M90
M90 M95EB M7EB
Series 90R(L)100
M96
M97EB M8EB
M95K
X1 X1
P M97 P
M97K M95K
X1
X2 X2 M1EB P
X2
M1E* M1K*
B TB
Genuine Parts
TA A
P
E000 006
T8** T6**
of
T001
von
T009
12
500328,Rev. L
E000 001
P001 677D
500328,Rev. L
Original Seite von
Ersatzteile
Genuine Parts Page 6 of 12
Baureihe 90R(L)100
Series 90R(L)100
M101
M0MO
M1M*
M95M
M11M*
M7M*
M71
M72
E000 021
M90
M0FB
M0FA
M1F*
M11M
M20
M92
T00A
M10
M91
T00T
E000 056
T00B
E000 001
P001 677D
M9P*
M100
M97E
M96E M98
M90 M90
Series 90R(L)100
M95E
Baureihe 90R(L)100
M1H*
M1P*
(M1E*)
M11H M11H
E000 029
A
B
P
TA TB
Original
Ersatzteile
Genuine Parts
T601
T809/
T001 T699 T8A9
of
von
T009
12
500328,Rev. L
E000 001
P001 677D
M78M
MBAS
M72 M83M
M90 M90
M71
Series 90R(L)100
M77NE
M72
M7N* M71
Baureihe 90R(L)100
M1N*
M7N*
M11N
E000 024 M1N*
E000 060
M11N
M0NU
M0NA
B
A
Original
Ersatzteile
P
Genuine Parts
E000 023
8
T001 T801T809
T8A1T8A9
of
von
T009
12
500328,Rev. L
E000 001
P001 677D
G54 K90
G53 K10 G53
K50 K0** G54 G53A
G53A
G54A K70 G54A "A"
"A" K80 K0**
G55
(G18) K50 K10
B K80
G55A
Series 90R(L)100
(G18A)
G51A
G90 G51 G90
Baureihe 90R(L)100
K70 K90
(G50A) G95 G51A
G95 G57A (G50) A
G57 G51
G50
Ersatzteile
Genuine Parts
G52 G50A
von
G50 G50
12
500328,Rev. L
E000 001
P001 677D
N00M
N35A
N35 N00S
N40P E000 069 N35A
N10S
N10P
N10L N10SA
Series 90R(L)100
N35A
Baureihe 90R(L)100
N00P
N00L N40L
N35
P2B*
N10R N20 H90LA
N15 H90L
N25 P06
N35A E000 085
P13
N35 P2A*
P06
N10M N00R
N20
N15
N35A
N40M N25 P13
P2AX E000 089
P06
N00M E000 105 P13
N35
N20 H50
N15 H05*
N25
E000 070
H60
H90LA
Original
H40
Ersatzteile
Genuine Parts
H05*
H90L
H50
H60
H40
H30
H50
Seite
Page
H30
H05*
10 of
H05*
von
12
500328,Rev. L
E000 001
P001 677D
500328,Rev. L
Original Seite von
Ersatzteile
Genuine Parts Page 11 of 12
Baureihe 90R(L)100
Series 90R(L)100
N0J3
E000 280
N0J2
N0J4
N0J1
N00J
N16
N25*
N40*
N15
N20*
N10*
N00Z
N95
N41
E000 279
N20
N41A
N10
N40
N0G2
N0G3
N40A
N0G4
N42A
N42
N0G1
N00G
E000 001
P001 677D
500328,Rev. L
Original Seite von
Ersatzteile
Genuine Parts Page 12 of 12
Baureihe 90R(L)100
Series 90R(L)100
J0NN
JVNN E000 073
H80
J10*
H70
J40
J15
J901
J90A E000 074
J50 J10*
J95
J60*
J40
J70 J15
J92*
J80
E000 075
J90B
J50
J0E* J0A* J95 J60*
JLA*
JRA* J70
J92*
J80 J10*
J40
J0B* J15
JLB*
JRB* J50 E000 076
J60*
J95
J90C
J70
J92*
J80
J0C* J10*
JLC* J40
JRC*
J15
E000 077
J50
J60*
J95
J90C J70
J80 J10*
J92* J40
J0CP J15
JLCP
JRCP J50
E000 139
J60*
J95
J90C
J70
J92*
J80
JRCR
E000 001
P001 677D
51****
Baureihe Series
W30
W32
{W50}
B72 B70 W30
{W25}
B70A
B70
W30
W30
B70A
Y20
W30
Y10 Y10 B71A
Y10 W30A
B71A B71
Y20 Y20
Genuine Parts
Ersatzteile
Original
B71 Q120
B72
{W25}
Q120
W32
{W50}
782 870R
Page
Seite
E000 033
W30 E000 032
1
Y10
B71A
of
von
Y20
B71
7
Q120
51****
Baureihe Series
L70
L35
L40
L50D
L0**
B80V
L35 L70
Q030
L40
L50V
L0**
G34
W10 Q030
G32
G60
L80
L75
L40
L50C
B80C L80
U4C9
U4D2 B50
W10
Genuine Parts
Ersatzteile
Original
E000 037 B10
L70
C40
C60
C50 Q020 L35
C01 L95
782 870R
L81
Page
Seite
C02
C20
C05 L82
2
L35
of
von
C10
L0** L95
7
B05 L85
E000 036
L90
B10
782 870R
Original Seite von
Ersatzteile
Page 3 of 7
Genuine Parts
Baureihe Series
51****
E000 039
L60
L10
L30
E000 033 L1** L20
L150
L130
L120
L0** L60
L84
L10
L230
L30
L20
L110
L150
L130 L1**
L120 L0**
L140
E000 040
L84
L230
782 870R
Original Seite von
Ersatzteile
Page 4 of 7
Genuine Parts
Baureihe Series
51**** G24
G110
(060-250)
G110A
G260 (....) = Nur fr die angebene BG
erforderlich.
G110A
G26 = Applies to the indicated
G110
(250)
frame size(s).
G36 F28
G100
F26
F10*
F11
F120
J70 F20* F10
{S50} F120
J60 F11 F12
{S30} (060)
J100 F10
J50
{S40} F12
J90+J30
siehe Seite 6 F24
see page 6 (080) F24
J40 (060)
{S60} F30
(060)
F26
F28
F24 F26
(110,160,250) F28 K90
Y40
G20 K10 K95
G20A Y50 K95A
K20
K70
K0** K70
(250) K0**
G20 K14 K80
G20A K80
K16
K10
K50
K50 K90
G12 G50
G12A G50A K90A
G30 G30A
(250) G30A G30 (250) K18
(250) (250) G10
K18
G12
K16
G12A K14 K20
G12A (250)
G30 G20A
G12 G20
G30A
G80A
G80 (060,080)
(060,080) G30A
(250)
G30 G20A
(250) G20
Baureihe Series
51****
M28/
N28 M84/N84 M27A/N27A/N99A
M28A/ M84A/ {M34A}/{N34A}
N28A N84A M27/N27/N99
M27/N27/N99 {M34}/{N34}
N32/M32 M52/ {M34}/{N34}
N52 M27/N27
{M72}/{N72} M27A/N27A/N99A
M27A/N27A {M34A}/{N34A}
M26/N26
{M66}/{N66} {M72A}/{N72A}
M27/N27/N99
M26A/N26A {M34}/{N34}
{M66A}/{N66A} M30/N30
M27A/N27A/N99A
M27A/N27A {M34A}/{N34A} M84/N84
{M34A}/{N34A} M27/N27
M27/N27 {M34}/{N34}
{M34}/{N34}
M27A/N27A
{M34A}/{N34A}
M84A/N84A
M10/N1A* M28/N28
M27A/N27A
{M90A}/{N90A} M26A/ M28A/N28A
M26/N26
N26A
M27/N27
{M90}/{N90} M27/N27 M28/N26
M27A/N27A {M34}/{N34} M28A/N26A {N66}
{M34A}/{N34A} {N66A}
M58/N58 N24
N82
N11
N29
M23/N23
M27A/
N27A M99A
E000 043
M99
M23A/N23A M27/
N27
782 870R
Original Seite von
Ersatzteile
Page 6 of 7
Genuine Parts
Baureihe Series
51****
G110 U8**
(60-250)
U8**
(250)
M11
T1** M11
M1U5 T3**
M1U5 G110
G12
G30
E000 047
M11
T2** N52 M27/N27/N99
M1U5 T4** {M34}/{N34}
N1U5 M27/N27/N99
U5** G30 {M34}/{N34}
(250)
G36
N46
S10 G90 T5**
S10* M27/N27/N99
(160, 250) {M34}/{N34}
S20
S10* N52
(060, 080, G42 T6**
110)
G38
E000 044
G38
J30
(siehe Pos. J100, G42
Seite 4) J10*
seePos.J100 page 4
U6**
J20/S70 U7**
T7**
T8**
T7**
F32
F324
E000 165
F32
F324P
51****
Baureihe Series
M0EP
M0EQ
M0ER M28 M28
M0ES M24
M24
M38
M36 M0HP
M10
M30
M32 M18
M32A M28
M26
M40 M30 M14 M0HS
M32
M42A M24
M30H M12H
M42
M26 M1HP M1HS
M17A
M17
M1EP M16
M1EQ
M16 M0E1/M0E2/ M0R2
M12 M14
M10 M0E5/ M0S1
M18 M12 M0F1/M0F2/
M20 M16E
M10 M0H1/M0H2/
M22 M36 M0K1/M0K2
M10 M20 M20 M22
M20 M20
M22 M16S
M22A M16S
Genuine Parts
M22 M24A
Ersatzteile
Original
{N90A} M10
E000 045 M24
{N90}
M10
M30 M18
M14 {X003}
M19A
M1S1
782 870R
M1E1E2E5 M19 M23
Page
Seite
M1F1F2 M1R2
M1H1H2 M1S1
M1K1K2 M2E5
7
M14
of
von
7
Spare parts list Brueninghaus Hydromatik
Order No.: 02404901 Horb Plant
Denomination: A A6V M 250 EP2D /63W2-VZB157 B-SO109
Drawing no.:
Drawing no.:
Info:
190000159.gb.doc Seite 1
GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Surveying mechanisms for machines and gearboxes get more and more important, because the
requirements and service conditions are often differing from the ones that are foreseen from the designers.
Systematic oil tests during regular intervals give a trendy reliable diagnostic regarding the wear development
and beginning damage. The point at issue will be which oil, permitted according the lubrication
recommendation, has really been used.
Simple surveillance:
In order to get a detailed information on the status of the gearbox, regular oil analyses prevent partial or
complete disassemblies.
190000781.gb.doc Seite 1
Particles of a size of 40 m in clear oil are visible with the eye. If so there is certainly already a progressed
damage of the gear.
190000781.gb.doc Seite 2
INSTALLATION INSTRUCTION
General
Please also note the indications in our installation drawing.
The ZOLLERN rope winch is supplied completely assembled.
For installation of the winch dismount the flange.
Before assembly, verify the steel construction of the winch according to our installation drawing.
The screw-on-surfaces have to be worked properly to the same level.
Disassembly
Draw off flange.
Assembly
Please note installation position of winch according to our installation drawing!
Clean all screw-on-surfaces and tape holes at the gear and the flange metallically clean.
Secure with Loctite Type 242 all ZOLLERN screw-on-connections which were loosened during disassembly.
Please note Loctite-processing- information.
Strength classes and torque moments for screws see installation drawing.
Turn the marking "O" (= top) at gear flange to the position indicated in the installation drawing.
Put rope winch into steel frame.
Centre gear in the steel frame.
Fix gear with screws.
Fit flange equally and straight and centre it in the steel frame.
Do not use force !
Fix flange with screws.
Check oil level with oil dipstick.
Refill oil if necessary.
If the 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.
Remove transport covers off the motor flanges.
Connect brake line (see installation drawing).
Release hydraulically multiple disc brakes.
The drive sleeves in the drive units must turn easy.
Remove plugs off the drive sleeves in the drive units.
For protection against corrosion the drive sleeves are provided with gear oil from the gear. The plugs
prevents a filling with oil of the motor flanges before montage of the motors.
Attention: Motor shafts grease-free!
Centre motors in the motor flanges.
Seal connecting surfaces.
Fix motors with screws.
Before test-running, fill motor flanges completely with gear oil.
Control rope winch with running motors as to function.
Check above all the control and function of the holding brakes and the drive motors.
190000705.gb.doc Seite 1
After test-running check oil level once more with oil dipstick.
During the test-running, the oil level in the gear and motor flanges is adjusting itself and so fills the space
to the motor shafts slowly with gear oil. Therefore the oil level may be reduced.
If necessary, refill oil.
Insert rope.
Fix rope with pressure screws.
Secure pressure screws accordingly.
190000705.gb.doc Seite 2
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.
190000751.gb.doc Seite 1
RECOMMENDATION FOR LUBRICANTS
Choice list
190000752.gb.doc Seite 1
ERSATZTEILLISTE
SPARE PART LIST
19007973
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**********************************************************************************************************************
______________________________________________________________________________________________________________________
1 1,0 193007974 GETRIEBE GEAR + OUTPUT
-----------------------------------------------------------------------------------------------------------
1/ 1 1,0 193007975 ABTRIEB OUTPUT DRIVE
-----------------------------------------------------------------------------------------------------------
1 / 11 1,0 100100754 PLANETENSTUFE PLANETARY STAGE
************************************************************************************************* SEITE - 2
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**********************************************************************************************************************
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
1 / 21 1,0 100100549 PLANETENSTUFE PLANETARY STAGE
-----------------------------------------------------------------------------------------------------------
1 / 24 1,0 100100526 PLANETENTRGER PLANETARY CARRIER COMPLETE
-----------------------------------------------------------------------------------------------------------
1 / 27 1,0 100020701 ZWISCHENGEHUSE INTERMEDIATE HOUSING
-----------------------------------------------------------------------------------------------------------
1 / 31 1,0 100100686 PLANETENSTUFE PLANETARY STAGE
-----------------------------------------------------------------------------------------------------------
1 / 34 1,0 100010712 PLANETENTRGER PLANETARY CARRIER
-----------------------------------------------------------------------------------------------------------
1 / 39 1,0 100020702 DECKEL COVER
-----------------------------------------------------------------------------------------------------------
21 1,0 193007976 SEILTROMMEL CABLE DRUM CPL.
************************************************************************************************* SEITE - 3
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ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
22 1,0 193006870 FLANSCH FLANGE + PLATE CPL.
-----------------------------------------------------------------------------------------------------------
24 1,0 193007977 ANTRIEB DRIVE CPL.
-----------------------------------------------------------------------------------------------------------
24 / 4 4,0 193005741 ANTRIEBSHLSE DRIVING SLEEVE
************************************************************************************************* SEITE - 4
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ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************
______________________________________________________________________________________________________________________
24 / 62 4,0 414030008 VERSCHLU-SCHRAUBE PLUG M 26x 1,5 ZN DIN 908
24 / 63 4,0 441000220 FLACH-DICHTRING SEALING RING A 26,00x 31,00x 2,00
24 / 64 5,0 414030005 VERSCHLU-SCHRAUBE PLUG M 18x 1,5 ZN DIN 908
24 / 65 5,0 441000213 FLACH-DICHTRING SEALING RING A 18,00x 22,00x 1,50
24 / 66 4,0 242400143 DECKEL COVER
24 / 69 4,0 543400040 ENTLFTUNGSVENTIL VENT FILTER M 10x1,0 0,02B
24 / 70 8,0 404300244 PASS-SCHEIBE WASHER 70,00x 90,00x 1,00 DIN 988
24 / 74 4,0 404300748 STTZSCHEIBE WASHER 90,00x110,00x 3,50 DIN 988
24 / 75 48,0 402100310 DRUCKFEDER SPRINGS 15,7N/MM-S= 27,3-RE
24 / 76 48,0 402100311 DRUCKFEDER SPRINGS 5,9N/MM-S= 33,0-LI
24 / 79 16,0 404130013 SCHEIBE WASHER 17,00x 30,00x 3,00 DIN 125
24 / 84 1,0 414030004 VERSCHLU-SCHRAUBE PLUG M 16x 1,5 ZN DIN 908
24 / 85 1,0 441000211 FLACH-DICHTRING SEALING RING A 16,00x 20,00x 1,50
24 / 95 4,0 506701093 LDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE =STEP-SEAL====L 48,0
24 / 96 4,0 506700225 LAMELLENGEHUSE CLUTCH PLATE CARRIER
24 / 97 44,0 506700162 AUENLAMELLE MULTIPLE DISK DIN 867RAD-NUT-L2,30
24 / 98 40,0 506700163 INNENLAMELLE MULTIPLE DISK DIN 867--------L2,20
24 /122 4,0 414030002 VERSCHLU-SCHRAUBE PLUG M 12x 1,5 ZN DIN 908
24 /123 4,0 441000208 FLACH-DICHTRING SEALING RING A 12,00x 16,00x 1,50
24 /600 1,0 540500101 LEITUNG PIPE I M18x1,5-----EL 186
24 /605 2,0 540500040 LLEITUNG HYDR.-PARTS LEINFLLUNG---L 240
24 /606 1,0 543400070 MESTAB OIL DIPSTICK 0,20B/MM-------L 400
24 /607 1,0 441000213 FLACH-DICHTRING SEALING RING A 18,00x 22,00x 1,50
24 /611 4,0 540100829 VERSCHRAUBUNG THREADED JOINT CONNECTION M 12x 1,5 DKA-400B
24 /612 2,0 620100060 ROHR PIPE
24 /613 4,0 540100722 REDUZIERANSCHLUSS THREADED JOINT CONNECTION M 20x 1,5 630B
24 /614 2,0 540100702 VERSCHRAUBUNG THREADED JOINT CONNECTION +KOR12/6-M20x1,5630B
24 /615 2,0 540100511 VERSCHRAUBUNG THREADED JOINT CONNECTION M 20x 1,5 OMD-630B
24 /616 2,0 234200085 HALTEWINKEL HOLDING PLATE
24 /617 2,0 411130454 SECHSKANTSCHRAUBE BOLT M 8x 20 8.8 DIN 933
24 /618 2,0 541800156 VERSCHLUSTOPFEN SEALING PLUG ---,--x 13,70x10,00
24 /619 1,0 540100868 VERSCHRAUBUNG THREADED JOINT CONNECTION -100B
24 /621 2,0 540100813 VERSCHRAUBUNG THREADED JOINT CONNECTION M 10x 1,0 100B
24 /622 1,0 620100061 ROHR PIPE
24 /623 1,0 540100361 VERSCHRAUBUNG THREADED JOINT CONNECTION M 18x 1,5 315B
24 /710 1,0 240000312 BOLZEN BOLT
24 /711 1,0 505100081 DU-BUCHSE DISC I 50 A 55 -----L30,0
24 /712 1,0 505100076 GELENKLAGER 35x 55x25-GE 35 UK-
24 /713 1,0 230001614 BUCHSE BUSH
24 /714 1,0 230001616 BUCHSE BUSH
24 /715 1,0 230001386 HALTEBLECH HOLDING PLATE
24 /717 2,0 411130498 SECHSKANTSCHRAUBE BOLT M 12x 30 8.8 DIN 933
24 /750 1,0 243400218 PENDELSTTZE PENDULUM CARRIER
24 /751 1,0 243400217 RING RING
24 /752 4,0 411230099 ZYLINDERSCHRAUBE BOLT M 20x 50 8.8 DIN 912
24 /753 1,0 243400240 RING RING
24 /754 1,0 244000022 SCHEIBE WASHER
24 /755 12,0 411230090 ZYLINDERSCHRAUBE BOLT M 16x 60 8.8 DIN 912
24 /756 1,0 541000481 O-RING SEALING RING 800,00x4,00 NBR-72
24 /757 1,0 441100032 WELLENDICHTRING SHAFT SEALING RING 800x840x16B2---/NBR- DIN3760
DATUM ERSATZTEIL-LISTE ZOLLERN VERTRIEBS-GMBH + CO
-------- ------------------------------- HEUSTRASSE 1
16.01.03 SPARE-PART-LIST D-88518 HERBERTINGEN/WRTT.
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**********************************************************************************************************************
______________________________________________________________________________________________________________________
24 /758 1,0 243400219 PLATTE PLATE
24 /760 6,0 411230340 ZYLINDERSCHRAUBE BOLT M 16x110 8.8 DIN 912
24 /761 2,0 417000215 SPANNSTIFT PIN 10,0x 32,0 DIN1481
24 /770 1,0 455000004 FLACHBAND STEEL BAND 25,9 x 1,0
24 /771 1,0 453943422 FLACHKFIG BAND ROLLER BEARING L1478
24 /772 1,0 455000004 FLACHBAND STEEL BAND 25,9 x 1,0
24 /952 1,0 244000021 DECKEL COVER
24 /953 1,0 541000419 O-RING SEALING RING 225,00x3,00 NBR-70
24 /958 1,0 242901509 ABDECKUNG COVER GUARD
24 /959 2,0 411130477 SECHSKANTSCHRAUBE BOLT M 6x 12 8.8 DIN 933
24 /974 1,0 243400239 SCHEIBE WASHER
24 /975 6,0 411230067 ZYLINDERSCHRAUBE BOLT M 10x 70 8.8 DIN 912
24 /976 1,0 243400237 HALTESCHEIBE HOLDING DISC
24 /985 1,0 541000313 O-RING SEALING RING 235,00x3,00 NBR-70
24 /988 2,0 243800016 RING RING
24 /989 2,0 541000209 O-RING SEALING RING 55,00x4,00 NBR-72
24 /990 2,0 541000133 O-RING SEALING RING 88,27x5,33 NBR-70
24 /991 2,0 404300243 PASS-SCHEIBE WASHER 65,00x 85,00x 1,00 DIN 988
24 /992 1,0 541800007 VERSCHLUSTOPFEN SEALING PLUG ---,--x 10,70x 5,50
______________________________________________________________________________________________________________________
Abteilung :
Department :
Service :
_________________________________________________________________________
-------------------------------------------------------------------------
ZOLLERN VERTRIEBS-GmbH + Co.
Heustrae 1
D-88518 Herbertingen
Telefon 07586-959-0, Telefax-Kundendienst 07586-959-710, Telex 732 218
-------------------------------------------------------------------------
Dok.-Nr.: ANWEISD1/TXTKD Seite 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung fr Getriebeinspektion 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.
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.
Overall Assessment:
-------------------------------------------------------------------------
ZOLLERN VERTRIEBS-GmbH + Co.
Heustrae 1
D-88518 Herbertingen
Telefon 07586-959-0, Telefax-Kundendienst 07586-959-710, Telex 732 218
-------------------------------------------------------------------------
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.
! ! !
! Schmierl-Auswahl ! Schmierlauswahl ! Schmierfett Auswahl
! nach API GL5 ! nach DIN 51502 ! nach DIN 51502
_________!___________________!___________________!
! ! !
! Schmierl ! Schmierl ! Schmierfett
! SAE 90 ! DIN 51517-CLP 220 ! DIN 51825-KP2K
_________!___________________!___________________!
! ! !
ARAL ! Aral Getriebel ! BG 220 ! Aral Fett HLP 2
! HYP 90 ! !
_________!___________________!___________________!
! ! !
AVIA ! Avia Getriebel ! 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 Getriebel ! Spartan EP 220 ! Esso Beacon 2 EP
! GX-D90 ! !
_________!___________________!___________________!
! ! !
FUCHS ! Fuchs Getriebel ! 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
_________!___________________!___________________!
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Dok-Nr: 19OOOO159.DEF/OO
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- SLEWING GEAR GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Maintenance Instruction
Lubrication:
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:
-------------------------------------------------------------------------
Oil change after 200-1000-2000 operation hours, but at least once a year.
- Install slewing gear forcelessly into the holding fixture of the unit.
- 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.
- Screw plug removed on the surface (for transport only) and added
air vents screwed in.
- 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.
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Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
1/ 11 1,0 100100315 PLANETENSTUFE PLANETARY STAGE
-----------------------------------------------------------------------------------------------------------
1/ 21 1,0 100100265 PLANETENSTUFE PLANETARY STAGE
-----------------------------------------------------------------------------------------------------------
1/ 24 1,0 100010375 PLANETENTRGER PLANETARY CARRIER
-----------------------------------------------------------------------------------------------------------
1/ 27 1,0 100020251 ZWISCHENGEHUSE INTERMEDIATE HOUSING
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/WRTT.
*************************************************************************************************
SEITE - 2
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**********************************************************************************************************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
1/ 34 1,0 100010254 PLANETENTRGER PLANETARY CARRIER
-----------------------------------------------------------------------------------------------------------
29 1,0 132541069 TRIEBSTOCK LANG LONG OUTPUT HOUSING
-----------------------------------------------------------------------------------------------------------
40 1,0 113125014 ANTRIEB DRIVE IN
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/WRTT.
*************************************************************************************************
SEITE - 3
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**********************************************************************************************************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
______________________________________________________________________________________________________________________
-----------------------------------------------------------------------------------------------------------
75 14,0 100003006 FEDERN SPRINGS
-----------------------------------------------------------------------------------------------------------
76 14,0 100003007 FEDERN SPRINGS
______________________________________________________________________________________________________________________
*************************************************************************************
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*********************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
------------------------------------------------------------------------
-----------------------------------
21 1,0 193001822 SEILTROMMEL CABLE DRUM CPL.
*************************************************************************************
************ SEITE - 2
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ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
*************************************************************************************
*********************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
------------------------------------------------------------------------
-----------------------------------
22 1,0 193001823 FLANSCH FLANGE + PLATE CPL.
------------------------------------------------------------------------
-----------------------------------
24 1,0 193001824 ANTRIEB DRIVE CPL.
------------------------------------------------------------------------
-----------------------------------
24/ 4 1,0 193001324 ANTRIEBSHLSE DRIVING SLEEVE
*************************************************************************************
************ SEITE - 3
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*************************************************************************************
*********************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
------------------------------------------------------------------------
-----------------------------------
60 1,0 193001825 LLEITUNG OIL PIPE
------------------------------------------------------------------------
-----------------------------------
75 16,0 100003010 FEDERN SPRINGS
*************************************************************************************
************ SEITE - 4
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*************************************************************************************
*********************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
------------------------------------------------------------------------
-----------------------------------
76 16,0 100003011 FEDERN SPRINGS
_____________________________________________________________________________________
_________________________________
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
pos. article-no. g identifier amount unit
1 15000490001 ESG-GLASS 400 x 960 x 6 MM GREEN 2.00 St
2 1500940109R ESG-GLASS 1162 X 542 X 10 MM GREEN 2.00 St
3 15009401110 ESG-GLASS 1162 X 622 X 6 MM GREEN 1.00 St
4 15009401060 ESG-GLASS 542 X 382 X 6 MM GREEN 2.00 St
5 15009401100 ESG-GLASS 1162 X 542 X 6 MM GREEN 1.00 St
6 003-450-R ESG-GLASS 10 MM GREEN 1.00 St
7 060-23-01 FRAME FOR FRONT WINDOW 1.00 St
8 060-23-02 FRAME FOR SIDE WINDOW 2.00 St
9 060-23-03 FRAME FOR SIDE WINDOW 1.00 St
10 060-23-04 FRAME FOR ATTIC WINDOW 1.00 St
11 002-194 CELLULAR RUBBER 14.00 m
12 15000400337 EDGE PROTECTION WITH SEALING 16.50 in
13 15000400376 TRANSPARENT KITT 6.00 St
14 15000400323 LABEL EMERGENCY EXIT ONLY 1.00 St
15 003-455 1 WINDOW WIPER SYSTEM 1.00 St
01 003-452 WINDOW WIPER MOTOR 1.00 St
02 003-453 WIPER ARM 1.00 St
03 003-454 WIPER BLADE 1.00 St
16 15000903000 COVER FOR SCREEN WIPER MOTOR 1.00 St
17 15000603100 CROSS HANDLE 7.00 St
18 15000608400 1 LEVER LOCK 1.00 St
01 15000608401 LEVER 1.00 St
02 15000608402 LEVER 1.00 St
03 15000609403 ROSETTE 2.00 St
04 15000608404 TONGUE 1.00 St
05 15000608405 AXLE 1.00 St
06 516843 WASHER POLYAMIDE 2.00 St
19 516677 RING 1.00 St
20 003-564 BRASS BALL 2.00 S~
21 001-20-05 HEXAGONAL CAP 2.00 St
22 003-621 TKR.EADED BOLT 2.00 St
23 044-17-03 BRASS ROD 2.00 St
24 15000601010 STEEL STRIP 3.00 St
25 15000601000 STEEL STRIP 6.00 St
26 15000672110 LUBRICATOR NIPPLE 9.00 St
27 15000672120 CAP 5.00 St
28 531217 BED 4.00 St
29 531219 BED 5.00 St
30 531220 BED 2.00 St
31 15000810035 FAN HEATER 1.00 St
32 001-758 1 DRIVERS SEAT 1.00 St
01 000-867 DRIVERS SEAT 1.00 St
02 000-450 INDEXING BOLT GNG13-B-GI( 1.00 St
03 15000603330 SET SCREW 1.00 St
04 15000603331 THRUST 1.00 St
05 15000608110 TILT-JAM LEVER GAI~V~NIZED 1.00 St
06 15000603090 CROSS HANDLE 1.00 St
33 15000653110 SUNSHADE HOLDER 1.00 St
34 15000653100 CUTTING OF SAFETY GLASS GREEN 1.00 St
35 15000653210 ASHTRAY ~ St
36 15000653220 HANGER 1.00 St
37 15000677150 GRATING 2.00 St
38 516881 FIXING CLAMP 4.00 St
39 15000690306 INSULATION BLACK 50 mm 4.50 m2
40 15000690410 INSULATION 50mm 0.80 m2
Manual Instruction
www.kml-miller.de
Contents
2
Karl Miller GmbH
Systemlsungen im Kabinenbau
www.kml-miller.de
3
Karl Miller GmbH
Systemlsungen im Kabinenbau
www.kml-miller.de
4
Karl Miller GmbH
Systemlsungen im Kabinenbau
www.kml-miller.de
General description
Performance data:
- Cooling rating: ca. 2500 W
- Current: 230 V, 50 Hz
- Refrigerant: R134a
5
Karl Miller GmbH
Systemlsungen im Kabinenbau
www.kml-miller.de
Operating Instructions:
Master switch on 1.
Master switch on 0.
Technische Daten
Dimensions:
Heigth (mm) 150 mm 335 mm 271 mm 225 mm
Width (mm) 420 mm 300 mm 235 mm
Depth (mm) 285 mm 65 mm 170 mm 71 mm
6
Karl Miller GmbH
Systemlsungen im Kabinenbau
www.kml-miller.de
Maintenance jobs:
After 500 operating hours the blowers are to be checked for contaminations and cleaned if
necessary.
Important
Doors and windows of the cabin must be closed while the air-condition equipment is in
operation.
Openings for condensate ventilation on the external side should not be closed!
7
Rckenbreite bis 10 mm (1 Blatt = 0,106 mm)
A
Think future. Switch to green.
A
Think future. Switch to green.
Rckenbreite festlegen! (1 Blatt = 0,106 mm)
Disconnect the power supply of the device. Suitable safety hardware and software
Ensure that devices cannot be accidentally measures should be implemented for the
restarted. I/O interface so that a line or wire breakage
on the signal side does not result in
Verify isolation from the supply. undefined states in the automation
Earth and short circuit. devices.
Cover or enclose neighbouring units that Ensure a reliable electrical isolation of the
are live. low voltage for the 24 volt supply. Only
Follow the engineering instructions (AWA) use power supply units complying with
of the device concerned. IEC 60364-4-41 (VDE 0100 Part 410) or
HD 384.4.41 S2.
Only suitably qualified personnel in
accordance with EN 50110-1/-2 Deviations of the mains voltage from the
(VDE 0105 Part 100) may work on this rated value must not exceed the tolerance
device/system. limits given in the specifications, otherwise
this may cause malfunction and dangerous
Before installation and before touching operation.
the device ensure that you are free of
electrostatic charge. Emergency stop devices complying with
IEC/EN 60204-1 must be effective in all
The functional earth (FE) must be operating modes of the automation
connected to the protective earth (PE) or devices. Unlatching the emergency-stop
to the potential equalisation. The system devices must not cause restart.
installer is responsible for implementing
this connection. Devices that are designed for mounting in
housings or control cabinets must only be
Connecting cables and signal lines should operated and controlled after they have
be installed so that inductive or capacitive been installed with the housing closed.
interference does not impair the Desktop or portable units must only be
automation functions. operated and controlled in enclosed
Install automation devices and related housings.
operating elements in such a way that they
are well protected against unintentional
operation.
Safety instructions
Moeller GmbH
I
Measures should be taken to ensure the Wherever faults in the automation system
proper restart of programs interrupted may cause damage to persons or property,
after a voltage dip or failure. This should external measures must be implemented to
not cause dangerous operating states even ensure a safe operating state in the event
for a short time. If necessary, emergency- of a fault or malfunction (for example, by
stop devices should be implemented. means of separate limit switches,
mechanical interlocks etc.).
II
Contents
1
6 Operation 55
Power-up behaviour 55
Shut-down behaviour 55
Operating states of the PLC 56
Start-up behaviour 59
Program transfer 61
Starting the PLC with a program stored in
the memory module 63
Programming via Suconet K 63
7 Testing/Commissioning/Diagnostics 65
Status LEDs 65
Diagnostics 66
Message byte 69
Appendix 71
Optimizing the exchange of send and
receive data 71
Accessories 75
Slave addressing 76
Technical Data 79
Index 85
03/02 AWB 27-1184-GB
2
About this Manual
3
About this Manual
Programming manual
Information on programming the PS4-200 is
contained in the Language elements of the
PS4-150/-200/-300 and PS416 manual
(AWB2700-1306GB).
Training guide
The training guide AWB27-1307GB uses practical
examples to illustrate the key functions of the
Sucosoft S 40 software.
Warning!
Warns of the possibility of damage. The product,
anything in the immediate vicinity and data may
be damaged.
Caution!
Warns of the possibility of severe damage. The
product, anything in the immediate vicinity and
data may be severely damaged or totally
destroyed. There is also a risk of injury or even
death.
4
1 About the PS4-200 Compact PLC
5
About the PS4-200
Compact PLC
Warning!
Make sure that you are free of electrostatic
charge before touching the PLCs, in order to
protect the components from static electrical
discharges.
6
Setup
a bc d
24V 0V
Power Supply e
n 1=Ready Digital
f
2=Run Input
3=Not Ready
1 2 3 4 4=Battery
m
PRG Suconet K
PS4-201-MM1
g
Digital Analog
Output Input/Output
1 2 .0 .1 .2 .3 .4 .5 U0 U1 U10 0VA
e
S1 P1 P2
l k j i h
24 V DC power supply
High-speed counter input (alternative to I 0.0), 3 kHz
Alarm input (alternative to I 0.1)
8 digital inputs 24 V DC and 24 V DC input for the
outputs
Plug-in screw terminal
Status LEDs for digital inputs
Status LEDs for digital outputs
6 digital outputs 24 V DC/0.5 A;
short-circuit and overload proof
2 analog inputs U0, U1 (0 to 10 V)
1 analog output U10 (0 to 10 V)
Suconet K interface
Setpoint potentiometers P1, P2
03/02 AWB 27-1184-GB
7
About the PS4-200
Compact PLC
8
Elements
Analog inputs/outputs:
The controller has two analog inputs and one analog
output. The signal range is 0 to 10 V. The resolution
of the inputs is 10 bits (1024 increments), while that
of the output is 12 bits (4096 increments)..
All the inputs and outputs are wired via plug-in screw
terminals.
03/02 AWB 27-1184-GB
9
About the PS4-200
Compact PLC
Suconet K interface
The RS 485 interface is galvanically isolated from the
CPU. It has the following functions:
Networking of Suconet K stations (e.g. EM4...
expansion modules)
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This
communication interface is used for process data
acquisition, visualization, etc. Data for process
control must not be exchanged here.
Programming networks for several PLCs via a PC
(see section Programming with Suconet K in
the Operation chapter).
Serial communication in transparent mode (see
the following paragraph):
With this function, the PLC exchanges data with a
partner device. The data can be sent or received
using the half-duplex method with the aid of the SCO
function block (see "Language Elements of the PS4/
PS416" manual, AWB2700-1306GB). The settings of
the interface can be taken from the configurator
under Parameterization General settings with
transparent mode. The "Baud rate", "Parity" and
"Stop bit" count are adjustable and must correspond
with the settings on the partner device. The data bit
setting is a fixed value.
1 1 8 odd
1 2 8
10
Elements
Setpoint potentiometers
You can set the two setpoint potentiometers P1 and
P2 externally, in other words direct adjustment
without the need for a programming device. The
resolution is 10 bits (1024 increments). They can be
accessed with the operands IAW0 and IAW2.
Switch S1 for bus terminating resistors
You can set the bus terminating resistors for the first
and last physical stations with switch S1.
Programming device interface (PRG)
The RS 232 interface is galvanically isolated from the
CPU. It has the following functions:
Programming the PLC via the PC
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This type of
communication is used for process data
acquisition, visualization etc. but should not be
used to exchange data for process control (see
also Function block SCO in the manual
Language Elements of the PS4-150/-200/-300
and PS416 in AWB2700-1306GB, chapter 6).
Memory modules
The PS4-200 has an internal, battery-backed,
32 kByte RAM. The memory is subdivided into a data
memory and a user program memory.
Up to 24 Kbyte are available for the user program.
This allocation is dynamic, i.e. if the data memory
requires more than 8 Kbyte, the size of the user
program memory is reduced accordingly.
The memory capacity of the internal RAM can be
expanded with plug-in memory modules. The
available modules are as follows:
03/02 AWB 27-1184-GB
11
About the PS4-200
Compact PLC
RAM memory
PS 4
24 Kbyte program memory
Programm memory
Memory module
32 Kbyte program memory (external)
12
Elements
Diag.
b
Battery
+ Reset
c
1
1 Halt/Diag. 2
2 Run 3
3 Run M-Reset S2
Back-up battery
Reset button
Plug connector for local expansion modules
Operating mode selector switch
Back-up battery
The battery backs up the internal RAM and the real-
time clock.
Warning!
The back-up battery must only be replaced with
the power supply switched on, or data will be
lost.
03/02 AWB 27-1184-GB
13
About the PS4-200
Compact PLC
14
2 Engineering
15
Engineering
M4
24 V
0V
PS 4/EM 4
16
Connections
Overview
c
b
a
24V 0V
Power Supply
+
d
PRG Suconet K
1 2 .0 .1 .2 .3 .4 .5 U0 U1 U10 0VA
S1 P1 P2
f e
b
c
Figure 5: Overview of connections
17
Engineering
7 8
18
Programming device
interface
1
5 2
2 3
4
3 5
6
7
8
9
Jumpers
Warning!
In order to avoid potential equalization currents
between the PLC and the PC, devices attached
to the PRG and Suconet K interfaces must have
the same ground potential. If the ground
potentials differ, the interfaces can be destroyed.
19
Engineering
2
4 5
1 3
20
Setting the bus terminating
resistors
Setting the bus Set the bus terminating resistors on the module
terminating resistors for the first and last physical stations on a line. To
do this, both S1 switches should be set to the
ON position. Both switches must be set to the
OFF position for all other stations.
1 2
OFF
21
Engineering
Ventilation
In order to ensure that the PS4-200 is adequately
cooled, a minimum clearance of 5 cm (2) must be
allowed between other components and the
ventilation slots in the housing. The values specified
in the technical data must be observed
(see Appendix).
Device arrangement
The PS4-200 should be installed horizontally in the
03/02 AWB 27-1184-GB
22
Power supply
PS 4-
201-MM1
Power supply The next few pages show circuit diagrams for the
following power supply arrangements:
Figure 11:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for grounded operation
Figure 12:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for non-grounded
(floating ground) operation
23
Engineering
24
Power supply
L1
L2
L3
N
PE
I> I> I>
+24 V 0V +24 V 0V
+24 V 0V
.0
.1
.2
.3
.4
.5
.6
.7
24 VQ
0 VQ
24 V
0V
PS 4-201-MM1
0 VA
U10
U0
U1
.0
.1
.2
.3
.4
.5
03/02 AWB 27-1184-GB
25
Engineering
26
Power supply
L1
L2
L3
N
PE
I> I> I>
C1 C1
K1 P1
P1
K1
+24 V +24 V 0V
0V
+24 V 0V
24 VQ
0 VQ
.0
.1
.2
.3
.4
.5
.6
.7
24 V
0V
PS 4-201-MM1
0 VA
U10
U0
U1
.0
.1
.2
.3
.4
.5
03/02 AWB 27-1184-GB
27
Engineering
28
Avoiding interference
Cover
Communication cables
Cable duct
Measuring cables, analog
cables
Control cables
Power cables
Continuous partition
Figure 13: Using separate ducts for power and signal
cables
03/02 AWB 27-1184-GB
29
Engineering
Screening
Only use screened cables for the programming
device interface (PRG) and the Suconet K
interface of the PS4-200.
General rule: the lower the coupling impedance, the
better the screening effect. The screen is then able to
carry high interference currents.
30
Avoiding interference
Lightning protection
External lightning protection
All cables which are laid between two different
buildings must be screened. Metal conduits are
recommended for this purpose. Protective elements
against overvoltage, such as varistors or other types
of lightning arrester, should be used for signal
cables. The cables must be protected at the point at
which they enter the building, or at the latest at the
control cabinet.
Internal lightning protection
Internal lightning protection includes all measures
that reduce the effects of the lightning current and its
electrical and magnetic fields on the metal
installations and electrical systems inside a building.
These measures comprise:
Lightning-protection potential equalization
Screening
Overvoltage protection devices
Further information on this subject is provided in the
TB27-001GB manual from Moeller entitled
Electromagnetic Compatibility (EMC) of Automation
Systems.
03/02 AWB 27-1184-GB
31
32
03/02 AWB 27-1184-GB
3 Mounting
3 2
33
Mounting
34
4 Software Configuration
General You can configure the PLCs and all the other
components you need for your application with the
Sucosoft S 40 Topology Configurator. These
components are as follows:
Master PLC (with local expansion modules for the
inputs/outputs)
Network stations (slaves for expanding the
remote I/O or intelligent slaves)
Local expansion modules (LE4-...)
35
Software Configuration
36
Topology configuration
procedure
e.g. PS 4-201-MM1
Line 0
Station 0
e.g. PS 4-201-MM1
Station 1
Line 1
Module 0
Module 0 Module 1
Figure 17: Master configuration
numbered consecutively.
37
Software Configuration
Module 0 Module 1
Figure 18: Slave configuration
Configuring and setting The configuration steps for the PS4-200 PLCs
parameters described here differ according to the functions the
stations must perform:
Suconet K master
Suconet K slave
SCO (from PLC firmware version 05)
38
Configuring and setting
parameters
39
Software Configuration
40
Configuring and setting
parameters
41
Software Configuration
Table 4: Maximum values for send and receive bytes for the
PS4-200
42
Configuration example with
local expansions
PS 4-201-
MM1
03/02 AWB 27-1184-GB
43
Software Configuration
PS 4-201-MM1
Device A
PS 4-151-MM1
Device C
Line 1
Station 2
Master: Device A
Intelligent slaves: Devices B and C
03/02 AWB 27-1184-GB
44
Configuration example
Configuration of device A
PS 4-201-MM1
Device A
PS 4-151-MM1
Device C
Line 1
Station 2
45
Software Configuration
Configuration of device B
3rd LE4 0 0 3
46
Configuration example
Configuration of device C
PS 4-151-MM1
47
48
03/02 AWB 27-1184-GB
5 Slave Addressing
Slaves for expanding The PS4-200 master PLC and the slaves for
remote inputs/outputs expanding the remote inputs/outputs can
communicate with one another using the Suconet K
or K1 protocols. The protocol is selected by the
master automatically according to the capabilities of
the slaves. It is not necessary to parameterize the
send or receive data length in the Topology
Configurator. Suconet K/K1 selects the appropriate
telegram length and automatically addresses the
relevant data ranges in your application.
You can thus access remote input/output operands
just as easily as local operands.
Communication data
Operands Line Station Module Word/byte Bit
I/Q 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master) 0, 2, 4, ... (word)
IB/QB IAB/
QAB ICB
IW/QW IAW/
QAW/ ICW
Status/diagnostics
IS 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master)
ISB
49
Slave Addressing
Example
You wish to scan the inputs of slaves 1 and 2 marked
in the diagram below.
PS 4-201-MM1
Master
EM 4-201-DX2 LE 4-116-DX1
.7 Slave 1
Line 1
EM 4-201-DX2
.0 ... .7 Slave 2
Line 1
50
Intelligent slaves
IL program Data Ope- Data Line Station Module Byte/ Bits S 40 syntax
in ... flow rand type word
Master Master I Bit 1 1 1 0 7 LD % I1.1.1.0.7
Slave 1
Master IB Byte 1 2 0 0 LD% IB1.2.0.0
Slave 2
Communication data
Operands Line Station Module Word/byte Bit
RD/SD 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master) 0, 2, 4, ... (word)
RDB/SDB
RDW/SDW
Status/diagnostic
IS 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master)
ISB
51
Slave Addressing
Example
The PS4-200 (master) exchanges word data with an
intelligent slave. You can define the number of send
and receive bytes when you set the station
parameters in the Sucosoft S 40 Topology
Configurator (see chapter 4, Software
Configuration).
RD RD
SD SD
PS 4-151-MM1
Station 1
Line 1
Figure 24: Configuration example for sending and receiving
communication data to/from an intelligent slave 03/02 AWB 27-1184-GB
52
Intelligent slaves
IL program Data flow Ope- Data Line Sta- Module Byte/ Bit Syntax
in ... rand type tion word
Master Master Slave RDW/ Word 1 1 0 0 RDW1.1.0.0/
Master Slave SDW SDW1.1.0.0
Slave Slave Master RDW/ Word 0 0 0 0 RDW0.0.0.0/
Slave Master SDW SDW0.0.0.0
03/02 AWB 27-1184-GB
53
54
03/02 AWB 27-1184-GB
6 Operation
Power-up behaviour After the power supply is switched on, the PS4-200
carries out its own system test. The PLC then
switches to the Ready or Run status if no
hardware errors have been found.
The system test consists of the following routines:
Memory test
User program test
The results of the test are indicated by the Ready,
Run and Not Ready LEDs. If the test is
successful, these LEDs light up briefly when the
power supply is switched on; if not, they blink.
The PLC's status depends on how the operating
mode selector switch is set (see Table 13).
Shut-down behaviour The power supply unit of the PLC detects when the
power supply is switched off. Voltage dips of 10 ms
can be bridged by the power supply unit. If a longer
voltage dip occurs, the internal 5 V supply remains
stable for at least a further 5 ms. This time is used by
the microcontroller to save all the data required for a
restart in the memory ranges provided for this
purpose.
03/02 AWB 27-1184-GB
55
Operation
Operating states of the The PLC can have the following operating states:
PLC Run, Ready, Not Ready.
Ready
The Ready status means the following:
There is a user program loaded in the PLC;
The user program is not running;
The outputs are reset and disabled.
The PLC is switched to the Ready status:
If the Reset button is pressed when the
operating mode selector switch is set to Halt;
After the power supply is switched on if the
operating mode selector switch is set to Halt;
By means of the programming software on the
PC;
In slave mode, if the master switches to the Halt
(stop) status and you have set in the slave
parameters the remote control function to ON in
the Sucosoft Topology Configurator (see
AWB2700-1305GB, chapter 5);
If the tab of the memory module is pulled out.
03/02 AWB 27-1184-GB
56
Operating states of the
PLC
Run
Run status means that the user program is running
cyclically.
The PLC is switched to the Run status:
If the Reset button is pressed when the
operating mode selector switch is set to Run or
Run M-Reset;
After the power supply is switched on if the
operating mode selector switch is set to Run or
Run M-Reset;
By means of the programming software on the
PC.
Not Ready
The user program does not run in Not Ready
status.
The PLC is switched to the Not Ready status:
If there is no program loaded in the PLC;
As a result of a hardware error;
As a result of a serious error in the user program
(e.g. cycle time violation)
Once the error has been rectified, you can cancel the
Not Ready status as follows:
By pressing the Reset button; if the operating
mode selector switch is set to Run M-Reset, the
PLC will be switched to the Run status;
By switching the power supply off and then on
again; if the operating mode selector switch is set
to Run M-Reset the PLC will be switched to the
03/02 AWB 27-1184-GB
Run status;
By means of the programming software on the
PC.
57
Operation
Overview
58
Start-up behaviour
Cold start
A cold start causes all the data fields (marker ranges,
inputs/outputs, module parameters) to be reset. The
user program is executed from the beginning.
03/02 AWB 27-1184-GB
59
Operation
Warm start
A warm start causes the user program to be
continued from the point at which it was interrupted
to the end of the cycle. The outputs and the
communication data are set to 0 for the remainder
of this cycle. The PLC is then initialized and the
program is executed cyclically. Retentive data fields
remain stored.
The setting of retentive marker ranges is described in
the manual Sucosoft S 40 User Interface
(AWB2700-1305GB, chapter 7).
03/02 AWB 27-1184-GB
60
Program transfer
Warning!
If you initiate a warm start via the system
parameters, your data may lose its consistency.
Program transfer If the user program does not contain any syntax
errors, the compiler in the programming device (PC)
translates it into a code that can be understood and
executed by the CPU. You must then load the user
program into the RAM of the CPU using the
Transfer menu. The microprocessor executes the
program there in the Run status.
03/02 AWB 27-1184-GB
61
Operation
PC PLC
When a program is transferred from the PC to the
PLC, the PS4-200 must be in the Ready or Not
Ready status. The setting of the operation mode
selector switch on the operator console is not
important.
Transfer the program to the PLC; refer to the
manual Sucosoft S 40 User Interface
(AWB2700-1305GB, chapter 8).
62
Starting the PLC with a
program stored in
the memory module
Starting the PLC with a The procedure for starting a user program in the
program stored in memory module is as follows:
the memory module
Plug the memory module into the PLC (the PLC
must be switched off). The setting of the operate
mode selector switch is not important.
Switch on the PLC. The program in the memory
module is then copied to the PS4-200 and the
PLC is started up according to the configured
startup conditions.
63
Operation
PC
PLC program
PS 4-141-MM1
PS 4-201-MM1*) LE 4-501-BS1
PS 4-151-MM1
PS 4-151-MM1
Version 05 or higher.
64
7 Testing/Commissioning/Diagnostics
1)Caution!
Data may be lost if the battery does not supply
03/02 AWB 27-1184-GB
65
Testing/Commissioning/
Diagnostics
66
Diagnostics
67
Testing/Commissioning/
Diagnostics
68
Message byte
69
70
03/02 AWB 27-1184-GB
Appendix
71
Appendix
40 Byte
Master Slave A
50 Byte
30 Byte
Slave B
40 Byte
48 Byte
Slave C
38 Byte
72
Optimizing the exchange of
send and receive data
Send Receive
free 10
A 40 A 50
B 30 B 40
C 48 C 38
Sequence of communication:
1. Master sends 40 bytes to slave A:
Free COB memory at this stage = 50 bytes
2. Master receives 50 bytes from slave A:
Free COB memory at this stage = 0 bytes
3. Master sends 30 bytes to slave B:
Free COB memory at this stage = 30 bytes
4. Master receives 40 bytes from slave B:
Overlapping of 10 bytes between send and
receive data. The controller goes to the Not
Ready state.
!
03/02 AWB 27-1184-GB
73
Appendix
free 10
C 38
C 48
B 40
B 30
A 50
A 40
74
Accessories
Accessories
Designation Type Description/application
Programming cable ZB4-303-KB1 Adapter for programming the PS4-200 with a PC
Memory module ZB4-160-SM1 32 Kbyte RAM module for expanding the user program
memory and 128 Kbyte flash EPROM
Memory module ZB4-032-SR1 32 Kbyte RAM module for expanding the user program
memory
Memory module ZB4-128-SF1 128 Kbyte flash EPROM
Plug-in screw terminal ZB4-110-KL1 Plug-in screw terminal for the input/output level
Twin-level terminal ZB4-122-ML1 Twin-level terminal block for distributing potential, e.g. for
block connecting 3-pole proximity switches to a PLC or a local
expansion module
Hinged cover ZB4-101-GZ1 Hinged cover with space for labelling inputs/outputs (PS4,
EM4, LE4)
Feet ZB4-101-GF1 Feet for screwing the PS4 onto a mounting plate
Backup battery ZB4-600-BT1 Battery for backing up the RAM of the PS4-200
Simulator ZB4-108-ES1 Simulator for digital inputs
Data cable KPG 1-PS3 Cable between the PS4-200 and a slave; length: 0.5 m
T connector TBA 3.1 For connecting a station to the Suconet K/K1 line
Data plug connector S1-PS3 5-pole DIN plug connector for the RS 485 interface of the
PS4-200-MM1
Cable LT 309.096 Cable, 2 0.5 mm2, screened and twisted for making your
own Suconet K cable
Screen grounding kit ZB4-102-KS1 Screen grounding kit for Suconet incl. screen grounding clips
Snap fastener for the FM4/TS35 Weidmller, Order no. 068790
top-hat rail
Terminal clip for snap KLB3-8SC Weidmller, Order no. 169226
fastening
03/02 AWB 27-1184-GB
75
Appendix
76
Slave addressing
x = line, y = station
Send data
77
Appendix
x = line, y = station
78
Technical Data
79
Appendix
80
Technical Data
81
Appendix
Outputs
No. of outputs 6
Rated voltage Ue 24 V DC
Permissible range 20.4 to 28.8 V DC
Polarity reversal protection Yes
Max. ripple 5%
Galvanic isolation
in groups No
Rated current Ie
For 1 signal 0.5 A DC for 24 V DC
Lamp load 4 W without series resistor
Utilization factor 1
Relative duty factor 100 %
Parallel connection of outputs
No. of outputs max. 4
Total maximum current 2A
Total minimum current 250 mA
Residual current with 0 signal Approx. 140 A
Short-circuit protection Yes, without set
Max. short-circuit release current 1.2 A over 3 ms per output
Off delay Normally 100 s
Limiting of breaking voltage
With inductive loads Yes, 21 V (with UN = 24 V DC)
Operations per hour
With time constant 4800 (G = 1)
t 72 ms 7500 (G = 0.5)
With time constant 18000 (G = 1)
t 15 ms
Power supply
Polarity reversal protection Yes
03/02 AWB 27-1184-GB
82
Technical Data
83
84
03/02 AWB 27-1184-GB
Index
A
Addressing
Slaves ................................................................... 49, 76
Alarm input ....................................................................... 8
Analog inputs/outputs ...................................................... 9
Arrangement of the control cabinet ............................... 22
B
Backup battery ......................................................... 13, 75
Backup memory ............................................................. 12
Base module (i.e. module 0) .......................................... 36
Battery
Backup ....................................................................... 13
Baud rate ....................................................................... 40
Bus cable ....................................................................... 20
C
Cable .............................................................................. 75
Cabling ........................................................................... 28
Clock (real-time) ............................................................. 14
Cold start ....................................................................... 59
Combination memory module (160 Kbyte) .................... 12
Commissioning .............................................................. 65
Communication with PC ................................................ 56
Configuration ................................................................. 38
Intelligent slaves ......................................................... 37
Local expansion ......................................................... 36
Master with remote expansions ................................. 36
Slaves for expanding remote inputs/outputs ............. 38
Configuration example ................................................... 44
Connection
Overview ..................................................................... 15
Connections
Programming device .................................................. 19
Suconet K field bus .................................................... 20
03/02 AWB 27-1184-GB
85
Index
Controls .......................................................................... 13
Counter, high-speed ........................................................ 8
CRC ................................................................................ 41
D
Data cable ...................................................................... 75
Data exchange ......................................................... 10, 11
Data integrity .................................................................. 41
Data plug connector ....................................................... 75
Data transfer
LEDs ........................................................................... 62
Daylight savings time ..................................................... 14
Device arrangement ....................................................... 22
Diagnostics ............................................................... 65, 66
Diagnostics byte for Suconet K stations ........................ 68
Diagnostics status word ................................................. 66
Digital inputs ..................................................................... 8
Status LEDs .................................................................. 9
Digital outputs .................................................................. 9
DST ................................................................................. 14
Dynamic memory allocation ........................................... 12
E
Elements, PS 4-200 .......................................................... 8
EMC regulations ............................................................. 15
Engineering instructions ................................................. 15
F
Fastening ........................................................................ 22
Features ............................................................................ 6
Feet ................................................................................ 75
Flash module .................................................................. 12
H
Hardware requirements for programming ........................ 5
High-speed counter ......................................................... 8
Hinged cover .................................................................. 75
I
03/02 AWB 27-1184-GB
86
Index
Interface
Programming device .................................................. 11
Suconet K ................................................................... 10
Interference .................................................................... 22
L
LED ................................................................................ 65
LED display ...................................................................... 9
LEDs ........................................................................... 9, 13
Status ......................................................................... 12
Light-emitting diodes ..................................................... 65
Lightning protection ....................................................... 31
Limit values, send and receive bytes ............................. 42
Line ................................................................................ 40
Local expansion modules .............................................. 35
M
Master PLC .................................................................... 35
Memory
128 Kbyte flash module .............................................. 12
160 Kbyte combination module ................................. 12
32 Kbyte RAM module ............................................... 12
Backup ....................................................................... 12
Recipe data ................................................................ 12
Memory allocation, dynamic .......................................... 12
Memory capacity ........................................................... 11
Memory module ....................................................... 11, 75
Memory test ................................................................... 55
Message byte for Suconet K stations ............................ 69
Module ........................................................................... 40
Module 0 (base module) ............................................. 36
Mounting
On feet ........................................................................ 34
On top-hat rail ............................................................ 33
N
Network programming ............................................. 62, 63
Networking ..................................................................... 10
Not Ready (operating state) ........................................... 57
03/02 AWB 27-1184-GB
87
Index
O
Operand addresses
Intelligent slaves ......................................................... 51
Slaves for expanding remote inputs/outputs ............. 49
Operating mode selector switch .................................... 14
Operating states (PLC), overview ................................... 58
Output data .................................................................... 41
P
Parameters, setting ........................................................ 38
PC, connections ............................................................. 19
Peripheral command ........................................................ 9
Pin assignments
Programming device interface (PRG) ......................... 18
Suconet K interface .................................................... 20
Plug-in screw terminal .................................................... 75
Potential equalization ..................................................... 19
Power supply
grounding arrangements ............................................ 23
Power supply unit ............................................................. 8
Power-up behaviour ....................................................... 55
Program transfer
LEDs ........................................................................... 62
Program transfer to PLC ................................................ 61
Programming cable .............................................. 5, 19, 75
Programming device interface (PRG) ............................. 11
Pin assignments ......................................................... 18
Programming device, connections ................................. 19
Programming networks .................................................. 10
Programming via
Suconet K ................................................................... 63
Programming with
PC ............................................................................... 11
R
RAM memory ................................................................. 11
RAM module ................................................................... 12
Rated voltage ................................................................... 8
Ready ............................................................................. 56
03/02 AWB 27-1184-GB
88
Index
S
Screen connection to reference potential surface ......... 16
Screen grounding kit ...................................................... 75
Screening ....................................................................... 30
Send bytes ..................................................................... 41
Setpoint potentiometers ................................................ 11
Setting parameters ........................................................ 38
Setting the bus terminating resistors ............................. 21
Setup, PS 4-200 ............................................................... 6
Shutdown behaviour ...................................................... 55
Signal range ..................................................................... 9
Simulator ........................................................................ 75
Slave address ................................................................ 41
Slave addressing ...................................................... 49, 76
Slaves for expanding the remote I/O ............................. 35
Software requirements for programming ......................... 5
Start-up behaviour ......................................................... 59
Station ............................................................................ 40
Status LEDs ................................................................... 65
Digital inputs ................................................................. 9
Outputs ......................................................................... 9
PLC ............................................................................. 12
Suconet K
Programming via ........................................................ 63
Suconet K connection ................................................... 20
Suconet K interface ....................................................... 10
pin assignments ......................................................... 20
Summer time, winter time .............................................. 14
Suppressor circuits ........................................................ 30
Switch S1 ....................................................................... 11
Symbols ........................................................................... 4
03/02 AWB 27-1184-GB
89
Index
T
T connector .................................................................... 75
Test of memory .............................................................. 55
Test of user program ...................................................... 55
Testing ............................................................................ 65
Time
Summer/winter ........................................................... 14
Topology configuration, procedure ................................ 36
Transfer .......................................................................... 61
Transfer of program to PLC ........................................... 61
Twin-level terminal block ................................................ 75
U
Up counter ........................................................................ 8
User program test .......................................................... 55
V
Ventilation ....................................................................... 22
W
Warm start ...................................................................... 60
Wiring ............................................................................. 28
90
Ersatzteilliste Fahrhebel - 1210 FH108/109
Spare Parts List Control Lever
1210FH021
1210FH025
1210FH032/
33/34
Text angeben
1210FH023
1210FH026
1210FH022
1210FH019
Betriebsanleitung
Bordkran Typ DK II 45025/40028/36029 NMF
124 Drawings
Instruction Manual
Board crane type DK II 120016/55033 NMF
13 Drawings
Drawings 125
Betriebsanleitung
Bordkran Typ DK II 45025/40028/36029 NMF