NMF DK II Deck Crane Instruction Manual – DK II 60016/40025/34028 Order 80449 PDF

Description

NMF DK II Deck Crane Instruction Manual – Order 80449

The DK II board crane is a heavy-duty loading device built by Neuenfelder Maschinenfabrik GmbH (NMF) for loading and unloading heavy cargo, consignments and containers onto and from ships. This instruction manual covers crane type DK II 60016/40025/34028, order no. 80449, build no. 786, year of construction 2007, edition 1.12.2007. It is the complete documentation set supplied with the machine – operation, maintenance, repair, hydraulic and electrical systems, PLC diagnostics, spare parts, and the full drawing package.

The crane operates with 60t, 40t, 34t and 22t load steps, a maximum outreach of 28.0 m at 22t, and a 22t half-load fast speed that doubles the hoisting speed to 0-25 m/min. The manual explains each load step’s hoisting speed, slewing speed, outreach limits and the interlocks that stop the crane when a load step is exceeded.

File Details

• Manual type: Instruction manual – operation, maintenance, repair, spare parts and drawings
• Brand / Manufacturer: NMF Neuenfelder Maschinenfabrik GmbH, Neuenfelder Fährdeich 120, 21129 Hamburg
• Model / Type: DK II 60016/40025/34028
• Order no.: 80449
• Build no.: 786
• Year of construction: 2007
• Edition: 1.12.2007
• Language: English
• Page count: 586 pages
• File format: PDF

Chapters Covered

• 1. About this instruction manual – manufacturer details, operator’s duty of care, terms and abbreviations, technical changes, guarantee terms, copyright, and a complete hydraulic symbol reference covering pumps, motors, cylinders, way valves, triggering types, throttling valves, pressure valves, flow control valves, non-return valves, and pipe connections.
• 2. Safety – intended use, general safety instructions, personnel requirements, symbols on the crane, warning signals, safety devices and their functional tests (control levers, pressure switches, hoisting gear pressure sensor, hydraulic overload protection, limit switches), noise hazards, residual energy hazards, behaviour in case of danger and critical situations, and the emergency exit procedure.
• 3. Crane description – technical data table, construction details of the 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, load measurement system and pressure transducer; hydraulic functions including starting the pump unit, ventilation, heating/cooling, electro-hydraulic control system, hoisting gear modes (idling, 60t, 40t, fast speed 0-22t, lowering, hydraulic overload disconnect), luffing gear, slewing gear; electrical equipment including the 4-channel current regulator card, fault indicator cards, switches in the switch box, test operation procedures, load master/load measurement system (DMSA), and the PS2-200 Compact PLC.
• 4. Operation – safety instructions, personnel requirements, operating range diagram, crane cab layout, control panels, before starting up checks, switching on, during operation procedures, setting load steps, switching on 0-22t fast speed, switching off, and emergency shutdown.
• 5. Maintenance and repair – general safety instructions for electrical and hydraulic work, environmental protection, functional check and safety inspection, detailed maintenance schedule, lubricant table, lubrication chart, images of lubrication points (door hinges, electric motor, slewing ring, jib sheaves, crane housing sheaves, bottom hook block, slewing gear, winch), crane cleaning, lubrication procedures, changing oil, gearbox inspection with oil analysis guidelines, pump drive unit service, filter changes, bottom hook block maintenance, slewing ring lubrication and inspection, slip ring assembly service, slack rope switch adjustment, rope maintenance, care and discard criteria with wire breakage tables, disc brake service and emergency manual lifting, gear cam limit switch settings, and PLC replacement procedures.
• 6. Spare parts – how to order spare parts, complete spare parts list.
• 7. Table of figures
• 8. Spare parts catalogue – variable axial piston pumps, motors, winches, slewing gear drive, oil cooler, gear oil cooler, pump distribution gear, solenoid valves, pipe filter, cabin, descending device, bottom hook block, compact PLC.
• 9. Drawings + parts lists – maintenance chart (860-0500-00), electric wiring diagram (824-0700-151), crane housing complete (860-0800-00), general arrangement (860-0900-00), jib complete (860-1500-00), jib foot complete (822-2100-07 and 822-2100-12), rope sheave (800-2400-20), hydraulic circuit (840-4900-28), pump unit (820-5000-14), hydraulic oil tank (845-6100-00), fan flap (800-7300-03), slack rope connection (897-8800-07), energy supply (860-9000-00), crane rig.

The manual’s hydraulic circuit drawing (840-4900-28) is the central reference for understanding the closed-circuit hydrostatic drive. It shows the reversible axial piston pumps for hoisting, slewing and luffing, the integrated control and feed pumps, the proportional valve controls, pressure relief valves, flush valves, vent flaps, oil-air coolers, and the complete routing of high-pressure hoses to the winch motors and slewing gear motors. The hydraulic functions chapter walks through each circuit – how the pump unit starts, how the 4/2-way directional control valve blocks depressurised flow, how the pressure switches monitor feed pressure, and how the system shuts down on loss of pressure or oil.

Electrical and control system coverage

The electrical section explains the 4-channel current regulator card (SRK 04) used to control the proportional valves, including its PWM outputs, control lever potentiometer input, parameter menu structure for minimum and maximum currents, creep speeds, ramp times, overload thresholds and synchronous regulation. It documents the fault indicator cards, the switches in the switch box (test operation, reset, bridge hoisting gear brake pressure sensor, bridge luffing gear brake pressure sensor, test load), brake relay monitoring, and the PS2-200 Compact PLC with its construction, elements, bus termination resistors, operating states and test/initial operation procedures.

Specialist component documentation

Several appendices provide complete service parts manuals for the OEM components installed on the DK II crane:

• Sauer-Danfoss Series 90 180 cc axial piston pump – order codes, common parts, displacement limitation, end cap, charging system, auxiliary mounting flange, charge pressure, shaft, control, filtration, high pressure regulation, orifice, special hardware, overhaul seal kit, and service bulletins SB-9507, SB-9625, SB-9711, SB-9713, SB-9714.
• Sauer-Danfoss Series 90 130 cc axial piston pump – complete service parts with common parts, displacement limitation, end cap, charging system, auxiliary mounting, charge pressure, shaft, control, filtration, high pressure regulation, orifice, special hardware/side cover, overhaul kit, and service bulletins SB-9102, SB-9114, SB-9203, SB-9302, SB-9312, SB-9413, SB-9425, SB-9436, SB-9503, SB-9510, SB-9514, SB-9518, SB-9601, SB-9604, and BLN-10107.
• Rexroth A6VM 250 HD1D/63W2-VZB157 axial piston motor – spare parts lists for the complete motor and its sub-assemblies including rotary group, drive shaft with bearing assembly, control housing, adjustment parts, cover, and the brake release valve.
• Zollern ZHP 4.29 rope winch – gear, rope drum, flange bearing, drive, oil line, brake, installation instructions, maintenance instructions, lubricant recommendations, gearbox inspection procedures, and tightening torques.
• Karl Miller Type NG cabin – general drawing and spare parts list covering glass, profiles, door hardware, windscreen wiper, hinges, handles, insulation and interior fittings.
• RK Sicherheitstechnik Descender Device AG 10 K – instructions for use, technical data, abseiling procedures for one and two persons, storage and transportation, cleaning, maintenance, inspection schedules, and inspection book format.
• Hoisting Block SWL 80t – assembled drawing and detailed parts lists for the hoisting block, swivel and double hook with weights and materials.
• Moeller PS4-201-MM1 Compact PLC – complete hardware and engineering manual (AWB27-1184-GB) covering installation, engineering, electromagnetic compatibility, power supply, mounting, software configuration, slave addressing, operation, testing/commissioning/diagnostics, and technical data.

Why this manual matters for the DK II owner

The DK II is a 60-tonne crane with four selectable load steps, a 37.5 m lifting height, and a hydraulic system that runs on proportional electro-hydraulic control with closed-loop pump and motor circuits. The load limiter, overload protection and load measurement system (DMSA) are integral to safe operation – and the manual explains exactly how they interact, how to test them during test operation mode, and what each fault indication means. The maintenance schedule spans daily visual checks through to 1500-hour oil changes and 5-yearly class renewal inspections, with a lubricant table listing ISO VG 46 and ISO VG 220 oils with specific brand equivalents from ELF, BP, Castrol, ExxonMobil, Shell and Famm.

For rope maintenance, the manual provides the wire breakage discard criteria in accordance with DIN 15020 and classification society guidelines – including tables of visible wire breaks for different rope constructions, reduction in rope diameter thresholds, corrosion assessment, abrasion limits, and deformation types. This is the kind of information that determines whether a rope can stay in service or must be replaced.

Get instant access

Whether you operate a DK II deck crane, maintain one, or are responsible for its classification and inspection, this instruction manual gives you the manufacturer’s procedures, specifications and spare parts data in a single PDF. No shipping, no waiting – the file is available for immediate download and works on any device. Print the pages you need for the workshop or keep the full PDF on a laptop or tablet for reference during maintenance and repair.

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