NMF DK Vs 35028 Board Crane Instruction Manual – Job 83085 – 35t Capacity

Description

NMF DK Vs 35028 Board Crane Instruction Manual — Job 83085

The complete instruction manual for the NMF DK Vs 35028 board crane, Job No. 83085, Build No. 1411, constructed at STX Offshore & Shipbuilding in 2011. This 621-page PDF is the full factory documentation for the 35-tonne SWL board crane with 28-metre outreach, covering commissioning, normal and special operation, troubleshooting, and the complete maintenance schedule through to decommissioning.

File Details

• Manual Type: Instruction Manual
• Brand: Neuenfelder Maschinenfabrik GmbH (NMF)
• Model: DK Vs 35028
• Job Number: 83085
• Build Number: 1411
• Year of Construction: 2011
• Construction Yard: STX Offshore & Shipbuilding
• Language: English
• Page Count: 621
• File Format: PDF

Chapters Covered

• 1. Introduction — manufacturer/service address, about this instruction manual, representation conventions, warnings and safety instructions, text markings, target group, list of abbreviations
• 2. Safety — intended use, basic safety instructions, specific safety instructions, emergency procedures (emergency escape via descending device, heeling >5°, fire), safety devices (emergency stop, hydraulic overload protection, feed pressure control, power control, warning devices, system control, oil level control, contamination monitoring, winch monitoring, brake monitoring, anti-collision system), warning and information signs
• 3. Technical Data — name plate, general data, electrical data, technical components
• 4. Design and Function — overview, power units, pump unit, hoisting gear, slack rope switch, luffing gear, slewing bearing, cooling (gear oil cooler, oil cooler, fan flaps), hydraulic oil filter, brakes (stopping brakes), electrical components (electric cabinet, slipring unit, limit switch, absolute encoder, pressure transmitter, press switch, feed pressure switch), heater, lighting
• 5. Operating and Display Elements — crane driver cabin control panels, emergency stop key, jib/slewing gear control lever, power request signal key, waiting/ready for start lamps, failure/heeling/overload lamps, crane ON/OFF keys, oil cooler operation lamp, socket, main hoist control lever, horn, anticollision key switch, fast speed key switch, jib in resting position key switch, grab operation key switch, cabin light/warning light/windscreen wiper/flood lights turn switches, electric cabinet door, switch panel, key switches, fault indicator card, current regulator print card
• 6. Operation in Normal Mode — before each start, requesting permission to start, starting the crane, selecting load step for grab operation, hoisting the load, placing the jib in resting position, switching off the crane
• 7. Operation in Special Mode — test mode (switching on, testing inputs/outputs on PLC, testing current regulator print cards), zero-point adjustment, emergency lowering of the load (opening the brakes)
• 8. Troubleshooting — error messages on fault indicator card, fault indicator card, switching off acoustic warning device signal, switching off optical warning device signal
• 9. Maintenance and Servicing — safety instructions, staff requirements (electrical equipment, hydraulic equipment), maintenance rates (50/100/200/800 operating hours, before each cargo operation, weekly, monthly, quarterly, six-monthly, annual, 2/3/5/6 years), lubricants, lubrication points, cleaning and care, checking safety devices (emergency stop, hydraulic overload protection, acoustic warning devices, limit switch settings, stopping brakes, slack rope switch), checking screw connections, checking bottom hook block, checking ball slewing bearing (seals, grease sample, lubrication, ring gear, screw connections, settling measurement), checking wire rope system (monitoring, cleaning/lubricating/greasing, discard criteria), hydraulic system (oil level, float switch, filter element, oil change, vent valve, dirt indicator), checking gear box oil level (slewing gear, hoisting/luffing winch, pump distribution gear, oil change), air conditioner
• 10. Decommissioning — temporary decommissioning during sea passage
• 11. Spare and Reserve Parts and Accessories — spare parts, guide to ordering spare parts, complete spare parts list
• 12. Appendix — glossary, lubrication charts, designations for stop valves, crane drawings, supplier documentation for hydraulic components and equipment, supplier documentation for electrical components

Beyond the core crane chapters, the appendix contains extensive supplier documentation: the ZOLLERN rope winch ZHP 4.27/4.270 (hoisting winch) with its complete spare parts list and service instructions, the ZOLLERN slewing gear ZHP 3.25, LINDOS hydraulic pumps (HPV 135-02) and remote controls (E1P), HYDROPA pressure switches (DS-307/302), INTERNORMEN pressure filters (ML 170-450), Karl Miller cabin air conditioning, and the Moeller XC200 PLC control system. This makes the manual a complete service reference for the entire crane assembly, not just the NMF-built structure.

Technical Scope of the DK Vs 35028

The DK Vs 35028 is a 35-tonne safe working load board crane with 28-metre maximum outreach. The type designation decodes as: DK = slewing crane, Vs = compact with grab operation, 35028 = 35 t / 28 m outreach. The main hoist operates in load steps with SWL 35 t at 4.0–28.0 m and grab operation at 28 t SWL. Hoist speed ranges from 0–20 m/min at 35 t to 0–40 m/min at 14 t. Luffing time is 65 seconds and slewing speed is 0–0.85 rpm with unlimited 360-degree rotation.

The crane is powered by a 154 kW electric motor (S1-100% DC) driving three HPV135-02 hydraulic pumps through a pump distribution gear. Maximum intermittent power input is 215 kW (S6-20% DC). The hoisting wire rope is 30 mm diameter, 215 m long; the luffing wire rope is 66 mm diameter, 503 m long. Both are multilayer round strand ropes with minimum breaking forces of 851 kN and 742 kN respectively. The hydraulic system operates with feed pressure monitored at approximately 20 bar, and the oil coolers activate automatically at hydraulic oil temperatures above 40°C.

What This Manual Covers in Detail

Safety systems: The manual details every safety device on the crane — the emergency stop function (located on the left control panel, access ladder, electric cabinet, and deckhouse), the hydraulic overload protection through pressure relief valves and press switches, feed pressure control that switches off pump units below 20 bar, power request management for generator load sharing, oil level monitoring through a float switch, contamination monitoring with mechanical dirt indicators, winch monitoring via absolute encoders and overspeed detection, brake monitoring through dual brake relays and pressure transmitters, and the anti-collision system for multi-crane installations.

Operation: Normal operation procedures cover the pre-start checks, power request signal, start sequence, load step selection (35 t or grab operation), hoisting and lowering the load, placing the jib in the resting position on the park support, and switching off. Special mode procedures cover the test mode for troubleshooting electrical inputs/outputs and current regulator cards, zero-point adjustment of the absolute encoders, and emergency lowering of the load by manually opening the stopping brakes using the brake opening manual pump.

Maintenance: The maintenance schedule is laid out by operating hours and calendar intervals — first 50, 100, 200, and 800 hours after commissioning; before each cargo operation; weekly; monthly; quarterly; every six months; every 12 months or 1500 hours; every 2, 3, 5, and 6 years. Tasks cover the hydraulic oil filter replacement, ball slewing bearing lubrication and settling measurement, wire rope inspection and discard criteria, brake testing, slack rope switch function checks, oil sampling and analysis, and the complete gear oil change procedure for the slewing gear, hoisting winch, luffing winch, and pump distribution gear.

Troubleshooting: The fault indicator card section maps 16 error messages to their meaning and remedy — circuit breaker faults for oil coolers, asymmetric relay faults, gear oil temperature, low temperature sensor on motor windings, oil temperature over 85°C, low oil level, hydraulic hose damage, brake activation faults for main hoist and jib, overspeed faults, encoder faults, and CAN bus communication failure.

Why This Manual Matters

Operating and maintaining a 35-tonne board crane without the manufacturer’s procedures is a risk no vessel should take. This instruction manual provides the correct start-up sequence, the load-step limitations, the emergency lowering procedure, the anti-collision system logic, and the exact maintenance intervals and torque values that keep the crane in class. It is the reference document for crane drivers, service technicians, and classification surveyors working with the DK Vs 35028.

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