Technical Training PDF

TECHNICAL TRAINING
CUSTOMER TRAINING PROGRAM TEREX PORT SOLUTIONS

Foreword
Please contact us!
In this brochure, you will find details of the courses available within the Terex Port Solu-
tions (TPS) customer training program.
Should you have any further questions about this TPS Customer Training Program or do
you want to order one of our trainings, please do not hesitate to contact us.
Alexander Bongart
Manager Training Operation
Training (PSS 26)
Forststrae 16
40597 Dsseldorf, Germany
T +49 211 7102-3546
M +49 173 29 27 361
F +49 211 7102-53546
E alexander.bongart@terex.com
Deborah Schriegel
Training Administration & Coordination
Training (PSS 26)
Forststrae 16
40597 Dsseldorf, Germany
T +49 211 7102-3792
M +49 162 25 96 648
F +49 211 7102-53792
E deborah.schriegel@terex.com
2 Terex Port Solutions 2014

Customer training program Terex Port Solutions
Foreword
Making skills work

develop your staff through our training courses
Making skills work true to this motto we support you with high quality training solu-
tions to exploit the full potential of your TPS products and to boost your productivity.
We offer you a comprehensive range of training courses that qualify your staff in the safe
and efficient operation and maintenance of TPS products and their components. You ben-
efit from our many years of experience. We continuously develop our training courses on
the basis of intensive customer interaction and local expertise. With practical work carried
out on the products, we ensure that your staff acquires the relevant know-how. We docu-
ment the participants successful completion of the course with our training certificates,
which are recognised by the industry.
The most important highlights

Modular, practice-oriented training program
German-educated technical trainers
Operator trainers with more than 20 years experience in Port of Antwerp
State-of-the-art equipment used in training
Comprehensive training documentation for each course
Training courses held at our training centers in
Dsseldorf (Germany)
Wrzburg/Hamburg (Germany)
Antwerp (Belgium)
Montceau les Mines (France)
Training courses held onsite at your port
Renowned Terex Port Solutions training certificate
Terex Port Solutions 2014 3

Foreword
Training centre in Dsseldorf, Germany
Highlights:
Highly experienced trainers
State-of-the-art training workplaces with
their own PC and the Simatic Manager
Simulators to represent the overall
crane control system
Comprehensive training documentation
for each course
Renowned Terex Port Solutions training
certificate
Training centre in Antwerp, Belgium
Highlights:
Trainers from experience
Two state-of-the-art simulators featuring many
operating scenarios that are adapted to Terex
Gottwald mobile harbour cranes
HMK 260 E mobile harbour crane for hands-on
training

Foreword
Training centre in Montceau les Mines, France
Highlights:
Terex Port Solutions certified trainers
TPS training quality workplace
Terex reach stacker for hands-on training
Technical documentation for training
Renowned Terex Port Solutions training
certificate
Training centre in Wrzburg/Hamburg, Germany
Highlights:
Well-educated trainers
Terex straddle carrier for hands-on training
Detailed training documentation

Contents
Content
1 Mobile harbour crane 7
1.1 Technical training 1 8
1.3 Hydraulic training12
1.4 Troubleshooting training (onsite & hands-on)14
2 Automated guided vehicle 16

2.3 Battery exchange station & battery training20
3 Straddle carrier & sprinter carrier 22

3.1 Technical training 1 for Noell NSC E22
3.2 Technical training 2 for Noell NSC E24
3.3 Technical training 1 for Noell NSC H26
3.4 Technical training 2 for Noell NSC H28
4 Reach stacker 30

4.1 Technical training for Terex TFC 45H/TFC 45HC 30
5 General products32
5.1 Basic training Simatic S732

1 Mobile harbour crane
Targets Target groups

Concept:
Acquiring and Maintenance staff and

improving the service technicians
necessary skills Technical training 1 & 2
Application of Maintenance staff and

skills gained from service technicians
Basic training hydraulics
classroom training
course to practical Basic training Simatic S7
use
Improved productivity Troubleshooting training Experienced service

through minimum technicians
downtimes and well (on-site)
trained staff
Safe operation and

maximum handling rates

1.1 Technical training 1

Number of participants:
Min. 3 and max. 8 participants
Duration:
5 days
Location:
Dsseldorf, Germany
On site
In this course, fundamental knowledge about Terex Gottwald cranes is conveyed to the
trainees. Trainees will first learn about the general set-up of their crane(s) and become
familiar with the product documentation. To be able to perform the maintenance work and
fault diagnosis, trainees are introduced to the fundamentals of the electrics and hydraulics
of their Terex Gottwald products. The training also includes learning to read the circuit
diagrams and hydraulic drawings. Trainees also receive instruction on the functions and
settings of drive units and assemblies such as the hoists, slewing gears and luffing gear
as well as on the brakes, steering and stabilisers.
The technical training 1 is designed for electricians and mechanics involved in work or
maintenance work on mechanical, hydraulic or electric components of a Terex Gottwald
product.
Seminar contents:
Mobile harbour cranes
General diagram G HxK/HxK
Superstructure/chassis/etc. G HxK/HxK
Documentation
Training manual
Operating and maintenance manuals
Spare parts catalogue (CD ROM)
Electrics
Designation system for control systems and auxiliary units
Functional groups, function designations, etc.
Circuit diagram booklet
Hydraulics
Introduction to hydraulics
Illustration of hydraulic symbols
Hydraulics circuit diagrams
Continued on next page

Continued from course program technical training 1
Functions and design

Crane control system
Superstructure and tower setup
Hoist function and setup
Slewing gear function and setup
Luffing gear function and setup
Chassis setup
Travel gear function and setup
Steering function and setup for G HMK/HMK
Brake function and setup
Stabilizer function and setup


Duration:
5 days
Location:
Dsseldorf, Germany
On site
Trainees are communicated the relevant knowledge to diagnose and remedy faults oc-
curring on Terex Gottwald cranes. After fundamental explanations of the way the control
system, consisting of hardware and software components, is made up, key aspects of
the bus systems are examined in detail. Additional insights into programming and the
programming language used make subsequent troubleshooting that much easier. Train-
ees will become familiar with one of the tried-and-tested aids for diagnosing faults the
Visumatic control and visualisation system. Hands-on training enables the trainees to
learn practical fault diagnosis skills and remedies.
The technical training 2 is designed for electricians involved in more complex mainte-
nance work or tougher troubleshooting.
Seminar contents:
Programmable logic control (PLC)
PLC on mobile harbour cranes
Industrial PC/hardware/software/ethernet
Controller S7 300/S7 400 setup/displays
PROFIBUS DP
PROFIBUS DP components and interface
S7 hardware configuration
ET 200S
IM 151 interface module setup and displays
ET 200S input and output modules
ASI bus
Setup/function
Master and slave module setup/function
CAN bus (G HxK only)
Setup/function
Master and slave module setup/function

STEP 7 programming environment

Organisation blocks (OB)
Function blocks (FB)
Function (FC)
Data blocks (DB)
Programming languages
Structured text (STL)
Function block diagram (FBD)
Ladder diagram (LAD)
Online functions
Main window
Menu and toolbar
Object organiser
Variable table (VAT)
User program
Components
User program blocks
Block types
Functions

1.3 Hydraulic training

Duration:
5 days
Location:
Dsseldorf, Germany
In this course, fundamental knowledge about Terex Gottwald cranes is conveyed to the
trainees. Trainees will first learn about the general set-up of their crane(s) and become
familiar with the product documentation. To be able to perform the maintenance work
and fault diagnosis, trainees are introduced to the fundamentals of the hydraulics of their
Terex Gottwald products. The training also includes learning to read the hydraulic draw-
ings. Trainees also receive instruction on the functions and settings of hydraulic units and
assemblies such as the travel gears and luffing gear as well as on the brakes, steering
and stabilisers.
The hydraulic training is designed for electricians and mechanics involved in work or
maintenance work on hydraulic components.
Seminar contents:
What is hydraulic fluid technology?
Generation of force using hydraulics
Layout of hydraulic drawings
Hydraulic systems in the 4th or 5th generation of mobile harbour cranes
Hydraulic system on HMK or G HMK platforms
Four-rope grab crane superstructure hydraulic system
Hydraulic power generation and distribution
HMK or G HMK pump system on platforms
A11VO hydraulic pump
Control block
Distributor block
Pressure stages
Set-up and function of hydraulic drives in the superstructure
Luffing gear hydraulic system
Design of rexroth and tries block
Luffing-in or raising the boom
Luffing-out or setting down the boom
Description of the hoist and slewing gear brakes

Continued from course program hydraulic training
Set-up and function of the hydraulic drives in the chassis

HMK or G HMK chassis hydraulic system on platforms
Description of travel gear, steering, travel gear brake, stabiliser system
Valve lists
HMK or G HMK platforms

1.4 Troubleshooting training (onsite & hands-on)

Duration:
5 days
Location:
On site
Requirements:
Mobile harbour crane must be available
curring on Terex Gottwald cranes. After fundamental explanations of the way the control
system, consisting of hardware and software components, is made up, key aspects of
the bus systems are examined in detail. Additional insights into programming and the
programming language used make subsequent troubleshooting that much easier. Train-
ees will become familiar with one of the tried-and-tested aids for diagnosing faults the
Visumatic control and visualisation system. Hands-on training enables the trainees to
learn practical fault diagnosis skills and remedies.
The troubleshooting training is designed for electricians involved in more complex mainte-
Seminar contents:
Electrics
Fault finding with visumatic
Fault finding with electrical booklet and multimeter
Hydraulics
Fault finding with visumatic and hydraulic diagram
Programmable logic control (PLC)
Introduction of the user program
Pinpoint faults in the program
Error logging
Error recovery
Profibus DP
Review connections at components and interfaces
Bypass faulty components
ET 200S
Evaluate status LEDs
Check input and output modules

Continued from course program troubleshooting training
ASI Bus
Evaluate status LEDs
Replace faulty components
Readdress connected slaves
Display digital and analogue values
Online functions
Diagnose online status of the crane
Display variable in VAT
Compare online/offline user program
Download user program

2 Automated guided vehicle
Duration:
2,5 days
Location:
On site
Requirements:
AGV must be available
In this course, fundamental knowledge about AGVs is conveyed to the trainees. Train-
ees will first learn about the general set-up of their AGVs and become familiar with the
product documentation. To be able to perform the maintenance work and fault diagnosis,
trainees are introduced to the fundamentals of the electrics and hydraulics of their Terex
Gottwald products. The training also includes learning to read the circuit diagrams and
hydraulic drawings.
maintenance work on mechanical, hydraulic or electric components of a Terex Gottwald
product.
Seminar contents:
Automated guided vehicle
General view of the components
Technical data
Documentation
Training manual
Electrics
Designation system for control systems and auxiliary units
Circuit diagram booklet
Hydraulics


Functions and design
Control system
Sensors
Chassis setup
Travel gear function and setup
Steering function and setup
Brake function and setup


Duration:
2,5 days
Location:
On site
Requirements:
AGV must be available
Trainees are communicated the relevant knowledge to diagnose and remedy faults occur-
ring on AGVs. After fundamental explanations of the way the control system, consisting
of hardware and software components, is made up, key aspects of the bus systems are
examined in detail. Additional insights into programming and the programming language
used make subsequent troubleshooting that much easier. Hands-on training enables the
trainees to learn practical fault diagnosis skills and remedies.
Seminar contents:
Basics of programmable logic control (PLC)
PLC on automated guided vehicles
User program
Software update
Troubleshooting
CAN bus
CAN bus components and interface
Hardware configuration
Introductions to TEAMS, FMDS, BMS, FCS
Inverters
Basics
Manufacturers documentation
User-specific parameters
Change parameters
Firmware update
Trace function

Steering controller
Basics
User program
Trace function
Software update
IO Box
Ltze locc box
Display
Sensors used on the AGV
Software
AGV-monitor
FMDS

2.3 Battery exchange station & battery training

Duration:
1,5 days
Location:
On site
Requirements:
Battery-AGV and battery exchange station must be available
In this course, fundamental knowledge about the AGVs battery and the battery changing
station is conveyed to the trainees. Trainees will first learn about the general set-up of the
battery and the battery changing station and become familiar with the product documen-
tation to perform the maintenance work. Hands-on training enables the trainees to learn
practical fault diagnosis skills and remedies.
The battery & battery changing station training is designed for electricians involved in
work or maintenance work on electric components or involved in troubleshooting.
Seminar contents:
Safety
Electrical hazards
Safe handling of batteries
Documentation
Training manual
Batteries
Design
Charge manually
Maintenance
Water refill
Measure acid density
Measurement of cell voltage
Manual remove of the batteries
Function of WI-IQ
Battery charger
Functions
Status lamps
Fault messages

Continued from course program battery & battery changing station training
Battery changing station

Automatic mode
Manual operation
Maintenance
Calibration
Fault messages
Troubleshooting

3 Straddle carrier & sprinter carrier
3.1 Technical training 1 for Noell NSC E

Duration:
5 days
Location:
Wrzburg, Germany
On site
Requirements:
For onsite training, a straddle carrier and/or a sprinter carrier must be available
In this course, fundamental knowledge about straddle carrier & sprinter carrier is con-
veyed to the trainees. Trainees will first learn about the general set-up of their straddle
carrier & sprinter carrier and become familiar with the product documentation. To be able
to perform the maintenance work and fault diagnosis, trainees are introduced to the fun-
damentals of the electrics and hydraulics. The training also includes learning to read the
circuit diagrams and hydraulic drawings.
maintenance work on mechanical, hydraulic or electric components of a straddle carrier &
sprinter carrier.
Seminar contents:
Straddle carrier & sprinter carrier
Inspection of the main straddle carrier components
Explanation and location of the safety features
Introduction of the operational controls of the straddle & sprinter carrier
Documentation
Training manual
Operating and maintenance manual
Electrics
Designation systems for control systems and auxiliary units
Circuit diagrams
Basic description of individual electric systems (hoist system, drive system)

Continued from course program technical training 1 for Noell NSC E
Hydraulics
Basic description of individual hydraulic systems
Steering system
Brake system
Spreader
PLC System
Description and function of the CAN-bus
Basic description of the PLC system
PLC Software update with a USB memory stick
Generator
Basic description of the generator
Generator/frequency converters
Basic description of the converters
Diagnostic using the frequency converter/CAN fault list
Basic description of the emergency recovery procedure
Diesel engine
Overview of the main diesel engine components
Straddle carrier & sprinter carrier maintenance
Maintenance schedule

3.2 Technical training 2 for Noell NSC E

Duration:
5 days
Location:
Wrzburg, Germany
On site
Requirements:
curring on straddle carrier & sprinter carrier. After fundamental explanations of the way
the control system, consisting of hardware and software components, is made up, key
aspects of the bus systems are examined in detail. Additional insights into programming
and the programming language used make subsequent troubleshooting that much easier.
Hands-on training enables the trainees to learn practical fault diagnosis skills and rem-
edies.
Seminar contents:
Electrics
Overview of the electrical system
Electrical components (e.g. absolute encoder, keyboard etc.)
Description and function of the individual electric systems
Hoist system
Drive system
Troubleshooting the electrical system
PLC System
Working with PCanView to diagnose the CAN-bus
Working with CoDeSys (monitoring the program and creating HEX files)
Working with WinFlash (downloading HEX files to ESX controller)
Working with the Mvision software to setup and programming the display
PLC software update with a USB memory stick
PLC data upload with a USB memory stick

Continued from course Program technical training 2 for Noell NSC E
Description and changing of important PLC parameters

Troubleshooting the PLC system
Generator
Description and function of the generator
Troubleshooting the generator
Frequency converters
Description and function of converters
Diagnostic using the frequency converter/CAN fault list
Downloading and changing parameters
Troubleshooting the frequency converter
Description and function of the emergency recovery procedure
Hydraulics
Steering system
Diagnostic software (only for electrical steering system)
Brake system
Spreader
Troubleshooting the hydraulic systems
Diesel engine
Diagnose the diesel engine

3.3 Technical training 1 for Noell NSC H

Duration:
5 days
Location:
Wrzburg, Germany
On site
Requirements:
In this course, fundamental knowledge about straddle carrier & sprinter carrier is con-
veyed to the trainees. Trainees will first learn about the general set-up of their straddle
carrier & sprinter carrier and become familiar with the product documentation. To be able
to perform the maintenance work and fault diagnosis, trainees are introduced to the fun-
damentals of the electrics and hydraulics. The training also includes learning to read the
circuit diagrams and hydraulic drawings.
maintenance work on mechanical, hydraulic or electric components of a straddle carrier &
sprinter carrier.
Seminar contents:
Inspection of the main straddle carrier & sprinter carrier components
Introduction of the operational controls of the straddle carrier & sprinter carrier
Documentation
Training manual
Operating and maintenance manual
Electrics
Designation systems for control systems and auxiliary units
Circuit diagrams
Hydraulics
Hydraulic principles

Continued from course program technical training 1 for Noell NSC H
Basic description of individual hydraulic systems

Steering system, brake system, spreader, hoist system and drive system
Basic description of the emergency recovery procedure
PLC system
Basic description of the PLC system
Diesel engine
Overview of the main diesel engine components
Straddle carrier & sprinter carrier maintenance

3.4 Technical training 2 for Noell NSC H

Duration:
5 days
Location:
Wrzburg, Germany
On site
Requirements:
curring on straddle carrier & sprinter carrier. After fundamental explanations of the way
the control system, consisting of hardware and software components, is made up, key
aspects of the bus systems are examined in detail. Additional insights into programming
and the programming language used make subsequent troubleshooting that much easier.
Hands-on training enables the trainees to learn practical fault diagnosis skills and rem-
edies.
Seminar contents:
Electrics
Overview of the electrical system
Electrical components (e.g. absolute encoder, keyboard etc.)
Description and function of the individual electric systems
Troubleshooting the electrical system
PLC System
Working with PCanView to diagnose the CAN-bus
Working with CoDeSys (monitoring the program and creating HEX files)
Working with WinFlash (downloading HEX files to ESX controller)
Working with the Mvision software to setup and programming the display
PLC data upload with a USB memory stick
Description and changing of important PLC parameters
Troubleshooting the PLC system

Continued from course program technical training 2 for Noell NSC H
Hydraulics
Description and function of the individual hydraulic systems
Steering system
Diagnostic software (only for electrical steering system)
Brake system
Spreader
Hoist system
Drive system
Troubleshooting the hydraulic systems
Description and function of the emergency recovery procedure
Diesel engine
Diagnose the diesel engine

4 Reach stacker
4 Reach stacker
4.1 Technical training for Terex TFC 45H/TFC 45HC

Duration:
5 days
Location:
Montceau les mines, France
On site
Requirements:
For onsite training, a reach stacker must be available
This course will introduce the TFC 45 reach stackers to the service engineers. Treating
the main differences between the two version TFC 45 H and TFC 45 HC.
After presentation of the all pilots control unit, we analyse the two different transmission
and all functions through the hydraulic and electric system.
This will give useful basics in order to approach the different methods for trouble shooting
and repair.
During the training the student will get a training manual and the standard CD containing
manual of conduct, spare parts and schematics.
Course activities
Theoretical lessons on training room and practical lessons on the reach stacker
Completion of benefits
Machine working and systems understanding
Acquiring and improving hydraulic, electric and pneumatic knowledge for troubleshoot-
ing
Operation knowledge
LMI use and adjustments procedure.
Duration
Courses started monday 2.00 pm till friday 12.00 am.
Seminar contents:
Historic of the reach stacker
Summary of the pilot unit
Control panel

4 Reach stacker
Continued from course program technical training for Terex TFC 45H/TFC 45HC
Transmission analyse
Dana TE 27000 vfs-booster (APC 200)
Dana TE 27418 full flow ( APC 216)
Gear box calibration
Load sensing pump
Cooling circuit
Parker control valve (M400LS-L90LS)
Pilot pressure regulation
Steering function
Brake system
Spreader functions
Logic module reading (practice on millennium type)
Telescope and boom hoist functions
MD3 Display
Description of the menu
Diagnostic mode
Adjustments (angle, pressure, boom length)

5 General products
5 General products
5.1 Basic training Simatic S7

Duration:
5 days
Location:
Dsseldorf, Germany
Trainees are communicated the relevant knowledge Siemens S7 PLC Systems, the Hard-
ware setup and the programming languages. Trainees will work with the belt model and
start to develop their own programming solutions. Hands-on training enables the trainees
to learn practical fault diagnosis skills and remedies.
Seminar contents:
Programmable logic controller (PLC)
Fundamental programmable logic controller (PLC)
Memory areas
Program cycle
Block types
Data types
Addressing
Programming of the PLC
Programming languages
Structured text (STL)
Function block diagram (FBD)
Ladder diagram (LAD)
Digital and analog instructions
PLC hardware
Central device S7 300/S7 400 (CPU)
Decentralised periphery (ET 200 station)
Hardware configuration
Profibus connection
Simatic manager
General set up

5 General products
Continued from course program basic training Simatic S7
User interface and operation

Applications
Creating logic blocks
Multiple instances in the variable declaration
Entering and editing addresses and parameters
Editing FBD and STL elements
Establishing online connections
Download/upload
Deleting on the programmable controller
Compressing the user memory
Managing multilingual texts
Simulation tool
SIMATIC S/-PLCSIM
Belt model (hands-on)

5 General products
Notes

5 General products
Notes

Customer training program Terex Port Solutions - Version 07.14
Subject to change without notice
www.terexportsolutions.com
Effective date: August, 2013. Product specifications and prices are subject to change without notice or obligation. The photographs and/or drawings
in this document are for illustrative purposes only. Refer to the appropriate Operators Manual for instructions on the proper use of this equipment.
Failure to follow the appropriate Operators Manual when using our equipment or otherwise failure to act responsibly may result in serious injury or death.
The only warranty applicable to our equipment is the standard written warranty applicable to the particular product and sale and Terex Port Solutions makes
no other warranty, express or implied. Products and services listed may be trademarks, service marks or trade-names of Terex Corporation and/or its subsidiaries
in the USA and other countries. All rights are reserved. Terex is a registered trademark of Terex Corporation in the USA and many other countries.
2014 Terex Corporation.

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TECHNICAL TRAINING

CUSTOMER TRAINING PROGRAM TEREX PORT SOLUTIONS

Please contact us!

2 Terex Port Solutions 2014

Making skills work

The most important highlights

Terex Port Solutions 2014 3

Training centre in Dsseldorf, Germany

Training centre in Antwerp, Belgium

4 Terex Port Solutions 2014

Training centre in Montceau les Mines, France

Training centre in Wrzburg/Hamburg, Germany

Terex Port Solutions 2014 5

2 Automated guided vehicle 16

3 Straddle carrier & sprinter carrier 22

4 Reach stacker 30

6 Terex Port Solutions 2014

1 Mobile harbour crane

Targets Target groups

Acquiring and Maintenance staff and

Application of Maintenance staff and

Improved productivity Troubleshooting training Experienced service

Safe operation and

Terex Port Solutions 2014 7

1.1 Technical training 1

Continued on next page

8 Terex Port Solutions 2014

Continued from course program technical training 1

Functions and design

Terex Port Solutions 2014 9

1.2 Technical training 2

Continued on next page

10 Terex Port Solutions 2014

Continued from course program technical training 2

STEP 7 programming environment

Terex Port Solutions 2014 11

1.3 Hydraulic training

Continued on next page

12 Terex Port Solutions 2014

Continued from course program hydraulic training

Set-up and function of the hydraulic drives in the chassis

Terex Port Solutions 2014 13

1.4 Troubleshooting training (onsite & hands-on)

Continued on next page

14 Terex Port Solutions 2014

Continued from course program troubleshooting training

Terex Port Solutions 2014 15

2 Automated guided vehicle

2.1 Technical training 1

Continued on next page

16 Terex Port Solutions 2014

Continued from course program technical training 1

Hydraulics circuit diagrams

Terex Port Solutions 2014 17

2.2 Technical training 2

Continued on next page

18 Terex Port Solutions 2014

Continued from course program technical training 2

Terex Port Solutions 2014 19

2.3 Battery exchange station & battery training

Continued on next page

20 Terex Port Solutions 2014

Battery changing station

2 Automated guided vehicle 16

3 Straddle carrier & sprinter carrier 22

4 Reach stacker 30