h1002 Deck Crane

Ship yard : Shin An Heavy Industries Co.
,Ltd
Dongnam Marine Crane Hull No. : H1002
INSTRUCTION AND 1. GENERAL
SERVICE MANUAL
Model No. : DDKC-3026-00 2. TECHNICAL
SPECIFICATION
3. FUNCTION
4. OPERATION
5. MAINTENANCE
6. SERVICE
7. DRAWING
#1196, Myeongdong-ri, Hallim-myeon Tel. : +82-55-720-3031~3040

Gimhae-si, Gyeongnam, Korea Fax. : +82-55-720-3039
E-mail : dongnam@dongnam-crane.co.kr
Homepage : http://www.dmcrane.co.kr
DECK CRANE
Model No. : DDKC-3026-00
GENERAL
1. PREFACE
2. CONTENTS
3. SAFETY INSTRUCTIONS
Dongnam Marine Crane co., ltd Issued date : 2008/12/530 Rev :
2009/9/1730
G EN ERAL 1/8
Preface
It is intended as a guide to both the operator and the maintenance personnel to assist them in obtaining the
maximum performance and life of the equipment.
The manual does not include manufacturing drawings and in the event of major repairs of replacements,
DONGNAM MARINE CRANE or their nearest representative should be contacted.
To use this manual, refer to next page for an abridged table of contents. Refer to the section which contains
the information then refer to table of contents at the front of this section for the specific paragraph, drawing or
part required.
All information disclosed in this manual is to be considered confidential and proprietary by DONGNAM
MARINE CRANE and the owner. Communication of the contents to others should not take place without prior
written consent.
Dongnam Marine Crane Co.,Ltd
ATTENTION
The crane has designed to operate cargo handling only except personnel handling.
General
Contents; Safety instructions;
Technical specification
Technical data; Description of crane
Function
Function instruction of the crane
Operation
Operating instructions; Safety instruction during using crane
Maintenance
Lubricating chart and maintenance instructions
Service
General advice how to order spare parts; General service instructions for the hydraulic system, mechanical,
control system and electrical equipment.
Drawing
Mechanical, hydraulic and electrical drawing of the crane
INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

2009/9/1730
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Contents
1. General
Preface --------------------------------------------------- 1/8
Contents --------------------------------------------------- 2/8
Safety Instructions --------------------------------------------------- 4/8
2. Technical Specification
Main Data --------------------------------------------------- 1/11
Description --------------------------------------------------- 4/11
3. Function
Function --------------------------------------------------- 1/9
4. Operation
Safety Operation --------------------------------------------------- 1/27
Description of Safety Equipment --------------------------------------------------- 6/27
Operating Procedure --------------------------------------------------- 7/27
Control operation --------------------------------------------------- 12/27
Emergency Operation --------------------------------------------------- 25/27
5. Maintenance
Safe Maintenance Practices --------------------------------------------------- 1/14
Maintenance Chart --------------------------------------------------- 3/14
Inspection of Stressed Components --------------------------------------------------- 7/14
and Structures
Recommended lubricating oil & --------------------------------------------------- 8/14
hydraulic System oil
Lubrication and Maintenance --------------------------------------------------- 10/14

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6. Service
How to Order Spare Parts --------------------------------------------------- 1/338
Service Network --------------------------------------------------- 2/338
Measures before Starting Service --------------------------------------------------- 5/338
/ Maintenance Work
Trouble Shooting --------------------------------------------------- 6/338
Tightening Torques of Bolt --------------------------------------------------- 11/338
Winches(hoist, luffing, slewing) --------------------------------------------------- 12/338
Pump Drive --------------------------------------------------- 90/338
Slewing bearing --------------------------------------------------- 95/338
Installation and Maintenance - Wire Rope --------------------------------------- 97/338
Installation and Maintenance - Sheave -------------------------------------------- 109/338
Replacement - Hook Block --------------------------------------------------- 111/338
Electrical Equipments --------------------------------------------------- 113/338
Hydraulic Equipments --------------------------------------------------- 249/338
7. Drawing
Mechanical Drawing --------------------------------------------------- 1/93
Hydraulic Drawing --------------------------------------------------- 16/93
Electrical Drawing --------------------------------------------------- 20/93
Spare & Tool list --------------------------------------------------- 89/93

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Safety Instructions
Cargo Handling Equipment crane. DMC will take responsibility only for its own
The Dongnam-Marine Crane is a marine crane professional services. Our product guarantee is not
maker. It is designed and manufactured to meet valid unless DMC authorized service is used.
international cargo handling standards for quality,
safety and performance within capacity The use of proper Spares and Exchange details
specifications and outreach as per certificate. DMC shall be contacted for ordering of exchange
equipment and spares for this crane. Articles
The crane is designed for operation in harbor or supplied by DMC are designed and quality tested
sheltered water environments where there is no for this application and are supplied with our
significant movement of the ship due to wave action. warranty for correct function and safe working of the
crane.
Safe Operating Conditions, Proper Instructions
and Precautions DMC accepts no liability for the functioning of the
The responsible officer on board shall ensure that crane systems, nor for the safe use of the crane,
the crane is operated under safe conditions, by unless original spare parts are used.
personnel familiar with its functions and operating
instructions. All safety and precautionary issues Supervision, Instructions, Signs and Warnings
contained in this manual must be observed. Proper Proper use of this crane and its equipment is
instructions and precautions are prerequisites for possible as long as the owners, users and
proper use. operators maintain the crane to meet full
operational standards. This includes the
Preparation for Use and Operation According to replacement of signs, instructions and warnings as
Manual per delivery. DMC does not accept responsibility for
The crane operator, authorized by the responsible any party who fails to ensure that this manual, sign,
officer on board, must be familiar with all safety instructions, and warnings are legible and easily
issues contained in this Chapter and with accessible to personnel.
preparation for use and operating instructions
before work is started. Improper Use
1. Elevation of persons.
Maintenance and Service 2. Exposing persons to the risks of falling cargo.
Prerequisite for proper use is regular maintenance 3. Overloading.
(see Chapter 5) and service (see Chapter 6). 4. Unlocking the crane or crane jib or operating the
equipment at sea without full acceptance and
DMC are available for full service of this cargo control of personnel and equipment safety.

2009/9/1730
G EN ERAL 5/8
5. Unprofessional, intended or unintended, Lubrication chart; Cable Winch and Stabilizing

adjustment of safety locks, hydraulic or electric Equipment
settings. Lubrication chart; Power Swivel
Filters
6. Disregard of occupational and safety standards Handling and Checking Steel Wire Ropes.
of work. Checking brake settings
Before maintenance and service work is started,

Functions, Installations and Equipment certain measures and procedures must be followed.
General Chapter 6 contains:

The DMC crane has built-in safety functions and Measures before Starting Service/Maintenance
installations to allow for safe normal use, operation, Work
care and control. This is applicable to instructed Electrical Equipment, General Maintenance
personnel without specific professional education or
certification, but working according to this manual.
Safety Functions and Equipment
Specific service and repair of the electrical,
hydraulic and the mechanical functions, controls Specific safety equipment is installed and delivered
and settings require professional service personnel with this crane and must be available for its
knowledgeable of risks involved. intended use. The owner/operator of the ship and
its equipment is responsible to ensure that safety
Regular Care and Control (Maintenance) functions, installations and equipment are
This manual contains checklists for regular care maintained to operational standards and are not
and control of crane equipment, wire ropes and being removed, bypassed or worn to non-working
hydraulic filters. These checklists routine contain condition.
inspections and maintenance regularly prescribed This manual features important presentations of
for safe function, e.g.: safety functions, installations and equipment. A
summary is presented below.
Chapter 4 contains:
Safety Precautions Checklists for Single and Twin 1. Safety Functions
Cranes a. Maneuvering functions:
1) All the crane’s working functions are stopped
Chapter 5 contains, if applicable: and the brakes will automatically be activated
Inspection of Stressed Components and Structures when the emergency stop button is pressed.
Lubrication chart; Crane The button is located in cabin. This activates
Lubrication chart; Twin Platform safety stops and automatic lock positions.

2009/9/1730
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2) At twin crane operation the crane available. (Valid for winches equipped with low-
movements automatically stop and speed motors.)
Synchronizing failure indicator lamp lights if the 6) If there is a multiple-disc failure caused by
hooks or jibs get out of synchronizing position. worn out brake discs, sticking cylinder, brake
3) The crane has several fail-safe functions for pilot valve or valve spool, hydraulic braking by
over-ruling or stopping the operator’s pumps and motor is still available. (Valid for
maneuvering in the event that normal hydraulic winches equipped with high-speed motors)
or electrical functions fail, a sudden 7) In case of overheating oil, a temperature
uncontrolled movement occurs or during over- sensor stops the main electric motor, locking
speed operation. (see below) crane operation.
4) There are limit switches for reducing speed 8) Efficient oil filters with exclusive bypass to
of or stopping all dangerous motions. the hydraulic oil reservoir protects the system
from harmful oil conditions. A warning light on
b. Hydraulic functions: the operator’s panel indicates if the filter has to
1) Hydraulic valve functions are set for exact be changed. Dirty filter might cause mal
pressure. Any change in the settings adversely function to the system.
affects crane operation and must exclusively 9) If the hydraulic oil tank oil level drops below
be set by professional service personnel. (see the minimum permissible level. A warning light
instructions Hydraulic function and High on the operator’s panel is activated. An
pressure pumps) indicator stops the main electric motor and
2) Hydraulic oil pressure sensor automatically crane functions are closed while all brake
indicates an overload. For safe hoisting or systems are automatically activated.
lowering, the system automatically switches
from a high-speed movement to a lows-peed c. Electrical functions:
movement or may stop the hoisting movement. 1) During a complete power failure all solenoid
3) In case of a ruptured high-pressure oil valves are de-energized, causing brakes to be
pipe/hose or other feed pressure drops, the oil activated.
feed pressure will collapse. A feed pressure 2) The electronic cabinets have power failure
switch stops the crane and the mechanical indicators. This function closes the electronic
brakes are automatically applied. signals down which automatically activates all
4) Each winch has a hydraulic motor brake mechanical brakes.
valve flanged to the motor. Mounted directly to 3) Heat sensors located in the main electric
the motor it also provides hydraulic braking in motors and feed pump motor stop all crane
case of a pipe rupture. (Valid for winches operations and activate all brakes.
equipped with low speed motors.) 4) The over-current protections on all electric
5) If there is brake band failure, e.g. caused by motors prevent the electric motors from
worn-out lining, hydraulic braking capacities by overloading. The main electric motor and feed
the pump and motor brake systems are still pump electric motor over-current protections

2009/9/1730
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stop all crane operations and activate all 2) During crane start-up a warning light on the
brakes. operator’s panel indicates that starting
5) A separate electrical feed for the crane procedures are still running and that working
house lights operator’s cab and on jib, conditions are not acceptable before the
maintains function of lights even during feed warning light goes out.
disruption to the crane operating functions. As 3) A pushbutton siren is located in the crane
there is not a separate emergency illuminating operator’s cabinet, allowing the operator to
system for the crane (this is dependent on the alert persons in the working area. (e.g. against
ship’s systems) the owner of the crane must prohibited riding on the load or against load
provide a battery type flash-light for the movements)
operator’s cab. 4) Measuring instruments and meters (e.g. for
checking the crane functions, adjusting valve
d. Mechanical functions: positions, and setting functional positions) are
1) Automatic sensors recognize dangerous supplied as per agreement with the crane
wire slacks and stop hoisting and luffing buyer/owner. Tools and equipment which are
movements that threaten safe control and the eliminated from the original order to DMC are
equipment itself. delivered at the discretion of the owner.
2) Each working circuit has at least two
independent brake systems. Dynamic braking b. Covers and houses:
(hydraulic braking), deceleration, is achieved 1) Unauthorized visitors in the crane house,
by the regenerative function of motor and pump. especially during crane operation, is prohibited.
True static braking (parking brakes) is provided The crane is a dangerous working area, and
by multiple disc-brakes or band brakes. There requires special permission to enter.
are band brakes for low-speed winches and an Instructions given by the superintendent or
extra mechanical pawl-brake for luffing. The responsible officer must be followed.
mechanical brakes are automatically activated 2) Covers for electric boxes must be opened
in the event of dangerous oil pressure. High only by authorized personnel.
speed winches are provided with multiple disc-
brakes. One for each gear unit. Each slewing 3. Safety Equipment
gear unit is equipped with one multiple disc a. Locks, seals and keys:
brake. 1) Functions and equipment that are essential
for oil pressure settings, coordination of
2. Safety Installations controls and crane movements or expose
a. Warning lights, measuring instruments and dangerous high-voltage electricity are locked.
meters: All keys to locked positions and switches must
1) The operator’s panel is provided with be kept and controlled by the responsible
warning lights which indicate clogged filters or officer onboard and are only to be used by
low oil level in the oil tank. qualified personnel.

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2) Safety valves for hydraulic pressure settings

and switches for electric safety circuits are
sealed to secure correct position and trim.
Sealed equipment may be opened and
positions changed only after consulting the
DMC service organizations for proper handling.
b. Safety belt, rescue line, safety chains:

1) For work or entry to the open-air crane top,
authorized personnel must wear a safety belt.
The connector hook should be anchored to
rails and fixed position while staying or working
on crane top.
2) The rescue line and equipment for
emergency evacuation of the crane operator
must always be easily accessible on the
interior wall-side of the crane cabin. The
equipment status and completeness must be
inspected regularly by the responsible officer
onboard.
3) The safety chains on the open-air crane top
and work platforms inside the crane must be
used for attendant’s safety during stay and
work.
c. Firefighting equipment:
A fire extinguisher shall be made available by
owner in the operator’s cabin. The fire
extinguisher is for emergency use inside the
crane. The equipment must be regularly
inspected for proper pressure reading at the
meter and must be serviced annually. This is to
be supervised by the responsible office on
board.

DECK CRANE
TECHNICAL
SPECIFICATION
1. MAIN DATA
2. DISCRIPTION
Dongnam Marine Crane co., ltd Issue : 2009/7/6 Rev : 2009/9/17
T ECHN ICAL SPEC IFICT ION 1 / 11
Main data
1. Technical Data
Capacity : 30 tonnes for Cargo/ 24 tonnes for Grab
Outreach : Max. On even keel 26 m
Min. On even keel 4.5 m
Max. Hoisting height : In hook operation 35 m
Self weight : approx. 71.89 tonnes with 10.2m Pedestal
Design conditions
Maximum admissible Heeling/Trim : 5°/2°
Design temperature : -10°C to +45°C
Ambient temperature : -20°C to +45°C
Humidity: maximum : 100 %
Max. Wind speed during working condition: 20m/sec
Stowed (parking) condition: 63m/sec
Certifying authority, Rules / Regulations : DNV
2. Operating Speeds
Hoisting / Lowering
- 100 percent infinitely variable speed control from zero to maximum speed:
0 – 20 m/min at 30 tonnes at 2nd layer
0 – 30 m/min at 12 tonnes at 2nd layer
Slewing
- 100 percent infinitely variable speed control from zero to maximum speed.
- Electronic-controlled acceleration and retardation (adjustable), in order to avoid shocks to load and crane
and to enable smoother speed control
- Automatic power output regulator
- Slewing range: 360° unlimited
- Slewing speed: 0 – 0.7 RPM at full load
Luffing
- 100 percent infinitely variable speed control from zero to maximum speed.
- Luffing Time: 75 sec with full load from max. to min. operating radius

3. Application equipments and system

Drive system
Prime mover : Electric squirrel cage motor
- Nominal output: 220 kW, S6-40% ED
- Starting current: 2273A
- Nominal current: 345.3A
- Class of protection: IP 55
- Class of insulation: “F” Class
- Starting: Star Delta
- Maker: HYOSUNG
- Main power supply: 440 V, 60 Hz, 3 PH.
- Aux. Power supply: 220 V, 60 Hz, 1 PH.
- Power transmission via slipring collector from base column to crane.
Hydraulic oil
- Required hydraulic oil, quantity: Approx. 500 Liters
- Oil cooler is located on top of the slewing column,
- Cooling medium is fresh Air.
Lighting
- Appropriate lightings are provided:
In the machinery room (Inside king post),
In the switch cabinet room,
In the driver's cabin,
and at ascent to the crane
- Floodlights (type Sodium, Rating : each 500 W) are provided:
under cabin (500W x 2sets),
and on the jib (500W x 2sets)
Heating
- Standstill heating in the electric motor
- Heating in driver's cabin
- Heating of the hydraulic tank, thermostat controlled
- Heating of electrical switchboard
- Standstill heating in slipring collector
4. Documentation / Name plates

Standard scope of delivery includes:
One(1) Installation manual
Three(3) Instruction manual / maintenance manual
Three(3) Technical information
Three(3) Spare parts list
Three(3) Data books
Name plates

5. Protective Coating :
Deck crane inside (Accessible part)
Priming: Brand name: BANNOH 2000 , DFT: 100 microns
Colour: Brown
Deck crane outside

Priming: Brand name: BANNOH 2000 , DFT: 100 microns, colour: Grey
2nd coat: Brand name: UNY MARINE, DFT: 50 microns, colour: BUFF(CS-619)
Finish coat: brand name: UNY MARINE, DFT: 50 microns, colour: BUFF(CS-619)
6. FEM Classification
The minimum group classification according to F.E.M. 1.001, latest edition, relates to full load cycles and is
as follows:
Group classification of: Grab duty Hook duty
The crane as a whole: U4/A5/Q3 U5/A5/Q2
The hoisting mechanism: T5/M5/L2 T5/M5/L2
The luffing mechanism: T5/M5/L2 T5/M5/L2
He steel construction: B5/E5/P3

Description
1. Structural parts
< Fig. 2.1 General arranegent >
The Crane is a electric drive-hydraulic operated, wire rope luffed boom crane, with a rotating upper
structure. It consist 26m boom with a 30T hoisting winch.

Slewing column
Main Fan Cooler
Fan
Feed Unit
Level Sensor
T6CC
Temp. Sensor Main Block
Cooling Part Filter

Heater
ON&OFF Valve
Main Pump Unit

Gear Box Cooling Unit
Hoisting P7R
Luffing P6P
Inline Filter
Slewing P6P
“DR” PIPE
Gear Box Tank

“D” PIPE
Main Control Panel

“C” PIPE
Operation Panel Shuttle “T” Block
Luffing Winch Slewing Port Block
Hyd. Motor F12-110

Emergency Block
Hoisting Winch Brake Block
Hyd Motor V14-160 Slewing Ass’y
Hyd. Motor F12-040
< Fig. 2.2 Slewing column assembly >

The slewing column is a totally enclosed welded steel structure which houses the central hydraulic power
aggregate, the electric/electronic control gear, the slewing gear and the driver's cabin.
The hoisting winches are mounted at the rear of the slewing column, allowing easy and safe access for
maintenance. Appropriate ventilation of the machinery room will be provided.
Elec. Motor
Gear Box Tank
Bell Housing
Gear Box
Slewing Pump
Luffing Pump
Hoisting Pump
< Fig. 2.3 Main Pump UNIT >

Driver's cabin
Full vision driver's cabin provides with ergonomic seat with electric/electronic control of movements, lighting,
heating and ventilation. The cabin features clear safety glass, top window, side windows (left hand side open
able), front window with electric wind shield wiper and washers, floor window and safety frame around the
cabin.
The cabin is mounted on rubber dampers and is sound insulated to ensure a comfortable working
environment for the crane driver. It is installed as far forward as possible to improve driver's visibility.
Two self-centering joysticks for crane control (right side: hoisting/lowering, left side: slewing, luffing) allow all
motions to be operated at the same time. The crane control instrumentation also includes a start/stop switch
for the electric-motor and an indication light for 'main switch on'.
Access to crane
The access through the base column allows easy and safe accessibility for operating and maintenance
personnel to driver's cabin and machinery room as well as to the winch frame of the crane through a
watertight hatch. A platform with handrail is installed on top of the slewing column to allow convenient
maintenance of the sheaves.
Emergency exit
Emergency exit is provided through the side door of the driver's cabin by means of an emergency rope down
device.
Boom
The boom is a completely enclosed box-welded computer designed construction, which ensures high
strength, torsional rigidity, stiffness and low weight. Capacity is marked with numbers and letters on both
sides of the boom.
Sheaves on the boom head are lubricated via pipes from a battery of nipples located at the boom rest. Actual
details to be agreed with the shipyard.
Boom pivoting point

Axle made of SCM440-H material running in a spherical roller bearing of sufficient size and protected and
maintained through a centralized greasing system.
2. Machinery parts
Hosting and Luffing winch

Hoisting and Luffing gear are Installed inside the slewing column. Hoisting and luffing winch with rope
grooving, planetary gear box (Running in oil-bath), axial type hydraulic motor of variable/fixed displacement
and multi disc brake (fail-safe, spring-loaded, hydraulically released). Hosting and Luffing rope are spooled to
the winch in multiple layers with safety windings left when the rope is fully spent out (according to

classification rules) manual release device of brake is provided on hoisting device for emergency (e.g.
Electric power failure)
Slewing gear / Slewing bearing

The crane is connected to the top part of the base column via the slewing bearing. The slewing motor drive
pinions mesh on the internal gear of the slewing bearing. Back lash is adjustable.
The slewing bearing is designed and built for marine application. Each slewing gear consists of a closed
planetary gearbox running in oil-bath, slewing pinion, fixed displacement hydraulic motor and spring loaded,
hydraulically released multi-disc brake.slewing-bearing(s) is made of ball or roller bearing with enough
carrying capacity and life. Hydraulic disc brake is provided on the reduction gear.
Slewing bolts and nuts exposed to the salt laden marine environment are fully protected by grease filled
rubberized slip-over shrouds.
Pump unit
The pump is driven coupled with electric motor with reduction gear.
Ropes and Sheaves

Anti-twist type hoisting ropes with class certificate are galvanized and suitably anti-drip greased. The
sheaves with large diameters run in sealed anti-friction bearings.
Hook traverse
For handling of break bulk and other general cargo or containers, a hook traverse with ramshorn hook and
safety latches with class certificate for the required safe working load (SWL) and of sufficient weight is
provided to ensure correct spooling of the rope on the drum during unloaded operations. The change over
procedure from grab to hook operation or vice versa is a matter of a few minutes.
3. Electrical parts
The electric equipment complies with the relevant IEC and VDE-Standards.
Electric motor
Three-Phase squirrel cage electric motor with thermistor protection and stand still heating. A star delta starter
is built in as a standard to ensure low starting currents. A running hour counter meter is installed on the main
electric switch gear cabinet.
Ventilation
A sufficiently dimensioned ventilator takes care of the ventilation of the machinery room. The air inlet is
through the base column, the air outlet through an opening at the top side of the slewing column.
4. Hydraulic system
The three phase squirrel cage electric motor drives the separate hydraulic pumps for each motion through a
splitter gear box. Hydraulic circuits for hoisting, luffing slewing are independent closed hydraulic circuits.

Independent swash plate variable

Displacement pumps drive the hoisting, luffing and slewing gears through fixed axial displacement motors.
An additional hydraulic pump is provided for feed oil pressurizing the hydraulic system and control purposes.
The power pack is suitably sized to operate all three functions at a time with max. Load. Hoisting, luffing and
slewing drives are equipped with automatic constant power regulators. These units automatically determine
the maximum speed for each load in such a way that the maximum power consumption remains constant.
The crane operator can achieve the maximum speed by moving the control lever to the max. position. The
system selects automatically the max. speed, however, any intermediate speed from zero to maximum can
be selected.
5. Safety devices
- Motion control levers return automatically to neutral position when released limit switches for highest and
lowest hook position.
- Limit switch for maximum working radius.
- In case of power failure or pressure drop in the hydraulic circuit the spring-actioned hydraulically released
brakes close automatically.
- Safety valves in all circuits prevent overloading of crane.
- Sensors for hydraulic oil temperature and oil level.
- Emergency stop push buttons in driver's cabin and pedestal outside to access easily.
The following safety devices are provided for the motions listed below. When the safety device(s) is actuated,
the hydraulic and/or electric motor are/is stopped
- Hydraulic safety valves: each safety valve protects the pumps as well as hoisting, luffing and slewing
motors from over load.
- Hoisting limit:
Upper limit of hoist motion : Weight type limit switch
Lower limit of hoist motion : Differential type limit switch
- Luffing limit: max. and min. jib angle and jib lower position
- Rope slack detector: for hoisting and luffing wire rope.
- Resistance thermometer sensor: max. 70℃ & min. 5℃ of oil temp
- Deadman switch : Activate operating condition to push toggle switch on each Joystick at the same time.
If push again, activation is stopped and then the Joystick cannot be used
- Float switch: high, low and low-low level of hyd. tank.
- Emergency stop: all motion are stopped in case of emergency
- Limit switch for slewing parking position.
Note
Jib is lowered rest position by the select switch with key (by pass key) under no load

6. Certification
The crane will be approved by classification authority stating that the cranes is built in accordance with DNV
class rules and that the construction is in compliance with approved drawings.
Certificates of components and crane structure for third party Inspection:
- Hook block, wire rope : ILO Form Certificate

- Material for primary steel structure crane : 3.1B
- Slewing gears : Manufacture’s Certificate 2.2
- Luffing gears : Manufacture’s Certificate 2.2
- Slewing ring, bolts and nuts : 3.1B
- Hoisting winch and gear : Manufacture’s Certificate 2.2
- Main electric motor and panel : Class Certificate 3.1C
Data book containing below mentioned documents retained by client:
- DNV certificate
- Wire rope certificate
- Loose gear certificate
- Certificate of compliance

7. Inspection and Testing
Inspection
After finishing the manufacture of crane, temporary assembly shall be done to check each part by
manufacturer's inspector. It will be as certain whether the driving mechanical parts can be driven well.
Shop Test
All sets of crane will be tested on the horizontal bench in the presence of classification's surveyor and
manufacturer's inspector In accordance with the manufacturer's test schedule as follow. The test record for
all sets of crane will be submitted to the customer. About the typical one set of crane per ship, following tests
will be carried out in case that the customer attends the shop test.
Test item Test content

Performance test Hoisting, Luffing and Slewing at rated and over load
Confirm of emergency Stop Hoisting, Luffing and Slewing at rated load.
Hoisting, Luffing and Slewing brake manual release by handpump
Emergency Operation
at rated load
Confirm of limit Switch Hoisting upper, Luffing upper and Lower,
(at no load) Slack detector
Measurement of Insulation The insulation resistance will be measured between charging
resistance electric motor parts.
Return Filter Element Check Return filter element will be checked a particle of metal.
On-board Test
The on-board test will be carried out by shipbuilder in the presence of classification's inspector and ship's
owner on-board test Schedule and test load with rope shall be prepared by shipbuilder. As a general
standard, all cranes are function tested in the factory before delivery.
8. Commissioning Material / Tools / Spare parts

For each shipset of cranes, one set of commissioning spares, and tools will be provided for installation, start-
up, and final testing on board of ship.
9. Preparation for Shipment

The crane will be dismantled into major components and properly prepared and packed for export shipment.
Adequate lugs and pad eyes will be provided on the crane to facilitate safe handling, lifting and installation of
the crane on board the vessel.
10. Quality / ISO 9001

Ship cranes are the result of continuous quality assurance and quality control at all stages of design,
production and after-sale service.
The quality system has been certified by DNV (Certificate no. 32949-2008-AQ-KOR-RvA 20 August 2008)
to conform to the quality standard ISO 9001 (2000) / KS A 9001(2001).

DECK CRANE
FUNCTION
Dongnam Marine Crane Issue : 2009/3/4 Rev : 2009/7/3
FUNC T ION 1/9
Function
1. General
The following description refers to the standard hydraulic system of DMC hydraulic deck cranes, normal
version.
Minor variations in the hydraulic system may occur in individual cranes of the same type, and the
objective of this description is only to provide a general orientation concerning the arrangement of the
hydraulic system.
Three separate hydraulic work circuits, ie, the hoisting, luffing, and slewing circuits, plus feed and control-
pressure circuits, make up the complete crane operating system.
Each of these work circuits may have one or more pumps located in the pump unit, in Figure 1 marked
PH, PL, and PS. Pump PF for the feed and control- pressure system is located tank top the hydraulic
reservoir.
2. Identifying circuits in the hydraulic diagram

Figure 1 shows the arrangement of the three work circuits, hoisting, luffing, and slewing circuits, together
with the feed and control-pressure circuit. The circuits appear in the same order in the hydraulic diagram.
3. Symbols
Every hydraulic component is represented by a special symbol in the circuit diagram. The meaning of the
symbols is explained in section “General” in the manual. The symbol for the reservoir is shown in several
places in the diagram for greater simplicity of drawing; but there is naturally only one reservoir in actual
fact.
4. Component identification
The main components are identified by four-digit numbers in the diagram and on the actual components
in the crane. The first digit of each number signifies the circuit to which the component belongs:
1…Hoisting circuit
2…Luffing circuit
3…Slewing circuit TANK P.C
4…Feed and control-pressure circuit
5…Additional programming equipment *)
6…Twin crane hydraulic equipment
7…Other additional hydraulic equipment *) P.H P.L P.S
*) Equipment installed at request of customer M.H M.L M.S
Legend
HOISTING LUFFING SLEWING
M.H Hydraulic motor, hoisting circuit
CIRCUIT CIRCUIT CIRCUIT
M.L Hydraulic motor, luffing circuit
M.S Hydraulic motor, slewing circuit
P.H Pump, hoisting circuit
P.L Pump, luffing circuit FEED AND CONTROL CIRCUIT
P.S Pump, slewing circuit
P.C Pump, feed circuit < Fig. 3.1 Identifying hydraulic circuit. >

FUNC T ION 2/9
5. Cooling and control circuits
Cooling line circuit

The function of this circuit is mainly to refrigerate the hyd. oil.
Brake pressure circuit

The function of this circuit is to supply fluid to the brakes ie, to control brakes, slewing, luffing and hoisting.
The system operates at approx. 3MPa (30 bar) and is measured at test point 3GP2
NOTE
For exact pressure settings, see pressure list the hydraulic diagram.
(3GP2.) Brake Pressure
Pump & Motor

Cooling line
case drain
Brake Pressure
<Fig. 3.2 Feed and control circuit>

FUNC T ION 3/9
6. Hoisting winch circuit
Introduction
Fig 3.5 shows a hoisting winch circuit diagram,
with the following main components:
Pumps 5P1
Hydraulic motors 5M1
Brakes 5BR1
The brake is mounted inside the winch gearbox.

<Fig.3.3. Control lever in neutral, hoisting>
Function
With the control lever in neutral, Fig 3.3 or Fig 3.6,
and the pump running, the hoisting circuit performs
no actual work.
Low-speed range, brake release

When the switch lever is moved to the left for
normal operation of the winch and control lever
is pull down, Fig. 3.4, valve 5SO1 in the actuated
mode, “b”, and connects full control pressure to the
brake valve 5SO1 which releases the brake.
With SWL 12~30tonnes on the cargo hook and the

control lever in brake release position, Fig. 3.4, the
hoisting winch should produce a slow hoisting <Fig.3.4. Control level, hoisting, brake release
movement, so called flushing. See instruction under position and low speed hoisting>
section 6.1 “High pressure pumps”.

FUNC T ION 4/9
High Speed
Shuttle outlet
Pressure
to valve Motor case
and Brake flushing
Pump & Motor

case drain Pump case
flushing
Booster inlet
<Fig.3.5. Hoisting winch circuit>

FUNC T ION 5/9
High speed range, brake release

When the switch lever is moved to the right
for high-speed operation of the winch and control
lever is pull down, Fig. 3.7, valve 5SO1,5SO2 in the
actuated mode, “b”, and connects full control pressure
to the brake valve 5SO1 which releases the brake.
.
With SWL 0~12tonnes load on the cargo hook and the control
lever in brake release position, Fig. 3.7, the hoisting
winch should produce a high hoisting movement.
<Fig.3.6. Control lever in neutral, hoisting>
High-speed range overload

If the load on the cargo hook is too heavy for handling in
the high-speed range, the load cell will cause valve 5SO2
to shift to low-speed range.(Full displacement)
Hoisting and lowering, high speed or low speed

Pulling the control lever backwards from the brake
release position will start the winch to lift the load,
Fig. 3.4 low speed and Fig. 3.7 high speed. The
servo valves 5P1-1 affect the servo and thus the
pump displacement. The pumps 5P1 thereby produce
a flow of fluid that is proportional to deflection of the
control lever.
If, instead, the control lever is moved forward, the

<Fig.3.7. Control level, hoisting, brake release position
load will be lowered, ie, the function is the same as
for hoisting, except for the direction of flow. and high speed hoisting>
Safety function
The hoisting winch circuit embodies three safety features:
- Main pressure limiting valves 5P1-2

- Pressure switch 5PS1 (overload valve) stops the crane in the event of overloading at low speed. Shifts to low-
speed when running in the high-speed mode
- Pressure switch 5PS1 stops the crane in the event of insufficient feed pressure
Note!
It is not allowed to adjust sealed safety valves without contacting DMC Cranes, Service Department.

FUNC T ION 6/9
7. Luffing winch circuit

Introduction
Fig. 3.9 shows a luffing winch circuit diagram, with the following main components:
Variable displacement pump 6P1

Hydraulic motor 6M1
Brake 6BR1
The luffing movements are generally operated by a common control lever, Fig. 3.8.
<Fig.3.8. Control lever, luffing >
Brake release
Moving the control lever from neutral, eg, rearward to raise the jib, causes the 6SO1 to shift position and
control pressure is admitted to the brake 6BR1 which shifts position from the unloading mode.
With the control lever in the brake release position, the luffing winch should produce a slow movement of
the crane jib.
Raising and lowering the jib

Moving the control lever further backward starts operation of the luffing winch. The servo valve 6P1-1
affects the servo and thus the pump displacement. The pump 6P1 thereby produces a flow of fluid at a
rate that is proportional to lever deflection.
To lower the jib, move the lever forward from neutral. The function is the same as for luffing-in, except for
the direction of the fluid flow.
Safety functions
The luffing winch circuit embodies two safety features:
- Pressure limiting valves 6P1-2

- Pressure switch 6PS1; stops the crane in the event of insufficient feed pressure
Note!
It is not allowed to adjust sealed safety valves without contacting DMC Cranes, Service Department.

FUNC T ION 7/9
Motor flushing
Pressure to valves
and brake
Shuttle outlet
Pump & Motor

case drain
Pump case
flushing
Booster inlet
<Fig.3.9. Luffing circuit>

FUNC T ION 8/9
8. Slewing circuit
Introduction
Fig. 3.11 shows a slewing circuit diagram for the crane, with the following main components:
Variable displacement pump 7P1

Hydraulic motors 7M1
Brake 7BR1
The slewing movements are generally operated by a common control lever, Fig. 3.10
Slewing left Slewing right

(Anti-Clockwise) (Clockwise)
<Fig.3.10. Control lever slewing>
Brake release
Moving the control lever, eg, to the left for slewing left (anti-clockwise), will affect valve 7SO1. The
brakes will be released.
Slewing left and right

By moving the control lever further to the side, the crane will start to slew in the direction chosen. The
servo valve 7P1-1 affects the servo and thus the pump displacement. The pump 7P1 thereby produces
a flow of fluid at a rate that is proportional to lever deflection.
To slew to the right (clockwise), move the lever to the right instead. The function is the same as for
slewing left, except for the direction of the fluid flow.
Safety functions
The slewing circuit embodies one safety features:
- Main pressure limiting valves 7P1-2

FUNC T ION 9/9
Pressure to valves
and brake
Shuttle outlet
Pump & Motor

case drain
Booster inlet Pump case flushing
<Fig.3.11. Slewing circuit>

DECK CRANE
OPERATION
1. SAFETY OPERATION
2. DESCRIPTION OF SAFETY EQUIPMENT
3. OPERATING PROCEDURE
4. CONTROL OPERATION
5. EMERGENCY OPERATION
O PERAT ION 1 / 28
Safety Operation
1. Preface
The importance of safe operation cannot be over emphasized. Carelessness and neglect on the part of
operators, job supervisors and death or injury and costly damage to the crane or property.
The safety information in this publication is intended only as a guide to assist qualified operators in safe
operation. Dongnam Marine Cranes cannot foresee all hazards that will arise in the field; therefore safety
remains the responsibility of crane operator, maintenance workers and crane owner.
2. Operator qualifications
The crane shall be operated only by the following qualified personnel :
- Designated operators.
- Trainee under the direct supervision of a designated operator.
- Inspectors and maintenance or test personnel when necessary in the performance of their duties.
ATTENTION
No other personnel shall be allowed to enter operator’s cabin while crane is in operation
Qualified person is defined as one who by reason of training and experience is thoroughly familiar with crane
operations and the hazards involved. Such a person shall be physically and mentally fit to operate cranes.
ATTENTION
Operator training and qualifications is crane owner’s responsibility
3. Operator Conduct
- The operator shall not engage in any practice, which diverts their attention while operating the crane.
- The operator shall be responsible for all operations under their direct control. When the safety of an
operation is in doubt, the operator shall have the authority to stop the operation and refuse to continue until
the unsafe conditions have been corrected.
- The operator shall be thoroughly familiar with operation of the crane and its proper care. If adjustments or
repairs are necessary of if there are know defects that impair safe operation, the crane shall not be operated
until the unsafe conditions have been corrected.
- The operator shall be thoroughly familiar with operation of the crane and its proper care.
If adjustments or repairs are necessary of if there are know defects that impair safe operation, the crane shall
not be operated until the unsafe conditions have been corrected.
- If there is a warning sign at the start controls, the operator shall not start the main electric motor until the
sign has been removed by the person who installed it.
- Before starting the electric motor, the operator shall make sure that :
a) All daily inspection and maintenance services have been performed

b) All controls are in the off position and all brakes and locking devices are applied or engaged.
- The operator shall test all controls, limits and communication systems at the start of each shift. Any defects
found shall be corrected before operation is begun. The operator shall not lift any loads if the machine

O PERAT ION 2 / 28
exceeds the levelness tolerance of 1% the machine must be level before lifting loads.
- The operator shall not start crane movement if the load or designated signal person is not within their range
of vision.
- The operator shall respond to signals from the person directing the lift or from the designated signal person.
When a signal person or crane follower is not required, the operator is responsible for the lift, Operator shall
obey a stop signal at all times, no matter who gives the command.
- The operator shall verify that the capacity chart being used is the correct one for how the crane is equipped
(boom length, load line reeving, etc)
WARNING
The only load charts that may be used with this crane are those included in the Drawing Section of
this manual and located inside the operator’s cabin. Do not use any other capacity charts with this
crane. If capacity charts are missing contact Dongnam Marine Crane Co., Ltd.
- The operator shall perform the following operations before leaving the operators cabin for any reason:
a) Park the crane and position the upper works so the crane does not interfere with operation of
other equipment
b) Land any attached load
c) Move all controls to off
d) Stop the electric motor
- The operator shall perform the following operations if power of a control function fails during operation:
a) Land all suspended loads

b) Switch all controls to off
- If the crane will be operated at night, the operator shall make sure that there is sufficient lighting for safe
operation. The load and landing area shall be illuminated.
- The operators shall not operate the crane during periods of bad weather if his ability to see the load or
signal person is impaired by darkness, fog, fain snow, etc.
- Wind can cause the crane to tip or the boom and other attachments to collapse. The operator or the
designated person directing the lift shall compensate fort he effect of wind load and boom by reducing
speeds, or combination of both. Unless otherwise specified on the load chart, stop operation under the
following wind conditions :
a) If the wind causes the load tops wing forward past the allowable operating radius or sideways
past either the boom heel pin, land the load.
b) If the wind exceeds the limit stated on the appropriate load chart, land all loads and apply brakes,
lower the boom onto blocking at ground level or otherwise restrain it.

O PERAT ION 3 / 28
WARNING
Do not operate in winds speeds in excess of 20m/s
Booms sections are being assembled or disassembled on ground and shall be securely blocked to prevent
dropping of the boom section.
Workers shall not go under boom sections when removing connecting pins.
4. Handling the load
Size of load
- The crane shall not be loaded beyond the applicable rated capacity (SWL=30mt)
- The operator or designated person directing the lift shall verify that the weight of the load is within the rating
for the radius which the load will be lifted.
- The load chart for the crane is kept in the operator’s cabin.
Attaching the load

- Attach the hook to the load with slings, or other suitable rigging. Each hook shall have a latch that is in
proper working order. Hook latches shall not be wired open.
- Only use sling and other rigging, which are in safe operation condition and have a rating equal to or greater
than the load to be lifted.
- Do not warp the load line around the load.
- Use suitable protection between slings and sharp edges on the load.
- Secure unused legs of a multi leg sling before handling a load with one leg of the sling.
Lifting / Moving the load

- Before lifting or moving the load, the operator or the designated person directing the lift shall make the
following checks:
a) The load is secured and properly balanced in the slings or lifting device before lifting the load
more than few centimeters/inches.
b) The lift and swing paths are clear of personnel and obstructions.
c) The lift and swing paths are clear of personnel and obstructions.
d) The load line is not kinked or otherwise damaged.
e) Multiple part load lines are not twisted around each other in such a manner that the lines will not
separate when the load is lifted.
f) The hook is brought over load in a manner that will minimize twisting or swinging.
g) The load line and boom hoist ropes are properly spooled on the drums and seated in the
sheaves.
h) The operator shall test the brakes each time a load approaching the rated load is handled by
lifting the load a few centimeters/inches and positioning the control handle in neutral.
- While lifting the load, the operator shall take the following precautions:
a) Accelerate and decelerate the load smoothly to avoid excessive stress on the crane boom and
machinery.
b) Avoid sudden starts and stops while swinging. Keep the swing speed under control to prevent the
load from swinging out beyond the radius at which the load can be handled and to minimize the

O PERAT ION 4 / 28
pendulum action of the load.

c) Use taglines or other restraints to control the load when necessary (if fitted).
d) Do not exceed any preset swing limitations (areas of operation) without authorization.
e) Do not allow the load, the boom or any other part of the crane to contact obstructions.
f) Do not hoist, or lower, or swing the load while personnel are on the load hook(if fitted).
g) Avoid carrying the load over personnel. Loads, which are suspended, shall be blocked or
supported by the ground or a suitable structure before personnel are allowed to work under or
between them.
h) Operate with caution when using two or more cranes to lift the same load. One designated
person shall be responsible for the operation when two or more cranes are used to lift the same
load. The designated person shall analyze the lift and instruct all personnel involved in the proper
rigging and positioning of the load and all movements to be made. Decisions such as the necessity
to reduce crane ratings, load position, boom position, ground support, and speed of movements
shall be in accordance with the designated persons decision.
i) Do not lower the load or the boom to the point that less than three full wraps of wire remain on the
respective drum.
Holding the Load

When a load is suspended, the operator shall take the following precautions;
- Not leave their position at the controls.

- Not allow personnel to stand or pass under the load.
- Move controls to off.
Signals
- Signals to the operator shall be in accordance with the standard signals.
- The operator should easily understand all signals to the operator at all times. The operator shall not
respond to any signals, which are not clearly understood.
- When it is necessary to give instructions to the operator, all crane motions shall be stopped.
- The signal person shall :
a) Be qualified by experience with crane operations and thoroughly familiar with the standard
signals.
b) Be positioned in clear view of the operator. The signal person’s position should give him or her
clear view of the load, the crane and the operating area.
c) Direct the load so the load does not pass over personnel.
d) Keep unnecessary personnel out of the crane’s operating area.
Getting onto or off crane

- Personnel getting onto or off the crane shall do so only at designated areas and only while the crane is
parked.
- When personnel use ladders to get onto and off the crane, their hands shall be free of any objects. Objects
that cannot be carried in pockets or tools belts shall be lifted into place with a hand or hoist.
Cabin, Ladders and Walkways

- Necessary clothing and personal belongings shall be stored so they do not interfered with access to the
operator’s cabin or with operation of the crane.

O PERAT ION 5 / 28
- Tools, oil cans spare parts and other necessary equipment shall be stored it toolboxes and not allowed to lie
around loose in the operators cabin or walkways and stairs. All waste shall be disposed off.
Fire Extinguishers (If fitted)

- A portable fire extinguisher shall be installed at the cabin at all time.
- The operator and all maintenance personnel shall be thoroughly familiar with the location, use and care of
the fire extinguisher.

O PERAT ION 6 / 28
Description of Safety Equipment
1. Safe Load Indicators

This provides the operator with a clear and continuous picture of his margin of safety by indicating hook
radius, the load on the hook and the permitted safe working load for a given radius. Visual and audible
indication of approaching overload is provided. A ‘self check’ system to allow operator to check correct
functioning of equipment is also provided.
2. Alarm Buzzer
This provides audio alarm warring for engine “Low Oil Pressure” and “High Water Temperature”
3. Motor Stop
This is a pulled-knob lock down button mounted in the operator cabin. When activated, ceases all motions.
4. Low Oil Level

Mechanical operated level gauge shows hydraulic oil tank level.
5. Temperature Gauge
Indicates oil temperature in the tank and must never exceed 70 Celsius.
6. Limit Switches
Hoist
Hoist Limit Switch is operated through drum shaft. Contacts within the limit switch are automatically reset
when the motion is driven in the opposite direction. Up limits must be set with boom at maximum radius and
starting with the ultimate up limit. Set ultimate limit, which stops all crane motions, with hook at approximately
2.0 meters below boom head.
The up limit is set approximately 3 meters below ultimate limit setting and stops the hoist motion and applies
the brakes.
Slew
The slew control is fitted with mechanical operated valves which stops the motion and apply the brake when
tripped.
Luff
The luff limit is operated through on luffing winch. This limit is ignored by selecting the luff down “by pass”
selector switch located in cabin.
Horn
The horn is automatically operated when an overload condition exists or it can be energized through manual
control by the operator to warn personnel.

O PERAT ION 7 / 28
Operating Procedure
1. Operating Instructions
Before starting the electric motor and during the warm up period, the operator is required to check the crane
according to the daily checklist (refer Maintenance Chart) as required by relevant inspection authority.
When the crane is assembled for the first time, circuit breakers in the electric cubicle must be engaged to
provide power. Lognition is switched on and annunciator shows oil and boost pressure until the prime mover
is started. The Safe Load indicator is switched on through the ingnition switch and show boom radius, load in
tones and permitted load in tones. When the prime mover is started with cold, thick hydraulic oil in the
system, the filter blocked relay might indicate on the annunciator, but should stop when the oil temperature is
rising. If after a significant rise in the oil temperature and the indicator is still on, the filter element must be
exchanged prior to the operation of crane.
WARNING
Hoist and luff motions in some cranes are equipped with hydraulic motors, which will change their
displacement according to the load and the deflection of control valve level. In others, the motor
displacement is fixed.
The safe load indicator, which will continually show the radius, actual and permitted load at any specific
radius must be observed at all time to avoid tripping the motion cutout while luffing out. Dive out of the
overload condition by either luffing in or lowering the load to the ground immediately.
ATTENTION
Overload may be reset with key held by a person other than the operator only during extreme
circumstances.
For repetitive work, the safe load indicator can be set to indicate minimum and maximum required radius
through the light and sound by pressing the push button indicated by arrows when the required radius is
reached the first time.
ATTENTION
Do not totally rely on the before described indicators, as circumstances may arise which will not
show on the indicator.

O PERAT ION 8 / 28
2. Handling of heavy loads

When raising heavy loads the control is pulled slowly to accelerate the load to maximum hoist speed.
ATTENTION
Should a load or the boom ever accelerate out of control, never counter switch controls, let all
controls go and hit the emergency stop button to arrest load or boom.
3. Crane shut down and out of operation condition

Pumps and hydraulic components should be allowed a sufficient “cooling off” period prior to shut down.
Running pumps at approximately half speed for at least 5 minutes after crane had been working hard should
be sufficient. Before leaving the cabin, ensure that all windows are closed.
Switch off all lights and shut cabin door securely. Before leaving the crane, a visual check of component
should be undertaken and the maintenance supervisor or the responsible person informed of any
discrepancies.
4. Wind speed indicator with weather vane ( If fitted )
Cranes free standing with 360 slewing. Whether the crane is luff unattended (without driven in control), it
must be put into the weather vane mode before the engine is shutdown.
Proceed as follows:
a) Swing crane boom away from the general wind direction that is so the wind comes from behind
the crane and luff out as much as possible.
b) With slew brake released or open, slew lock valve on the control panel tightly to lock in the slew
release pressure.
c) Proceed to the power pack and open the lock valve on the slew pump to assist oil flow across the
ports.
d) When returning to normal duty, the slew lock must be fully opened before commencing work.

O PERAT ION 9 / 28
Standard Hand Signals
<Fig 4.1 hand signals>

O PERAT ION 10 / 28
EMERGENCY ESCAPE INSTRUCTIONS

LEAVING CRANE OPERATOR’S CABIN USING ESCAPE LINE
AND SAFETY BELT
1. Make sure that the loop at the upper end of the

Escape rope is securely fastened in the dee-eye
at the crane house wall.
2. Don the safety belt and pull tight.
3. Drop the reel out of the cabin window to make

The rope uncoil and hang down.
Take care that the reel does not hit anybody in

Falling, or causes other damage.
4. Exit through the window on the escape ladder

On the cabin outside, and grip the rope firmly
Just below the brake buckle. Adjust the speed of
Descent by alternately holding the rope tight and
Letting go by degrees.
Braking of the lowering speed may also be controlled

By a person on deck alternately tightening and
Slackening the rope.
If more than one person is to descend by the rope,

Reverse it after each lowering operation.

O PERAT ION 11 / 28
Load & Radius Chart
<Fig 4.2 load & radius chart>

O PERAT ION 12 / 28
Control Operation
1. Description of Main Arrangement

DECK CRANE is composed of Main panel and Control switch panel
Main Panel Components
It is composed of over load circuit breaker, Magnet, Fuse, PLC and Amplifier, and for protection of Motor,
EOCR (Electric Over Circuit Relay) and TH (Thermal Relay) are installed.
It is also composed of PLC system that can compute several input signals and involve a function for each
alarm
2. Control Switch Panel

It is composed of each main switch, warning lamps and Load Cell.
3. Primary Causes of Alarm

Emergency switch operation, EOCR trip, TH trip, OIL temperature or level state and PLC problem and when
Crane slewing, Alarm and from Joystick switch Alarm.
: visual (Lamp), Audible (Buzzer, Warning lamp)

O PERAT ION 13 / 28
4. Switch instruction
(PIC-1)
5. Operation Summary
1) Turn ON Main Circuit Breaker (MCCB01) in Starter Panel, then AC440 power will be supplied.
2) Turn select switch ON (PIC-1-12): Control Source will be supplied.
3) Press PMS START illuminated push button (PIC-1-6): request AC440V supply from Ship
- When Ship permitted this, lamp will turned on. (PIC-1-6)
- As soon as it is turned on, the worker can start working.
4) Push HYD’ PUMP MOTOR START illuminated push button (PIC-1-5), Cavitation Motor is operated and
Main Hyd’ Pump Motor is started. After 5 sec, Lamp of HYD’ PUMP MOTOR START illuminated push
button (PIC-2-5) is turned on as operation of Delta.
5) Push HYD’ PUMP MOTOR STOP illuminated push button (PIC-1-11), Hyd’ pump is stopped and red lamp
is turned on.
6) FAULT RESET push button (PIC-1-4)

- Releases System error
- Buzzer and Indicator Light are operated when the thermal relay of each motors are operating, Filter Switch
is operating, and various Alarms or Warning Signals are operating.
At the time of alarm and warning signal is OFF, alarm is canceled if presses the Fault Reset PB.
If presses the Falult Reset PB, nevertheless buzzer and indicator light does not OFF, it is "ON" alarm and
warning signal.
7) Push BUZZER STOP push button (PIC-1-10)

- Stop alarm sound

O PERAT ION 14 / 28
- When alarm or warning Buzzer are ringing, if pressed Buzzer Stop PB, it will be a stop for one minute.
If occured alarm is continuously "ON" ,it will be a ringing one minute later.
8) BY PASS OFF/ON select key switch (PIC-2-3)

- Turn key switch ON: Decrease speed up to 50%
- When Crane operating, operator can operate over the limited section (already set) with this key switch ON.
- BY PASS lamp will be illuminated (PIC-2-13)
(Caution: Set Limit for protection crane will be released, be careful of Crane Damage)
9) OIL LOW, LOWLOW select switch

- When OIL LEVEL LOW lamp (PIC-2-7) is ON and alarm sounded, operator has to turn OIL LEVEL selector
switch (PIC-1-9) to LOW
- When Oil Low Alarm is occured, Buzzer rings and informs Oil Low Warning to Operator. This time, Operator
turns Selector Switch with Low Position from "Off", then Buzzer becomes Off.
(Can operate crane continuously. When finish working, have to check oil leakage and need to fill oil up)
- When OIL LEVEL LOW LOW lamp (PIC-2-12) is ON and alarm sounded, operator has to turn OIL LEVEL
selector switch (PIC-1-9) to LOW LOW
(Operator have to finish working, Hyd’ pump will be stopped in 5 minute.)
(Caution : Need close examination for Oil leakage, Turn the switch OFF after examination)
10) WARNING LIGHT USE / NOT-USE selector switch. (PIC-1-2)

- WARNING LIGHT USE / NOT-USE selection.
11) OIL HEATER MANU./ OFF/ AUTO selector switch (PIC-1-8)

- Select Manual : Keep increase temperature of Oil Tank regardless actual temperature
- Select Auto : Oil Heater is operate up to set up temperature on DX3 (Temperature controller)
- Select Off : Oil heater is off.
12) SPEED LOW/HIGH selector switch (PIC-1-1)

- Selector switch for speed selection
- If Select Switch becomes "ON", Hoisting & Lowering speed increase to 36[m/min] when the load is below
15Tons.
- If Select Switch becomes "ON" Hoisting & Lowering speed increase to 40[m/min] when no load.
- If selector switch becomes "ON" it operate normal speed to 24[m/min] when the load is above 15tons.
13) AIRCRAFT MANU/AUTO selector switch (PIC-1-2)

- Selector switch for Aircraft Light manu/auto selection
- Auto: Automatically ON/OFF by 24H timer in Main panel.
- Manu: Can ON/OFF regardless setting time.
(To reset time: Use circle plate of 24H timer)

O PERAT ION 15 / 28
6. Indicator Lamp instruction
(PIC-2)
1) CONTROL RUN LAMP (PIC-2-1)
- When the Main & Control source supplied normally, lamp is ON.
2) OIL LEVEL HIGH LAMP (PIC-2-2)
- When the oil level high alarm is operated, lamp is ON.
3) MAIN FILTER LAMP (PIC-2-3)
- When the Line Filter or the Return Filter are blocked, lamp is ON.
4) OIL TEMP HIGH LAMP (PIC-2-4)
- When the hydraulic oil temperature was rose at above of 70 degrees, lamp is ON.
5) LIMIT POSITION WARNING (PIC-2-5)
- When hit hoisting limit, lowering limit, luffing up and luffing down, lamp is ON.
6) DEADMAN LAMP (PIC-2-6)
- After HYD’ PUMP is ON, DEADMAN LAMP will be On with three alarm sound when press push button on
Joystick 1, 2 at the same time.
- Could use Joystick when this signal has occurred.
- For security reasons, one alarm sounded and DEADMAN lamp will be OFF when there is no movement
of Joystick over 3 minutes.
- Could use with press push button on Joystick 1, 2 at the same time again.
7) OIL LEVEL LOW LAMP (PIC-2-7)
- When the oil level low alarm is operated, lamp is ON.
8) PUMP FILTER LAMP (PIC-2-8)
- When even one of the Hoisting Filter(5S1), the Luffing Filter(6S1), the Slewing Filter(7S1) are operated,
lamp is ON.
9) MOTOR FAULT LAMP (PIC-2-9)

O PERAT ION 16 / 28
- When EOCR or Thermal Relay of each motors are operated and alarm was ringing, lamp is ON.
10) SLEWING PARKING POSITION (PIC-2-10)
- When do slewing operation and reached to parking position after press parking on button, lamp is ON.
11) DO NOT OPERATE (PIC-2-11)
- When hoisting pressure sensor operates, lamp is ON.
- When luffing pressure sensor operates, lamp is ON.
12) OIL LEVEL LOW LOW LAMP (PIC-2-12)
- When the oil level low low alarm is operated, lamp is ON.
13) GATE VALVE CLOSE (PIC-2-13)
- When gate valve was closed, lamp is ON.
14) EMERGENCY STOP LAMP (PIC-2-14)
- When Emergency Stop Push button is operating, lamp is continuously ON.
- when the Gate valve Closing Confirmation Sensor(1T1) operates and alarm ringing, the lamp does on/off
in 2 second intervals.
15) JIB PARKING POSITION (PIC-2-15)
- When JIB was arrived safe to jib rest, lamp is ON.
7. Square Push-Button Operating
(PIC-3)
1) PARKING ON illuminated push button (PIC-3-1)
- Push button for parking
- Use under 15 degree of Luffing angle and can find parking location when Slewing.
- Can re-adjust angle with Joystick upper push button.(By Slewing brake release function)
- At the time of parking mode, Slewing and Luffing reduce a half of speed and luffing down limit position (15
degree) is ignored.
2) INSIDE CABIN A/C, HEATER ON illuminated push button (PIC-3-4)

- Power ON/OFF wall outlet of Air-conditioner and heater.
3) MOTOR HEATER ON illuminated push button (PIC-3-2)

- Hyd’ Pump Motor Heater ON/OFF push button
- If each motors are ON, no matter what illuminated push button is ON, starter panel inside Space Heater
Magenic Contactor (M321) do not operate

O PERAT ION 17 / 28
4) WIPER ON illuminated push button (PIC-3-3)

- Wiper ON/OFF push button for Cabin front window
5) OUTSIDE CABIN LIGHT 1 ON illuminated push button (PIC-3-6)

- AC 220V 500W
6) JIB FLOOD LIGHT 1 ON illuminated push button (PIC-3-5)

- AC 220V 500W
7) JIB FLOOD LIGHT 2 ON illuminated push button (PIC-3-11)

- AC 220V 500W
8) OUTSIDE LIGHT 2 ON illuminated push button (PIC-3-12)

- AC 220V 500W
9) WIPER WATER PUMP ON illuminated push button (PIC-3-9)

- Wiper Water Pump ON/OFF push button for Cabin front window
10) LAMP TEST illuminated push button (PIC-3-8)

- Can check PIC-2 lamps and buzzer sound
11) VENTILATION FAN illuminated push button (PIC-3-10)

- Ventilation fan ON/OFF push button
- No matter what push button is OFF, when the hydraulic oil temperature is above of 40℃ and then
Ventilation Fan are operated with automatic.
12) illuminated push button (PIC-3-7)

- Spare

O PERAT ION 18 / 28
8. Joystick Operating
※ ATTENTION ※
At Slewing Operation
Do not adjust Joystick drastically
(PIC-4)
(This picture shows back side of chair)
1) Hoisting Joystick lever (PIC-4-4)
Hoisting – Pull Joystick 6 direction (PIC-4-6)
- Controls angle of displacement of hoisting pump, adjusts speed of Hoisting Winch when Hoisting operating.
- Start and Stop Ramp Time settled about 1.5second by Amplifier Unit (Amp3& 4) inside start panel, and did
operated start and stop softly.
Lowering – Push Joystick 5 direction (PIC-4-5)
Control lever will be located immediately neutral position when you release joystick.
- Controls angle of displacement of hoisting pump, adjusts speed of Hoisting Winch when Lowering operating.
- Start and Stop Ramp Time settled about 1.5second by Amplifier Unit(Amp3& 4) inside start panel, and did
Push button switch of Hoisting Joystick (PIC-4-3)
- Used for deadman function & external alarm.
2) Luffing & Slewing Joystick lever (PIC-4-1)

Luffing up – Pull Joystick 8 direction (PIC-4-8)
- Luffing Controls angle of displacement of Luffing pump, adjusts speed of Luffing Winch when Luffing up
operating.
operated start and stop softly

O PERAT ION 19 / 28
Luffing down – Push Joystick 7 direction (PIC-4-7)

- Controls angle of displacement of Luffing pump, adjusts speed of Luffing Winch when Luffing down
operating.
Slewing left (Anti-Clockwise) – Turn Joystick 9 direction (PIC-4-9)

- Controls angle of displacement of Slewing pump, adjusts speed of Slewing Winch when Slewing left
operating.
- Start and Stop Ramp Time settled about 3second by Amplifier Unit(Amp3& 4) inside start panel, and did
Slewing right (Clockwise) – Turn Joystick 10 direction (PIC-4-10)
Control lever will be located immediately neutral position when you release Joystick
- Controls angle of displacement of Slewing pump, adjusts speed of Slewing Winch when Slewing right
operating.
- Start and Stop Ramp Time settled about 3second by Amplifier Unit(Amp3& 4) inside start panel, and did
Push button switch of Luffing & Slewing Joystick (PIC-4-1)

- Used for deadman & Slewing brake ON/OFF
- Used for Slewing brake OFF/ON (first pressing is brake OFF & second pressing is brake ON)
- When brake ON, will be brake OFF automatically when you move lever any direction and will be brake ON
automatically when Joystick located neutral.
3) Grab
a) Joystick lever
- Grab close – Pull Joystick 13 direction (PIC-4-13)
- Grab open – Push Joystick 14 direction (PIC-4-14)
b) Selector switch (PIC-4-11)
- Turn selector switch is MANUAL : Joystick can be used.
- Turn selector switch is OFF : Grab can not operated.
- Turn selector switch is SEMI-AUTO - Foot switch can be used.
c) Lift At Signal (PIC-4-12)
- Closing operation 15 seconds later, lamp is ON.
Then, 8 seconds later Grab will stop.
d) Foot Switch.
- Grab OPEN / CLOSE control by foot.
e) Reversing Switch.
- For reeling off of cable and rope for the sake of preparing the grab operation, the motors can be switched
on by respective actuation of the reversing switches for a short time in reeling off direction.

O PERAT ION 20 / 28
9. Emergency Push-Button Switch & Siren Amp Operating
(PIC-5)
(PIC-6)
1) Emergency Push Button Switch (PIC-5-1)
- Used for just in case of Emergency situation.
- If press push button, Main hydraulic pump motor and Cavitation Motor are tripped immediately. And then,
an alarm ring by Warning light, crane is stop.
- Resetting: Turn the switch right side.
2) Voice Transmission equipment to outside (PIC-6-1)
- Adjust power & volume.
- Can change sound tone with small buttons.
3) Microphone of Voice Transmission equipment (PIC-6-2)

O PERAT ION 21 / 28
10. Load Indicator Operating
(PIC-7)
1) HOIST OVER LAMP.(RED COLOR) (PIC.7.1)

- When hoisting weight heavier than setting weight, lamp is ON.
2) HOIST SLACK LAMP (YELLOW COLOR) (PIC.7.2)
- When hoisting weight lighter than setting weitgh, lamp is ON.
3) LUFFING SLACK LAMP (YELLOW COLOR) (PIC.7.3)
- When luffing weight lighter than setting weight, lamp is ON.
4) HOISTING WEIGHT (PIC.7.4)
- Displaying actual WEIGHT that loaded at hoisting hook during the operating.
5) ANGLE (PIC.7.5)
- Displaying ANGLE of boom of present time.
6) RADIUS (PIC.7.6)
- Displaying RADIUS of boom of present time.
7) LIMIT (PIC.7.7)
- Displaying the value of the limit load which corresponds in trolley locations of present time.
8) AUTO ZERO & LOADCELL SETTING BUTTON. (PIC.7.8)
- Any loaded weight value to make Zero point.
9) LOADCELL SETTING BUTTON. (PIC.7.9)
- Setting of loadcell function.
CAUTION!
CONTROL BY AUTHORIZED PERSONNEL ONLY.

O PERAT ION 22 / 28
11. Remote Push Button Switch Box Operating
2 3
4 5
6 7
(PIC-8)
1) Oil Temperature (PIC-8-1)

- Display actual temperature of Oil
2) Control Source Lamp (PIC-8-2)
3) CONTROL RUN OFF/ON Selector Switch (PIC-8-3)
- Turn select switch ON, then Control Source will be supplied
4) PMS START illuminated push button switch.
- Request AC440V supply from Ship
- When Ship permitted this, lamp will turned on. (PIC-8-4)
- As soon as it is turned on, the worker can start working.
5) PUMP START push button.
- Cavitation Motor is operated and Main Hyd’ Pump Motor is started.
6) ALARM BUZZER (PIC-8-6)
- Alarm sounded through Buzzer
- When the hydraulic oil temperature is above of 70 degrees and Buzzer operates.
7) PUMP STOP button (Pic-8-7)
(CAUTION: Control Run Select switch always has to be ON)

O PERAT ION 23 / 28
12. Trouble Shooting
Motor Starting Abnormality

1) Abnormal operating of Main Motor & trip out
- Check Circuit Breaker (MCCB01)
a) When tripped out, pull lever OFF direction enough then push lever ON direction
- Check EOCR
b) Inverse phase trip out EOCR: Make OFF inverse phase dip switch
c) Over current trip out: Press reset button
2) Abnormal operating of Fan Cooler & trip out
a) When tripped out, pull lever OFF direction enough then push lever ON direction.
- Check Thermal relay (TH201)
a) Press red reset button which is upside of TH
3) Abnormal operating of Cavitation Motor & trip out
b) Press red reset button which is upside of TH
4) Abnormal operating of Heater & trip out
5) Abnormal operating of Gear Pump & trip out
a) When tripped out, pull lever OFF direction enough then push lever ON direction.2
Control Source Abnormality

1) Check Circuit Breaker (MCCB02,03)

O PERAT ION 24 / 28
Etc. Abnormality
Unit Tag. No. Check list 1 Check list 2 Check list 3

Cabin Inside Wall outlet F230(2A) Fuse Check Wall Outlet
F232(6A) Fuse
Jib Light
F233(6A) Fuse
F234(2A) Fuse
Control Supply DC24V MCCB240
F235(2A) Fuse
Outside Speaker F236(2A) Fuse Speaker resistance
Window Wiper
F237(6A) Fuse Switch Motor Voltage (DC24V)
Window Wiper Water
Hyd’ Pump Heater F240(2A) Fuse
Spare F241(2A) Fuse
Cavitation Motor F242(2A) Fuse
Jib Light 1 F243(4A) Fuse Switch Lamp
Jib Light 2 F244(4A) Fuse Switch Lamp
Air Craft Light F261(2A) Fuse Switch Lamp
Cabin Outside Light 1 F262(4A) Fuse Switch Lamp
Cabin Outside Light 2 F263(4A) Fuse Switch Lamp
Cabin Inside Light 1 F264(2A) Fuse Switch Lamp
Cabin Inside Light 2 F265(2A) Fuse Switch Lamp
King Inside Light F266(2A) Fuse Switch Lamp
Pedestal Light F267(2A) Fuse Switch Lamp

O PERAT ION 25 / 28
Emergency Operating
1. Introduction
In the case of a partially power failure in the supply to the main electric motor, or if the main electric motor
cannot be run for some reason, the hoisting, luffing and slewing circuits of a deck crane may still be operated
to limited extent by releasing their respective brakes, while observing the greatest care.
The releasing of the brakes can be done by means of hydraulic pressure supply from the normal feed and
control system.
CAUTION
- This work has to be done by skilled persons with great caution.
- Only one function to be activated at the moment.
- Verify that no persons are in the working area of the crane.
2. Hoist winch emergency lowering with hand pump

1) Hand pump of SUCTION(1E2) is connected in TANK(1E1).
2) Hand pump of PILOT “A”(1E3) is connected in BRAKE(5E1).
3) Hand pump of PILOT “B”(1E4) is connected in “B” Port(5E3).
4) Hand pump of PILOT “C”(1E5) is connected in “A” Port(5E2).
5) Hand pump of Manual Hand is closed.
6) Hand pump is activated.
7) Pump to release the winch brake and fill the system with oil.
8) Lowering speed control by THROTTLE VALVE(1TH1).
9) Open hand pump valve to stop lowering.
10) Reset all valves when completed.
3. Luffing winch emergency luffing down with hand pump

4) Hand pump of PILOT “C”(1E5) is connected in “A” Port(6E2).
8) Boom down speed control by THROTTLE VALVE(1TH1).
9) Open hand pump valve to stop luffing.

O PERAT ION 26 / 28
4. Slew winch emergency slewing with hand pump

4) Hand pump of PIOT “C”(1E5) is connected in “A” Port(7E2).
8) Slewing speed control by THROTTLE VALVE(1TH1).
9) Open hand pump valve to stop lowering.
*note : In case of emergency operation for slewing, the motion is only possible from upside to downside under
inclination base. Once brake is opened by hand pump, the crane will be slowly and gravitationally
moved to downside by own load.

O PERAT ION 27 / 28

O PERAT ION 28 / 28

DECK CRANE
MAINTENANCE
1. SAFE MAINTENANCE PRACTICES
2. MAINTENANCE CHART
3. INSPECTION OF STRESSED COMPONENTS
AND STRUCTURES
4. RECOMMENDED LUBRICATION OIL &
HYDRAULIC SYSTEM OIL
5. LUBRICATION AND MAINTENANCE

M AINT ENANC E 1 / 14
Safe Maintenance Practices
ATTENTION
Training/ qualification of maintenance personnel is responsibility of the crane owner.
- Perform the following steps before starting a maintenance procedure:

a) Park the boom where it will not interfere with other equipment or operations.
b) Lower all loads to the ground.
c) Move all controls to off and secure all functions against movement by applying or engaging all
brakes.
d) Stop the electric motor and render the starting means inoperative.
e) Place warning signs alerting other personnel that the crane is being serviced.
ATTENTION
Do not remove sign until it is safe to return crane to service.
- Do not attempt to maintain or repair any part of the crane while the electric motor is running, unless
absolutely necessary.
If the electric motor must be run, keep your clothing and all parts of your body away from moving parts.
Maintain constant communication between person at controls and person performing maintenance or repair
procedure.
- Wear clothing that is relatively tight and belted.
ATTENTION
Do not wear loose fitting clothing
1. Wear appropriates eye protection and an approved hard hat.

2. When climbing onto the crane, use both hands and the handrails, steps and ladders.
3. Lift tools and other equipment, which cannot be carried in pockets or tools belts onto and off the crane with
hand lines or hoist.
4. Lower the boom onto the boom rest before doing work on the boom.
5. Pressurized air and hydraulic oil can cause serious injury. Make sure all air and hydraulic lines, fittings and
components are tight and serviceable.
6. Relieve pressure before disconnecting air and hydraulic lines and fittings.
7. Hydraulic oil can be also flammable. Do not smoke or allow open flames in the area when filling hydraulic
tanks.
8. Never handle wire rope with bare hands. Wear leather rigging gloves.

9. Only use cleaning solvents, which are non-volatile and non-flammable.

10. Do not lift heavy components by hand. Use a hoist jack, or blocking to lift components.
11. Use care while welding or burning on crane. Cover all hoses and components with non-flammable
shields or blankets to prevent a fire or other damage.
12. Disconnect and lock the power supply switch before attempting to service high voltage electrical
components and before entering tight areas containing high voltage components.
13. When assembling and disassembling booms, jibs or masts on ground, securely block each section to
provide adequate support and alignment. Do not go under boom or mast sections while connecting bolts or
mast sections while connecting bolts or pins are being removed.
14. Unless authorized in writing by DMC do not alter the crane in any way that might affect the
performance(to include welding, cutting, or burning of structural members or changing pressures and flow of
air/hydraulic components) Doing so will invalidate all warranties and load charts and make the crane owner
liable for any resultant accidents.
15. Keep crane clean. Accumulations of dirt grease, oil rags, paper and other waste will not only interfere
with safe operation and maintenance but also create a fire hazard.
16. Store tools, oils cans, spare parts and other necessary equipment in toolboxes. Do not allow these items
to lie around loose in the cabin or on walkways.
17. Do not return the crane to service at the completion of maintenance or repair until all guards and covers
have been reinstalled, trapped air has been bled from the hydraulic systems, safety devices have been
reactivated, and maintenance equipment has been removed.
18. Perform a function check to ensure proper operation at the completion of maintenance or repair.

Maintenance Chart
1. Daily Maintenance / Checks
Operators Name
(Where Applicable) Mark “S” or Mark “U.S”
Item & Cert No
Criteria : Satisfactory/Unsatisfactory
& Signature
Mon Tue Wed Thu Fri Sat Sun
Time
Overall inspection
Check engine oil level
Check radiator water level
Check diesel fuel level
Check pump drive oil level
Check hydraulic oil level
Check air start-oil level
(if applicable)
Check air tank-drain water
Check engine air cleaner
Check hoist rope lay
Check the annunciator to
ensure the visual and audible
alarms are working
Check the hoist up limit
Check the hoist down limit
Check the engine/crane
battery (if applicable)
Check powerpack
Holding down bolts
Check the emergency stop
function
Check the slew limits
(if applicable)
Remarks

2. Weekly Maintenance
Maintenance Log Weekly or Every 40 Working Hours

Date
Time
Overall inspection including visual checking for oil
leakage around the powerpack and the winch
Check the hoist rope for defects and/or failure
Check the fly rope for defects and/or Failure
Inspect & grease slew ring bearing
Inspect & grease the hoist drum gear
Inspect & grease the slew ring gear
Grease the boom heel bushes(bearings)
Remarks

3. Monthly Maintenance
Maintenance Log Monthly or Every 100 Working Hours

Date
Time
Check the engine oil level
Check the radiator water level
Check the pump drive oil level
Check the hoist brake
Inspect & grease the sheave bearings of mast,
bride, boom and hook sheaves assemblies
Inspect & grease hoist drum bearing
Inspect & grease hoist drum drive bearings
Inspect & grease slew drive bearings
Inspect the hydraulic oil tank
Check slew ring bolt tension
Remarks

4. Quarterly Maintenance
Maintenance Log Every Three Months or 250 Working Hours

Date
Time
Inspect & grease hoist drum bearings
Inspect & grease hoist drum drive bearings
Inspect & grease slew drive bearings
Lubrication of limit switch drives
Inspect the hydraulic oil tank
Check slew ring bolt tension
Remarks
Maintenance Log Every 1000 Working Hours

Date
Time
Inspect the slew drive pinions
Inspect the hoist drive pinions
Remarks

Inspection of Stressed Components and Structures
1. Introduction
Stressed parts of the crane structure are subjected to high loads require inspection for signs of cracks and
other damage at regular intervals.
Cracks detected at an early stage do not generally impair the handling safety to the crane unless they are
not repaired.
For safety reasons, service routines should include a regular inspection of the entire crane, with particular
attention paid to stressed parts.
2. Inspection
A thorough visual inspection is fairly easy to carry out as cracks will generally show by cracking or flaking of
the paint followed by a brownish discoloration by rust. (Inspect welds and surrounding material.)
This inspection should be performed at intervals according to the Maintenance Chart.
NOTE
Rust on a painted surface does not necessarily mean that there is a crack in the underlying material.
3. Remedy
When rust is found on top of or near a weld, grind the topmost surface layer away to expose the crack clearly.
When in doubt, use a liquid penetrant to identify the crack.
Before repairing of a crack in all stressed part, always contact DMC Service Department for advice.

Recommended lubricating oil & hydraulic System oil
1. Lubricating points

2. Lubricating chart
Viscosity Reference temp Pour

Maker Brands (CST) (CST) V.L Point
40℃ 100℃ 5000 3000 25 20 (℃)
SHOWA TELLUS OIL ST68 68.7 10.3 -20 -15 66 74 135 -37.5
SHELL TELLUS OIL T68 70.1 11.2 -22 -17 68 76 152 -37.5
EXXON
MOBIL DTE16M 68 10.02 -22 -18 68 76 131 -45
MOBIL
BP BARTRAN HV68 70 10.8 -21 -16 68 75 142 -39
CALTEX RANDO OIL HDZ68 66 10.7 -23 -18 67 74 151 -33
CASTROL HYSPIN AWH-M68 68 10.9 -23 -18 67 75 150 -39
FAMM
TEXACO & RANDO HDZ68 68 10.8 -22 -17 67 75 149 -39
CHEVRON
TOTAL VISGA 68 73 11.7 -22 -17 70 78 155 -36
< Table 5.1 Recommended hydraulic system oil>
Lubricating Enclosed gear and Open gear

Bearing or links
Point bearing (or wire rope)
Method of
Oil bath Brush Grease gun or hand
Lubrication
SHOWA MALLEUS GL 95 ALVANIA EP
OMALA OIL 220
SHELL (MALLEUS FLUID RL) GREASE 22
MOBIL GEAR 630
EXXON MOBILUX EP2
MOBIL SHC 630 MOBILTAC 375NC
MOBIL BEACON EP2
SPARTAN EP220
ENERGOL
BP ENERGREASE MP-MG2 ENERGREASE MP-MG2
GR-XP220
MEROPA LUBRICANT
CALTEX CRATER 2X MULTIFAK EP2
220
CASTROL ALPHA SP220 SPHEEROL SX2 SPHEEROL SX2
FAMM (TEXACO &
MEROPA 220 CRATER 2X MULTIFAK EP2
CHEVRON)
TOTAL EPONAZ 220 CERAN AD EPEXA 2
< Table 5.2 Recommended lubricating oil>

Lubrication and Maintenance
1. Daily or before taking crane into operation

Hydraulic oil tank
- Check oil level.
Slewing gear case
- Check oil level. (See instruction Service Part section “Hydraulic Motor”)
- The oil quantity is marked on the name plate and in instruction “Technical Data”
Winches, hoisting and luffing
- Check oil level. (See instruction Service section Hydraulic Motor)
- The oil quantity is marked on the name plate and in instruction “Technical Data”
Filter service indicator
- Check filter service indicator
- If necessary change filter cartridges, “see Maintenance Filters”
Slack wire switch

- Function test
Loose gear
- Check that block, beam, hook, swivel and shackle are intact.
2. After 50 operating hours (running-in period)

Oil tank, power swivel (optional)
- The first oil change.
3. Every month
Escape device
- Visual inspections should be carried out with particular attention being paid to the condition of the rope.
4. Every 200 operating hours or every two months

Pumps
- check leakage.
Multiple-disc brake, slewing gear set/winches

- The drain plug shall be taken out every 200 hours of operation, to drain off oil that may have been collected.
Slewing bearing screws

- Inspect visually the slewing bearing screws from deck and inside pedestal. If any screw shows any
tendency to slacken, tightly all screws with a torque wrench or a hydraulic tensioner according to drawing
“Slewing bearing, yard mounting” and “Slewing bearing, mounting.
5. After 200 operating hours

Slewing gear case
- The first oil change. (Running-in period 200 hours.)
Winches, hoisting and luffing

- The first oil change. (Running-in period 200 hours.).

6. Every 500 operating hours or every six months

Oil cooler
- Inspect oil cooler externally. Clean when required.
Heating elements, cubicle MB

- Check that the element in cubicle MB is working i.e. gets warm.
Hydraulic system
- Measure the pressures according to the hydraulic circuit diagram’s adjoining list
- Reset as required.
Oil analysis (Oil tank) - Sample oil and analyze every six months.
Pump servo
- Check plussing
- If necessary adjust.
Filter service indicator - Change filter cartridge. (see Maintenance Filters)
7. Every 1000 operating hours or at least every year

Slewing gear case - Change oil.
Winches - Change oil.
Air breather, hydraulic oil tank - Check and change air breather in top of the tank.
Hydraulic accumulators
- Check pressure, re-charge as required. See instruction “Hydraulic Accumulators”
-
8. Every 2000 operating hours or every two years

Hydraulic oil tank
- Take out the drain plug
- Drain oil clean the reservoir.
- Verify that the oil level float switch is working properly.
This inspection is verified when changing oil or cleaning of oil tank
- Check air breather cap
- Top up with fresh oil according to “Lubricants for deck machinery”
- Change all oil filter cartridges.
Oil tank, cable winch (optional)

- Drain oil, turbo coupling
- Drain oil, spur gear
Oil tank, power swivel (optional)

- Drain oil and clean the reservoir.

9. Filters
Introduction
For cleaning hydraulic oil, the hydraulic system is equipped with four filters.
Two kinds filters are marked 3S1(Offline) , 5S1 , 6S1 ,7S1(Pump Inline Filter) [Fig.5.1] , [Fig.5.2]
Filter Indicators
The filter indicators function only when the crane is started.
Replacing Filter Cartridge

The cartridges in the crane should be replaced at the same time. Flush all other parts of the filters with white
spirit when changing cartridges. Use new seals. Reassemble the filters.
Indicator
HP-5S1
LP-6S1
3S1(Offline)
SP-7S1
Fig.5.1. Filter Fig.5.2.Filter
Indicator
Cartridge
(Element)
Fig.5.4 Cartridge Filter Element
Fig.5.3 Filter inside

10. Hydraulic Oil Tank

The main pump unit is cooling or system oil Supply continually lubricated by oil from the hydraulic system, surplus oil
being returned to the tank by a drain line.
Checking oil level

The oil tank has a dipstick to indicate the oil level. Check that oil level is between min. and max on the dipstick.
Oil level float switch

If the oil level drops below a certain minimum level an oil level float switch installed in the oil tank, operates alarm signals
on the control panel in the operator’s cab.
Verify that the switch is working properly by starting the crane, loosen the nut that holds the switch and lifting it up slowly.
Filling oil
Oil is filled at an “aero-quip” type quick-release coupling, placed on the filter unit, see Fig 5.2. When filling oil the
hydraulic system must be at rest and the electric power switched off.
Fill oil to just under the MAX mark on the dipstick. Use oil according to the “Lubricating chart”.
NOTE! Oil must not be filled directly into the tank.
Cleaning the oil tank

Before cleaning the oil tank, immobilize the crane jib in a suitable manner, push the stop button and switch off the power.
Drain off the oil into clean empty barrels or drums.
Remove the tank cover. Scrape off sediment, if any, from the tank bottom and sides using a rubber scraper.
Flush the tank with white spirit.
Wipe the tank dry with clean rags. DO NOT USE COTTON WASTE, or other linting material. Apply new sealing
compound and reinstall the tank cover.
If the drained oil is in good condition and can be used anew, it should be filtered before refilling.
Pump and hoses used for filling must be perfectly clean.
Fill oil to just under the MAX mark on the dipstick. Use oil according to the “Lubricating chart”.
① Oil Tank
② Power Pack
③ Level Sensor
④ Temp. Sensor
⑤ Heater
⑥ Air Breather
⑦ Level Gauge
⑧ Butterfly Valve
⑨ Drain Valve

Table 5.3. Cleanliness Level Correlation Table.
Cleanliness Level Correlation Table
Particles/milliliter
≥15 ACFTD NAS Disavowed
ISO ≥5 Micro-
Micro- Gravimetric 1638 "SAE" Level
Code meters
meters Level, mg/L (1964) (1963)
26/23 640.000 80.000 1000
25/23 320.000 80.000
23/20 80.000 10.000 100
Not 21/18 20.000 2.500 12

20/18 10.000 2.500
OK 20/17 10.000 1.300 11

20/16 10.000 640 10
19/16 5.000 640 10
18/15 2.500 320 9 6
17/14 1.300 160 8 5
16/13 640 80 1 7 4
15/12 320 40 6 3
14/12 160 40
OK 14/11 160 20 5 2
13/10 80 10 0.1 4 1
12/9 40 5 3 0
11/8 20 2.5 2
10/8 10 2.5
10/7 10 1.3 1
10/6 10 .64 0.01

DECK CRANE
SERVICE
1. HOW TO ORDER SPARE PARTS
2. SERVICE NETWORK
3. MEASURES BEFORE STARTING
SERVICE/MAINTENANCE WORK
4. TROUBLE SHOOTING
5. TIGHTENNING TORQUES OF BOLTS
6. WINCHES(HOIST, LUFFING, SLEWING)
7. PUMP DRIVE
8. SLEWING BEARING
9. INSTALLATION AND MAINTENANCE – WIRE ROPE
10. INSTALLATION AND MAINTENANCE – SHEAVES
11. REPLACEMENT – HOOK BLOCK
12. ELECTRICAL EQUIPMENT
13. HYDRAULIC EQUIPMENT

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How to Order Spare Parts
Important details when inquiring or ordering spare parts
To speed up the process we request you to provide us with below information:
- State name of company as well as your name

- Vessel’s name and IMO number
- Crane type (see manual or name plate in operator’s cabin)
- Crane place on the vessel. No. 1 counted from the fore
- Crane serial number (see manual or name plate in operator’s cabin)
- Spare part figure or drawing number.
- Part description
- Item number from spare part figure or drawing respectively
- Quantity of order
- Deadline – when and where do you need the parts?
- Delivery details such as: consignee as well as phone and fax numbers
- Mode of transport: aviation, truck, ship, etc.
The more you can provide us with above details the faster and more reliable replies and
deliveries will be made.
Address:
Dongnam Marine Crane
#1196, Myeongdong-ri, Hallim-myeon, Gimhae-si, Gyeongnam, Korea
Telphone : +82-55-720-3031~3040
Telefax : +82-55-720-3039

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Service Network

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Measures before Starting Service / Maintenance Work
WARNING
When it is necessary to search for/or correct faults in the crane’s electrical, hydraulic or mechanical systems
with the crane powered up, only authorized personnel may carry out such work.
The following measures must be taken before any service or maintenance work is started.
1. The jib must be secured preferably in the parking support.
2. All lifting equipment must be parked/secured.
3. All power supplies to the crane must be cut.

a. Cut the main power supply to the crane and all separate supplies such as heating, lighting etc., with the
power switch(es) in the ship’s engine room.
b. Warning signs must be hung on the switches involved.
4. Make sure that the crane is completely without power. If necessary, lock switches, take out fuses etc. so
nobody by mistake can start the crane.
5. When special work has to be done see separate instruction or contact our service department.
6. If some special arrangements are done for testing during the service, these arrangements have to be
removed after completed service.
7. Function test safety items i.e. limits, brakes etc. after completed work.
8. Protections i.e. covers, rails etc. to be reinstalled after completed work.

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Trouble Shooting
1. General Trouble Shooting
The following table will be very useful for finding and solving causes of break-downs and common problems
that occur during crane operation. Needles to say this table is not exhaustive, as it is impossible to set down
all the cause and their associated solutions.
PROBLEM PROBABLE CAUSE REMEDY

A 1. Fault pressure gauge. 1. Replace
No boost pressure(or 2. Damaged/blocked boost pump suction 2. Stop immediately-call DMC.
very low) (with motor hose(s). 3. Stop immediately-call DMC.(replace)
running)-motor should 3. Damage drive coupling/between motor 4. Check reason. Boost pressure relief valve
cut out[motion] and gearbox. should match circuit. Consult DMC.
4. Boost pressure setting too low. 5. Adjust or replace as necessary.
5. (Faulty) anti-cavitation switch or setting
incorrect.
B 1. Lines between cabin & winch frame 1. Check lines. If in doubt, consult DMC.
No motions(with motor connected incorrectly. 2. Stop immediately-call DMC.
running) 2. No boost pressure(or very low boost 3. Reset or replace as necessary-Consult
pressure). DMC.
3. Limits are tripped or malfunctioning. 4. Replace levers.
4. Cabin control levers not functioning 5. Adjust or replace as necessary.
correctly. 6. Check wiring.
5. (Faulty) anti-cavitation switch or setting 7. Check solenoid and spool movement.
incorrect. Repair/replace as necessary.
6. Faulty relay.
7. Faulty/jammed main oil solenoid.
C 1. Hoist winch is overload. 1. Reduce load to comply with load chart.
No hoist up 2. S.L.I. not calibrated correctly-showing 2. Re-calibration necessary. Temporary
(other motions OK) overload. bypass may be done only by qualified
3. Brake not releasing. personnel.
4. Pump relief valves set incorrectly. 3. Check brake valve & check cabin control
5. Pump controller not functioning correctly. lever functioning.
6. Emergency lowering bypass valve open 4. Qualified personnel can adjust.
or leaking. Check reason.
7. Winch drives damaged. 5. Replace controller. Qualified personnel to
8. Hoist up limit is tripped. inspect/repair.
9. Leakage or block in hoist up control line 6. Close or replace.
from lever. 7. Consult DMC.
8. Qualified personnel can bypass or reset
as necessary if at top hoist down.
9. Fix leak or replace hose as necessary.
D 1. Hoist down limit tripped(if fitted). 1. Qualified personnel can bypass or reset
No hoist down 2. Brake not releasing. as necessary.
(other motions OK) 3. Pump controller not functioning correctly. 2. Check brake valve & check cabin control
4. Leakage or block in hoist down control lever functioning.
line from lever. 3. Replace controller.
Qualified personnel to inspect/repair.
4. Fix leak or replace hose as necessary.
E 1. Brake releasing too early. 1. Qualified personnel to adjust.
Loaded hook drops 2. Pump not correctly in neutral. 2. Qualified personnel to adjust.
slightly before lifting. 3. Excessive leakage in pump or motor. 3. Consult DMC.

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F 1. Brake releasing too late. 1. Qualified personnel to adjust.

Empty hook 2. Pump not correctly in neutral. 2. Qualified personnel to adjust.
(or light load)
Initially jumps up when
hoisting.
J 1. Slew brake is on. 1. Move slew brake lever to ‘off’ position.
Crane will not slew 2. Slew limit is tripped(if fitted) 2. Slew in opposite direction.
(other motions OK) 3. Brake not releasing. Qualified personnel can bypass or reset
4. Pump control lever not functioning as necessary.
correctly. 3. Check brake valve in cabin.
5. Cabin control lever not functioning 4. Replace controller. Qualified personnel to
correctly. inspect/repair.
6. Slew drive damaged. 5. Replace lever. Qualified personnel to
7. Pump relief valves set incorrectly. inspect/repair.
6. Consult DMC.
7. Qualified personnel can adjust-check
reason.

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2. Planetary Drives
PROBLEM CAUSE SOLUTION

With motor running the shaft Incorrect motor assembly Check coupling between gear unit and
output doesn’t run motor
Internal malfunction Contact DMC or service Center
Brake blocked Check hydraulic circuit

Oil leak from breather during Level too high Lower oil level
operation
Incorrect breather poison Check breather position
Possible wear of multi-disk seals or Contact DMC or Service Center
hydraulic motor
Oil leak from seal Clogging breather plug Unscrew and thoroughly clean the
plug/breather
Stiffening of seals due to prolonged Clean the area and check for leakage
storage again after a few days
Damaged or worn seals Contact DMC or service Center
Excessive noise Internal malfunctions Contact DMC or service Center
Disk brake does not release Residual pressure in hydraulic circuit Check hydraulic circuit
Excessive vibrations Gear unit incorrectly installed Check the connection and inline
configuration
Coupling structure weak Strengthen the structure
Excessive heating No ventilation Removing fairing
High thermal pressure Insert oil circulation
Multi-disk brake does not release No pressure to the brake Check connections to hydraulic circuit
No pressure in the circuit Check hydraulic circuit
Multi-disk brake does not brake Pressure delivered to brake Check hydraulic circuit
Worn disks Contact DMC or service Center

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3. Ropes
PROBLEM CAUSE / ACTION

Mechanical damaged caused by the rope contacting the z generally results from operational conditions.
structure of the crane on which it is operating or an z Check sheave guards and supports/guides sheave to
external structure-usually of a localized nature. ensure that the rope has not jumped out of the
intended reeving system.
z Review operating conditions.
Opening of strands in rotation resistant, low rotation and z Check sheave and drum groove radii using sheave
parallel closed ropes-in extreme circumstances the rope gauge to ensure that they are no smaller than
may develop a birdcage distortion or protrusion of inner nominal rope radius +5%
strands z Repair or replace drum/sheave
z Check feet angles in the reeving system
z Check installation method-turn induced during
installation causes excessive rope rotation resulting
in distortion.
z Check if the rope has been cut on site prior to
installation or cut to remove a damaged section. If
so, was the correct cutting method used. Incorrect
cutting of rotation resistant, low rotation and parallel
closed ropes can cause distortion in operation.
z Rope may have experienced a shock load
Broken wires or crushed or flattened rope on lower z Check tension on underlying layers.
layers at crossover points in multi-layer coiling z Review wire rope construction
situations. z Do not used more than necessary.
z Check drum diameter. Insufficient bending ratio
Wire breaks usually resulting from crushing or abrasion. increase tread pressure.
Wire looping from strands z Insufficient service dressing.
z Consider alternative rope construction.
z If wire are looping out of the rope underneath a
crossover point, there may be insufficient tension on
the lower wraps on the drum
z Check areas for rope crushing or distortion
Wire looping from strands z Insufficient service dressing.
z Consider alternative rope construction.
z If wire are looping out of the rope underneath a
crossover point, there may be insufficient tension on
the lower wraps on the drum
z Check areas for rope crushing or distortion
Pigtail or severe spiraling in rope z Check that the sheave and drum diameter is large
enough
z Indicates that the rope has run over a small radius or
sharp edge
z Check to see if the rope has jumped off a sheave
and has over a shaft
Two single axial lines of broken wires running along z Check sheave and drum groove radii using sheave
the length of the rope approximately 120 degrees apart gauge to ensure that they are no smaller than
indicating that the rope is being nipped in a tight nominal rope radius +5%
sheave. z Repair or replace drum/sheave if necessary
One line of broken wires running along the length of the z Check to see if the groove diameter is no greater
rope indicating insufficient support for the rope, than 15% the nominal rope diameter.
generally caused by oversize sheave or drum grooving. z Repair or replace drum/sheave is necessary
z Check for contact damage

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Short rope life resulting from evenly/randomly z Bending fatigue is accelerated as the load increases
distributed bend fatigue wire breaks caused by bending and as the bending radius decrease. Consider
through the reeving system. improving factor.
Fatigue induced wire breaks are characterized by flats z Check wire rope construction.
ends on the broken wires.
Short rope life resulting from localized bend fatigue wire z Bending fatigue is accelerated as the load increases
breaks. Fatigue induced wire breaks are characterized and as the bending radius decrease. Consider
by flats ends on the broken wires. improving factor.
z Check wire rope construction.
z Localized fatigue breaks indicate continuous
repetitive bends over a short length. Consider
whether it is economic to periodically shorten the
rope in order to move the rope to the system and
progressively expose fresh rope to severe bending
zone.
Broken rope-ropes are likely to break when subjected to z Review operating condition.
substantial overload or misuse particularly when a rope
has already been subjected to mechanical damaged.
Corrosion of rope both internally or externally can also
result in a significant loss in metallic area.
The rope strength is reduced to a level where it is
unable to sustain the normal working load.
Wave or corkscrew deformations normally associated z Check sheave and drum radii using sheave gauge to
with multi-strands ropes. ensure that they are no smaller than nominal rope
radius +5%
z Repair drum or sheaves
z Check fleet angles in the reeving system
z Check the rope has been secured in accordance with
manufactures instructions
z Check operating conditions for induced turn
Rotation of the load in a single fall system z Review rope selection
z Consider use of rotation resistant or low rotation rope
Rotation of the load in a multi-fall system resulting in z Review rope selection
cabling of the rope. z Consider use of rotation resistant or low rotation rope
Possibly due o induced turn installation or operation z Review installation procedure or operating
procedures.
Core protrusion or broken cores in a single layer six or z Caused by repetitive shock loading-review operating
eight strand rope. conditions
Rope accumulating or stacking at drum flange-due to z Review drum design with original equipment
insufficient fleet angle. manufacturer-consider adding rope kicker, fleeting
sheave
Sunken wraps of rope on the drum normally associated z Check correct rope diameter
with insufficient support from lower layers of rope or z If grooved drum check groove pitch
grooving z Check tension on underlying layers
z Make sure that the correct rope length is being used.
Too much rope may aggravate the problem
Shot rope life induced by excessive wear and abrasion z Check fleet angle to drum
z Check general alignment of sheaves in the reeving
system
z Check that all sheaves are a free to rotate
z Review rope selection
External corrosion z Consider selection of galvanized rope
z Review level and type of service dressing
Internal corrosion z Consider selection of galvanized rope
z Review frequency amount and type of service
dressing
z Consider selection plastic impregnated wire rope

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Tightening Torques of Bolt
A thorough examination of the crane should be carried out after the initial 100 hours
of operation.
Bolts, screws and hydraulic fittings should be checked and re-tighted if necessary.
For recommended bolt tightening torque, refer as following Torque Chart Table.

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Winches

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1. Hoist winch

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2. Luffing winch

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3. Slewing winch

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Pump Drive

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Slewing Bearing

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Installation and Maintenance – Wire Rope
1. Handling of Ropes
When unreeling or uncoiling rope, attention should be given to avoid the introduction of kinks or twists into
the rope. This type of damage is permanent and places weak spots in the rope.
Mount the reel on a vertical or horizontal axle and rotate the reel as the rope is pulled off.
When pulling rope out of a coil, roll the coil on the ground to uncoil the rope. Treat it the same as if you were
uncoiling it from a spool.
2. Fitting a New Rope
When anchoring a new rope on the drum, make sure that the entire cross section of the rope is held solid,
otherwise the inner strands may draw from the attachment and leaving only the outer strands anchored. In
such a case core protrusion will result.
Always wind the new rope on from a reel, wind from the top of the reel to the top of the drum or from the reel
to the bottom of the drum. Failing to do this will put a reverse bend in the rope and shorten its life check with
reeving diagram to ensure correct winding.
The first layer on the drum must be wound on tight and true. Open or wavy winding will cause serious
damage to multiple layers.
Adjacent turns should be tapped against each other with a wooden mallet, when drum is not grooved.
The whole rope should be wound on the drum tightly and correctly. A poor start will mean poor winding and
short life.
Never allow ropes to become slack. This causes incorrect coiling on the drum and allows rope to jump off the
drum of sheaves. If rope has become slack, check coiling on drum before continuing.
WARNING
Limits must be reset when new ropes are fitted. See manual section on Limits.

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3. Wire Rope Reeving Diagram

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4. Correct Reeving
Reeving of hoist ropes must always conform to Reeving Diagram. After installing, run the rope through its
operating cycle several times with a light load and at reduced speed. This allows the new rope to adjust itself
gradually to working conditions, the strands to become seated, some stretch to occur and the diameter to
reduce slightly as the stand and core are compacted. The rope is then less liable to damage when full load is
applied.
WARNING
Always observe the first spooling onto the drum of a new rope.
Correct Method for Reeving Ropes

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5. Rope Inspection
All running ropes in continuous service should be visually inspected once every working day. A thorough
inspection of all ropes in use should be made at least once a month. Any deterioration, resulting in
appreciable loss of original strength, should be carefully noted and determination made as to whether further
use of the rope would constitute a safety hazard.
No precise rules can be given to determine the exact time for replacements of ropes, since many variable
factors are involved. Safety in this respect depends largely upon the use of good judgment by and appointed
or authorized person. Conditions such as the following should be sufficient reason for questioning rope
safety and for consideration of replacement.
1. In running ropes, six randomly distributed broken wires in one rope lay or three broken wires in one strand
in one rope lay.
2. Wear of one-third the original diameter of outside individual wires.
3. Kinking, crushing, bird-caging, or any other damage resulting in distortion of the rope structure.
4. Evidence of any heat damage from any cause.
5. Any marked reduction in rope diameter.
Wire rope diameter
Reductions from rope diameter in a non-working area(an area away from the sheaves) compared to the
lowest diameter of rope measured in three(3) working areas(areas where the rope regularly goes over a
sheave) of more than the following is observed :
- 1.19mm(3/64 inch) for diameters up to and including 19.05mm(3/4 inch)
- 1.59mm(1.16 inch) for diameters of 22.22mm(7/8inch) through 28.58mm(1 1/8inch)
- 2.36mm(3/32inch) for diameters of 31.75mm(1 1/4inch) through 38.1 mm(1 1/2inch)
See below for proper method of measuring rope diameters
Right Wrong
Proper method of measuring rope diameters

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Broken wires
For non rotation-resistant ropes used in the main hoist fly hoist and/or the luff.
In running ropes, six(6) randomly distributed broken wires within one(1) lay length or three(3) broken wires in
one strand within one(1) lay length.
For rotation-resistant ropes used in the main hoist

In running ropes, four(4) randomly distributed broken wires within one(1) lay length or two(2) broken wires in
one strand within one(1) lay length.
For standing ropes such as boom pendants

In running ropes, three(3) broken wires within one(1) lay length or two(2) broken wires at the end of
connection.
Wire rope wear
Wear of more than one-third of the original diameter of the outside wires of the strand are worn.
Wire rope deterioration
Kinking, crushing, bird-caging, or any other damage resulting in the distortion of the rope construction.
Heat damage to wire rope
There is evidence of any heat damage from any source. Heat can be generated by passing a rope over a
frozen or non-turning sheave, contact with structural members of the crane, improperly grounded welding
leads or lightning strikes.
Valley break to wire rope
If one(1) valley break is observed, this may indicate internal rope damage requiring close inspection of this
section of the rope. When two(2) or more valley breaks are found in one(1) lay length the rope should be
discarded.
Wire rope length
There is an observation of the increase in the length of an individual rope lay. This increase in lay length and
accompanying reduction in diameter can be caused by failure of the core. This usually occurs more readily in

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ropes of rotation-resistant construction.
Wire rope corrosion
Extensive external and/or internal permanent corrosion is caused for rope replacement.
In the case of rotation resistant ropes which consist of a number of strand layers, internal corrosion may not
be readily detectable. During inspection, outer strands must be separated to assess internal rope condition.
Wires in the rope which are corrosively pitted have greatly reduce flexibility and will break much earlier as a
result of rope bending over sheaves.
Typical example of each defect
a. Wire protrusion
b. Core protrusion — single-layer rope

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c. Local reduction in rope diameter (sunken strand)
d. Strand protrusion/distortion
e. Flattened portion 3.5.11.7
f. Kink (positive)

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g. Kink (negative) 3.5.11.8
h. Waviness 3.5.11.2
i. Basket deformation 3.5.11.3
j. External wear 3.5.8

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k. Enlargement of Figure D.10 3.5.8
l. External corrosion 3.5.10.2
m. Enlargement
n. Crown wire breaks

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o. Valley wire breaks
p. Protrusion of inner rope of rotation-resistant rope 3.5.11.4
q. Local increase in rope diameter due to core distortion
r. Kink 3.5.11.8

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s. Flattened portion
t. Internal corrosion
6. Rope Lubrication
A wire rope is made up of hundreds of wires which move relative to each other when a rope is manufactured
it is completely filled with lubricant; firstly, to minimize frictional wear; and secondly, to keep out moisture and
resulting corrosion.
It is vital that this lubrication be preserved to get the maximum life from the rope. An external coating of
lubricant must be applied to the rope regularly to prevent the escape of the internal lubricant and also reduce
friction on the sheaves.
Lubricating the rope is as important as greasing any other part of the crane.
Points to Remember
ᆞ Never overload.
ᆞ Do not shock load, take up the slack carefully and apply the power smoothly and steadily.
ᆞ Protect rope from sharp edges.
ᆞ Avoid dragging the rope from under loads.
ᆞ Avoid rolling loads with ropes.
ᆞ Avoid dropping the rope from heights.

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WARNING
Never use a rope that has been cut, kinked or crushed.
Prevent loops in slack lines from being pulled tight and kinking. A weak spot will always remain no matter
how well the kink seems to have straightened out. If a loop forms do not full it out, unfold it. Avoid reverse
bends.
Never wind more than the proper amount of rope on any drum.
Ensure rope ends are properly seized.
Watch for local wear. Premature wear at one spot is common. Uneven wear can be minimized by moving the
rope so that different sections are at critical wear points. The wear can be distributed by cutting a few feet of
rope from the drum and re-anchoring it.
Maintain the equipment over which the rope runs. Worn grooves, poor alignment of sheaves and worn
bearings can result in shock loads and excessive vibration.

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Installation and Maintenance - Sheave
1. Sheave Location
Boom sheaves refer to boom assembly drawing :

ᆞDeflector sheaves on boom
ᆞHead sheaves(Fly and Main) on boom top
Mast ( If fitted )
ᆞMast sheaves are located on the mast head. Refer to Mast Assembly drawing
Luff Bridle (If fitted)

ᆞRefer to bridge Assembly drawing
2. Parts of Sheave

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3. Root
The root area is the inner concave area of the sheave rim, where the rope sits on. Check for excessive wear,
corrosion and deformations which could damage the rope.
4. Flange Wear
The flanges are the side walls of the rim. Check for excessive wear and deformation which can damage the
rope.
5. Lateral wobble
Move the side of the sheave and check for excessive play. Check bearings, seals, spacers and pins for wear.
6. Cracks in Web, hubs or flange
Check the welded joints for signs of cracks or corrosion. Check the web for straightness and alignment to the
center.
7. Sample Inspection Table
Sheave Cracks inWeb,

Root Wear Flange Wear Lateral Wobble Comments
Location, No Hubs of Flange

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Replacement - Hook Block
WARNING
Where equipment has swiveling and moving parts there are potential safety hazards. Care
should be taken when working with or repairing such equipment. If used incorrectly
breakage could occur inflicting injury or death
1. General Safety
When equipment is in use, do not put hands:

a. Between sheaves, sideplates and guards.
b. In area of becket, hook, hooknut and crosshead
Take great care to avoid clothing becoming trapped.
Repair and reeving should be carried out by trained personnel only. Power should be
switched off before operations are carried out. Work should only take place when
equipment is supported on a firm surface.
2. Maintenance and Service
Inspection should be carried out, on every occasion before taking into operation.
Particular attention should be paid to the following:

a. Wear in hook, centre pin, becket and threads in hook and nut.
b. Play in sheave bushes or bearings.
c. Spacer bolts, nuts and lynch pins
d. Check for cracks in welds.
e. Condition of safety catch and grease nipples.
f. Wear to holes in sideplates and becket.
If cracks or heavy gouges appear, the equipment should not be used and qualified opinion
should be sought. If grooved and the section reduced by more than 5% the item should be
replaced.
Repairs should be effected by grinding. NO welding should be carried out unless prior
authoritly is obtained. If the holes in the crosshead, sideplates, becket, eyes or yaws are
enlarged by more than 5%, the part should be replaced.

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All repairs should be carried out by responsible personnel, and great care should be taken
in the re-assembly of the equipment and retaining parts, i.e., grub screws, lynch pins, etc.
Check and refit only correct sizes and threads.
IMPORTANT
When replacing genuine parts an overload test of the complete unit must be performed
and new certificate must be issued.
3. Lubrication
As a general rule sheaves, crossheads and bodies should be oiled through nipples every
100 working hours, see also separate lubrication chart.
4. Limitation of use
a. Safe working load should never be exceeded.

b. Crane blocks should be used in vertical lift only.
c. Rigging blocks should be used only as in design specifications.
Blocks should not be used for towing, unless specifically designed and marked for that
purpose.
d. Swivels should be used in either the vertical or horizontal plane only.
e. Horizontal and vertical lead sheaves should only be used as indicated in the description.
f. Shock or side loading should not be applied, unless equipment is designed for that
purpose.
g. Load should always be in seat of hook or eye.
5. Allowed wear on lifting eyes and links
Wear and tear is allowed to take away maximum 7% of the diameter. Thereafter the
component has either to be replaced or repaired. The repair recommended is a hardened
cage, which shall be shrinked according to the instruction from DMC Cranes.

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Electrical Equipments
1. Slip ring unit

2. Fluorescent light
3. Buzzer
4. Air craft light
5. Warning light
6. Wall outlet
7. Moment limitter
8. Load cell controller
9. Ventilation fan
10. Temperature controller
11. Emergency push button switch
12. EOCR
13. Illuminated push button switch(circle type)
14. Illuminated push button switch(square type)
15. Pilot lamp
16. Push button switch
17. Selector switch
18. Wall switch
19. Power supply
20. Circuit breaker, Magnetic contactor & Thermal relay
21. Limit switch
22. Joystick

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1. Slip ring unit

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2. Fluorescent Light

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3. Buzzer

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4. Air Craft Light

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5. Warning Light

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6. Wall Outlet

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7. Moment Limitter

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8. Load Cell Controller

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9. Ventilation Fan

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10. Temperature Controller

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11. Emergency Push Button Switch

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12. EOCR

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13. Illuminated Push Button Switch (Circle type)

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14. Illuminated Push Button Switch (Square Type)

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15. Pilot Lamp

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16. Push Button Switch

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17. Selector Switch

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18. Wall Switch

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19. Power Supply

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20. Circuit Breaker, Magnet Contact & Thermal Relay

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21. Limit switch

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22. Joystick

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Hydraulic Equipment
1. Trouble-Shooting Chart, Overheating
Fault Probable cause Remedy
A. Overheating in Oil cooler fan motor not Check connections, contactor

hydraulic system working. effect repair as required.
Oil cooler flanges load

Dismantle and clean cooler.
with dirt.
Pressure control valves

Correct setting.
incorrectly set.
Trace leak and replace

Internal leakage. defective seals, packings,
and other parts.
B. Overheating caused
Internal leakage
by pump, valving, or Contact DMC Cranes.
because of wear
hydraulic motor
N.B.
When the hydraulic system is overheated thermostat FB (+85℃) opens.
To cool the system set the switch “Winter-Summer-Test” in “Test” position and press the “Start”
button on driver’s panel. Only cool fan and feed pump start and oil circulates in the system.

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2. Trouble Shooting, Pumps
Pumps, general
Fault Probable cause Remedy
A. Pump not supplying

Servo error. Contact DMC Cranes.
and fluid.
Worn or cracked parts Measure leakage,

in the pump. Contact DMC Cranes.
Check filters. Change

B. Excessive wear of the Hydraulic fluid contains
cartridge, if necessary.
pump. abrasive particles.
Analyze sample of the fluid.
Check pressure switch

Low feed pressure.
“5PS1” and “6PS1”.
C. Fracture of parts in Check valve functions and

Pressure shocks.
the pump. valve settings.
Check pressure switch

Low feed pressure.
“5PS1” and “6PS1”.
More detailed information regarding the pumps will be found in the instruction manual.

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3. Hydraulic Motors (Hoisting, Luffing and Slewing Circuits)
Hydraulic Motor 5M1(Hoisting)

Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil.

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Hydraulic Motor 6M1 , 7M1(Luffing , Slewing)

Before the first operation the hydraulic motor housing should be pre-filled with hydraulic oil.

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4. Trouble-Shouting Chart, Hydraulic High Speed Motors
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pressure
has risen to the relief valve setting,
The motor does no tdeliver remove the load from the drive.
enough torque because the
pressure difference across the Investigate the pressure level in the
motor is not great enough for the system and correct the setting of the
load. pressure limiting valve if necessary.
Insufficient or no oil being Check the hydraulic system.
supplied to motor. Check the external leakage of the
motor.
(The T connection)
Oil supply connections to motor

Motor rotates in wrong direction. Connect the oil supply correctly.
incorrectly connected
Motor runs jerkily.. Pressure or flow fluctuations in Find the cause in the system or in the
the hydraulic system. driven unit.
The motor is being operated with Adjust the charge pressure to the correct
Noise in the motor.
the charge pressure too low. level. See Hydraulic Circuit - gauge
connection 1.
Internal faults in the motor.
Investigate the drain oil.
External oil leakage on the motor. The radial seal is worn. Replace the radial lip seal.
Dismantle the brake and replace the

Insufficient braking torque. The brake discs are worn out.
worn discs.
Insufficient brake opening See Hydraulic Circuit – gauge

The brake does not open.
pressure. connection 2.
Replace seals. Replace the piston.

IMPORTANT!
The springs in the brake cylinder are
tensioned.

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5. Trouble-Shouting Chart Variable hydraulic motors
Fault Probable cause Action
Motor only works at one speed. Pilot pressure low. Suitable pilot pressure. See Hydraulic
Circuit – gauge connection 2.
The valve 1221 has stuck due to Inspect valve piston and remove
No electric supply to the valve Check the electric system.

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6. Feed Pump Unit

Introduction
The pump is a screw-type pump with fixed displacement which supplies the feed and control circuits of the
crane. The pump is submerged in the hydraulic oil. Thus, one pipe only connects the pump to the hydraulic
system.
The pump is separately driven by an electric motor which is mounted in the oil tank.
To overhaul the pump or the electric motor, the entire pump unit - motor and pump - should be taken out.
Caution!
Maintain cleanliness throughout!
1. Removing and dismantling pump unit

- Park crane jib, stop crane, switch off main switch
- Remove tank cover (2)
- Loosen the upper end of the hose (5)
- Disconnect the electric connections to the electric motor (6)
- Lift electric motor (6) with pump (7), using the chain (4)
- Remove mounting screws holding electric motor (6) onto the pump (7)
- Withdraw pump (7) from motor (6)
2. Reassembling pump
- Reassemble pump unit in reverse order to dismantling.
- Replace pump unit. Reinstall and reconnect hydraulic pipes and components. Reconnect electric motor
power cable.
- Jog start pump unit to check rotation.

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7. Vane Pump

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8. High Pressure Pumps

General
All pumps are the straight axial piston type with variable displacement controlled by a Proportional valve
mounted on the pump housing.

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h1002 Deck Crane

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h1002 Deck Crane

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Ship yard : Shin An Heavy Industries Co.

INSTRUCTION AND 1. GENERAL

#1196, Myeongdong-ri, Hallim-myeon Tel. : +82-55-720-3031~3040

Dongnam Marine Crane Co.,Ltd

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

5. Unprofessional, intended or unintended, Lubrication chart; Cable Winch and Stabilizing

Before maintenance and service work is started,

General Chapter 6 contains:

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

2) Safety valves for hydraulic pressure settings

b. Safety belt, rescue line, safety chains:

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 1 / 11

Certifying authority, Rules / Regulations : DNV

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 2 / 11

3. Application equipments and system

4. Documentation / Name plates

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 3 / 11

Deck crane outside

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 4 / 11

< Fig. 2.1 General arranegent >

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 5 / 11

Main Fan Cooler

Temp. Sensor Main Block

Cooling Part Filter

Main Pump Unit

Gear Box Tank

Main Control Panel

Operation Panel Shuttle “T” Block

Luffing Winch Slewing Port Block

Hyd. Motor F12-110

Hoisting Winch Brake Block

Hyd Motor V14-160 Slewing Ass’y

Hyd. Motor F12-040

< Fig. 2.2 Slewing column assembly >

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 6 / 11

Gear Box Tank

< Fig. 2.3 Main Pump UNIT >

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 7 / 11

Boom pivoting point

Hosting and Luffing winch

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 8 / 11

Slewing gear / Slewing bearing

Ropes and Sheaves

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 9 / 11

Independent swash plate variable

INSTRUCTION MANUAL for Deck Crane Make by DMC,.Ltd.

T ECHN ICAL SPEC IFICT ION 10 / 11

Certificates of components and crane structure for third party Inspection:

- Hook block, wire rope : ILO Form Certificate

Data book containing below mentioned documents retained by client: