BAL 8958 en

10)
Instruction Manual
Board crane
Typ: DK II 250012/100026
Order-No.: 8958
Hull-No.: 325
Shipyard: Xingang Shipyard
Name of Ship:
Year of Construction: 2002
Neuenfelder Maschinenfabrik GmbH

Neuenfelder Fährdeich
21129 Hamburg
Phone: 040 / 7451102
Fax: 040 / 74511867
e-mail: info@nmf-kran.de
Internet:www.nmf-crane.com
Instruction Manual
Board crane type DK II 250012/100026
Table of Contents
1 What is worth knowing about this operating manual 11

1.1 Manufacturer 11
1.2 The operator´s duty of care 11
1.3 Terms, short cuts and symbols 12
1.4 Technical Amendments 13
1.5 Guarantee 13
1.6 Copyright 13
2 Description of the Crane 15

2.1 Technical Data 15
2.2 Construction 17
2.3 General Aspects 18
2.4 Pump unit 18
2.5 Lifting gear 18
2.6 Luffing gear 18
2.7 Turning gear 18
2.8 Gear oil cooler 18
2.9 Hydraulic oil cooler 19
2.10 Heating 19
2.11 Slack rope switch 19
2.12 Gear limit switch 19
2.13 Slip ring assembly 20
2.14 Load measuring bolts 20
3 Safety 21
3.1 Use for the designed purpose 21
3.2 General safety instructions 21
3.3 Requirement of personnel 21
3.4 Symbols on the crane 21
3.5 Warning signals during the crane operation 22
3.6 Safety devices on the crane and their functional test 22
3.7 Dangers and behaviour in case of danger 23
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Instruction Manual
10) Board crane type DK II 250012/100026
4 Operation 25
4.1 Safety instructions 25
4.3 Working range of the crane 26
4.4 Operation 27
4.4.1 Operator´s cabin 27
4.4.2 Control panels 28
4.5 Commissioning 30
4.5.1 Before starting 30
4.5.2 Switching on 30
4.5.3 Switch on main lifting gear 31
4.5.4 Switch on auxiliary lifting gear 31
4.5.5 Switch off 32
4.6 Emergency shutdown of the crane 32
4.6.1 „TEST OPERATION“ switch 32
4.6.2 „TEST LOAD“ switch 32
5 Monitoring, Failure, Troubleshooting and Elimination 35

5.3 Monitoring, Failure, troubleshooting and elimination 35
5.4 Brake relay monitoring 35
5.5 Speed monitoring of the jib winch, lifting gear winch and the auxiliary lifting
gear winch36
5.6 Fault notification card 36
5.7 Fault Search Diagram 38
6 Maintenance and Repair 49

6.3 Maintenance schedule 50
6.4 Maintenance and repair 52
6.4.1 Cleaning the crane 52
6.4.2 Greasing 52
6.4.3 Gear 52
6.4.4 Oil change 52
6.4.5 Gear box inspection 52
6.4.6 Pump distribution gear 53
6.4.7 Gear oil cooler filter 53
6.4.8 Changing the hydraulic oil 54
6.4.9 Changing the hydraulic oil filter 54
6.4.10 BOTTOM HOOK BLOCK 57
6.4.11 Function and safety inspection 57
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Instruction Manual
6.4.12 Lamellar brakes 58

6.4.13 Changing the lamellars 58
6.4.14 Gear cam limit switch 60
6.4.15 Slack rope switch gear 61
6.4.16 Slip ring assembly 62
6.4.17 Load measuring bolts 63
6.5 Maintenance, service and discard criteria for wire rope 65
6.5.1 Cleaning and greasing the wire rope 65
6.5.2 Monitoring 65
6.5.3 Wire changing 67
6.5.4 Replacement state of wear 67
6.6 Setting of the limit switches 71
6.6.1 Lifting gear 71
6.6.2 Luffing gear 72
6.6.3 Auxiliary lifting gear 73
6.7 How do I exchange a Memory-Programmable Control (MPC)? 75
6.8 List of lubricants 81
7 Description of the hydraulic circuit 83

7.1 GENERAL ASPECTS 83
7.2 STARTING THE PUMP UNIT 83
7.2.1 START THE PUMP UNITS INDIVIDUALLY 83
7.3 HYDRAULIC OVERLOAD CUT-OFF 84
7.3.1 LOAD STAGE SECURING 84
7.3.2 PRESSURE RESTORAGE 84
7.4 VENTING 85
7.5 HEATING / COOLING 85
7.6 FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL 85
7.7 HOISTING GEAR 87
7.7.1 LIFTING OF THE NOMINAL LOAD 250T 87
7.8 FUNCTIONAL DESCRIPTION OF THE INDIVIDUAL LOAD STAGES87
7.8.1 GENERAL ASPECTS 87
7.8.2 LIFTING THE 200T 87
7.8.5 LIFTING THE 25 T 88
7.8.6 AUTOMATIC STAGE 88
7.8.7 LIFTING THE 35T STAGE (AUXILIARY LIFTING GEAR) 88
7.8.8 OVERDRIVE 88
7.8.9 LUFFING GEAR 89
7.8.10 "LUFFING UP"KEY SWITCH POSITION 25-100T 89
7.8.11 "LUFFING UP"KEY SWITCH POSITION 150-250T 89
7.8.12 "LUFFING DOWN" 89
7.9 TURNING GEAR 89
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7.9.1 TURNING "RIGHT-LEFT" 90
8 Lifting of brakes in case of emergency 91

8.1 Lifting gear 91
8.1.1 Connect the hand pump for opening the brakes as follows. 91
8.2 Turning gear 95
9 Spare Parts 97
9.1 Ordering spare parts 97
9.1.1 List of Spare parts 98
10 Drawings 119
11 Appendix 125
11.1 Drawings 125
11.2 Supplier Documents 127
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Instruction Manual
List of Figures
Overall view 17
Working range of the crane 26
Operator´s cabin 27
Control panel right 28
Control panel left 29
Electrical fault 38
Pump unit fault 39
Lifting gear fault (electr.) 40
Lifting gear fault 41
Lifting gear fault 42
Luffing gear fault (electr.) 43
Luffing gear fault 44
Luffing gear fault 45
Turning gear fault (electr.) 46
Turning gear fault 47
Filter 56
Lamellar brake 59
Cam disc 60
Slack rope switch 61
Load measuring bolts 63
Setting of the lifting gear limit switches 71
Setting of the luffing gear limit switches 72
Setting of the switches for the auxiliary lifting gear 73
Replace MPC1 77
Replace MPC 2 78
Replace MPC 3 79
Connections for the solenoid valve block 92
Brake lifting pump 93
Pressure limit valves at hoisting pump (Sauer) 94
Remove the turning gear motors 95
Pump unit 119
Load Measuring Device 120
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Emergency exit 120

Switch cabinet switch 121
Switch cabinet door 122
Fault notification card 123
Gear oil cooler 124
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Instruction Manual
List of Tables
Terms and short cuts 12

Symbols 12
Technical Data 15
Maintenance Intervals 50
List of drawings 125
List of Supplier Documents 127
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Instruction Manual
10
Instruction Manual
Board crane type DKII 250012/100026 10)
1 What is worth knowing about this operating

manual
1.1 Manufacturer
The crane manufacturer is NMF Neuenfelder Maschinenfabrik GmbH
The address is:
NMF Neuenfelder Maschinenfabrik GmbH
Neuenfelder Fährdeich
21129 Hamburg
You can contact us under
Telephone 040 / 74511-02
Fax 040 / 74511-867
e-mail: info@nmf-kran.de
1.2 The operator´s duty of care

The operator must ensure that
• the crane is only to be used in accordance with the designed purpose (see
Chapter 3.1, Use for the designed purpose, Page 21).
• the crane is only used in a fault-free, operational condition,
• the safety devices are regularly checked in order to ensure that they function as
stipulated,
• personal protective clothing and equipments is provided for the operating,
maintenance and repair personnel and tthat this is worn or used.
• the instruction manual is always complete and legible and situated at the crane´s
location,
• only sufficiently qualified and authorised personnel operate, maintain and repair
the crane,
• this personnel is regularly instructed in all pertinent aspects of works safety and
environmental protection and are familiar with the instruction manual and in
particular the safety instructions enclosed in it
• alls safety and warning instructions on the crane are legible and are not removed.
Operating instructions in the sense of industrial safety legislation and regulations for
the use of the work materials are also to be provided.
What is worth knowing about this operating manual 11

Instruction Manual
1.3 Terms, short cuts and symbols

The terms used in the instruction manual are explained in Table 1, Page 12.
Terms / short cuts Meaning
NMF Neuenfelder Maschinenfabrik GmbH

Operator Company or person responsible for using the crane
Table 1: Terms and short cuts
Together with the text in the safety instructions, the safety symbols draw attention to
rest hazards when handling the crane. These rest hazards are related to
• People
• the crane
• other objects and items
• the environment
The safety symbols included in Table 2, Page 12 are used in this instruction manual
Symbols Explanation
NOTE
Information which is important for operating the product
CAUTION
Hazards which can result in the device and / or other plant
components suffering damage, but which do not pose a threat to
life and limb
DANGER
Hazards which pose a threat to life and limb or additional hazards
which can result in the device and / or other plant components
suffering damage
Table 2: Symbols
A safety symbol can never replace the text in a safety instruction. For this reason,
always completely read the text of a safety instruction.
12 What is worth knowing about this operating manual

Instruction Manual
1.4 Technical Amendments

For safety reasons, no unauthorised changes are to be made to the crane - this also
applies to the welding work on bearing parts All planned changes must be approved
by Neuenfelder Maschinenfabrik GmbH in writing.
We reserve the right to make technical amendments which serve to improve the
product. The figures in this instruction manual can slightly deviate from the real
situations.
1.5 Guarantee
Unless otherwise stipulated in the contract, any warranty claims shall be dealt with in
accordance with the Neuenfelder Maschinenfabrik GmbH "General Terms and
Conditions of Supplies and Services" applicable at the time the contract has been
concluded.
The Neuenfelder Maschinenfabrik GmbH guarantee will become void if:
• the product is modified without our consent,
• this instruction manual is not observed,
• spare parts and additional devices have been fitted and removed which have not
been supplied or approved by us
• the crane is overloaded, e. g. the carrying force is exceeded,
• the crane is not used in accordance with the designed purpose, e. g. by oblique
pull,
• the technical data stipulated in Chapter 2.1, Technical Data, Page 15 are
exceeded or not reached,
• the product is improperly handled.
1.6 Copyright
The copyright in this instruction manual and the drawings remains with Neuenfelder
Maschinenfabrik GmbH. The instruction manual and the drawings are only to be used
for the purpose it was transferred to the recipient. The documents are no to be handed
over or disclosed to third parties without our express consent in writing. Any
reproduction (including details) is prohibited. Any contraventions will be subjected to
prosecution.
What is worth knowing about this operating manual 13

Instruction Manual
14 What is worth knowing about this operating manual

Instruction Manual
2 Description of the Crane
2.1 Technical Data

The DK II 250012/100026 board crane is a loading device. The technical data is
compiled in Table 1, Page 15.
Feature Value
Crane
Crane type DK II
Capacity (SWL) 250 t
Length of main hoist
SWL 250 t 4.5 -12.0m
SWL 200t 4.5 -15.0m
SWL 150t 4.5 -20.0m
SWL 100t 2.5 -26.0m
SWL 25t 2.5 -26.0m
Length of auxiliary hub
SWL 35t Crane 1: 4.5 -34.5m
Crane 2: 4.5 -31.5m
Lifting height ca. 36m
Luffing
SWL 0-250 t T = 45 sec.
SWL 0-200t T = 45 sec
SWL 0-150t T = 60 sec
SWL 0-100t T = 85 sec
Hoisting speed
SWL 0 - 250 t 0 - 5,0 m/min
SWL 0 - 200t 0 - 6,0 m/min
SWL 0 - 150t 0 - 8,0 m/min
SWL 0 - 100t 0 - 12,5 m/min
Auxiliary hoist hoisting speed
35t 0 -14m/min.
14t 0 -28m/min.
Turning speed> 100t 0 -0.4 rpm
Turning speed< 100t 0 -0.6 rpm
Slewing range 360°
Specification 250 t load and 26 m outreach at +/- 5° heeling and simultaneous
trim of +/- 2°
Automatic Operation
Working range 4,5 - 26,0
Hoisting speed 0 -4.4 m/min.
Voltage
Table 1: Technical Data
Description of the Crane 15

Instruction Manual
Feature Value
Nominal Voltage (U) 380 V / 50 Hz

Motor speed (n) 1,475 r/min
Mounting power 2 x 110 kW
Max. input, temporarily 2 x 175 kW
Auxiliary supply 230 V / 50 Hz
Heating ___ kW
Total lighting ___ kW
Main pump motor
Type 280 M4
Manufacturer Schorch
Performance 110 kW
System of protection Insulation class IP 23
Structural shapem standstill F; 45° GL
heating with three posistors
Miscellaneous Star-delta start-up
Table 1: Technical Data

Instruction Manual
2.2 Construction
Abbildung 1: Overall view

Instruction Manual
2.3 General Aspects

All of the working motions can be regulated infinitely from zero to max. speed: all
operations can take place simultaneously . With a nominal load on the hook, an
electric capacity governor reduces the control current to the pump adjustment of the
hoisting, turning and luffing gear, depending on the power input to the electric motor.
These speeds are reduced and the power input to the electric motor is kept at the
same level.
2.4 Pump unit

Two pump units are installed in the crane casing. Each of the pump unit comprises
an electric motor, a pump distribution gear and three hydraulic pumps.
The pumps are driven by the electric motor through the distribution gear. The pump
unit provides the lifting gear, turning gear and and luffing gear with pressure oil.
The hydraulic pumps are variable, reversible high-pressure, axial piston pumps which
are connected to the hydraulic motors by high-pressure hoses.
2.5 Lifting gear

The lifting gear is mounted in the crane casing, consisting of the winch drum, the winch
gear and four hydraulic motors. The winch gear is installed in the winch drum, the
hydraulic motors being flanged onto the latter.
The hydraulic motors are axial piston angular axial motors with adjustable absorption
volumes.
2.6 Luffing gear

The luffing gear is of the same design as the lifting gear but only has one hydraulic
motor.
2.7 Turning gear

The turning gear consists of four turning gears which are mounted on the floor of the
crane.
Each turning gear engages via a gear wheel into a gear rim of the spherical turning
connection, hereby transmitting the turning motion to the crane. An angular axial
piston motor is mounted on each of the turning gears.
2.8 Gear oil cooler

The gear oil cooler is an oil-air cooling aggregate (see Gear oil cooler, Page 124)
which cools the gear oil in the pump distribution gear . A gear oil cooler is to be
provided for each pump distribution gear.
This starts at an hydraulic oil temperature of 20 °C.

Instruction Manual
2.9 Hydraulic oil cooler

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

The lifting rope and auxiliary lifting ropes are secured against slack rope by means of
a slack rope switch.
As soon as the rope of the lifting gear or the auxiliary lifting gear within the crane
column tends to slacken so that the rope threatens to jump out of the grooves, the
inductive proximity switch is actuated by the rocker. This immediately switches the
lifting gear off in "lowering" mode. However, a lifting operation is possible.
The correct positioning of the rope must be checked (see Chapter 6.5, Maintenance,
service and discard criteria for wire rope, Page 65).
2.12 Gear limit switch

A gear limit switch is fitted to each of the winch gears.
The limit switches are provided with a variable number of cams which are actuated as
required by the various crane-operating conditions (see Supplier Documents,
Page 127 ).
CAUTION
The limit switches are only to be operated, serviced and repaired by authorized,
skilled and instructed personnel.
This personnel must have read and understood the complete instruction
manual and it must also have received instruction in the ensuing hazards (see
Chapter 6, Maintenance and Repair, Page 49).

Instruction Manual
2.13 Slip ring assembly

The slip ring assembly guides the tension from the fixed part of the crane (foundation)
to the turning part of the crane and can therefore be turned without restriction.
Due to its enclosed design, the slip ring assembly is splashwater-proof and fitted to
the rotary transmission leadthrough, it can be accessed after the cover has been
opened.
CAUTION
Prior to opening the slip ring assembly cover
• switch off the voltage,
• protect the voltage against unauthorised activation,
2.14 Load measuring bolts

The load measurement is electrically carried out via load measuring bolts in the rope
end fixing point. The load is shown on a display in the cabin.
Under no circumstances should the load measuring bolts be driven into the bore hole
with a hammer or other tool. A non-adherence to this warning can result in the load
measuring bolts suffering mechanical damage and incorrect measuring results being
produced.
Should such a non-observance be determined, the warranty rights are deleted.
The load measuring system can be switched off with a key switch in the switch
cabinet. (see Load Measuring Device, Page 120) The load bolts are therefore
electrically bypassed and the electrical load measurement deactivated. This has no
effect on the hydraulic load measurement.
CAUTION:
If the load measuring system is deactivated, the loadmaster is unable to initiate
a deactivation by overload.

Instruction Manual
3 Safety
3.1 Use for the designed purpose

The board crane type DK II250012/100026 is designed for use as a loading device
for the loading and unloading of heavy goods, small consignments and containers off
ships.
3.2 General safety instructions

The products manufactured by Neuenfelder Maschinenfabrik GmbH are designed and
constructed on the basis of a risk analysis and subject to additional national standards
and technical specification. They therefore meet the latest state of the art and
guarantee the highest possible degree of safety.
This safety level can only be achieved if all of the necessary measures have been
taken . It is therefore a part of the crane operator´s duty of care to plan these
measures and ensure that they are correctly executed (see Chapter 1.2, The
operator´s duty of care, Page 11).
3.3 Requirement of personnel

The crane is only to be operated by persons who
• are trained, instructed and authorised,
• are familiar with the instruction manual and act in accordance with it,
• confirm with their signature that they have understood the instruction manual.
In addition, the personnel must be especially instructed in the following activities and
know them:
• Emergency shutdown of the crane (see Emergency shutdown of the crane,
Page 32),
• escape hatch if the operator´s cabin via a ladder or a descending device (see
Emergency exit, Page 24),
• emergency lowering of the load and the jib (see Lifting gear, Page 91),
• behaviour in critical situations, e. g. heeling and trimming (see Behaviour in
critical situations, Page 24).
The respective areas of authority of the operating personnel must be clearly defined.
3.4 Symbols on the crane

Always keep all safety instruction plate and operating instruction plates on the crane
in a legible state. Replace any damaged or illegible plates without delay.
Safety 21
Instruction Manual
3.5 Warning signals during the crane operation

Acoustic warning signals
• horn
Optical warning signals
• Warning lamps on the left control panel
3.6 Safety devices on the crane and their functional test

Electrical overload safety
The electrical overload safety is provided with the load measurement bolts in the rope
fixing points of the main lifting gear and auxiliary lifting gear. The SPC evaluates the
electrical signals from the load measurement bolts. If the load moment is too large, the
crane switches off in "lifting".
If the nominal load reaches 5t the main lifting gear is switched off.
Contol lever
The control levers are spring loaded and automatically return to the neutral position
when released. The brakes for hoisting, luffing and turning gears are spring loaded
and always closed. They are only opened when the corresponding control lever is
shifted.
The brakes close automatically
• when the control levers are at zero position,
• there is a pressure loss in the system (in this case the pump unit is immediately
switched off),
• power failure
• in case of overload
• when the limits of the outreach are reached in the individual load ranges,
• when the slack rope is at "lower" in the lifting gear.
Pressure switch
A pressure switch for monitoring the feed pressure is installed in each of the high-
pressure lines.
• 3.4 Luffing down
• 4.4 Luffing down
• 5.4 Feed pressure system
In the case of a pressure loss, this pressure switch switches the pump unit off
immediately. A niveau switch in the hydraulic oil tank also switches the pump unit off
if there is a lack of oil. The pumps are then protected against running dry.
If the crane is switched off due to a pressure switch opening or a failure of the gear oil
cooler:
• the crane operator is unable to re-start the crane.
• It is possible that a hose has burst.
22 Safety
Instruction Manual
• before, restarting subject the hydraulic system to a visual inspection. Should you
not find any defects, press the "Reset" button in the switch cabinet. Then restart
the crane.
Hydraulic overload safety

The complete hydraulic oil system is protected agains excess pressure by pressure
limitation valves. A load pressure switch is fitted in the lifting gear hoisting pipe.
[3.11] lifting 250t
[3.12] lifting 100-150-200t
[3.13] lifting 0-35t
In case of overload
• the load pressure switch cuts the activated function off,
• the pump unit continues to run,
• the lifting winch brake is applied immediately,
• the lifting gear pump returns to the neutral position.
Limit switch
The lifting and luffing gears are limited in the working range of the individual load range
by limit switches (see Setting of the limit switches, Page 71). When this final position
is reached, the corresponding function is deactivated and the brakes are applied.
However, a reverse operation is possible. All limit switches only work concerning the
triggering of the pumps, e. g. the electric motor continues to run at a constant speed,
whereby only the idling speed is applied.
When crane operations are recommenced, no current peaks are achieved due to the
centrifugal masses produced by the electric motor and the smoothly operating
hydraulics.
Anti-collision
Crane 2 is equipped with an anti-collision system. This prevents the crane from
coming into content with the deck house during operation.
3.7 Dangers and behaviour in case of danger

Danger from noise
Depending on the local conditions, higher sound levels can occur outside the crane
operator´s cabin which can result in deafness, a loss of balance or diminished
alertness.
Always use the personal protective equipment and clothing.
Please note that if the crane is in operation, the communication of speech and the
discernment of acoustic signals e. g. warning signals etc.
Safety 23
Instruction Manual
Danger from "residual" energy

Please not that various forms of energy can still exist after the crane has been
switched off or at a standstill - examples of these are:
• raised jibs or loads
• hydraulic pressure hoses
• live power cables
Please advise the personnel accordingly when instructing them.
Behavious in case of danger
In case of danger, press the emergency-stop button immediately Emergency
shutdown of the crane, Page 32 .
In case of fire, switch the crane off at the main switch immeidately.
Take the special action with regard to fire fighting in the following areas:
• with operational materials (hydraulic oil, lubricants),
• electric cables
Behaviour in critical situations
Critical situations are given if the heeling exceeds 3°.
Warning of this critical situation is provided in the form of both optical and acoustic
signals.
Take the following action.
• luff the jib up
• turn the crane across the shortest path to the centre of the ship.
• place the load on the ground.
• determine the cause of the heavy heeling.
Emergency exit
In case of emergency, leave the crane via the emergency exit (see Emergency exit,
Page 120)in the crane operator´s cabin.
• or via an external ladder placed against the crane (should one exist)
• or via the emergency descending device in the crane operator´s cabin (see
Supplier Documents, Page 127).
24 Safety
Instruction Manual
4 Operation
4.1 Safety instructions

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

The crane is only to be operated by persons who are trained, instructed and
authorised. These persons must be familiar with the instruction manual and are to act
in accordance with it. The respective areas of authority of the operating personnel
must be clearly defined.
Operating personnel who are in training are only to initially work on the crane under
supervision of an experienced person. The successful completion of the training
period should be confirmed in writing.
All control and safety devices are only to be operated by persons who have been
suitably instructed.
All persons working on the crane are to read the instruction manual and confirm with
their signature that they have understood it.7
Operation 25
Instruction Manual
4.3 Working range of the crane
Abbildung 1: Working range of the crane
26 Operation
Instruction Manual
4.4 Operation
4.4.1 Operator´s cabin
The crane operating elements are situated in the operator´s cabin.
Abbildung 2: Operator´s cabin
Operation 27
Instruction Manual
4.4.2 Control panels
The control levers are delicate and are to be actuated continuously.
Abbildung 3: Control panel right
28 Operation
Instruction Manual
Abbildung 4: Control panel left
Operation 29
Instruction Manual
4.5 Commissioning
4.5.1 Before starting
Before every start

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

2. Start the pump units with the button on the left control panel. The pump unit
„1A“is the first to start. After ca. 15 seconds, the pump unit „1B“ starts, the
green pilot lamp on the left control panel illuminates. The crane is ready for
use. (This start-up only runs when the key switch is in the „O“ position).
NOTE
Should one pump unit not work, the crane can be operated with another unit.
(Turn the key switch on the switch cabinet to „1“ or „2“.)
3. Check whether the vent flap is open.

4. Switch on load step 25t with the key switch at the right control panel.
5. Luff the jib down completely and check whether the luffing jib stops without
difficulty when the max. position is reached.
6. Move the lifting gear in „Lift“. The bottom hook block must stop ca. 1 m below
the jib head.
7. Switch on auxiliary switch cabinet at the right control panel.
8. Move the auxiliary lifting gear in „Lift“. The bottom hook block must stop ca.1 m
below the jib head.
9. Luff the jib up completely and check whether the jib stops without difficulty
when the min. position is reached.
30 Operation
Instruction Manual
NOTE
From a jib position of 70°, the luffing up speed is automatically reduced to
crawling speed and the jib moves slowly to the top final position. From the top
final position, the jib moves faster from 70%.
10. Remove the key from the „lay resting jib down“ key switch so as to avoid
misuse by the crane operator during normal cargo handling.
During operation
• Do not remove any safety devices and do not taken them out of operation.
• You and other operating personnel are only to be in the stipulated workplaces.
• Ensure that no unauthorised persons are within the crane operating area.
• Never suspend accepted loads above peoples´ head.
• The load shift is only to be activated with an empty load hook and for the
corresponding load.
• An angular pulling with the load rope is not permitted.
• Only activate the „lay resting jib down“ key switch if the jib is situated in the rest
parking support.
• Caution: All other limit switches do not function.
• It is imperative that a slack rope is avoided.
4.5.3 Switch on main lifting gear
The load steps are switched on at the right panel (see Control panels, Page 28.) The
selected load step is only shown by pilot lamps in the display unit (see Operator´s
cabin, Page 27) if the jib has moved to the working area of the load step and the
control lever has subsequently been positioned at „O“. The load weight is calculated
by the load measurement and also shown on the pilot lamp.
NOTE:
The load steps are only to be changed when the hook is not subjected to a load. If the
load n the hook is greater than the set load, step, the crane switches to „lift“.
„Lowering“ can pose a risk.
4.5.4 Switch on auxiliary lifting gear
Switch on the key switch (6) on the left control panel.

Auxiliary lifting gear fast running
Switch on the key switch (5) on the left control panel.
Operation 31
Instruction Manual
NOTE
The main and auxiliary lifting gears are not to be loaded simultaneously. The main
lifting gear is switched off as soon as the auxiliary lifting gear exceeds a nominal load
of 5t.
4.5.5 Switch off
Shutting down.
1. Extend the jib to the maximum outreach. Actuate the „rest jib“ key switch and
hold the key switch in position. Place the jib in the resting position and relieve
the topping lift a little.
2. Fasten the jib in the resting support.
3. Place the bottom hook block under the jib head, DO NOT lift the jib head.
4. Switch the pump unit off.
5. Check whether the vent flap is closed
6. Close the cabin window and the cabin vent.
7. Switch the main switch in the machine room off. Do not switch off the auxiliary
supply.
4.6 Emergency shutdown of the crane

3 emergency-off buttons are installed in the crane and the crane housing.
• in the crane exit on the ladder
• in the switch cabinet
• on the right control panel
4.6.1 „TEST OPERATION“ switch
(see Switch cabinet switch, Page 121).

In „Test Operation“, the control can be driven to all areas electrically. The E-motor or
the hydraulic pumps respectively do not also run. The „Test Operation“ mainly serves
for troubleshooting.
4.6.2 „TEST LOAD“ switch
The switch is in the switch cabinet. (see Switch cabinet switch, Page 121).
The switch is only to be activated if the crane is to be subjected to a loading test.
32 Operation
Instruction Manual
4 .6 .3 „RESET“ button
(see Switch cabinet switch, Page 121).

„HOSE RUPTURE“
Should the crane switch off by the opening of a pressure control device or a
breakdown in the gear oil cooler, the crane operator is unable to restart the crane.
It is possible that a hose has ruptured. Before restarting, the hydraulic system should
be subjected to a visual inspection. If this is carried out and no defects are determined,
the "Reset button" in the switch cabinet must be activated. The crane can then be
restarted.
"EXCESSIVE SPEED"
If the winch reaches an excessive speed, it is switched off and the brake falls in. A
restart is not possible. Before restarting, the hydraulic system should be subjected to
a visual inspection. If this is carried out and no defects are determined, the „Reset
button“ in the switch cabinet must be activated.
Operation 33
Instruction Manual
34 Operation
Instruction Manual
5 Monitoring, Failure, Troubleshooting and

Elimination

• All work on the crane´s electrical equipment must be carried out by trained
electrical specialists only.
• Any interventions in the crane´s control programme are only to be carried by
Neuenfelder Maschinenfabrik GmbH or with its approval.
• Repairs and inspections are only to be carried out when there is no load on the
hook. Place the load on the ground first. (see Chapter 8, Lifting of brakes in case
of emergency, Page 91).

Only remedy a fault if you are qualified to do so.
Please also read Chapter 3.2, General safety instructions, Page 21.
5.3 Monitoring, Failure, troubleshooting and elimination

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

For safety reasons, the solenoid valves for the lifting gear, turning gear and jib brakes
are triggered by 2 relays situated in a row. This switching guarantees the greatest
possible security. Should a relay bond and the contact no longer open, the second
relay is still able to switch the brake off safely. The relays are always monitored by the
SPC. The relay is checked 0.5 sec. after the brake has been released. Should a relay
still have a closed contact, an error message is transmitted to the crane operator. At
the switch cabinet, it is possible to determine which brake control is defect.
Lifting gear brake: Relay 1K26, 1K41 error message lamp 1H6
Jib brake: Relay 1K25, 1K40 error message lamp 1H7
Auxiliary lifting gear brake: Relay 1K27, 1K42 error message lamp 1H8
Monitoring, Failure, Troubleshooting and Elimination 35

Instruction Manual
5.5 Speed monitoring of the jib winch, lifting gear winch and the auxiliary
lifting gear winch
The jin and lifting gear winches are equipped with a speed monitoring. Should the
maximum speed be exceeded due to a drive fault, a forced braking is automatically
activated. The "FAULT" lamp on the left control panel in the cabin is illuminated, in the
switch cabinet, the lamps "excess winch speed", "excess jib winch" or excess auxiliary
lifting gear speed. The crane operator is unable to restart the winch. The fault can be
eliminated with the "Reset excess speed" button (see Switch cabinet switch, Page 121
).
Should there be a deactivation due to excess speed and there are no faults on the
drive, the excess speed monitoring can be deactivated.
NOTE:
A deactivation of the excess speed is only to be carried out with the agreement
of the manufacturer.
See sheet 23 of the electric wiring diagram.

Terminal strip 1X2 terminal 47+48
If the link between terminals 47+ 48 is removed, the lifting gear is no longer switched
off by excess speed. Only the fault lamps "2H4" and "1H7" are illuminated. The fault
lamps are automatically extinguished after 5 sec.
If the link between terminals 46+ 45 is removed, the auxiliary lifting gear is no longer
switched off by excess speed. Only the fault lamps "2H4" and "1H9" are illuminated.
The fault lamps are automatically extinguished after 5 sec.
If the link between terminals 50+ 49 is removed, the jib gear is no longer switched off
by excess speed. Only the fault lamps "2H4" and "1H8" are illuminated. The fault
lamps are automatically extinguished after 5 sec.
5.6 Fault notification card

See Fault notification card, Page 123.
Any crane faults are shown acoustically and optically.
• acoustic with a horn,
the horn is switched off using the "Acknowledge Alarm" button on the switch
cabinet.
• optical with the signal lamp at the left control panel "Fault Lamp" and
• the signal lamp on the fault notification card
36 Monitoring, Failure, Troubleshooting and Elimination

Instruction Manual
FAULT 1 OIL COOLER 1

FAULT OIL COOLER 2/
FAULT 3 OIL COOLER 3/
FAULT 4 GEAR OIL COOLER 1
FAULT 5 GEAR OIL COOLER 2
FAULT 6 MOTOR 1
FAULT 7 MOTOR 2
FAULT 8 EXCESS SPEED WINCH 250t (main lifting winch)
FAULT 9 WINCH EXCESS SPEED jib (
FAULT 10 EXCESS SPEED WINCH 35t (auxiliary lifting winch)
FAULT 11 CONTROL BRAKE TURNING GEAR
FAULT 12 CONTROL BRAKE WINCH 250t (main lifting gear winch)
FAULT 13 CONTROL BRAKE WINCH JIB.
FAULT 14 CONTROL BRAKE WINCH 35t (auxiliary lifting gear winch)
FAULT 15 OIL TEMPERATURE TOO HIGH
FAULT 16 HOSE RUPTURE
Should the crane have a fault, the corresponding lamp on the fault message card is
illuminated. After acknowledgement (press button) the lamp continues to illuminate
until the fault is cleared.
Monitoring, Failure, Troubleshooting and Elimination 37

38
5.7
10)
F a ilu re o f e le c tric
F a u lt P ro b a b le c a u s e R em edy
Figure 1:
Fault Search Diagram

E m e rg e n c y O ff p u s h b u tto n s in c o n tro l
E l. m o to r d o e s n o t s ta rt U n lo c k e m e rg e n c y o ff p u s h b u tto n s b y
c o n s o le a t a c c e s s o r in s w itc h c a b in e t o r
p u llin g o r tu rn in g .
c ra n e fo u n d a tio n a re a c tu a te d .
M a in s w itc h is c u t – o ff. S w itc h o n m a in s w itc h in e n e rg iz e ro o m
C h e c k o il le v e l. R e p le n is h if re q u ire d . If o il
Electrical fault
L a c k o f o il. S e e fa ilu re p u m p u n it le v e l is c o rre c t, th e a u x . c o n ta c to r m u s t

re s p o n d
Monitoring, Failure, Troubleshooting and Elimination
C h e c k a u to m . c irc u it b re a k e r lo c a te s h o rt
N o 2 3 0 V c o n tro l v o lta g e a v a ila b le .
c irc u it.
N o v o lta g e a t 4 4 0 /4 0 0 V c o n tro l
A s y m m e tric re la y h a s trip p e d , th e re d a n d C h e c k fu s e s . M e a s u re m a in fe e d e r.
g re e n L E D d o n o t lig h t.
T rip p in g d e v ic e h a s trip p e d o w in g to A m b ie n t te m p e ra tu re to o h ig h . C ra n e is
w in d in g te m p e ra tu re , L E D ’s a re a lig h t. p e rm a n e n tly o p e ra te d a t its lo a d p e a k .
C o o l d o w n e l. m o to r.
C o n tro l o f m a in fu s e s b lo w n . R e p la s e s fu s e s . In c a s e o f re p re a te d
d e fe c t lo o k fo r p o s s ib le s h o rt c irc u it in m a in
c a b le a n d s lip rin g u n it.

F a ilu re la m p in th e c o n tro l c o n s o l lig h ts u p . S e e in te rfre n c e p ilo t p rin t c a rd .
(s w itc h b o a rd )
E l. m o to r s ta rts in S ta r/ D e lta , b u t
S e e fa ilu re o f p u m p u n it.
s to p s a g a in im m e d ia te ly .
C h e c k th e h y d r. s y s te m (h y d r. h o s e
R e s e t – S w itc h is a c tu a te d . d a m a g e ) R e s e t – s w itc h s w itc h in g o ff.
Instruction Manual
C o n tro l lig h t 're a d y fo r o p e ra tio n '
T h e s w itc h fo r te s t o p e ra tio n is T h e s w itc h fo r te s t o p e ra tio n
a lig h t, b u t e l. m o to r d o e s n o t
s w itc h in g o n . s w itc h o ff.
s ta rt.
P o w e r L E D d o e s n o t lig h ts u p ,
o r R U N L E D fla s h e s . N o 2 4 V D C in p u t ; S P S – 4 d e fe c tiv e C h e c k 2 4 V D C in p u t ; c h a n g e S P S - 4
Instruction Manual
Figure 2: Fault of power pack
Fault Probable cause Remedy
Power pack start- up

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

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

switching off.
Repeat start procedure and watch LED's in

Gear oil cooler is no starting. switch cabinet for proper function of gear
Oil cooler. Check the motor circuit breaker.
39
40
10)
Failure of Lifting Gear (el.)
Figure 3:
Lifting winch does not turn. Current Regulator print card are not contacted. Input LED Memory-Programmable Control (MPC) do
not light up.
Check potentiometer on control lever, whether it is
Lifting gear fault (electr.)
maladjusted or defective.
Current Regulator print card are defective and/or the Check Current Regulator print card. Depending on
32 V AC power supply has failed. operation direction one LED must be alight, and the
ammeter must indicate.
Alternative set in and check Current Regulator print
Card into the other crane.
Input LED for the control lever do not light up. Check aux. contacts on control lever.
Crosspoint relay does not tighten up, brake do not

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

"Lifting" mode. Slack wire rope switch has switched. Input LED light Solenoid valve defective.
up. LED of the solenoid valve light up.

Check, whether over load system has turned off.
Find cause for overload (perhaps reduce load).
(if available).
Lifting winch turns only at Current Regulator print card are defective; one or
Check Current Regulator print card, the red current
half speed. both proportional solenoids on one lifting gear is/are
instrument must be alight. Depending on operation
defective.
direction one LED must be alight, and the ammeter
Instruction Manual
must indicate. Alternative set in and check Current
Regulator print Card into the other crane.
Check proportional solenoid valve.
Instruction Manual
Failure Lifting Gear

Figure 4:
Lifting winch does not lift; Pressure relief valve on one lifting
nominal load at half speed gear pump is defective or fouled. One
resp., but the brake remains pressure cut-off is maladjusted or This repair must only be carried out by an expert,
open. defective.
The lifting gear pumps, one pump

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

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

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

and take up nominal load Loosen safety catch of pressure
adjustment screw, Lift up the load and turn pressure
Load pressure switch maladjusted. adjustment screw clockwise until the nominal load can be
lifted properly from its suspended position. Rescue
pressure adjustment screw, It should now not be able to lift
nominal load + 5 per cent. The brake must close.
The lifting gear motor is still switched Check half-load solenoid for proper operation and fouling.
to half-load.
The lifting winch should be checked by an " expert”. Prior to

The two-speed valve on lifting winch
dismounting the lifting winch motor, if required, the load
motor jams.
should be lowered first.
41
42
10)
Failure of Lifting Gear
Figure 5:
Lifting winch does not turn. Defective or fouled brake solenoid valve. No
Brake does not vent. No control pressure.
power supply to solenoid valve.
Lifting gear pump is not contacted/does not

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

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

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

Hydraulic motor is defective. solenoids. The system pressure required must
be achieved, as the brake is closed.
Limit switches are jamming; supply line Check limit switch for proper working and
is defective resp. adjustment Check whether supply line is clear.

Lifting winch turns only in Check limit switches and readjust if required.
"Lifting" mode and for a short Slack wire rope switch or " Lowering" limit The 'Lowering` limit switch must be so adjusted
time; not in "Lowering" mode switch have switched/responded. that three safety wire rope turns remain on
resp. winch drum at lowest hook position.
Pump control solenoid "Lowering" is Actuate by hand the pump control solenoid and
defective, fouled or is not contacted/does check to assure maximum working condition.
not respond electrically. See list of el. failures.
Instruction Manual
The pressure relief valve on one lifting gear
The lifting winch does not hold Check pump pressure with the brake being
pump or packing are defective. Leak oil
the load with the brake being closed. In case of a pressure drop stop crane
portion too excessive i.w.o. lifting winch
open. operation and request Suppliers .Service.
motor.
Instruction Manual
Failure of Luffing Gear(el.)
Figure 6:
Current Regulator print Card does not Input LED (MPC) do not light up.
Topping winch does not turn
respond. Check potentiometer on control lever whether it
is maladjusted or defective.
Luffing gear fault (electr.)
The LED for "Topping Up" and/or Aux. contacts on control lever to be checked.
"Lowering" do not alight.
On the Capacity Regulating Card the Check Capacity Regulating Card.

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

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

not ventilate. Output LED do not light up. Check crosspoint relay and output LED of MPC
43
44
10)
Failure of Luffing Gear
Figure 7:
Foult Probable cause Remedy
Brake solenoid valve defective or fouled. Actuate

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

The luffing gear winch does not respond. Pump
Luffing gear fault
and check whether they are working correctly. Check

control solenoids are defective or fouled.
solenoids and clean, renew resp, if required.
Current Regulator print card is defective.

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

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

capacity regulating is activated. The crane jib has No fault; normal operation.
reached its creeping speed range.

Luffing gear winch does not keep Pressure relief valve "Topping Up" is defective or Check pump pressure at closed brake. In case of a
the crane jib, with the brake being packing is defective. Too large leak oil portion pressure drop the crane to be put out of order and
open. occurs in luffing gear winch motor.. request Supplier's service .
With load on the hook the luffing The spring in the pressure relief valve "Topping Up"
gear winch does not lift the crane is weak. The pressure cut-off on the pump is This repair should only be carried out by an expert.
jib very slowly resp. maladjusted. Control pressure too low.
Instruction Manual
Current Regulator print card maladjusted or
defective. Potentiometer on luffing gear control See List of el. failures.
lever is maladjusted.
Blank off pressure pipe lines and actuate pump control

Defective luffing gear pump; no or little pressure
solenoid valves by hand. In case of a pressure drop or
only available.
no pressure at all, the pump should be renewed.
Instruction Manual
Figure 8: Failure of Luffing Gear

Luffing gear fault
Luffing gear winch does

The crane jib has reached its maximum
not turn in direction of No fault; normal operation.

outreach at the individual load stages.
"lowering.
Lifting gear to be operated approx. 1 m

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

Luffing gear limit switch maladjusted or is
by no means to be bridged. For
jamming, wire rupture.
adjustment see el. Circuit Diagram.
Luffing gear pump does not respond. Power Check pump control solenoid valve
control p.c.b. defective. Potentiometer at Lowering" for easy working; exchange
luffing gear control lever defective. solenoid if required. See list of el.
failures.
Luffing gear winch stop at no Key-type switch "Put Down Jib" is defective or Check key-type switch and limit switch
maximum outreach. jams. Limit switch for jib 0° position is for correct working. Defective switches
defective must be renewed.
45
46
10)
Figure 9:
Failure of Slewing Gear (el.)
Check potentiometer on control lever, whether

Turning gear fault (electr.)
Crane does not slew Power control is not contacted.

maladjusted or defective.
Input LED does not light up. aux. contactors on control lever.
Slewing gear control part on Capacity

Regulating Card is maladjusted or Check Capacity Regulating Card. Defective card to
defective. be renewed

Check Current Regulator print card, the red current
instrument must be alight. Depending on operating
Current Regulator print card is defective or direction the red LED must light and the ammeter
the 32 V AC supply has failed. must indicate value.
Alternative set in and check Current Regulator print
into the other crane.
Instruction Manual
The brakes do not close with
"zero-position" of the control Contacts on the control lever do not open. Check contacts, perhaps exchange.
lever.
Instruction Manual
Figure 10: Failure of Slewing Gear
Crane does not slew, but pump Slewing gear brakes do not vent, no control Brake solenoid valve defective or fouled. Actuate solenoid by hand to check
pressure is available. pressure. whether it works freely. Clean or renew solenoid, if required.
Turning gear fault
Slewing gear pump is not contacted electrically.

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

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

defective. Potentiometer on slewing gear control See list of el. failures.
lever is maladjusted.
Slewing gear pump is defective; and does not Blank off pressure lines and actuate pump control solenoid valves manually.
produce any pressure or only little pressure. In case of a pressure drop or no pressure at all, renew pump.
47
Instruction Manual
48 Monitoring, Failure, Troubleshooting and Elimination

Instruction Manual
6 Maintenance and Repair

Before maintenance and repair
1. Take the crane out of operation
2. Switch the central power supply off with the master switch.
3. Lock the master switch and put up a warning sign prohibiting it being switched
on again.
4. Block the access to the crane´s working area and ensure that no unauthorised
persons are within the crane´s working area.
5. Ensure that suitable lifting gear and weight-carrying equipment is available for
replacing large crane parts
6. Replace all defective crane parts immediately.
7. Only use original NMF-parts.
Working on electrical equipment
Electrical equipment must be checked regularly: Loose connections must be made
secure, damaged wires or cables must be replaced immediately.
The switch cabinet and all electrical supply units must always be kept locked. Access
is only permitted for authorised persons with a key or a special tool.
Never clean electrical equipment with water or similar liquids.
Working on hydraulic installations and equipment:
Before starting work depressurise all hydraulic installations / installation parts.
During preventive servicing during work, the hoses pipes should always be replaced
- even if no damage is discernible.
Environmental protection
During all work on and with the crane, the regulations for waste avoidance and proper
waste disposal or recycling respectively must be observed.
In particular, when carrying out erection and servicing work and taking the crane out
of operation, ensure that substances which can contaminate ground water such as
grease, oil, coolants, solvent-based cleaning fluids, et c. are unable to contaminate
the environment.
These substances are to be collected, stored, transported and disposed of in suitable
receptacles.
After maintenance and repair
Before starting the crane, observe the following,
• Double-check all previously loosened screws in order to ensure that they are
tightly secured
• Check that all previously removed protective devices, covers, filters, pressure
switches and limit switches have been replaced correctly
• Make sure that all previously used tools, materials and other equipment have
been removed from the working area.
Maintenance and Repair 49

Instruction Manual
• Clean the working area and remove any spilled liquids or similar substances.
• Make sure that all of the crane´s safety devices are functioning properly again
• Check all of the functions and the limit switches for the individual load steps
without load.

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

Maintenance is deemed to be the regular inspection of and caring for the crane in
order to ensure a trouble-free operation
The maintenance intervals are stated in Table 1, Page 50 .
The lubricating schedule stipulates the maintenance schedule see Chapter 11,
Appendix, Page 125.
Interval Parts Work See page /

appendix
Prior to any operation or Crane visual inspection

after any sea journey check oil level
weekly Gear: (winch gear, turning check oil level Zollern gear,
gear, pump distribution Stiebel
gear)
Gear rim and pinions, greaing Rothe Erde
revolving bearing
every three months Crane cleaning
Crane rope greasing
every six months Slip ring assembly visual inspection
yearly Crane function and safety

inspection
Table 1: Maintenance Intervals

Instruction Manual
Interval Parts Work See page /

appendix
Prior to any operation or Crane visual inspection

after any sea journey check oil level
lamellar brakes Brake inspection

Hydraulic system testing of a hydraulic oil
sample
for the first time after 50 Hydraulic oil filter change filter Eppensteiner,
hours of operation gear oil filter Hydac
for the first time after Revolving bearing retighten the bolts with the Rothe Erde
100 hours of operation specified tightening torque
for the first time after Gear: (winch gear, turning oil change Zollern gear,
200 hours of operation, gear, pump distribution Stiebel
gear)
every 500 hours of Hydraulic oil filter change filter
operation gear oil filter
for the first time after Hydraulic system oil change

800 hours of operation,
every 1000 hours of Gear: (winch gear, turning oil change Zollern gear,
operation gear, pump distribution Stiebel
gear)
every 1500 hours of Hydraulic system oil change
operation
min. once a year Gear: (winch gear, turning oil change Zollern gear,
gear, pump distribution Stiebel
gear)
Hydraulic oil filter change filter Eppensteiner,
gear oil filter Hydac
Table 1: Maintenance Intervals
NOTE
Please also observe the subsupplier´s documents (see Chapter 11.2, Supplier
Documents, Page 127 ).

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

• Please check the tight fit of all screwed connections and leaks in the line system.
• Do not repair damaged pipes and hoses, replace them.
6.4.2 Greasing
Use the lubricants stipulated in Table 6.8, Page 81.
6.4.3 Gear
The Zollern planetary gear is provided with splash lubrication. The antifriction bearing
on the main drive pinion is filled with grease. As it is a lifetime lubrication it is not
necessary to renew or refill it.
6.4.4 Oil change
CAUTION
Only change the oil when
• the gear is at a standstill
• in a warm operating state.
1. Remove the ventilation filter

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

The used oil is of a dark, black colour
• This indicates that temperatures over 100 °C have occurred during operation. This
results in the oil ageing faster with a reduced lubricity.
• The oil change must be carried out at more frequent intervals.

Instruction Manual
The used oil has a cloudy colouring:

• It is possible that water penetration has taken place.
• Change the oil immediately flushing the gearbox out thoroughly several times with
new oil.
• It is recommended that the gearbox be disassembled and the parts examined for
corrosion.
Checking the oil level
Compare the amount of oil drained off with the stipulated amount of oil.
Checking for solid foreign matter
We recommend that a check be carried out for foreign matter in accordance with DIN
51592. The samples is dissovled in pure benzol. If necessary, it should be heated up
a little, this then be filtered through a benzol-resistnt, fine-pored membrane filter. The
rest is washed, dried, weighed and stated as an amount of solid foreign matter.
The maximum permissible weight of foreign matter is approx. 0.15 % of the total
weight of the oil in the gearbox. However, the foreign matter particles is only to consist
of fine abrasion up to max. 25 .
If the permitted value is not exceeded, the gearbox can continue to be used after the
oil change.
If coarse abrasion (above 25 my) or flakes of materials from the profiles of the gear
teeth are discovered, the gearbox must be disassembled, irrespective of the amount
of foreign matter. The profiles of the gear wheels, in particular the large sun wheel of
the output planetary gear set, should be subjected to a visual inspection
6.4.6 Pump distribution gear
Cleaning
• Clean the gear externally.
• Pay attention to leakage or loose screwed connections.
• Oil samples should be taken. Considerable signs of metal abrasion in the oil or on
the drain plug indicate increased wear or the occurrence of a fault and in such
cases the gear should be examined carefully.
Oil change
• When changing the oil for the first time, clean the gear with flushing oil.
• The air breather filter and the magnetic plug on the draing plug must be cleaned
each time the oil is changed.
6.4.7 Gear oil cooler filter
(See Chapter 11.2, Supplier Documents, Page 127).

Instruction Manual
Cleaning and changing the oil filter cartridge

1. Screw off the filter casing.
1. Take out the dirt collector vessel together with the cartridge.
2. The separate dirt sump is to be disposed of in the used oil container.
3. Pull the element out of the dirt collector vessel.
4. Clean the collector vessel.
CAUTION
Only clean wire gauze elements (type 25W) in cleaning fluid.
5. Insert a new cartridge with collector vessel into the filter casing.
6.4.8 Changing the hydraulic oil
We recommend that oil samples be examined by the oil supplier. The supplier then
provides you with information concerning the oil condition and suggests a date for the
oil change.
6.4.9 Changing the hydraulic oil filter
Indicator
The filters are equipped with an optical dirt indicator (see Chapter 11.2, Supplier
Documents, Page 127.
Changing filter elements.
Generally speaking, the element is to be changed when the dirt indicator is triggered
under normal operating conditions. If the dirt indicator is only triggered by a cold start,
the filter element need not be changed.
When taking the crane into operation, repairing, changing the oil, etc in the hydraulic
system, shorter change intervals are to be expected.
1. Switch the crane off.
2. Depressurise the filter.
CAUTION
If the filter is not depressurised prior to any work being carried out, this may
result in a sudden, violent evacuation resulting in a risk of injuries or material
damage.
3. Screw off the casing (2).

Instruction Manual
4. Dispose of the liquid in a suitable container. Do not reuse the liquid in the
system.
5. Remove the element (1).
6. Examine the surface of the elements for any remaining dirt and larger particles.
This may indicate damage caused to components.
7. Clean or replace the element (1) respectively.
CAUTION:
Only clean elements with wire gauze (W) and metal fleece (V). Elements
containing filter material such as BETAMICRONe-2 (BH/HC, BN/HC, BH and BN)
cannot be cleaned.
8. Clean the inside of the casing (2). Ensure that no dirt is deposited on the clean
side.
9. Examine the filter, in particular the sealing surfaces and threads for signs of
mechanical damage. If necessary, replace the parts.
10. Inspect the O-ring (6) on the casing (2). In case of damage replace the O-ring.
11. Wet the thread and sealing surfaces on the filter and the O-ring (7) of the
element (1) with a clean medium.
A non-depressurised filter and dirt particles in the screw-in thread of the casing
(2) can jam.
12. Check whether the designation of the new element corresponds with that of the
removed element.
NOTE
Replace disposable filter elements, soiled Betamicton‘N-2 (BN, BN/HC) or
Betamicron 9H-2 (BH, BH/HC) elements with new elements.
13. Mount the element on the centering pivot. Screw the casing (2) in as far as it
will go.
14. Check the seal for leakage.

Instruction Manual
Figure 1: Filter

Instruction Manual
6.4.10 BOTTOM HOOK BLOCK
1. MAINTENANCE
The inspection and lubrication intervals depend on the number of operating hours, the
conditions of use, the operating conditions and the user assessing the situation
correctly. The following guidelines are valid for normal use:
2. INSPECTION
Each of the bottom hook blocks are to be inspected at intervals of max. 1 year by a
specialist. The following must be inspected at regular intervals:
• Wear to the side plates, rope sheave surfaces, exes, bushes and bearings,
• Any deformations on the bottom hook block;
• Seating and play of the rope sheaves;
• Securing devices on nuts, bolts and other fixing elements,
• Corrosion
• Welding seams for cracks.
For repair work, the user or owner should contact NMF.
3. LUBRICATION
Grease specification: see List of lubricants, Page 81.
• Rope sheave bearing:
Roller bearing: Daily during continuous use or every 14 days with periodic use,
• Thrust bearing on the hooks:
Roller bearing: 14 days during continuous use or monthly with periodic use,
4. PERMISSIBLE LOAD
It is to be ensured that the permissible load, Save Working Load (SWL) or Working
Load Limit (WLL) stated on the bottom hook block are not exceeded.
5. Warning
• Do not pull diagonally.
• Apply load gradually without jerking.
• A double hook is not to be loaded from one side.
• Max. force applied to the rope lug = 1/3 SWL
• Do not carry out any welding work on bottom hook block parts.
• Keep your hands out of the way of the rope sheaves and other moving parts.
• In those areas in which loads are transported or in which loads are moved using a
bottom hook block, employees must where personal protective clothing.
also see Supplier Documents, Page 127.
6.4.11 Function and safety inspection
The function and safety inspection of the crane is to be carried out according to
guideline issued by the responsible classification society. If necessary, request that
the manufacturer send a specialist.

Instruction Manual
Carry out the following inspections:

1. Visual inspection of the steel structures for any damage
2. Inspect the main welding seams of the foundation and the crane for cracks.
3. Inspect the rope for wire ruptures.
4. Inspect the sheaves for damages, easy run and wear at the bottom of the
grooves.
5. Inspect the swivel of the load hook for easy turn.
6. Check the setting of the limit switch.
7. Check the nominal speed of the various functions when the crane is idling.
8. Test the system with nominal load.
9. Determination of the system pressures and comparison with the figures stated
in the circuit diagram, if necessary amend.
10. Pratise brake manoeuvres with all movements and activation of the
emergency-off switch. The brakes should apply immediately and the load
should be held perfectly.
11. If necessary, secure maladjusted relief valves, pressure switches, etc. , mark
their position with marking paint.
6.4.12 Lamellar brakes
The lamellar brakes are mounted as a compact unit between the propulsion motor and
the gear. They are laid out for two components:
• as a run-dry brake with a greater brake moment with the same springs and
lamellars.
• as a wet-run brake which achieve the required brake moment even when
subjected to oil.
6.4.13 Changing the lamellars
The lamellars have to be changed when subjected to wear. The wear makes itself
known when the brake moment is not longer achieved ( see Chapter 6.4.12, Lamellar
brakes, Page 58 ). The metallised lamellars are then worn down to the base of the oil
and dust separation grooves. As a result, the main drive pinion or the oil stick between
the lamellars, thereby reducing the brake moment. Fit the lamellars in the correct
sequence.

Instruction Manual
Figure 2: Lamellar brake

Instruction Manual
6.4.14 Gear cam limit switch
Each contact is co-ordinated by an adjustable pacl of cam discs consisting of the cam
discs (6) and (7). The cam disc packet and the selector shaft are held in the selector
shaft groove by means of a ring (2) and the tóothing of the disc.
The cam disc part (7) is infinitely adjustable in a radial direction by turning the self-
locking screw (8) in a ratio of 74 : 1. An extremely fine adjustment is possible with the
turn of a screwdriver.
In order to reach the screw (8) with a screwdriver, the nut (3) must be loosened
somewhat. The corresponding cam disc pack can then be radially adjusted without the
other cam disc packs being adjusted.
The cam diss (7) is designed in such a way that the effective path and an overrun path
are provided. No damage is caused by an exceeding of the overrun path but there is
once more an opening or closing of the contact.
(see Chapter 11.2, Supplier Documents, Page 127 ).
Adjustment of crane cam discs (see Chapter 6.6, Setting of the limit switches,
Page 71).
Figure 3: Cam disc

Instruction Manual
6.4.15 Slack rope switch gear
Adjustment of switch 2
1. Loosen the clamp bolt (1.1).
2. Lower the load hook onto the deck and run out some slack rope.
3. turn the cam disc 1 by 1 cm clearance past switch 2 until the red pilot lamp is
extinguished. Tighten clamp bolt 1.1
4. Repeat the lowering process.
The "lowering" lift gear must be perfectly deactivated when the load hook is
resting. No rope layers are to jump over each other.
Figure 4: Slack rope switch

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

Instruction Manual
6. Screw on the housing cover and check that it is tightly fitted.
6.4.17 Load measuring bolts
Figure 5: Load measuring bolts

Instruction Manual

Instruction Manual
6.5 Maintenance, service and discard criteria for wire rope
NOTE
Maintenance at regular intervals ensures a safe crane operation and
considerably increaes the rope lief. When exposed to the same test condition,
a well-greased rope has produced four times as many working cycles than an
ungreased rope.
6.5.1 Cleaning and greasing the wire rope
A crane rope is a moving and slightly twisting part, producing friction on the rope
sheaves and drums during operation.
1. Clean heavily soiled wire ropes with a brush. Should there be heavy soiling or
rope grease become resinous, clean the rope, rope pulleys and the rope drum
with a non-caustic cold cleaning agent and dry it afterwards.
2. Especially grease the rope at the bending zones (drums and pulleys) The
lubricants to be used are stipulated in Table 6.8, Page 81. The re-greasing
agents are to be the same as those used for the original greasing of the rope.
CAUTION
Ensure that 3 safety windings remain on the drum when the rope is unwound.
Grease the ropes again with a suitable lubricant and operate the crane for some
load cycles without load in order to distribute the lubricant properly.
If the lower layers on the drum are seldom used or not at all, they are to be unwound
and replaced under pre-tension. A rope works most economically if the complete
length is always used. Therefore, it is recommended that the appropriate rope length
be used fur crane operations lasting longer periods of time.
Should parts of a rope be unequally loaded, one can turn the rope around after a
certain operation period. The end which was formerly free is fixed in the drum, so that
the part of the rope which was nor formerly used is positioned in the zone previously
occupied by the part exposed to wear, the part exposed to wear now being positioned
where there is less wear, this then resulting a noticeably longer useful life.
if the wear mainly occurs in the multiple-layer coiling on the lebus drum, the rope life
can be increased by cutting a length corresponding to 1/3 of the drum circumference.
This can be repeated max. twice.
6.5.2 Monitoring
If necessary, the wire rope and the fastenings of the rope end should be inspected for
damage on a daily basis. Any irregularities discerned are to be reported to the
decision-making party.
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Instruction Manual
Wire ropes are to be inspected by trained specialists at regular intervals in order to

ascertain that they are in a safe operational condition. The inspection intervals are to
be so determined that damage can be detected at an early stage. Therefore, the
intervals during the first few weeks of a new wire rope being laid on and after the first
wire breaks are to be shorter than during the remaining laying on duration. After being
subjected to extraordinary loads or if there is a suspicion of non-visible damage, the
intervals are to be shortened accordingly. Such an inspection is also to be carried after
the crane is taken into operation after it has been at a standstill for longer periods and
after an accident otr damaging event which has occurred in connection with the use
of the rope drive.
During this monitoring, special attention is to be paid to those parts of the rope which
move over the rope pulleys or which are close to differential pulley, rope suspensions
or rope fastenings.
Crane ropes are so designed that should an initial wire brakage take place, there is
still sufficient room for a safe laying on.
The operational safety of the rope can be determined on the basis of this criteria
• type and number of wire breakages,
• position and temporal succession of the wire breakages,
• reduction of the rope diameter during the period of operation,
• Corrosion,
• Abrasion,
• Rope deformations,
• Heat effects,
• Lay-on duration
Special attention should be paid to changes in the rope behaviour which are just
discernible.
CAUTION
As soon as the rope lines strike together above the crane block, there is a risk
of serious rope damage. This twisting is always caused by an additional torsion
in the rotation-resistant hoisting rope originating from a number of adverse
effects but it may also be due to an overstitching of the hoisting rope during
heavy duty operation. The compensation of such a torsion requires extreme
care and profound know-how.
Untwisting of the crane pulley block with rotation-stable rope fixed point:
1. Set the pulley block down.
2. Determine the direction of twist.
3. Detach the rope at the fixed point.
4. Carefully turn the rope at the free end by approx. 180-360 degrees to
compensate the pulley block twist. If necessary, determine the direction of the
twist by means of a string.
5. Reattach the rope at the fixed point.
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6. Carefully lift the pulley block and operate the crane unloaded with a pulley
block and a crane trolley if one exists.
7. Repeat if necessary.
Ensure that the twist is distributed to a long free rope end. By operating the crane in
an unloaded condition, the twist is to be distributed along the entire rope length
CAUTION
Under no circumstances should a short length of rope be forcefully twisted; this
may permanently damage the rope structure.
If the hoisting rope was operated with an open swivel, an untwisting can be achieved
by operating the trolley several times under no load. If not successful, follow the same
procedure given for ropes with a fixed point, e. g. if no swivel exists or the rope is
already damaged or the reason for the twisting cannot be remedied otherwise.
The rope end connections and suspensions are also to be inspected in order to ensure
that they function correctly. The individual components of the rope drive unit, drums
and pulleys must turn freely in their bearings, grooves should not show any rope
marks.
6.5.3 Wire changing
To avoid readjustments of the limit switches, please follow this procedure when
changing a wire.
Please note that the life of a rope depends on many influences. The ropes are mainly
subjected to internal friction and corrosion. However, a rope is to be changed after 5-
6 years of service.
1. Put the crane in its resting position
2. Slightly pull the luffing and hoisting wire.
3. Count the reels on the hoisting / luffing drum.
4. Make a note of the number of reels.
5. Remove the limit switch from the drum and secure it. Do not touch the shaft of
the switch.
6. Now change the ropw.
7. When the new rope has been installed, count the reels. The number of reels
must agree with Pos. 4. Reinstall the limit switch.
8. For safety reasons, check the adjustments. Also refer to the assembly
instructions for the crane
6.5.4 Replacement state of wear
In the interest of safety in hoist operations, the wire rope must be replaced in good
time. On the basis of the criteria included in Chapter 6.5.2, Monitoring, Page 65, the
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Instruction Manual
following information stipulates when the wire cable is to be replaced depending on

the scope of the damage. A continued use can result in the operation of the hoist
posing a risk.
1. Type and number of wire breakages
Rope drives are so designed that the wire ropes are not durable. For this reason, wire
breakages occur during operation.
A wire rope is to be replaced if one of the number of visible wire breakages stipulated
in the table on page 3 are determined.
2. Position of the wire breakages
The wire rope is to be replaced upon occurrence of wire breakage clusters. The wire
rope is to be replaced immediately should a strand break.
Temporal sequence of the occurrence of wire breakages. In importance cases it may
be advisable to determine the number of wire breakages in relation to the time. From
this, a further increase in the number of wire breakages and the expected time of
replacement can be concluded.
In doing so, it should be taken into account that the initial wire breakages occur after
a certain operational period and subsequently increase at a faster rate.
3. Reduction of the rope diameter during the period of operation
The wire rope must be replaced if the rope diameter is reduced by structural changes
by 15% or more along longer lengths, when compared with the nominal size.
The requirement for this is that the tolerances of the new wire rope are also adhered
to in accordance with DIN 3055 - DIN 3070 even if the wire rope is not of a standard
design.
4. Corrosion
Corrosion especially occurs when subjected to a saltwater atmosphere, with operation
in a corrosive atmosphere and with wire ropes which are laid on outside for longer
periods. A corrosion of the external rope can be determined by examination. Corrosion
on wires which cannot be perceived from the outside is difficult to determine.
Corrosion can reduce both the static breaking force of the wire rope due to a reduction
of the metallic cable cross section and the operational capacity due to corrosion pit.
If the rope diameter is reduced by 10% or more when compared with the nominal size,
the wire rope is also to be replaced if no wire breakages are determined.
5. Abrasion
Abrasion on the rope wires as "internal abrasion" resulting in the movement of the
strands and wires against each other when bending the wire rope and as "external
abrasion" resulting from movements between the wire rope and the rope groove (e.g.
due to the wire rope slipping in the groove when starting and braking) or as a result of
the wire rope trailing along the floor or the items to be hoisted. Abrasion is encouraged
by insufficient or no lubrication and the effects of dust.
Abrasion can reduce both the static breaking force of the wire rope due to a reduction
of the metallic cable cross section and the operational capacity due to wear chamfer.
If the rope diameter is reduced by 10% or more when compared with the nominal size,
the wire rope is also to be replaced if no wire breakages are determined.
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6. Rope deformations
Deformation of the wire cable and visible changes in the rope bond. On the basis of
their appearance, differences are made between the following deformations:
Deformations in corkscrew form, contractions,
Basket formation, flattening,
Looping of wires, curl-shaped deformations,
Loosening of individual wires or strands, kinks and knots, buckling.
Deformations normally result in a loosening of the rope structure, at least close to the
deformation location. If the deformations are in a corkscrew form (see figure), the axis
of the non-loaded wire rope is helical.
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6.6 Setting of the limit switches
6.6.1 Lifting gear
Abbildung 6: Setting of the lifting gear limit switches
71
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6.6.2 Luffing gear
Abbildung 7: Setting of the luffing gear limit switches
72
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6.6.3 Auxiliary lifting gear
Abbildung 8: Setting of the switches for the auxiliary lifting gear
73
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74
Instruction Manual
6.7 How do I exchange a Memory-Programmable Control (MPC)?

Designation of the instruments
PS 4--201-MM1
EM 4-201-DX2
LE 4-116-DX1
LE 4-116-DX1
One of these instruments must be changed if 24 VDC is at the input but the input LED
is not illuminated
If an output LED is illuminated but no 24 VDC has been applied Check in advance
whether the power supply for the outputs are working
The PS4 is also to be replaced if the POWER LED is no longer illuminated but the
power supply has been applied
If the RUN LED flash, the PS4 or a EM4/LE4 could be defect.
Before replacing an instrument, disconnect the power supply.
PS4:
Disconnect wiring of the power supply (see Seite 77 Figure 1).
Open the cover of the input and output terminals (see Seite 77 Figure 2 Do not
disconnect the wiring
Pull the cover to disconnect the plug (see Seite 77 Figure 3)
After the new PS4 has been installed, the memory is to be inserted. (see Seite 77
Figure 5-6).
EM4:
Disconnect the wiring of the power supply lines(see Seite 78Figure 7
Open the cover of the input terminal(see Seite 78Figure 8). Do not disconnect the
wiring of the cable
Pull the cover to disconnect the plug (see Seite 78Figure 9) Open the cover in the
middle and relaese the data lines to the next LE (see Seite 78Figure 10 Now release
the plug of the data line of socket 1 (see Seite 78Figure 12). This data line connects
the PS4 with the EM4.
The EM4 can be removed from the top hat rail after all wires have been released.
Before the new EM4 can be switched on, all codification switches are to be adjusted
following the instructions given in the electric diagram (see Seite 78 Figure 13).
LE4:
Open the cover of the input or output terminals(see Seite 79Figure 14).
Do not disconnect the wiring
Pull the cover to disconnect the plug (see Seite 79Figure 15) Then open the cover in
the middle and release the data lines to the other LE4 (see Seite 79 Figure 16).
The instrument can now be removed from the top-hat rail.
Changing the battery.
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Instruction Manual
(see Seite 79Fig. 16)

Only change the battery when switched on as there could otherwise be a loss of data.
when changing the battery
Only disconnect the plug when switched on!
Caution:
Change the battery every year!!!
Prove that the battery has been changed with date and signature.
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Instruction Manual
Abbildung 9: Replace MPC1
77
Instruction Manual
Abbildung 10: Replace MPC 2
78
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Abbildung 11: Replace MPC 3
79
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Board crane type DK II 250012/100026 10)
6.8 List of lubricants
Neuenfelder Schmierstofftabelle für Schiffshilfsmaschinen

Maschinenfabrik GmbH
NMF 21129 Hamburg Table of Lubricant for Hull Auxiliaries
BEDINGUNGEN / CONDITIONS 2001
Außentemp. x)
Viskosität Hydraulikanlagen in:
Outdoor Pourpoint ELF BP Castrol Exxonmobil SHELL FAMM Füllmenge
Viscosity Hydr. Equipm. Installed in:
temp. Oil Quantity
Tief -20°C Bordkran/Deck Crane 1600 l
Low Lastdrehvorrichtung
l
Univis Rando oil Load Turning Devise
Visga Batram Hyspin N 46 Tellus oil HDZ 46 Spannwinde
l
46cST/40°C <-15° 46 HV46 AWH-M 46 Nuto T 46 HD46 Span winch
ISO VG 46 Vitam H 46 Rudermaschine
l
HF 46 Mohil DTE Steering Gear
Normal 45°C 15 M Sonstige hydr. Anlagen
l
Normal Other hydr. Drives
Tief -30°C Hubwindengetriebe 1
x )2x90,0 l
Low Cargo Winch Gear
Hangerwindengetriebe 1
x ) 27,0 l
Spartan Omala Topping Winch Gear
SEP HD Drehwerksgetriebe 1
x )4x24,0 l
Turning Gear
. Hilfswindengetriebe 1
x ) 15,0 l
220cST/40°C <-25° C Syntherma Enersyn Alphasyn Mobil Tivela Pinnacle Auxiliary Winch Gear
ISO VG 220 P 270 HTX T SHC 630 WB Marine Bootswindengetriebe l
220 GEL Boat Winch Gear
Kabeltrommelgetriebe l
Cable drum gear
Sonstige Getriebe l
Other Gears
Normal 45°C Pumpenverteilergetriebe 1
x ) 2x 7,5 l
Normal Pump Distribution Gear
Energrease Spheerol MobilTac Alvania Offene Zahnradgetriebe 20 kg
LS-EP2 SX2 375 NC EP2 OpenToothed Gearings
Cardrexa Eneregol Spheerol Mobilarma Novatex
DC1 WRL SX2 798 EP2 Seile
50 kg
Novatex Rope
FK10
EPEXA 2 Energrease Spheerol Mobil Grease Alvania
LS EPL2 XHP 222 G2 Lager(Fettschmierung)
20 kg
Mobilith Bearings (Grease Lubrication)
SHC 460
x) für einen Kran/for one crane Erzeugnis/Produkt Auftrag/Order NB/Hull No.

x1)Werksfüllung/filling in the factory 8958 325
R 09/01
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Board crane type DK II 250012/100026 10)
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7 Description of the hydraulic circuit
7.1 GENERAL ASPECTS

The crane drives work electro-hydraulically and in a closed circuit.
The electric motors [1.0] drive the reversible axial piston pumps [3.0-5.0] via a
distributor gear [1.1]. The pump unit [1] is flexibly supported and connected to the
consumers with high pressure hoses.
Each of the axial piston pumps is fitted with an integrated, externally lighting control
and feed pump [2.0].
The oil flow hoisting device of the axial piston pumps [3.0-5.0] are reversed by electro-
hydraulic proportional valves and current regulator print cards.
Both the complete systems and the individual functions are protected against
overload by means of pressure limitation valves.
In addition, a electro/hydraulic pressure switch is mounted in the pressure lines as a
pipe rupture protection. These pressure switches immediately interrupt the control
current by a pressure loss or line rupture, the E-motors [1.0] are immediately
deactivated.
The float type switch [2.5] in the hydraulic oil tank [2.8] also cuts off the system should
there be an oil loss.
This protects the pumps [3.0 -5.0] and [2.0] from running dry and avoids heavy
hydraulic oil losses.
7.2 STARTING THE PUMP UNIT

To this purpose, the selection switch must be positioned at "O".
The pump units 1A and 1B are started with the start button at the left control panel.
The start motor of unit 1A starts first, the gear oil cooler [1.2] is switched on from an
oil temperature of 20°C The way valve [2.2] is energized and interrupts the
pressureless circulation of the control and feed pressure for the control and feed
pumps [2.0], the fan flaps [2.7] open.. The E-motor of unit [1B] starts up after ca. 7-10.
When all of the pressure switches [3.4, 4.3, 5.4] in the system lines have been
actuated by feed pressure, the green pilot lamp is illuminated. If the E-motors [1.0]
stop and the red fault lamp does not illuminated, repeat the starting process.
7.2.1 START THE PUMP UNITS INDIVIDUALLY
The selection switch in the switch cabinet must be positioned at "1" or "2".
The individual functions only work at half speed. All limit switches activate somewhat
earlier due to the low speed.
During the crane operation, the heated hydraulic oil is fed to the hydraulic oil tank [2.8]
through the feed-out valves [3.5 and 4.5] at a rate of ca. 25 l/min. Cooled hydraulic oil
Description of the hydraulic circuit 83

Instruction Manual
is redelivered by the control and feed pumps [2.0 ] through the combined pressure
limitation valves with delivery valves [3.1-5.2].
The washed-down pressure oil from the pressure limitation valves [2.1] of the control
and feed pumps [2.0] is fed to the hydraulic oil tank [2.8] after being cooled by the oil-
air cooler [2.6]
7.3 HYDRAULIC OVERLOAD CUT-OFF

The complete hydraulic system is protected against overload with pressure limitation
valves.
7.3.1 LOAD STAGE SECURING
Load pressure switches for the individual load stages are installed in the lifting line of
the lifting gear:
Test load 275 t
Nominal load 250 t
Nominal load 100-150-200t
Nominal load 0-35t
Nominal load 35 t-200 t (lower)
Nominal load 35 t (auxiliary lifting gear)
These load pressure switches deactivate the activated function by overload but not the
pump units.
The lifting winch brakes fall in immediately, the lifting gear pumps swivel to the "0"
position.
The lifting and luffing gear are limited in the working area of the individual load stages
by limit switches. When the final position is reached, the corresponding function is
deactivated, the brakes fall in. However, a reverse operation is possible.
All limit switches only work concerning the triggering of the pumps, e.g. the electric
motors continue to run at a constant speed, whereby only the idling speed is applied.
When crane operations are recommenced, no current peaks are achieved due to the
centrifugal masses produced by the electric motor and the pumps together with the
smoothly operating hydraulics.
7.3.2 PRESSURE RESTORAGE
The pressure value transmitters [3.20], [4.20], [6.20] in the lifting line store the last
working pressure and only open the lifting gear brake by the next working process
when this is reached.

Instruction Manual
7.4 VENTING
The spring-loaded vent flap [2.7] is automatically hydraulically opened when the pump
units 1A and 1B are started.
Air and oil warmed during the crane operation to a temperature exceeding 40°C is
drawn-off through the open vent flap [2.7] by automatically starting oil-oil coolers [2.6].
7.5 HEATING / COOLING

Electrical heating elements are installed in the hydraulic oil tank [2.8] and the crane
housing.
The room heaters are controlled by thermostats and cut-off at an ambient temperature
of 20°.
A thermal feeler monitors the oil temperature.
The tank heater [2.4] is actuated when the oil temperature is below 20°. When the oil
temperature reaches 40°, the tank heater [2.4] is switched off and the oil-air coolers
[2.6] start.
At ca. 85°oil temperature, all of the controls are interrupted, no functions work. The
pump unit and the oil-air coolers 2.6 continue to run, the vent flaps [2.7] remain closed.
7.6 FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL

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

Instruction Manual

Instruction Manual
7.7 HOISTING GEAR
7.7.1 LIFTING OF THE NOMINAL LOAD 250T
In this load stage the lifting winch motors [3.8 A-D] are switched to Q max.
The electro-solenoid valves [3.15-3.18] are currentless.
They are held in this position with elasticity and the load pressure.
If the turning and luffing gear are moved at full speed when lifting the nominal load, a
power reduction card reduces the control current for the luffing, turning and lifting gear
pumps depending on the power input of the E-motors [1.0]. The speed of this function
is reduced. This results in the power input of the E-motors [1.0] being kept constant.
7.8 FUNCTIONAL DESCRIPTION OF THE INDIVIDUAL LOAD STAGES
7.8.1 GENERAL ASPECTS
The individual load stages are adjusted using the key switch at the right control panel
in the crane operator´s cabin, this activating the corresponding solenoid valves
simultaneously. Should a solenoid valve in a lifting gear motor receive current, this is
switched to Qmin, i.e. with a reduction of the absorption volume, the torque is reduced
and the hook speed is increased.
The maximum jib lengths are automatically set.
7.8.2 LIFTING THE 200T
The solenoid on the way valve [3.15] receives a current. The lifting gear motor [3.8A]
is switched to Q min
The solenoids on the way valves [3.15 and 3.16] receive voltage. The lifting winch
motors 3.8A and 3.8B are switched to Q min.
The solenoids on the way valves [3.15 and 3.16, 3.17] receive voltage. The lifting
winch motors [3.8A,3.8B and 3.8C] are switched to Q min.
The overload protection of these load stages is provided by the activated load
pressure switch [3.11, 3.12, 3.13]. The load pressure switch [3.14] is activated during
lowering.
When deactivating the overload, immediately position the control lever to "0" and then
select the load stage which corresponds to the load. Observe the jib length.

Instruction Manual
NOTE
Wait at least 5s before starting to move.
7.8.5 LIFTING THE 25 T
The solenoids on the way valves 3.15, 3.16, 3.17 receive voltage. The lifting winch
motors 3.8A,33.8B and 3.8C are switched to Q min.
The solenoid on the way valve 3.18 is actived with time delay.
7.8.6 AUTOMATIC STAGE
Switch position "Automatic"

The solenoid valves are switched in the automatic stage as with the 250t stage.
7.8.7 LIFTING THE 35T STAGE (AUXILIARY LIFTING GEAR)
Activate switch position "35t"

Proportional to the control lever deflection, the lifting gear pump swivels out of the "0"
position and commences with the pressure oil delivery. The solenoid valve [6.14] is
not activated. The angle of inclination of the swash plate is at max so that the motor
runs with the max. absorption volume Þ, max torque, Þ low winch speed.
7.8.8 OVERDRIVE
"Overdrive" switch activate right control lever.

The solenoid valve [6.14] is activated. The motor now runs load-dependent, i.e. 0-16t
small load, Þ small absorption volume, Þ small torque, Þ high winch speed.
250t A u to m a tic 200t 15t 10t 25t
3 .1 5
3 .1 6
3 .1 7
3 .1 8 z e ita b h ä n
Q m a x . V a lv e n o t
a c tiv a te d
Q m in . V a lv e a c -
tiv a te d

Instruction Manual
7.8.9 LUFFING GEAR
The adjustable luffing gear motor [4.8] si supplied with pressure oil via the luffing gear
pump [4.0].
7.8.10 "LUFFING UP"KEY SWITCH POSITION 25-100T
If the luffing gear control lever is deflected, the way valves [4.6] and [4.9] receive
current and the released control pressure opens the topping winch brake [4.7]. The
luffing gear motor is activated by the control oil of the lifting gear motor [4.8] to small
lifting volumes.
In this switching situation the hydraulic motor can be variably adjusted by the load
pressure via the servo piston. If the load pressure exceeds 240 bar (pre-adjusted at
the spring). the motor pivoting angle is increased resulting in an increased absorption
volume and in turn a pressure reduction.
7.8.11 "LUFFING UP"KEY SWITCH POSITION 150-250T
The way valve [4.9] is currentless.

The motor disk position is set at max. absorption volume, i.e. lower winch speed and
large torque.
In case of overburden, the pressure cut-off valve [4.1] is actuated at the luffing gear
pump [4.0]. The luffing gear pumps [4.0] are swivelled in the direction of "0" and only
deliver as much pressure oil as is necessary for the jib to retain its position. The
topping winch brakes [4.7] do not fall in.
7.8.12 "LUFFING DOWN"
The function of the luffing down is the same as with the luffing up. It is restricted by a
limit switch and the max. outreach position.
The max. jib length is limited by the individual load steps .
With the highest hook position all load steps "luffing down" is automatically activated.
"Lower" the lifting gear by ca. 1 m. "Luffing down" is then only possible up to the max.
length of the corresponding load step.
The excess pressure protection is provided with pressure limitation valves.
4.1 luffing up
4.2. Luffing down
7.9 TURNING GEAR

The turning gear is equipped with four turning gears. A turning gear motor is mounted
on each of the turning gears. All of the turning gear motors run simultaneously.

Instruction Manual
The turning gear motors [5.6] are supplied with pressure oil by the turning gear pumps
[5.0]
7.9.1 TURNING "RIGHT-LEFT"
When the turning control lever is shifted the way valve 5.5 is provided with voltage and
the turning gear brakes [5.7] open. When the control lever is returned to the neutral
position, the turning gear pumps [5.0] turns to the "0" position. Due to an electrical time
relay, the turning gear brakes [5.7] close slowly. This results in the crane slowing down
smoothly. By overburdening, this being a turning against the heel with load and a large
outreach, the pressure cut-off valve [5.1] at the turning gear pump [5.0] is triggered.
Shift the control lever into the "0" position and luff up the jib to reduce heel.

Instruction Manual
8 Lifting of brakes in case of emergency

Should there be a total power failure, the crane can be turned to its resting position
and the load be lowered if necessary
In order to do so, the corresponding brake must be lifted using the brake lifting hand
pump.
Open the corresponding bypass valve 3.1;3.2 / 4.1;4.2 / 5.1;5.2 of the hydraulic
pumps.
The working steps are described on the following pages.
Important Note:
Under no circumstances are the working lines A and B between the pump and the
winch motor to be disconnected or connected to each other as if the lamella brake is
opened using the brake lifting pump, the load is immediately dropped. Life is placed
at a risk and extensive material damage is caused. All stop valves are to be opened
with the exception of the oil drainage valve.
8.1 Lifting gear
8.1.1 Connect the hand pump for opening the brakes as follows.
1. Find the solenoid valve block (seeConnections for the solenoid valve block, Page
92 ) and the marking for the lifting gear brake.
2. Disconnect the brake hose 6 of the lifting gear brake (see Connections for the
solenoid valve block, Page 92 )to the solenoid valve.
3. Connect the hose 2 of the hand pump for lifting the brake to the brake hose 6.
4. Plug the connection Y to the solenoid valve of the lifting gear using a screwed
plug.
5. Connect the pressure release valve 5 to the hand pump for lifting the brake and
check the oil level in the pump tank (Brake lifting pump, Page 93)
6. Open the corresponsinf bypass valves 3.1:3.2 on the lifting gear hydraulic pump.
(seePressure limit valves at hoisting pump (Sauer), Page 94 ).
7. Carefully increase the pressure at the hand pump (max. brake opening pressure ca.
20 bar) until the winch drum starts to rotate slowly (max. 2-3 rpm). If the winch
drum rotates faster immediately open the pressure release valve 5 for the hand
brake lifting pump.
CAUTION:
If the hook is under load the jib already lowers the load at a braking air pressure
of 3-4 bar.
Lifting of brakes in case of emergency 91

Instruction Manual
Abbildung 1: Connections for the solenoid valve block

Instruction Manual
Abbildung 2: Brake lifting pump

Instruction Manual
Abbildung 3: Pressure limit valves at hoisting pump (Sauer)

Instruction Manual
8.2 Turning gear

Should there be a power failure, the crane can be turned as follows.
1. Find the solenoid valve block (seeConnections for the solenoid valve block, Page
92 ) and the marking for the turning gear brake.
2. Close the ball valve (1)
3. Remove the screwed plug (2)
4. Connect the hand pump hose to the screwed connection.
5. Loosen the turning gear motors on the turning gear (seeRemove the turning gear
motors, Page 95 ( Figure 1) .
Lift the motor out of the coupling (Figure 2), do not separate the hose.
6. Open the brake by activating the hand brake lifting pump (seeBrake lifting pump,
Page 93 ). Ensure that the pump pressure does not exceed 20 bar.
7. The brakes are now open, the turning gears are free.
The crane can be turned with the assistance of an external winch.
Abbildung 4: Remove the turning gear motors

Instruction Manual

Instruction Manual
9 Spare Parts
9.1 Ordering spare parts

Only use original NMF spare parts as these parts have been designed for the crane.
As far as parts from other sources are concerned, it cannot be guaranteed that they
are designed and manufactured so as to support the loads and meet safety
requirements.
The spare parts designations are our property and protected by copyright in
accordance with the legal provisions. The are only to be used and exploited in
accordance with our written approval, this especially being the case with regard to
tthird parties being granted access. Any objects manufactured from these
presentations are only to be photographed with our written approval. The prohibited
use or exploitation will be prosecuted under civil or penal law.
Spare Parts 97
Instruction Manual
9.1.1 List of Spare parts
Ersatzteilbestellanleitung/How to order spare parts

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

Drawing -No. Part Denomination Quantity
879-4900-01(0) 20 4/2 Wegeventil 1 Stück
4/2 Way solenoid valve 1 piece
P10P
Diese Darstellung(Zeichnung, Skizze, Fotografie, Plan ,Liste u.a.) ist unser Eigentum
und nach Maßgabe der gesetzlichen Bestimmungen urheberrechtlich geschützt. Sie darf
ohne unsere schriftliche Einwilligung weder benutzt noch verwertet, insbesondere nicht
Dritten zugänglich gemacht werden. Aufgrund dieser Darstellung hergestellte
Gegenstände dürfen ohne unsere schriftliche Einwilligung nicht fotografiert werden . Die
unbefugte Benutzung oder Verwertung hat zivil- und gegebenenfalls auch strafrechtliche
Folgen.
We have the proprietary right in this presentation (drawing, sketch, photo, plan,
statement etc.) which is copyrighted according to provision of law. Without written
consent it must neither be used or exploited nor made available to third parties. Photos
from the goods manufactured according to this presentation must not be taken without
our written consent. The unauthorised use or exploitation is liable to civil or - should the
case occur- penal prosecution.
98 Spare Parts
NMF
Reserveteilliste
Spare Parts List
Auftrags-Nr. Erzeugnis Typ Bauwerft Bau-Nr. Schiffsname Baujahr
Order-No. Product Type Ship yard Hull-No Name of ship Building Year
8958/59 Bordkran/Deckkran DK II Xingang Shipyard 325/326

Pos. Stück Zeichnungs-Nr. Teil Benennung Abmessung Ident-Nr.
Item. Piece Drawing-No. Part Denomination Dimension-Type Ident-No.
Handhebelfettpresse, best. aus Pos. 02 – 04
01 1
Manual grease gun, consists of Items. 02 – 04
PK 56
02 1 Grease gun 1250 FT 010
160 L 300 mm lg
03 1 Hose 1250 FT 011
04 1 Coupling 515G 1250 FT 007
Ø 63 0 – 60 bar
05 1 Pressure gauge 1680 MH 003
Verteiler: AV EK MA MV SV BE Seite/Page 99
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NMF
Reserveteilliste
Spare Parts List

Ø 63 0 – 400 bar
06 1 Pressure gauge 1680 MH005
DN 2/400 lg
07 2 Hose for gauge 1681 MN 202
In einem Kran montiert!

Fitted to one of crane
Manual pump for brackes

08 1 E 558 – 03(4) 1855 PH 310

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Spare Parts List

Ø 36
09 1 Wire rigging socks 1980 SL 001
010 10 Grease Shell Alvania G2 3000 FT 004
AM 10x1 Din 71412 MS

011 10
Tapered grease nippel
4DO1
Wegeventile
012 1 820-4900-13(1) 15 2600 VT 039
Way valve

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4DO2
Wegeventile
013 1 820-4900-13(1) 12 2600 VT 051
Way valve
691 – 000 – 12
O – Ring für 4D01

014 10
O-ring for 4D01
240 DO 20BN/HC
Filterelement
015 4 1262 FI 226
Filter element

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0160 MG 010 P
Filterelement
016 4 1262 FI 200
Filter element
8x2 DN 6
O – Ring für HD – Schlauch
017 2
O – ring for HP – hose
9x2 DN 6
018 2
13x2 DN 12
019 2

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17x2,5 DN 16
020 2
22x2,5 DN 20
021 2
27x2,5 DN 25
022 2
35x2,5 DN 32
023 2

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48x3 DN 40
024 2
33x3,53 SAE 1”
025 2
37,7x3,53 SAE 1 ¼”
026 2
G 8 – PS
Ermeto – Verschraubungen
027 2
Ermeto – fitting

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Spare Parts List

G 12 – PS
028 2
Ermeto – fitting
G 16 – PS
029 2
Ermeto – fitting
G 20 – PS
030 2
Ermeto – fitting
G 22 – PL
031 2
Ermeto – fitting

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G 25 – PS
032 2
Ermeto – fitting
G 30 – PS
033 2
Ermeto – fitting
G 38 – PS
034 2
Ermeto – fitting
G 42 – PS
035 2
Ermeto – fitting

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SAE 1 ¼ “ AFC 404
6000 PSI
SAE – Verschlußflansch
036 2 1343 FL 330
SAE – closed flange copanion
SAE 1 ¼ “ GFC 404

6000 PSI
SAE – Verschlußflansch
037 2 1343 FL 350
SAE – closed flange copanion
VK – 8
038 4
Ermeto – fitting
VK – 12
039 4
Ermeto – fitting

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VK – 16
040 4
Ermeto – fitting
VK – 20
041 4
Ermeto – fitting
VK – 22
042 4
Ermeto – fitting
VK – 25
043 4
Ermeto – fitting

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VK – 28
044 4
Ermeto – fitting
VK – 35
045 4
Ermeto – fitting
VK – 38
046 4
Ermeto – fitting

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VK – 42
047 4
Ermeto – fitting
G 35 – PL
048 4
Ermeto – fitting
G 28 – PL
049 2
Ermeto – fitting

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WFS 65/38-PS
Winkel SAE-
050 4
Flanschverschraubung
VK – 30
051 4
Ermeto – fitting
052 1 820-0900-15(0) Cargo runner ∅ 65mm ; 195m lg

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Hydraulikschlauch DN 8-2SN x 3000
053 1 820-490-15(1) 98
Hydraulik hose DKO/DKO 90°
054 Hydraulikschlauch DN 12-2SN x 6500
1 820-490-15(1) 75
Hydraulik hose DKO/DKO
1 820-490-15(1) 81
Hydraulik hose DKO/DKO 90°
1 820-490-15(1) 92
Hydraulik hose DKO/DKO
057 Hydraulikschlauch DN 25-4SH x 2300
1 820-490-15(1) 97
Hydraulik hose DKOS/SFS 90° 1”
Hydraulikschlauch DN 32-4SH x 1000
058 1 820-490-15(1) 124
Hydraulik hose DKOS/ SFS 1 ¼ ”
059 1 820-490-15(1) 110
Hydraulik hose DKOS/DKOS 90°
060 1 820-490-15(1) 116
Hydraulik hose DKOS/SFS 90° 1 ¼ ”
061 1 820-490-15(1) 108
Hydraulik hose DKOS/DKOS
Hydraulikschlauch DN 40-1SN x 3600
062 1 820-490-15(1) 132
Hydraulik hose DKOL/DKOL
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Störmeldekarte
063 1 1810PR018
Interferenc pilot print card
Stromregelkarte
064 1 1810 PR 017
Current regulator print card
PS4 – 201 – MM 1
Ersatzgerät
065 1 1170 ES 010
Spare appliance

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Spare Parts List

24V
Gleichrichter
066 1 1420 GR 001
Rectifier
Natriumdampflampe
067 1 1650 LE 900
Sodium lamp
5 kΩ
Potentiometer
068 1 1800 PT 008
Potentiometer
Kontakte
069 1 Satz/set 2364 SU 711
Contacts

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Kontakte
070 1 Satz/set 2364 SU 710
Contacts
BA 9s 30 V/2 W
Glühlampe
071 5 1055 BT 003
Bulb
Externe module, digital

072 1 1170 ES 006
LE4 – 116 – DX1
Externe module, digital

073 1 1170 ES 007
LE4 – 116 – XD1
Decentral module, digital

074 1 1170 ES 011
EM4 – 201 – DX2

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ECO-TRONIC; 0-400bar;0-10V
075 1 820-4900-13(1) 21 Pressure transmitter 1151 DK 500
Programmspeicher
076 1 1170 ES 012
EDV – memory

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Instruction Manual
10 Drawings
Abbildung 1: Pump unit
Drawings 119
Instruction Manual
Abbildung 2: Load Measuring Device
Abbildung 3: Emergency exit
120 Drawings
Instruction Manual
Abbildung 4: Switch cabinet switch
Drawings 121
Instruction Manual
Abbildung 5: Switch cabinet door
122 Drawings
Instruction Manual
Abbildung 6: Fault notification card
Drawings 123
Instruction Manual
Abbildung 7: Gear oil cooler
124 Drawings
Instruction Manual
11 Appendix
11.1 Drawings
Seq. Part Drawing No. 8958

No.
1 Lubrication schedule 820 -0500- 13(1)

2 Electric Wiring Diagram 824 -0700- 27(4)
3 Crane housing complete 820 -0800- 14(0)
4 Main compilation 820 -0900- 15(0)
5 Main compilation 820 -0900- 16(0)
6 Jib complete 820 -1500- 14(1)
7 Jib foot complete 820 -2100 12(2)
8 Rope sheave 800 -2400- 19(3)
9 Rope Sheave 800 -2400- 40(2)
10 Rope Sheave 800 -2400- 41(3)
11 Rope Sheave 800 -2400- 31(3)
12 Rope Sheave 800 -2400- 45(2)
13 Rope Sheave 800 -2400- 23(3)
14 Bottom hook block for auxiliary 800 -2500- 65(1)
lifting gear 40t
15 Anti-collission crane 2 820 -3900- 07(1)
16 Hydraulic circuit diagram 820 -4900- 15(1)
17 Pump unit 820 -5000- 17(1)
18 Hydraulic oil tank 820 -6100- 02(1)
19 Fan Flap 800 -7300- 03(2)
20 Slack rope switch 897 -8800 06(2)
21 Slack rope switch 897 -8800- 03(2)
22 Energy Supply 820 -9000- 15(1)
23 Tackle Plan for Crane 1
24 Tackle Plan for Crane 2
8958
25
26
Table 1: List of drawings
Appendix 125
Instruction Manual
126 Appendix
Instruction Manual
11.2 Supplier Documents
Seq Parts Type Manufacturer NMF-Item No.

.
No.
1 Adjustable axial piston pump 90R 130 Sauer

2 Adjustable axial piston pump 51V250-RF2N-E2A2 Sauer
A6VM 250EP Hydromatik
A6VM 200EP Hydromatik
3 Axial piston fixed F12-080 VOAC
displacement motor
4 Hoisting Gear Drive ZHP 4.36 04.29 10004 Zollern
5 Turning device drive ZHP 3.27 03.25 10192 Zollern
6 Topping Winch ZHP 4.32 04.29 10078 Zollern
7 Auxiliary hoisting winch ZHP 4.29 04.29 10638
8 Oil cooler T8 2000.002.0000 AKG
9 Gear oil cooler OKAF-R2S Hydac
10 Pump distribution gear i=0,605; 4387.01 Stiebel
11 Solenoid valve 4D01 Denison 2600VT039
12 Solenoid valve 4D02 Denison 2600VT051
13 Hydraulic system line filter LFBN/HC 240 Hydac 1262FI226
14 Gear oil cooler line filter 0160 MG 010 P Hydac 1262FI200
15 Gear Limit Switch Series 110 Stromag
16 Roller Revolving Joint 192.50.2586.000.41.1501 Rothe Erde
17 NMF Cabin Type SF with air SP Miller
conditioning system
18 Driving lever NMF 1210FH 102
19 Decender Device AG 10 K RK
Sicherheitstec
hnik
20 Bottom hook block complete 250t DE-HANN
Table 2: List of Supplier Documents
Appendix 127
Instruction Manual
128 Appendix

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Neuenfelder Maschinenfabrik GmbH

1 What is worth knowing about this operating manual 11

2 Description of the Crane 15

5 Monitoring, Failure, Troubleshooting and Elimination 35

6 Maintenance and Repair 49

6.4.12 Lamellar brakes 58

7 Description of the hydraulic circuit 83

7.9.1 TURNING "RIGHT-LEFT" 90

8 Lifting of brakes in case of emergency 91

Emergency exit 120

Terms and short cuts 12

1 What is worth knowing about this operating

1.2 The operator´s duty of care

What is worth knowing about this operating manual 11

1.3 Terms, short cuts and symbols

Terms / short cuts Meaning

NMF Neuenfelder Maschinenfabrik GmbH

Table 1: Terms and short cuts

12 What is worth knowing about this operating manual

1.4 Technical Amendments

What is worth knowing about this operating manual 13

14 What is worth knowing about this operating manual

2 Description of the Crane

2.1 Technical Data

Table 1: Technical Data

Description of the Crane 15

Nominal Voltage (U) 380 V / 50 Hz

Table 1: Technical Data

16 Description of the Crane

Abbildung 1: Overall view

Description of the Crane 17

2.3 General Aspects

2.4 Pump unit

2.5 Lifting gear

2.6 Luffing gear

2.7 Turning gear

2.8 Gear oil cooler

18 Description of the Crane

2.9 Hydraulic oil cooler

2.11 Slack rope switch

2.12 Gear limit switch

Description of the Crane 19

2.13 Slip ring assembly

2.14 Load measuring bolts

20 Description of the Crane

3.1 Use for the designed purpose

3.2 General safety instructions

3.3 Requirement of personnel

3.4 Symbols on the crane

3.5 Warning signals during the crane operation

3.6 Safety devices on the crane and their functional test

Hydraulic overload safety

3.7 Dangers and behaviour in case of danger

Danger from "residual" energy

4.1 Safety instructions

4.2 Requirement of personnel

4.3 Working range of the crane

Abbildung 1: Working range of the crane

4.4.1 Operator´s cabin

The crane operating elements are situated in the operator´s cabin.

Abbildung 2: Operator´s cabin

4.4.2 Control panels

The control levers are delicate and are to be actuated continuously.