NMF Crane DK II 250012/100026 (Operating Manual + Assembly instruction) [2002, PDF]

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Assembly Instruction
This Assembly Instruction is based on a flow chart which indicates the
succession of works to be committed when installing the cranes.
Necessary informations are given under the running numbers.
Particular information abt. drawings, weights power supply are given in the
data sheet.
Assembly Instruction
HEAVY CARGO CRANE Deck Crane Type DK II 250012/100026

NMF-ORDER NO. 8958/8959
Xingang Shipyard
Flow Chart and Content
1 Data Sheet 3
2 Preparation of the columns and cranes 4
2.1 All materials of „Energy Supply“ to be stowed in the column.
see drawing no: 820-9000-15(1) 4
2.2 All bolts, washer and nuts to be stowed in the column.
This material is packed per crane in wooden boxes. 4
2.3 Clean top-flange upper-side, downside, if requested, check evenness of the top-flange. 5
2.4 Arrange light, compressed air, electricity, welding equipment, all necessary tools
in the column. 6
2.5 Unpack crane houses, clean bottom flanges, prepare shackles and sling materials. 7
2.6 Crane to be hooked on and to be erected. Put the crane house on
wooden gratings. 13
2.7 The cranes are delivered without hydraulic oil.
The oil is to be filled in, through connection "DRAIN" in the hydraulic oil tank. 14
2.8 Turning gear to prepared as per instruction. before installing the jib, the crane is
to be turned exactly into the direction of the jib´s support. 18
3 Installation of the cranes and jibs on the vessel 21
3.1 For the installation of the jib, it is necessary to have the foot- bearings access able.
Platforms must be arranged accordingly.The crane is to be turned into the right position,
in order to meet the jibs resting support. 22
3.2 Jib to be installed. 25
4 Installation of the energy-supply and access ladders 27
4.1 Junction box to be placed in the crane´s column. Cable tracks to be installed.
See drawing 820-9000-15(1) 27
4.2 Slip ring construction to be installed as per instruction. 27
4.3 Electric cable installation to be carried out, following electric diagram 29
4.4 Pretension of the foundation bolts to be carried out, by means of hydraulic tools,
following the instruction. 30
5 Commission the crane 34
5.1 Electric supply, temporary or final to be arranged. 34
5.2 All oil levels to be checked. 34
5.3 Commission crane, following the instruction, given by NMF service engineers. 34
HEAVY CARGO CRANE Deck Crane Type DK II 250012/100026

6 General Rigging Instructions 35
6.1 General advice for the installation procedure 35
6.2 Unwinding the steel wire rope from a coil 35
6.3 Unwinding the steel wire rope from a reel 36
6.4 Installation procedure 39
6.5 Winding the steel wire rope from the reel onto a drum 39
7 Rigging the crane 42
8 Crane Adjustment Function Check 53
9 Final load - test under supervision of the classification society and following the
requirements of the surveyor. 55
10 Table of Illustration 56

Table of Contents

1 What is worth knowing about this operating manual 11
1.1 Manufacturer 11
1.2 The operator´s duty of care 11
1.3 Terms, short cuts and symbols 12
1.4 Technical Amendments 13
1.5 Guarantee 13
1.6 Copyright 13
2 Description of the Crane 15
2.1 Technical Data 15
2.2 Construction 17
2.3 General Aspects 18
2.4 Pump unit 18
2.5 Lifting gear 18
2.6 Luffing gear 18
2.7 Turning gear 18
2.8 Gear oil cooler 18
2.9 Hydraulic oil cooler 19
2.10 Heating 19
2.11 Slack rope switch 19
2.12 Gear limit switch 19
2.13 Slip ring assembly 20
2.14 Load measuring bolts 20
3 Safety 21
3.1 Use for the designed purpose 21
3.2 General safety instructions 21
3.3 Requirement of personnel 21
3.4 Symbols on the crane 21
3.5 Warning signals during the crane operation 22
3.6 Safety devices on the crane and their functional test 22
3.7 Dangers and behaviour in case of danger 23
Instruction Manual 
 Board crane type DK II 250012/100026
4
4 Operation 25
4.1 Safety instructions 25
4.2 Requirement of personnel 25
4.3 Working range of the crane 26
4.4 Operation 27
4.4.1 Operator´s cabin 27
4.4.2 Control panels 28
4.5 Commissioning 30
4.5.1 Before starting 30
4.5.2 Switching on 30
4.5.3 Switch on main lifting gear 31
4.5.4 Switch on auxiliary lifting gear 31
4.5.5 Switch off 32
4.6 Emergency shutdown of the crane 32
4.6.1 „TEST OPERATION“ switch 32
4.6.2 „TEST LOAD“ switch 32
5 Monitoring, Failure, Troubleshooting and Elimination 35
5.1 Safety instructions 35
5.2 Requirement of personnel 35
5.3 Monitoring, Failure, troubleshooting and elimination 35
5.4 Brake relay monitoring 35
5.5 Speed monitoring of the jib winch, lifting gear winch and the auxiliary lifting
gear winch36
5.6 Fault notification card 36
5.7 Fault Search Diagram 38
6 Maintenance and Repair 49
6.1 Safety instructions 49
6.2 Requirement of personnel 50
6.3 Maintenance schedule 50
6.4 Maintenance and repair 52
6.4.1 Cleaning the crane 52
6.4.2 Greasing 52
6.4.3 Gear 52
6.4.4 Oil change 52
6.4.5 Gear box inspection 52
6.4.6 Pump distribution gear 53
6.4.7 Gear oil cooler filter 53
6.4.8 Changing the hydraulic oil 54
6.4.9 Changing the hydraulic oil filter 54
6.4.10 BOTTOM HOOK BLOCK 57
6.4.11 Function and safety inspection 57
6.4.12 Lamellar brakes 58
6.4.13 Changing the lamellars 58
6.4.14 Gear cam limit switch 60
6.4.15 Slack rope switch gear 61
6.4.16 Slip ring assembly 62
6.4.17 Load measuring bolts 63
6.5 Maintenance, service and discard criteria for wire rope 65
6.5.1 Cleaning and greasing the wire rope 65
6.5.2 Monitoring 65
6.5.3 Wire changing 67
6.5.4 Replacement state of wear 67
6.6 Setting of the limit switches 71
6.6.1 Lifting gear 71
6.6.2 Luffing gear 72
6.6.3 Auxiliary lifting gear 73
6.7 How do I exchange a Memory-Programmable Control (MPC)? 75
6.8 List of lubricants 81
7 Description of the hydraulic circuit 83
7.1 GENERAL ASPECTS 83
7.2 STARTING THE PUMP UNIT 83
7.2.1 START THE PUMP UNITS INDIVIDUALLY 83
7.3 HYDRAULIC OVERLOAD CUT-OFF 84
7.3.1 LOAD STAGE SECURING 84
7.3.2 PRESSURE RESTORAGE 84
7.4 VENTING 85
7.5 HEATING / COOLING 85
7.6 FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL 85
7.7 HOISTING GEAR 87
7.7.1 LIFTING OF THE NOMINAL LOAD 250T 87
7.8 FUNCTIONAL DESCRIPTION OF THE INDIVIDUAL LOAD STAGES87
7.8.1 GENERAL ASPECTS 87
7.8.2 LIFTING THE 200T 87
7.8.3 LIFTING THE 150T 87
7.8.4 LIFTING THE 100T 87
7.8.5 LIFTING THE 25 T 88
7.8.6 AUTOMATIC STAGE 88
7.8.7 LIFTING THE 35T STAGE (AUXILIARY LIFTING GEAR) 88
7.8.8 OVERDRIVE 88
7.8.9 LUFFING GEAR 89
7.8.10 "LUFFING UP"KEY SWITCH POSITION 25-100T 89
7.8.11 "LUFFING UP"KEY SWITCH POSITION 150-250T 89
7.8.12 "LUFFING DOWN" 89
7.9 TURNING GEAR 89
7.9.1 TURNING "RIGHT-LEFT" 90
8 Lifting of brakes in case of emergency 91
8.1 Lifting gear 91
8.1.1 Connect the hand pump for opening the brakes as follows. 91
8.2 Turning gear 95
9 Spare Parts 97
9.1 Ordering spare parts 97
9.1.1 List of Spare parts 98
10 Drawings 119
11 Appendix 125
11.1 Drawings 125
11.2 Supplier Documents 127

List of Figures

Overall view 17
Working range of the crane 26
Operator´s cabin 27
Control panel right 28
Control panel left 29
Electrical fault 38
Pump unit fault 39
Lifting gear fault (electr.) 40
Lifting gear fault 41
Lifting gear fault 42
Luffing gear fault (electr.) 43
Luffing gear fault 44
Luffing gear fault 45
Turning gear fault (electr.) 46
Turning gear fault 47
Filter 56
Lamellar brake 59
Cam disc 60
Slack rope switch 61
Load measuring bolts 63
Setting of the lifting gear limit switches 71
Setting of the luffing gear limit switches 72
Setting of the switches for the auxiliary lifting gear 73
Replace MPC1 77
Replace MPC 2 78
Replace MPC 3 79
Connections for the solenoid valve block 92
Brake lifting pump 93
Pressure limit valves at hoisting pump (Sauer) 94
Remove the turning gear motors 95
Pump unit 119
Load Measuring Device 120
Instruction Manual 
 Board crane type DK II 250012/100026
Emergency exit 120
Switch cabinet switch 121
Switch cabinet door 122
Fault notification card 123
Gear oil cooler 124
Instruction Manual
Board crane type DK II 250012/100026
Terms and short cuts 12
Symbols 12
Technical Data 15
Maintenance Intervals 50
List of drawings 125
List of Supplier Documents 127
Instruction Manual 
 Board crane type DK II 250012/100026
Instruction Manual
Board crane type DKII 250012/100026