NMF DK II Board Crane Instruction Manual – 45t Ship Crane 45027.5/35032.2 & 45027.5/35031.5 – Order 80099

Description

NMF DK II Board Crane Instruction Manual – Order 80099

The NMF DK II Board Crane Instruction Manual is the complete operating, maintenance and repair reference for the DK II shipboard loading crane built by Neuenfelder Maschinenfabrik GmbH. Issued under Order No. 80099 for Hull No. 2023, this Edition 27.06.2005 document covers both crane configurations delivered to the shipyard: Crane 1 – DK II 45027,5/35032,2 and Crane 2 – DK II 45027,5/35031,5. Every major crane system is addressed – hoisting gear, luffing gear, turning gear, the hydraulic pump unit, the electro-hydraulic proportional control, the electrical monitoring and fault system, and the gear cam limit switches – with the level of detail needed by the crane operator, the ship’s engineer, and the shore-side maintenance technician.

File Details

• Manual type: Instruction Manual (Operation, Maintenance, Troubleshooting, Spare Parts)
• Brand / Manufacturer: Neuenfelder Maschinenfabrik GmbH (NMF), Neuenfelder Fährdeich, 21129 Hamburg
• Model / Type: Board Crane DK II – Crane 1: DK II 45027,5/35032,2; Crane 2: DK II 45027,5/35031,5
• Order No.: 80099
• Hull No.: 2023
• Building yard: Zhoushan Shipyard
• Year of construction: 2005
• Edition: 27.06.2005
• Language: English (with original German/English bilingual technical tables and subcontractor documentation)
• Page count: Approximately 320 pages
• File format: PDF

Chapters Covered

• 1. What is worth knowing about this operating manual – Manufacturer, operator’s duty of care, terms and symbols, technical amendments, guarantee, copyright
• 2. Description of the Crane – Technical data, construction, pump unit, lifting gear, luffing gear, turning gear, gear oil cooler, hydraulic oil cooler, heating, slack rope switch, gear limit switch, slip ring assembly, load measuring bolt, electrical components, electronic regulator print card
• 3. Safety – Use for designed purpose, general safety instructions, requirement of personnel, symbols on the crane, warning signals, safety devices and functional tests, dangers and behaviour in case of danger, emergency exit
• 4. Operation – Safety instructions, requirement of personnel, working range of the crane, operator’s cabin, control panels, inspection before starting, switching on, during operation, switching the load stage on, switching the half-load stage on, switch off, emergency shutdown
• 5. Monitoring, Failure, Troubleshooting and Elimination – Safety instructions, brake relay monitoring, TEST OPERATION switch, RESET button, fault notification card, fault search diagrams (electrical, lifting gear, luffing gear, turning gear)
• 6. Maintenance and Repair – Cleaning, greasing, gear oil change, gear box inspection, pump distribution gear, gear oil cooler filter, hydraulic oil and filter change, bottom hook block, roller revolving joint, function and safety inspection, lamellar brakes, changing the lamellars, slack rope switch gear, slip ring assembly, load measuring bolts, wire rope maintenance/service/discard criteria, gear cam limit switch setting, exchanging the Memory-Programmable Control (MPC), changing the battery, list of lubricants
• 7. Functional description of hydraulic – General aspects, starting the pump unit, venting, heating/cooling system, electro-hydraulic control, hoisting gear (nominal load, half load, hydraulic overload cut-off), luffing gear, turning gear
• 8. Hoisting of brakes in case of emergency – Hoisting gear, jib, slewing gear, hand pump connection
• 9. Illustration – Pump unit, load measuring system, current pilot print card, emergency exit, interference pilot print card, gear oil cooler, reset/test switches
• 10. Spare parts – Ordering spare parts, part lists (NMF reserve parts, hydraulic hoses, current regulator card)
• 11. Subcontractor documentation – Brueninghaus Hydromatik pumps and motors, Zollern winch and turning gear, Stiebel gearbox, Karl Miller cabin, control lever, load measuring system, solenoid valves
• 12. Drawings – Maintenance chart, electric wiring diagram, crane housing, general arrangements, jib, rope sheave, anti-collision, pump unit, hydraulic circuit, hydraulic oil tank, fan flap, rope end connection, slack rope connection, energy supply, crane rigging

This NMF DK II instruction manual goes well beyond a simple operator’s booklet. It is a full lifecycle document for the 45-tonne board crane: it tells the operator how to bring the crane into service and handle the 45 t, 35 t and 16 t load stages safely, it tells the engineer how the closed-circuit hydraulic system actually works, and it tells the maintenance team how to keep the crane in class – from the weekly oil level check through to the 1500-hour hydraulic oil change, the wire rope discard criteria, the gear cam limit switch setting procedure, and the emergency hand-pump brake release that lets a load be lowered after a total power failure. The troubleshooting chapter is built around fault search diagrams that trace electrical, lifting, luffing and turning faults from symptom to probable cause to remedy, so a technician can diagnose rather than guess.

What This NMF DK II Manual Enables You To Do

With this manual in hand, a crane technician can safely operate, adjust, maintain and repair the DK II board crane without relying on guesswork. The document supports:

• Safe operation – start-up sequence, load stage selection (45 t / 35 t / 16 t), half-load stage activation, working range limits, warning signals, emergency shutdown.
• Hydraulic diagnosis – understanding the axial piston pump and motor circuits, proportional valve control, pressure cut-off, overload protection, and the venting and heating/cooling logic.
• Mechanical maintenance – gear oil changes with the correct oil grades and intervals, gearbox inspection for water ingress or metal abrasion, lamellar brake inspection and renewal, bottom hook block and roller revolving joint greasing.
• Wire rope care – cleaning and greasing, monitoring, replacement state of wear criteria including wire breakage counts, diameter reduction limits, corrosion and abrasion thresholds.
• Limit switch and safety settings – the complete gear cam limit switch setting procedure for hoisting and luffing, including the home position, cam designations (HW1-HW6, WW0-WW7) and the matching PLC LEDs.
• Electrical and control repair – the 4-channel current regulator print card parameters, the Memory-Programmable Control (MPC) exchange procedure, battery change, brake relay monitoring and fault notification card.
• Emergency procedures – the hand pump connection for opening the hoisting, luffing and slewing brakes after power failure, with the pressure limits and safety warnings.
• Spare parts identification – NMF reserve parts list plus the complete Brueninghaus Hydromatik, Zollern, Stiebel and Karl Miller subcontractor documentation with part numbers, drawings and tightening torques.

The value of a document like this is that it removes the risk of working from memory or from a generic crane manual that does not match the DK II. Torque values, pressure settings, oil grades, cam positions and brake pressures are all specific to this crane – getting them wrong can damage the hydraulic system, overload the structure or, in the worst case, drop a load. This manual provides the correct procedure and the correct figure every time.

Who This Manual Is For

The NMF DK II Board Crane Instruction Manual is written for the people who actually work the crane and keep it running: the crane operator, the ship’s chief engineer and electro-technical officer, the shore-side crane service technician, and the workshop that overhauls the winch, turning gear or hydraulic pump unit. It is also the reference document for a superintendent or class surveyor who needs to verify that maintenance and safety inspections have been carried out against the manufacturer’s schedule.

Delivery

IMAGES PREVIEW

This NMF DK II board crane instruction manual is delivered as an instant PDF download. There is no shipping, no waiting for a courier, and no risk of a lost paper copy. After checkout the file is available immediately and can be read on a laptop, tablet or smartphone in the engine room, on deck or in the workshop. The pages can be printed individually for the crane cabin or the maintenance file. Search for the section you need, zoom in on a cam designation or a hydraulic symbol, and carry the whole DK II documentation set with you.