NMF Board crane DK III 45026,8/40029,5 (Instruction Manual + Addons) [2002, PDF]

Description of the Crane

General Aspects
All of the working motions can be regulated infinitely from zero to max. speed: all operations can take place simultaneously. With a nominal load on the hook, an electric capacity governor reduces the control current to the pump adjustment of the lifting, turning and luffing gear, depending on the power input to the electric motor. These speeds are reduced and the power input to the electric motor is kept at the same level.
2.4 Pump unit
A pump unit is installed in the crane housing. It comprises an electric motor, a pump distribution gear and three hydraulic pumps. The pumps are driven by the electric motor through the distribution gear. The pump unit provides the lifting gear, turning gear and luffing gear with pressure oil. The hydraulic pumps are variable, reversible high-pressure, axial piston pumps which are connected to the hydraulic motors by high-pressure hoses.
2.5 Lifting gear
The lifting gear is mounted in the crane casing, consisting of the winch drum, the winch gear and an hydraulic motor. The winch gear is installed in the winch drum, the hydraulic motor being flanged onto the latter. The hydraulic motor is a axial piston-bent axis motor. The motors start at a maximum displacement volume and therefore at a maximum starting moment
2.6 Luffing gear
The setup of the luffing gear is the same as that of the lifting gear.
2.7 Turning gear
The turning gear consists of three turning gears which are mounted on the floor of the crane. Each turning gear engages via a gear wheel into a gear rim of the spherical turning connection, hereby transmitting the turning motion to the crane. A constant bent axis motor is fitted to each of the turning gears.
2.8 Gear oil cooler
The gear oil cooler is an oil-air cooler which cools the gear oil in the pump distribution gear (see Subcontractor documentation, Page 105). This starts at an oil temperature of 20 °C. The gear oil cooler has an oil filter which must be replaced at regular maintenance intervals (see Maintenance Intervals, Page 42).
2.9 Hydraulic oil cooler
The hydraulic oil coolers are oil-air cooler which are mounted in the return line of the hydraulic system. The spring-loaded vent flap [2.7] is automatically hydraulically opened when the pump unit is started. The oil-air cooler is switched on at an oil temperature of 40 °C. The heated air is fed-off through the opened vent flap. All functions are switched off when the oil temperature exceeds 85 °C. The pump unit and the oil-air coolers continue to run.
2.10 Heating
Electrical heating elements are installed in the hydraulic oil tank and the crane housing. The ambient temperature is controlled by a room thermostat. The oil temperature in the oil tank is controlled by a thermo sensor. The tank heating is continuously switched in at an oil temperature under 20 °C. At ca. 22 °C the tank heating is switched off.
2.11 Slake 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 Chapter 6.5, Maintenance, service and discard criteria for wire rope, Page 59).
2.12 Gear limit switch
A gear limit switch is fitted to each of the winch gears. The limit switches are provided with a variable number of cams which are actuated as required by the various crane-operating conditions. (see Subcontractor documentation, Page 105).

Instruction manual Board crane type DK III 45026,8/40029,5 Index

1 What is worth knowing about this operating manual 7
1.1 Manufacturer 7
1.2 The operator?s duty of care 7
1.3 Terms, short cuts and symbols 8
1.4 Technical Amendments 9
1.5 Guarantee 9
1.6 Copyright 9
2 Description of the Crane 11
2.1 Technical Data 11
2.2 Construction 13
2.3 General Aspects 14
2.4 Pump unit 14
2.5 Lifting gear 14
2.6 Luffing gear 14
2.7 Turning gear 14
2.8 Gear oil cooler 14
2.9 Hydraulic oil cooler 15
2.10 Heating 15
2.11 Slake rope switch 15
2.12 Gear limit switch 15
2.13 Slip ring assembly 16
2.14 Load measuring bolt 16
3 Safety 17
3.1 Use for the designed purpose 17
3.2 General safety instructions 17
3.3 Requirement of personnel 17
3.4 Symbols on the crane 17
3.5 Warning signals during the crane operation 18
3.6 Safety devices on the crane and their functional test 18
3.7 Dangers and behaviour in case of danger 19
Instruction manual
 Board crane type DK III 45026,8/40029,5
4
4 Operation 21
4.1 Safety instructions 21
4.2 Requirement of personnel 21
4.3 Working range of the crane 22
4.4 Operation 23
4.5 Commissioning 26
4.6 Switch off 28
4.7 Emergency shutdown of the crane 28
5 Monitoring, Failure, Troubleshooting and Elimination 29
5.1 Safety instructions 29
5.2 Requirement of personnel 29
5.3 Monitoring, Failure, troubleshooting and elimination 29
5.4 Brake relay monitoring 29
5.6 Fault Search Diagram 31
6 Maintenance and Repair 41
6.1 Safety instructions 41
6.2 Requirement of personnel 42
6.3 Maintenance schedule 42
6.4 Maintenance and repair 44
6.5 Maintenance, service and discard criteria for wire rope 59
6.6 Setting of the limit switches 65
6.7 How do I exchange a Memory-Programmable Control (MPC)? 67
7 List of lubricants 73
8 Functional description of hydraulic 75
9 Lifting of brakes in case of emergency 81
9.1 Lifting gear 81
9.2 Turning gear 85
10 Spare parts 87
10.1 Ordering spare parts 87
11 Figures 99
12 Appendix 105
12.1 Drawings 105
12.2 Subcontractor documentation 107

List of figures

Instruction manual Board crane type DK III 45026,8/40029,5

Overview 13
Working range of the crane 22
Operator?s cabin 23
Control panel right 24
Control panel left 25
Electrical fault 31
Pump unit fault 32
Lifting gear fault (electr.) 33
Lifting gear fault 34
Lifting gear fault 35
Luffing gear fault (electr.) 36
Luffing gear fault 37
Luffing gear fault 38
Turning gear fault (electr.) 39
Turning gear fault 40
filter 48
Lamellar brake 52
Cam disc 53
Slake rope switch 54
load measuring bolt 57
Setting of the lifting gear limit switches 65
Setting of the luffing gear limit switches 66
Replace MPC 69
Replace MPC 70
Replace MPC 71
Half load function 78
Pressure regulator 79
Connections for the solenoid valve block 82
Brake lifting pump 83
Pressure limit valves at hoisting pump (Sauer) 84
Remove the turning gear motors 86
Pump unit 97
Instruction manual
 Board crane type DK III 45026,8/40029,5
6
Load measuring system 98
Emergency exit 99
Interfrence pilot print card 100
Gear oil cooler 101
Reset-Switch 102

Drawings

12.1
Item.
no.
Denotation
Drawing no.
1 Maintenance chart 824 -0500- 12(1)
2 Electric Wiring Diagram 824 -0700- 103(4)
3 Crane housing complete 824 -0800- 12(0)
4 General Arrangement c 824 -0900- 31(0)
5 Jib complete 824 -1500- 17(1)
6 Jib Foot complete 822 -2100 00(2)
7 Rope Sheave 800 -2400- 20(3)
8 Rope Sheave 800 -2400- 45(3)
9 Bottom Hook Block R0 11895
10 Hydraulic Circuit 824 -4900- 23(1)
11 Pump Unit 820 -5000- 18(1)
12 Hydraulic Oil Tank 824 -6100- 03(1)
13 Fan Flap 800 -7300- 03(2)
14 Rope End Connection 820 -8700- 07(3)
15 Slack Rope Connection 897 -8800- 03(2)
16 Energy Suply 824 -9000- 17(1)
17 Crane Rig
Table 5 : List of the drawings
Betriebsanleitung
Bordkran Typ DK II 45025/40028/36029

Instruction manual
Board crane type DK III 45026,8/40029,5

Appendix 107
12.2 Subcontractor documentation
Table 6 : List of the subcontractor documentation
Item.no
.
Denotation Type Manufacturer
1 Regulating Axial Piston Pump
Turning gear
A4VG 125 EP Hydromatic
2 Regulating Axial Piston Pump
Hoisting gear
A4VG 180 EP Hydromatic
3 Regulating Axial Piston Pump
Luffing gear
A4VG 125 EP Hydromatic
4 Regulating Axial Piston Motor A6VM 250 HZ Hydromatic
5 Axial Piston Constant Motor A2FM 125/61W-PAB 106 Hydromatic
6 Axial Piston Constant Motor A2FM 80 Hydromatic
7 Hoisting Winch Gear ZHP 4.29 04.29 10615 Zollern
8 Turning Gear ZHP 3.27 03.27 10144 Zollern
9 Luffing Winch Gear ZHP 4.29 04.29 10495 Zollern
10 Oil cooler T7 200000100 AKG
11 Gear oil cooler OKAF-R2S Hydac
12 Pump Distributor Gear i=0,741
4387.24
Stiebel
13 Solenoid Valve 4D01 Denison
14 In-Line Filter 160 LEN 0400 - 09 A0,6 Eppensteiner
15 Gear Limit Switch Reihe 110 Stromag
16 Antifriction Bearing 192.32.2587.100.41.1502 Rothe Erde
17 CabineNMF 1500NMF893H Miller
18 Control Lever 1210FH 102/104 NMF
19 Descender Device RG-10 RK Sicherheitstechnik
Lifting Block 50 t Rope Block
Instruction manual
 Board crane type DK III 45026,8/40029,5
108 Appendix