NMF DK II 120016/55032 Board Crane Instruction Manual – 120t Deck Crane PDF

Description

The NMF DK II 120016/55032 board crane instruction manual is the complete factory documentation package issued by Neuenfelder Maschinenfabrik GmbH for this 120-tonne deck crane — order no. 80598, new build H 1526 A, year of construction 2009. It is the single document the crane operator, the maintenance technician and the ship’s technical superintendent all work from: operating instructions, hydraulic and electrical descriptions, lubrication schedules, brake maintenance, troubleshooting flowcharts, spare-parts data and the full drawing list in one file.

File Details

• Manual type: Instruction manual — operation, maintenance, repair and troubleshooting
• Manufacturer: Neuenfelder Maschinenfabrik GmbH (NMF), Hamburg
• Crane type: DK II 120016/55032
• Order number: 80598
• New build: H 1526 A
• Year of construction: 2009
• Edition: 17 February 2009
• Language: English, with bilingual German/English headings, tables and diagrams
• Page count: approximately 425 pages
• File format: PDF

Chapters Covered

• About this instruction manual — manufacturer, operator’s duty of care, terms, abbreviations and symbols, technical changes, warranty, copyright, hydraulic symbols
• Safety — intended use, general safety instructions, personnel requirements, symbols on the crane, warning signals, safety devices and their functional testing, hazards and behaviour in case of danger, emergency exit
• Crane description — technical data, construction, pump unit, hoisting gear, luffing gear, slewing gear, gear oil cooler, hydraulic oil coolers, heating, slack rope switch, gear cam limit switch, slip ring assembly, air conditioner, hydraulic diagram description, load-step functionality, luffing gear, electrical equipment, fault indicator card
• Operation — operating range, crane cab, left and right control panels, starting up, start authorisation, setting main hoist load steps, switching off, emergency shutdown
• Maintenance and repair — maintenance schedule, lubricant table, lubrication chart, lubrication point images, crane cleaning, changing the oil, gearbox and pump distribution gear, filters, bottom hook block, slewing ring, slip ring assembly, load measuring pin, slack rope switch, rope maintenance, care and discard criteria
• Monitoring, faults and troubleshooting — brake relay monitoring, boom winch and hoisting winch speed monitoring, overload, disc brake description and maintenance, lifting the brakes in an emergency, gear cam limit switch, replacing a PLC, changing the battery
• Spare parts — ordering instructions and spare parts catalogue
• Figures and drawings — exploded views, hydraulic circuit diagrams, wiring and assembly drawings

Read as a whole, the NMF DK II 120016/55032 instruction manual gives the technician a complete working picture of a 120-tonne electro-hydraulic board crane. The hydraulic chapter does not just list components — it explains how the two pump units are started, how pressure transmitters store working pressure, how the hydraulic overload disconnect behaves, how the flush valves feed warmed oil back to the tank, and how the pressure regulator steps in when system pressure climbs. The electrical chapter opens up the four-channel current regulator card, the fault indicator card, the XC-200 modular PLC, the load measuring unit (DMSA), and the settings for load-measuring pin correction and overload thresholds. The maintenance chapter carries the full lubrication schedule with illustrated grease-nipple locations, plus the oil change intervals for winch gears, slewing gears, pump distribution gears, gear oil coolers and the hydraulic tank.

Load Steps, Lifting Gear and Rigging Data

Because the DK II is a variable-load-step crane, the manual walks through each step in detail: hoisting 120 t nominal load, then 95 t, 75 t, 55 t and 38 t, with the solenoid valve combinations and Q-min settings for each. Luffing is covered for both the 0–55 t key-switch position and the 95–120 t creep-speed position, including the automatic speed reduction as the jib approaches its top end position and the 6 m reduced-speed zone down to 4 m. The hoisting, luffing and slewing gear descriptions explain the winch drum, winch gear and hydraulic motor layout, the bent-axis motor types used, the 360° unrestricted slewing range, and how the brakes behave under pressure loss, power failure, overload and outreach-limit conditions.

Brakes, PLC and Emergency Procedures

One of the most valuable parts of this NMF DK II manual is the brake and emergency section. It explains the multiple disc brake design, the release pressure requirements, the 320 bar operating limit and the 250–320 bar danger range, how to manually lift the brake with the brake lift hand pump when the hydraulic system is down, and the exact step sequence for the hoisting gear, luffing gear and slewing gear. The bypass ball cock, the brake lift hand pump connections, the choke wheel setting and the multi-function valve operations are all documented. Alongside that, the PLC replacement procedure covers the XC-CPU 101, XIOC input/output, counter and analog modules, the coding switches that must be set on the new module, and the lithium backup battery replacement with the correct power-on condition to prevent data loss.

Why the NMF DK II 120016/55032 Instruction Manual Matters

A 120-tonne board crane is not something you service by feel. Every lift, every luff and every slew on this machine runs against a defined load-step envelope, a defined outreach limit and a defined hydraulic pressure. The NMF DK II 120016/55032 board crane instruction manual is the document that tells you which load step applies at which outreach, which pressure switch protects which function, which lubrication point takes which grease, and what to do when a limit switch, pressure sensor or brake relay reports a fault. Without it, routine work like rope greasing, slewing ring settlement measurement, filter replacement and disc brake inspection becomes guesswork — and on a crane, guesswork is expensive.

This manual also carries the rope discard criteria: the wire breakage counts by driving gear group and rope type, the diameter reduction limits, the corrosion and abrasion thresholds, and the deformation types that force replacement. For a deck crane in a saltwater environment, that section alone pays for the manual many times over. The spare parts catalogue and the drawing list round it out, so the same file that explains the system also helps you identify the replacement part.

IMAGES PREVIEW

Delivery is instant. Once your order is complete you download the PDF immediately — no shipping, no waiting, no physical book. The file opens on any laptop, tablet or phone, and every page can be printed for use in the crane cabin, the workshop or the ship’s technical office. Keep a copy on board, keep a copy ashore, and you always have the NMF DK II documentation to hand.