NMF Crane

Neuenfelder Maschinenfabrik GmbH
Neuenfelder Fhrdeich
21129 Hamburg
Phone: 040 / 7451102
Fax: 040 / 74511867
e-mail: info@nmf-crane.de
Internet:www.nmf-crane.com
NMF
Instruction Manual
Board crane
Typ: DK II 120016/50033
Order-No.: 80211
Hull no. SF 0078
Year of Construction: 2006
Edition: 6. Mrz, 2007
Instruction Manual
Board crane type DK II NMF
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Table of contents
1 What is worth knowing about this operating manual
1.1......................Manufacturer ...................................................................................... 1
1.2......................The operators duty of care................................................................ 1
1.3......................Terms, short cuts and symbols .......................................................... 1
1.4......................Technical Amendments...................................................................... 2
1.5......................Guarantee .......................................................................................... 2
1.6......................Copyright............................................................................................ 3
1.7......................Hydraulic symbols .............................................................................. 1
1.7.1...............Pumps/ Hydro motors......................................................................... 1
1.7.2...............Cylinders ............................................................................................ 1
1.7.3...............Way valves......................................................................................... 2
1.7.4...............Triggering type for way valves............................................................ 3
1.7.5...............Throttling way valves.......................................................................... 4
1.7.6...............Pressure valves...................................................................................5
1.7.7...............Flow control valves............................................................................. 6
1.7.8...............Non-return valves............................................................................... 6
1.7.9...............Pipe connections................................................................................ 7
1.7.10............. Others ............................................................................................... 7
2 Safety
2.1......................Intended Use...................................................................................... 1
2.2......................General safety instructions................................................................. 1
2.3......................Personnel Requisites ......................................................................... 1
2.4......................Symbols on the crane......................................................................... 1
2.5......................Warning signals during the crane operation....................................... 1
2.6......................Safety devices on the crane and their functional test......................... 2
2.6.1...............Control lever....................................................................................... 2
2.6.2...............Pressure switch.................................................................................. 2
2.6.3...............Pressure sensor hoisting gear............................................................ 2
2.6.4...............Hydraulic overload safety....................................................................3
2.6.5...............Limit switch......................................................................................... 3
2.7......................Dangers and behaviour in case of danger ......................................... 3
2.7.1...............Danger from noise.............................................................................. 3
2.7.2...............Danger from residual energy: .......................................................... 4
2.7.3...............Behaviour in case of danger............................................................... 4
2.7.4...............Behaviour in critical situations............................................................ 4
2.7.5...............Emergency exit................................................................................... 4
Instruction Manual
NMF Board crane type DK II
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3 Description of the Crane
3.1...................... Technical Data.................................................................................... 1
3.2...................... Construction........................................................................................ 3
3.3...................... General Aspects ................................................................................. 4
3.4...................... Pump unit............................................................................................ 4
3.5...................... Hoisting gear....................................................................................... 4
3.6...................... Luffing gear......................................................................................... 4
3.7...................... Slewing gear....................................................................................... 4
3.8...................... Gear oil cooler .................................................................................... 4
3.9...................... Hydraulic oil cooler ............................................................................. 5
3.10.................... Heating............................................................................................... 5
3.11.................... Slack rope switch................................................................................ 5
3.12.................... Gear limit switch................................................................................. 5
3.13.................... Slip ring transmitter............................................................................. 6
3.14.................... Air conditioner..................................................................................... 6
3.15.................... Functional description of hydraulics.................................................... 7
3.15.1............ General Aspects ................................................................................. 7
3.15.2............ Starting the pump unit......................................................................... 7
3.15.4............ Hydraulic Overload Disconnection...................................................... 8
3.15.5............ Pressure value transmitters................................................................ 8
3.15.6............ Ventilation........................................................................................... 8
3.15.7............ Heating / Cooling................................................................................ 9
3.15.8............ Function of the electro-hydraulic control............................................. 9
3.16.................... Lifting gear........................................................................................ 11
3.16.1............ Hoisting the nominal load 120t ......................................................... 11
3.17.................... Functional description of the individual load stages ......................... 11
3.17.1............ General information.......................................................................... 11
3.17.2............ Hoisting 95t....................................................................................... 11
3.17.3............ Hoisting 75t....................................................................................... 11
3.17.4............ Hoisting 55t....................................................................................... 11
3.17.5............ Hoisting 38t....................................................................................... 11
3.17.6............ Hydraulic overload safety................................................................. 12
3.18.................... Luffing gear....................................................................................... 14
3.18.1............ Luffing up key switch position 0-55t ............................................... 14
3.18.2............ Luffing up key switch position 95-120t ........................................... 14
3.18.3............ Luffing down................................................................................... 14
3.19.................... Slewing gear.................................................................................... 15
3.19.1............ Slewing RIGHT-LEFT..................................................................... 15
3.20.................... Electrical Equipment......................................................................... 17
3.20.1............ Electronic regulator print card........................................................... 17
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3.20.2.............Fault notification card........................................................................20
3.20.3.............Switches in the switch board.............................................................21
3.20.4.............Load measuring unit / Loadmaster (DMSA)..................................... 23
3.20.5.............Setting instructions........................................................................... 24
3.20.6............. .......................Load-measuring pin change / correction adjustment 24
3.20.7.............Test operation.................................................................................. 27
3.21....................PS4-200 Compact PLC.................................................................... 29
3.21.1.............Setup................................................................................................ 29
3.21.2.............Elements .......................................................................................... 29
3.21.3.............Setting the bus terminating resistors................................................ 31
3.21.4.............Operating states of the PLC............................................................. 32
3.21.5.............Testing/Commissioning/Diagnostics .................................................34
4 Operation
4.1......................Safety instructions.............................................................................. 1
4.2......................Requirement of personnel .................................................................. 1
4.3......................Working range of the crane................................................................ 2
4.4......................Operation............................................................................................ 3
4.4.1...............Operators cabin................................................................................. 3
4.4.2...............Control panels .................................................................................... 4
4.5......................Before starting.................................................................................... 6
4.5.1...............Before every start............................................................................... 6
4.5.2...............Switching on....................................................................................... 6
4.5.3...............During operation................................................................................. 7
4.5.4...............Switch on main lifting gear ................................................................. 7
4.5.5...............Switch off............................................................................................ 7
4.5.6...............Emergency shutdown of the crane..................................................... 8
5 Maintenance and Repair
5.1......................Safety instructions.............................................................................. 1
5.1.1...............Before maintenance and repair.......................................................... 1
5.1.2...............Working on electrical equipment........................................................ 1
5.1.3...............Working on hydraulic installations and equipment: ............................ 1
5.1.4...............Environmental protection.................................................................... 1
5.1.5...............After maintenance and repair..............................................................2
5.1.6...............Requirement of personnel .................................................................. 2
5.1.7...............Function and safety inspection........................................................... 2
5.2......................Maintenance schedule ....................................................................... 4
5.3......................Lubrication schedule .......................................................................... 8
5.4......................Lubricating Chart................................................................................ 9
5.4.1...............Symbols.............................................................................................. 9
5.4.2...............Lubrication diagram...........................................................................10
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5.5...................... Illustrations of the lubrication points.................................................. 11
5.5.1.............. Door hinges grease points.................................................................12
5.5.2.............. E-motor..............................................................................................13
5.5.3.............. Slewing bearing teeth....................................................................... 13
5.5.4.............. Wire sheave jib..................................................................................14
5.5.5.............. Wire sheave crane house................................................................. 14
5.5.6.............. Bottom hook block............................................................................ 15
5.5.7.............. Slewing gear......................................................................................16
5.5.8.............. Winch.................................................................................................17
5.6.1.............. Cleaning the crane............................................................................ 18
5.6.2.............. Greasing........................................................................................... 18
5.6.3.............. Gear.................................................................................................. 18
5.6.4.............. Oil change......................................................................................... 18
5.6.5.............. Gear box inspection.......................................................................... 18
5.6.6.............. Pump distribution gear...................................................................... 19
5.6.7.............. Filter.................................................................................................. 20
5.6.8.............. Bottom hook block............................................................................ 22
5.6.9.............. Slew ring gear....................................................................................24
5.6.10............ Slip ring assembly..............................................................................27
5.6.11............ Load measuring bolts ....................................................................... 28
5.6.12............ Slack rope switch gear.......................................................................29
5.7...................... Maintenance, service and discard criteria for wire rope ................... 31
5.7.1.............. Cleaning and greasing the wire rope................................................ 31
5.7.2.............. Monitoring..........................................................................................32
5.7.3.............. Wire changing................................................................................... 33
5.7.4.............. Replacement state of wear................................................................34
6 Monitoring, Failure, Troubleshooting and Elimination
6.1...................... Safety instructions .............................................................................. 1
6.2...................... Requirement of personnel .................................................................. 1
6.3...................... Monitoring, failure, troubleshooting and elimination........................... 1
6.4...................... Brake relay monitoring........................................................................ 1
6.5...................... Speed monitoring of the jib winch and lifting gear winch.................... 2
6.6...................... Fault notification card.......................................................................... 2
6.6.1.............. TEST OPERATION switch............................................................... 2
6.6.2.............. TEST LOAD 132t switch...................................................................3
6.6.3.............. RESET button.................................................................................. 3
6.6.4.............. Switch Bridge Limit Switch Lifting gear............................................ 3
6.7...................... Diagram Overload............................................................................... 4
6.8...................... Fault Search Diagram......................................................................... 5
6.9...................... Brake ................................................................................................ 15
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6.9.1...............Description ....................................................................................... 15
6.9.2...............Connections ..................................................................................... 15
6.9.3...............Pressure media................................................................................ 17
6.9.4...............Operation.......................................................................................... 17
6.9.5...............Manual emergency release.............................................................. 17
6.9.6...............Brake maintenance .......................................................................... 17
6.9.7...............Dismounting and assembly.............................................................. 17
6.9.8............... Malfunctions .....................................................................................19
6.10....................Lifting of brakes in case of emergency............................................. 20
6.11....................Lifting gear........................................................................................ 21
6.11.1.............Connect the hand pump for opening the brakes as follows. ............ 21
6.12....................J ib..................................................................................................... 22
6.13....................Slewing gear..................................................................................... 23
6.14....................Gear cam limit switch....................................................................... 27
6.14.1.............Maintenance..................................................................................... 27
6.14.2.............Contact adjustment .......................................................................... 27
6.14.3.............Home position : ................................................................................ 28
6.14.4.............Perform the following work............................................................... 28
6.15....................How do I exchange a Memory-Programmable Control (MPC)?....... 33
6.15.1.............Changing the battery. ........................................................................34
7 Spare Parts
7.1......................Ordering spare parts .......................................................................... 1
7.1.1...............How to order spare parts.................................................................... 2
8 Figures
9 Spare Parts Catalog
10 Drawings
Instruction Manual
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Instruction manual
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Table of figures
1...................................Overall view..................................................................................3
2...................................Hydraulic overload safety.............................................................13
3...................................4-Channel current regulator print card..........................................17
4...................................Fault notification card...................................................................20
5...................................Switches........................................................................................22
6...................................Loadmaster....................................................................................25
7...................................Indication-Display.........................................................................26
8...................................Throttle graphic.............................................................................28
9...................................Bus terminating resistors active....................................................31
10.................................Working range of the crane...........................................................2
11.................................Operators cabin............................................................................3
12.................................Control panel left...........................................................................4
13.................................Control panel right........................................................................5
14.................................skylight grease points....................................................................12
15.................................Grease point e-motor.....................................................................13
16.................................lubrication gear rim/pinion............................................................13
17.................................Grease point jib head.....................................................................14
18.................................Grease point crane house...............................................................14
19.................................Grease point bottom hook block...................................................15
20.................................oil filling slewing gear...................................................................16
21.................................oil filling hoisting gear..................................................................17
22.................................Filter..............................................................................................22
23.................................Load measuring bolts....................................................................28
24.................................Electrical fault...............................................................................5
25.................................Pump unit fault..............................................................................6
26.................................Lifting gear fault (electr.)..............................................................7
27.................................Lifting gear fault............................................................................8
28.................................Lifting gear fault............................................................................9
29.................................Luffing gear fault (electr.).............................................................10
30.................................Luffing gear fault..........................................................................11
31.................................Luffing gear fault..........................................................................12
32.................................Slewing gear fault (electr.)............................................................13
33.................................Slewing gear fault..........................................................................14
34.................................Structure parts of brake.................................................................15
35.................................Lamellar brake...............................................................................16
36................................. .......................................................................................................18
37.................................Connections for the solenoid valve block.....................................24
38.................................Brake lifting pump........................................................................25
39.................................Pressure limit valves at the pump (Sauer).....................................26
40.................................Gear cam limit switch...................................................................27
41.................................Limit switch adjustment hoisting gear..........................................30
42.................................Limit switch adjustment luffing gear............................................31
43.................................limit switch adjustment jib............................................................32
44.................................Pump unit......................................................................................1
45.................................Pressure Switch/solenoid valve.....................................................2
46.................................Load Measuring Device................................................................3
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NMF Board crane type DK II 120016/55033
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47................................ Emergency exit............................................................................. 4
48................................ Switch cabinet switch................................................................... 5
49................................ Switch cabinet door....................................................................... 6
50................................ Fault notification card/current regular print card.......................... 7
51................................ Gear oil cooler............................................................................... 8
52................................ Slewing gear.................................................................................. 9
Copyright 2005 What is worth knowing about this operating manual 1
Instruction manual
Board Crane type DK II 120016/55033 NMF
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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 Fhrdeich 120
21129 Hamburg
Germany
You can contact us under
Telephone 040 / 74511-02
Fax 040 / 74511-867
e-mail: info@nmf-crane.de
1.2 The operators duty of care
The operator must ensure that:
the crane is only to be used in accordance with the designed purpose (see item 2.1,
page 1).
the crane is only used in a fault-free, operational condition,
the safety devices are regularly checked in order to ensure that they function as stipu-
lated,
personal protective clothing and equipment is provided for the operating, maintenance
and repair personnel and that this is worn or used,
the instruction manual is always complete and legible and situated at the cranes loca-
tion,
only sufficiently qualified and authorised personnel operate, maintain and repair the
crane,
this personnel is regularly instructed in all pertinent aspects of works safety and environ-
mental protection and are familiar with the instruction manual and in particular the safety
instructions enclosed in it,
all safety and warning instructions on the crane are legible and are not removed.
Operating instructions in the sense of industrial safety legislation and regulations for the use
of the work materials are also to be provided.
1.3 Terms, short cuts and symbols
The terms used in the instruction manual are explained in (see table 1, page 1).
Terms / short cuts Meaning
NMF Neuenfelder Maschinenfabrik GmbH
Operator Company or person responsible for using the crane
Table 1: Terms and short cuts
Instruction manual
NMF Board Crane type DK II 120016/55033
2 What is worth knowing about this operating manual Copyright 2005
Together with the text in the safety instructions, the safety symbols draw attention to rest
hazards when handling the crane. These rest hazards are related to
People
the crane
other objects and items
the environment
The safety symbols included in (see table 2, page 2) are used in this instruction manual
A safety symbol can never replace the text in a safety instruction. For this reason, always
completely read the text of a safety instruction.
1.4 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,
Symbols Explanation
NOTE
Information which is important for operating the product
CAUTION
Hazards which can result in the device and / or other plant compo-
nents suffering damage, but which do not pose a threat to life and
limb
DANGER
Hazards which pose a threat to life and limb or additional hazards
which can result in the device and / or other plant components suf-
fering damage
Table 2: Symbols

Copyright 2005 What is worth knowing about this operating manual 3
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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 (see item 3.1, page 1) are exceeded or not reached,
the product is improperly handled.
1.6 Copyright
The copyright in this instruction manual and the drawings remains with Neuenfelder
Maschinenfabrik GmbH. The instruction manual and the drawings are only to be used for
the purpose it was transferred to the recipient. The documents are no to be handed over or
disclosed to third parties without our express consent in writing. Any reproduction (including
details) is prohibited. Any contraventions will be subjected to prosecution.
Instruction manual
4 What is worth knowing about this operating manual Copyright 2005
1
Instruction manual
Board Crane Type DK II 120016/55033 NMF
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1.7 Hydraulic symbols
1.7.1 Pumps/ Hydro motors
1.7.2 Cylinders
Pumps
-with one direction of flow
Pumps
-with two directions of flow
Hydraulic motor
-with one direction of flow
Hydraulic motor
-with two directions of flow
Cylinder
-single-acting
-single-acting with spring return
Instruction manual
NMF Board Crane Type DK II 120016/55033
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1.7.3 Way valves
Way valves are valves with different flow paths.
They are characterized through:
-Number of switching positions; representation by an
appropriate number of quadrants,
Marking through 0, a, b
-Number of the connections and
linkages within the switching positions;
representation through lines and arrows
Marking of the connections by letters
(at the basic position 0)
P pump, pressure
T tank, return
A, B user
X, Y, Z control line
L leak oil,
Description e.g.
4/3 way valve

number of the switching positions
number of connection
3
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1.7.4 Triggering type for way valves
directly working
Reel/tappet
hand lever
with spring return
electromagnetic triggering
with spring centring
electromagnetic triggering
with spring return
hydraulically triggering
with spring return
servo-controlled
simplified
-hydraulically operated
electro magnetically controlled
-larger way valve are operated
hydraulically by a pilot valve.
the pilot valve operated electrically
In this valve both triggering are in one,
on the side directly and
the other side
Description:
3/4 way-valve, constantly variable
working
servo-controlled,
detailed

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1.7.5 Throttling way valves
Throttling way valves (servo valve);
Way valve with stepples transition
between the switching positions during
variable throttle effect.
Representation by parallel line over
the entire length
Hydraulically controlled
proportional-way valve
electro-hydraulically controlled
proportional-way valve
5
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1.7.6 Pressure valves
-Pressure relief valve
direct acting
normally closed,
opens with reaching adjusted
inlet pressure
-Pressure relief valve
pilot operated
Control oil outlet intra
-Pressure reducing valve
direct acting
-Pressure regulating valve or
Pressure regulator
normally opened, closes with reaching
adjusted outlet pressure
pilot operated sequence valve,
a hydraulic connection switches
with reaching the adjusted pressure
-Pressure switch
an electric contact switches with
reached the adjusted pressure
-Pressure emitter
an electric contact switches with
reaching the adjusted pressure
to the PLC
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6
1.7.7 Flow control valves
1.7.8 Non-return valves

-Throttle
firm resp. adjustable
-aperture
short throttle way
-non-return valve
with recoil spring
-non-return valve
with adjustable throttle
-shuttle valve
7
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1.7.9 Pipe connections
1.7.10 Others
-Main pipe
-Control and leak oil pipe
-Flexible hoses
-Pipe connection
-Crossed lines without connection
Filter
Heating
Cooler
Manometer
Instruction manual
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Safety 1
korr So/ho2007
Instruction manual
Board Crane Type: DK II 120016/55033 NMF
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2 Safety
2.1 Intended Use
The board crane type Dk II is designed to be used as a loading device for the loading and
unloading of small consignments and containers of ships.
2.2 General safety instructions
The products designed and constructed by the Neuenfelder Maschinenfabrik GmbH take
the following factors into account: a risk analysis, a careful selection of the harmonised
standards that are to be complied with, as well as further technical specifications. They,
therefore, reflect the 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 are taken. It is, there-
fore, a part of the crane operators duty of care to plan these measures and ensure that they
are correctly executed (see item 1.2, page 1).
2.3 Personnel Requisites
The personnel operating the crane must
be trained, instructed and authorised,
be familiar with the instruction manual and act in accordance with it,
confirm with their signature that they have understood the instruction manual.
Furthermore, the personnel must be especially instructed in and know the following activi-
ties:
Emergency shutdown of the crane (see item 4.5.6, page 8),
Escape hatch and escape of the operators cabin via a ladder or a descending device
(see item 2.7.5, page 4),
Emergency lowering of the load and the jib (see item 6.10, page 20),
Behaviour in critical situations, e. g. heeling and trimming (see item 2.7.4, page 4).
The operating personnels particular areas of authority must be clearly defined.
2.4 Symbols on the crane
Always keep all safety and operating instruction signs on the crane in a legible state. Imme-
diately replace any damaged or illegible signs.
2.5 Warning signals during the crane operation
Acoustic warning signals
Horn
Optical warning signals
Warning lamps on the left control panel
Instruction manual
NMF Board Crane Type: DK II 120016/55033
2 Safety
2.6 Safety devices on the crane and their functional test
2.6.1 Control lever
The control levers are spring loaded and automatically return to the neutral position when
released. The brakes for hoisting, luffing and slewing gears are spring loaded and generally
closed. They are only opened with a time-delay when the corresponding control lever is
shifted.
The brakes close automatically
if the control levers are at the neutral position,
if there is a pressure loss in the system (in this case, the pump unit is immediately
switched off),
during a power failure
in case there is an overload
when the limits of the outreach are reached in the individual load levels,
when the slack rope in the hoisting gear is set at lower.
2.6.2 Pressure switch
A pressure switch for monitoring the charge pressure is installed in each of the high-pres-
sure lines.
3.4 lower
4.4 luffing down
5.4 slewing
In the case there is a pressure loss, this pressure switch turns the pump unit off immediately.
A float switch in the hydraulic oil tank also switches the pump unit off if there is insufficient
oil. The pumps are then protected against running dry.
If the crane switches off because a pressure switch opens or a gear oil cooler fails:
the crane operator is unable to restart the crane.
It is possible that a hose has burst.
Before restarting, visually inspect the hydraulic system. If you do not find any defects,
press the Reset button in the switch cabinet.
Then restart the crane.
2.6.3 Pressure sensor hoisting gear
The pressure sensor [3.15] in the hoisting line registers the last working pressure.
In the following working operation, the sensor will only open the hoisting winch brake when
this registered pressure is achieved again.
Safety 3
korr So/ho2007
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2.6.4 Hydraulic overload safety
The complete hydraulic oil system is protected against excess pressure by pressure limita-
tion valves. A load pressure switch is fitted in the hoisting gears hoisting pipe.
[3.10] test load 132t
[3.11] nominal load 120t
[3.12] nominal load 38-55-75-95t
[3.14] 0-120t lower
In case of overload
Nominal load: Stop Hoisting gear hoist, luffing up, luffing down
It is only possible to lower.
Over speed: Stop: Hoisting gear hoist, luffing up, luffing down;
only lowering is possible, but the change over valves become current-free,
Hoisting gear works in full load level.
the load pressure switch cuts off the activated function,
the pump unit continues to run,
the hoisting winch brake is applied immediately,
the hoisting gear pump 3.0 returns to the 0 position,
the magnetic valve [14] becomes current-free,
When moving the control lever, the hoisting gear immediately rotates to the max. dis-
placement, max. torque.
2.6.5 Limit switch
Limit switches limit the hoisting and luffing gears in the operating ranges of the individual
load levels (see item 6.14, page 27). When this final position is reached, the corresponding
function is deactivated and the brakes are applied. A reverse operation is possible, though.
All limit switches only have an affect on the triggering of the pumps, i.e. the electric motor
continues to run at a constant speed although only the idling speed has been applied.
When crane operations are re-commenced, no current peaks are triggered as a result of the
centrifugal masses produced by the electric motor and the smoothly operating hydraulics.
2.7 Dangers and behaviour in case of danger
2.7.1 Danger from noise
Depending on the local conditions, higher sound levels can occur outside the crane opera-
tors cabin which can result in deafness, a loss of balance or reduced alertness.
Always use the personal protective equipment and clothing.
Please note that when the crane is operating, oral communication and the discernment of
acoustic signals e.g. warning signals etc. are impaired.
Instruction manual
NMF Board Crane Type: DK II 120016/55033
4 Safety
2.7.2 Danger from residual energy :
Please note that various forms of energy can still exist after the crane has been switched off
or is at a standstill - such as:
when jibs or loads are raised
in hydraulic pressure lines
in live power lines
Please advise the personnel accordingly during instruction.
2.7.3 Behaviour in case of danger
In case of danger, press the emergency stop button immediately, (see item 4.4.2, page 4).
In case of fire, immediately switch off the crane using the main switch.
Follow special procedures when fighting a fire with:
working materials (hydraulic oil, lubricants),
electric lines
2.7.4 Behaviour in critical situations
Critical situations arise when the heel exceeds 3.
Optical and acoustic signals warn that this critical range has been entered.
Take the following action:
luff the jib up
following the shortest path, turn the crane to the centre of the ship.
place the load on the ground.
determine the cause of the heavy heeling.
2.7.5 Emergency exit
In case of an emergency, leave the crane through the emergency exit in the crane opera-
tors cabin.
using an external ladder mounted on the side of the crane (if present)
or using the emergency rope-down device in the crane operators cabin (see Kapitel 9,
Seite 1, )
Copyright 2005 Description of the Crane 1
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3 Description of the Crane
3.1 Technical Data
The board crane DK II 120014/90018,6/55030 is a loading device. The technical data are com-
piled in (see table 3, page 1).
Feature Value
Crane
Crane type DK II
Capacity (SWL) 120 t
Length of jib
SWL 120t
SWL 95t
SWL 75t
SWL 55t
SWL 38t
4,0 - 16,0m
4,0 - 19,0m
4,0 - 24,0m
3,3 - 33,0m
3,3 - 33,0m
Lifting height approx. 46m
Luffing
SWL 0-38t at 3,3m - 33,0m -
SWL 0-120t at 4,0m - 16m
T =50 sek
T =80 sek
Hoisting speed
SWL 120t
SWL 95t
SWL 75t
SWL 55t
SWL 38t
0 - 7,5 m/min
0 - 8,5 m/min
0 - 10,0 m/min
0 - 13,0 m/min
0 - 18,0 m/min
Slewing speed>55t
Slewing speed<38t
0 -0.5 rpm
0 -0,7 rpm
Slewing range 360unlimited
Specification 120 t load and 16 m outreach at +/- 5 heeling and simultaneous
trim of +/- 2
Voltage
Nominal voltage (U) 380 V / 50 Hz
Motor speed (n) 1,475 r/min
Installed power 2 x 110 kW
Max. input, temporarily 320 kW
Auxiliary supply 230 V / 50 Hz
Main pump motor
Type 280 S4
Manufacturer Schorch
Performance 110 kW
Table 3: Technical Data
Instruction manual
2 Description of the Crane Copyright 2005
System of protection Insulation class IP 23
Structural shape F; 45 LRS, tandstill heating with three PTC resistors
Miscellaneous Star-delta start-up
Feature Value
Table 3: Technical Data
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3.2 Construction
Illustration1: Overall view
Instruction manual
3.3 General Aspects
All of the working motions are infinitely variable from zero to the maximum speed and can
take place simultaneously. With a nominal load, an electrical power limitation reduces the
control current flowing to the pump adjustment of the hoisting, slewing and luffing gears,
depending on the power input to the electric motor. These speeds are reduced and the
power input to the electric motor is kept constant.
3.4 Pump unit
Two pump units are installed in the crane casing. Each of the pump unit comprises an elec-
tric motor, a pump distribution gear, and three hydraulic pumps.
The pumps are driven by the electric motor through the distribution gear. The pump unit pro-
vides the lifting gear, slewing gear and luffing gear with pressure oil.
Each hydraulics circuit is supplied through two hydraulic pumps (per aggregate a pump).
The hydraulic pumps are adjustable, reversible high-pressure, axial piston pumps which are
connected to the hydraulic motors by high-pressure hoses.
3.5 Hoisting gear
The lifting gear is mounted in the crane housing and consists of the winch drum, the winch
gear and four(4) hydraulic motors. The winch gear is installed into the winch drum, the
hydraulic motors being flanged onto the latter.
The hydraulic motors are axial piston tilted axial motors with spherical piston.
The motors start at a maximum cylinder volume and, therefore, at a maximum torque and
minimum rotation speed.
3.6 Luffing gear
The luffing gear is of the same design as the lifting gear but only have one (1) hydraulic
motors.
3.7 Slewing gear
The rotary driver consists of four(4) slewing gears which are mounted on the bottom of the
crane.
Each slewing gear engages via a gear wheel into a gear rim of the spherical slewing con-
nection, hereby transmitting the slewing motion to the crane. An axial piston motor is
mounted on each of the slewing gears.
3.8 Gear oil cooler
The gear oil cooler is an oil-air cooling aggregate (see item 51, page 8)) which cools the gear
oil in the pump distribution gear. A gear oil cooler is to be provided for each pump distribution
gear.
This begins at a hydraulic oil temperature of 20 C.
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The gear oil cooler has an oil filter which must be replaced at regular maintenance intervals
(see item 51, page 8))
3.9 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 tempera-
ture exceeds 85 C. The pump unit and oil-air cooler continue to run so that the hydraulic
oil is still cooled.
3.10 Heating
Electrical heating elements are installed in the hydraulic oil tank and in the crane housing.
The oil temperature in the oil tank is controlled by a thermo sensor. The tank heating is con-
stantly switched on at an oil temperature below 20C. At approx. 22C, the tank heating
switched off.
The room heating is controlled by a thermostat.
3.11 Slack rope switch
The lifting rope is secured against slack rope by means of a slack rope switch.
As soon as the rope of the lifting gear within the crane column tends to slacken so that the
rope threatens to jump out of the grooves, the inductive proximity switch is actuated by the
rocker. This immediately switches the lifting gear off in lowering mode. However, a lifting
operation is possible.
The correct positioning of the rope must be checked (see item 5.7, page 31).
3.12 Gear limit switch
A gear limit switch is mounted on the winch gear and the luffing gear.
The limit switches are equipped with a varying number of cams that are activated as
required during the execution of the cranes assigned tasks. (see item 6.14, page 27).
CAUTION
The limit switches are only to be operated, serviced and repaired by authorised,
skilled and instructed personnel.
This personnel must have read and understood the complete instruction manual and
they must also have received instructions about the ensuing hazards (see item 6.14,
page 27).

Instruction manual
3.13 Slip ring transmitter
The slip ring transmitter conducts the voltage from the fixed part of the crane (foundation) to
the slewing crane and can, therefore, be turned without restriction.
Due to its enclosed design, the slip ring transmitter that is mounted onto the rotary feed
through is water-proof and can be accessed after the cover has been opened.
CAUTION
Prior to opening the slip ring elements cover
switch off the voltage,
protect the voltage from unauthorised activation,
3.14 Air conditioner
The cabin is equipped with an air conditioning system.
(see item 9, page 1)

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3.15 Functional description of hydraulics
820-4900-16(1)
3.15.1 General Aspects
The crane drives work electric-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, an 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 el.-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.
3.15.2 Starting the pump unit
To this purpose, the selection switch in the switch cabinet must be positioned at 0.
The pump units 1A and 1B are started with the start button at the left control panel.
The electric motor of unit 1A starts first, the gear oil cooler [1.2] is switched on from an oil
temperature of 20C. The directional control valve [2.2] is energized and interrupts the
pressureless circulation of the control and feed pressure for the control and feed pumps
[2.0], the fan flaps [2.7] open. The el.-motor of unit [1B] starts up after approx. 7-10.
When all of the pressure switches [3.4, 4.3, 5.4] in the system lines have been actuated by
feed pressure, the green lamp indicating operation is illuminated. If the el. motors [1.0] stop
and the red fault lamp does not illuminate, repeat the starting process.
Instruction manual
8 Copyright 2005
3.15.3 Start the pump units separately
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 a little 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 flush valves [3.5 and 4.5] at a rate of approx. 25 l/min. Cooled hydraulic oil is re-
covered by the control and feed pumps [2.0] through the combined pressure limitation
valves with feed 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]
3.15.4 Hydraulic Overload Disconnection
The complete hydraulic system is protected against overload with pressure limitation valves.
3.15.4.1 Load stages protection
Load pressure switches for the individual load stages are installed in the lifting line of the
lifting gear:
[3.10] Test load 132t
[3.11] Nominal load 120t
[3.12] Nominal load 38t-55t-75t-95t
[3.14] Nominal load 0 - 120t (senken)
These load pressure switches deactivate the activated function by overload but not the
pump units.
The lifting winch brakes apply immediately, the lifting gear pumps swivel to the 0 position.
The lifting and luffing gear are limited in the working area of the individual load stages by
limit switches. When the final position is reached, the corresponding function is deactivated,
the brakes apply. However, a reverse operation is possible.
All limit switches only work concerning the triggering of the pumps, e.g. the electric motors
continue to run at a constant speed, whereby only the idling speed is applied. When crane
operations are recommenced, no current peaks are achieved due to the centrifugal masses
produced by the electric motor and the pumps together with the smoothly operating hydrau-
lics.
3.15.5 Pressure value transmitters
The pressure value transmitters [3.20], [4.20], in the lifting line store the last working pres-
sure and only open the lifting gear brake by the next working process when this is reached.
3.15.6 Ventilation
The spring-loaded vent flap [2.7] is automatically hydraulically opened when the pump units
1A and 1B are started.
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Heat from the air and oil warmed during the crane operation to a temperature exceeding
40C is drawn-off through the open vent flap [2.7] by automatically starting oil-air coolers
[2.6].
3.15.7 Heating / Cooling
Electrical heating elements are installed in the hydraulic oil tank [2.8] and the crane housing.
The room heaters are controlled by room thermostats and cut off at an ambient temperature
of 20.
A thermal feeler monitors the oil temperature.
The tank heater [2.4] is actuated when the oil temperature is below 20. When the oil tem-
perature reaches 40, the tank heater [2.4] is switched off and the oil-air coolers [2.6] start.
At approx. 85oil temperature, all of the controls are interrupted, no functions work. The
pump unit and the oil-air coolers 2.6 continue to run, the vent flaps [2.7] remain closed.
3.15.8 Function of the electro-hydraulic control
The servo valve [2.1.2] uses an external, electrical input signal at the pressure control pilot
valve [2.1.1] of the solenoid. The pressure control pilot valve [2.1.1] works on the basis of
a nozzle-swashplate principle and creates a hydraulic differential pressure which is propor-
tional to the electrical input signal.
The servo valve [2.1.2] converts the electrical input signal to a position controlling output
signal. This position controlling signal determines the angular rotation of the variable dis-
placement pump.
The delivery volume of the variable displacement pump is proportional to the electrical input
signal. A mechanical feedback to the swashplate retains the per-selected swashplate posi-
tion and stabilises the delivery volume which has already been selected. This makes the
handling of the working functions fast, exact and safe:
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3.16 Lifting gear
3.16.1 Hoisting the nominal load 120t
In this load stage the lifting winch motors [3.8 A-D] are switched to Q max.
The electro-solenoid valves [3.15-3.18] are current less.
They are held in this position with spring force and the load pressure.
If the slewing and luffing gear are moved at full speed when lifting the nominal load, a power
reduction card reduces the control current for the luffing, slewing and lifting gear pumps
depending on the power input of the el. motors [1.0]. The speed of this function is reduced.
This results in the power input of the el. motors [1.0] being kept constant.
3.17 Functional description of the individual load stages
3.17.1 General information
The individual load stages are adjusted using the key switch at the right control panel in the
crane operators cabin, this activating the corresponding solenoid valves simultaneously.
Should a solenoid valve in a lifting gear motor receive current, this is switched to Qmin, i.e.
with a reduction of the absorption volume, the torque is reduced and the hook speed is
increased.
The maximum jib lengths are automatically set.
3.17.2 Hoisting 95t
The solenoid on the way valve [3.15] receives a current. The lifting gear motor [3.8A] is
switched to Q min
3.17.3 Hoisting 75t
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.
3.17.4 Hoisting 55t
The solenoids on the way valves [3.15, 3.16 and 3.17] receive voltage. The lifting winch
motors [3.8A, 3.8B 3.8C und 3.8D] are switched to Q min.
3.17.5 Hoisting 38t
The solenoids on the way valves [3.15, 3.16, 3.17 and 3.18] receive voltage. The lifting
winch motors [3.8A, 3.8B 3.8C und 3.8D] are switched to Q min.
The overload protection in these load stages is provided by the active load pressure switch
[3.12]. The load pressure switch [3.14] is activated when lowering the overload. When deac-
Instruction manual
12 Copyright 2005
tivating the overload, immediately position the control lever to 0 and then select the load
stage which corresponds to the load. Observe the jib length.
3.17.6 Hydraulic overload safety
Each of the axial piston pumps [3.0-5.0] is equipped with a step valve (see Pressure Regu-
lator, page 88) which successively actuates a pressure regulator and a pressure relief valve
in succession.
When the pre-adjusted pressure is reached, the pressure regulator quickly returns the
pump. The pressure relief valve is fitted for unusual pressure increases.
If the set pressure of the regulator is exceeded, operating (pressure) fluid flows through the
pressure valve (A) and through a throttle point in the control piston in port (B) thus increasing
the pressure on the servo side where at the moment low pressure exists. The low pressure
relief valve in (C) limits this pressure to an appropriate pressure level. The pressure regula-
tor overrides the signal of the supply quantity adjustment and adjusts the pressure on both
actuating cylinders to an equal level. The swing disk reset moments alter the displacement
volume until the system pressure has reached the set pressure again.
120t 90t 75t 55t

38t

3.15

3.16

3.17
3.18

Q
max
. Ventil spannungslos
Q
min
. Ventil geschaltet

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Illustration2: Hydraulic overload safety
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14 Copyright 2005
3.18 Luffing gear
The adjustable luffing gear motor [4.8] is supplied with pressure oil via the luffing gear pump
[4.0]. In the load stages 0-55t, the luffing up speed is controlled load-related. In the load
stages 90t-120t, the speed control is at crawling speed.
3.18.1 Luffing up key switch position 0-55t
If the luffing gear control lever is deflected, the way valves [4.6] and [4.17] receive current
and the released control pressure opens the topping winch brake [4.7]. The magnet on the
proportional valve [4.9a+b] is (only black/white) switched and receive a passage through to
the distributing valve [4.10] controlling this against the elastic force. This closes the passage
between the servo-pistons to the tank side and created the connection between the high-
pressure line and the servo-pistons of the motor. In this switching situation the hydraulic
motor can be variably adjusted by the load pressure via the servo piston. If the load pressure
exceeds 240 bar (pre-adjusted at the spring), the distributing valve [4.11] is adjusted against
the elastic force and is connected with the tank side. The motor pivoting angle is increased,
thereby resulting in an increased absorption volume and a pressure reduction which reduc-
tion which in turn results in the distributing valve [4.11] being reset. The connection with the
tank side is interrupted once more.
3.18.2 Luffing up key switch position 95-120t
The proportional valve [4.17] has no voltage. The motor disk position is set at max. absorp-
tion volume, i.e. lower winch speed and large torque.
Before reaching the upper end position, the luffing up speed is reduced (crawling speed) as
from a radius of 7.0 m and it is deactivated as from a 4,0 m radius, the luffing winch brakes
[4.7] will engages automatically. Luffing down is, however, fully possible.
In case of overburden, the pressure cut-off valve [4.1] is actuated at the luffing gear pump
[4.0]. The luffing gear pumps [4.0] are swivelled in the direction of 0 and only deliver as
much pressure oil as is necessary for the jib to retain its position. The topping winch brakes
[4.7] do not fall in.
3.18.3 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 approx. 1 m. Luffing down is then only possible up to the max.
length of the corresponding load step.
The excess pressure protection is provided with pressure limitation valves.
4.1 luffing up
4.2. luffing down
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3.19 Slewing gear
3.19.1 Slewing RIGHT-LEFT
When the slewing control lever is shifted, the way valve [5.5] is provided with voltage and
the slewing gear brakes [5.7]open. When the control lever is returned to the neutral position,
the slewing gear pumps [5.0] turns to the 0 position. Due to an electrical time relay, the
slewing gear brakes [5.7] close slowly. This results in the crane slowing down smoothly. By
overburdening, this being a slewing against the heel with load and a large outreach, the
pressure cut-off valve [5.1] at the slewing gear pump [5.0] is triggered. (see Hydraulic over-
load cut-off, Page 86). Shift the control lever into a neutral position and luff up the jib to
reduce heel.
The excess pressure protection is hereby provided with pressure limitation valves.
5.1 Slewing right,
5.2 Slewing left
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Board Crane type DK II NMF
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3.20 Electrical Equipment
3.20.1 Electronic regulator print card
3.20.1.1 4-Channel current regulator print card
Illustration 3: 4-Channel current regulator print card
Short description
Magnet current regulator print cards for triggering proportional valves.
The card is equipped with a total of four PWM-outlets, from which max. two can be simul-
taneously active. The set value triggering is carried out via a driving lever potentiometer.
Functions:
Individual operation for pump 1, pump 2 or both pumps
Normal operation, creep speed 1. Creep speed 2.
Synchronous drive as Master for a second crane.
Synchronous drive as Master for a second crane.
Parametrizing operation, operated via buttons of the front plate.
Instruction manual
NMF Board Crane type DK II
18 Copyright 2005
Extended parametrised operation via RS232 from laptop
Power limitation
Technical Data:
Supply voltage: 24VDC(1 -32V) residual ripple max. 5%
Range of output current: 10 -999mA (PWM 122 Hz)
Five ramp generators, durations up to 10sec. from Imin Imax, or Imax Imin
Supply voltage for driving lever: 15VDC
Incremental transducer (24 VDC) for Gemini-operation
RS485- interface for Gemini operation
Ten inputs (24VDC) for the function selection
Two AC-inlets for convertor (10 VAC)
Status information via display (2x 16 characters)
Mechanical:
Europe card (100x160 mm) Front:12TE,3 HE
Operating instructions
If the enable signal has not been applied, one can enter the parameter mode by pressing
the ENTER button The parameter number and the abbreviation for the turning direction
appear in the top line of the display. In the bottom line, one can see the abbreviation for the
value which is to be edited left, the current value with the abbreviation of the dimensioning
being right. If one now wishes to amend a value, the ENTER button is to be pushed. EDIT
appears in the top line. The value can now be increased or reduced using the arrow keys.
The Autorepeat function enables a setting to be made even with large changes. The new
value is stored by pushing ENTER once more. EDIT disappears again and one can change
to a different parameter number by pressing the arrow keys (also Autorepeat here). If one
NO. Display Dim Note
1 UP (RIGHT) I min mA INPUT CURRENT FOR HOIST (RIGHT)
2 UP(RIGHT) I max. mA MAX.CURRENT FOR HOIST (RIGHT)
3 UP(RIGHT) I max.1 mA MAX.CURRENT REDUCE SPEED 1 FOR HOIST (RIGHT)
4 UP(RIGHT) I max.2 mA MAX.CURRENT REDUCE SPEED 2 FOR HOIST (RIGHT)
5 DOWN (LEFT) I min. mA INPUT CURRENT FOR LOWER (LEFT)
6 DOWN (LEFT) I max. mA MAX.CURRENT FOR LOWER (RIGHT)
7 DOWN (LEFT) I max.1 mA MAX.CURRENT REDUCE SPEED 1 FOR LOWER (LEFT)
8 DOWN (LEFT) I max.2 mA MAX.CURRENT REDUCE SPEED 2 FOR LOWER (LEFT)
9 UP SPEED UP sec TIME RELAY FOR HOIST (RIGHT) SPEED UP
10 UP SLOW DOWN sec TIME RELAY FOR HOIST (RIGHT) SPEED UP
11 DOWN SPEED UP sec TIME RELAY FOR LOWER (LEFT)
12 DOWN SLOW DOWN sec TIME RELAY FOR LOWER (LEFT)
13 OVERLOAD THRESHOLD V
14 ATTACK / / BEGINNING OF POWER CONTROL
15 RELEASE / / LOW END OF POWER CONTROL

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only wishes to store the old value instead of the new value, only the ESC button needs to
be pressed. The parameter menu is terminated with ESC.
Setting hints.
1. Maximum current:
Here the current that will flow when the joystick is fully open can be set:
N: Value for normal operation
S1: Value for creep speed 1
S2: Value for creep speed 2
2. Minimum current
Initial current for the Hydraulic (start of rotation of the hoist) also the value for pressure in-
crease.
3. J oystick neutral position
Minimum required movement on the joystick to start.
4. Ramps
Ramp times in seconds for the current values set above.
5. Synchronous regulator
P-part: regulator settings for dual use.
Synchronous alarm: maximum allowed divergence.
6. Hydraulic overload
Reactivity value for reducing and reacting: the higher the value the changes to current will
be done more slowly (from v1.07). Limit value: Setting for the transformer voltage (V AC) at
which the power limiter is triggered.
7. Current regulator Suppressor:
Setting for the Solenoid valve current. It is not envisaged that the default setting (9) needs
to be changed. Start factor: Value for the PWM controller after a restart. The default value
(52) has been optimised for the solenoid valve currently used and should only be changed
if after a restart the solenoid valve current rises too slowly or a huge wobble is seen.
3.20.1.2 Description of the request for the start release
The start request/start release signals are blocked with the crane control system. The crane
cannot be started without the release signal. This is an active system.
The system works as follows:
A Permission to start request button is situated on the control console. A relay is activated
with this button. The relay goes into self-locking and a floating contact closes. The relay
remains in self-locking until the motor is started. The signal voltage for this contact is pro-
vided from the ship, max. 230V.
After the Permission to start request button has been pushed, the Wait for permission to
start lamp illuminates.
A floating Permission to start contact is provided from the ship. The contact closes if there
is enough power for the start. In the cabin a Permission to start signal lamp illuminates.
The signal voltage for this contact comes from the crane control and amounts to 230VAC.
The crane can be subsequently restarted.
Instruction manual
20 Copyright 2005
3.20.2 Fault notification card
Any crane faults are shown acoustically and optically.
acoustically with a horn,
the horn is switched off using the Acknowledge Alarm button on the switch cabinet.
optically with the signal lamp at the left control panel Fault Lamp and
the signal lamp on the fault notification card
Should the crane have a fault, the corresponding lamp on the fault message card is illumi-
nated. After acknowledgement (press button) the lamp continues to illuminate until the fault
is cleared.
Illustration 4: Fault notification card
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3.20.3 Switches in the switch board
3.20.3.1 Switch Test load
The switch is only to be activated if the crane is to be subjected to a loading test.
3.20.3.2 Switch TEST
(see item 2.15.3, page 9).
3.20.3.3 RESET button
(see illustration 5, page 22)
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.
3.20.3.4 Switch PRESSURE TRANSMITTER HOISTING BRAKE
If the pressure transmitter (3.15) is defective, with this switch can be bridged.
3.20.3.5 Switch Speed control Hoisting gear
3.20.3.6 Switch Speed control Luffing gear
Instruction manual
22 Copyright 2005
Illustration 5: Switches
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3.20.4 Load measuring unit / Loadmaster (DMSA)
The load measuring unit consists of the loadmaster (DMSA) in the switch cabinet (see illus-
tration 6, page 25), the display for the indication in the cabin (see illustration 7, page 26)
and the load measuring bolt.
The DMSA 04 is for load acquisition on a ship's crane, based on the values of load-meas-
uring pins and (in automatic mode) jib angles (potentiometer on the jib).
1. Parametering and calibration
Crane-specific data may be input and the measuring system may be calibrated with known
loads. Due to the arrangement of the load-measuring pins, correction values between lifting
and lowering must be determined with the system.
2. Load-level mode
The jib position is recorded in stages ( PLC). The DMSA 04 displays the maximum permis-
sible load according to the selected load level and evaluates the corresponding thresholds
(warning, deactivation). Thresholds may be entered for a maximum of 10 load levels.
3. Automatic mode
Calculation of the sliding maximum load depending on the jib position. This mode possesses
highest priority. The maximum permissible loads as well as warning and deactivation thresh-
olds are calculated on the basis of the crane data ( maximum permissible torque for the
crane column) as well as the jib sizes.
Operating mode card
The key switch for selecting operating modes is located on this card.
1. Operation ( load monitoring ON)
2. Parameter mode ( access to the operating data possible)
3. Alarm bridge (deactivates warning and alarm outputs) it is only possible to remove
the key when it is in the operating position.
Besides the key switch, this card also houses the fuses for the external components. Light-
emitting diodes indicate whether the external circuits are being supplied with 24 VDC.
3.20.4.1 At overload
Stop: hoisting lifting up, only to lifting down possible.
Luffing gear luffing up, luffing down.
In the case of overload all change over valves (Magnetic valves) are de-energized. The lift-
ing gear motor slewing on max. displacement, max. torque, small rotation speed.
3.20.4.2 At bridgeover loadmaster (DMSA)
The load measuring system can be switched off with a key switch in the switch cabinet.
(see illustration 6, page 25) The load bolts are therefore electrically bypassed and the
electrical load measurement deactivated.
The crane works in the biggest load stage, that means the lifting gear motor slewing on
max. displacement, max. torque, small rotation speed. It can not switched onto a
smaller load stage.
Instruction manual
24 Copyright 2005
CAUTION:
This has no effect on the hydraulic load measurement.
3.20.5 Setting instructions
The required settings are made through a PC or laptop using the DMSA04 parameter pro-
gram. The hardware is connected via a COM interface and a null-modem cable. Settings
may only be transferred to the card if
a. the key switch is switched to PARAMETER MODE
b. the password has been entered correctly.
Note: the password is currently DMSA04.
The setting of system parameters always distinguishes between the data by the crane man-
ufacturer ( e.g. load thresholds, jib length, etc.) and measured data determined by corre-
sponding calibration methods. It is possible to overwrite all data ( even the measured
data!).The setting of system parameters is naturally easiest with the help of a computer (lap-
top) because sufficient labelling is available here. The data may, however, also be modified
without a laptop because all parameters may be accessed by the four keys on the controller
card. The password must also be entered for this process. A list with the corresponding
numbers and short names has been provided.
3.20.6 Load-measuring pin change / correction adjustment
Calibration without calibration loads and without laptop!
Set key switch to parameter operation
Press both the and arrows simultaneously for at least two seconds.
The following text appears:
lift w/o load ( lift without load)
Now the crane driver must lift the empty crane hook and push simultaneously the
ENTER button until the display SET ZERO lights up.
The following checks are carried out:
a. Is the LIFT input active?
b. Does the load-measuring signal range between 2.5 and 6.5 mA?
c. Is the wire rope in it the lowest position.
If all three conditions are met, the new load-measuring value is accepted as the new zero
value and all calibration curves are shifted by the difference to the previously measured
value for the lifting of the empty crane hook.
Text displayed when measuring has been successful:
set to new
zero-values
If the conditions a. b. or c. were not fulfilled,
the old values will remain and the following text will appear briefly: BREAK! NO CHANGES!

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Illustration6: Loadmaster
1 = Parameter running -
only for the regulation of
the Parameter.
2 = Operation - Switch
position at crane opera-
tion.
3 =Overbrigde alarm and
warning - switch off the
load master
4 = Fuses - in case of
defective fuse the LED
goes out.
5 = Display + manuall
Parameter input
6 =PC-connection
1
2
3
5
4
6
Caution:
Parameter settings and modification may be practised only
of authorize personnel.
Instruction manual
26 Copyright 2005
Illustration7: Indication-Display
Indication for normally operation
admissible load Load at the hook
outreach
Running mode
Heeling
Indication blinks with failure and
overload of the DMSA.
With overload through pressure
switch no indication at the DMSA.
Fehlerbehebung siehe
Indication at deactivated Load-
master (DMSA)
Indication blinks with defective
load measuring bolt.
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3.20.7 Test operation
No hydraulic pressure is created up during the test operation phase and the main motor and
oil cooler are not started. The electrical connection to the actuators and sensors may be
tested as well as the activation of the current regulation boards.
1. Switch off the crane and turn on the Test operation switch in the switch panel.
2. The crane is now ready for operation (usual only when the main motor is running).
3. The DMSA load-measurement system DMSA (optional) is activated.
4. The feed pressure and pressure switches cannot be tested, as no pressure has been
created.
5. Test the PLC 's input and output:
All sensors and actuators can be tested, if they are connected to the PLC. These are
indicated by the LEDs in the PLC input/output modules.
Look at the switch diagram and find the sensors or actuators to be tested (e.g. pres-
sure switch for load steps). Disconnect the pressure switch plug, the LED on the cor-
responding PLC input module will go out (check with switch diagram) and the
overload alert LED on the PLC output module will come on (if the corresponding load
steps are selected).
3.20.7.1 Testing the current regulation board in test operation:
The operation of the corresponding current regulation boards can be tested by using the
throttle.
When the throttle is activated (contact 1/2 shows the direction), the amount of current
displayed on the current regulation board increases to a mid-point, preset value. The
direction (Up /Down) is also indicated. (See page 2, Fig. 1)
The valve corresponding to the pump is activated
If the value in the display remains at 0, check contacts 1 / 2 on the throttle.
3.20.7.2 Potentiometer and solenoid valve test when brakes are opened:
At the Test operation switch, switch on the LG pressure sensor bridge switch for the
lifting gear or the extending arm switch. See Fig.
When the throttle is activated, the amount of current increases up to the maximum value
according to the movement of the throttle (Potentiometer 3).
If the mid-point, preset value remains, despite the movement of the throttle to the maxi-
mum and the fact that the LG pressure sensor bridge is switched on potentiometer 3 is
to be checked on the throttle
If the throttle moves, the corresponding brake valve must receive a signal. (LED indica-
tion on the solenoid valve).
Instruction manual
28 Copyright 2005
Illustration8: Throttle graphic
After the test, the Test operation and Pressure sensor switches for the lifting gear
and extending arm are switched off and disconnected again.
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3.21 PS4-200 Compact PLC
a complete description you find
see (Chapter 7, Spare Parts)
3.21.1 Setup
1. 24VDC power supply
2. High-speed counter input (alternative to I 0.0), 3 kHz
3. Alarm input (alternative to I 0.1)
4. 8 digital inputs 24VDC and 24VDC input for the outputs
5. Plug-in screw terminal
6. Status LEDs for digital inputs
7. Status LEDs for digital outputs
8. 6 digital outputs 24V DC/0.5 A; short-circuit and overload proof
9. 2 analog inputs U0, U1 (0 to 10 V) 1 analog output U10 (0 to 10 V)
10.Suconetk interface
11.Set point potentiometers P1, P2
12.Switch S1 for bus terminating resistors
13.Programming device interface (PRG)
14.Memory module Status LEDs for the PLC
3.21.2 Elements
1. Power supply unit
The PS4-200 is operated with a rated voltage of 24VDC. The power supply connection is
protected against polarity reversal. The 24V connection enables the PLC in the control cab-
inet to be supplied with voltages to industrial standards (IEC).
2. High-speed counter input
Instruction manual
30 Copyright 2005
You can count pulses at up to 3 kHz via the digital input I 0.0, irrespective of the cycle time.
The up counter is capable of processing square-wave pulses with a pulse/pause ratio of 1.
3. Digital inputs
The PLC has 8 digital inputs. They are galvanically isolated from the CPU. The inputs are
designed for 24V DC. The input delay of normally 55 ms ensures short response times (e.g.
for direct peripheral scans and alarm evaluations). Inputs I 0.0 to I 0.7 can be addressed in
bit or byte format with peripheral I/O commands.
4. Status LEDs for digital inputs
The physical states of the inputs and the diagnostics status word are indicated by LEDs.
5. Status LEDs for outputs
The logical states of the outputs are indicated with light-emitting diodes (LEDs). Outputs Q
0.6 and Q 0.7 are only provided as LEDs.
6. Digital/analog outputs, analog inputs Digital outputs:
The PS4-200 has 6 24V/0.5 A digital outputs. They are galvanically isolated from the CPU
and protected against short-circuits and overloads. Up to four outputs can be connected in
parallel.
Outputs Q 0.0 to Q 0.5 can be addressed either in bit or byte format with peripheral
commands (see chapter 5 Slave addressing ).
Analog inputs/outputs: The controller has two analog inputs and one analog output. The sig-
nal range is 0 to 10 V. The resolution of the inputs is 10 bits (1024 increments), while that of
the output is 12 bits (4096 increments).
7. Switch S1 for bus terminating resistors
You can set the bus terminating resistors for the first and last physical stations with switch S1
8. Memory modules
The PS4-200 has an internal, battery-backed, 32kByte RAM. The memory is subdivided into
a data memory and a user program memory.
9. Status LEDs for the PLC
The PLC states are indicated by means of the Ready, Run, Not Ready and Battery
LEDs
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1. Back-up battery
2. Reset button
3. Plug connector for local expansion modules
4. Operating mode selector switch
to 1. Back-up battery
The battery backs up the internal RAM and the real-time clock.
Warning! The back-up battery must only be replaced with the power supply switched
on, or data will be lost.
to 2; 4 Operating mode selector switch/reset button
You can select the Halt (stop), Run and Run M-Reset modes with the operating mode
selector switch. The selected mode is activated when you press the Reset button. The oper-
ating states are described in detail in the chapter Operation.
to 3. Plug connector for local expansion module
The plug connector provides the interface for connecting the LE4-... local expansion mod-
ules
3.21.3 Setting the bus terminating resistors
Set the bus terminating resistors on the module for the first and last physical stations on a
line. To do this, both S1 switches should be set to the ON position. Both switches must be
set to the OFF position for all other stations.
Illustration 9: Bus terminating resistors active
Instruction manual
32 Copyright 2005
In order for the PLC to function correctly the two S1 switches must be set to the same
position ( ON or OFF ).
3.21.4 Operating states of the PLC
The PLC can have the following operating states: Run, Ready, Not Ready.
Communication with the PC is possible in all three operating states. Accordingly, the
current status of the PLC and the real-time clock can always be read, for example.
Ready
The Ready status means the following:
There is a user program loaded in the PLC;
The user program is not running;
The outputs are reset and disabled.
The PLC is switched to the Ready status:
If the Reset button is pressed when the operating mode selector switch is set to
Halt;
After the power supply is switched on if the operating mode selector switch is set to
Halt;
By means of the programming software on the PC;
In slave mode, if the master switches to the Halt (stop) status and you have set in
the slave parameters the remote control function to ON in the Sucosoft Topology
Configurator;
If the tab of the memory module is pulled out.
Run
Run status means that the user program is running cyclically.
The PLC is switched to the Run status:
If the Reset button is pressed when the operating mode selector switch is set to
Run or Run M-Reset;
After the power supply is switched on if the operating mode selector switch is set to
Run or Run M-Reset;
By means of the programming software on the PC.
Not Ready
The user program does not run in Not Ready status.
The PLC is switched to the Not Ready status:
If there is no program loaded in the PLC;
As a result of a hardware error;
As a result of a serious error in the user program (e.g. cycle time violation)
Once the error has been rectified, you can cancel the Not Ready status as follows:
By pressing the Reset button; if the operating mode selector switch is set to Run M-
Reset, the PLC will be switched to the Run status;
By switching the power supply off and then on again; if the operating mode selector
switch is set to Run M-Reset the PLC will be switched to the Run status;
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By means of the programming software on the PC.
When ever the PLC is started by switching on the power supply, by pressing the
Reset button or by means of the PC, the backup program is compared with the pro-
gram in the RAM. If the programs are not the same, the program in the memory mod-
ule (backup program) is copied to the RAM.If the user program in the memory module
is defective, it is updated, providing the user program in the RAM is valid. An update
is also carried out every time the user program is transferred from the PC to the PLC.
Instruction manual
34 Copyright 2005
3.21.5 Testing/Commissioning/Diagnostics
Status LEDs
The coloured light-emitting diodes (LEDs) allow fast and simple diagnostics of the PLC func-
tions. The states of the inputs/outputs are easy to monitor.
1) CAUTION!
Data may be lost if the battery does not supply sufficient power. Always replace the
battery with the power supply switched on!
Copyright 2005 Operation 1
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4 Operation
4.1 Safety instructions
Before operation, make yourself familiar with
the instruction manual,
the cranes operating and controlling elements,
the immediate environment of the crane
the cranes safety equipment,
action top be taken in case of danger.
4.2 Requirement of personnel
The crane is only to be operated by persons who are trained, instructed and authorised.
These persons must be familiar with the instruction manual and are to act in accordance with
it. The respective areas of authority of the operating personnel must be clearly defined.
Operating personnel who are in training are only to initially work on the crane under super-
vision of an experienced person. The successful completion of the training period should be
confirmed in writing.
All control and safety devices are only to be operated by persons who have been suitably
instructed.
All persons working on the crane are to read the instruction manual and confirm with their
signature that they have understood it.
Instruction manual
2 Operation Copyright 2005
4.3 Working range of the crane
Illustration10: Working range of the crane
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4.4 Operation
4.4.1 Operators cabin
The crane operating elements are situated in the operators cabin.
Illustration11: Operators cabin
control panel left control panel right
Load indicator
Instruction manual
4.4.2 Control panels
The control levers are delicate and are to be actuated continuously.
Illustration12: Control panel left
15
13
11
9
7
5
4
1
2
6
8
10
12
14
3
1) NO FUNCTION
2) CONTROL LEVER LUFFING GEAR/SLEWING GEAR
3) PUSH BUTTON POWER REQUEST SIGNAL
4) PUSH BUTTON EMERGENCY STOP
5) LAMP POWER AVAILABLE SIGNAL
6) LAMP READY FOR START
7) LAMP FAULT
8) LAMP HEELING 5
9) LAMP WARNUNG OVERLOAD
10) LAMP OVERLOAD
11) PUSH BUTTON MOTOR OFF
12) PUSH BUTTON MOTOR ON
13) LAMP OIL COOLER WORKING
14) LAMP READY FOR OPERATIONT
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Illustration13: Control panel right
1
3
2
4
5
6
7
8
10
9
1) NO FUNCTION
2) CONTROL LEVER
3) PUSH BUTTON HORN
4) KEY SWITCH LAOD STEP 38t; 55t; 57t; 95t; 120t; AUTOM
5) KEY SWITCH FAST SPEED
6) KEY SWITCH J IB IN PARKPOSITON
7) SWITCH WINDOWS SCREEN WIPPER
8) SWITCH LIGHT CABIN
9) SWITCH FLOOD LIGHT
10)SWITCH WARNING LIGHT J IB
Instruction manual
4.5 Before starting
4.5.1 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 are open and if necessary open the valves
Check whether the oil drain valve is closed.
Only use the crane if it is free from faults.
4.5.2 Switching on
1. Set the key position in the switch cabinet to O
2. Operate push button PERMISSION TO START REQUEST, this activates the yellow
pilot light POWER AVAILABLE SIGNAL
3. Wait until green pilot lamp READY FOR START illuminates, than start crane.
4. Start the pump units with the button on the left control panel. The pump unit 1A is
the first to start. After approx. 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 0 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 .)
5. Check whether the vent flap is open.
6. Switch on load step 38t with the key switch at the right control panel.
7. Luff the jib down completely and check whether the luffing jib stops without difficulty
when the max. position is reached.
8. Move the lifting gear in Lift. The bottom hook block must stop approx. 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.
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%.

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10. Remove the key from the lay resting jib down key switch to avoid misuse by the
crane operator during normal cargo handling.
4.5.3 During operation
Do not remove any safety devices and do not taken them out of operation.
You and other operating personnel are only to be in the stipulated workaholics.
Ensure that no unauthorised persons are within the crane operating area.
Never suspend accepted loads above peoples head.
The load shift is only to be activated with an empty load hook and for the corresponding
load.
An angular pulling with the load rope is not permitted.
Only activate the lay resting jib down key switch if the jib is situated in the rest parking
support.
Caution: All other limit switches do not function.
It is imperative that a slack rope is avoided.
4.5.4 Switch on main lifting gear
The load steps are switched on at the right panel (see item 4.4.2, page 4). The selected
load step is only shown by pilot lamps in the display unit (see item 11, page 3)) if the jib has
moved to the working area of the load step and the control lever has subsequently been
positioned at O. The load weight is calculated by the load measurement and also shown
on the pilot lamp
NOTE:
The load steps are only to be changed when the hook is not subjected to a load. If the
load on the hook is greater than the set load step, the crane switches off hoisting .
Lowering is possible.
4.5.5 Switch off
4.5.5.1 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.

Instruction manual
4.5.6 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 (upper part of the foundation)
in the switch cabinet
on the right control panel
Copyright 2005 Maintenance and Repair 1
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5 Maintenance and Repair
5.1.1 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 cranes working area and ensure that no unauthorised per-
sons are within the cranes working area.
5. Ensure that suitable lifting gear and weight-carrying equipment is available for replac-
ing large crane parts
6. Replace all defective crane parts immediately.
7. Only use original NMF-spare parts.
5.1.2 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.
5.1.3 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.
5.1.4 Environmental protection
During all work on and with the crane, the regulations for waste avoidance and proper waste
disposal or recycling respectively must be observed.
In particular, when carrying out erection and servicing work and taking the crane out of oper-
ation, ensure that substances which can contaminate ground water such as grease, oil,
coolants, solvent-based cleaning fluids, etc. do not to contaminate the environment.
These substances are to be collected, stored, transported and disposed in suitable recep-
tacles.
Instruction manual
2 Maintenance and Repair Copyright 2005
5.1.5 After maintenance and repair
5.1.5.1 Before starting the crane, observe the following,
Double-check all previously loosened screws in order to ensure that they are tightly
secured
Check that all previously removed protective devices, covers, filters, pressure switches
and limit switches have been replaced correctly
Make sure that all previously used tools, materials and other equipment have been
removed from the working area.
Clean the working area and remove any spilled liquids or similar substances.
Make sure that all of the cranes safety devices function properly again
Check all of the functions and the limit switches for the individual load steps without
load.
5.1.6 Requirement of personnel
5.1.6.1 Working on electrical equipment
All work on the cranes electrical equipment must be carried out by trained electrical spe-
cialists only.
When working on all live crane parts or cables, a second person must be present who can
deactivate the master switch in an emergency.
5.1.6.2 Working on hydraulic installations and equipment:
All work on the cranes hydraulic equipment must be carried out by persons especially
trained for such work.
5.1.7 Function and safety inspection
The function and safety inspection of the crane is to be carried out according to guideline
issued by the responsible classification society. If necessary, request that the manufacturer
send a specialist.
Carry out the following inspections:
1. Visual inspection of the steel structures for any damage
2. Inspect the main welding seams of the foundation and the crane for cracks.
3. Inspect the rope for wire ruptures.
4. Inspect the sheaves for damages, easy run and wear at the bottom of the grooves.
5. Inspect the swivel of the load hook for easy turn.
6. Check the setting of the limit switch.
7. Check the nominal speed of the various functions when the crane is idling.
8. Test the system with nominal load.
9. Determination of the system pressures and comparison with the figures stated in the
circuit diagram, if necessary amend.
10. Practise brake manoeuvres with all movements and activation of the emergency-off
switch. The brakes should apply immediately and the load should be held perfectly.
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11. If necessary, secure maladjusted relief valves, pressure switches, etc., mark their
position with marking paint.
Instruction manual
5.2 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 lubricating schedule stipulates the maintenance schedule (see Maintenance plan).
Interval Parts Work
Prior to any operation or after any
sea journey
Crane -visual inspection
Hydraulic oil tank -check oil level
Gear:
(winch gear, slewing gear, pump distribution
gear)
-check oil level
see instruction (see illu.20); (see
illu.21)
-the oil quantity indicated on the
type plate (see item 5.3, page 8)
Filter service indicator -check filter service indicator
-if necessary change filter car-
tridges,(Chapter 7, Spare Parts)
Limit switch -test run all functions and check
that they are working properly
(see item 6.14, page 27)
Slack wire switch -check function (see item 5.6.12,
page 29)
Weekly Gear rim - adequate greasing
Monthly Visual check - visual inspection should be car-
ried out with particular attention
being paid to the condition of rope
and escape harness.
Bottom hook block - check visual:
hook, rope sheave, swivel,
shackle, bearing, to tighten all
screws.
(see item 5.6.8, page 22)
Every three months Crane - cleaning
Crane ropes - greasing
Rope end connection, swivel - greasing
Rope sheave - greasing
Winch bearing - greasing
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Every six months Slip ring assembly -visual inspection (see item
5.6.10, page 27)
Oil cooler -visual inspection
Screw connection -to check, that screws and nuts are
firmly positioned,
-particularly rope end connection,
jib foot and bottom hook block.
Slewing rim -check seals.
Yearly Crane - function and safety inspection
Multiple disc brake:
(winch gear, slewing gear)
- check for leakage
- check braking torque
- check brake disc
according to instruction. (see item
6.9, page 15)
Hydraulic system oil analysis (oil tank),
testing of a hydraulic oil sample
Slew ring grease sample:
- grease sample checked of the
manufacturer.
-extruded grease is to be checked
for abraded particles.
Bottom hook block examination by experts
For the first time after 50
hours of operation
Hydraulic system change filter (see item 5.6.7.3,
page 21)
gear oil cooler change filter (see item 5.6.7.1,
page 20)
Slew ring (roller bearing) to grease
hours of operation
Slew ring to check that screws and nuts are
firmly positioned. (see item 5.6.9,
page 24)
Pumps -check visual and leakage
hours of operation,
Gear:
(winch gear, slewing gear, pump distribution
gear)
oil change
Interval Parts Work
Instruction manual
Every 500 hours of operation Hydraulic system change filter (see item 5.6.7.3,
page 21)
Hydraulic system oil analysis (oil tank),
Gear oil cooler change gear oil filter (see item
5.6.7.1, page 20)
Gear oil sample
(winch gear, slewing gear,
pump distribution gear)
oil analysis,
testing of a gear oil sample
Oil cooler visual check, clean with necessity
Wire ropes, rope end connec-
tion
rope inspect for wear, see
- wire ropes are inspected accord-
ing to stipulations issued by clas-
sification associations and
national bodies.
- check that wire thimbles are
safety secured.
Rope sheaves - inspect for wear
- check that shafts are safely
secured.
Bottom hook block -check that block, beam, hook,
swivel and shackle are intact.
Slack rope switch (optional) check rollers for wear or damage.
Electrical equipment including
slip ring unit.
Heating elements -check
Crane house, foundation and
jib welding joints
-inspect for any sign of crack.
Slewing rim -check seals.
Slewing gear and pinion -check backlash
Cable drum (optional) - v-belt, check tension
- slipring unit, check
- brake disk, check
- brush holder, check
see
for the first time after 800
hours of operation,
Hydraulic system - oil change;
- oil analysis (oil tank),
Interval Parts Work
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NOTE
Please also observe the subsuppliers documents (Chapter 7, Spare Parts).
every 1000 hours of operation Gear: (winch gear, slewing
gear, pump distribution gear)
-oil change
Crane -the crane should be inspected by
competent person or returned to
NMF-Cranes for serving.
every 1500 hours of opera-
tion;
or min. once a year
Hydraulic system - oil change
- oil analysis (oil tank), testing of a
hydraulic oil sample
Hydraulic system -change filter (see item 5.6.7.3,
page 21)
Gear oil cooler change gear oil filter (see item
5.6.7.1, page 20)
Gear brake,
(winch gear, slewing gear,
- disassembled motor and brake,
to check the splint shafts at the
drive side.
Every two years Hydraulic oil tank - take out the drain plug,
- drain oil and clean the reservoir,
- verify that the oil level float switch
is working properly. This inspec-
tion is verified when changing oil
or cleaning of oil tank,
- check air breather cap,
-change filter (see item 5.6.7.3,
page 21)
Every three years
Quinquennial examinations
class renewal surveys
Gears - inspection gears
Slewing rim studs/screw - tighten all studs or screw with a
hydraulic crew tensioner or a
torque wrench.
( siehe Seite 24, Absatz 5.6.9)
- consult NMF-service before
replacing studs or screws with
any other specifications than rec-
ommended.
Rope - inspect wire,
- check discard criteria for wire
rope
(see item 5.7, page 31)
Crack test - inspect for any sign of crack.
- as requested by the class sur-
veyor to be checked for cracks,
using the procedure appropriate to
each case.
Interval Parts Work

Instruction manual
5.3 Lubrication schedule
NMF
Neuenfelder
Maschinenfabrik GmbH
21129 Hamburg
Schmierstofftabelle fr Schiffshilfsmaschinen
Table of Lubricant for Hull Auxiliaries
BEDINGUNGEN / CONDITIONS 2003
Auentemp.
Outdoor
temp.
Viskositt
Viscosity
Pourpoint ELF BP Castrol Exxonmobil SHELL FAMM
Hydraulikanlagen in:
Hydr. Equipm. Installed in:
x)
Fllmenge
Oil Quantity
Tief -20C Bordkran/Deck Crane 1300 l
Low Lastdrehvorrichtung
Rando oil Load Turning Devise
l
Visga Bartran Hyspin Tellus oil HDZ 46 Spannwinde
46cST/40C <-15 46 HV46 AWH-M 46 Nuto T 46 HD46 Span winch
l
ISO VG 46 Vitam H 46 Rudermaschine
HF 46 Mobil DTE Steering Gear
l
Normal 45C 15 M Sonstige hydr. Anlagen
Normal Other hydr. Drives
l
Tief -30C Hubwindengetriebe
Low Cargo Winch Gear
x
1
) 130,0 l
Hangerwindengetriebe
Spartan Omala Topping Winch Gear
x
1
) 27,0 l
SEP HD Drehwerksgetriebe
220 220 Turning Gear
x
1
)4x13,5 l
. Hilfswindengetriebe
220cST/40C <-25 C Epona Enersyn Alphasyn Mobil Tivela Pinnacle Auxiliary Winch Gear
l
ISO VG 220 SA 220 HTX HG SHC 630 WB Marine Bootswindengetriebe
220 220 220 GEL Boat Winch Gear
l
Synthetical
PAO Oil
220 Kabeltrommelgetriebe
Cable drumgear
l
Sonstige Getriebe
Other Gears
l
Normal 45C Pumpenverteilergetriebe
Normal Pump Distribution Gear
x
1
) 7,5 l
Energrease Spheerol MobilTac Alvania Offene Zahnradgetriebe
MP-MG2 SX2 375 NC EP2 OpenToothed Gearings
30 kg
CERANA Energrease Spheerol Mobilarma Rhodina Novatex
AD MP-MG 2 SX2 798 Grease EP2
Seile
Mobil Grease EP Novatex
XHP 222 FK10
Rope
50 kg
CERANA Energrease Spheerol Mobil Grease Alvania
VR2 MP-MG 2 SX2 XHP 222 RL
Lager(Fettschmierung)
Mobilith
Achtung: Synthetisches Getriebel auf PAO-
Basis darf nicht mit synthetischen Getriebel auf
Polyglykolbasis gemischt werden.
lwechsel und Fettschmierintervalle siehe
Wartungsanleitung
Attention: Synthetically gear oil on PAO-base
may not be mixed with synthetically gear oil on
polyglycol base
Oil change and greasing intervals see
maintenance instruction.
SHC 460
Bearings (Grease Lubrication)
30 kg
x) fr einen Kran/for one crane
x
1
)Werksfllung/filling in the factory
Erzeugnis/Produkt
Deckskran
Auftrag/Order NB/Hull No.
R 03/0
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5.4 Lubricating Chart
5.4.1 Symbols
(Chapter 10, Drawings) Drawing 845-0500-00(1)
Check hydraulic oil ISO VG 46 a for every operation, weekly
Check gear oil ISO VG 220 b every 100 hours; monthly
Grease for open spur gears c every 200 hours, every free month
Grease NLGI 2 d every 500 hours
Grease for wire ropes e every 1000 hours
Oil input f annual or every 1500 hours
Oil output
dipstick check
Indicator glass
Oil filter check; first filter change to be
done 50 hours.
Hydraulic oil change
first oil change to be done after 800
hour.
Gear oil change
first oil change to be done after 200
hour.
Air breather cab
Instruction manual
5.4.2 Lubrication diagram
Pos. Bauteil a b c d e f
(see illu.14) Door hinges
(see illu.15) E-motor
(see illu.16) Grease for open spur gears, pin-
ion, slew rim
(see illu.17) Wire sheave-jib
(see illu.18) Wire sheave-crane house
(see illu.19) Bottom hook block, swivel, wire
sheave
(see illu.20) Slewing gear
(see illu.21) Hoisting winch, Luffing winch
(see item 5.7, page 31) All wire ropes
(see item 5.6.6, page 19) Pump distribution gear
Oil tank
(see item 5.6.7.3, page 21) Hydraulic oil filter
(see item 5.6.7.1, page 20) Gear oil cooler
Air breather cab on hydraulic oil
tank
Locking cylinder (optional)
Cable drum (optional)
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5.5 Illustrations of the lubrication points
Instruction manual
5.5.1 Door hinges grease points
Illustration14: skylight grease points
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5.5.2 E-motor
Illustration15: Grease point e-motor
5.5.3 Slewing bearing teeth
Illustration16: lubrication gear rim/pinion
Grease nipple upper bearing
Grease nipple lower bearing
Grease: gear rim
Grease nipples: slewing gear
Instruction manual
5.5.4 Wire sheave jib
Illustration17: Grease point jib head
5.5.5 Wire sheave crane house
Illustration18: Grease point crane house
grease nipples wire rope sheaves both sides
grease nipples
Wire rope end connection
Grease nipples
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5.5.6 Bottom hook block
Illustration19: Grease point bottom hook block
grease nipples
Instruction manual
5.5.7 Slewing gear
Illustration20: oil filling slewing gear
Oil indicator glass
Oil inlet
Grease nipple
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5.5.8 Winch
Illustration21: oil filling hoisting gear
Grease nipple
oil inlet
oil dipstick
oil outlet
Instruction manual
5.6 Maintenance and repair
5.6.1 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.
5.6.2 Greasing
Use the lubricants stipulated in (see item 5.4, page 9).
5.6.3 Gear
The Zollern planetary gear is provided with splash lubrication. The anti friction bearing on
the main drive pinion is filled with grease. As it is a lifetime lubrication it is not necessary to
renew or refill it.
5.6.4 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.
5.6.5 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 a faster oil ageing with a reduced lubricity.
The oil change must be carried out at more frequent intervals.
The used oil has a cloudy colouring:
It is possible that water penetration has taken place.
Change the oil immediately flushing the gearbox out thoroughly several times with new
oil.
It is recommended to disassemble the gearbox and to examine the parts for corrosion.
that the gearbox be disassembled and the parts examined for corrosion.

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Checking the oil level
Compare the amount of oil drained off with the stipulated amount of oil.
Checking for solid foreign matter
We recommend a check carried out for foreign matter in accordance with DIN 51592. The
sample is dissolved in pure benzol. If necessary, it should be heated up a little, this then be
filtered through a benzol-resistant, fine-pored membrane filter. The rest is washed, dried,
weighed and stated as an amount of solid foreign matter.
The maximum permissible weight of foreign matter is approx. 0.15 % of the total weight of
the oil in the gearbox. However, the foreign matter particles are only to consist of fine abra-
sion up to max. 25 ym.
If the permitted value is not exceeded, the gearbox can continue to be used after the oil
change.
If coarse abrasion (above 25 ym) or flakes of materials from the profiles of the gear teeth are
discovered, the gearbox must be disassembled, irrespective of the amount of foreign matter.
The profiles of the gear wheels, in particular the large sun wheel of the output planetary gear
set, should be subjected to a visual inspection.
For safety reasons, check the screws for tight fit before resp. after long period of con-
tinuous operation and in case of frequent maximum load. If inspections or repairs are
necessary, we recommend sending the works under all circum stances so that a max-
imum of reliability is guaranteed for safety reasons we recommend an inspection of
the gear (inside and outside) every 3 years.
5.6.6 Pump distribution gear
Cleaning
Clean the gear externally.
Pay attention to leakage or loose screwed connections.
Oil samples should be taken. Considerable signs of metal abrasion in the oil or on the
drain plug indicate increased wear or the occurrence of a fault and in such cases the
gear should be examined carefully.
Oil change
When changing the oil for the first time, clean the gear with flushing oil.
The air breather filter and the magnetic plug on the drain plug must be cleaned each
time the oil is changed.
The markings of screwed-in dipsticks apply in unscrewed state.
Instruction manual
The markings of put-in dipsticks (not screwed execution) apply in the status put in up to
impact.
5.6.7 Filter
5.6.7.1 Gear oil cooler filter
(Chapter 7, Spare Parts).
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 in the used oil container.
3. Pull the element out of the dirt collector vessel.
4. Clean the collector vessel.
5. Insert a new cartridge with collector vessel into the filter casing.
CAUTION
Only clean wire gauze elements (type 25W) in cleaning fluid.
5.6.7.2 Changing the hydraulic oil
We recommend to oil examine oil samples by the oil supplier. The supplier then provides
you with information concerning the oil condition and suggests a date for the oil change.

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5.6.7.3 Changing the hydraulic oil filter
Indicator
The filters are equipped with an optical dirt indicator(Chapter 7, Spare Parts).
Changing filter elements.
Generally speaking, the element is to be changed when the dirt indicator is triggered under
normal operating conditions. If the dirt indicator is only triggered by a cold start, the filter ele-
ment needs not be changed.
When taking the crane into operation, repairing, changing the oil, etc in the hydraulic system,
shorter change intervals are to be expected.
1. Switch the crane off.
2. Depressurise the filter.
CAUTION
If the filter is not depressurised prior to any work being carried out, this may result in
a sudden, violent evacuation resulting in a risk of injuries or material damage.
3. Screw off the casing (2).
4. Dispose the liquid in a suitable container. Do not reuse the liquid in the system.
5. Remove the element (3).
6. Examine the surface of the elements for any remaining dirt and larger particles. This
may indicate damage caused to components.
7. Clean or replace the element (3) respectively.
CAUTION:
Only clean elements with wire gauze (W) and metal fleece (V). Elements containing
filter material such as BETAMICRONe-2 (BH/HC, BN/HC, BH and BN) cannot be
cleaned.
8. Clean the inside of the casing (2). Ensure that no dirt is deposited on the clean side.
9. Examine the filter, in particular the sealing surfaces and threads for signs of mechan-
ical damage. If necessary, replace the parts.
10. Inspect the O-ring (4) on the casing (2). In case of damage replace the O-ring.
11. Wet the thread and sealing surfaces on the filter and the O-ring (5) of the element (3)
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.
13. Mount the element on the centring pivot. Screw the casing (2) in as far as it will go.
14. Check the seal for leakage.
NOTE
Replace disposable filter elements, soiled Betamicton`N-2 (BN, BN/HC) or
Betamicron 9H-2 (BH, BH/HC) elements with new elements.

Instruction manual
Illustration22: Filter
5.6.8 Bottom hook block
1. Maintenance
The inspection and lubrication intervals depend on the number of operating hours, the con-
ditions of use, the operating conditions and the user assessing the situation correctly. The
following guidelines are valid for normal use:
2. Inspection
Each of the bottom hook blocks are to be inspected at intervals of max. 1 year by a special-
ist. The following must be inspected at regular intervals:
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Wear to the side plates, rope sheave surfaces, axes, bushes and bearings,
Any deformations on the bottom hook block;
Seating and play of the rope sheaves;
Securing devices on nuts, bolts and other fixing elements,
Corrosion
Welding seams for cracks.
For repair work, the user or owner should contact NMF.
3. Lubrication
Grease specification: (see item 5.4, page 9).
Rope sheave bearing:
Roller bearing: Daily during continuous use or every 14 days with periodic use,
Thrust bearing on the hooks:
Roller bearing: 14 days during continuous use or monthly with periodic use,
4. Permissible Load
It is to be ensured that the permissible load, Save Working Load (SWL) or Working Load
Limit (WLL) stated on the bottom hook block are not exceeded.
5. Warning
Do not pull diagonally.
Apply load gradually without jerking.
A double hook is not to be loaded from one side.
Max. force applied to the rope lug =1/3 SWL
Do not carry out any welding work on bottom hook block parts.
Keep your hands out of the way of the rope sheaves and other moving parts.
In those areas in which loads are transported or in which loads are moved using a bot-
tom hook block, employees must wear personal protective clothing.
Instruction manual
5.6.9 Slew ring gear
5.6.9.1 Lubrication and Maintenance
The first relubrication of the raceway and lubrication of the gear must be carried out imme-
diately after installation. For this and each subsequent lubrication, the lubricants named in
Table of lubricant (see item 5.4, page 9) are to be used. These raceway greases are solely
KP 2 K greases, i.e. lithium-saponified mineral oils of NLGI Grade 2 with EP additives. The
raceway lubricants listed in Table of lubricant can be mixed together. The lubricants are
listed in random order and not according to quality. The grease filling is there to reduce fric-
tion, seal the bearing and provide protection against corrosion. Therefore, the bearing must
always be greased liberally so that a collar of fresh grease forms around the whole circum-
ference of the bearing gaps and seals. The bearing should be rotated during relubrication.
5.6.9.2 Lubricants
The appropriate manufacturer should answer queries concerning lubricants. The greases
listed in Table of lubricant are approved for our large diameter anti friction bearings and
tested for compatibility with the materials stipulated by us for spacers and seals.
It is the responsibility of the maintenance personnel to ensure individual consumption rates
by accurate checking of the lubricated condition of both the raceway and gear.
Lubrication intervals
are to be selected according to the operating condi-
tions; generally every 100 operating hours, roller
bearings every 50 operating hours.
Shorter greasing intervals must be used:
in tropical regions in the presence of high
humidity, dust or dirt strong temperature fluctua-
tions, and for continuous rotation,
If there are standstill times between bearing
installation and equipment start-up, respective
maintenance procedures will be required, e.g.
relubrication under rotation no later than after 3
months and every 3 months thereafter.
Before and after prolonged stoppage of the
equipment relubrication is absolutely necessary.
This is especially important after a winter shutdown. When cleaning the equipment care
must be taken to prevent cleaning agents from damaging the seals or penetrating into
the raceways. The seals must be checked every 6 months.
Lubrication intervals for the gear
Pinion and gear are to be greased sufficiently with grease recommended in table of lubri-
cant. Weekly gear lubrication is recommended. The gear should always have sufficient
grease.
Checking of bolts
The stud bolts are tightened twice at assembly / when fitted using a clamping cylinder, which
stretches the screws with a corresponding tensile force.
The bolts connection has to keep a sufficient pre-load during the whole bearing life. For com-
pensation of settlement phenomena a refastening on regular base may be necessary.
It is necessary to check that the foundation bolts are secure. This is only possible by lightly
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knocking the nuts. If such knocking produces a different sound, it is mandatory to secure the
corresponding nuts with a striking-face wrench and hammer.
Checking of the raceway system
In their delivered condition large diameter anti-friction bearings have clearances which war-
rant good operating conditions and functional safety. When the bearing is put into operation,
we recommend to perform a base measurement. After a prolonged operating time, bearing
clearances will increase. It is, therefore, necessary to check the axial movement or settling
at regular intervals.
For assessing the condition of a bearing, we recommend that its normal wear rate is deter-
mined. The wear present in the raceway system shows itself by a change in the axial motion
of the bearing. Depending on the individual conditions, wear can be determined either by
measuring the tilting clearance or by depression measurements.
Axial reduction measurement
An axial reduction measurement can be made when the centre of gravity of the load combi-
nations is within the track diameter of the bearing. The following picture (Fig. 26) shows the
loading principle:
A base value for the axial reduction measurement must already be determined when the
equipment is put into operation. The bolt connection must be properly tightened. Mark the
respective measuring positions on the circumference while keeping the boom in a specified
position.
The measurement is performed between the lower mating structure and the bearing bolted
to the superstructure. Record the base values obtained in tabular form and allocate them to
the respective base measurements (Fig. 28).The axial reduction measurement should be
repeated every twelve months as a minimum, under identical conditions. In case of heavy
wear the time intervals between measurements should be shortened. If the deviation from
the base measurement exceeds the maximum values, please consult NMF- Service.
Instruction manual
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5.6.10 Slip ring assembly
CAUTION
Prior to opening the slip ring assembly cover
switch off the voltage
protect the voltage against unauthorised activation.
1. The complete slip ring assembly including the brush holder and the insulating mate-
rial must be dry, dustless and free from grease.
The abrasion is to be carefully removed from the contact carbons.
Smooth oxidised parts of the running surfaces with a fine emery cloth.
2. Inspect the jointed arms of the brush holders for well running and force of pressure
by lifting them.
Replace tight jointed arms and brush holders which have a too low force of pressure.
Check whether all of the brush holders are positioned centrally to the slip rings.
CAUTION
Under no circumstances are the joints of the brush holder or the ring surfaces to be
greased or oiled!
3. Replace heavily worn contact carbons and carbons with burnt spots with new ones.
The contact carbons are only to be worn down to max. 1/3 of the original length.
If new contact carbons are necessary, it is important that both carbons in the brush
holder are replaced and that only contact carbons from the same manufacturer are
used.
The life time of the carbons depends on the operating time and the speed of the slip
ring assembly so it is impossible to state exact changing intervals.
New contact carbons have to be ground into the ring radius in order to achieve a large
contact surface. This is achieved by placing the emery cloth on the ring surface and
pushing it back and forth underneath the new carbons several times in order to grind
the ring radius into the carbon. The resulting dust is to be removed.
4. Check the tight fit of the connection cable at the ring and the brush holders. If neces-
sary, re-tighten the bolts.
5. Check the shaft blind flange, the cable screwed connection and the profile rubber
sealing of the slip ring assembly housing for impermeability. Defective parts have to
be replaced immediately in order to avoid moisture penetration.
6. Screw on the housing cover and check that it is tightly fitted.

Instruction manual
5.6.11 Load measuring bolts
Illustration23: Load measuring bolts
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5.6.12 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 extin-
guished. Tighten clamp bolt 1.1
4. Repeat the lowering process.
The lowering lift gear must be perfectly deactivated when the load hook is resting.
No rope layers are to jump over each other.
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5.7 Maintenance, service and discard criteria for wire rope
NOTE
Maintenance at regular intervals ensures a safe crane operation and considerably
increase the rope life. When exposed to the same test condition, a well-greased rope
has produced four times as many working cycles than an ungreased rope.
5.7.1 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 sheaves and the rope drum with a
non-caustic cold cleaning agent and dry it afterwards.
2. Especially grease the rope at the bending zones (drums and sheaves) The lubricants
to be used are stipulated in (see table 7.9, page 33). The re-greasing agents are to
be compatible with those used for the original greasing of the rope.
CAUTION
Ensure that 3 safety windings remain on the drum when the rope is unwound. Grease
the ropes again with a suitable lubricant and operate the crane for some work cycles
without load in order to distribute the lubricant properly.
If the lower layers on the drum are seldom used or not at all, they are to be unwound from
time to time and replaced under pre-tension. A rope works most economically if the com-
plete length is always used. Therefore, it is recommended that the appropriate rope length
be used for crane operations lasting longer periods of time.
Should parts of a rope be unequally loaded, one can turn the rope around after a certain
operation period. The end which was formerly free is fixed in the drum, so that the part of
the rope which was not formerly used is positioned in the zone previously occupied by the
part exposed to wear, the part exposed to wear now being positioned where there is less
wear, this results in a noticeably longer life.
If the wear mainly occurs in the multiple-layer coiling on the Lebus drum, the rope life can
be increased by cutting a length corresponding to 1/3 of the drum circumference. This can
be repeated max. twice.

Instruction manual
32 Copyright 2005
5.7.2 Monitoring
If necessary, the wire rope and the fastening of the rope end should be inspected for dam-
age on a daily basis. Any irregularities discerned are to be reported to the decision-making
party.
Wire ropes are to be inspected by trained specialists at regular intervals in order to ascertain
that they are in a safe operational condition. The inspection intervals are to be so deter-
mined that damage can be detected at an early stage. Therefore, the intervals during the
first few weeks of a new wire rope being laid on and after the first wire breaks are to be
shorter than during the remaining laying on duration. After being subjected to extraordinary
loads or if there is a suspicion of non-visible damage, the intervals are to be shortened
accordingly. Such an inspection is also to be carried after the crane is taken into operation
after it has been at a standstill for longer periods and after an accident or damaging event
which has occurred in connection with the use of the rope drive.
During this monitoring, special attention is to be paid to those parts of the rope which move
over the rope pulleys or which are close to differential pulley, rope suspensions or rope fas-
tenings.
Crane ropes are so designed that should an initial wire breakage take place, there is still
sufficient room for a safe laying on.
The operational safety of the rope can be determined on the basis of this criteria
type and number of wire breakages,
position and temporal succession of the wire breakages,
reduction of the rope diameter during the period of operation,
Corrosion,
Abrasion,
Rope deformations,
Heat effects,
Lay-on duration
Special attention should be paid to changes in the rope behaviour which are just discernible.
CAUTION
As soon as the rope lines strike together above the crane block, there is a risk of
serious rope damage. This twisting is always caused by an additional torsion in the
rotation-resistant hoisting rope originating from a number of adverse effects but it
may also be due to an over expansion of the hoisting rope during heavy duty
operation. The compensation of such a torsion requires extreme care and profound
know-how.
Untwisting of the crane pulley block with rotation-stable rope fixed point:
1. Set the pulley block down.
2. Determine the direction of twist.
3. Detach the rope at the fixed point.
4. Carefully turn the rope at the free end by approx. 180-360 degrees to compensate
the pulley block twist. If necessary, determine the direction of the twist by means of a
string.
5. Reattach the rope at the fixed point.

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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 proce-
dure given for ropes with a fixed point, e. g. if no swivel exists or the rope is already dam-
aged or the reason for the twisting cannot be remedied otherwise.
The rope end connections and suspensions are also to be inspected in order to ensure that
they function correctly. The individual components of the rope drive unit, drums and pulleys
must turn freely in their bearings, grooves should not show any rope marks.
5.7.3 Wire changing
To avoid readjustments of the limit switches, please follow this procedure when changing a
wire.
Please note that the life of a rope depends on many influences. The ropes are mainly sub-
jected to internal friction and corrosion. However, a rope is to be changed after 5-6 years of
service.
1. Put the crane in its resting position
2. Slightly pull the luffing and hoisting wire.
3. Count the reels on the hoisting / luffing drum.
4. Make a note of the number of reels.
5. Remove the limit switch from the drum and secure it. Do not touch the shaft of the
switch.
6. Now change the rope.
7. When the new rope has been installed, count the reels. The number of reels must
agree with item. 4. Reinstall the limit switch.
8. For safety reasons, check the adjustments. Also refer to the assembly instructions for
the crane

Instruction manual
34 Copyright 2005
5.7.4 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 (see item 5.7.2, page 32), the following information stip-
ulates when the wire cable is to be replaced depending on the scope of the damage. A con-
tinued use can result in the operation of the hoist posing a risk.
1. Type and number of wire breakages
Rope drives are so designed that the wire ropes are not durable. For this reason, wire break-
ages occur during operation.
A wire rope is to be replaced if one of the number of visible wire breakages stipulated in the
table on page 3 are determined.
2. Position of the wire breakages
The wire rope is to be replaced upon occurrence of wire breakage clusters. The wire rope
is to be replaced immediately should a strand break.
Temporal sequence of the occurrence of wire breakages. In importance cases it may be
advisable to determine the number of wire breakages in relation to the time. From this, a
further increase in the number of wire breakages and the expected time of replacement can
be concluded.
In doing so, it should be taken into account that the initial wire breakages occur after a cer-
tain operational period and subsequently increase at a faster rate.
3. Reduction of the rope diameter during the period of operation
The wire rope must be replaced if the rope diameter is reduced by structural changes by
15% or more along longer lengths, when compared with the nominal size.
The requirement for this is that the tolerances of the new wire rope are also adhered to in
accordance with DIN 3055 - DIN 3070 even if the wire rope is not of a standard design.
4. Corrosion
Corrosion especially occurs when subjected to a saltwater atmosphere, with operation in a
corrosive atmosphere and with wire ropes which are laid on outside for longer periods. A
corrosion of the external rope can be determined by examination. Corrosion on wires which
cannot be perceived from the outside is difficult to determine.
Corrosion can reduce both the static breaking force of the wire rope due to a reduction of
the metallic cable cross section and the operational capacity due to corrosion pit.
If the rope diameter is reduced by 10% or more when compared with the nominal size, the
wire rope is also to be replaced if no wire breakages are determined.
5. Abrasion
Abrasion on the rope wires as internal abrasion resulting in the movement of the strands
and wires against each other when bending the wire rope and as external abrasion result-
ing from movements between the wire rope and the rope groove (e.g. due to the wire rope
slipping in the groove when starting and braking) or as a result of the wire rope trailing along
the floor or the items to be hoisted. Abrasion is encouraged by insufficient or no lubrication
and the effects of dust.
Abrasion can reduce both the static breaking force of the wire rope due to a reduction of the
metallic cable cross section and the operational capacity due to wear chamfer.
If the rope diameter is reduced by 10% or more when compared with the nominal size, the
wire rope is also to be replaced if no wire breakages are determined.
6. Rope deformations
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Deformation of the wire cable are visible changes in the rope bond. On the basis of their
appearance, differences are made between the following deformations:
Deformations in corkscrew form, contractions,
Basket formation, flattening,
Looping of wires, curl-shaped deformations,
Loosening of individual wires or strands, kinks and knots, buckling.
Deformations normally result in a loosening of the rope structure, at least close to the defor-
mation location. If the deformations are in a corkscrew form (see figure), the axis of the non-
loaded wire rope is helical.
36
Betriebsanleitung
Bordkran Typ DK II 40025 NMF
N u m b e r o f vis ib le w ire b re a k a g e s wh e n w ire ro p e is to b e re p la c e d
d rivin g g e a r g ro u p s
1E
m
, 1D
m
, 1C
m
, 1 B
m
1 A
m

d rivin g g e a r g ro u p s
2
m
, 3
m ,
4
m ,
5
m

c ro s s la y lo n g la y c ro s s la y lo n g la y
N u m b e r o f b e a rin g w ire s
in th e e xte rn a l s tra n d s o f
th e w ire ro p e
3
)
a lo n g a le n g th o f
6d 30d
6d 30d
6d 30d
6d 30d
B is 5 0 2 4 1 2 4 5
51 b is 75 3 6 2 3 6 12 3 6
76 b is 10 0 4 8 2 4 5 16 4 ~8
101 b is 1 20 6 10 2 6 10 19 ~ 10
121 b is 1 40 6 11 3 6 11 22 6 11
141 b is 1 60 6 13 3 6 13 26 6 13
161 b is 1 80 7 14 4 7 14 29 7 14
181 b is 2 00 8 16 4 8 16 12 8 16
201 b is 2 20 9 18 4 9 18 35 9 18
221 b is 2 40 10 19 5 10 19 38 10 19
241 b is 2 60 10 21 5 10 21 42 10 21
261 b is 2 80 11 22 6 11 22 45 11 22
281h i. 3 00 12 24 6 13 24 48 12 24
b e r 3 00
4
) 0. 04 n 0.08 *rn 0, 01 *n 0 .04 *n 0. 08 *n 0 ,16 *n 0.04 *n 0. 08 *n
W ith ro p e d e s ig n s with s p e c ia lly th ic k wire s in th e e xte rn a l la ye r o f th e e xte rn a l s tra n d s , e . g . 6 x 19 S e a le -
typ e ro u n d s ta n d ro p e in a c c o rd a n c e w ith D I N 3 058 o r 8 x 19 ro u n d s tra n d ro p e in a c c o rd a n c e w ith D I N
3062 , th e n u m b e r o f vis ib le w ire b re a k a g e s a re to b e s e e n a s b e in g 2 lin e s le s s th a n th e ta b le va lu e s .
D rivin g g e a r g ro u p s in a c c o rd a n c e w ith s h e e t 1 o f D I N 15 0 20.

d wire ro p e d ia m e te r
3) F ille r wire is n o t s e e n a s b e in g b e a rin g
I f wire ro p e s h a ve n u m e ro u s s tra n d la ye rs o n ly th e s tra n d s in th e e xte rio r s tra n d la ye rs a re "e xte rn a l
s tra n d s ".
I f s te e l ro p e s h a ve a s te e l re in fo rc e m e n t, o n ly th e re in fo rc e m e n t u s is to b e s e e n a s b e in g a n in te rio r
s tra n d .

4) T h e c a lc u la te d fig u re s a re to b e ro u n d e d u p .

Copyright 2005 Monitoring, Failure, Troubleshooting and Elimination 1
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6 Monitoring, Failure, Troubleshooting and Elimination
All work on the cranes electrical equipment must be carried out by trained electrical
specialists only.
Any interventions in the cranes control programme are only to be carried out by Neuen-
felder Maschinenfabrik GmbH or with its approval.
Repairs and inspections are only to be carried out when there is no load on the hook.
Place the load on the ground first. (see item 6.10, page 20).
6.2 Requirement of personnel
Only remedy a fault if you are qualified to do so.
Please also read (see item 2.2, page 1).
6.3 Monitoring, failure, troubleshooting and elimination
The troubleshooting list is provided in order to assist you with the remedying of any faults on
the slewing 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.
6.4 Brake relay monitoring
For safety reasons, the solenoid valves for the lifting gear, slewing gear and jib brakes are
triggered by 2 relays situated in a row. This switching guarantees the greatest possible secu-
rity. Should a relay bond and the contact no longer open, the second relay is still able to
switch the brake off safely. The relays are always monitored by the SPC. The relay is
checked 0.5 sec. after the brake has been released. Should a relay still have a closed con-
tact, an error message is transmitted to the crane operator. At the switch cabinet, it is pos-
sible to determine which brake control is defect.
Lifting gear brake: Relay 1K26, 1K35
J ib brake: Relay 1K25, 1K34
Slewing gear brake: Relay 1K24, 1K33
Instruction manual
2 Monitoring, Failure, Troubleshooting and Elimination Copyright 2005
6.5 Speed monitoring of the jib winch and lifting gear winch
The jib and lifting gear winches are equipped with a speed monitoring. Should the maximum
speed be exceeded due to a drive fault, a forced braking is automatically activated. The
FAULT lamp on the left control panel in the cabin is illuminated, in the switch cabinet, the
lamps excess winch speed, excess jib winch speed. The crane operator is unable to
restart the winch. The fault can be eliminated with the Reset excess speed button (see
illustration 50, page 7).
Should there be a deactivation due to excess speed and there are no faults on the drive, the
excess speed monitoring can be deactivated.
NOTE:
A deactivation of the excess speed is only to be carried out with the agreement of the
manufacturer.
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 lamp 2H9 is illuminated.
Terminal strip 1X2 terminal 49+50
If the link between terminals 49+50 is removed, the jib gear is no longer switched off by
excess speed. Only the fault lamps 2H9 is illuminated.
6.6 Fault notification card
(see item 50, page 7).
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.
Should the crane have a fault, the corresponding lamp on the fault message card is illumi-
nated. After acknowledgement (press button) the lamp continues to illuminate until the fault
is cleared. (see E-Drawing)
6.6.1 TEST OPERATION switch
In Test Operation, (see item 3.20.7, page 27) the control can be driven to all areas electri-
cally. The E-motor or the hydraulic pumps respectively do not also run. The Test Operation
mainly serves for troubleshooting.

Copyright 2005 Monitoring, Failure, Troubleshooting and Elimination 3
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6.6.2 TEST LOAD 132t switch
The switch is in the switch cabinet. (see item 48, page 5).
The switch is only to be activated if the crane is to be subjected to a loading test.
6.6.3 RESET button
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 inspec-
tion. If this is carried out and no defects are determined, the Reset button in the switch cab-
inet must be activated. (see item 48, page 5)
6.6.4 Switch Bridge Limit Switch Lifting gear
(Switch cabinet switch, Seite 5)
The switch is located in the switch cabinet. If this switch is switched on, the limit switch lifting
gear 5 Hook up on jib 21,0 m may be subjected to overriding. This may be required for very
heavy loads in order to ensure a greased lifting height.
CAUTION:
The hook my collide with the jib.
Instruction manual
4 Monitoring, Failure, Troubleshooting and Elimination Copyright 2005
6.7 Diagram Overload
Choose the next bigger load
step. Luffing up the luffing gear
into the necessary position.
(Outreach)
Set key switch of the DMSA on
ALARMS AND WARNING
DEACTIVATEDLifting down
the load. If necessary manually
from hand. (see item. 8)
Set key switch on the DMSA on
Running.
Lifting up the load again
Overload through DMSA .
Overload
RED PILOT LAMP OVERLOAD LIGHTS IN THE RIGHT CONTROL PANEL
yes
no
Overload through pressure switch
If necessary manually from
hand. (see item. 8)
Choose the next bigger load
step. Luffing up the luffing gear
into the necessary position.
(Outreach).
Display
on the
DMSA
blinks.
again
Overload?
no
yes
o.k.

L ook f or the pressure swi tch i n
the el ectri c di agram; f or exempl e
.:
C heck the i nput (f .e. i nput 5) on
the P L C - modul e (f .e. 1A 7).
L i ghts no thi s pi l ot l amp at
acti vated control l ever, check the
pressure swi tch, i f necessary
change thi s.
Monitoring, Failure, Troubleshooting and Elimination 5
Betriebsanleitung
Bordkran Typ DK II 120016/55033 NMF
6.8 Fault Search Diagram
Illustration24: Electrical fault
Unlock emergency off pushbuttons by
pulling or turning.
Fault R emedy P robable cause
C heck autom. circuit breaker locate short
circuit.
C heck oil level. Replenish if required. If oil
level is correct, the aux. contactor must
respond
C heck fuses. Measure main feeder.
Ambient temperature too high. C rane is
permanently operated at its load peak.
C ool down el. motor.
C heck 24 VDC input ; change S P S - 4
The switch for test operation is
switching on.
S ee failure of pump unit.
E l. motor does not start
E l. motor starts in S tar/ Delta, but
stops again immediately.
C ontrol light 'ready for operation'
alight, but el. motor does not
start.
E mergency Off pushbuttons in control
console at access or in switch cabinet or
crane foundation are actuated.
No 230 V control voltage available.
No voltage at 440/400 V control
Lack of oil. S ee failure pump unit
Asymmetric relay has tripped, the red and
green LE D do not light.
P ower LE D does not lights up,
or R UN LE D flashes.
F ailure of electric
Tripping device has tripped owing to
winding temperature, LE Ds are alight.
Main switch is cut off. S witch on main switch in energize room
R eplases fuses. In case of repreated
defect look for possible short circuit in main
cable and slip ring unit.
C ontrol of main fuses blown.
S ee interfrence pilot print card.
(switch board)
Failure lamp in the control consol lights up.
R eset S witch is actuated.
C heck the hydr. system (hydr. hose
damage) R eset switch switching off.
The switch for test operation
switch off.
No 24 VDC input ; S P S 4 defective
Betriebsanleitung
Illustration25: Pump unit fault
Fault Remedy Probable cause
Repeat start procedure and watch LED's in
switch cabinet for proper function of feed
pressure switches. The pilot lamp will not
show for defective feed pressure (to be 25
bar) to find whether pump or hydraulic piping
is defective. Remedy fault. Do not bridge over
defective feed pressure switch!
Change the pump.(see check the pump)
Power pack startup
and close down again.
One or more feed pressure switches not
working.
Pump defect.
Fault of power pack
Meter current supply. Examine valve for being
clogged. Exchange solenoid.
Control pressure bypass valve does not
switch or is mechanically blocked.
Trace source of leakage, remedy leakage and
refill oil (for oil types see table of lubricant).
Leak of oil. Failure lamp lights up.
Change the hydr. hose. Reset switch
switching off.
Hydr. Hose damage.
Repeat start procedure and watch LED's in
switch cabinet for proper function of gear
Oil cooler. Check the motor circuit breaker.
Gear oil cooler is no starting.
Betriebsanleitung
Illustration26: Lifting gear fault (electr.)
Input LED Memory-Programmable Control (MPC) do
not light up.
Check potentiometer on control lever, whether it is
maladjusted or defective.
Check aux. contacts on control lever.
Check Current Regulator print card, the red current
instrument must be alight. Depending on 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.
Check proportional solenoid valve.
Slack wire rope switch has switched. Input LED light
up. LED of the solenoid valve light up.
Check Current Regulator print card. Depending on
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.
Lifting winch turns only at
half speed.
Current Regulator print card are not contacted.
Current Regulator print card are defective and/or the
32 V AC power supply has failed.
Lifting winch turns only in
"Lifting" mode.
Current Regulator print card are defective; one or
both proportional solenoids on one lifting gear is/are
defective.
Failure of Lifting Gear (el.)
Lifting winch does not turn.
Find cause for overload (perhaps reduce load).
Check, whether over load system has turned off.
(if available).
Check crosspoint relay and output LED of MPC.
Crosspoint relay does not tighten up, brake do not
ventilate. Output LED do not light up.
Input LED for the control lever do not light up.
Solenoid valve defective.
Betriebsanleitung
Illustration27: Lifting gear fault
Lifting winch starts to lift the
load, but the brake responds
again.
This repair must only be carried out by an expert,
Fault
Remedy Probable cause
See list of el. Failures
Remove alternatingly the pump control solenoid plugs to
locate the defective pump. Separate all pressure connections
of the defective pump from the system and all connections to
be blanked off.
The pump pressure should be measured. If the pressure
drops, the motor or the pump are defective.
Select corresponding load stage, reduce load resp.
The jib to be topped up or the load to be attached shorter.
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
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 two-speed valve on lifting winch
motor jams.
The lifting gear motor is still switched
to half-load.
Lifting winch does not lift;
nominal load at half speed
resp., but the brake remains
open.
Pressure relief valve on one lifting
gear pump is defective or fouled. One
pressure cut-off is maladjusted or
defective.
The lifting gear pumps, one pump
resp, are not actuated electrically.
One lifting gear pump is defective.
Leak oil portion of lifting winch motor
is too excessive.
Incorrect load stage selected or the
load is too heavy.
Lifting gear has reached its highest
hook position at maximum outreach.
Load pressure switch maladjusted.
Check half-load solenoid for proper operation and fouling.
Failure Lifting Gear
The lifting winch should be checked by an " expert. Prior to
dismounting the lifting winch motor, if required, the load
should be lowered first.
Betriebsanleitung
Illustration28: Lifting gear fault
Failure of Lifting Gear
Lifting winch turns only in
"Lifting" mode and for a short
time; not in "Lowering" mode
resp.
Defective or fouled brake solenoid valve. No
power supply to solenoid valve.
Actuate pump control solenoids manually,
whether the pump supplies pressure.
Oil-air cooler has failed; perhaps the fuses or
motor protective device are defective. V-belt for
gear oil cooler slips or is defective. Excessive
heat will occur in pump distr. gear, pump and
hydraulic oil.
See list of el. failures
Actuate by hand alternatingly the pump control
solenoids. The system pressure required must
be achieved, as the brake is closed.
Check limit switch for proper working and
adjustment Check whether supply line is clear.
Check limit switches and readjust if required.
The 'Lowering` limit switch must be so adjusted
that three safety wire rope turns remain on
winch drum at lowest hook position.
The pressure relief valve on one lifting gear
pump or packing are defective. Leak oil
portion too excessive i.w.o. lifting winch
motor.
Pump control solenoid "Lowering" is
defective, fouled or is not contacted/does
not respond electrically.
Lifting winch does not turn.
The lifting winch does not hold
the load with the brake being
open.
Brake does not vent. No control pressure.
Lifting gear pump is not contacted/does not
respond. Pump control solenoids are
defective.
Operating and oil temperatures too high
thus switching off the pump contact for
crane functions all;
Current Regulator print card defective.
Potentiometer on lifting gear control lever
defective.
Hydraulic motor is defective.
Limit switches are jamming; supply line
is defective resp.
Slack wire rope switch or " Lowering" limit
switch have switched/responded.
Actuate by hand the pump control solenoid and
check to assure maximum working condition.
See list of el. failures.
Check pump pressure with the brake being
closed. In case of a pressure drop stop crane
operation and request Suppliers .Service.
Betriebsanleitung
Illustration29: Luffing gear fault (electr.)
Input LED (MPC) do not light up.
Check potentiometer on control lever whether it
is maladjusted or defective.
Fault
Aux. contacts on control lever to be checked.
Current Regulator print card. Depending on
direction of operation the red must be alight
LCD and the ammeter must indicate a value.
Alternative, set in and check Current Regulator
print Card into the other crane.
Check Capacity Regulating Card.
Exchange defective Capacity Regulating Card.
Topping winch does not turn
Current Regulator print Card does not
respond.
The LED for "Topping Up" and/or
"Lowering" do not alight.
Current Regulator print card the 32 A AC
supply has defective or failed.
On the Capacity Regulating Card the
luffing gear control part is maladjusted or
defective.
Failure of Luffing Gear(el.)
Check crosspoint relay and output LED of MPC
Crosspoint relay does not tighten up, brake do
not ventilate. Output LED do not light up.
Betriebsanleitung
Illustration30: Luffing gear fault
Luffing gear winch does not keep
the crane jib, with the brake being
open.
Brake solenoid valve defective or fouled. Actuate
solenoid valve by hand, to check whether it works
properly. Clean or renewsolenoidif required.
Foult
Pump control solenoid valves to be actuated by hand
and check whether they are working correctly. Check
solenoids and clean, renew resp, if required.
No fault; normal operation.
Check pump pressure at closed brake. In case of a
pressure drop the crane to be put out of order and
request Supplier's service .
This repair should only be carried out by an expert.
Defective luffing gear pump; no or little pressure
only available.
Luffing gear winch turns only very
slowly.
With load on the hook the luffing
gear winch does not lift the crane
jib very slowly resp.
The brake does not vent. No control pressure on
brake.
The luffing gear winch does not respond. Pump
control solenoids are defective or fouled.
Capacity Regulating Card is defective.
Potentiometer on luffing gear control lever is
maladjusted. Automatic creeping speed is
permanently switched.
Current Regulator print card is defective.
Potentiometer on luffing gear control lever is
defective, Limit switches jam or supply is defective.
Under full load and actuating all functions the
capacity regulating is activated. The crane jib has
reached its creeping speed range.
Pressure relief valve "Topping Up" is defective or
packing is defective. Too large leak oil portion
occurs in luffing gear winch motor..
The spring in the pressure relief valve "Topping Up"
is weak. The pressure cut-off on the pump is
maladjusted. Control pressure too low.
See List of el. failures.
Failure of Luffing Gear
Luffing gear winch does not turn,
but pump pressure is available.
Current Regulator print card maladjusted or
defective. Potentiometer on luffing gear control
lever is maladjusted.
Blank off pressure pipe lines and actuate pump control
solenoid valves by hand. In case of a pressure drop or
no pressure at all, the pump should be renewed.
Betriebsanleitung
Illustration31: Luffing gear fault
Luffing gear winch stop at no
maximum outreach.
No fault; normal operation.
Fault
Lifting gear to be operated approx. 1 m
in "Lowering
Check pump control solenoid valve
Lowering" for easy working; exchange
solenoid if required. See list of el.
failures.
Check limit switch, readjust if required;
by no means to be bridged. For
adjustment see el. Circuit Diagram.
Check key-type switch and limit switch
for correct working. Defective switches
must be renewed.
Luffing gear winch does
not turn in direction of
"lowering.
The crane jib has reached its maximum
outreach at the individual load stages.
Lifting gear is at its uppermost hook position.
Luffing gear pump does not respond. Power
control p.c.b. defective. Potentiometer at
luffing gear control lever defective.
Luffing gear limit switch maladjusted or is
jamming, wire rupture.
Key-type switch "Put Down J ib" is defective or
jams. Limit switch for jib 0 position is
defective
Failure of Luffing Gear
Betriebsanleitung
Illustration32: Slewing gear fault (electr.)
Failure of Slewing Gear (el.)
Check potentiometer on control lever, whether
maladjusted or defective.
aux. contactors on control lever.
Check Current Regulator print card, the red current
instrument must be alight. Depending on operating
direction the red LED must light and the ammeter
must indicate value.
Alternative set in and check Current Regulator print
into the other crane.
Check Capacity Regulating Card. Defective card to
be renewed
Crane does not slew Power control is not contacted.
Input LED does not light up.
Current Regulator print card is defective or
the 32 V AC supply has failed.
Slewing gear control part on Capacity
Regulating Card is maladjusted or
defective.
Check contacts, perhaps exchange. Contacts on the control lever do not open.
The brakes do not close with
"zero-position" of the control
lever.
Betriebsanleitung
Illustration33: Slewing gear fault
Brake solenoid valve defective or fouled. Actuate solenoid by hand to check
whether it works freely. Clean or renewsolenoid, 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
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.
Actuate pump control solenoid valves manually and check whether they
work freely. Check solenoids, and clean or renewif required.
No fault; is normal operation.
This repair must only be carried out by an expert.
Slewing gear pump is defective; and does not
produce any pressure or only little pressure.
Crane does not slew, but pump
pressure is available.
Slewing gear brakes do not vent, no control
pressure.
Slewing gear pump is not contacted electrically.
Current Regulator print card is defective.
Potentiometer on slewing gear control lever is
defective.
Slewing gear motor(s) may be defective.
Slewing gear pump is not contacted. Pump control
solenoid valves are defective or fouled.
At full load and actuating all functions, the power
limit is activated.
The pressure cut-off on pump is maladjusted. The
pressure springs in pressure relief valves are weak.
Current Regulator print card is maladjusted or
defective. Potentiometer on slewing gear control
lever is maladjusted.
Blank off pressure lines and actuate pump control solenoid valves manually.
In case of a pressure drop or no pressure at all, renewpump.
Failure of Slewing Gear
Crane does not slew; but brakes
open.
Crane slews very slowly or comes
to a standstill.
Copyright 2005 15
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6.9 Brake
The multiple-plate brakes are installed as compact unit between driving motor and transmis-
sion.
Illustration 34: Structure parts of brake
6.9.1 Description
In the case of hydraulically-controlled, spring loaded brakes the disk assembly is pressed
together by a set of coil springs. The annular housing (2) with toothing for engagement with
the outer disks (5) and piston (1/1) and cylinder (1/2) are combined in a unit (see picture 7).
This brake unit is secured on the gear by anti-fatigue bolts (12). The disk ring (4) is provided
with toothing to engage with the inner disk (6) and is connected with the shaft to be braked.
The brake is released by oil pressure.
6.9.2 Connections
The brake is provided with connections for the intake of the pressure media. These have to
be connected with the hydraulic system of your installation. Dimensions and position of con-
nections can be taken from the mounting design enclosed.
Unscrewing or removing of hydraulic pipes under pressure resp. of connections are
hazardous. Take care that -in case of works at the brake (mounting, dismounting)- the
brake and the belonging hydraulic pipes are depressurized.
!
Instruction manual
16 Copyright 2005
Illustration 35: Lamellar brake
Copyright 2005 17
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6.9.3 Pressure media
Hydraulic oil is necessary to release the brake. Viscosity should not exceed 32 to 68 cSt at
40 C.
6.9.4 Operation
The brakes are designed for max. 320 bar operating pressure. The minimally needed
release pressure can be taken from the rating plate.
Never operate the brake with higher pressures than 320 bar, because there is danger
of screw breaks resp. the break of safety rings. Don`t operate the brake with low
release pressure because it isn`t layed out to work as a dynamically brake. In such
case it will be damaged.
6.9.5 Manual emergency release
In case of breakdown of the hydraulic system or in case of maintenance work the brake can
be opened mechanically. For that purpose a hand operated hydraulic pump can be con-
nected to the compressed oil connection of the brake. According to with the minimum
release pressure see rating plate admit the brake.
6.9.6 Brake maintenance
The brake adjusts it self automatically.
Low leakage oil quantities at the piston are unavoidable as a result of high pressure forces
and frequent switching.
The lamellars have to be changed when subjected to wear. The wear makes itself known
when the brake moment is not longer achieved. The 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.
When the seals are replaced, all sealing elements must be renewed and not just the dam-
aged seal ring, i. e. seals must be replaced in sets.
GUARANTEE THAT THERE IS NO PRESSURE AT THE HYDRAULIC CONNECTIONS
OF THE BRAKE. BEFORE DISMOUNTING THE BRAKE - RELEASE IT MANUALLY AS
DESCRIBED IN (SEE ITEM 6.9.5, PAGE 17) (SEE ITEM 6.9.7, PAGE 17).
6.9.7 Dismounting and assembly
The flange (1/3) is under spring pressure. It can suddenly come off when unscrewing the
screws(12). It is necessary to release the brake manually before dismounting. Insert two
screws of suitable length with nuts in the threaded borings of the piston (1/1) opposite each
other at 180on the face ends (see picture 7.7). Each nut must be tightened alternately with
a half turn, by that with draw the piston to the flange (1/3) - (Avoid tilting the piston!). Then
unscrew the screws(12), the closed brake can be removed from the gear.
!
!
Instruction manual
18 Copyright 2005
Illustration 36:
To dismantle further, unscrew the two screws (1/7). It is now possible to pull the flange (1/
3) with piston (1/1) out of the cylinder (1/2). When replacing the outer and inner seals, pay
attention to the position of the seals to ensure that they are reinstalled in the same way.The
chromium-plated and super-finished piston tracks must not be damaged in any way. Ensure
complete cleanliness! (Do not use cleaning wool).When replacing disks, first guide the
annular housing (2) alone onto the gear centre. The disk assembly should then be fitted.
Ensure that the correct disks are fitted. Pay attention to right disk placement because it is
important for the braking torque. The correct disk placement can be taken from the technical
data sheet enclosed.If it will be necessary to pull the flange (1/3) of the piston (1/1), it will be
done by alternate unscrewing the nuts, placed on the screws for emergency release. Never
screw out the screws for emergency release before complete releasing of springs between
piston and flange (danger of accident!).
The brake is assembled in reverse order.
MOIST THE DISCS BEFORE ASSEMBLING.
Take care that no foreign lubricants (mounting grease, greases, lubricating masses or oth-
ers) penetrate in the disk housing, because the coefficient of friction of the disk pairs can be
influenced and the good functioning may be made doubtful.
Spare disks are supplied in sets. The designations of the disks and brake as well as the size
and number of disks are specified on the packaging. It is not possible to identify the disks
for functional reasons.
!
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6.9.8 Malfunctions
Braking torque falls down or is too low
Check the right disk placement.
Replace disk assembly if excessively worn.
In the case of dry operation, check whether it was possible for leakage oil to escape.
Brake becomes warm
Check that release pressure is sufficiently high.
Brake constantly receives upstream pressure.
Instruction manual
20 Copyright 2005
6.10 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
For this, the following is necessary:
1. Open the corresponding bypass valves 3.1; 3.2 lifting gear pump, 4.1; 4.2 luffing
gear pump, 5.1; 5.2 of the slewing gear pump. (see illustration 39, page 26).
2. with the brake lifting pump lift the corresponding brake. (see item 6.11.1, page 21)
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.
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6.11 Lifting gear
CAUTION:
If the hook is under load, the jib already lowers the load at a braking air pressure of 3-4 bar.
When the hook is under load, the braking torque is reduced by 30%.
6.11.1 Connect the hand pump for opening the brakes as follows.
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the lift-
ing gear brake.
2. Disconnect the brake hose 5 of the lifting gear brake to the solenoid valve(see illustra-
tion 37, page 24)
3. Connect the hose 2 of the hand pump for lifting the brake (see item 38, page 25) to the
brake hose5.
4. Plug the connection Y to the solenoid valve of the lifting gear using a screwed plug.
5. Connect the pressure release valve 5 to the hand pump for lifting the brake and check the
oil level in the pump tank (see illustration 38, page 25).
6. Open the corresponding bypass valves 3.1; 3.2 on the lifting gear hydraulic pump. (see
7. Carefully increase the pressure at the hand pump (max. brake opening pressure approx.
20 bar) until the winch drum starts to rotate slowly (max. 2-3 rpm). If the winch drum
rotates faster immediately open the pressure release valve 5 for the hand brake lifting
pump.
8. After the load is lowered, restore the original situation.
Instruction manual
22 Copyright 2005
6.12 Jib
CAUTION:
Due to the tare weight of the jib, this already lowers at a hand brake air pressure of 3-
4 bar. This reduces the braking torque by 30%.
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the luff-
ing gear brake.
2. Disconnect the brake hose 4 of the luffing gear brake to the solenoid valve (see illustra-
tion 37, page 24)
3. Connect the hose 2 of the hand pump for lifting the brake (see illustration 38, page 25) to
the brake hose 4.
4. Plug the connection Y to the solenoid valve of the luffing gear using a screwed plug.
6. Open the corresponding by-pass valves 4.1;4.2 on the luffing gear hydraulic pump. (see
7. Carefully increase the pressure at the hand pump until the winch drum starts to rotate
slowly (max. 2-3 rpm). If the winch drum rotates faster immediately open the pressure
release valve 5 for the hand brake lifting pump.
8. After lowering the jib, restore the original situation.
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6.13 Slewing gear
1. Find the solenoid valve block (see illustration 37, page 24) and the marking for the
slewing gear brake.
2. Close the ball valve (1)
3. Remove the screwed plug underneath the ball valve
4. Connect the hand pump hose to the screwed connection.
6. Open the corresponding bypass valves 5.1; 5.2 on the slewing gear hydraulic pump. (see
7. Increase the pressure at the hand pump. The brakes are now fully open at 20 bar, the
slewing gears are free. The crane can be turned with the assistance of an external winch.
8. To close the brakes, open the pressure release valve 5 at the hand pump for lifting the
brake.
9. After completing the work, restore the original situation.
CAUTION:
When releasing the brake, take care of the heel/trimming of the ship.
Instruction manual
24 Copyright 2005
Illustration37: Connections for the solenoid valve block
1. =Connection brake hose lifting gear
2. =Connection brake hose luffing gear
3. =Ball valve slewing gear
4. =Connection brake lifting pump
3.9 Solenoid valve for the lifting gear break
4.6 Solenoid valve for the luffing gear break
5.5 Solenoid valve for the slewing gear brake
2.2 Solenoid valve for the bypass
1
2
3
4
2.2 5.5 4.6 3.9
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Illustration38: Brake lifting pump
Instruction manual
26 Copyright 2005
Illustration39: Pressure limit valves at the pump (Sauer)
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6.14 Gear cam limit switch
Every person involved in operation, maintaining and repairing the limit switch must
be authorized, adequately trained and instructed.
6.14.1 Maintenance
When carrying out maintenance and inspection works, pay attention to chapter Safety
instruction
Generally no maintenance or inspection works at the geared limit switch are necessary. Do
not remove dust deposits on the contacts or in the contact space by means of compressed
air. The dust would penetrate into the contacts and would affect the switching capacity.
Do no use benzine for cleaning of the limit switch. The cap sealing has to be replaced
after having opened the cap after a longer period of operation.
6.14.2 Contact adjustment
Each contact is coordinated by an adjustable pack of cam discs consisting of the cam discs
(6) and (7). The cam disc packet and the selector shaft are held in the selector shaft groove
by means of a ring (2) and the toothing of the disc.
The cam disc part (7) is infinitely adjustable in a radial direction by slewing the self-locking
screw (8) in a ratio of 74 : 1. An extremely fine adjustment is possible with the turn of a
screwdriver.
In order to reach the screw (8) with a screwdriver, the nut (3) must be loosened somewhat.
The corresponding cam disc pack can then be radially adjusted without the other cam disc
packs being adjusted.
The cam disc (7) is designed in such a way that the effective path and an overrun path are
provided. No damage is caused by an exceeding of the overrun path but there is once more
an opening or closing of the contact.
Adjustment of crane cam discs (see illustration 40, page 27)
Illustration40: Gear cam limit switch

Instruction manual
28 Copyright 2005
6.14.3 Home position :
J ib is in the park position
Cam controllers for luffing gear WW0 and WW1 switch during lowering.
Cam controllers luffing gear WW2 - WW7 switch during hoisting.
Cam controllers hoisting gear HW1 - HW6,HW8 switch during hoisting.
Cam controller hoisting gear HW7 switches during lowering.
Direction of rotation A on the gear side =lower
Direction of rotation B on the gear side =hoist
The direction of rotation is opposite on the cam controller side
(see Figs. 1+2)
6.14.4 Perform the following work
1. J ib is in the park position,
turn cam WW0 on luffing gear limit switch towards B until the LED 0 on the 1A12
goes out. (see illustration 42, page 31)
2. Measure maximum length for the hoisting gear (33m) from the middle of the crane's
pivot to the middle of the hook.
Luff up the jib - up to the measured point (maximum length of jib)
Turn cam WW1 on the luffing gear limit switch (see Fig. 2) in the direction B until
LED 1 on the 1A12 goes out.
3. Move bottom hook block to around 1m below the jib head.
Turn cam HW1 on the hoisting gear limit switch in the direction A until the LED 8 on
the 1A12 goes out.
4. Turn cam HW2 on the hoisting gear limit switch (see Fig. 2) in the direction A until
LED 9 on the 1A12 goes out, then back again in the direction B so that the LED 9
only just comes on again.
5. Run-on stage for bottom hook block.
Measure 24m length of jib from the middle of the crane pivot to the middle of the
hook.-Luff up jib to the measured point.
Turn cam WW2 on the luffing gear limit switch in the direction A until the LED 2 on the
1A12 lights.
6. Move bottom hook block again to around 1m below the jib head.
the 1A12 goes out.
7. Measure 19m length of jib from the middle of the crane pivot to the middle of the
Turn cam WW3 on the luffing gear limit switch in the direction A until the LED3 on
the 1A12 lights.
the 1A12 goes out.
9. Measure 16m length of jib from the middle of the crane pivot to the middle of the
the 1A12 lights.
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the 1A12 goes out.
11. Measure 6,0m length of jib from the middle of the crane pivot to the middle of the
hook.
Luff up jib to the measured point.
(This is where the speed reduction range 6,0m -3.3m begins for the jib.)
the 1A12 goes out.
hook.
the 1A12 goes out.
hook.
Between crane housing and stop bumper of the jib should be a distance of approx.
100 mm remain.
the 1A12 goes out.
NOTE:
The jib should not touch the crane housing, to turn off absolutely before.
14. The rope from the hoisting gear can be wound twice around the drum.T
the 1A12 goes out.
15. Move the bottom hook block down until the hook is approx. 1m above the double bot-
tom. There must be at least 3 safety windings left on the hoisting drum.
Turn cam HW7 in the direction B until LED 14 on the 1A12 goes out.
16. If the drum full, turn cam HW8 on the hoisting gear limit switch in the direction A until
the LED 15 on the 1A12 goes out.
17. After adjusting the limit switch, run through the luffing and hoisting gear.
When luffing down the jib and switching off the hoisting gear the jib may not touch the
bottom hook block.
18. Slew the crane into the park position.
Press the Park jib key switch and hold down, the jib moves to the park position.

Instruction manual
30 Copyright 2005
Illustration41: Limit switch adjustment hoisting gear
HW0
HW1
HW5
HW3
HW2
HW4
B
A
B
A
Modul 1A12
HW6
HW7
HW8
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Illustration42: Limit switch adjustment luffing gear
WW0
WW1
WW2
WW3
WW4 WW6
WW7
B
A
B
A
Module 1A12
Instruction manual
32 Copyright 2005
Illustration43: limit switch adjustment jib
33,0m
Parkposition
24m
16m
6m
4,2m
WW0
WW/1HW1
WW2/HW2
WW3/HW3
WW4/HW4
WW5
19m
3,3m
WW6
WW7
Copyright 2005 33
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6.15 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 Figure 1).
Open the cover of the input and output terminals (see Figure 2 Do not disconnect the wir-
ing
Pull the cover to disconnect the plug (see Figure 3)
After the new PS4 has been installed, the memory is to be inserted. (see Figure 5-6).
EM4:
Disconnect the wiring of the power supply lines (see Figure 7
Open the cover of the input terminal (see Figure 8). Do not disconnect the wiring of the cable
Pull the cover to disconnect the plug (see Figure 9) Open the cover in the middle and
release the data lines to the next LE (see Figure 10 Now release the plug of the data line of
socket 1 (see Figure 12). This data line connects the PS4 with the EM4.
The EM4 can be removed from the top hat rail after all wires have been released.
Before the new EM4 can be switched on, all codification switches are to be adjusted follow-
ing the instructions given in the electric diagram (see Figure 13).
LE4:
Open the cover of the input or output terminals (see Figure 14).
Do not disconnect the wiring
Pull the cover to disconnect the plug (see Figure 15) Then open the cover in the middle and
release the data lines to the other LE4 (see Figure 16).
The instrument can now be removed from the top-hat rail.
Instruction manual
34 Copyright 2005
6.15.1 Changing the battery.
(see Fig. 16)
Only change the battery when switched on as there could otherwise be a loss of data.
When changing the battery:
Only disconnect the plug when switched on!
Caution:
Change the battery every year!!!
Prove that the battery has been changed with date and signature

Copyright 2005 35
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PS4.
break button
insert memory card
memory card
switch to position 3
Fig.1 Fig.2
Fig.3 Fig.4
Fig.5 Fig.6
Fig.1 Fig.2
Instruction manual
36 Copyright 2005
Codierschalter
1
Fig.7 Fig.8
Fig.9 Fig.10
Fig.11 Fig.12
Copyright 2005 37
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Battery
Fig.13 Fig.14
Fig.15 Fig.16
Instruction manual
38 Copyright 2005
Copyright 2005 Spare Parts 1
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7 Spare Parts
7.1 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 writ-
ten approval, this especially being the case with regard to third 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.
Instruction manual
2 Spare Parts Copyright 2005
7.1.1 How to order spare parts
How to order spare parts
When ordering spare parts the following data are necessary:
Auftrags-Nr./Order -No.
Product See type plate
Type
Drawing -No. Part Denomination Quantity
879-4900-01(0) 20
4/2 Way solenoid valve 1 piece
P10P
We have the proprietary right in this presentation (drawing, sketch, photo, plan,
statement etc.) which is copyrighted according to provision of law. Without written
consent it must neither be used or exploited nor made available to third parties. Photos
from the goods manufactured according to this presentation must not be taken without
our written consent. The unauthorised use or exploitation is liable to civil or - should the
case occur- penal prosecution.
Indication:
Hinweis:
Reserveteilliste
Benennung:
NMF - Stckliste / NMF - Partlist
F02-6095 FA-Nr. / FA-No.
Bestellung Bemerkung Gewicht
Weight
Montage / Assembly Mechanik / Mechanical Stahlbau / Steelwork
Artikelnr.
Item-No.
Fertigungs-Beginn
Werkstatt-Termine / Date of workshop
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
Auftrags-Nr./Order No.: Baugruppe/Assembly:
DIN
Seite:
1
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
Zeichnungs-Nr./Drawing No.:
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Quantity: Date of production
Designation:
Date of issue
Handhebelfettpresse, besteht aus Pos. 02..04 1 01
Manual grease gun, consists of items 02..04
1250FT010 FETTPRESSE PK 56 1 02
grease gun PK 56
1250FT011 SCHLAUCH 160L 300 MM LANG 1 03
hose
1250FT005 KUPPLUNG 521A 1 04
coupling
1680MN003 MANOMETER 1 05
pressure manometer
1680MN005 MANOMETER 1 06
pressure manometer
1681MN202 MANOMETERMESSSCHLAUCH DN2 2 07
hose for gauge
1855PH310 BREMSLFTHANDPUMPE 1 08
manual pump for brackes
36 1980SL001 SEILEINZIEHSTRUMPF 1 09
wire rigging socks
3000FT004 SHELL ALVANIA FETT RL 2 10 010
greasr SHELL RL 2
3000SN004 FLACHSCHMIERNIPPEL H 1, M 10 x 1 10 011
flat grease nippel
2600VT039 4/2 WEGEVENTIL 1 012
4/2 way valve
O-Ring fr 4D01 20 013
o-ring for 4D01
2.460H 20LLP 1262FI321 FILTERERSATZELEMENT 2 014
filter element
kg Gesamtgewicht ca./Total weight approx.
Holler von/by: 27.02.03 Erstellt am/Prepared:
VS MV Mon Be Me St AV Verteiler/Distributor:
Anzahl/No. off:
TB EK Ma Druckdatum
30.06.05
Indication:
Hinweis:
Reserveteilliste
Benennung:
F02-6095 FA-Nr. / FA-No.
Weight
Artikelnr.
Item-No.
Fertigungs-Beginn
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
DIN
Seite:
2
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Designation:
Date of issue
1262FI200 ERSATZPATRONE 4 015
o-ring for HD -hose
9x2 DN 6 O-Ring fr HD-Schlauch 5 016
o-ring for HD-hose
o-ring for HD-hose
17x2,5 DN 16 O-Ring fr HD-Schlauch 5 018
o-ring for HD-hose
o-ring for HD-hose
o-ring for HD-hose
o-ring for HD-hose
o-ring for HD-hose
33x3,53 SAE 1" O-Ring fr HD-Schlauch 5 023
o-ring for HD-hose
37,7x 3,53 SAE 1 O-Ring fr HD-Schlauch 5 024
o-ring for HD-hose
G 8-PS Ermeto-Verschraubung 4 025
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Anzahl/No. off:
TB EK Ma Druckdatum
30.06.05
Indication:
Hinweis:
Reserveteilliste
Benennung:
F02-6095 FA-Nr. / FA-No.
Weight
Artikelnr.
Item-No.
Fertigungs-Beginn
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
DIN
Seite:
3
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Designation:
Date of issue
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
G 35-PL Ermeto-Verschraubung 4 033
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
SAE 1 " AFC 4 1343FL330 SAE-VERSCHLUFLANSCH 2 036
SAE- closed flange copanoin 6000 PSI
SAE 1 " GFC 4 1343FL350 SAE-VERSCHLU-GEGENFLANSCH 2 037
SAE- closed flange copanoin 6000 PSI
VK - 8 Ermeto-Verschraubung 4 038
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Anzahl/No. off:
TB EK Ma Druckdatum
30.06.05
Indication:
Hinweis:
Reserveteilliste
Benennung:
F02-6095 FA-Nr. / FA-No.
Weight
Artikelnr.
Item-No.
Fertigungs-Beginn
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
DIN
Seite:
4
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Designation:
Date of issue
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
Ermeto-fitting
049

050

051

052

053

054

055

056

Anzahl/No. off:
TB EK Ma Druckdatum
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Indication:
Hinweis:
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Benennung:
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Weight
Artikelnr.
Item-No.
Fertigungs-Beginn
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
DIN
Seite:
5
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Designation:
Date of issue
HYDRAULIKSCHLUCHE 057
hydraulik hoses
DN 8-2SNx4000 1 820-4900-16(1) Pos.61 058
DKOS/DKOS 90
DN 12-2SNx4900 1 820-4900-16(1) Pos.66 059
DKO/DKO
DN 16-2SNx3000 1 820-4900-16(1) Pos.80 060
DKOS/DKOS90
DN 20-4SHx1200 1 820-4900-16(1) Pos.97 061
DKOS/SFS 90 3/4" 6000PSI
DN 32-4SHx4800 1 820-4900-16(1) Pos.111 062
DKOS/SFS 90 1" 6000PSI
DN 32-4SH x5800 1 820-4900-16(1) Pos.116 063
DKOS/SFS 90 1" 6000PSI
DN25 -4SH x1400 1 820-4900-16(1) Pos.124 064
DKOS/SFS 90 1 6000PSI
DN 40-1SNx1400 1 820-4900-16(1) Pos139 065
DKOL/DKOL90
DN 32-1SNx4200 1 820-4900-16(1) Pos.134 066
DKOL/DKOL90
DN 25-1SNx2900 1 820-4900-16(1) Pos.100 067
DKOL/DKOL90
DN20 -4SH x1500 1 820-4900-16(1) Pos.71 068
DKOS/SFS 90 3/4" 6000PSI
069

070

Anzahl/No. off:
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Benennung:
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Weight
Artikelnr.
Item-No.
Fertigungs-Beginn
80211 9901 00
Werkstoff
Material
Ausgabedatum
Menge:
1
Von:
6
DIN
Seite:
6
Klassifizierung:
Benennung
Designation
Stk.
Qty.
Zeichnungs-Nr.
Drawing-No.
820-9900-03(o.Z.)
Pos
Item
30.06.05
F
Bereitst./Supply
Page: of:
Classification:
Remark Order
Designation:
Date of issue
1810PR018 Strmeldekarte 1 071
Interference pilot print card
1810PR017 Stromregelkarte 1 072
Current regulator print card
1170ES010 Ersatzgert 1 073
Spare appliance
1170ES012 Programmspeicher 1 074
EDV - memory
1420GR001 Gleichrichter 1 075
Rectifier
1650LE901 NATRIUM-DAMPFLAMPE SON-T 250 W 1 076
sodium lamp
1800PT008 POTENTIOMETER 5 KOHM 1 077
potentiometer
2364SU723 SCHALTKONTAKTE 3RT1954-6A 1 Satz 078
set contacts
2364SU730 Schaltkontakte 3RT19 56-6A 1 Satz 079
set contacts
1055BT003 GLHLAMPE 30 V BA 9S 10 080
bulb
LE4-116-DX1 1170ES006 LOKALE ERWEITERUNG 1 081
externe module
LE4-116-XD1 1170ES007 LOKALE ERWEITERUNG 1 082
externe module
EM4-201-DX2 1170ES011 DEZENTRALE ERWEITEUNG 1 083
decentral mmodule
Anzahl/No. off:
TB EK Ma Druckdatum
30.06.05
Copyright 2005 Figures 1
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8 Figures
Illustration44: Pump unit
Instruction manual
2 Figures Copyright 2005
Illustration45: Pressure Switch/solenoid valve
Pressure switch Pressure emitter
Brake hoisting gear
Load pressure indikator
Solenoid valve for brake
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Illustration46: Load Measuring Device
Instruction manual
Illustration47: Emergency exit
Emergency exit
Instruction manual
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Illustration48: Switch cabinet switch
Instruction manual
Illustration49: Switch cabinet door
Instruction manual
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Illustration50: Fault notification card/current regular print card
Instruction manual
Illustration51: Gear oil cooler
Filter
Instruction manual
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Illustration52: Slewing gear
Instruction manual
Instruction manual
1 Spare Parts Catalog Copyright 2005
Table 4: List of Spare parts catalog
Seq.
No.
Parts Type NMF-Item No.
1 Adjustable axial piston pump 90R 100 1831PA422
2 Adjustable axial piston motor 51V160-AD4N-E2 1702MH652
3 Adjustable axial piston motor A6VM 250EP 1702MH150
4 Axial piston fixed displacement
motor
A2FM56/6 1702MH020
5 Hoisting Gear Drive ZHP 4.34 04.34 10048 1391GT942
6 Slewing device drive ZHP 3.25 03.25 10310 1391GT335
7 Topping Winch ZHP 4.32 04.32 10078 1391GT900
8 Oil cooler T7 2000.007.0000 1587KU009
9 Gear oil cooler OKAF-R2S 1588KU005
10 Pump distribution gear i=0,605; 4387.11 1392GT111
11 Solenoid valve 4D01 2600VT039
12 Solenoid valve 4D02 2600VT051
13 Hydraulic system line filter LFBN/HC 240 1262FI321
14 NMF Cabin NG 1540kb004
15 Air conditioner 70501
16 Dokumation for the PS4-200 PS4
17 Control lever 1210FH108
1210FH109
18 Bottom hook block 120t
Copyright 2005 Spare Parts Catalog 2
Instruction manual
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
1 12
C
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
2 12
F
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
3 12
M
1
1
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
4 12
M
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0
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
5 12
M
1
1
M
M
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
6 12
M
1
1
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
7 12
M
1
1
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
8 12
M
1
N
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E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
9 12
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Page
von
of
E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
10 12
N
3
5
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1
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8
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Seite
Page
von
of
E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
11 12
N
0
J
1
N
0
J
3
N
0
J
2
N
0
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4
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2
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Seite
Page
von
of
E000 001
P001 677D
Original
Ersatzteile
Genuine Parts
500328,Rev. L
Baureihe 90R(L)100
Series 90R(L)100
12 12
J80
J15
J40
H80
H70
E000 073
J60*
J10*
J40
J15
J50
J95
J92*
J90C
J80
J70
E000 077
J40
J15
J50
J70
J80
J92*
J60*
J10*
J90A
J95
E000 074
J40
J50
J70
J80
J92*
J60*
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J15
J90B
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E000 075
J10*
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JLCP
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JLA*
JRA*
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J10*
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J92*
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E000 139
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E000 032
Y20
Y10
Q120
B70
B70A
B70A
B70
W30
W30
W30A
B71A
B71
W30
W30A
Y20
Y10
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B71
B71A
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W30A
B71
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W30A
W30
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Y10
W32
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W30
W32
{W50}
B72
{W25}
W30
E000 033
E000 033
E000 033
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L85
L90
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C50
C60
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L75
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L82
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L40
L50D
Q030
L0**
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B50
G60
B05
G34
G32
U4C9
U4D2
E000 037
Seite von
Page of
Baureihe Series
51****
3 7
782 870R
Original
Ersatzteile
Genuine Parts
L60
L10
L20
L84
L30
L1**
L120
L130
L150
L230
L0**
E000 039
E000 033
L1**
L60
L10
L20
L84
L30
L120
L130
L110
L150
L230
L140
L0**
E000 040
Seite von
Page of
Baureihe Series
51****
4 7
782 870R
Original
Ersatzteile
Genuine Parts
= Applies to the indicated
frame size(s).
(....) = Nur fr die angebene BG
erforderlich.
G50A
G50
K90
F11
F120
F10
F12
J100
siehe Seite 6
see page 6
F26
F28
K50
K10
K70
K95
K95A
K50
K0**
K0**
K70
K10
K80
F120
F26
F28
F26
F28
Y40
Y50
F11
F10
F12
(060)
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(080) F24
(060)
F30
(060)
F24
(110,160,250)
K80
F20*
K90A
K90
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K18
K16
K14
G20A
G20
K20
(250)
K20
(250)
K18
G20
G20A
G20A
K14
K16
G20
G20
G20A
G12A
G12
G12A
G12
G30A
(250)
G30
(250)
G30A
(250)
G30
(250)
G80
(060,080)
G80A
(060,080)
G30
(250)
G30A
(250)
G18
G12
G12A
G12
G12A
G12A
G12
G30A
G30
G30A
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G30
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G18
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G24
G26
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G100
G110A
G110
(060-250)
G110
(250)
G110A
J50
{S40}
J60
{S30}
J70
{S50}
E000 035
Seite von
Page of
Baureihe Series
51****
5 7
782 870R
Original
Ersatzteile
Genuine Parts
M28/N28
M27/N27
{M90}/{N90}
M26/N26
{M66}/{N66}
M58/N58
M27A/N27A
{M90A}/{N90A}
M27A/N27A
{M34A}/{N34A}
M27/N27
{M34}/{N34}
M28A/N28A
M27/N27
{M34}/{N34}
M27A/N27A
{M34A}/{N34A}
M26A/N26A
{M66A}/{N66A}
M27A/N27A
{M72A}/{N72A}
M27/N27
{M72}/{N72}
M30/N30
M26A/
N26A
M26/N26
M28/
N28
M28A/
N28A
M27A/N27A/N99A
{M34A}/{N34A}
M27/N27/N99
{M34}/{N34}
N32/M32
M28A/N26A
{N66A}
M28/N26
{N66}
M10/N1A*
M27A/N27A/N99A
{M34A}/{N34A}
M27/N27/N99
{M34}/{N34}
M27A/N27A
{M34A}/{N34A}
M27/N27
{M34}/{N34}
M84A/N84A
M84/N84
M84A/
N84A
M84/N84
N29
N11
M52/
N52
N82
N24
M27A/N27A/N99A
{M34A}/{N34A}
M27/N27/N99
{M34}/{N34}
M24P/N24
M82/N82
M29/N29
M23/N23
M23A/N23A
M2PC
M1PD
M1PB
N87(N11&N21)
M1PC&M21/
M22&M20/
N22&N20
M14/N14
M18/N18
M16J
Z001
Z0**
Z002
M27A/
N27A
M27/
N27
M27/N27
M27A/
N27A
M99A
M99
E000 043
Seite von
Page of
Baureihe Series
51****
6 7
782 870R
Original
Ersatzteile
Genuine Parts
M11
T2**
M1U5
F32
J20/S70
J30
(siehe Pos. J100,
Seite 4)
seePos.J100 page 4
J10*
S20
S10
S10*
(060, 080,
110)
F324
S10*
(160, 250)
T7**
T8**
G30
(250)
G12
G30
G110
G110
M11
T3**
M1U5
M11
T1**
M1U5
N1U5
U5**
G90
U8**
(250)
U8**
(60-250)
E000 047
M27/N27/N99
{M34}/{N34}
M27/N27/N99
{M34}/{N34}
M27/N27/N99
{M34}/{N34}
N52
T6**
N46
T5**
N52
T4**
U6**
U7**
G42
G42
G38
G38
G36
E000 044
F32
T7**
F324P
E000 165
S
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s
M18
M14
M28
M26
M32
M12
M10
M36
M16
M1HP
M24
M30H
M30
M0HP
M20
M22
M0HS
M12H
M1HS
M10
M17
M17A
M24
{N90}
M24A
{N90A}
M30
{X003}
M10
M1E1E2E5
M1F1F2
M1H1H2
M1K1K2
M14
M20
M19A
M19
M22A
M22
M16E
M2E5
M0E1/M0E2/
M0E5/
M0F1/M0F2/
M0H1/M0H2/
M0K1/M0K2
M38
M32
M32A
M36
M28
M30
M24
M18
M14 M12
M26
M16
M1EP
M1EQ
M10
M42A
M42
M0EP
M0EQ
M0ER
M0ES
M40
M20
M22
M24
M28
M0R2
M0S1
M20
M1S1
M14
M16S
M18
M10
M22 M20
M1R2
M1S1
M16S
M23
M10
E000 045
Spare parts list
Order No.: 02404901
Denomination: A A6V M 250 EP2D /63W2-VZB157 B-SO109
Brueninghaus Hydromatik
Horb Plant
Drawing no.: 00939288
Item Order No. Denomination Quantity
1 02404895 PUMP A6VM 250/63W -VZB -SO108 1 ST L
2 02404902 CONTROL A6V M 250 EP2D/63-V157 -SO 68 1 ST L
3 00800755 FLUSHING AND FEED PRE.VALVE 1 ST
L = Assembly group D = Sealing element
->In order to assure a correct processing of spare parts orders,
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.
Page: 1 Following page: 2 Date: 06.02.2001
Telephone responder out of normal working time (0 74 51) 92 14 80
Status of version: 08/2000
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
Spare parts list
Order No.: 02404895
Denomination: PUMP A6VM 250/63W -VZB -SO108
Horb Plant
1 00906477 ROTARY GROUP A6VM 250/63W-VZ 1 ST L
2 00946732 ADJUSTING DEVICE M16X150-V 1 ST L
3 00933592 ADJUSTING DEVICE M16X90-V 1 ST L
5 00905221 PUMP HOUSING A6VM 250/63 1 ST
9 00647187 PLUG M22X1,5 V 1 ST D
10 00532347 PLUG M14X1,5 V 1 ST D
Spare parts list
Order No.: 00906477
Denomination: ROTARY GROUP A6VM 250/63W-VZ
Horb Plant
1 02407113 DRIVE SHAFT Z SIZE 32 SERIES 6 1 ST
3 00798754 PISTON BG32/BR6 CAT 7 ST
4 00798789 PISTON RING SIZE 32 BR6 'X' 14 ST
6 00900129 CYLINDER BG32/BR6 CAT 1 ST
7 00922503 CONTROL LENS A6VM 250/63W 1 ST
8 00900130 PRESSURE PIN CAT 1 ST
9 00709042 RETAINING PLATE CAT 1 ST
11 00904784 SEALING FLANGE SIZE 32 SERIES 6 1 ST
13 00969915 TUNING RING CAT 1 ST
14 00900002 SPRING 17,2 05,30 145,00 086,2 1 ST
15 00900003 DISC CAT 1 ST
16 00999169 SHIM SET ROTARY GROUP-BEARING SIZE 32/6 1 ST L
17 00969893 DISTANCE SCREW 1 ST
21 00904776 TAPERED ROLLER BEARING 1 ST
22 00693944 PLAIN ROLLER BEARING NJ 217 EM 1 ST
24 00963544 SHAFT END SEAL V 1 ST D
26 00928968 O-RING 117 X4 V80 1 ST D
29 00797448 SAFETY RING 125X4 1 ST
30 00188034 SAFETY RING 85X3 1 ST
34 00203297 SHIM PS 85X105X1,0 SEE 1 ST
39 00584614 SOCKET SCREW M8X16 -10.9 14 ST
Spare parts list
Order No.: 00906477
Denomination: ROTARY GROUP A6VM 250/63W-VZ
Horb Plant
Spare parts list
Order No.: 00999169
Denomination: SHIM SET ROTARY GROUP-BEARING SIZE 32/6
Horb Plant
Drawing no.:
1 00999012 CONTROL PLATE SPACER SIZE 32 SERIES 6 1 ST
5 00904782 CONTROL PLATE SPACER SIZE 32 SERIRES 6 1 ST
Spare parts list
Order No.: 00946732
Denomination: ADJUSTING DEVICE M16X150-V
Horb Plant
1 00917555 STOP PIN M16X150 A6V 355 SERIES 6 1 ST
2 00933539 CAP NUT M16 1 ST
3 00912737 NUT M16 1 ST
4 00903130 O-RING PRP 017' 17,17X1,78' V90 2 ST D
Spare parts list
Order No.: 00933592
Denomination: ADJUSTING DEVICE M16X90-V
Horb Plant
1 00323497 THREADED PIN M16X90 1 ST
2 00933540 CAP NUT M16 1 ST
3 00912737 NUT M16 1 ST
4 00903130 O-RING PRP 017' 17,17X1,78' V90 2 ST D
Spare parts list
Order No.: 02404902
Denomination: CONTROL A6V M 250 EP2D/63-V157 -SO 68
Horb Plant
1 00936728 VERSTELLTEIL A6VM 250/63-V157 1 ST L
2 00934354 PILOT BLOCK A6VM 250 EP2/63-V 1 ST L
3 00935604 DECKEL A6VM 250 HDD/63-V -SO 68 1 ST L
Spare parts list
Order No.: 00936728
Denomination: VERSTELLTEIL A6VM 250/63-V157
Horb Plant
4 00935855 ABSCHL.PL. A6VM 250/63-157 1 ST
5 00929870 ADJUSTING PISTON A6,A7 250/63 1 ST
6 00943756 ADJUSTING PIN A6/A7 250/63 1 ST
7 00819891 THREADED PIN 1 ST
14 00802013 R-RING 50X2,5 -S1 2 ST D
15 00917440 O-RING PRP 176'234,62X2,62' V90 1 ST D
16 00907799 TURCON-STEPS. RS1300400-T46 B+S 1 ST D
17 00973147 O-RING PRP 328' 46,99X5,33' V90 1 ST D
18 00514179 DOWEL PIN 12 M 6X24 2 ST
20 00977645 DP TEAR-OFF-PLUG M8 3 ST D
21 00532347 PLUG M14X1,5 V 2 ST D
Spare parts list
Order No.: 00934354
Denomination: PILOT BLOCK A6VM 250 EP2/63-V
Horb Plant
1 00926601 VALVE CARTRIDGE A6/A7 HD1/63-V 1 ST L
2 00930803 PILOT HOUSING A6VM/A7VO 250 EP/63 1 ST
3 00929872 SPRING RETAINER A6/A7 250/63 1 ST
5 00930556 SPRING 1 ST
6 02408868 VALVE 1 ST L
8 00974659 CARTRIDGE CHECK VALVE A6,A7 250,355/63 2 ST L
13 00976410 O-RING 14 X2 V80 2 ST D
14 00518336 O-RING PRP 112' 12,37X2,62' V90 2 ST D
15 00929855 O-RING PRP 132' 44,12X2,62' V90 2 ST D
16 00929791 THRUST RING SP/SS11109-132-P 2 ST D
20 00532347 PLUG M14X1,5 V 2 ST D
22 00575143 DP TEAR-OFF PLUG M5 1 ST
Spare parts list
Order No.: 00926601
Denomination: VALVE CARTRIDGE A6/A7 HD1/63-V
Horb Plant
1 00942919 VALVE CARTRIDGE A6/A7 HD1/63-V 1 ST
2 00977027 SAFETY RING 24X1,2 1 ST
17 00972079 SEAL KIT VALVE CARTR.A6/A7HD/HA/DA/63-V 0 ST L
Spare parts list
Order No.: 00972079
Denomination: SEAL KIT VALVE CARTR.A6/A7HD/HA/DA/63-V
Horb Plant
1 00916166 O-RING PRP 024' 28,30X1,78' V90 1 ST D
2 00609994 O-RING PRP 019' 20,35X1,78' V90 1 ST D
3 00931328 THRUST RING SP/SS11109-019-P B+S 2 ST
Spare parts list
Order No.: 02408868
Denomination: VALVE
Horb Plant
1 00928614 PROP.DRV DRE4K 3X/30G24-10V 1 ST
2 00988104 SOCKET GDM 2011-A 1 ST
Spare parts list
Order No.: 00974659
Denomination: CARTRIDGE CHECK VALVE A6,A7 250,355/63
Horb Plant
1 00974661 VALVE SEAT A6,A7 250,355 /63 1 ST
2 00974662 VALVE POPPET A6,A7 250,355 /63 1 ST
4 00974636 SPRING 1 ST
Spare parts list
Order No.: 00935604
Denomination: DECKEL A6VM 250 HDD/63-V -SO 68
Horb Plant
1 00935503 VALVE CARTRIDGE A6 DR/63-V -SO 68 1 ST L
2 00934358 SWIVEL TIME LIMITING VALVE-V 1 ST L
3 00930674 COVER A6VM 250 HDD /63 1 ST
4 00960086 STOP DISC 1 ST
6 00930295 SOCKET SCREW M16x65-8.8 4 ST
7 00788317 PLUG M8X1 V 1 ST D
10 00529044 DP-TEAR-OFF PLUG M4 1 ST
11 00518336 O-RING PRP 112' 12,37X2,62' V90 3 ST D
12 00929855 O-RING PRP 132' 44,12X2,62' V90 1 ST D
13 00929791 THRUST RING SP/SS11109-132-P 1 ST D
14 00921703 ORIFICE M4 X 0,8 1 ST
15 00532347 PLUG M14X1,5 V 3 ST D
Spare parts list
Order No.: 00935503
Denomination: VALVE CARTRIDGE A6 DR/63-V -SO 68
Horb Plant
1 00946861 VALVE CARTRIDGE A6 DR/63-V -SO 68 1 ST
17 00972082 SEAL KIT VALV.CAR.A6/A7DR/DRG/FR/LR/63-V 0 ST L
Spare parts list
Order No.: 00972082
Denomination: SEAL KIT VALV.CAR.A6/A7DR/DRG/FR/LR/63-V
Horb Plant
1 00934357 O-RING PRP 120' 25,07X2,62' V90 3 ST D
2 00642827 USIT-RING U60 9,3X13,3X1,0 FP 2 ST D
3 00515256 O-RING PRP 118' 21,89X2,62' V70 2 ST D
Spare parts list
Order No.: 00934358
Denomination: SWIVEL TIME LIMITING VALVE-V
Horb Plant
1 00591998 PISTON 1 ST
2 00931238 PLUG 2 ST
3 00592056 SPRING RETAINER 2 ST
4 00592072 SPRING RETAINER 2 ST
5 00591955 SPRING 2 ST
6 00832278 THROTTLE SCREW 1 ST
7 00302139 O-RING PRP 114' 15,54X2,62' V90 2 ST D
9 00642827 USIT-RING U60 9,3X13,3X1,0 FP 4 ST D
10 00913806 NUT M8 X 1 2 ST
11 00913805 CAP NUT M8X1 2 ST
12 00914466 THREADED PIN M8X1,0X35 2 ST
Spare parts list
Order No.: 00934358
Denomination: SWIVEL TIME LIMITING VALVE-V
Horb Plant
Page: 19 Following page: - Date: 06.02.2001
Spare parts list
Order No.: 09422129
Denomination: A2FM56/61W-VAB020
Elchingen Plant
Type: 211.17.25.62
Info:
1 02031626 ROTARY GROUP 1 ST L
3 02040495 HOUSING 1 ST
4 09421620 PORT PLATE 1 ST
5 09084150 CYLINDER PIN 1 ST
DIN 7- 5 M6X 12-ST-S
6 09085571 O-RING 1 ST D
N 02.079- 78,97 X 3,53-S-FKM70
7 09083060 SOCKET-HEAD SCREW 2 ST
DIN 912-M10X 25-8.8 #51NM
10 09083068 SOCKET-HEAD SCREW 4 ST
DIN 912-M10X 60-8.8 #51NM
19 09156651 LOCKING SCREW 1 ST D
N 02.009-M18X1,5-FKM #40NM
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustrae 2, D-89275 Elchingen
Spare parts list
Order No.: 02031626
Denomination: ROTARY GROUP
Elchingen Plant
Type: 201.17.33.61
Info:
1 02028933 ROTARY GROUP, HYDR. SECTION 1 ST L
2 02030594 DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 09408442 COVER 1 ST D
12 09154528 RETAINING RING 1 ST
DIN 472-105X4
14 09830383 SHAFT SEAL RING 1 ST D
BAFSL1SF 40X 55X 7/5-FKM
15 09154986 O-RING 1 ST D
N 02.079- 98,02 X 3,53-S-FKM70
17 09152831 SHIM 2 ST
DIN 988- 85X105X0,1
18 09084592 SHIM 1 ST
DIN 988- 85X105X0,3
Spare parts list
Order No.: 02028933
Denomination: ROTARY GROUP, HYDR. SECTION
Elchingen Plant
Type: 201.17.33.90
Info:
1 09421305 CYLINDER 1 ST
2 09650831 CONTROL PLATE 1 ST
3 02028565 CENTER PIN 1 ST
4 02031674 PISTON WITH PISTON RINGS 7 ST L
5 09409994 WASHER 1 ST
20118.0710
6 02028559 ADJUSTMENT SHIM 1 ST
7 02028810 PRESSURE SPRING 1 ST
' 2,80/ 9,80/ 32,20'
11 09444063 RETAINING PLATE 1 ST
12 09831106 PAN HEAD SCREW W. TORX 7 ST
N 02.119-M 5X16-10.9-MK#9,1NM
Spare parts list
Order No.: 02028933
Denomination: ROTARY GROUP, HYDR. SECTION
Elchingen Plant
Type: 201.17.33.90
Spare parts list
Order No.: 02031674
Denomination: PISTON WITH PISTON RINGS
Elchingen Plant
Type: 201.17.33.90
Info:
1 02028620 PISTON 1 ST
2 09831887 STEEL SEALING RING 2 ST
15 X16,8X2,3
Spare parts list
Order No.: 02031674
Denomination: PISTON WITH PISTON RINGS
Elchingen Plant
Type: 201.17.33.90
Spare parts list
Order No.: 02030594
Denomination: DRIVE SHAFT WITH BEARING ASSY
Elchingen Plant
Type: 201.18.33.10
Info:
2 02028564 DRIVE SHAFT 1 ST
3 09430338 BEARING RING 1 ST
6 02030518 BACK-UP PLATE 1 ST L
7 09083363 RETAINING RING 1 ST
DIN 471- 45X1,75
10 09156194 TAPERED-ROLLER BEARING 1 ST
T 7FC 050
11 09154608 TAPERED-ROLLER BEARING 1 ST
DIN 720-32009 X
Spare parts list
Order No.: 02030594
Denomination: DRIVE SHAFT WITH BEARING ASSY
Elchingen Plant
Type: 201.18.33.10
Spare parts list
Order No.: 02030518
Denomination: BACK-UP PLATE
Elchingen Plant
Type: 201.18.33.10
Drawing no.:
Info:
1 02028800 BACK-UP PLATE 1 ST
12 09084737 BACK-UP PLATE 1 ST D
DIN 988-S 45X 55
Page: 9 Following page: - Date: 17.07.2000

ZOLLERN Vertriebs-GmbH & Co. Telefon: 07586 / 959 - 0
Heustrasse 1 Telefax: 07586 / 959 - 710
E-Mail: kundendienst@zollern.de
D-88518 Herbertingen Homepage: www.zollern.de
190014219.doc Seite 2
SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE

Getriebe Typ:
Gear Type:
Rducteur Type:
ZHP 4.34
Gerte Nr.:
Aggregate No:
Appareil No:
0 4.34 10048
Serien Nr.:
Serial No:
Srie No:
101 - 102
Auftrags Nr.:
Order No:
Commande No:
6741110 vom 04.03.2002

Firma :
Company:
Socit:
Neuenfelder Maschinenfabrik GmbH

Anschrift :
Address:
Adresse:
Neuenfelder Fhrdeich 120
D-21129 Hamburg

Abteilung :
Department:
Service:
zu Hd. Hr. Holler

Bestell Nr.: Sach Nr.:
Order No: Ident. No:
Commande No
202305 vom 27.03.2002
Produit No:
1391GT942
Gerte Typ: Pos Nr.:
Aggregate Type: Pos. No:
Appareil Type:
---
Pos. No:
---
Bau / Komm Nr. Projekt Nr.:
Constr. No: Project No:
Constr. Spc. No:
NMF 30008 0001
Projet No:
---

Lieferumfang: 1-fach per e-mail 18.12.2003 MA/KD

ZOLLERN Vertriebs-GmbH & Co. Telefon: 07586 / 959 - 0
Heustrasse 1 Telefax: 07586 / 959 - 710
E-Mail: kundendienst@zollern.de
D-88518 Herbertingen Homepage: www.zollern.de
190014219.doc Seite 1
INHALT
CONTENS

Typ Gerte-Nr. Bezeichnung Description Serien-Nr.
Type Aggregate-No.
Serial-No.
ZHP 4.34 0 4.34 10048 Seilwinde Rope winch 101 - 102

Dokument-Nr. Bezeichnung Description
Document-No.

190014219 Service-Blatt Service form
043410048 Einbauzeichnung Installation-drawing
Seilwinde
Getriebe
Seiltrommel
Flansch
Antrieb
Hydrauliklamellenbremse
Rope winch
Gear
Rope drum
Flange
Drive in
Hydr. multiple disc brake
193007973 Ersatzteilliste Spare part list
190000705 Einbauanleitung Installation instruction
190000751 Wartungsanleitung Maintenance instruction
190000752 Schmierstoffempfehlung Recommendation for lubricants
190000781 Getriebeinspektion Gearbox inspection
190000159 Anzugsmomente Tightening torques

190000159.gb.doc Seite 1
TIGHTENING TORQUES
Tightening torques for fixing screws M 4 to M 36 and for strength classes 8.8, 10.9
and 12.9 at a coefficient of friction 0,125.

8.8 10.9 12.9
M 4 = 2,7 Nm 3,8 Nm 4,6 Nm
M 5 = 5,5 Nm 8,0 Nm 9,5 Nm
M 6 = 9,5 Nm 13,0 Nm 16,0 Nm
M 8 = 23,0 Nm 32,0 Nm 39,0 Nm
M 10 = 46,0 Nm 64,0 Nm 77,0 Nm
M 12 = 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
M 36 = 2350,0 Nm 3300,0 Nm

The indicated tightening torques are maximum values.
Screws secured by Loctite Type 242.
Fitting surfaces sealed by Loctite Type 640.
Surfacing on brake sealed by Loctite Type 573.
Screwing of the tubing and the connection surfaces of the drive motor to the gear are sealed with
Loctite Type 572.

Note application instructions of Loctite

GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Surveying mechanisms for machines and gearboxes get more and more important, because the
requirements and service conditions are often differing from the ones that are foreseen from the designers.
Systematic oil tests during regular intervals give a trendy reliable diagnostic regarding the wear development
and beginning damage. The point at issue will be which oil, permitted according the lubrication
recommendation, has really been used.
Why oil analyses ?
Advanced diagnosis of damages:
Wear-particles float in the oil. These can be stated by oil analysis and give notes as to the wear of the
construction part from which they have been abrased.
Maintenance depending on status:
A damage that was stated early enough through an oil analysis obviously means less repair and still-stand
charges.
Damage analysis to small expenses:
An estimated reason for the damage can be given by such an oil inspection to small expenses. Spurs of dirt
by dust and water, mixture with other oils, parts of worn metals as well as changements of the oil level give a
detailed early recognition of damages.
Simple surveillance:
In order to get a detailed information on the status of the gearbox, regular oil analyses prevent partial or
complete disassemblies.
Influencing interference factors of the lubrication oil:
Worn metals, dirt, changements of oil level and additives may influence very negatively the effectiveness of
the used lubricating oil. Oil analyses, effected by an authorised laboratory, give information regarding worn
metals, dirt etc.
The analysis is commented according to the disposed dates and information.
The more exact the indications regarding the used oil, service time and operation conditions are, the more
detailed and effective can be instructed preventive measurements.
There are no reliable comparing and limit values as to wear metal and contaminations. An important factor is
always the oil quantity from which the oil sample was taken.
A reliable possibility to diagnose is not possible than by a competent laboratory. Extremely high values
resulting in the evaluation must not absolutely show a beginning damage.
Based on their experience all values noted are considered in the correct coordination by the laboratory
analysing the oil. Oil analyses made in regular intervals show a sure value as to wear resp. as to a beginning
damage of a certain construction unit.
Each gear shows its own wear according to the corresponding conditions of operation.
Magnetizing particles larger than 5 m noted in the analysis, are probably showing a beginning pitting of a
construction part.

Particles of a size of 40 m in clear oil are visible with the eye. If so there is certainly already a progressed
damage of the gear.
Taking of an oil sample
A certain evidencing diagnostics of an oil sample depends decisively of the kind of taking the sample.
The taking of the sample has to e made always in the same manner. In principle the oil should be at least
hand warm when taking it. If possible the oil to be analysed has to be taken in about the middle of the oil
level.
At winch gear where it is not possible to have access to the oil level, the oil to be analysed has to be taken
off the oil drain line. About 1-2 l oil have to be drained into a container and an oil sample has to be taken
from the draining oil.
The access to a good oil level at the slewing gears is also difficult. Here too we recommend to have a part of
oil drained by removing the accessible oil draining screw and to take an oil sample off the draining oil.

INSTALLATION INSTRUCTION
General
Please also note the indications in our installation drawing.
The ZOLLERN rope winch is supplied completely assembled.
For installation of the winch dismount the flange.
Before assembly, verify the steel construction of the winch according to our installation drawing.
The screw-on-surfaces have to be worked properly to the same level.
Disassembly
Draw off flange.
Assembly
Please note installation position of winch according to our installation drawing!
Clean all screw-on-surfaces and tape holes at the gear and the flange metallically clean.
Secure with Loctite Type 242 all ZOLLERN screw-on-connections which were loosened during disassembly.
Please note Loctite-processing- information.
Strength classes and torque moments for screws see installation drawing.
Turn the marking "O" (= top) at gear flange to the position indicated in the installation drawing.
Put rope winch into steel frame.
Centre gear in the steel frame.
Fix gear with screws.
Fit flange equally and straight and centre it in the steel frame.
Do not use force !
Fix flange with screws.
Check oil level with oil dipstick.
Refill oil if necessary.
If the winch is supplied without oil, this is indicated on a corresponding label.
Oil type see name plate resp. maintenance instruction.
Oil quantity see name plate resp. spare parts list.
Remove transport covers off the motor flanges.
Connect brake line (see installation drawing).
Release hydraulically multiple disc brakes.
The drive sleeves in the drive units must turn easy.
Remove plugs off the drive sleeves in the drive units.
For protection against corrosion the drive sleeves are provided with gear oil from the gear. The plugs
prevents a filling with oil of the motor flanges before montage of the motors.
Attention: Motor shafts grease-free!
Centre motors in the motor flanges.
Seal connecting surfaces.
Fix motors with screws.
Before test-running, fill motor flanges completely with gear oil.
Control rope winch with running motors as to function.
Check above all the control and function of the holding brakes and the drive motors.

After test-running check oil level once more with oil dipstick.
During the test-running, the oil level in the gear and motor flanges is adjusting itself and so fills the space
to the motor shafts slowly with gear oil. Therefore the oil level may be reduced.
If necessary, refill oil.
Insert rope.
Fix rope with pressure screws.
Secure pressure screws accordingly.

MAINTENANCE INSTRUCTION
Lubrication
The Zollern planetary gear of rope winch has splashed lubrication.
Oil filling ex factory :MOBIL SHC 630
Description :synthetically PAO-oil
The oil quantity is marked on the name plate. If the gear is delivered without oil, we point out to that with a
sticker.

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

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

RECOMMENDATION FOR LUBRICANTS
Choice list

CHOOSEN ACCORDING

CHOOSEN ACCORDING
TO DIN 51502
DESCRIPTION ACC. TO DIN
OIL, DIN 51517
CLP PAO 220
GREASE; DIN 51825
KP2K
ARAL ARAL DEGOL PAS 220 ARAL GREASE HLP 2
AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP
BP ENERSYN HTX 220 BP ENERGR. LS EP 2
CASTROL ---
CASTROL SPHEEROL EPL 2
GREASE
DEA DEA UBTOR HCLP 220
ELF --- ELF EPEXA 2
ESSO --- ESSO BEACON 2 EP
FUCHS --- FUCHS RENOLIT FEP 2
GULF --- GULF CROWN GREASE NO.2
MOBIL MOBIL SHC 630 MOBILUX 2 EP
SHELL OMALA HD 220 SHELL ALVANIA EP 2

Attention: Synthetical gear oil on PAO-base may not be mixed with
synthetical gear oil on polyglycol base.
Oil change and greasing intervals see maintenance instruction.

193007973.doc Seite 1
ERSATZTEILLISTE
SPARE PART LIST
19007973

Typ Gerte-Nr. Bezeichnung Description Serien-Nr.
Type Aggregate-No. Serial-No.
ZHP 4.34 0 4.34 10048 Seilwinde Rope winch 101 - 102
BEI ERSATZTEILBESTELLUNG TYP, GERTE-NR, SER.-NR UND TEILE-NR ANGEBEN!
IF YOU ORDER SPARE PARTS INDICATE TYPE, AGGREGATE-NO, SERIAL-NO AND PART-NO!

Pos-Nr. Stck Teile-Nr. Bezeichnung Description
Pos-No. Quantity Part-No.

1
21
22
24
1,0
1,0
1,0
1,0
193007974
193007976
193006870
193007977
Getriebe
Seiltrommel
Flansch
Antrieb
Gear
Rope drum
Flange
Drive in

Gewicht :7830,0 kg lmenge :115,0 l
Weight : Oil quantity :
DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIEBS-GMBH + CO
-------- ------------------------------- HEUSTRASSE 1
16.01.03 S P A R E - P A R T - L I S T D-88518 HERBERTINGEN/WRTT.

ZHP 4.34 - 043410048 193007973 GEWICHT LEINFLLMENGE
WEIGHT OIL QTY
SERIEN - NR. 101 - 102 SERIAL - NO. 101 - 102 7.830,000 KG 115,0 LITER

************************************************************************************************* SEITE - 1
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************

Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA

______________________________________________________________________________________________________________________
1 1,0 193007974 GETRIEBE GEAR + OUTPUT

-----------------------------------------------------------------------------------------------------------
1 / 1 1,0 193007975 ABTRIEB OUTPUT DRIVE

1 / 1/ 1 1,0 243400270 PLANETENTRGER PLANETARY CARRIER
1 / 1/ 3 1,0 243400210 ZWISCHENFLANSCH INTERMEDIATE FLANGE
1 / 1/ 6 1,0 243400266 ZWISCHENGEHUSE INTERMEDIATE HOUSING
1 / 1/ 21 24,0 411200678 ZYLINDERSCHRAUBE BOLT M 30x260 10.9 DIN 912
1 / 1/ 27 24,0 240700321 SCHEIBE WASHER 31,00x 46,00x 5,00
1 / 1/ 31 1,0 441100055 WELLENDICHTRING SHAFT SEALING RING 1100x1140x20 DIN3760
1 / 1/ 41 1,0 442000002 PROFILSCHNUR SEALING RING WZ NR 6/2824
1 / 1/ 42 1,0 542000010 BEFESTIGUNGSBAND STEEL BAND
1 / 1/ 43 1,0 542100010 HLSE NUT 8x0,4
1 / 1/ 53 1,0 453000255 RILLENKUGELLAGER BALL BEARING 300x460x74,00 DIN 625
1 / 1/ 60 1,0 403100163 SICHERUNGSRING CIR CLIP 380x---x6,00 WELLE-- DIN 471
1 / 1/ 62 1,0 403200221 SICHERUNGSRING CIR CLIP ---x460x7,00 BOHRUNG DIN 472
1 / 1/201 1,0 243400212 ENDGEHUSE SUPPORTING HOUSING
1 / 1/202 36,0 411230454 ZYLINDERSCHRAUBE BOLT M 30x 70 8.8 DIN 912
1 / 1/205 2,0 414030010 VERSCHLU-SCHRAUBE PLUG M 33x 2,0 ZN DIN 908
1 / 1/206 2,0 441000225 FLACH-DICHTRING SEALING RING A 33,00x 39,00x 2,00
1 / 1/220 1,0 455000010 FLACHBAND STEEL BAND 40,4 x 2,0
1 / 1/221 1,0 453900053 FLACHKFIG BAND ROLLER BEARING L2000
1 / 1/434 1,0 453000142 RILLENKUGELLAGER BALL BEARING 70x125x24,00 DIN 625
1 / 1/444 1,0 403200063 SICHERUNGSRING CIR CLIP ---x125x4,00 BOHRUNG DIN 472
1 / 1/980 1,0 243400215 ZWISCHENFLANSCH INTERMEDIATE FLANGE
1 / 1/981 1,0 243400238 LAGERFLANSCH BEARING FLANGE
1 / 1/982 10,0 411230386 ZYLINDERSCHRAUBE BOLT M 16x130 8.8 DIN 912
1 / 1/983 1,0 541000482 O-RING SEALING RING 340,00x3,00 NBR---
1 / 1/984 1,0 541000391 O-RING SEALING RING 450,00x3,00 NBR-70
1 / 1/986 1,0 453000259 RILLENKUGELLAGER BALL BEARING 240x300x28,00 DIN 625
1 / 1/987 1,0 403200088 SICHERUNGSRING CIR CLIP ---x300x5,00 BOHRUNG DIN 472

-----------------------------------------------------------------------------------------------------------
1 / 11 1,0 100100754 PLANETENSTUFE PLANETARY STAGE

1 / 11/ 1 1,0 233401003 INNENRAD INTERNAL-WHEEL
1 / 11/ 3 1,0 243400193 SONNENRAD SUN WHEEL

-------- ------------------------------- HEUSTRASSE 1

WEIGHT OIL QTY

************************************************************************************************* SEITE - 2
**********************************************************************************************************************


______________________________________________________________________________________________________________________

-----------------------------------------------------------------------------------------------------------


-----------------------------------------------------------------------------------------------------------
1 / 24 1,0 100100526 PLANETENTRGER PLANETARY CARRIER COMPLETE

1 / 24/ 4 1,0 503100070 SPRENGRING CIR CLIP 170x---x2,50 WELLE--

-----------------------------------------------------------------------------------------------------------
1 / 27 1,0 100020701 ZWISCHENGEHUSE INTERMEDIATE HOUSING

1 / 27/ 1 1,0 242901354 ZWISCHENGEHUSE INTERMEDIATE HOUSING

-----------------------------------------------------------------------------------------------------------


-----------------------------------------------------------------------------------------------------------
1 / 34 1,0 100010712 PLANETENTRGER PLANETARY CARRIER


-----------------------------------------------------------------------------------------------------------
1 / 39 1,0 100020702 DECKEL COVER

1 / 39/ 1 1,0 243200226 DECKEL COVER
1 / 39/ 21 1,0 453000049 RILLENKUGELLAGER BALL BEARING 35x80x21,00 DIN 625

-----------------------------------------------------------------------------------------------------------
21 1,0 193007976 SEILTROMMEL CABLE DRUM CPL.

21 / 1 1,0 243400267 SEILTROMMEL ROPE DRUM
21 / 5 1,0 243400119 SEILBLECH CABLE FIXING AND WEDGES
21 / 20 36,0 411130597 SECHSKANTSCHRAUBE BOLT M 30x 70 8.8 DIN 933
21 / 23 6,0 412300011 GEWINDESTIFT GRAB SCREW M 24x 50 FLECKBE.33H DIN 915

-------- ------------------------------- HEUSTRASSE 1

WEIGHT OIL QTY

************************************************************************************************* SEITE - 3
**********************************************************************************************************************


______________________________________________________________________________________________________________________

-----------------------------------------------------------------------------------------------------------
22 1,0 193006870 FLANSCH FLANGE + PLATE CPL.

22 / 1 1,0 243400179 FLANSCH FLANGE
22 / 2 1,0 243400180 FLANSCHPLATTE FLANGE PLATE
22 / 3 1,0 234805086 SCHEIBE WASHER
22 / 4 1,0 403200084 SICHERUNGSRING CIR CLIP ---x260x5,00 BOHRUNG DIN 472
22 / 5 1,0 688100002 FILZ-DICHTSTREIFEN FELT STRIP 9,0x 7,5 DIN5419
22 / 6 1,0 453400066 PENDELROLLENLAGER PENDULUM ROLLER BEARING 170x260x67,00 DIN 635
22 / 8 1,0 243400209 DECKEL COVER
22 / 9 1,0 242200389 MITNEHMER DRIVER
22 / 10 1,0 411230417 ZYLINDERSCHRAUBE BOLT M 8x 85 8.8 DIN 912
22 / 12 1,0 417000094 SPANNSTIFT PIN 4,0x 16,0 DIN1481
22 / 13 1,0 417000094 SPANNSTIFT PIN 4,0x 16,0 DIN1481
22 /401 1,0 449900003 KEGELSCHMIERNIPPEL GREASE NIPPLE M 10x1,00-KEGEL A- DIN71412
22 /421 1,0 230001181 DECKEL COVER
22 /422 3,0 411230035 ZYLINDERSCHRAUBE BOLT M 6x 12 8.8 DIN 912

-----------------------------------------------------------------------------------------------------------
24 1,0 193007977 ANTRIEB DRIVE CPL.

24 / 1 1,0 144090002 STIRNRADGEHUSE SPUR GEAR HOUSING
24 / 2 4,0 243800013 RITZELWELLE PINION SHAFT
24 / 3 1,0 243800012 STIRNRAD SPUR GEAR

-----------------------------------------------------------------------------------------------------------
24 / 4 4,0 193005741 ANTRIEBSHLSE DRIVING SLEEVE

24 / 7 4,0 230000217 MOTORFLANSCH MOTOR FLANGE
24 / 15 1,0 243400213 ZAHNWELLE SHAFT
24 / 17 4,0 243100891 SCHEIBE WASHER
24 / 18 4,0 242400085 DECKEL COVER
24 / 21 20,0 411230094 ZYLINDERSCHRAUBE BOLT M 16x100 8.8 DIN 912
24 / 22 48,0 411230395 ZYLINDERSCHRAUBE BOLT M 12x160 8.8 DIN 912
24 / 23 24,0 411230078 ZYLINDERSCHRAUBE BOLT M 12x 50 8.8 DIN 912
24 / 29 2,0 416100117 ZYLINDERSTIFT PIN 10,0x 36,0 DIN 7
24 / 38 2,0 453000021 RILLENKUGELLAGER BALL BEARING 150x225x35,00 DIN 625
24 / 39 8,0 453300041 ZYLINDERROLLENLAGER CYLINDER ROLLER BEARING 60x110,000x28,00 DIN5412
24 / 50 4,0 441100668 WELLENDICHTRING SHAFT SEALING RING 85x110x12 BA---/FPM- DIN3760
24 / 53 4,0 441100665 WELLENDICHTRING SHAFT SEALING RING 110x130x8 B1---/FPM- DIN3760
24 / 59 4,0 541000291 O-RING SEALING RING 183,82x2,62 NBR-75
24 / 60 8,0 414030001 VERSCHLU-SCHRAUBE PLUG M 10x 1,0 ZN DIN 908
24 / 61 8,0 441000207 FLACH-DICHTRING SEALING RING A 10,00x 13,50x 1,00

-------- ------------------------------- HEUSTRASSE 1

WEIGHT OIL QTY

************************************************************************************************* SEITE - 4
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______________________________________________________________________________________________________________________
24 / 66 4,0 242400143 DECKEL COVER
24 / 69 4,0 543400040 ENTLFTUNGSVENTIL VENT FILTER M 10x1,0 0,02B
24 / 70 8,0 404300244 PASS-SCHEIBE WASHER 70,00x 90,00x 1,00 DIN 988
24 / 74 4,0 404300748 STTZSCHEIBE WASHER 90,00x110,00x 3,50 DIN 988
24 / 75 48,0 402100310 DRUCKFEDER SPRINGS 15,7N/MM-S= 27,3-RE
24 / 76 48,0 402100311 DRUCKFEDER SPRINGS 5,9N/MM-S= 33,0-LI
24 / 79 16,0 404130013 SCHEIBE WASHER 17,00x 30,00x 3,00 DIN 125
24 / 95 4,0 506701093 LDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE =STEP-SEAL====L 48,0
24 / 96 4,0 506700225 LAMELLENGEHUSE CLUTCH PLATE CARRIER
24 / 97 44,0 506700162 AUENLAMELLE MULTIPLE DISK DIN 867RAD-NUT-L2,30
24 / 98 40,0 506700163 INNENLAMELLE MULTIPLE DISK DIN 867--------L2,20
24 /122 4,0 414030002 VERSCHLU-SCHRAUBE PLUG M 12x 1,5 ZN DIN 908
24 /123 4,0 441000208 FLACH-DICHTRING SEALING RING A 12,00x 16,00x 1,50
24 /600 1,0 540500101 LEITUNG PIPE I M18x1,5-----EL 186
24 /605 2,0 540500040 LLEITUNG HYDR.-PARTS LEINFLLUNG---L 240
24 /606 1,0 543400070 MESTAB OIL DIPSTICK 0,20B/MM-------L 400
24 /607 1,0 441000213 FLACH-DICHTRING SEALING RING A 18,00x 22,00x 1,50
24 /611 4,0 540100829 VERSCHRAUBUNG THREADED JOINT CONNECTION M 12x 1,5 DKA-400B
24 /612 2,0 620100060 ROHR PIPE
24 /613 4,0 540100722 REDUZIERANSCHLUSS THREADED JOINT CONNECTION M 20x 1,5 630B
24 /614 2,0 540100702 VERSCHRAUBUNG THREADED JOINT CONNECTION +KOR12/6-M20x1,5630B
24 /615 2,0 540100511 VERSCHRAUBUNG THREADED JOINT CONNECTION M 20x 1,5 OMD-630B
24 /616 2,0 234200085 HALTEWINKEL HOLDING PLATE
24 /617 2,0 411130454 SECHSKANTSCHRAUBE BOLT M 8x 20 8.8 DIN 933
24 /618 2,0 541800156 VERSCHLUSTOPFEN SEALING PLUG ---,--x 13,70x10,00
24 /619 1,0 540100868 VERSCHRAUBUNG THREADED JOINT CONNECTION -100B
24 /621 2,0 540100813 VERSCHRAUBUNG THREADED JOINT CONNECTION M 10x 1,0 100B
24 /622 1,0 620100061 ROHR PIPE
24 /623 1,0 540100361 VERSCHRAUBUNG THREADED JOINT CONNECTION M 18x 1,5 315B
24 /710 1,0 240000312 BOLZEN BOLT
24 /711 1,0 505100081 DU-BUCHSE DISC I 50 A 55 -----L30,0
24 /712 1,0 505100076 GELENKLAGER 35x 55x25-GE 35 UK-
24 /713 1,0 230001614 BUCHSE BUSH
24 /714 1,0 230001616 BUCHSE BUSH
24 /715 1,0 230001386 HALTEBLECH HOLDING PLATE
24 /750 1,0 243400218 PENDELSTTZE PENDULUM CARRIER
24 /751 1,0 243400217 RING RING
24 /753 1,0 243400240 RING RING
24 /754 1,0 244000022 SCHEIBE WASHER
24 /756 1,0 541000481 O-RING SEALING RING 800,00x4,00 NBR-72
24 /757 1,0 441100032 WELLENDICHTRING SHAFT SEALING RING 800x840x16B2---/NBR- DIN3760

-------- ------------------------------- HEUSTRASSE 1

WEIGHT OIL QTY

************************************************************************************************* SEITE - 5
**********************************************************************************************************************


______________________________________________________________________________________________________________________
24 /758 1,0 243400219 PLATTE PLATE
24 /760 6,0 411230340 ZYLINDERSCHRAUBE BOLT M 16x110 8.8 DIN 912
24 /761 2,0 417000215 SPANNSTIFT PIN 10,0x 32,0 DIN1481
24 /770 1,0 455000004 FLACHBAND STEEL BAND 25,9 x 1,0
24 /771 1,0 453943422 FLACHKFIG BAND ROLLER BEARING L1478
24 /772 1,0 455000004 FLACHBAND STEEL BAND 25,9 x 1,0
24 /952 1,0 244000021 DECKEL COVER
24 /958 1,0 242901509 ABDECKUNG COVER GUARD
24 /974 1,0 243400239 SCHEIBE WASHER
24 /976 1,0 243400237 HALTESCHEIBE HOLDING DISC
24 /988 2,0 243800016 RING RING
24 /991 2,0 404300243 PASS-SCHEIBE WASHER 65,00x 85,00x 1,00 DIN 988
24 /992 1,0 541800007 VERSCHLUSTOPFEN SEALING PLUG ---,--x 10,70x 5,50

______________________________________________________________________________________________________________________

<-- Ende der Stckliste -->

_________________________________________________________________________
ZOLLERN SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE
_________________________________________________________________________
Getriebe Typ ZHP 3.25
Gear Type
Reducteur Type
Gerte Nr. 0 3.25 10310
Aggregat No.
Appareil No.
Serien Nr. 101 - 125
Serial No.
Serie No.
Auftrags Nr. 6/63330 vom 21.07.98
Order No. 6/64190 19.08.98
Commande No.
_________________________________________________________________________
Firma : Neuenfelder Maschinenfabrik GmbH
Company :
Societe :
Anschrift : Neuenfelder Fhrdeich 120
Adress : 21129 Hamburg
Adresse :
Abteilung :
Department :
Service :
_________________________________________________________________________
Bestell- Nr.: 807186 vom 17.07.98 Firmen Nr.: ---
Order- No.: 808089 vom 11.08.98 Company No.:
Commande- No.: Societe No.:
Gerte Type: --- Sach Nr.: ---
Aggregat Type: Ident. No.:
Appareil Type: Produit No.:
Bau/Komm. Nr.: 30008 0001 Pos. Nr.: ---
Constr. No.: Pos. No.:
Constr.Spec. No.: Rep. No.:
Projekt Nr.: ---
Project No.:
Projet No.:
ZOLLERN VERTRIEBS-GmbH + Co.
Heustrae 1
D-88518 Herbertingen
Telefon 07586-959-0, Telefax-Service-Dep. 07586-959-710, Telex 732 218
berprfen.
-------------------------------------------------------------------------
Heustrae 1
Telefon 07586-959-0, Telefax-Kundendienst 07586-959-710, Telex 732 218
-------------------------------------------------------------------------
Dok.-Nr.: ANWEISD1/TXTKD Seite 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Anweisung fr Getriebeinspektion GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Bei normalem Verschleiss und nach der Einlaufperiode sind die
Rauhigkeitsspitzen vom Zahnflanken schleifen geglttet und die
Zahnflanken haben eine glatte, helle, glnzende Oberflche.
Bei allen anderen Merkmalen, wie Schleifverschlei, Riefen, Fressen,
Grbchen, Abbltterungen, Risse und plastische Verformung mssen die
Zahnrder getauscht werden, bzw. ist es dann zweckmig, eine
Generalberholung des Getriebes durchzufhren.
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Instruction for Gearbox Inspection GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
1. Inspection Intervals
The drained gearbox oil should be checked every 1.000 operating hours,
but at least once per year. In order to obtain a representative oil
sample, the oil should be drained with the gear box at operating
temperature.
2. Checking the Drained Oil
In order to check whether there was a sufficient quantity of oil in the
gearbox, the quantity of oil drained has to be compared with the quantity
prescribed. The prescribed oil quantity is indicated on the gearbox
rating plate or specified in the maintenance instructions.
3. Checking for Oil Discolouration
If the used oil displays a dark, black colouring, this indicates that
temperatures of over 100 degrees C. have occurred during operation. As a
consequence, more rapid ageing of the oil occurs, causing reduced
lubricating properties. The oil change must then be carried out at more
frequent intervals.
If the oil sample has a cloudy colouring, this can indicate the
penetration of water.
An immediate oil change must be performed and the gearbox flushed out
thoroughly several times with fresh oil. It is to be recommended that
the gearbox is disassembled and the parts examined for corrosion.
4. Checking for Solid Foreign Matter
We recommend to check for foreign substances regarding DIN 51592.
The sample will be dissolved in pure benzol, if necessary warm up a
little, and then filter it through a benzol resistant, fine-pored
membrane filter. The rest will be washed, dried, weighed and inicated as
amount of solid foreign substances.
Overall Assessment:
The max. permissible weight of foreign matter is approx. 0.15 % of the
total weight of oil in the gearbox. However, the foreign matter must
consist only of fine abrasion (up to max. 25 ym). If the permitted value
is not exceeded, the gearbox can continue to be operated after the oil
change.
If coarse abrasion (above 25 ym) or flakes of material from the profiles
of the gear teeth are discovered, the gearbox must be disassembled,
irrespective of the amount of foreign matter. The profiles of the gear
-------------------------------------------------------------------------
Heustrae 1
-------------------------------------------------------------------------
Doc.-No.: ANWEISE1/TXTKD Page 1
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- Instruction for Gearbox Inspection GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
wheels, in particular the large sun wheel of the output planetary gear
set, should be inspected visually. With normal wear and after the
running-in period, the rough peaks should have been smoothed by the
friction between the tooth profiles and the profiles should have a
smooth, bright, shiny surface.
If any other characteristics are detected, such as wear due to grinding,
scores, scuffs, pits, flaking, cracks or plastic distortion, the gear
wheels should be replaced and/or a general overhaul of the gearbox
carried out.
ZOLLERN Schmierstoffempfehlung ZOLLERN
VERTRIEBS- fr ZOLLERN - Getriebe Getriebe
GmbH + Co. Abt. KD
! ! !
! Schmierl-Auswahl ! Schmierlauswahl ! Schmierfett Auswahl
! nach API GL5 ! nach DIN 51502 ! nach DIN 51502
_________!___________________!___________________!
! ! !
! Schmierl ! Schmierl ! Schmierfett
! SAE 90 ! DIN 51517-CLP 220 ! DIN 51825-KP2K
_________!___________________!___________________!
! ! !
ARAL ! Aral Getriebel ! BG 220 ! Aral Fett HLP 2
! HYP 90 ! !
_________!___________________!___________________!
! ! !
AVIA ! Avia Getriebel ! RSX 220 ! Avia Avialith 2 EP
! Hypoid 90 EP ! !
_________!___________________!___________________!
! ! !
BP ! BP Hypogear EP 90 ! GR-XP 220 ! BP Energr. LS EP 2
_________!___________________!___________________!
! ! !
CASTROL ! Castrol EPX 90 ! Alpha SP 220 ! Castrol Spheerol EPL 2
! ! ! Grease
_________!___________________!___________________!
! ! !
ELF ! Tranself Typ B ! Reductelf SP 220 ! ELF Epexa 2
! SAE 90 ! !
_________!___________________!___________________!
! ! !
ESSO ! Esso Getriebel ! Spartan EP 220 ! Esso Beacon 2 EP
! GX-D90 ! !
_________!___________________!___________________!
! ! !
FUCHS ! Fuchs Getriebel ! Compound 106 ! Fuchs Renolit FEP 2
! Renogear Hypoid 90! VG 220 !
_________!___________________!___________________!
! ! !
GULF ! Gulf Multi-Purpose! EP Lubricant ! Gulf Crown Grease No.2
! Gear Lubricant ! HD 220 !
! SAE 90 ! !
_________!___________________!___________________!
! ! !
MOBIL ! Mobilube HD-A 90 ! Mobilgear 630 ! Mobilux 2 EP
_________!___________________!___________________!
! ! !
SHELL ! Shell Spirax MB 90! Omala 220 ! Shell Alvania EP 2
_________!___________________!___________________!
lwechsel- und Fettschmierintervalle siehe Wartungsanleitung.
-------------------------------------------------------------------------
ZOLLERN Anzugsmoment fr Befestigungsschrauben. ZOLLERN
VERTRIEBS- Tightening torques for screws. GETRIEBE
GmbH + Co. Moment de serrage pour vis de fixation (mN). Abt. KD
Pares de apriete para tornillos de fijacion.
------------------------------------------------------------------------
Festigkeitsklassen (Reibungszahl 0,125)
strength-class (frictioncoefficient)
Classe de resistance (coefficient de frict.)
Clases de resistencia (coeficciente de fric.)
8.8 10.9 12.9
M 4 = 2,7 Nm 3,8 Nm 4,6 Nm
M 5 = 5,5 Nm 8,O Nm 9,5 Nm
M 6 = 9,5 Nm 13,O Nm 16,O Nm
M 8 = 23,O Nm 32,O Nm 39,O Nm
M 10 = 46,O Nm 64,O Nm 77,O Nm
M 12 = 8O,O Nm 11O,O Nm 135,O Nm
M 14 = 125,O Nm 18O,O Nm 215,O Nm
M 16 = 195,O Nm 275,O Nm 33O,O Nm
M 18 = 27O,O Nm 39O,O Nm 455,O Nm
M 20 = 385,O Nm 54O,O Nm 650,O Nm
M 22 = 510,O Nm 72O,O Nm 870,O Nm
M 24 = 660,O Nm 93O,O Nm 11OO,O Nm
M 27 = 98O,O Nm 1400,O Nm 165O,O Nm
M 30 = 135O,O Nm 185O,O Nm 225O,O Nm
-------------------------------------------------------------------------
Schrauben gesichert mit Loctite Typ 242.
Secured by Loctite Type 242.
Frein de vis par Loctite Type 242.
Tornillos asegurados con Loctite Tipo 242.
Verbindungsflchen an den Getriebeteilen mit Loctite Typ 640 abgedichtet
Fitting surfaces sealed by Loctite Type 640.
Les surfaces des elements de fixation sont assurees par Loctite Type 640.
Superficies de union hermetizadas con Loctite Tipo 640.
Planflchen an der Haltebremse mit Loctite Type 573 abgedichtet.
Surfacing on brake sealed by Loctite Type 573.
Les surfaces du frein de retenue sont etanches par Loctite Type 573.
Superficies planas en el freno de retencion hermetizadas con Loctite
Tipo 573.
Verschraubungsgewinde der Rohrleitungen und die Verbindungsflche des
Antriebsmotors zum Getriebe mit Loctite Typ 572 abgedichtet.
Screwing of the tubing and the connection surfaces of the driving motor
to the gear are sealed with Loctite type 572.
Raccord a vis des conduites et la surface du moteur d'entrainement au
reducteur ont ete etanches par Loctite type 572.
Rosca del racor de los tubos y la superficie de union del motor de
accionamiento con el engranaje estan estanqueizadas con Loctite
Tipo 572.
Anwendervorschriften der Firma Loctite beachten.
Note application instructions of Loctite.
Faites attention aux instructions d'utilisation de Loctite.
Tenganse en cuenta las instrucciones de utilizacion dadas por Loctite.
-------------------------------------------------------------------------
Heustrae 1
-------------------------------------------------------------------------
Doc.-No.: ANZUGSM5/TXTKD Page 1
ZOLLERN ANZUGSMOMENTE
TIGHTENING TORQUES
MOMENT DE SERRAGE

____________________________________________________________________________________
D - Anzugsmomente fr Befestigungsschrauben von M 4 bis M 36 und fr
Festigkeitsklassen 8.8, 10.9 und 12.9 bei Reibungszahl 0,125.
GB - Tightering torques for fixing screws M 4 to M 36 and for strength classes
8.8, 10.9 and 12.9 ata coefficient of friction 0,125.
F - Moment de serrage pour vis de fixation de M 4 M 36 et pour degres de
resistances 8.8. 10.9 et 12.9 un nombre de friction 0,125.
8.8 10.9 12.9
M 4 = 2,7 Nm 3,8 Nm 4,6 Nm
M 5 = 5,5 Nm 8,O Nm 9,5 Nm
M 6 = 9,5 Nm 13,O Nm 16,O Nm
M 8 = 23,O Nm 32,O Nm 39,O Nm
M 10 = 46,O Nm 64,O Nm 77,O Nm
M 12 = 8O,O Nm 11O,O Nm 135,O Nm
M 14 = 125,O Nm 18O,O Nm 215,O Nm
M 16 = 195,O Nm 275,O Nm 33O,O Nm
M 18 = 27O,O Nm 39O,O Nm 455,O Nm
M 20 = 385,O Nm 54O,O Nm 650,O Nm
M 22 = 510,O Nm 72O,O Nm 870,O Nm
M 24 = 660,O Nm 93O,O Nm 11OO,O Nm
M 27 = 98O,O Nm 1400,O Nm 165O,O Nm
M 30 = 135O,O Nm 185O,O Nm 225O,O Nm
M 36 = 2350,0 Nm 3300,0 Nm

____________________________________________________________________________________
D - Schrauben gesichert mit Loctite Typ 242.
- Verbindungsflchen an den Getriebeteilen mit Loctite Typ 640 abgedichtet.
- Planflchen an der Haltebremse mit Loctite Type 573 abgedichtet.
- Verschraubungsgewinde der Rohrleitungen und die Verbindungsflche des
Antriebsmotors zum Getriebe mit Loctite Typ 572 abgedichtet.
Anwendervorschriften der Firma Loctite beachten!
GB - Secured by Loctite Type 242.
- Fitting surfaces sealed by Loctite Type 640.
- Surfacing on brake sealed by Loctite Type 573.
- Screwing of the tubing and the connection surfaces of the driving motor
to the gear are sealed with Loctite type 572.
Note application instructions of Loctite!
F - Frein de vis par Loctite Type 242.
- Les surfaces des elements de fixation sont assurees par Loctite Type 640.
- Les surfaces du frein de retenue sont etanches par Loctite Type 573.
- Raccord a vis des conduites et la surface du moteur d'entrainement au
reducteur ont ete etanches par Loctite type 572.
Faites attention aux instructions d'utilisation de Loctite!

____________________________________________________________________________________
Dok-Nr: 19OOOO159.DEF/OO
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- SLEWING GEAR GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Maintenance Instruction
Lubrication:
The Zollern-Slewing gear has splashed lubrication.
Oil filled in ex factory : AVIA gear oil Hypoid 90 EP.
Choosen according to DIN : DIN 51502.
Description according to DIN: Oil, DIN 51517-CLP 220.
Oil quantity is marked on the name plate. If the gear is delivered
without oil, we point out to that with a sticker.
The hydraulically ventilated disc brake has to be filled with 0,1 ltr.
oil when fitting the engine. Suitable are above all hydraulic oil
scustomary in commerce relatively to friction, coking of the oil, foam
formation, a. s. o. Especially qualified:
AUTOMATIC-TRANSMISSIONS-FLUID (ATF Dexron or Suffix A, Donax TM,
HLP 22, 32, 68, 100.)
The roller bearing of the gear output is filled with grease.
Grease filled in ex factory : AVIA Avialith 2 EP
Choosen according to DIN : DIN 51502.
Description according to DIN: Grease, DIN 51825-KP2K.
This is life-time lubrication and it is not necessary to renewal or to
refill it.
Further oil and grease types see recommendations for lubricants.
-------------------------------------------------------------------------
Recommendation for maintenance intervals:
Weekly inspection of oil.
Oil change after 200-1000-2000 operation hours, but at least once a year.
Attention: oil level can only be inspected with non-running gear.
If possible, oil change only with service temperature condition,
therefore remove the ventilating filters.
It is highly recommendable to clean with a pre-heated part of new oil
if the ambient temperatures are low in order to allow the flowing off
wearness and contaminations.
-------------------------------------------------------------------------
ZOLLERN ZOLLERN
VERTRIEBS- SLEWING GEAR GETRIEBE
GmbH + Co. Abt. KD
-------------------------------------------------------------------------
Instructions for design and assembly
- Install slewing gear forcelessly into the holding fixture of the unit.
- Release brake (disc brake) hydraulically with manual pump.
Drive sleeve must be slightly turnable.
- Tooth flank clearance between pinion and wheel rim of the bearing
slewing ring to be adjusted acc. to the indications of the crane
manufacturer (for ex. clearance = 0,03 - 0,04 x module). For this
it is necessary to put the dial gauge on the tooth of
the pinion. By manual turning at the input, the pinion can be moved
in both directions up to contact with the teeth. Now, the tooth
flank clearance can be exactly read on the dial gauge.
- With excentricity of the gear-housing the flank clearance can be
changed by means of turning by one or more screw holes of the whole
slewing gear.
- Fix the gear by tightening the screws up to the recommended torque.
We recommend add. to use Loctite Type 242 for screw security.
The tensile shear, i.e. the shear tension can be increased
by means of e.g. Loctite Type 640 on the surface of the
flange.
- Screw plug removed on the surface (for transport only) and added
air vents screwed in.
- If necessary fill in gear oil (type see maintenance instructions).
Approx. oil quantity is marked on the type plate.
- Fill disc space of the holding brake with hydraulic oil. .
(Oil type and quantity, see maintenance instructions)
- Before assembly of the hydr. motor, the shaft and the tooth profile
has to be protected with appropriate grease against corrosion. We
recommend Optimoly Paste White T.
- Check function of slewing gear when motor is running,
esp. function of brake and control of input motor.
- Furthermore we point out to the technical data in our installation
drawing.
DATUM E R S A T Z T E I L - L I S T E
ZOLLERN VERTRIEBS-GMBH + CO
-------- -------------------------------
HEUSTRASSE 1
9.03.01 S P A R E - P A R T - L I S T
D-88518 HERBERTINGEN/WRTT.
DREHWERKSGETRIEBE ZHP 3.25 032510310 PLANETARY GEAR
GEWICHT LEINFLLMENGE

WEIGHT OIL QTY
SERIEN - NR. 101 - 125 SERIAL - NO. 101 - 125
319,0 KG 13,5 LITER

*************************************************************************************************
SEITE - 1

**********************************************************************************************************************
Pos-Nr. Stck Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH
Technische - Daten
POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH
TECHNICAL - DATA

______________________________________________________________________________________________________________________
1 1,0 132513034 PLANETENSTUFE PLANETARY STAGE

-----------------------------------------------------------------------------------------------------------
1/ 11 1,0 100100315 PLANETENSTUFE PLANETARY STAGE
1/ 11/ 1 1,0 233700002 INNENRAD INTERNAL-WHEEL
1/ 11/ 2 3,0 232500827 PLANETENRAD PLANETARY WHEEL
1/ 11/ 3 1,0 232500533 SONNENRAD SUN WHEEL
1/ 11/ 4 6,0 453300216 ZYL.ROLLENLAGER CYLINDER ROLLER BEARING
30X 68,15X31/L31,5
1/ 11/ 5 3,0 403200042 SICHERUNGSRING CIR CLIP
---,--X 68,00X 2,50 DIN 472
1/ 11/ 6 6,0 503400034 SCHEIBE WASHER
61,00X 68,00X 3,25

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

-----------------------------------------------------------------------------------------------------------
1/ 24 1,0 100010375 PLANETENTRGER PLANETARY CARRIER
1/ 24/ 1 1,0 232000267 PLANETENTRGER PLANETARY CARRIER
1/ 24/ 2 3,0 234502512 PLANETENACHSE PLANETARY AXLE
70,00X---,--X 2,50 DIN 471
1/ 24/ 4 1,0 503100045 SPRENGRING CIR CLIP
70,00X---,--X 2,00

-----------------------------------------------------------------------------------------------------------
1/ 27 1,0 100020251 ZWISCHENGEHUSE INTERMEDIATE HOUSING
1/ 27/ 1 1,0 232000040 ZWISCHENGEHUSE INTERMEDIATE HOUSING
1/ 27/ 2 18,0 411130083 SECHSKANTSCHRAUBE HEXAGON BOLT
M 12X 80 ZN 8.8 DIN 931

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

WEIGHT OIL QTY
319,0 KG 13,5 LITER

*************************************************************************************************
SEITE - 2

**********************************************************************************************************************
Technische - Daten
TECHNICAL - DATA

______________________________________________________________________________________________________________________

-----------------------------------------------------------------------------------------------------------
1/ 34/ 1 1,0 231500313 PLANETENTRGER PLANETARY CARRIER
1/ 34/ 2 3,0 231500301 PLANETENACHSE PLANETARY AXLE
45,00X---,--X 1,75 DIN 471
1/ 34/ 4 1,0 503100036 SPRENGRING CIR CLIP
45,00X---,--X 1,50

-----------------------------------------------------------------------------------------------------------
29 1,0 132541069 TRIEBSTOCK LANG LONG OUTPUT HOUSING
29/ 1 1,0 232500787 SCHAFTRITZEL PINION SHAFT
29/ 3 1,0 232500790 ABTRIEBSGEHUSE OUTPUT HOUSING
29/ 5 3,0 232500419 PLANETENACHSE PLANETARY AXLE
29/ 7 1,0 232500792 SCHEIBE WASHER
29/ 9 1,0 232500791 HALTESCHEIBE HOLDING DISC
29/ 20 3,0 411200005 ZYLINDERSCHRAUBE CYLINDRICAL SCREW
M 20X 70 10.9 DIN 912
M 16X110 10.9 DIN 912
29/ 30 1,0 453400050 KEGEL-ROLLENLAGER TAPER ROLLER BEARING
130X230X 67,75 DIN 720
29/ 31 1,0 453400110 KEGEL-ROLLENLAGER TAPER ROLLER BEARING
120X215X 43,50 A DIN 720
29/ 50 1,0 441300013 V-RING V-RING
D1= 210- 233/B1= 8
29/ 51 2,0 441100386 WELLENDICHTRING SHAFT SEALING RING
125X150X12 BA NBR DIN3760
29/ 52 1,0 541000013 O-RING SEALING RING
130,00X3 NBR-70
29/ 60 1,0 414430007 VERSCHLUSS-SCHRAUBE PLUG
M 22X 1,5 ZN MAGN. DIN 908
M 22X 1,5 ZN DIN 908
29/ 63 4,0 441000216 FLACH-DICHTRING SEALING RING
A 22X 27X1,5 DIN7603
29/ 70 3,0 404300792 PASS-SCHEIBE WASHER
120,00X150,00X 1,00 DIN 988
120,00X150,00X 0,20 DIN 988

-----------------------------------------------------------------------------------------------------------
40 1,0 113125014 ANTRIEB DRIVE IN
40/ 1 1,0 231500347 BREMSFLANSCH BRAKE FLANGE
40/ 4 1,0 242400952 ANTRIEBSHLSE DRIVING SLEEVE
40/ 6 1,0 242400052 HLSE SLEEVE
40/ 7 1,0 230000022 MOTORFLANSCH MOTOR FLANGE
40/ 12 1,0 242400038 SCHEIBE WASHER
M 10X 90 ZN 8.8 DIN 912
M 10X120 ZN 8.8 DIN 912
40/ 30 1,0 453000037 RILLENKUGELLAGER BALL BEARING
45X 75X16 DIN 625
40/ 40 1,0 403200045 SICHERUNGSRING CIR CLIP
---,--X 75,00X 2,50 DIN 472
45,00X---,--X 1,75 DIN 471
---,--X 26,00X 1,20 DIN 472
50X 68X 8 BA NBR DUO
47,00X2 NBR-72
-------- -------------------------------
HEUSTRASSE 1
9.03.01 S P A R E - P A R T - L I S T

WEIGHT OIL QTY
319,0 KG 13,5 LITER

*************************************************************************************************
SEITE - 3

**********************************************************************************************************************
Technische - Daten
TECHNICAL - DATA

______________________________________________________________________________________________________________________
126,00X3 NBR-72
M 18X 1,5 ZN DIN 908
A 18X 22X1,5 DIN7603
19,00X 26,00X 1,00 DIN 988
40/ 95 1,0 506701002 LDRUCKEINHEIT HYDR.-PART FOR DISC BRAKE
40/ 96 1,0 506700218 LAMELLENTRGER CLUTCH PLATE CARRIER
40/ 97 9,0 506700146 AUSSENLAMELLE MULTIPLE DISK
DIN5480RAD-NUT-L2,30
40/ 98 7,0 506700147 INNENLAMELLE MULTIPLE DISK
DIN 867--------L1,45

-----------------------------------------------------------------------------------------------------------
70 1,0 130000101 LKONTROLLE OIL CONTROL
70/ 11 1,0 540100828 VERSCHRAUBUNG THREADED JOINT CONNECTION
M 22X 1,5 ED-160B
70/ 13 1,0 133290007 ROHR PIPE
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 36 1,0 540100828 VERSCHRAUBUNG THREADED JOINT CONNECTION
M 22X 1,5 ED-160B
70/ 37 1,0 133290007 ROHR PIPE
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 44 1,0 543400081 LUFTFILTER VENT FILTER
V=0,1L/0,2BAR/
A 10X 13,5X1,0 DIN7603
M 10X 1,0 ZN DIN 908
70/ 58 1,0 543400014 ENTLFTUNGSVENTIL VENT FILTER
0,04 BAR MESSING M10*1,0
A 22X 27X1,5 DIN7603
M 22X 1,5 ZN DIN 908
70/ 66 2,0 543100021 LSTANDAUGE-M 22*1,5 + DR. OIL SIGHT GLASS
WEICHEISEN /-30+120

-----------------------------------------------------------------------------------------------------------
75 14,0 100003006 FEDERN SPRINGS
75/ 1 14,0 402100306 DRUCKFEDER SPRINGS

-----------------------------------------------------------------------------------------------------------

______________________________________________________________________________________________________________________
*** ENDE DER STCKLISTE
________________________________________________________________________
ZOLLERN SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE
Getriebe Typ ZHP 4.32
Gear Type
Reducteur Type
Gerte Nr. 0 4.32 10078
Aggregat No.
Appareil No.
Serien Nr. 101 - 106
Serial No.
Serie No.
Auftrags Nr. 6/53247 vom 20.11.96
Order No. 6/53315 vom 07.11.96
Commande No.
_________________________________________________________________________
Firma : Neuenfelder Maschinenfabrik GmbH
Company :
Societe :
Anschrift : Neuenfelder Fhrdeich 120
Adress : D-21129 Hamburg
Adresse :
Abteilung : zu Hdn. Herrn Holler
Department :
Service :
_________________________________________________________________________
Bestell- Nr.: 609251 vom 24.09.96 Firmen Nr.: ---
Order- No.: Company No.:
Commande- No.: Societe No.:
Gerte Type: --- Sach Nr.: DIV 2670 WD
Aggregat Type: Ident. No.:
Appareil Type: Produit No.:
Bau/Komm. Nr.: --- Pos. Nr.: ---
Constr. No.: Pos. No.:
Constr.Spec. No.: Rep. No.:
Projekt Nr.: ---
Project No.:
Projet No.:
Heustrae 1
Telefon 07586-959-0, Telefax-Service-Dep. 07586-959-710, Telex 732 218
Lieferumfang: 3-fach deutsch/englisch
Doc.-No. : 19OO11576/SB 15.01.01 MA/KD
INHALT
CONTENTS
TYP GERTE-NR BEZEICHNUNG DESCRIPTION SERIEN-NR
Type Aggregat-No Serial-No
ZHP 4.32 043210078 SEILWINDE ROPE WINCH 101 - 106
DOKUMENT-NR BEZEICHNUNG DESCRIPTION
DOCUMENT-NO
190011576 SERVICE BLATT SERVICE FORM
043210078 EINBAUZEICHNUNG INSTALLATION-DRAWING
SEILWINDE ROPE WINCH
GETRIEBE GEAR
SEILTROMMEL ROPE DRUM
FLANSCH FLANGE
ANTRIEB DRIVE IN
LLEITUNG OIL PIPE
HYDRAULIKLAMELLENBREMSE HYDR. MULTIPLE DISC BRAKE
193001820 ERSATZTEILLISTE SPARE PART LIST
190000475 EINBAUANLEITUNG INSTALLATION INSTRUCTION
190000204 WARTUNGSANLEITUNG MAINTENANCE INSTRUCTION
190000315 SCHMIERSTOFFEMPFEHLUNG RECCOMANDATION F.LUBRICANTS
190000158 GETRIEBEINSPEKTION GEARBOX INSPECTION
190000159 ANZUGSMOMENTE TIGHTENING TORQUES
ZOLLERN VERTRIEBS-GmbH & Co
Heustrae 1
Telefon 07586-959-0,Telefax-Service-Dep. 07586-959-710,Telex 732 218
Doc.-No.: 19OO11576/SB Datum: 15.01.01
ERSATZTEILLISTE-NR: 193001820
SPARE PART LIST NO:
TYP GERTE-NR BEZEICHNUNG DISCRIPTION SERIEN-NR
TYPE AGGREGAT-NO SERIAL-NO
ZHP 4.32 043210078 SEILWINDE ROPE WINCH 101 - 106
BEI ERSATZTEILBESTELLUNG TYP,GERTE-NR,SER.-NR UND TEILE-NR. ANGEBEN
IF YOU ORDER SPARES INDICATE TYPE,UNIT-NO,SERIAL-NO AND PART-NO.
POS-NR STCK TEILE-NR BEZEICHNUNG DISCRIPTION
POS-NO QUANTITY PART-NO
1 1,0 193001821 GETRIEBE GEAR
21 1,0 193001822 SEILTROMMEL ROPE DRUM
22 1,0 193001823 FLANSCH FLANGE
24 1,0 193001824 ANTRIEB DRIVE IN
60 1,0 193001825 LLEITUNG OIL PIPE
75 16,0 100003010 DRUCKFEDER PRESSURE SPRING
76 16,0 100003011 DRUCKFEDER PRESSURE SPRING
GEWICHT: 3 020.0 KG LMENGE : 27.0 LTR
WEIGHT : OIL QUANTITY:
ZOLLERN VERTRIEBS-GmbH & Co
Heustrae 1
Telefon 07586-959-0,Telefax-Service-Dep. 07586-959-710,Telex 732 218
Seite: 1 Datum: 15.01.01
-------- -------------------------------
HEUSTRASSE 1
15.01.01 S P A R E - P A R T - L I S T
ZHP 4.32 - 043210078 193001820
WEIGHT OIL QTY
3.013,5 KG 27,0 LITER
*************************************************************************************
************ SEITE - 1
*************************************************************************************
*********************************
Technische - Daten
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
1 1,0 193001821 GETRIEBE GEAR + OUTPUT
1/ 11 1,0 234802503 INNENRAD INTERNAL-WHEEL
1/ 13 1,0 243200188 SONNENRAD SUN WHEEL
140,00X---,--X 4,00 DIN 471
1/ 30 1,0 503100061 SPRENGRING CIR CLIP
140,00X---,--X 2,50
100,00X---,--X 3,00 DIN 471
1/ 66 18,0 411130138 SECHSKANTSCHRAUBE HEXAGON BOLT
M 24X160 ZN 8.8 DIN 931
1/ 90 1,0 243200300 SCHEIBE WASHER
1/ 95 1,0 242700943 DECKEL COVER
1/ 96 1,0 453000265 RILLEN-KUGELLAGER BALL BEARING
25X 62X17 DIN 625
M 16X110 ZN 8.8 DIN 912
1/101 1,0 243200283 PLANETENTRGER PLANETARY CARRIER
1/103 1,0 243200228 LAGERRING BEARING RING
1/106 1,0 243200312 ZWISCHENGEHUSE INTERMEDIATE HOUSING
1/121 30,0 411230119 ZYLINDERSCHRAUBE CYLINDRICAL SCREW
M 24X200 ZN 8.8 DIN 912
M 16X 25 ZN 8.8 DIN 912
1/131 1,0 441100565 WELLENDICHTRING SHAFT SEALING RING
560X610X20 B2 NBR DIN3760
1/141 2,1 442000002 PROFILSCHNUR SEALING RING
WZ NR 6/2824
1/142 2,0 542000010 BEFESTIGUNGSBAND OTHER ACCESSORIES
PF 6180
1/143 1,0 542100010 HLSE NUT
8X0,4
1/151 1,0 453300172 ZYLINDERROLLENLAGER CYLINDER ROLLER
BEARING AD575,130V-4.32-L 66
1/153 1,0 453000169 RILLENKUGELLAGER BALL BEARING
260X400X65 DIN 625
1/160 1,0 403100085 SICHERUNGS-RING CIR CLIP
300,00X---,--X 5,00 DIN 471
1/161 1,0 403100082 SICHERUNGSRING CIR CLIP
260,00X---,--X 5,00 DIN 471
1/162 1,0 403200208 SICHERUNGSRING CIR CLIP
---,--X400,00X 6,00 DIN 472
1/201 1,0 243200350 ABTRIEBSGEHUSE OUTPUT HOUSING
M 30X 70 ZN 8.8 DIN 912
1/454 1,0 441100691 WELLEN-DICHTRING SHAFT SEALING RING
60X 95X10 BA NBR DIN3760
1/462 4,0 414030111 VERSCHLUSS-SCHRAUBE SCREW SPINDLE
M 30X 1,5 ZN DIN 908
1/463 4,0 441000223 FLACH-DICHTRING SEALING RING
A 30X 36X2,0 DIN7603
1/491 1,0 243200272 SCHEIBE WASHER
1/520 2,0 524100009 LVENTIL HYDR.-PARTS
HUB 3,5--1008050100
A 18X 22X1,5 DIN7603
------------------------------------------------------------------------
-----------------------------------
21 1,0 193001822 SEILTROMMEL CABLE DRUM CPL.
21/ 1 1,0 243200349 SEILTROMMEL ROPE DRUM
21/ 5 1,0 243100481 SEILBLECH CABLE FIXING AND
WEDGES
M 30X 70 ZN 8.8 DIN 933
-------- -------------------------------
HEUSTRASSE 1
15.01.01 S P A R E - P A R T - L I S T
ZHP 4.32 - 043210078 193001820
WEIGHT OIL QTY
3.013,5 KG 27,0 LITER
*************************************************************************************
************ SEITE - 2
*************************************************************************************
*********************************
Technische - Daten
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
M 30X 70 ZN 8.8 DIN 933
21/ 23 5,0 412300803 GEWINDE-STIFT SCREW
M 20X 50FLECKBESCH.
------------------------------------------------------------------------
-----------------------------------
22 1,0 193001823 FLANSCH FLANGE + PLATE CPL.
22/ 1 1,0 243200153 FLANSCH FLANGE
22/ 2 1,0 243200348 FLANSCHPLATTE FLANGE PLATE
22/ 3 1,0 234802564 SCHEIBE WASHER
---,--X225,00X 5,00 DIN 472
22/ 5 0,4 688100003 FILZ-DICHTSTREIFEN FELT STRIP
5,0X 4,0 DIN5419
22/ 6 1,0 453400090 PENDEL-ROLLENLAGER PENDULUM ROLLER
BEARING 150X225X 56 S.MB DIN 635
22/ 8 1,0 243200201 DECKEL COVER
22/ 9 1,0 234500242 MITNEHMER DRIVER
M 8X 85 ZN 8.8 DIN 912
22/ 12 1,0 417000094 SPANNSTIFT PIN
4,0X 16 DIN1481
22/ 13 1,0 417000094 SPANNSTIFT PIN
4,0X 16 DIN1481
22/ 14 1,0 412300409 GEWINDESTIFT SCREW
M 6X 6 DIN 913
22/401 1,0 449900003 KEGELSCHMIERNIPPEL GREASE NIPPLE
AM 10X 1 DIN71412
------------------------------------------------------------------------
-----------------------------------
24 1,0 193001824 ANTRIEB DRIVE CPL.
24/ 1 1,0 242400491 BREMSFLANSCH BRAKE FLANGE
------------------------------------------------------------------------
-----------------------------------
24/ 4 1,0 193001324 ANTRIEBSHLSE DRIVING SLEEVE
24/ 18 1,0 242400086 DECKEL COVER
M 16X 45 ZN 8.8 DIN 912
M 12X140 ZN 8.8 DIN 912
M 12X 60 ZN 8.8 DIN 912
M 20X 30 ZN 8.8 DIN 933
24/ 30 1,0 453000039 RILLENKUGELLAGER BALL BEARING
90X140X24 DIN 625
---,--X140,00X 4,00 DIN 472
90,00X---,--X 3,00 DIN 471
---,--X 55,00X 2,00 DIN 472
100X130X12 BA FPM DIN3760
24/ 53 1,0 441100665 WELLEN-DICHTRING SHAFT SEALING RING
110X130X 8 B1 FPM DIN3760
285 X3 NBR-70
200 X3 NBR-
24/ 60 3,0 414030001 VERSCHLUSS-SCHRAUBE SCREW SPINDLE
M 10X 1,0 ZN DIN 908
A 10X 13X1,0 DIN7603
M 18X 1,5 ZN DIN 908
A 18X 22X1,5 DIN7603
24/ 66 1,0 242400144 DECKEL COVER
-------- -------------------------------
HEUSTRASSE 1
15.01.01 S P A R E - P A R T - L I S T
ZHP 4.32 - 043210078 193001820
WEIGHT OIL QTY
3.013,5 KG 27,0 LITER
*************************************************************************************
************ SEITE - 3
*************************************************************************************
*********************************
Technische - Daten
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
24/ 69 1,0 543400074 ENTLFTUNGSVENTIL VENT FILTER
0,02-0,07BAR-EL 4,7 M10*1,0
45,00X 55,00X 1,00 DIN 988
24/ 79 4,0 404130015 SCHEIBE WASHER
21,00X 37,00X 3,00 DIN 125
24/ 95 1,0 506701019 LDRUCKEINHEIT HYDR.-PART FOR DISC
BRAKE
24/ 96 1,0 506700225 LAMELLENTRGER CLUTCH PLATE CARRIER
24/ 97 11,0 506700162 AUSSENLAMELLE MULTIPLE DISK
24/ 98 10,0 506700163 INNENLAMELLE MULTIPLE DISK
24/122 1,0 414030002 VERSCHLUSS-SCHRAUBE SCREW SPINDLE
M 12X 1,5 ZN DIN 908
A 12X 16X1,5 DIN7603
------------------------------------------------------------------------
-----------------------------------
60 1,0 193001825 LLEITUNG OIL PIPE
A 26X 31X2,0 DIN7603
60/ 2 1,0 243100784 GEWINDESTUTZEN PIPING PIECES
60/ 3 1,0 540100029 G.EINSCHR.VERS.-GE--22-PLM THREADED JOINT
CONNECTION M 26X 1,5 160B
60/ 4 1,0 540200012 SCHLAUCHARMATUR THREADED JOINT
CONNECTION GA 15701-12
60/ 6 1,0 540500012 HYDRAULIKSCHLAUCH HYDR.-PARTS
A=26,0 I=19,0
60/ 11 1,0 519000035 KREUZ THREADED JOINT
CONNECTION I 3/4" C 1
60/ 12 1,0 540100262 G.EINSCHR.VERS.-GE--22-PLR THREADED JOINT
CONNECTION -OMD-R3/4"- -160B
60/ 13 1,0 540200012 SCHLAUCHARMATUR THREADED JOINT
60/ 14 1,0 540100982 REDUZIERSTUTZEN THREADED JOINT
CONNECTION RI3/4"X1/2"--400B
A 21X 26X1,5 DIN7603
G 1/2 ZN DIN 910
G 3/4 ZN DIN 910
60/ 31 1,0 234200058 ROHR PIPING PIECES
60/ 32 2,0 540900020 ROHRSCHELLE CLAMP
4R3/4 RAP-
M 6X 40 ZN 8.8 DIN 912
A 26X 31X2,0 DIN7603
60/ 43 1,0 540100907 G.EINSCHR.VERS.-GE--15-PLM THREADED JOINT
CONNECTION ---OMD-M18X1,5--250B
60/ 44 1,0 540200008 SCHL.-ARMATUR-SCHL. NW 12- THREADED JOINT
60/ 46 0,5 540500011 SCHLAUCH-NW 12 1525-08 HYDR.-PARTS
A=19,0 I=12,7
60/ 47 1,0 540200008 SCHL.-ARMATUR-SCHL. NW 12- THREADED JOINT
60/ 48 1,0 540100910 G.EINSCHR.VERS.-GE--15-PLR THREADED JOINT
CONNECTION -OMD-G1/2"- -250B
60/ 49 1,0 519000221 T-STCK THREADED JOINT
CONNECTION I 3/4"-I 1/2"-A 3/4"
A 27X 32X2,0 DIN7603
60/ 63 1,0 543400071 MESTAB OIL DIPSTICK
ANSCHL.R3/4" -L=350
------------------------------------------------------------------------
-----------------------------------
15,7N/MM-S= 27,3-RE
-------- -------------------------------
HEUSTRASSE 1
15.01.01 S P A R E - P A R T - L I S T
ZHP 4.32 - 043210078 193001820
WEIGHT OIL QTY
3.013,5 KG 27,0 LITER
*************************************************************************************
************ SEITE - 4
*************************************************************************************
*********************************
Technische - Daten
TECHNICAL - DATA
_____________________________________________________________________________________
_________________________________
------------------------------------------------------------------------
-----------------------------------
5,9N/MM-S= 33,0-LI
_____________________________________________________________________________________
_________________________________
*** ENDE DER STCKLISTE
1
2
3
5
4
6
7
9
10
8
HYDAC Label
SAP CODE
DESCRIPTION
Position QTY.
1 1 Radiator BSR-70 3078616
1 2 Casing 3087762
Fan 300/6-6/25LD/PPG/D/FM14
3 1 3087898
4
5
6
7
8
9
10
1
1
1
1
1
1
2
Grid 294 strengthened 3087932
Filter Support 3087899
Filter MF-160
314858
Indicator 303854
Motor M. 220/480-50/60HZ 0.37KW 1500G B14-B14
2507124
Pump FZP-1/1.1/P/71/10/RV4.5 721068
Feet 295x30x15
3087930
Spare Parts
6
5
5
5
4
5
3
5
2
5
1
7
8
9
10
OKAF-EL2S/10/3.0/M/400-50/MF160/10/1/So61
pos. article-no. g identifier amount unit
1 15000490001 ESG-GLASS 400 x 960 x 6 MM GREEN 2.00 St
2 1500940109R ESG-GLASS 1162 X 542 X 10 MM GREEN 2.00 St
3 15009401110 ESG-GLASS 1162 X 622 X 6 MM GREEN 1.00 St
6 003-450-R ESG-GLASS 10 MM GREEN 1.00 St
7 060-23-01 FRAME FOR FRONT WINDOW 1.00 St
8 060-23-02 FRAME FOR SIDE WINDOW 2.00 St
9 060-23-03 FRAME FOR SIDE WINDOW 1.00 St
10 060-23-04 FRAME FOR ATTIC WINDOW 1.00 St
11 002-194 CELLULAR RUBBER 14.00 m
12 15000400337 EDGE PROTECTION WITH SEALING 16.50 in
13 15000400376 TRANSPARENT KITT 6.00 St
14 15000400323 LABEL EMERGENCY EXIT ONLY 1.00 St
15 003-455 1 WINDOW WIPER SYSTEM 1.00 St
01 003-452 WINDOW WIPER MOTOR 1.00 St
02 003-453 WIPER ARM 1.00 St
03 003-454 WIPER BLADE 1.00 St
16 15000903000 COVER FOR SCREEN WIPER MOTOR 1.00 St
17 15000603100 CROSS HANDLE 7.00 St
18 15000608400 1 LEVER LOCK 1.00 St
01 15000608401 LEVER 1.00 St
02 15000608402 LEVER 1.00 St
03 15000609403 ROSETTE 2.00 St
04 15000608404 TONGUE 1.00 St
05 15000608405 AXLE 1.00 St
06 516843 WASHER POLYAMIDE 2.00 St
19 516677 RING 1.00 St
20 003-564 BRASS BALL 2.00 S~
21 001-20-05 HEXAGONAL CAP 2.00 St
22 003-621 TKR.EADED BOLT 2.00 St
23 044-17-03 BRASS ROD 2.00 St
24 15000601010 STEEL STRIP 3.00 St
25 15000601000 STEEL STRIP 6.00 St
26 15000672110 LUBRICATOR NIPPLE 9.00 St
27 15000672120 CAP 5.00 St
28 531217 BED 4.00 St
29 531219 BED 5.00 St
30 531220 BED 2.00 St
31 15000810035 FAN HEATER 1.00 St
32 001-758 1 DRIVERS SEAT 1.00 St
01 000-867 DRIVERS SEAT 1.00 St
02 000-450 INDEXING BOLT GNG13-B-GI( 1.00 St
03 15000603330 SET SCREW 1.00 St
04 15000603331 THRUST 1.00 St
05 15000608110 TILT-JAM LEVER GAI~V~NIZED 1.00 St
06 15000603090 CROSS HANDLE 1.00 St
33 15000653110 SUNSHADE HOLDER 1.00 St
34 15000653100 CUTTING OF SAFETY GLASS GREEN 1.00 St
35 15000653210 ASHTRAY ~ St
36 15000653220 HANGER 1.00 St
37 15000677150 GRATING 2.00 St
38 516881 FIXING CLAMP 4.00 St
39 15000690306 INSULATION BLACK 50 mm 4.50 m
2
40 15000690410 INSULATION 50mm 0.80 m
2

Manual Instruction

Karl Miller GmbH
Industriestr. 19
77933 Lahr / Schwarzwald
Tel.: 07821 / 9476-0
Fax: 07821 / 9476-10
e-mail: info@kml-miller.de
www.kml-miller.de

Karl Miller GmbH
Systemlsungen im Kabinenbau

www.kml-miller.de

2

Contents

KML Article - No. : 70501................................................................................. 3
Article Name: Split-Air-Conditioning ............................................................ 3
Illustration of outside unit .............................................................................. 3
Illustration of inside unit ................................................................................ 4
Illustration of closed unit................................................................................ 4
General description......................................................................................... 5
Operating Instructions: ...................................................................................... 6
Switch on of the equipment............................................................................ 6
Switch off operation of the equipment ........................................................... 6
Technische Daten ........................................................................................... 6
Maintenance jobs:........................................................................................... 7

Karl Miller GmbH

www.kml-miller.de

3

KML Article - No. : 70501

Article Name: Split-Air-Conditioning

Illustration of outside unit

Karl Miller GmbH

www.kml-miller.de

4
Illustration of inside unit

Illustration of closed unit

Karl Miller GmbH

www.kml-miller.de

5
General description

The air condition is specially designed for installation in maritime range.

Therefor standard components as
- Evaporator unit with blower
- Refrigerator compressor
- Condenser
- Ventilator
Are installed in an outside unit and an inside unit. The outside unit is mounted on the top of
the cabin. The housing material is painted stainless stele plate.
The inside unit is mounted at the cabin ceiling and is connected with the outside equipment
over 3 junction lines. Two pieces for the refrigerant and one for the power.

Performance data:
- Cooling rating: ca. 2500 W
- Current: 230 V, 50 Hz
- Refrigerant: R134a

Karl Miller GmbH

www.kml-miller.de

6
Operating Instructions:

Switch on of the equipment

Master switch on 1.

Set air flow on the equipment switch Air:
off
lo
MIO
Hi
Set the desired temperature on the equipment switch Temp

Switch off operation of the equipment

Master switch on 0.

Technische Daten

AC with
evaporator
Condenser
FCE
Compressor Condenser
Blower R2E
Volts (V) 12 V 230 V 230 V
Frequency (Hz) 60 Hz 50/60 Hz
Watts (W) 880 W 160 W
Cooling capacity (W) 3200 kcal/h 2500 W 2500 W
Capacity heat pump (W)
max. air delivery (m/h) 400 (m/h) 2550 (m/h)
Indoor air flow (m/h)
Exhaust flow (m/h)

Rated load Amps compressor
/ fan motor (A)
5,2 A 0,71 A
Face area (m) 3,5 m

Dimensions:
Heigth (mm) 150 mm 335 mm 271 mm 225 mm
Width (mm) 420 mm 300 mm 235 mm
Depth (mm) 285 mm 65 mm 170 mm 71 mm

Weight (kg) 5,5 kg 3 kg 21,5 kg 2,5 kg

Karl Miller GmbH

www.kml-miller.de

7
Maintenance jobs:

The air-condition equipment requires low maintenance.

After 500 operating hours the blowers are to be checked for contaminations and cleaned if
necessary.

Check, if the water-outlet is open and free

Important

Doors and windows of the cabin must be closed while the air-condition equipment is in
operation.

Openings for condensate ventilation on the external side should not be closed!

Moeller GmbH
Industrieautomation
Hein-Moeller-Strae 711
D-53115 Bonn
E-Mail: info@moeller.net
Internet: www.moeller.net
2001 by Moeller GmbH
Subject to alteration
AWB27-1184-GB DMD/DMD/Ki 03/02
Printed in the Federal Republic of Germany (03/02)
Article No.: 48988
A A
Think future. Switch to green. Think future. Switch to green.
Industrial Automation Systems
Hardware and Engineering
03/02 AWB27-1184-GB
PS4-201-MM1
Building Automation
Rckenbreite bis 10 mm (1 Blatt = 0,106 mm)
All brand and product names are trademarks or registered
trademarks of the owner concerned.
1
st
published 1994, edition date 04/94
2
nd
edition 04/1994
3
rd
edition 06/1997
4
th
edition 04/1999
5
th
edition 03/2002
See revision protocol in the About this manual chapter
Moeller GmbH, 53105 Bonn
Author: Werner Albrecht
Editor: Thomas Kracht
Translator: Terence Osborn
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any other process) or
processed, duplicated or distributed by means of electronic
systems without written permission of Moeller GmbH, Bonn.
Subject to alteration without notice.
Rckenbreite festlegen! (1 Blatt = 0,106 mm)
I
Before commencing the installation
Disconnect the power supply of the device.
Ensure that devices cannot be accidentally
restarted.
Verify isolation from the supply.
Earth and short circuit.
Cover or enclose neighbouring units that
are live.
Follow the engineering instructions (AWA)
of the device concerned.
Only suitably qualified personnel in
accordance with EN 50110-1/-2
(VDE 0105 Part 100) may work on this
device/system.
Before installation and before touching
the device ensure that you are free of
electrostatic charge.
The functional earth (FE) must be
connected to the protective earth (PE) or
to the potential equalisation. The system
installer is responsible for implementing
this connection.
Connecting cables and signal lines should
be installed so that inductive or capacitive
interference does not impair the
automation functions.
Install automation devices and related
operating elements in such a way that they
are well protected against unintentional
operation.
Suitable safety hardware and software
measures should be implemented for the
I/O interface so that a line or wire breakage
on the signal side does not result in
undefined states in the automation
devices.
Ensure a reliable electrical isolation of the
low voltage for the 24 volt supply. Only
use power supply units complying with
IEC 60364-4-41 (VDE 0100 Part 410) or
HD 384.4.41 S2.
Deviations of the mains voltage from the
rated value must not exceed the tolerance
limits given in the specifications, otherwise
this may cause malfunction and dangerous
operation.
Emergency stop devices complying with
IEC/EN 60204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause restart.
Devices that are designed for mounting in
housings or control cabinets must only be
operated and controlled after they have
been installed with the housing closed.
Desktop or portable units must only be
operated and controlled in enclosed
housings.
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Warning!
Dangerous electrical voltage!
II
Measures should be taken to ensure the
proper restart of programs interrupted
after a voltage dip or failure. This should
not cause dangerous operating states even
for a short time. If necessary, emergency-
stop devices should be implemented.
Wherever faults in the automation system
may cause damage to persons or property,
external measures must be implemented to
ensure a safe operating state in the event
of a fault or malfunction (for example, by
means of separate limit switches,
mechanical interlocks etc.).
List of revisions to AWB 27-1184 GB
Edition date Page Description New Modifica-
tion
Omitted
04/99 gen. Sucosoft S 30-S4
Sucosoft S 4 S 40
AWB 27-1185/1186
AWB 27-1280-D AWB 2700-1305 D
AWB 27-1281-D AWB 2700-1306 D
14 Legend
41 Slave adress
52 Note
52/53 Grafic/Table
83 EMV: RFI, Surge
03/02 10 Function Suconet K interface
24-27 Figure and Legend
78 Send data PS3, last byte
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Contents
About this Manual 3
Documentation for the PS4-200 3
Symbols 4
1 About the PS4-200 Compact PLC 5
Hardware and software requirements 5
Features 6
Setup 6
Elements 8
2 Engineering 15
Electromagnetic compatibility (EMC) 15
Connections 15
Programming device interface 18
Suconet K interface 20
Setting the bus terminating resistors 21
Local expansion 21
Arrangement of the control cabinet 22
Power supply 23
Avoiding interference 28
3 Mounting 33
Mounting on a top-hat rail 33
Mounting on feet 34
4 Software Configuration 35
General 35
Topology configuration procedure 36
Configuring and setting parameters 38
Configuration example with local expansions 43
Configuration example 44
5 Slave Addressing 49
Slaves for expanding remote inputs/outputs 49
Intelligent slaves 51
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6 Operation 55
Power-up behaviour 55
Shut-down behaviour 55
Operating states of the PLC 56
Start-up behaviour 59
Program transfer 61
Starting the PLC with a program stored in
the memory module 63
Programming via Suconet K 63
7 Testing/Commissioning/Diagnostics 65
Status LEDs 65
Diagnostics 66
Message byte 69
Appendix 71
Optimizing the exchange of send and
receive data 71
Accessories 75
Slave addressing 76
Technical Data 79
Index 85
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About this Manual
Documentation for
the PS4-200
The documentation for the PS4-201-MM1 compact
PLC (referred to below as PS4-200) is subdivided
into four manuals with the following topics:
Hardware and engineering
User interface for the programming software
Programming
Training guide
Hardware and engineering manual
This manual, Hardware and Engineering, explains
how the PLCs are to be installed and engineered. It
describes the elements of the PS4-200 and tells you
how to alter the settings.
The configuration and setting of PLC parameters is
carried out in the topology configurator of the
programming software. This is described in the
chapter Software configuration.
The chapter Slave addressing defines the general
syntax rules for addressing the stations in a
Suconet K network.
The chapter Test/commissioning/diagnostics
provides an overview of the possible error and
diagnostic signals and their meanings.
Manual for user interface for the programming
software
To program the PS4-200 you need the Sucosoft S 40
programming software
(Windows, IEC 1131).
The user interface for the software is described in the
manual AWB2700-1305GB.
About this Manual
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Programming manual
Information on programming the PS4-200 is
contained in the Language elements of the
PS4-150/-200/-300 and PS416 manual
(AWB2700-1306GB).
Training guide
The training guide AWB27-1307GB uses practical
examples to illustrate the key functions of the
Sucosoft S 40 software.
Symbols The symbols in this manual have the following
meaning:
Indicates handling instructions
!
Draws your attention to interesting tips and
additional information
Warning!
Warns of the possibility of damage. The product,
anything in the immediate vicinity and data may
be damaged.
Caution!
Warns of the possibility of severe damage. The
product, anything in the immediate vicinity and
data may be severely damaged or totally
destroyed. There is also a risk of injury or even
death.
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1 About the PS4-200 Compact PLC
Hardware and software
requirements
Sucosoft S 40
To program the PS4-200 you need a PC (IBM or IBM-
compatible) with
at least a Pentium processor
a Windows 95, Windows 98 or Windows NT 4.0
1)
operating system
at least 16 Mbyte RAM
3.5disk drive/1.44 MByte and CD-ROM drive
Hard disk with at least 40 MByte free capacity;
the temporary directory C:\ {_S40_}.TMP is
created during the installation and deleted again.
This requires at least 250 Kbytes free space on
drive C:
Serial ports (COM 1 to COM 4)
Parallel printer port (LPT1)
VGA graphics card
Programming cable ZB4-303-KB1 (connecting
cable between PC and PS4-200)
1) (Sucosoft 3.x is the last version supported by
Windows 3.1x)
About the PS4-200
Compact PLC
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Features The main features of the PS4-200 compact PLC are
as follows:
24 V DC power supply
8 digital inputs, 24 V DC
6 digital outputs, 24 V DC
2 analog inputs
1 analog output
Setup Figure 1 provides an overview of the operating and
display elements of the programmable controller as
well as the device connections.
Warning!
Make sure that you are free of electrostatic
charge before touching the PLCs, in order to
protect the components from static electrical
discharges.
Setup
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Figure 1: Overview of the PS4-200
24 V DC power supply
High-speed counter input (alternative to I 0.0), 3 kHz
Alarm input (alternative to I 0.1)
8 digital inputs 24 V DC and 24 V DC input for the
outputs
Plug-in screw terminal
Status LEDs for digital inputs
Status LEDs for digital outputs
6 digital outputs 24 V DC/0.5 A;
short-circuit and overload proof
2 analog inputs U
0
, U
1
(0 to 10 V)
1 analog output U
10
(0 to 10 V)
Suconet K interface
Setpoint potentiometers P1, P2
Switch S1 for bus terminating resistors
Programming device interface (PRG)
Memory module
Status LEDs for the PLC
S1
Power Supply
24V 0V
1=Ready
2=Run
3=Not Ready
4=Battery
Suconet K
1 2
1 2 3 4
Digital
Input
Digital
Output
Analog
Input/Output
PS4-201-MM1
.0
Output
Power Supply
.1 .2 .3 .4 .5
.0 .1 .2 .3 .4 .5 U
0
U
1
U
10
0V
A
.6 .7 24VQ 0VQ
a b d
g
h j k i
c
PRG
f
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P1 P2
l
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About the PS4-200
Compact PLC
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Elements Power supply unit
The PS4-200 is operated with a rated voltage of
24 V DC. The power supply connection is protected
against polarity reversal. The 24 V connection
enables the PLC in the control cabinet to be supplied
with voltages to industrial standards (IEC).
High-speed counter input
You can count pulses at up to 3 kHz via the digital
input I 0.0, irrespective of the cycle time. The up
counter is capable of processing square-wave
pulses with a pulse/pause ratio of 1. A function block
is provided in the programming software for the high-
speed counter.
Alarm input
The digital input I 0.1 enables you to respond to
events quickly, irrespective of the cycle time. You
can use either the rising or the falling edge to
evaluate these events. A function block is provided in
the programming software for the alarm input.
Digital inputs
The PLC has 8 digital inputs. They are galvanically
isolated from the CPU. The inputs are designed for
24 V DC. The input delay of normally 55 ms ensures
short response times (e.g. for direct peripheral scans
and alarm evaluations). Inputs I 0.0 to I 0.7 can be
addressed in bit or byte format with peripheral I/O
commands.
Elements
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Status LEDs for digital inputs
The physical states of the inputs and the diagnostics
status word are indicated by LEDs.
Status LEDs for outputs
The logical states of the outputs are indicated with
light-emitting diodes (LEDs). Outputs Q 0.6 and Q 0.7
are only provided as LEDs.
Digital/analog outputs, analog inputs
Digital outputs:
The PS4-200 has 6 24 V/0.5 A digital outputs. They
are galvanically isolated from the CPU and protected
against short-circuits and overloads. Up to four
outputs can be connected in parallel.
Analog inputs/outputs:
The controller has two analog inputs and one analog
output. The signal range is 0 to 10 V. The resolution
of the inputs is 10 bits (1024 increments), while that
of the output is 12 bits (4096 increments)..
All the inputs and outputs are wired via plug-in screw
terminals.
!
Outputs Q 0.0 to Q 0.5 can be addressed either
in bit or byte format with peripheral commands
(see chapter 5 Slave addressing).
!
The section Power supply in the Engineering
chapter contains a connection diagram of the
analog inputs and outputs.
About the PS4-200
Compact PLC
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Suconet K interface
The RS 485 interface is galvanically isolated from the
CPU. It has the following functions:
Networking of Suconet K stations (e.g. EM4...
expansion modules)
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This
communication interface is used for process data
acquisition, visualization, etc. Data for process
control must not be exchanged here.
Programming networks for several PLCs via a PC
(see section Programming with Suconet K in
the Operation chapter).
Serial communication in transparent mode (see
the following paragraph):
With this function, the PLC exchanges data with a
partner device. The data can be sent or received
using the half-duplex method with the aid of the SCO
function block (see "Language Elements of the PS4/
PS416" manual, AWB2700-1306GB). The settings of
the interface can be taken from the configurator
under Parameterization General settings with
transparent mode. The "Baud rate", "Parity" and
"Stop bit" count are adjustable and must correspond
with the settings on the partner device. The data bit
setting is a fixed value.
Table 1: Interface parameter settings for serial
communication via the RS 485 interface
Start bit Stop bit Data bit Parity
1 1 8
1 1 8 even
1 1 8 odd
1 2 8
Elements
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Setpoint potentiometers
You can set the two setpoint potentiometers P1 and
P2 externally, in other words direct adjustment
without the need for a programming device. The
resolution is 10 bits (1024 increments). They can be
accessed with the operands IAW0 and IAW2.
Switch S1 for bus terminating resistors
You can set the bus terminating resistors for the first
and last physical stations with switch S1.
Programming device interface (PRG)
The RS 232 interface is galvanically isolated from the
CPU. It has the following functions:
Programming the PLC via the PC
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This type of
communication is used for process data
acquisition, visualization etc. but should not be
used to exchange data for process control (see
also Function block SCO in the manual
Language Elements of the PS4-150/-200/-300
and PS416 in AWB2700-1306GB, chapter 6).
Memory modules
The PS4-200 has an internal, battery-backed,
32 kByte RAM. The memory is subdivided into a data
memory and a user program memory.
Up to 24 Kbyte are available for the user program.
This allocation is dynamic, i.e. if the data memory
requires more than 8 Kbyte, the size of the user
program memory is reduced accordingly.
The memory capacity of the internal RAM can be
expanded with plug-in memory modules. The
available modules are as follows:
About the PS4-200
Compact PLC
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The 32 Kbyte RAM module expands the user
program memory. Up to 56 Kbyte can then be
allocated to this memory.
The 128 Kbyte flash module is subdivided into a
64 Kbyte backup memory (retentive storage of
the user program in the event of a voltage failure)
and a 64 Kbyte memory for recipe data, for
example.
The 160 Kbyte combination module integrates all
the features of the other two memory modules.
Figure 2: Dynamic memory allocation
Status LEDs for the PLC
The PLC states are indicated by means of the
Ready, Run, Not Ready and Battery LEDs
(see chapter entitled Test/Commissioning/
Diagnostics).
8 Kbyte data memory
P
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RAM memory
PS 4
Memory module
(external)
24 Kbyte program memory
32 Kbyte program memory
Elements
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Figure 3: Controls and display elements of the PS4-200
(with housing flap open)
Back-up battery
Reset button
Plug connector for local expansion modules
Operating mode selector switch
Back-up battery
The battery backs up the internal RAM and the real-
time clock.
b
c
d
a
Reset
1 Halt/Diag.
2 Run
3 Run M-Reset
+
Battery
1
2
3
S2
Diag.
Warning!
The back-up battery must only be replaced with
the power supply switched on, or data will be
lost.
About the PS4-200
Compact PLC
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, Operating mode selector switch/
reset button
You can select the Halt (stop), Run and
Run M-Reset modes with the operating mode
selector switch. The selected mode is activated
when you press the Reset button. The operating
states are described in detail in the chapter
Operation.
Plug connector for local expansion module
The plug connector provides the interface for
connecting the LE4-... local expansion modules
Real-time clock
The PLC is equipped with a battery-backed, real-
time clock. It facilitates the time-controlled switching
of machines and equipment. You can change
between summer and winter time in the user
program. A function block in the user program can be
used to address and scan the real-time clock.
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2 Engineering
Electromagnetic
compatibility (EMC)
Observe the engineering instructions in the manual
EMC Engineering Guidelines for Automation
Systems (AWB27-1287GB).
Connections Screened data and signal cables
Route screened data and signal cables on the left
and the right of the device along the shortest
possible distance and connect the screen braid
to the ground terminal using a low-impedance
connection and large contact areas (See Fig. 4,
item ).
Connect the screen braid with the metal sleeve of
the plug connector (DIN plugs) .
Insulate the end of the screen braid as close as
possible to the signal cable entry .
Engineering
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Figure 4: Screen connection to reference potential surface
M 4 4/E PS
0

V V
2
4

M4
Connections
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Overview
Figure 5: Overview of connections
Screw terminals: 24 V DC power supply
Terminal cross-sections:
Flexible with ferrule 0.22 - 2.5 mm
2
Solid 0.22 - 2.5 mm
2
Plug-in screw terminal
Terminal cross-sections:
Flexible with ferrule 0.22 to 1.5 mm
2
Solid 0.22 to 2.5 mm
2
Plug connector for local expansion modules (LE4)
Suconet K interface (RS 485)
Interface for programming device (RS 232)
+
S1 P1 P2
c
Power Supply
c
b
a
b
d
f e
24V 0V
Suconet K
1 2
.0 .1 .2 .3 .4 .5
.0 .1 .2 .3 .4 .5 U
0
U
1
U
10
0V
A
.6 .7 24VQ 0VQ
Output
Power Supply
PRG
Engineering
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Programming device
interface
Connector pin assignments
Figure 6: Pin assignment of the programming device
connector (PRG) (left-hand socket, top view)
The housing of the socket is connected to the ground
terminal of the power supply for the PS4-200 via a
capacitor (only applies to version 03 and earlier).
PIN 1 Not assigned
PIN 2 RxD
PIN 3 0 V of interface
PIN 4 Not assigned
PIN 5 TxD
PIN 6 8 Not assigned
1
2
3
4 5
6
7 8
Programming device
interface
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Connecting the programming device (PC)
Connect the PC to the PRG interface of the
PS4-200 (left-hand socket) using the
programming cable ZB4-303-KB1.
Figure 7: Pin assignment of the ZB4-303-KB1
programming cable
Jumpers
If identical ground potentials cannot be achieved,
either connect the PC to the mains supply via an
isolating transformer or use a laptop powered by an
internal battery.
PS4-201-MM1:
PRG interface
(8-pole. DIN pin
connector)
PC:
COM interface
(9-pole. socket)
5
2
3
1
2
3
4
5
6
7
8
9
Warning!
In order to avoid potential equalization currents
between the PLC and the PC, devices attached
to the PRG and Suconet K interfaces must have
the same ground potential. If the ground
potentials differ, the interfaces can be destroyed.
Engineering
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Suconet K interface Connector pin assignments
Figure 8: Pin assignment of the Suconet K interface (PRG)
(right-hand socket, top view)
The housing of the socket is connected to the ground
terminal of the PS4-200 power supply via a capacitor
(only applies to version 03 and earlier).
PIN 1 RS 485 data cable, Suconet K (TB/RB)
PIN 2 Assigned internally
PIN 4 RS 485 data cable, Suconet K (TA/RA)
Connecting to the Suconet K field bus
Use the bus cable KPG 1-PS3 to connect
additional Suconet K stations (PS4, EM4) to the
compact PLC.
5-pole DIN plug 5-pole DIN plug
(pins) (pins)
1--------------------------------1
4--------------------------------4
Connect the screen of the Suconet K data cable
both to the potential reference surface and to the
housing of the plug connector (see Fig. 4 Screen
connection to reference potential surface).
1
2
3
4 5
Setting the bus terminating

resistors
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Setting the bus
terminating resistors
Set the bus terminating resistors on the module
for the first and last physical stations on a line. To
do this, both S1 switches should be set to the
ON position. Both switches must be set to the
OFF position for all other stations.
Figure 9: Bus terminating resistors active
Local expansion The PS4-200 can be expanded locally. The local
expansion modules (LE4 modules) are connected to
the local bus connector of the PS4-200 using a local
bus ribbon cable. Up to six LEs can be connected
locally. All available LE types can be used. Up to two
of the LE4 shown in the legend under can be
connected to a local line. They must only be
connected directly adjacent to the master (from
version 05).
LE4-206-AA1, LE4-622-CX1, LE4-501-BS1,
LE4-503-BS1, LE4-505-BS1
2 1
OFF
!
In order for the PLC to function correctly the two
S1 switches must be set to the same position
(ON or OFF).
LE4-... LE4-... a a LE4-... LE4-...
PS4-201-
MM1

Engineering
22 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Arrangement of the
control cabinet
The arrangement of the components in the control
cabinet has a significant influence on the correct
operation of the machine or plant. When planning,
designing and installing the equipment, ensure that
the power section and the control section are
separated from one another. The power section
includes:
Contactors
Coupling modules
Transformers
Frequency converters
Power converters
DC power supply units
In order to effectively eliminate electromagnetic
interference, we recommend subdividing the control
cabinet into sections according to the different
power and interference levels. Simple partitions are
often sufficient to reduce interference in small control
cabinets.
Ventilation
In order to ensure that the PS4-200 is adequately
cooled, a minimum clearance of 5 cm (2) must be
allowed between other components and the
ventilation slots in the housing. The values specified
in the technical data must be observed
(see Appendix).
Device arrangement
The PS4-200 should be installed horizontally in the
control cabinet as shown in the following figure.
Power supply
23 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 10: Horizontal installation
At least 5 cm (2) clearance
Power section
Cable duct
Power supply The next few pages show circuit diagrams for the
following power supply arrangements:
Figure 11:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for grounded operation
Figure 12:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for non-grounded
(floating ground) operation
PS 4-
201-MM1
!
When you use the PS4-200 together with local
expansion modules, you must install the
controller horizontally.
!
An insulation monitoring device must be installed
if the supply voltage is not grounded (EN 60204,
Part 1 and VDE 0100, Part 725). For floating
operation, the 24 V DC power supply must be a
safety extra-low voltage version to IEC 364-4-41.
Engineering
24 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Legend for Figure 11:
Main switch
Protective device for power supply units
Miniature circuit-breakers
Power supply for the digital inputs
Power supply for the PS4-200
Power supply for the digital outputs
Reference potential for the digital inputs/outputs
Connect top-hat rail to mounting plate (galvanized
sheet steel) with a low impedance connection over a
large surface and with protection against corrosion.
!
Maintain a clearance of at least 30 cm (12)
between the analog cable and the power supply
cables.
Do not lay the 0 V of the analog signals together
with the 0 V of the PS4-200 and the 0 V of the
digital inputs/outputs.
Ensure that the analog actuators and
transmitters are galvanically isolated. If potential
isolation is not sufficient, the manufacturers of
the analog transmitters and actuators can
provide suitable filters.
Power supply
25 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 11: Common power supply wired for grounded operation

L2
N
L3
PE
L1
I > I > I >
0 V
0 V +24 V +24 V
+24 V 0 V
.
0
.
1
.
2
.
3
.
4
.
5
.
6
.
7
.
0
.
1
.
2
.
3
.
4
.
5
U
0
2
4

V
Q
0

V
Q
PS 4-201-MM1
U
1
U
1
0
0

V
A
2
4

V
0

V
Engineering
26 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Legend for Figure 12:
Main switch
Protective device for power supply units
Capacitive ground
Potential equalization rail
Earth fault monitoring device
Miniature circuit-breaker
Power supply for the digital inputs
Power supply for the PS4-200
Power supply for the digital outputs
Reference potential for the digital inputs/outputs
Connect top-hat rail to mounting plate (galvanized
sheet steel) with a low impedance connection over a
large surface and with protection against corrosion.
!
Maintain a clearance of at least 30 cm (12)
between the analog cable and the power supply
cables.
Do not lay the 0 V of the analog signals together
with the 0 V of the PS4-200 and the 0 V of the
digital inputs/outputs.
Ensure that the analog actuators and
transmitters are galvanically isolated. If potential
isolation is not sufficient, the manufacturers of
the analog transmitters and actuators can
provide suitable filters.
Power supply
27 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 12: Common power supply wired for non-grounded operation
.
0
.
1
.
2
.
3
.
4
.
5
.
6
.
7
.
0
.
1
.
2
.
3
.
4
.
5
U
0
2
4

V
Q
0

V
Q
PS 4-201-MM1
U
1
U
1
0
0

V
A
2
4

V
0

V

L2
N
L3
PE
L1
I > I > I >
0 V
0 V +24 V +24 V
K1
C1
C1
P1
K1
P1
+24 V
0 V
Engineering
28 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Avoiding interference Cabling and wiring
Cables come under the following categories:
Power cables (e.g. cables carrying heavy current
or cables to power converters, contactors or
solenoid valves)
Control and signal cables
(e.g. digital input cables)
Measuring and signal cables (e.g. field bus
cables)
In order to keep interference to a minimum ensure
that the cabling both inside and outside the control
cabinet is laid correctly as follows:
Avoid long, parallel cable runs with adjacent
cables of different power ratings.
Always lay AC cables separately from DC cables.
Observe the following minimum clearances:
At least 10 cm (4) between power cables and
signal cables.
At least 30 cm (12) between power cables and
data/analog cables.
Make sure that the supply and return cables
belonging to each circuit are laid together. The
opposing direction of current flow means that the
sum of all the currents is zero so that any fields
which are produced are compensated.
!
Power, control and signal cables must always be
laid as far apart from one another as possible, in
order to prevent capacitive and inductive
interference. If separate cabling is not possible,
the cables that represent the potential source of
interference must be screened above all.
Avoiding interference
29 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 13: Using separate ducts for power and signal
cables
Cover
Communication cables
Cable duct
Measuring cables, analog
cables
Control cables
Power cables
Continuous partition
Engineering
30 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Suppressor circuits for interference sources
All suppressor circuits must be installed as close
as possible to the interference sources
(contactors, relays, valves).
Screening
Only use screened cables for the programming
device interface (PRG) and the Suconet K
interface of the PS4-200.
General rule: the lower the coupling impedance, the
better the screening effect. The screen is then able to
carry high interference currents.
!
Suppressor circuits should be provided for all
switched inductances.
!
If you use the Suconet K or PRG interface,
connect the screen of the cable to the housing of
the plug connector. The housing of the socket is
connected via a capacitor to the earth terminal of
the power supply.
Avoiding interference
31 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Lightning protection
External lightning protection
All cables which are laid between two different
buildings must be screened. Metal conduits are
recommended for this purpose. Protective elements
against overvoltage, such as varistors or other types
of lightning arrester, should be used for signal
cables. The cables must be protected at the point at
which they enter the building, or at the latest at the
control cabinet.
Internal lightning protection
Internal lightning protection includes all measures
that reduce the effects of the lightning current and its
electrical and magnetic fields on the metal
installations and electrical systems inside a building.
These measures comprise:
Lightning-protection potential equalization
Screening
Overvoltage protection devices
Further information on this subject is provided in the
TB27-001GB manual from Moeller entitled
Electromagnetic Compatibility (EMC) of Automation
Systems.
32 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
33 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
3 Mounting
Mounting on a top-hat
rail
Proceed as follows to mount the PLC on a top-hat
rail:
Place the module on the top-hat rail so that the
top edge of the rail latches into the groove.
Insert a screwdriver into the slot of the sliding
clip and lever the clip down .
Press the module onto the top-hat rail .
Release the sliding clip. It will then snap into
position behind the top-hat rail.
Check that the module is seated firmly.
Figure 14: Mounting on a top-hat rail
1
2
3
Mounting
34 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Mounting on feet Proceed as follows to mount the PLC on feet:
Press in the feet so that they snap into position .
Check that they are correctly in position. The lug
must latch in the hole .
Fasten the feet to the mounting plate with M4
screws.
Figure 15: Mounting on feet
35 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
4 Software Configuration
General You can configure the PLCs and all the other
components you need for your application with the
Sucosoft S 40 Topology Configurator. These
components are as follows:
Master PLC (with local expansion modules for the
inputs/outputs)
Network stations (slaves for expanding the
remote I/O or intelligent slaves)
Local expansion modules (LE4-...)
Figure 16: Components of a topology configuration
LE 4-...
LE 4-...
LE 4-... LE 4-... LE 4-... LE 4-... LE 4-... LE 4-...
e.g. PS 4-201-MM1
e.g. EM 4-201-DX2
Intelligent slave
Slave for I/O expansion
e.g. PS 4-201-MM1
!
The following example describes the procedure
for configuring a topology.
Software Configuration
36 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Topology configuration
procedure
Each Suconet K line in an automation system is
assigned to a single master. All the other stations on
the masters line are slaves. A separate configuration
must be defined for every station with its own CPU,
i.e. for the master itself and for all intelligent slaves.
Configuration of the master with local expansion
modules
The masters configuration also specifies the local
expansion modules. Local expansion modules are
assigned the same line number and station number
as the master (0 for both line and station number).
The modules are numbered consecutively. The
master is module number 0 and the local
expansion modules are numbered 1 to 6.
Configuration of the master with remote
expansion modules
The masters configuration also specifies the slaves
that are connected to the masters line. The slaves
are classified according to whether they have their
own CPU (intelligent slaves) or not (slaves for
expanding the remote inputs/outputs):
In the case of intelligent slaves (e.g. PS4-200)
the master configuration only specifies the device
itself, and not any local expansion modules
(LE4...) that are connected to it.
In the case of slaves for expanding the remote
inputs/outputs the connected local expansion
modules (modules 1 to 6) are specified in the
masters configuration file as network stations
in addition to the base module (module 0).
Topology configuration
procedure
37 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 17: Master configuration
Configuration of intelligent slaves
All the local components of intelligent slaves are
configured in the slaves configuration file. Their line
and station numbers are always 0. The modules are
numbered consecutively.
LE 4-...
e.g. PS 4-201-MM1
e.g. PS 4-201-MM1
e.g. EM 4-201-DX2
Station 1
Station 2
Line 0
Station 0
Module 0
Module 0 Module 1
L
i
n
e

1
!
If intelligent Suconet K stations have local
expansion modules, you only specify the base
module (module 0) as a network station in the
masters configuration. The local expansion
modules are specified in the intelligent slaves
configuration but not in the masters
configuration.
38 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 18: Slave configuration
Configuration of slaves for expanding the remote
inputs/outputs
Slaves for expanding the remote inputs/outputs are
configured in the masters configuration file.
Configuring and setting
parameters
The configuration steps for the PS4-200 PLCs
described here differ according to the functions the
stations must perform:
Suconet K master
Suconet K slave
SCO (from PLC firmware version 05)
The table below shows how the various types of
station can be configured depending on their
functions. The fields which are not self-explanatory
are subsequently described in more detail.
LE 4-... e.g. PS 4-201-MM1
Line 0
Station 0
Module 0 Module 1
!
SCO stands for serial communication. This
function allows the PS4-200 to exchange serial
data with a partner device via its Suconet K
interface (see also Function block SCO in the
manual Language Elements of the
PS4-150/-200/-300 and PS416 in
AWB2700-1306GB, chapter 6).
parameters
39 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Table 2: Station configurations
(m) = Master's configuration
(s) = Slave's configuration
Table 3: Station parameters
a-d = See description of input/output data in the
table below
Master Intelligent slave
(m) (s)
Line 0 1 0
Station 0 1 to 8 0
Module 0 0 0
Master Intelligent slave
(m) (s)
Bus status Master Slave
Baud rate (kBaud) 187./375
(Suconet K1:
187.5 kBaud only)

Slave address 2 to 9
CRC Optional for slaves Optional
via
master
Input data
(Receive data)
a c
Output data
(Send data)
b d
Remote control Optional
40 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Line: Number of the network line to which a station is
connected. The master is always connected to line 0
and the slaves to line 1.
Station: Number of the station connected to a line
Module: Number of the module belonging to a station
Baud rate: Select 375 kBaud as the data transfer rate if only
Suconet K stations are connected to the Suconet K
line. The internal plausibility checks of Sucosoft S 40
will automatically set the baud rate of the line to
187.5 kBaud if the line includes Suconet K1 stations.
parameters
41 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Slave address: The station number must be entered here in order to
configure an intelligent slave. The station address is
always 1 higher than the station number (e.g. slave 1
has address 2).
CRC: Method of enhancing data transmission integrity.
You should activate CRC (ON) if you attach greater
importance to data integrity than to short response
times.
Remote Control: If this parameter is active (ON), the intelligent slave
always has the same status as the master. If the
master changes from the Halt (stop) state to the
Run state, for example, or vice versa, the intelligent
slave changes its state accordingly. However, the
operating mode selector switch of the intelligent
slave must not be set to Halt (stop).
Input data,
master (a):
Number of bytes which the master must receive from
the intelligent slave. This number must be identical to
the number of output bytes (d) defined in the
configuration of the intelligent slave.
Output data,
master (b):
Number of bytes which the master must send to the
intelligent slave. This number must be identical to the
number of input bytes (c) defined in the configuration
of the intelligent slave.
Input data,
slave (c):
Number of bytes which the intelligent slave must
receive from the master. This number must be
identical to the number of output bytes (b) defined in
the configuration of the master.
Output data,
slave (d):
Number of bytes which the intelligent slave must
send to the master. This number must be identical to
the number of input bytes (a) defined in the
configuration of the master.
42 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Maximum values for send and receive bytes
The Suconet K protocol allows data with a variable
length to be transferred cyclically, whereby the
number of bytes is dependent on the settings for the
master and the slave (see below). The data length for
communication with slaves for expanding the remote
inputs/outputs is dependent on the slave type. With
intelligent slaves you can specify the number of send
and receive bytes yourself. However, the following
maximum values must not be exceeded:
Table 4: Maximum values for send and receive bytes for the
PS4-200
* For certain configurations, the number of
send and receive bytes can be increased to
256 (see Appendix).
Send/receive bytes Master Slave
Max. no. of send bytes (output) 128 78
Max. no. of receive bytes (input) 128 78
Max. no. of send and receive bytes
(output/input)
128
*
78
!
The maximum number of receive bytes (input
bytes) also includes the diagnostics bytes of the
stations and of any local expansion modules
which are connected to the same line.
Configuration example with
local expansions
43 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Defining input and output data
First of all you must decide how many bytes an
intelligent slave should send to the master and
specify this number with the Input data
parameter in the masters configuration. When
you later specify the slaves own configuration,
you must specify the same number with the
Output data parameter.
Now decide how many bytes the master is to
send to the intelligent slave and specify this
number as the Output data parameter in the
master's configuration. When you later define the
slaves own configuration, you must specify the
same number with the Input data parameter.
Configuration example
with local expansions
Table 5: Configuration with local expansion modules
Type Line Station Module Parameter
PS4-200 0 0 0 Bus status:
master
1st LE4 0 0 1
2nd LE4 0 0 2
3rd LE4 0 0 3
4th LE4 0 0 4
5th LE4 0 0 5
6th LE4 0 0 6
PS 4-201-
MM1
6th LE 2nd LE 1st LE
44 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Configuration example This example requires topology configurations for
the master (device A) and the intelligent slaves
(devices B and C).
Figure 19: Configuration example
Master: Device A
Intelligent slaves: Devices B and C
Slave for expanding the remote I/O: D
!
Note that intelligent slaves are configured twice -
once in the masters configuration and once in
the slaves own configuration.
PS 4-201-MM1
PS 4-151-MM1
PS 4-201-MM1
EM 4-201-DX2
LE 4-... LE 4-... LE 4-...
LE 4-... LE 4-... LE 4-...
L
i
n
e

1
Device A
Device C
Station 2
Device B
Station 1
Device D
Station 3
45 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
The stations shown in the configuration example are
configured as follows:
Configuration of device A
Figure 20: Configuration of device A
PS 4-201-MM1
PS 4-151-MM1
PS 4-201-MM1
EM 4-201-DX2 LE 4-... LE 4-... LE 4-...
LE 4-... LE 4-... LE 4-...
L
i
n
e

1
Device A
Device C
Station 2
Device B
Station 1
Device D
Station 3
Module 0 Module 1 Module 2 Module 3
46 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Table 6: Configuration of device A
Configuration of device B
Figure 21: Configuration of device B
Table 7: Configuration of device B
Device Type Line Station Module Parameter
A PS4-201-MM1 0 0 0 Bus status: master
Baud rate: 375 kBaud
CRC status for slaves
1 to 3: OFF
B PS4-201-MM1 1 1 0 Input data: 20
Output data: 10
C PS4-151-MM1 1 2 0 Input data: 40
Output data: 38
D EM4-201-DX2 1 3 0
1st LE4 1 3 1
2nd LE4 1 3 2
3rd LE4 1 3 3
PS 4-201-MM1 LE 4-... LE 4-... LE 4-...
B PS4-201-MM1 0 0 0 Bus status: slave
Slave address: 2
Input data: 10
Output data: 20
Remote control: OFF
1st LE4 0 0 1
2nd LE4 0 0 2
3rd LE4 0 0 3
47 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Configuration of device C
Figure 22: Configuration of device C
Table 8: Configuration of device C
PS 4-151-MM1
C PS4-151-MM1 0 0 0 Bus status: slave
Slave address: 3
Input data: 38
Output data: 40
Remote control: OFF
48 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
49 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
5 Slave Addressing
Slaves for expanding
remote inputs/outputs
The PS4-200 master PLC and the slaves for
expanding the remote inputs/outputs can
communicate with one another using the Suconet K
or K1 protocols. The protocol is selected by the
master automatically according to the capabilities of
the slaves. It is not necessary to parameterize the
send or receive data length in the Topology
Configurator. Suconet K/K1 selects the appropriate
telegram length and automatically addresses the
relevant data ranges in your application.
You can thus access remote input/output operands
just as easily as local operands.
Table 9: Operand addressing of slaves for expanding
Communication data
Operands Line Station Module Word/byte Bit
I/Q 0, 1
(0 = master)
1 to 8
(0 = master)
0 to 6 0, 1, 2, ... (byte)
0, 2, 4, ... (word)
0 to 7
IB/QB IAB/
QAB ICB
IW/QW IAW/
QAW/ ICW
Status/diagnostics
IS 0, 1
(0 = master)
1 to 8
(0 = master)
0 to 6 0, 1, 2, ... (byte) 0 to 7
ISB
!
The RD/SD syntax must be used for certain types
of slave for expanding the inputs/outputs instead
of the I/Q syntax described here. Please refer to
the table in the Appendix for the correct
addressing for each station type.
Slave Addressing
50 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
The general syntax rule is as follows:
Operand-data type-line-station-module-byte-bit
Example
You wish to scan the inputs of slaves 1 and 2 marked
in the diagram below.
Figure 23: Configuration example for scanning the inputs
of remote slaves
You can derive the syntax for scanning the inputs
from the configuration:
EM 4-201-DX2
.7
EM 4-201-DX2
.0 ... .7
PS 4-201-MM1
LE 4-116-DX1
L
i
n
e

1
Master
Slave 1
Slave 2
L
i
n
e

1
Intelligent slaves
51 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Table 10: Syntax for addressing slaves for expanding
Intelligent slaves When the master and an intelligent slave
communicate with one another, the application
determines which data is exchanged. You cannot
access the input/output operands directly. You must
therefore address the communication data using the
RD/SD syntax.
The table below shows the operands which are
available when the PS4-200 master PLC is operated
with intelligent slaves.
Table 11: Operand addressing of intelligent slaves
RD = Receive Data; defined receive data
SD = Send Data; defined send data
IL program
in ...
Data
flow
Ope-
rand
Data
type
Line Station Module Byte/
word
Bits S 40 syntax
Master Master
Slave 1
I Bit 1 1 1 0 7 LD % I1.1.1.0.7
Master
Slave 2
IB Byte 1 2 0 0 LD% IB1.2.0.0
Communication data
Operands Line Station Module Word/byte Bit
RD/SD 0, 1
(0 = master)
1 to 8
(0 = master)
0 to 6 0, 1, 2, ... (byte)
0, 2, 4, ... (word)
0 to 7
RDB/SDB
RDW/SDW
Status/diagnostic
IS 0, 1
(0 = master)
1 to 8
(0 = master)
0 to 6 0, 1, 2, ... (byte) 0 to 7
ISB
Slave Addressing
52 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
The general syntax rule is as follows:
Operand-data type-line-station-module-byte-bit
Example
The PS4-200 (master) exchanges word data with an
intelligent slave. You can define the number of send
and receive bytes when you set the station
parameters in the Sucosoft S 40 Topology
Configurator (see chapter 4, Software
Configuration).
Figure 24: Configuration example for sending and receiving
communication data to/from an intelligent slave
!
If the PS4-200 is run as slave, it provides status
bytes %ISB0.0.0.0 for device status information
and %ISB0.0.0.1 for slave status information.
These status bytes cannot be scanned together
in one word but must be addressed separately.
PS 4-201-MM1
PS 4-151-MM1
RD
SD
RD
SD
Line 1
Station 1
Master
Slave
Intelligent slaves
53 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
You can derive the syntax for sending and receiving
the data from the configuration.
Table 12: Syntax for addressing intelligent slaves (data
type: word)
IL program
in ...
Data flow Ope-
rand
Data
type
Line Sta-
tion
Module Byte/
word
Bit Syntax
Master Master Slave
Master Slave
RDW/
SDW
Word 1 1 0 0 RDW1.1.0.0/
SDW1.1.0.0
Slave Slave Master
Slave Master
RDW/
SDW
Word 0 0 0 0 RDW0.0.0.0/
SDW0.0.0.0
54 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
55 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
6 Operation
Power-up behaviour After the power supply is switched on, the PS4-200
carries out its own system test. The PLC then
switches to the Ready or Run status if no
hardware errors have been found.
The system test consists of the following routines:
Memory test
User program test
The results of the test are indicated by the Ready,
Run and Not Ready LEDs. If the test is
successful, these LEDs light up briefly when the
power supply is switched on; if not, they blink.
The PLC's status depends on how the operating
mode selector switch is set (see Table 13).
Shut-down behaviour The power supply unit of the PLC detects when the
power supply is switched off. Voltage dips of 10 ms
can be bridged by the power supply unit. If a longer
voltage dip occurs, the internal 5 V supply remains
stable for at least a further 5 ms. This time is used by
the microcontroller to save all the data required for a
restart in the memory ranges provided for this
purpose.
Operation
56 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Operating states of the
PLC
The PLC can have the following operating states:
Run, Ready, Not Ready.
Ready
The Ready status means the following:
There is a user program loaded in the PLC;
The user program is not running;
The outputs are reset and disabled.
The PLC is switched to the Ready status:
If the Reset button is pressed when the
operating mode selector switch is set to Halt;
After the power supply is switched on if the
operating mode selector switch is set to Halt;
By means of the programming software on the
PC;
In slave mode, if the master switches to the Halt
(stop) status and you have set in the slave
parameters the remote control function to ON in
the Sucosoft Topology Configurator (see
AWB2700-1305GB, chapter 5);
If the tab of the memory module is pulled out.
!
Communication with the PC is possible in all
three operating states. Accordingly, the current
status of the PLC and the real-time clock can
always be read, for example.
Operating states of the
PLC
57 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Run
Run status means that the user program is running
cyclically.
The PLC is switched to the Run status:
If the Reset button is pressed when the
operating mode selector switch is set to Run or
Run M-Reset;
After the power supply is switched on if the
operating mode selector switch is set to Run or
Run M-Reset;
PC.
Not Ready
The user program does not run in Not Ready
status.
The PLC is switched to the Not Ready status:
If there is no program loaded in the PLC;
As a result of a hardware error;
As a result of a serious error in the user program
(e.g. cycle time violation)
Once the error has been rectified, you can cancel the
Not Ready status as follows:
By pressing the Reset button; if the operating
mode selector switch is set to Run M-Reset, the
PLC will be switched to the Run status;
By switching the power supply off and then on
again; if the operating mode selector switch is set
to Run M-Reset the PLC will be switched to the
Run status;
PC.
Operation
58 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Overview
Table 13: Overview of the operating states
Position of
operating
mode
selector
switch
PLC status
before
action
Action PLC status after action
(DSW = diagnostic status word)
Press
Reset
button
Power
supply off/
on
1 (Halt) Run

Ready
Ready

Ready; DSW acknowledged
1)
Not Ready

Ready; DSW acknowledged
1)
Run

Ready after remaining cycle processed
1)
Ready

Ready
1)
Not Ready

Not Ready
DSW (diagnostic)
DSW (error)
2 (Run) Run

DSW acknowledged
Ready

Run (depends on system parameter setup)
1) 2)
Not Ready

Via Ready to Run (depends on setup)
1)
Run

Run (with start condition)
1)
, after remaining
cycle processed
Ready

Run (depends on system parameter setup)
1) 2)
Not Ready

Via Ready to Run
(acc. to system parameter setup)
1)
3 (Run
M-Reset)
Run

DSW acknowledged
Ready

Run (cold start)
1)
Not Ready

Run (cold start)
1)
Run

Run (cold start)
1)
Ready

Run (cold start)
1)
Not Ready Run (cold start)
1)
Start-up behaviour
59 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Legend for Table 13:
1)

If the programs in the memory module and the RAM of
the PLC are not the same, the program in the memory
module (backup program) will be copied to the RAM.
2 ) After the user program has been transferred to the PLC
or after the memory module has been booted, the PLC
is switched to Not Ready if the start condition in the
system parameter setup has been set to Halt (stop),
i.e. a cold start is required.
Whenever the PLC is started by switching on the
power supply, by pressing the Reset button or by
means of the PC, the backup program is compared
with the program in the RAM. If the programs are not
the same, the program in the memory module
(backup program) is copied to the RAM.
If the user program in the memory module is
defective, it is updated, providing the user program
in the RAM is valid. An update is also carried out
every time the user program is transferred from the
PC to the PLC.
Start-up behaviour The PLC can be either cold-started or warm-started.
Cold start
A cold start causes all the data fields (marker ranges,
inputs/outputs, module parameters) to be reset. The
user program is executed from the beginning.
Operation
60 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
A cold start can be initiated as follows:
By pressing the Reset button if the operating
mode selector switch is set to Run M-Reset,
providing the PLC is currently in the Ready or
Not Ready status;
By switching on the power supply if the operating
mode selector switch is set to Run M-Reset;
PC provided that the PLC is currently in the
Ready or Not Ready status.
A cold start is always necessary after a new user
program has been transferred to the PLC.
Warm start
A warm start causes the user program to be
continued from the point at which it was interrupted
to the end of the cycle. The outputs and the
communication data are set to 0 for the remainder
of this cycle. The PLC is then initialized and the
program is executed cyclically. Retentive data fields
remain stored.
The setting of retentive marker ranges is described in
the manual Sucosoft S 40 User Interface
(AWB2700-1305GB, chapter 7).
!
A cold start can also be initiated via the system
parameters if the operating mode selector switch
is set to Run. For this activate the Cold Start
option in Behaviour after Not Ready in the
Parameters dialog.
Program transfer
61 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
A warm start can be initiated as follows:
By pressing the Reset button if the operating
mode selector switch is set to Run, providing
the PLC is currently in the Ready status;
By switching on the power supply if the operating
mode selector switch is set to Run, providing
the PLC contains a battery in working condition;
PC, providing the PLC is currently in the Ready
status.
Program transfer If the user program does not contain any syntax
errors, the compiler in the programming device (PC)
translates it into a code that can be understood and
executed by the CPU. You must then load the user
program into the RAM of the CPU using the
Transfer menu. The microprocessor executes the
program there in the Run status.
!
A warm start can also be initiated via the system
parameters if the operating mode selector switch
is set to Run. For this activate the Warm Start
option in Behaviour after Not Ready in the
Parameters dialog.
Warning!
If you initiate a warm start via the system
parameters, your data may lose its consistency.
Operation
62 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
PC PLC
When a program is transferred from the PC to the
PLC, the PS4-200 must be in the Ready or Not
Ready status. The setting of the operation mode
selector switch on the operator console is not
important.
Transfer the program to the PLC; refer to the
manual Sucosoft S 40 User Interface
(AWB2700-1305GB, chapter 8).
If the operating mode selector switch is set to Halt
(stop), the LEDs for Ready and Not Ready will
light up while the program is being transferred
together with the LED for input I 0.0. They confirm
that the data transfer between the PS4-200 and the
PC is progressing successfully.
PC PLC and memory module
Plug the memory module into the PLC (the PLC
must be switched off).
Switch on the PLC. The PLC must be switched to
the Ready or Not Ready status.
Transfer the program from the PC to the PLC. The
program is now loaded into both the PLC and the
memory module.
!
Please refer to the section Programming
through Suconet K for details of how to transfer
the user program to the PLC through Suconet K.
Starting the PLC with a
program stored in
the memory module
63 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Starting the PLC with a
program stored in
the memory module
The procedure for starting a user program in the
memory module is as follows:
Plug the memory module into the PLC (the PLC
must be switched off). The setting of the operate
mode selector switch is not important.
Switch on the PLC. The program in the memory
module is then copied to the PS4-200 and the
PLC is started up according to the configured
startup conditions.
Programming via
Suconet K
It is possible to program several networked stations
and to run test and startup functions from a single
programming device attached to Suconet K without
having to connect a programming cable to each of
the stations in turn. This method can be used for all
stations which are connected to the line served
directly by the master PLC. If one of these stations
(e.g. LE4-501-BS1) opens another line, you will not
be able to access the stations connected to it (see
broken line in figure below). For further information
on this topic refer to the manual Sucosoft S 40 User
Interface (AWB2700-1305GB, chapter 8).
Operation
64 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 25: Programming via Suconet K
*) Programming on the PS4-201-MM1 is possible with
Version 05 or higher.
PS 4-141-MM1
PS 4-201-MM1 LE 4-501-BS1
PS 4-151-MM1
PS 4-151-MM1
*)
PLC program
PC
65 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
7 Testing/Commissioning/Diagnostics
Status LEDs The coloured light-emitting diodes (LEDs) allow fast
and simple diagnostics of the PLC functions. The
states of the inputs/outputs are easy to monitor.
Table 14: Significance of the LEDs
LED Status Significance
Ready Off
On (yellow) Self-test successfully
completed and CPU ready to
start
Blinking
(3 seconds)
Suconet K error
Run Off Program in Halt (stop)
status
On (yellow) User program is running
Not Ready Off No errors in CPU and user
program
On (red) No user program or user
program incorrect
CPU error
Serious error in
user program
Battery Off Battery in good condition
On (red) Battery fault
1)
Status of
Inputs
Off Input not activated
On (green) Input activated
Status of outputs Off Output not activated
On (green) Output activated
1)
Caution!
Data may be lost if the battery does not supply
sufficient power. Always replace the battery with
the power supply switched on!
Testing/Commissioning/
Diagnostics
66 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Diagnostics Status information is scanned hierarchically using
the diagnostics status word and the stations
diagnostics byte as well as the diagnostics bytes of
any local expansion modules which are connected to
it.
Diagnostics status word
The diagnostics status word provides an overview of
the various error messages. It consists of 16 bits. The
diagnostics bits are subdivided into two categories:
Category D (diagnostics): bits 0 - 7
Category E (error): bits 8 - 15
The diagnostics bits in category D have an indication
function. They can become set while the PLC is still
in the Run or Ready status.
The diagnostics bits in category E cause the PLC to
be switched to the Not Ready status.
The diagnostics bits are displayed in the System
Diagnostics window of Sucosoft S 40 (see manual
Sucosoft S 40 User Interface AWB2700-1305GB,
chapter 8).
The diagnostics bits can also be displayed on the
controllers input LEDs. For this proceed as follows:
Set the operating mode selector switch to Halt
and refer to the following tables to interpret the
controllers operating state. Press the Reset
button if you want to acknowledge the error
signals.
Diagnostics
67 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Table 15: Diagnostics bit display
Table 16: Description of diagnostic (indication) bits (Run/
Ready status)
LED PLC status
Run/ Ready
PLC status
Not Ready
.0
.1 DDS ENR
.2 DDK ERT
.3 DLS EDR
.4 DLK EPM
.5 DMC EWD
.6 DBM EDC
.7 DAC ECT
Code Message name Diagnostics message description
DDS Diagnostic Remote
Status
Error in the status of a remote expansion device. The basic units Suconet K
interface has encountered a network error with one of the stations. The error
can be localized by inspecting the diagnostics byte for each of the stations.
DDK Diagnostics
Remote
Configuration
Error in the configuration of the remote expansion devices. Possible causes:
Less Suconet stations than the number defined in the
Topology Configurator
Suconet station not responding
Data transfer error
DLS Diagnostics
Local Status
Error in status of local expansion device.
DLK Diagnostics Local
Configuration
Error in the configuration of the local expansion devices.
DMC Diagnostics
Memory Card
Backup not present; the memory module is not present or faulty. DMC also
appears if the ZB4-032-SR1 memory module is used.
DBM Diagnostics Battery
Module
Battery monitoring: the battery voltage is too low. Change the battery.
DAC Diagnostics Power
Failure
Power supply failure.
Testing/Commissioning/
Diagnostics
68 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Table 17: Description of diagnostic (error) bits (Not Ready
status)
Diagnostics byte for Suconet K stations
In order to get more details about the information
contained in the diagnostics status word, you can
scan the diagnostics byte of each of the stations and
of any local expansion modules that are connected
to them. You only have read access to this
information.
Each station and each local expansion module on
the Suconet K line has its own status information.
The diagnostics information available is dependent
on the respective type of Suconet station or local
expansion module.
Code Message name Diagnostics message description
ENR Restart only with M-
Reset (retentive
marker reset).
This error appears if you have selected the option Halt under Start after
Not Ready in the PS4-200 configuration and have tried to carry out a warm
start after a category E error has occurred. You need to carry out a cold start
(M-Reset).
ERT Error Run Time The PLC has encountered a runtime error.
EDR Error Data Retention The data retention is corrupted in the operating system.
EPM Error Program
Module
Error in program memory; error found via checksum for user program.
EWD Error Watch Dog CPU failure; the CPU hardware watchdog has indicated a failure.
EDC Error DC DC supply failure in base module (module 0)
ECT Error Cycle Time Cycle time exceeded; the max. cycle time set in the program was exceeded.
!
There is a group message containing status
information for every station on the Suconet K
line. This information applies to the respective
CPU and to any local expansion modules (LE)
which are connected to it.
Message byte
69 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
The status information indicates, for example,
whether:
The device ID is incorrect
The device has been disconnected from the
Suconet bus or does not respond
There is a short-circuit at the digital output of the
station, etc.
The status information and its meaning are described
in the manuals for the respective Suconet stations
and local expansion modules.
Message byte The message byte contains information about the
status of the PLC, image data relating to the network
stations, the PLCs startup behaviour, etc. You only
have read access to this information.
For further information on message byte, refer to the
PLC_Message function block description in the
manual Language elements for the PS4-150/
-200/-300 and PS416 (AWB2700-1306GB).
70 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
71 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Appendix
Optimizing the
exchange of send and
receive data
The 128 byte communication buffer (COB) of the
PS4-200 master is used to alternately send and
receive data to and from each of the stations in turn.
After the master has sent the data (send data) to a
station, this now free area of the COB memory plus
any unused COB memory is available to receive data
(receive data) from the slave. As long as there is
sufficient free memory available in the COB each
time the master receives data from a slave in this
way, the 128 byte COB can be used alternately for
128 bytes of send data and 128 bytes of receive
data.
If there is not sufficient free memory when the master
receives data from a slave, valid data in the COB may
be overwritten and the PS4-201-MM1 may switch to
the Not Ready status (error messages ERT and
EPM) after transferring the program.
The reason for this behaviour and its remedy is
illustrated in the following examples.
Example
A PS4-201-MM1 (master) needs to exchange data
with three slaves A, B, C (also PS4-201-MM1) as
shown in the following figure. The number of bytes
received from each slave also includes the
diagnostics bytes from the slave and from any local
expansion modules which are connected to it.
Appendix
72 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 26: Data exchange between master and slaves
Incorrect station address assignment
Slave A: station 1
Slave B: station 2
Slave C: station 3
The subdivision of the communication buffer (COB)
in the master is then as follows:
Master
Slave A
Slave B
Slave C
40 Byte
50 Byte
30 Byte
40 Byte
48 Byte
38 Byte
Optimizing the exchange of
send and receive data
73 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Figure 27: Subdivision of the COB with incorrect station
address assignment
Sequence of communication:
1. Master sends 40 bytes to slave A:
Free COB memory at this stage = 50 bytes
2. Master receives 50 bytes from slave A:
3. Master sends 30 bytes to slave B:
4. Master receives 40 bytes from slave B:
Overlapping of 10 bytes between send and
receive data. The controller goes to the Not
Ready state.
A
B
C
10
40
30
48
A
B
C
50
40
38
128 128
free
Send Receive
Byte Byte
!
The Sucosoft S 40 software automatically
checks the configuration and warns about
possible overlapping.
Appendix
74 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Correct station address assignment:
The required amount of data can be sent and
received successfully by assigning different slave
addresses with the topology configurator as follows:
Slave A: station 3
Slave B: station 2
Slave C: station 1
Figure 28: Subdivision of the COB with functionally correct
station address assignment
No overlapping takes place in this case. After polling
the first station, the master has sent 48 bytes but only
received 38 bytes. Including the unused 10 bytes, a
total of 20 bytes of memory are now available. This is
used by the second and third polling process, where
the master receives 10 bytes more from both stations
2 and 3 (40/50 bytes) than it sends (30/40 bytes).
A
B
C
10
48
30
40
A
B
C 38
40
50
128 128
free
Send Receive
Byte
Byte
Accessories
75 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Accessories
Designation Type Description/application
Programming cable ZB4-303-KB1 Adapter for programming the PS4-200 with a PC
Memory module ZB4-160-SM1 32 Kbyte RAM module for expanding the user program
memory and 128 Kbyte flash EPROM
Memory module ZB4-032-SR1 32 Kbyte RAM module for expanding the user program
memory
Memory module ZB4-128-SF1 128 Kbyte flash EPROM
Plug-in screw terminal ZB4-110-KL1 Plug-in screw terminal for the input/output level
Twin-level terminal
block
ZB4-122-ML1 Twin-level terminal block for distributing potential, e.g. for
connecting 3-pole proximity switches to a PLC or a local
expansion module
Hinged cover ZB4-101-GZ1 Hinged cover with space for labelling inputs/outputs (PS4,
EM4, LE4)
Feet ZB4-101-GF1 Feet for screwing the PS4 onto a mounting plate
Backup battery ZB4-600-BT1 Battery for backing up the RAM of the PS4-200
Simulator ZB4-108-ES1 Simulator for digital inputs
Data cable KPG 1-PS3 Cable between the PS4-200 and a slave; length: 0.5 m
T connector TBA 3.1 For connecting a station to the Suconet K/K1 line
Data plug connector S1-PS3 5-pole DIN plug connector for the RS 485 interface of the
PS4-200-MM1
Cable LT 309.096 Cable, 2 0.5 mm
2
, screened and twisted for making your
own Suconet K cable
Screen grounding kit ZB4-102-KS1 Screen grounding kit for Suconet incl. screen grounding clips
Snap fastener for the
top-hat rail
FM4/TS35 Weidmller, Order no. 068790
Terminal clip for snap
fastening
KLB3-8SC Weidmller, Order no. 169226
Appendix
76 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Slave addressing Receive data
Slave Byte 1 Byte 2 Byte 3 ... Last byte Data type
EM4-111-DR1 IBx.y.0.0 Bit, byte
EM4-101-DD1/88 IBx.y.0.0 Bit, byte
EM4-101-DD1/106 IBx.y.0.0 IBx.y.0.1 Bit, byte
EM4-101-AA1 V 01 IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.5 Byte
EM4-101-AA1 V 02
AA1B64 (
8 Bit/SBI)
IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.5 Byte
AA1W33 (
12 Bit/SBI)
IAWx.y.0.0 IAWx.y.0.2 IAWx.y.0.4 Word
EM4-101-AA2
AA2B84 IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.7 Byte
AA2W84 IAWx.y.0.0 IAWx.y.0.2 ... IAWx.y.0.14 Word
EM4-201-DX1 IBx.y.0.0 IBx.y.0.1 Bit, byte
EM4-201-DX2 IBx.y.0.0 IBx.y.0.1 Bit, byte, word
PS4-1x1, passive IBx.y.0.0 IABx.y.0.0 IABx.y.0.1 (Bit), Byte
PS4-1x1, active RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte
PS4-141-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.77 Bit, byte, word
PS4-151-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.77 Bit, byte, word
PS4-401-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
PS316 (SBI)/306 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte, word
EPC335 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte, word
PS3-DC IBx.y.0.0 IBx.y.0.1 IABx.y.0.0 ... IABx.y.0.3 (Bit), Byte
PS3-AC IBx.y.0.0 IBx.y.0.1 IABx.y.0.0 ... IABx.y.0.3 (Bit), Byte
PS3-8 IBx.y.0.0 IBx.y.0.1 Bit, byte
LE4-501-BS1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.77 Bit, byte, word
CM-501-FS1 IBx.y.0.0 RDBx.y.0.1 RDBx.y.0.1 ... RDBx.y.0.5 Bit, byte
Slave addressing
77 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
x = line, y = station
Send data
SBI-AMD3 RDBx.y.0.0 RDBxBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
SBI-AMX RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
SIS Type 80D0
to
RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte, word
SIS Type 80EF RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte, word
A4-220.1 RDBx.y.0.0 RDBx.y.0.1 Byte, word
A5-220.1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
VTP0-H-Tx RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
VTP1/2-H-T6 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.17 Byte, word
ZB4-501-UM2 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.23 Bit, byte, word
RMQ16I IBx.y.0.0 IBx.y.0.1 Bit, byte
RBI1.1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte
EM4-111-DR1 QBx.y.0.0 Bit, byte
EM4-101-DD1/88 QBx.y.0.0 Bit, byte
EM101-DD1/106 QBx.y.0.0 QBx.y.0.1 Bit, byte
EM4-101-AA1 V 01 QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 QABx.y.0.4 Byte
EM4-101-AA1 V 02
AA1B64
( Bit/SBI)
QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 QABx.y.0.4 Byte
AA1W33
(2 Bit/SBI)
QAWx.y.0.0 QAWx.y.0.2 QAWx.y.0.4 Word
EM4-101-AA2
AA2B84 QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 QABx.y.0.3 Byte
AA2W84 QAWx.y.0.0 QAWx.y.0.2 ... QAWx.y.0.6 Word
Appendix
78 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
x = line, y = station
EM4-201-DX1 QBx.y.0.0 QBx.y.0.1 Bit, byte
EM4-201-DX2 QBx.y.0.0 QBx.y.0.1 Bit, byte, word
PS4-1x1, passive QBx.y.0.0 (Bit,) Byte
PS4-1x1, active SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte
PS4-141-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.77 Bit, byte, word
PS4-401-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
PS316 (SBI)/306 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
EPC335 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
PS3-DC QBx.y.0.0 QBx.y.0.1 QABx.y.0.0 (Bit), Byte
PS3-AC QBx.y.0.0 QBx.y.0.1 QABx.y.0.0 (Bit), Byte
PS3-8 QBx.y.0.0 QBx.y.0.1 Bit, byte
LE4-501-BS1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 .... SDBx.y.0.77 Bit, byte, word
CM-501-FS1 QBx.y.0.0 SDBx.y.0.1 SDBx.y.0.1 ... SDBx.y.0.5 Bit, byte
SBI-AMD3 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
SBI-AMX SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
SIS Type 80D0
to
SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
SIS Type 80EF SDBx.y.0.0 RDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
A4-220.1 SDBx.y.0.0 SDBx.y.0.1 Byte, word
A5-220.1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
VTP0-H-Tx SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
VTP1/2-H-T6 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.17 Byte, word
ZB4-501-UM2 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.23 Bit, byte, word
RMQ16I QBx.y.0.0 QBx.y.0.1 Bit, byte
RBI1.1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDB x.y.0.5 Bit, byte
Technical Data
79 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Technical Data
General
Standards EN 61 131-2, EN 50 178
Ambient temperature 0 to 55 C
Storage temperature 20 to 70 C
Vibration resistance 1 g/0 to 150 Hz
Shock resistance 15 g/11 ms
Vibration Constant 1 g, f = 0 up to
150 Hz
EMC see page 83
Programming interface RS 232, length of
programming cable < 3 m
Network interface RS 485
Bus Suconet K
Data cable length 600 m/300 m
Transfer rate 187.5 kBit/s to 375 kBit/s
Operating mode Master/slave
Degree of protection IP 20
Rated insulation voltage U
i
600 V AC
Real-time clock Yes
Accuracy of real-time clock 6.1 min./year (battery-backed)
Battery (life) Normally 5 years
Expandable (locally) Max. 6 LEs
Expandable (remotely) Max. 8 stations
User and data memory (internal) 32 Kbyte
Memory modules (external) 32 Kbyte RAM or 128 Kbyte
flash memory
or 32 Kbyte RAM and 128
Kbyte flash memory
Normally Cycle time for 1 K
instructions (bits, bytes)
5 ms
No. of inputs (local) 8
No. of outputs (local) 6
Max. no. of inputs/outputs (local) 104/102
Weight Approx. 540 g
Appendix
80 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Power supply for CPU
Rated voltage U
e
24 V DC
Permissible range 20.4 to 28.8 V DC
Residual ripple of input voltage < 5%
Polarity reversal protection Yes
Rated current I
e
Normally 250 mA + 300 mA
per LE
Inrush current and duration 4 A < 5 ms
Power consumption Approx. 6 W
Power dissipation (complete device) Approx. 6 W
Bridging of voltage dips
Duration of dip 10 ms
Repetition rate 1 s
Error indication Yes (LEDs)
Protection class 1
Galvanic isolation Yes
Terminals Plug-in screw terminals
Conductor cross-section
Flexible with ferrule 0.22 to 2.5 mm
2
2
Rated insulation voltage 600 V AC
Inputs
No. of inputs 8
Rated voltage U
e
24 V DC
For 0 signal 5 V DC (limit value type 1)
For 1 signal 15 V DC (limit value type 1)
Max. ripple < 5 %
Rated current I
e
For 1 signal Normally 6 mA for 24 V DC
Max. delay time
From 0 to 1 max. 100 s
From 1 to 0 max. 100 s
Technical Data
81 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Galvanic isolation Yes
Galvanic isolation between inputs No
Input status indication Yes (LEDs)
Flexible with ferrules 0.22 to 1.5 mm
2
2
High-speed counter input I0.0
Clock frequency 3 kHz
Pulse shape Square
Pulse duration 50 %
Edge duration 3 %
Alarm input I0.1
Analog inputs
No. 2
Signal range 0 V to 10 V
Total error Normally 0.8% of full scale
No. of conversions 1 per cycle
Input resistance 20 k
Connection type of signal transmitter Two-wire connection to
transmitter
Digital representation of input signal 10 bits (1024 increments)
Setpoint potentiometers
No. 2
Value range 10 bits (1024 increments)
Adjustment With screwdriver
Appendix
82 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Outputs
No. of outputs 6
Rated voltage U
e
24 V DC
Max. ripple 5 %
Galvanic isolation
in groups No
Rated current I
e
For 1 signal 0.5 A DC for 24 V DC
Lamp load 4 W without series resistor
Utilization factor 1
Relative duty factor 100 %
Parallel connection of outputs
No. of outputs max. 4
Total maximum current 2 A
Total minimum current 250 mA
Residual current with 0 signal Approx. 140 A
Short-circuit protection Yes, without set
Max. short-circuit release current 1.2 A over 3 ms per output
Off delay Normally 100 s
Limiting of breaking voltage
With inductive loads Yes, 21 V (with U
N
= 24 V DC)
Operations per hour
With time constant
t 72 ms
4800 (G = 1)
7500 (G = 0.5)
With time constant
t 15 ms
18000 (G = 1)
Power supply
Max. ripple 5 %
Technical Data
83 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Output status indication Yes (LEDs)
Flexible with ferrules 0.22 to 1.5 mm
2
2
Analog output
No. 1
Bit resolution 12 (4096 increments)
Total error Normally 0.4% of full scale
Output variables 0 to 10 V DC/2 mA
Connection type Two-wire connection
General specifications on electromagnetic compatibility (EMC) of automation equipment
Emission EN 55 011/22 Class A
Immunity to interference
ESD EN 61 000-4-2 Contact discharge
air discharge
4 kV
8 kV
RFI EN 61 000-4-3 AM/PM 10 V/m
Burst EN 61 000-4-4 Supply/digital I/O
Analog I/O, fieldbus
2 kV
1 kV
Surge EN 61 000-4-5 Digital I/O, asymmetrical
DC supply, asymmetrical
DC supply, symmetrical
AC supply, asymmetrical
AC supply, symmetrical
0.5 kV
1 kV
0.5 kV
2 kV
1 kV
Line-conducted
interference
ENV 50 141 AM 10 V
84 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
85 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Index
A
Addressing
Slaves ................................................................... 49, 76
Alarm input ....................................................................... 8
Analog inputs/outputs ...................................................... 9
Arrangement of the control cabinet ............................... 22
B
Backup battery ......................................................... 13, 75
Backup memory ............................................................. 12
Base module (i.e. module 0) .......................................... 36
Battery
Backup ....................................................................... 13
Baud rate ....................................................................... 40
Bus cable ....................................................................... 20
C
Cable .............................................................................. 75
Cabling ........................................................................... 28
Clock (real-time) ............................................................. 14
Cold start ....................................................................... 59
Combination memory module (160 Kbyte) .................... 12
Commissioning .............................................................. 65
Communication with PC ................................................ 56
Configuration ................................................................. 38
Intelligent slaves ......................................................... 37
Local expansion ......................................................... 36
Master with remote expansions ................................. 36
Slaves for expanding remote inputs/outputs ............. 38
Configuration example ................................................... 44
Connection
Overview ..................................................................... 15
Connections
Programming device .................................................. 19
Suconet K field bus .................................................... 20
Connector pin assignments
Suconet K interface .................................................... 20
Index
86 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Controls .......................................................................... 13
Counter, high-speed ........................................................ 8
CRC ................................................................................ 41
D
Data cable ...................................................................... 75
Data exchange ......................................................... 10, 11
Data integrity .................................................................. 41
Data plug connector ....................................................... 75
Data transfer
LEDs ........................................................................... 62
Daylight savings time ..................................................... 14
Device arrangement ....................................................... 22
Diagnostics ............................................................... 65, 66
Diagnostics byte for Suconet K stations ........................ 68
Diagnostics status word ................................................. 66
Digital inputs ..................................................................... 8
Status LEDs .................................................................. 9
Digital outputs .................................................................. 9
DST ................................................................................. 14
Dynamic memory allocation ........................................... 12
E
Elements, PS 4-200 .......................................................... 8
EMC regulations ............................................................. 15
Engineering instructions ................................................. 15
F
Fastening ........................................................................ 22
Features ............................................................................ 6
Feet ................................................................................ 75
Flash module .................................................................. 12
H
Hardware requirements for programming ........................ 5
High-speed counter ......................................................... 8
Hinged cover .................................................................. 75
I
Input data ....................................................................... 41
Input delay ........................................................................ 8
Insulation monitoring ...................................................... 23
Intelligent slaves ............................................................. 35
Index
87 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Interface
Programming device .................................................. 11
Suconet K ................................................................... 10
Interference .................................................................... 22
L
LED ................................................................................ 65
LED display ...................................................................... 9
LEDs ........................................................................... 9, 13
Status ......................................................................... 12
Light-emitting diodes ..................................................... 65
Lightning protection ....................................................... 31
Limit values, send and receive bytes ............................. 42
Line ................................................................................ 40
Local expansion modules .............................................. 35
M
Master PLC .................................................................... 35
Memory
128 Kbyte flash module .............................................. 12
160 Kbyte combination module ................................. 12
32 Kbyte RAM module ............................................... 12
Backup ....................................................................... 12
Recipe data ................................................................ 12
Memory allocation, dynamic .......................................... 12
Memory capacity ........................................................... 11
Memory module ....................................................... 11, 75
Memory test ................................................................... 55
Message byte for Suconet K stations ............................ 69
Module ........................................................................... 40
Module 0 (base module) ............................................. 36
Mounting
On feet ........................................................................ 34
On top-hat rail ............................................................ 33
N
Network programming ............................................. 62, 63
Networking ..................................................................... 10
Not Ready (operating state) ........................................... 57
Index
88 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
O
Operand addresses
Intelligent slaves ......................................................... 51
Slaves for expanding remote inputs/outputs ............. 49
Operating mode selector switch .................................... 14
Operating states (PLC), overview ................................... 58
Output data .................................................................... 41
P
Parameters, setting ........................................................ 38
PC, connections ............................................................. 19
Peripheral command ........................................................ 9
Pin assignments
Programming device interface (PRG) ......................... 18
Suconet K interface .................................................... 20
Plug-in screw terminal .................................................... 75
Potential equalization ..................................................... 19
Power supply
grounding arrangements ............................................ 23
Power supply unit ............................................................. 8
Power-up behaviour ....................................................... 55
Program transfer
LEDs ........................................................................... 62
Program transfer to PLC ................................................ 61
Programming cable .............................................. 5, 19, 75
Programming device interface (PRG) ............................. 11
Pin assignments ......................................................... 18
Programming device, connections ................................. 19
Programming networks .................................................. 10
Programming via
Suconet K ................................................................... 63
Programming with
PC ............................................................................... 11
R
RAM memory ................................................................. 11
RAM module ................................................................... 12
Rated voltage ................................................................... 8
Ready ............................................................................. 56
Real-time clock .............................................................. 14
Receive bytes ................................................................. 41
Recipe data
Memory ....................................................................... 12
Index
89 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
Remote control .............................................................. 41
Reset button .................................................................. 14
Resolution ........................................................................ 9
Retention of data ........................................................... 60
RS 232 ........................................................................... 11
RS 485 ........................................................................... 10
Run ................................................................................. 57
S
Screen connection to reference potential surface ......... 16
Screen grounding kit ...................................................... 75
Screening ....................................................................... 30
Send bytes ..................................................................... 41
Setpoint potentiometers ................................................ 11
Setting parameters ........................................................ 38
Setting the bus terminating resistors ............................. 21
Setup, PS 4-200 ............................................................... 6
Shutdown behaviour ...................................................... 55
Signal range ..................................................................... 9
Simulator ........................................................................ 75
Slave address ................................................................ 41
Slave addressing ...................................................... 49, 76
Slaves for expanding the remote I/O ............................. 35
Software requirements for programming ......................... 5
Start-up behaviour ......................................................... 59
Station ............................................................................ 40
Status LEDs ................................................................... 65
Digital inputs ................................................................. 9
Outputs ......................................................................... 9
PLC ............................................................................. 12
Suconet K
Programming via ........................................................ 63
Suconet K connection ................................................... 20
Suconet K interface ....................................................... 10
pin assignments ......................................................... 20
Summer time, winter time .............................................. 14
Suppressor circuits ........................................................ 30
Switch S1 ....................................................................... 11
Symbols ........................................................................... 4
Syntax rules for addressing slaves ................................ 50
System test .................................................................... 55
Index
90 0
3
/
0
2

A
W
B

2
7
-
1
1
8
4
-
G
B
T
T connector .................................................................... 75
Test of memory .............................................................. 55
Test of user program ...................................................... 55
Testing ............................................................................ 65
Time
Summer/winter ........................................................... 14
Topology configuration, procedure ................................ 36
Transfer .......................................................................... 61
Transfer of program to PLC ........................................... 61
Twin-level terminal block ................................................ 75
U
Up counter ........................................................................ 8
User program test .......................................................... 55
V
Ventilation ....................................................................... 22
W
Warm start ...................................................................... 60
Wiring ............................................................................. 28
1210FH023
1210FH025
1210FH021
1210FH032/
33/34
Text angeben
1210FH022
1210FH019
1210FH026
Ersatzteilliste Fahrhebel - 1210 FH108/109
Spare Parts List Control Lever
124 Drawings
Betriebsanleitung
Bordkran Typ DK II 45025/40028/36029 NMF
Instruction Manual
Board crane type DK II 120016/55033 NMF
Drawings 125
13 Drawings
Seq.
No.
Part Drawing No.
1 Lubrication schedule 820 -0500- 14(1)
2 Electric wiring Diagram 820 -0700- 40(4)
3 Crane housing complete 820 -0800- 15(0)
4 Main compilation 820 -0900- 21(0)
5 Jib complete 820 -1500- 15(1)
820 -2100 02(2)
6 Jib foot complete 820 -2100 13(2)
7 Rope sheave 820 -2400- 32(2)
8 Rope sheave 800 -2400- 31(2)
9 Hydraulic circuit diagram 820 -4900- 16(1)
10 Pump unit 820 -5000- 20(1)
11 Hydraulic oil tank 820 -6100- 03(1)
12 Fan flap 800 -7300- 03(1)
13 Slack rope switch 897 -8800- 01(2)
14 Energy supply 820 -9000- 16(1)
15 Rope sheave lubrication 800 -9500- 54(4)
16 Tackle plan
17
18
19
20
21
22
23
24
25
26
Table 6: List of drawings
Betriebsanleitung
Bordkran Typ DK II 45025/40028/36029 NMF
Copyright 2005 Drawings 1
Instruction manual
M
a
r
c
h
,

2
0
0
7
N
e
u
e
n
f
e
l
d
e
r

M
a
s
c
h
i
n
e
n
f
a
b
r
i
k

G
m
b
H
10 Drawings
Seq.
No.
Part Drawing No.
1 Lubrication schedule 820 -0500- 04(1)
2 Electric wiring Diagram 820 -0700- 40(4)
3 Crane housing complete 820 -0800- 15(0)
4 Main compilation 820 -0900- 21(0)
5 J ib complete 820 -1500- 15(1)
6 J ib foot 820 -2100- 02(2)
7 J ib foot 820 -2100- 13(2)
8 Rope sheave 820 -2400- 32(2)
9 Rope sheave 800 -2400- 31(2)
10 Hydraulic circuit diagram 820 -4900- 16(1)
11 Pump unit 820 -5000- 20(1)
12 Hydraulic oil tank 820 -6100- 03(1)
13 Fan flap 800 -7300- 03(1)
14 Slack rope switch 897 -8800- 01(2)
15 Energy supply 820 -9000- 16(1)
16 Rope sheave lubrication 800 -9500- 54(4)
17 Tackle plan
Table 5: List of drawings
Instruction manual
2 Drawings Copyright 2005

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