NMF DK II 180013/70033 Board Crane Instruction Manual – Order 80599 PDF

Description

NMF DK II 180013/70033 Board Crane Instruction Manual – Order 80599

This is the full instruction manual for the NMF Neuenfelder Maschinenfabrik GmbH board crane type DK II 180013/70033, issued under order no. 80599, new build H 1527 A, year of construction 2009. It is the working document supplied with the crane and covers the complete machine: the steel structure, the two pump units, the hoisting, luffing and slewing gear, the electro-hydraulic control system, the electrical cabinet, the crane cabin and the load measuring system.

The crane is rated at 180 t safe working load with a hoisting height of approximately 42 m and a slewing range of 360 degrees unlimited. Because the machine carries different load steps with different outreach limits, a large part of the manual is devoted to how those steps are selected, how the hydraulic overload protection responds, and how the limit switches are set so that each step is protected at the correct outreach.

File Details

• Manual type: Instruction manual / operating and maintenance manual
• Manufacturer: Neuenfelder Maschinenfabrik GmbH (NMF), Neuenfelder Fährdeich 120, 21129 Hamburg
• Crane type: DK II 180013/70033
• Order number: 80599
• New build: H 1527 A
• Year of construction: 2009
• Edition: 20. Juli, 2009
• Language: English
• File format: PDF
• Scope: Complete manual including hydraulic symbols, electrical documentation, maintenance schedule, lubricant table and spare parts catalogue

Chapters Covered

• 1 About this instruction manual – Manufacturer, operator’s duty of care, terms and abbreviations, technical changes, warranty, copyright, hydraulic symbols (pumps, motors, cylinders, directional control valves, pressure valves, flow control valves, non-return valves, pipe connections)
• 2 Safety – Intended use, general safety instructions, personnel requirements, symbols on the crane, warning signals, safety devices and their functional testing, electrical overload protection, control levers, pressure switches, pressure sensors, hydraulic overload protection, limit switches, hazards and behaviour in case of danger, noise hazards, residual energies, emergency exit
• 3 Crane description – Technical data, construction, general, 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, description of individual load step functionality, luffing gear, slewing gear, electrical equipment, electronic regulator cards, fault indicator card, brake relay monitoring, jib winch and hoisting winch speed monitoring, preset for crane data, switches in the switch box, XC-200 modular PLC, test operation, load measuring unit, multi-function display (MFD), multiturn absolute encoder, PLC replacement, remote maintenance and diagnosis
• 4 Operation – Safety instructions, personnel requirements, operating range of the crane, crane cab, control panels, starting up, start authorisation, before starting up, switching on, during operation, setting main hoist load steps, switching off, emergency shutdown
• 5 Maintenance and repair – General safety instructions, maintenance schedule, lubricant table, lubrication chart, images of the lubrication points, crane cleaning, lubrication, changing the oil, gearbox, gearbox inspection, pump distribution gear, filters, bottom hook block, slewing ring, slip ring assembly, load measuring pin, slack rope switch apparatus, rope maintenance and discard criteria, disc brake, lifting the brakes in an emergency, hoisting gear, jib, slewing gear, gear cam limit switch
• 6 Spare Parts – Ordering spare parts, how to order spare parts
• 7 Figures – Pictorial overview of pump unit, load measuring device, emergency exit, switch box door, fault indicator card, current regulator card, gear oil cooler, slewing gear
• 8 Spare parts catalogue – Detailed component lists for pumps, motors, winches, slewing gear, oil coolers, filters, valves and cabin equipment
• 9 Drawings – Lubrication schedule, electronic circuit diagram, entire crane housing, main assembly, entire jib, jib foot, sheaves, hydraulic diagram, pump unit, hydraulic oil tank, vent flap, slack rope switch, power supply, sheave lubrication, rigging plan, load diagram

Beyond the chapter structure, this document functions as a complete technical reference for the DK II board crane. It explains how the two pump units are started and how they can be run separately at half speed, how the closed-circuit hydraulic system is protected by pressure relief valves, and how the load pressure switches for the 180 t, 120-150 t and 38-70-95 t steps disconnect the hoisting function when the permitted load is exceeded. It documents the electrical side in depth: the 4-channel current regulator card with its parameter list and operating instructions, the fault indicator card, the start authorisation request circuit, the brake relay monitoring logic, the winch overspeed monitoring, and the multi-function display pages used by the crane operator for load step, load at hook, outreach, heeling and speed. For maintenance, it provides a full schedule keyed to operating hours, a lubricant table covering hydraulic oil ISO VG 46 and gear oil ISO VG 220, a lubrication chart with symbols, and detailed procedures for the bottom hook block, slewing ring, slip ring assembly, load measuring pin and gear cam limit switch. The rope section includes cleaning and greasing guidance, monitoring advice, replacement procedure and discard criteria with a wire breakage table. The disc brake chapter covers pressure media, manual emergency lifting, dismounting and mounting, and malfunction diagnosis.

What This Manual Lets You Do

With this instruction manual on hand, an operator, crane engineer or maintenance technician can work through the DK II 180013/70033 systematically rather than by guesswork. The load step functionality section shows exactly which solenoids are energised and which winch motors are set to Q min at each of the 38 t, 70 t, 95 t, 120 t, 150 t and 180 t steps, which is essential for understanding why the crane limits outreach the way it does. The hydraulic overload protection pages explain what happens when the crane disconnects, why the hoisting winch brake engages immediately, and how to bring the control lever back to the 0 position before resuming with a correct load step.

The maintenance schedule and lubricant table remove the uncertainty from servicing intervals. You get the oil check and filter change points, the gear oil sampling guidance, the slewing ring relubrication practice, the axial reduction measurement procedure with its table, and the rope discard criteria that decide when a wire rope must come off. The electrical chapters cover the Moeller XC-200 PLC operating states, how to replace a PLC module, how to change the CPU battery, how to set the multiturn absolute encoder node numbers and baud rate, and how the fault and event lists are read through the browser commands.

IMAGES PREVIEW

Everything is delivered as an instant PDF download after payment. There is no shipping and no waiting for a disc. The file opens on a laptop, tablet or phone, and any page can be printed for use at the crane or in the workshop, which is useful for the lubrication chart, the maintenance schedule and the limit switch setting procedure.