TTS Operating Instructions

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TTS Marine Cargo Cranes

OPERATION INSTRUCTION
AND
SPARE PARTS LIST

SINGLE DECK CRANE KL 30T – 28M

TTS YARD-NO. : 2-571-7/3165 – 7/3168


YEAR OF CONSTRUCTION : 2008
CLASSIFICATION SOCIETY : LR
DATE : January 2008
JES SHIPYARD HULL NO.: JES 06C-001

TTS-LMG Marine Cranes GmbH


Marine Crane Division
Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
E-mail: info@tts-lmg.de
Internet: www.tts-marine.com

© Copyright by TTS-LMG Printed in Germany


TTS-LMG Marine Cranes GmbH

7/3165-7/3168 PREFACE

1. PREFACE
2. CRANE DESCRIPTION

3. OPERATION
3.1 SAFETY REGULATIONS
3.2 CRANE OPERATION

4. MAINTENANCE
4.1 GENERAL REMARKS
4.2 MAINTENANCE SCHEDULE
4.3 LUBRICANTS
4.4 ELECTRICAL EQUIPMENT
4.5 HYDRAULIC EQUIPMENT
4.6 ASSEMBLY AND DISMANTLING

5. SPECIFICATION OF THE ELECTRICAL


EQUIPMENT FOR A SINGLE DECK CRANE

6. SPARE PARTS LIST


ASSEMBLY GROUP 00.00.00 DECK CRANE COMPL.
ASSEMBLY GROUP 01.00.00 SLEWING TOWER
ASSEMBLY GROUP 02.00.00 JIB COMPL.
ASSEMBLY GROUP 05.00.00 ROPE PLAN
ASSEMBLY GROUP 07.00.00 CARGO BLOCK
ASSEMBLY GROUP 12.00.00 PANEL LIST
ASSEMBLY GROUP 14.00.00 PART WITHOUT ATTACH IN WORKS
ASSEMBLY GROUP 15.00.00 AGGREGATE MODULE COMPL.
ASSEMBLY GROUP 18.00.00 DRIVING HOUSE COMPL.
ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.
ASSEMBLY GROUP 97.00.00 TECHNICAL DOKUMENTS

7. ASSEMBLY INSTRUCTION

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1. PREFACE

INDEX
1. PREFACE 2
1.1 PREFACE 3
1.2 SAFETY REGULATIONS – GENERAL REMARKS 4
1.3 EXPLANATION OF SAFETY SIGNS 5
1.3.1 PROHIBITION SIGNS 5
1.3.2 WARNING SIGNS 5
1.3.3 MANDATORY SIGNS 6
1.3.4 RESCUE SIGNS 7
1.4 SAFETY DEVICES – GENERAL REMARKS 8
1.4.1 BRAKES 8
1.4.2 LIGHTING 8
1.4.3 LIMIT SWITCHES 8
1.4.4 SAFETY DEVICES 8
1.5 SAFETY REGULATIONS 9
1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS 9
1.5.2 OPERATING INSTRUCTION FOR EMERGENCY
EXIT WITH ESCAPE DEVICE 11

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1.1 PREFACE
The documentation supplied with the deck crane includes the operating manual and the spare parts
catalogue.
The operating manual contains important information that is needed for safe crane operation. It is
intended mainly for the crane driver and maintenance personnel and belongs to the TTS-LMG deck crane.
The crane driver and maintenance personnel must be able to refer to it at all times. A copy must therefore be
kept on the crane in a place where it is immediately available.
Please study the operating manual carefully before putting the TTS-LMG deck crane into operation. Read
the
chapter on safety particularly thoroughly, and also acquaint yourself with the warning and instruction labels
on the crane and what they mean. You must also be thoroughly conversant with the layout and functions
of the controls, and know the direction in which they should be moved, before putting the crane into
operation for the first time.
The operating manual is divided into chapters and sub-chapters. It describes the crane that has actually
been delivered as well as any possible special equipment machinery. All information required can be found
easily and quickly by means of the index. The figures in the operating manual may differ in some respects
from the construction of your crane, but this does not detract from the actual information content.
Please pay attention to the instructions given in the operating manual at all times.
The generally accepted technical principles relating to safety and good operating practice must always be
observed beside the accident prevention regulations stated in the operating manual and the corresponding
legislation and rules applicable in the user´s country and at the actual site of operations.
Correct OPERATION and careful MAINTENANCE have a major impact on the perfor-mance and
availability of your TTS- LMG deck crane. Faulty operation and/or poor maintenance lead to avoidable
malfunctions. Only correct operation and careful maintenance can ensure satisfactory and continuous
operational safety.,
The chapter OPERATION provides all information needed for correct operation. Use only ORIGINAL
TTS-LMG SPARE PARTS when replacing components. TTS-LMG Marine Cranes GmbH accept no
liability for damage resulting from non-adherence to the operating manual or the instructions
contained therein or from the use of the crane for unusual purposes.
The operating manual is not extension of terms of sale and delivery of TTS-LMG Marine Cranes GmbH
Please direct all enquiries to the following address:

TTS-LMG Marine Cranes GmbH


Marine Crane Division
Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
E-mail: info@tts-lmg.de
Internet: www.tts-marine.com

Please state the crane no. and type (see data plate) with all enquiries.
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1.2 SAFETY REGULATIONS – GENERAL REMARKS


The purpose of this operating manual is to prevent malfunctions and damage by presenting appropriate
operating rules and to provide advice for rectifying all faults that may occur. Therefore, the operating
personnel should be familiar with the operating manual to the necessary degree and must be instructed to
follow strictly all instructions it contains and the safety regulations in particular. Moreover, attention must
be paid to the official regulations, accident prevention rules and in-house instructions applying to cranes
in the country in which the crane is used. A copy of this manual must be kept on the crane within easy
reach of the driver for quick reference.
The crane should be operated, and maintenance work performed only by suitably trained – and
appropriately qualified personnel. They must be conversant with the construction and working principles
of the crane and its safety devices and be fully acquainted with the appropriate safety and accident
prevention rules. A crane driver must be present at all times from the moment the crane is put into
operation until it is closed down. Maintenance, repair and other work is to be carried out only under
competent supervision and only when the crane is out of operation.
Records must be kept in the crane record book of all faults and damage that occur, especially if they
affect the safety of the crane. Moreover, the crane driver must enter all instructions given by supervisors,
times of starting, break-downs and other incidents in this book. The crane driver must also ensure that all
malfunctions, damage and other incidents that may affect crane operation or its safety are immediately
reported to the supervisor in charge and the person relieving him at the end of the shift.
If necessary, the crane must be closed down by the driver and not restarted until readiness for operation
has been completely restored, all hazards have been eliminated and permission has been received by
the supervisor in charge.
The crane is designed for handling bulk materials and general cargo.
IT IS FORBIDDEN TO USE THE CRANE FOR THE TRANSPORT OF PERSONS (e.g. on a working
platform) !
The area swept by the crane jib must be free from unauthorised persons.
Suspended loads must not pass above the heads of persons within this area.
If this cannot be avoided the persons concerned must be warned beforehand.
lf loads are attached by slingers, the crane driver must perform only the crane motions indicated by their
instructions. lf signals are used to communicate with the crane driver, they must be agreed beforehand
(see section 4.6.3).
The crane driver must keep his eyes on the load or, in the case of motions without load, on the hook at all
times. The ropes and hook block must not be dragged around corners or over edges.
The fitting of attachments, modification of the crane, changes and adjustment of the settings of important
assemblies and safety devices require the prior approval of the crane manufacturer if they affect the
operation or safety of the crane or the safety of operatives.

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1.3 EXPLANATION OF SAFETY SIGNS

1.3.1 PROHIBITION SIGNS

Fire, exposed flame and smoking prohibited Do not operate switch

No entrance for unauthorized personal Prohibited for persons with pacemaker

1.3.2 WARNING SIGNS

Warning of hanging load Warning of electro – magnetic field

Warning of high voltage Danger of falling


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Warning of danger through batteries Danger of slipping Danger through hot surface

1.3.3 MANDATORY SIGNS

Wear eye protection Wear safety gloves Wear safety protection

Wear safety helmet Wear safety boots Wear ear protection

Follow information on the Switch off power supply Use safety devices
Component, in the in-
structions for use and in-
structions for operating
the vehicle

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1.3.4 RESCUE SIGNS

First aid Fire extinguisher

Doctor

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1.4 SAFETY DEVICES – GENERAL REMARKS


The purpose of safety devices is to prevent damage and ensure trouble-free operation. Therefore, their
satisfactory operation must be checked at frequent intervals and ensured by appropriate maintenance.
Failures and malfunctions must be recorded in the crane record book. The supervisor in charge must be
informed immediately, and he must decide whether to continue using the crane and take and supervise
the appropriate measures.

1.4.1 BRAKES
After stopping the drives, the brakes remain closed to prevent unintended movement of the driven
components. Therefore, they are important safety devices and requiring particularly careful inspection
and maintenance owing to their varying coefficient of friction and wear .

1.4.2 LIGHTING
Adequate illumination is essential for safe access to the crane and for safe crane operation. Defective parts
of the lighting system should therefore be repaired or replaced immediately.

1.4.3 LIMIT SWITCHES


The limit switches are safety cut-outs. To avoid damage, they should not be actuated during normal
service. Limit switches are used to restrict the motions performed by the hoisting gear, luffing gear and
slewing gear and switch off the drive concerned when the limit positions are reached.

1.4.4 SAFETY DEVICES


The electrical safety devices switch off the corresponding drives in the event of danger.
The safety devices must be checked regularly to ensure that they work properly and are in perfect
condition. Defective parts must be replaced immediately by spare parts from the original manufacturer.
THE MODIFICATION OF MONITORING DEVICES AND THE INSTALLATION OF OTHER DEVICES IS
PERMITTED ONLY AFTER CONSULTATION WITH AND APPROVAL BY TTS-LMG.
Electrical safety devices may be removed, replaced or bridged only by authorised persons under
appropriate supervision when the crane is not in operation, and after all necessary safety precautions
have been taken. The satisfactory operation of the safety devices concerned must be checked after the
original state has been restored.
All monitoring devices such as limit switches, overload trips, pressure switches, etc., must be checked at
regular intervals to ensure that they are in good working order.
When checking equipment, make sure that all monitoring devices, especially safety switches and their
actuators, are firmly seated.
All safety devices must be rechecked after repairs or prolonged periods of idleness.
All monitoring devices should be checked after the crane or part of it has been cleaned. This should be
done regardless of the interval that has elapsed since the last check.
THE CHECKS MUST CONSIST OF AN INSPECTION AND A FUNCTION CHECK.

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1.5 SAFETY REGULATIONS

1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS


In the event of fire, immediately set off the fire alarm and switch off the whole electrical system.
A portable fire extinguisher is provided in the driver's cabin (5 kg ABC powder) extinguisher.

ATTENTION

Observe the official fire prevention regulations. Have portable fire extinguishers checked and serviced at
regular intervals to ensure that they are always ready for instant use!

Portable fire extinguishers : dry powder extinguishers

Extinguishing agent : 5 kg carbon dioxide

Duration : 9 seconds, so keep calm and use the extinguisher with forethought.

The extinguishing effect is achieved by dilution, thinning, isolation or reduction of the oxygen concentration.
The jet of dry powder can dislodge light substances such as hot or glowing ash, and may therefore cause
the fire to spread.

SUITABLE FOR FIRE CLASSES A, B AND C

Solids: e.g. wood, paper, coal

Liquids:e.g. petrol, benzene, oils, greases, paints, tar

Gases: e.g. methane, acetylene

PROCEDURE IN CASES OF FIRE:

Report fire Raise the alarm; give information on the source of the fire.

Move to safety Warn endangered persons. Remove the injured and


helpless. Close doors.

Fight the fire Take the fire extinguisher. Do not set it off until you
reach the source of the fire.

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FIRE EXTINGUISHING SYSTEM/FIRE EXTINGUISHERS

RULE NO. 1 IN FIREFIGHTING IS:

SAVING HUMAN LIFE IS MORE IMPORTANT THAN FIGHTING THE FIRE.


HOWEVER VALUABLE THEY ARE, OBJECTS CAN BE REPLACED.

CORRECT USE OF FIRE EXTINGUISHERS:

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1.5.2 OPERATING INSTRUCTION FOR EMERGENCY


EXIT WITH ESCAPE DEVICE

REMOVE ESCAPE DEVICE OUT OF BAG AT THE CABIN WALL.

Take the escape device below the sliding piece, so that the back belt
and the large opening are showing forward. Step into
the escape device with the legs - see Fig.left. Chest belt and catch
loop must be in front of the body. Sliding piece to be pushed
downwards.

REMOVE LEVER BRAKE OUT OF THE BAG

Fix carabine hook at lever brake onto the lug of the secured belt.
Remove lever brake from of the bag and fix carabine hook at
lever brake onto the lug of the secured belt.

GRATING TO BE HINGED UP FORWARD AND BOTTOM WINDOW


TO BE OPENED.

The free end is to be thrown out of the bag via the opening.
When actuating the hand, the rope-down procedure via the bottom
Window will be started.

The device remains in suspended condition when loaded by a person.


Only by pressing the hand lever into direction of the device, the
rope-down procedure will be started. The rope-down speed will be
regulated via the hand lever.

When releasing the hand lever, the rope-down procedure is interrupted


directly. When pressing hand lever fully down, the rope-down procedure
can also be interrupted (decelerated) until standstill.

Replace rope after 4-5 years

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2. DESCRIPTION

INDEX
2. DESCRIPTION 1
2.1 GENERAL 2
2.1.1 CRANE TOWER 2
2.1.2 CRANE CABIN 2
2.1.3 JIB 2
2.1.4 SLEW ASSEMBLY 2
2.1.5 HYDRAULIC SYSTEM 2
2.1.6 HOISTING AND LUFFING GEARS 2
2.1.7 SLEWING GEAR 2
2.1.8 ELECTRICAL EQUIPMENT 2
2.2 TECHNICAL DATA 3
2.2.1 OPERATING CONDITIONS FOR DECK CRANES 3
2.2.2 CRANE LAYOUT – MAIN DIMENSIONS 4
2.2.3 LOAD LIMITATION DEPENDING ON OUTREACH 5
2.2.4 PRINCIPAL DATA 6
2.2.5 GENERAL ARRANGEMENT DRAWING 6
2.2.6 POWER SUPPLY 7
2.2.7 ELECTRIC MOTORS 7
2.2.8 SPLITTER GEARBOX 7
2.2.9 SLEWING RING 7
2.2.10 SLEWING GEAR REDUCER 7
2.2.11 WINCHES 8
2.2.12 ROPES 8
2.2.13 WEIGHTS 10

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2.1 GENERAL
The electro-hydraulic deck crane is designed for handling containers and general cargo. It can be equipped
with load carrying means such as spreader, load turning device etc.
Access to the crane is through the inside of the foundation column and via a ladder which turns with the
crane. Access to the crane deck via a ladder in the crane tower.

2.1.1 CRANE TOWER


Torsion- and buckling-proof, for accomodation of the slewing gears, the hydraulic power pack, slewing ring,
electrical equipment (switchgear cubicles), cabin and the hoisting and luffing gears.

2.1.2 CRANE CABIN


With comfortable seat, fan heater, electrically operated windscreen wiper, safety glazing, fire extinguisher,
window in cabin bottom as an emergency exit ( can be opened from inside and outside ), emergency rope-
down device. The cabin is suspended elastically in the tower.

2.1.3 JIB
The jib is built as a welded two-beam box-type construction, the connection jib – crane tower is made by
maintenance free uniball bearings.

2.1.4 SLEW ASSEMBLY


The slew bearing is designed to enable a slewable connection of the crane with the fundamental tower in
the ship.

2.1.5 HYDRAULIC SYSTEM


The crane is driven by an electric motor which powers the hydraulic pumps over a splitter gearbox. The
hydraulic pumps feed the motors of the single drives in closed and independent circuits with pressure oil.

2.1.6 HOISTING AND LUFFING GEARS


Hoisting and luffing gears are designed as rope drive winches ; the winches are equipped with rope
grooves for two layer winding, internal planetary gears and hydraulically lifted multi-disc brakes.The drive is
given by hydraulic motors.The winches are monitored by limit switches and a slack rope switch.

2.1.7 SLEWING GEAR


The slew drive is designed with planetary gear-boxes with pinion that
intervene into the slew ring ; the slew gears are driven by hydraulic motors. Besides this the planetary gear
boxes are equipped with hydraulically lifted multi-disc brakes.

2.1.8 ELECTRICAL EQUIPMENT


The electrical equipment of the crane conforms to the rules of the classification society. It is designed for
operation at ambient temperatures between -20 to +45°C. The electrical equipment includes the drive of the
hydraulic pumps and the control of the entire crane.

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2.2 TECHNICAL DATA


2.2.1 OPERATING CONDITIONS FOR DECK CRANES
Crane Type: Deck crane for general cargo and container operation at SWL 30T
Rating according to FEM
CLASSIFICATION AND LOADING ON STRUCTURES AND MECHANISMS
KL 30t - 25m , TTS YARD-NO.: 7/3129 – 7/3148

Calculation of carrying steel structure in accordance with FEM


and Classification Society
hook operation 30t grab operation 25t
The Crane as a whole
Appliance group A4 A4
Load spectrum class Q2 Q2
Utilisation class U4 U4
Number of loading cycles during lifetime max.250.000 max.250.000

Calculation of drive in accordance with FEM

HOISTING GEAR

Mechanism group M5 M5
Class of load spectrum L2 L2
Class of utilization T5 T5

LUFFING GEAR

Mechanism group M5 M5
Class of load spectrum L2 L2
Class of utilization T5 T5

SLEWING GEAR

Mechanism group M5 M5
Class of load spectrum L2 L2
Class of utilization T5 T5

Standard operation
Cranes which hoist the safe working load farly frequently and, normally, loads
Between 1/3 and 2/3 of the safe working load

Corresponds to an average running time of 2 to 3 hours per day related to one year

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2.2.2 CRANE LAYOUT – MAIN DIMENSIONS

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2.2.3 LOAD LIMITATION DEPENDING ON OUTREACH

The crane has different load ranges (SWL).

The maximum outreach is 28 m, it is limited by the luffing gear limit switch.

At an outreach of 3,8 – 28 m, loads of up to 30 t by Hook operation can be lifted. If loads are heavier than
that, the hoisting gear only will be blocked in the direction "lifting".

At an outreach of 3,8 – 28 m, loads of up to 25 t by Grab operation can be lifted. If loads are heavier than
that, the hoisting gear only will be blocked in the direction "lifting".

If heavier loads are taken up in these limited ranges, the hoisting gear is blocked in the direction "lifting",
and the luffing gear in the directions "luffing in" and "luffing out". The load can only be lowered.

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2.2.4 PRINCIPAL DATA


Crane type KL 30t-28m

Type of drive electro – hydraulic


Ambient temperature -20ºC to +45ºC
Lifting capacity 30 t – 28 m Hook opeartion
25 t – 28 m Grab operation
Min. outreach 3,8 m
Max. lifting height 34,0 m
Slewing speed * 1,27 rpm
Hoisting speed * full load 22,0 m/min
Load 6t 44,0 m/min
no load 45,0 m/min
Luffing time * from max. in min. outreach 57,3 sec
Heeling angle 5º
Trim 2º
* all movements simultaneously

2.2.5 GENERAL ARRANGEMENT DRAWING

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2.2.6 POWER SUPPLY


Ship's mains voltage 440 V/ 60 Hz
Lighting and heating 220 V/ 60Hz
Nominal rating of motor 160 kW
Short-time load 10* duty cycle 380 kVA
Momentary peak 2 - 3 sec. 430 kVA
Reverse curr. full load lowering and luffing 100 kW

2.2.7 ELECTRIC MOTORS


SPLITTER GEARBOX

3-phase A.C. squirrel cage motor


Rated voltage 440 V,60 Hz
Rated output 160 kW, S1
Speed 1785 min-1
Enclosure IP 55
Structural shape V3(IEC34-7)

3-PTC-resistors for switching-off


Anti-condensation heating 230 V

2.2.8 SPLITTER GEARBOX

Power of el. motor 160 kW


Drive speed 1785min-1
Max. output 1x174kW (hoisting)
1x187 kW (luffing)
1x172 kW (slewing)
Output speed 2746 min-1
Transmission i = 0,65

2.2.9 SLEWING RING


Slew bearing
Number of teeth 171
Module 16

2.2.10 SLEWING GEAR REDUCER


Mounting position pinion bottom
Output speed 22,0 rpm
Transmission 125
Lantern shaft length short
P.T.O pinion module 16
P.T.O. pinion no. of teeth 10
P.T.O. pinion width 136 mm
Hydraulic motor type A2FM 56/61 W - PAB02

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2.2.11 WINCHES
HOISTING GEAR

Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically, slack rope limit switch
Transmission i = 83,4
Drum dia. to centre of rope 630 mm
Length of drum 892 mm
Rope dia. 30 mm
Rope lay 34 mm
Direction of rope lay r.h. DIN15061
Rope speed 44 / 88 m/min
Hydraulic motor A6VM200EP2D/63 VAB 02 B

LUFFING GEAR

Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically


Transmission i = 108,1
Drum dia. to centre of rope 630 mm
Length of drum 892 mm
Rope dia. 30 mm
Rope lay 34 mm
Direction of rope lay r.h. DIN15061
Rope speed 52 m/min
Hydraulic motor A2FM125 W6.1A2

2.2.12 ROPES

HOISTING ROPE

Rope diameter (mm) 30


Rope length (m) 262
Wire breaking strength (N/mm²) 1960
Operation force (kN) 169,2
Min. breaking strength (kN) 778,3
Rope design Olivera NR15K PPI
Left hand regular lay
Thimble DIN 3091-36GTW

LUFFING ROPE

Rope diameter (mm) 30


Rope length (m) 209
Wire breaking strength (N/mm²) 1770
Operation force (kN) 148,3
Min. breaking strength (kN) 682,2
Rope design Olivera SC8 PPI
Left hand regular lay
Thimble DIN 3091-36GTW

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2.2.13 WEIGHTS

Slewing tower compl 23 100 kg


Jib compl. 11 810 kg
Hoisting rope 1 190 kg
Luffing rope 843 kg
Tackle block 1 000 kg
Crane compl. approx. 37 943 kg

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3. OPERATION INSTRUCTION

INDEX
3. OPERATION INSTRUCTION 1
3.1 PREPARATORY WORKS 2
3.1.1 OPERATIONAL INSTRUCTIONS AND SAFETY REGULATIONS 2
3.1.2 SETTING OF GRAB/HOOK OPERATION 3
3.1.3 MONITORING DEVICES 4
3.2 GENERAL OPERATION MANUAL 5
3.2.1 CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS 5
3.2.2 CONTROL LEVER (JOY STICKS) 9
3.2.3 INTERACTIVE DIALOGUE SYSTEM ( DISPLAY ) 12
3.3 CRANE OPERATION 14
3.3.1 SAFETY REGULATIONS 14
3.3.2 SETTING OF GRAB/HOOK OPERATION 15
3.3.3 PUTTING INTO OPERATION 16
3.3.3.1 TANDEM OPERATION MODE OF DECK CRANES 22
3.3.4 CLOSING DOWN 23

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3.1 PREPARATORY WORKS

3.1.1 OPERATIONAL INSTRUCTIONS AND SAFETY REGULATIONS

The crane may only be put into operation by a TRAINED CRANE OPERATOR (ship’s crew) after he has
convinced himself that the crane is in orderly condition, i.e. :

♦ all repairs and maintenance work required to ensure that the crane is completely operable and safe have
been completed,
♦ all working areas are adequately illuminated during the hours of darkness,
♦ all drives and safety devices are complete and in good working order,
♦ all brakes are in good working order and the crane responds to the controls,
♦ none of the safety devices are in override status.
♦ All drives must be switched off before the crane driver leaves the cabin
(turn switch 26 into “OFF” - position) !

The crane driver must not leave the crane during operation without first handing over control to a suitable
authorized relief driver. This must be done while there is no load suspended from the hook. The relief of a
crane driver is to be entered in the crane record book as a special incident.
lf a driver is on the crane, other persons may enter and leave the crane only with the agreement of the crane
driver and while the crane is stationary.
The specified safe working load of the crane shall on no account be exceeded.
Safety devices must not be rendered inoperable or tampered with.
The crane must be put out of operation immediately if brakes or limit switches fail.

ATTENTION
The instruction contained in the descriptions of the electrical and hydraulic plants are an integral part of the
operation manual and must be strictly observed.

A warning signal must be given with the horn in the driver´s cabin before the crane is to start so that danger
zone ( e.g. area of work / slewing range ) can leave the area in good time.

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3.1.2 SETTING OF GRAB/HOOK OPERATION

For a change from grab to hook operation please see sketches below:

Sketch 1 : Hook Block for Hook operation


Sketch 2 : Hook Block with wire ring and chain lug of the grab

Sketch 1 Sketch 2

Grab operation will be selected by KEY-SWITCH 31.


During grab operation the maximum load is limited from 30 tons down to 25 tons.

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3.1.3 MONITORING DEVICES

The monitoring devices switch off the corresponding drives in the event of danger.
The crane is equipped with the following protection and safety equipment :

♦ limit switches for highest and lowest hook positions,


♦ limit switches for maximum and minimum outreach,
♦ automatic reduction of speed before the highest position is reached,
♦ safety valves to protect from overload,
♦ automatic application of hoisting, luffing and slewing gear brakes,
♦ automatic return of control levers to neutral position,
♦ temperature sensors to protect electric motors,
♦ digital display of operating and fault status of electrical and hydraulic systems,
♦ pressure gauging systems in the hydraulic circuits,
♦ emergency OFF switches in the driver's cabin and machinery space,
♦ switch-slack rope (hoisting gear),
♦ indicators for high oil temperature
♦ hoisting rope tension limiter (for parking the jib)
♦ a red warning light on the jib head
♦ alarm horn

The monitoring devices must be checked regularly to ensure that they work properly and are in perfect
con-dition. Defective parts must be replaced immediately by spare parts from the original manufacturer.
Monitoring devices may be removed, replaced or overridden only by authorised persons under appropriate
supervision when the crane is not in operation and after all necessary safety precautions have been taken.
The satisfactory operation of the monitoring devices concerned must be checked after the original state has
been restored.
All monitoring devices such as limit switches, overload trips, pressure switches, etc., must be checked at
regular intervals to ensure that they are in good working order.

When checking equipment, make sure that all monitoring devices, especially safety switches and their
actuators, are firmly seated.

All monitoring devices must be rechecked after repairs or prolonged periods of idleness.

All monitoring devices should be checked after the crane or part of it has been cleaned. This should be done
regardless of the interval that has elapsed since the last check. The checks must consist of an inspection
and a function check.

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3.2 GENERAL OPERATION MANUAL

3.2.1 CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS

CONTROL DESK LEFT CONTROL DESK RIGHT

CONTROL DESK LEFT HAND CONTROL DESK RIGHT HAND

1 Control lever Slewing gear / Luffing gear 2 Control lever Hoisting gear
10 Selector switch Windscreen wiper Grab open / close
11 Selector switch Cabin heater 20 Emerg.-off button Emergency off
12 Selector switch Decks light 26 illuminated switch Start / Stop
13 Selector switch Warning light red Ready for operation
14 Selector switch Working light 28 Indication lamp ( red ) Fault
15 Selector switch Cabin light 30 Key operated button Jib resting
Bp Blind cap for additional Installation 31 Key operated switch Grab operation
Bp Blind cap for additional Installation

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AIR SUPPLY

Make sure that air is supplied through crane column.


The bottom access door or the hatch must be opened to allow air to
get in.

THE AIR OUTLET OF THE OIL COOLER FAN IS COVERED´


BY A FLAP.
THIS FLAP MUST BE OPENED BEFORE THE CRANE WILL
BE STARTED.

Cabin door and hatch to winch platform must be closed during


peration.

CRANE - WORKING LIGHT

Switch on crane light.

CONTROL LEVERS

Before starting the drivers the control levers must be in upright


position (zero position).
The control lever in the left-hand desk controls luffing of the jib and
slewing of the crane.
The control lever in the right-hand desk controls the hoisting gear.

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STARTING

Turn switch 26 into „ON“ – position, the electric drive motors


will start up.
After abt. 15 secs, crane is ready for operation. Readiness for
operation is indicated by signal lamp inside the switch 26
and also on the display

HORN

A warning signal must be given with the horn (left control lever) in the
driver's cabin before the crane is to start so that any persons in the
danger zone (e.g. area of work / slewing range) can leave the area in
good time.

STOP

Switch off drive motors by turning switch 26 into „OFF“ - position

If the temperature sensor has switched on the cooling plant, booster


pump, hydraulic oil cooler and engine room ventilator keep on running
until the oil temperature has dropped down to below 50*C.The drives
are shut off after 10 mins at the latest.

EMERGENCY-OFF push-button

The crane must be switched off with the EMERGENCY-OFF


^ button 20 in case of an emergency or a dangerous situation, e.g.
if the crane drives do not follow the commands of the crane's
control levers.

The EMERGENCY-OFF button must never be used for switching


the crane off when it is operating normally.

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FAULT – Indication signal lamp

Signal lamp 28 is a collective alarm which lights up if one part of the


system is defective, or if a function is disturbed.

The reason of this fault is indicated on the DISPLAY.

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3.2.2 CONTROL LEVER (JOY STICKS)

LUFFING IN AND OUT OF THE JIB

Push control lever in l.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

SLEWING TO LEFT AND RIGHT

Push control lever in l.h. control desk toward l.h. or r.h. side.
The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

LIFTING AND LOWERING OF LOAD

Push control lever in r.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

If loads are small or if there is no load on the hook at all and the
Control lever is pushed right backward or forward, the hoisting speed is
automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever
must be reduced.

SLEWING

SLEWING TO LEFT AND RIGHT

Push control lever in l.h. control desk toward l.h. or r.h. side.
The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK:

Excursion angle to the left = slewing to the left


Excursion angle to the right = slewing to the right

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

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LUFFING IN AND OUT

LUFFING IN AND OUT OF THE JIB

Push control lever in l.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK:

Excursion angle forward = jib lowering


Excursion angle to the back = jib lifting

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

JIB STOPPED AUTOMATICALLY

LIFTING OR LOWERING STOPPED AUTOMATICALLY.

The end positions have been reached and cannot be overrun.

The limit position will be indicated on the DISPLAY.

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LIFTING AND LOWERING

LIFTING AND LOWERING OF LOAD

Push control lever in r.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.
If loads are small or if there is no load on the hook at all and the control lever is pushed right backward or
forward, the hoisting speed is automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever must be reduced.

CONTROL LEVER IN THE RIGHT-HAND DESK:

Excursion angle forward = crane hook down


Excursion angle to the back = crane hook up

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

CRANE HOOK STOPPED AUTOMATICALLY

CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.

The end positions have been reached and cannot be overrun.

The limit position will be indicated on the display.

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3.2.3 INTERACTIVE DIALOGUE SYSTEM ( DISPLAY )


A display is installed in the r.h. control desk, it is an interactive system divided in 2 menue areas.

Menue area 1 is for crane informations only, the information area will be automatically displayed

• progress of starting / shut down


• main operation data (e.g. load indication,
outreach indication)
• operation conditions (e.g. lifting limitation)
• possible system faults
• additional informations (e.g. oil temperature,
working hours, system pressures / must be
selected)

Menue area 1 with selected ACTUAL LOAD shows the information in detail

OPERATION SELECTED MENUE

• Actual Load
• Additional safety working load
• Additional outreach

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Condition information will be automatically displayed - .the message shows the reason for a possible crane
operation restriction.

CONDITION

• CONDITION code and text announcement


• Detailled informations are given in the elec-
trical manual

Menue area 2 is a code secured service menue, it must be activated - the functions are described in the
electrical maual ( part 5 ).

SERVIVE MENUE

• parameter setting
• activation of special conditions
• emergency opreation system

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3.3 CRANE OPERATION

3.3.1 SAFETY REGULATIONS

The crane may only be put into operation by a TRAINED CRANE OPERATOR (ship’s crew) after he has
convinced himself that the crane is in orderly condition, i.e. :

♦ all repairs and maintenance work required to ensure that the craneis completely operable and safe have
been completed,

♦ all working areas are adequately illuminated during the hours of darkness,

♦ all drives and safety devices are complete and in good working order,

♦ all brakes are in good working order and the crane responds to the controls,

♦ none of the safety devices are in override status.

All drives must be switched off before the crane driver leaves the cabin.

The crane driver must not leave the crane during operation without first handing over control to a suitable
authorized relief driver. This must be done while there is no load suspended from the hook. The relief of a
crane driver is to be entered in the crane record book as a special incident.
lf a driver is on the crane, other persons may enter and leave the crane only with the agreement of the crane
driver and while the crane is stationary.
The specified safe working load of the crane shall on no account be exceeded.
Safety devices must not be rendered inoperable or tampered with.
The crane must be put out of operation immediately if brakes or limit switches fail.

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3.3.2 SETTING OF GRAB/HOOK OPERATION

For a change from grab to hook operation please see sketches below:

Sketch 1 : Hook Block for Hook operation


Sketch 2 : Hook Block with wire ring and chain lug of the grab

Sketch 1 Sketch 2

Grab operation will be selected by KEY-SWITCH 31.


During grab operation the maximum load is limited from 30 tons down to 25 tons.

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3.3.3 PUTTING INTO OPERATION

SWITCH ON SUPPLY FROM SHIP’S MAINS.

Switch on crane control (power supply) with the main switch on the electrical control cabinet.

AIR SUPPLY

Make sure that air is supplied through crane column.


The bottom access door or the hatch must be opened to allow air to
get in.

THE AIR OUTLET OF THE OIL COOLER FAN IS COVERED´


BY A FLAP.
THIS FLAP MUST BE OPENED BEFORE THE CRANE WILL
BE STARTED.

Cabin door and hatch to winch platform must be closed during


operation.

CRANE - WORKING LIGHT

Switch on crane light.

HORN

A warning signal must be given with the horn (left control lever) in the
driver's cabin before the crane is to start so that any persons in the
danger zone (e.g. area of work / slewing range) can leave the area in
good time.

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STARTING

Turn switch 26 into „ON“ – position, the electric drive motors


will start up.
After abt. 15 secs, crane is ready for operation. Readiness for
operation is indicated by signal lamp inside the switch 26
and also on the display

Do not move the control lever out of zero position before


< READY FOR OPERATION > is displayed.

If the crane drives have been stopped by an emergency condition, the


start switch must be turned into OFF first before the drives can be
started.

EMERGENCY-OFF push-button

The crane must be switched off with the EMERGENCY-OFF


^ button 20 in case of an emergency or a dangerous situation, e.g.
if the crane drives do not follow the commands of the crane's
control levers.

The EMERGENCY-OFF button must never be used for switching


the crane off when it is operating normally.

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SLEWING

SLEWING TO LEFT AND RIGHT

Push control lever in l.h. control desk toward l.h. or r.h. side.
The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK:

Excursion angle to the left = slewing to the left


Excursion angle to the right = slewing to the right

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

LUFFING IN AND OUT

LUFFING IN AND OUT OF THE JIB

Push control lever in l.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK:

Excursion angle forward = jib lowering


Excursion angle to the back = jib lifting

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

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JIB STOPPED AUTOMATICALLY

LIFTING OR LOWERING STOPPED AUTOMATICALLY.

The end positions have been reached and cannot be overrun.

The limit position will be indicated on the DISPLAY.

LIFTING AND LOWERING

LIFTING AND LOWERING OF LOAD

Push control lever in r.h. control desk either forward or backward.


The speed is infinitely variable.
The drive speed is adapted using a ramp time function.
If loads are small or if there is no load on the hook at all and the control lever is pushed right backward or
forward, the hoisting speed is automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever must be reduced.

CONTROL LEVER IN THE RIGHT-HAND DESK:

Excursion angle forward = crane hook down


Excursion angle to the back = crane hook up

Wide excursion angle = quick movement


Narrow excursion angle = slow movement

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CRANE HOOK STOPPED AUTOMATICALLY

CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.

The end positions have been reached and cannot be overrun.

ATTENTION
If outreaches are small, care must be taken to work with utmost caution
in order to avoid damage to the cra-ne tower and in particular to the cabin.
The working movements of the lifting and luffing gears are limited by
Limit switches.
Before reaching a limit position, all speeds are reduced automatically.
The limit position will be indicated on the DISPLAY

NOTE

WORKING MOVEMENT LIMIT SWITCHES ARE SAFETY DEVICES


AND SHOULD NOT BE ACTUATED IN NORMAL OPERATION.

ATTENTION

THE INSTRUCTIONS CONTAINED IN THE DESCRIPTIONS OF THE


ELECTRICAL AND HYDRAULIC PLANTS ARE AN INTEGRAL PART
OF THE OPERATION MANUAL AND MUST BE STRICTLY
OBSERVED.

GRAB OPERATION

With the key-operated switch in the r.h. control desk the crane operation can be selected between hook
operation and grab operation.
In grab operation the maximum load capacity will be limited up to 25 tons.

The grab can be closed / opened by means of the hoisting gear control lever:
♦ Push the control lever into direction left for grab closing.
♦ Push the control lever into direction right and additionally press the button on the control lever handle
for grab opening.

OVERLOAD INDICATION

If the maximum lifting capacity ( SWL ) of the crane is exceeded,


the lifting and luffing-out procedure is blocked, this will be indicated
on the DISPLAY.

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FAULT - INDICATION SIGNAL LAMP (SIGNAL LAMP 28)

Signal lamp 28 is a collective alarm which lights up if one part of the


system is defective, or if a function is disturbed.
Please refer to the numbers on the inside of the control cabinet door
to find out the cause for the alarm, then refer to description of electrical
equipment and list given there for details.

The reason of this fault is indicated on the DISPLAY.

ATTENTION

The instructions contained in the descriptions of the electrical and


hydraulic plants are an integral part of the operation manual and must be
strictly observed.

STOP

Switch off drive motors by turning switch 26 into „OFF“ - position

If the temperature sensor has switched on the cooling plant, booster


pump, hydraulic oil cooler and engine room ventilator keep on running
until the oil temperature has dropped down to below 50*C.The drives
are shut off after 10 mins at the latest.

♦ Close cabin window.


♦ Switch off cabine fan, working light and cabin light.
♦ Switch off crane control ( voltage supply ) with main switch in control cabinet.
♦ When leaving crane, lock doors and hatches properly.

NOTE :

SUPPLY VOLTAGE FOR LIGHTING AND HEATING MUST REMAIN SWITCHED-ON DURING STANDSTILL
OF THE CRANE.

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3.3.3.1 TANDEM OPERATION MODE OF DECK CRANES

Prior to lifting a load with two (or more) cranes, the signal person and the crane drivers have to agree upon
signals and all operational steps. It is the signal person´s task to survey all operation.

During operation, the crane drivers strictly have to adher to the instructions of the signal person who has to
observe the load permanently.

The heavy-load-cross beam (item 1) is designed according to its specific operational conditions (such as
load capacity, arrangement of hooks, length of cross beam) and minimizes the total lifting capacity of the
cranes for tandem operation by its own weight.

The heavy-load-cross beam must always be kept in horizontal position !

In any case, the hoisting wire ropes must be operated vertically only (no slanting pull !)

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3.3.4 CLOSING DOWN

(SEE “CRANE OPERATION“ FOR SAFETY REGULATIONS)


ALL FUNTIONS AND SWITCHES ARE DESCRIBED IN CHAPTER “PUTTING INTO OPERATION“..

STARTING

Turn switch 26 into „ON“ – position, the electric drive motors


will start up.
After abt. 15 secs, crane is ready for operation. Readiness for
operation is indicated by signal lamp inside the switch 26
and also on the display

♦ Bring crane into sea voyage position - luff-down jib ( bridge limit switch with key-operated button 30 )
♦ Crane hook must be empty.

ATTENTION :

BRIDGING-OVER WITH KEY-OPERATED SWITCH 30 PUTS LIMIT SWITCHES FOR LIMITATION


OF HOISTING AND LUFFING MOVEMENTS OUT-OF-ACTION.
THE CRANE MUST BE OPERATED WITH THE UTMOST CARE. THE JIB MUST NEVER BE LUFFED
DOWN FURTHER THAN SPECIFIED IN THE TECHNICAL DATA (GENERAL ARRANGEMENT
DRAWING), AS THIS MAY DAMAGE THE JIB OR REEL THE LUFFING ROPE COMPLETELY OFF THE
DRUM.

♦ Lash crane hook.


♦ Pull ropes to tighten them slightly.

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STOP

Switch off drive motors by turning switch 26 into „OFF“ - position

If the temperature sensor has switched on the cooling plant, booster


pump, hydraulic oil cooler and engine room ventilator keep on running
until the oil temperature has dropped down to below 50*C.The drives
are shut off after 10 mins at the latest.

♦ Close cabin window.


♦ Switch off cabine fan, working light and cabin light.
♦ Switch off crane control ( voltage supply ) with main switch in control cabinet.
♦ When leaving crane, lock doors and hatches properly.

NOTE :

SUPPLY VOLTAGE FOR LIGHTING AND HEATING MUST REMAIN SWITCHED-ON DURING STANDSTILL
OF THE CRANE.

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7/3165-7/3168 MAINTENANCE

4. MAINTENANCE
INDEX
4. MAINTENANCE 1
4.1 GENERAL REMARKS 3
4.1.1 CHECKING OIL LEVELS, OIL CHANGES 4
4.1.2 VISIBLE OIL LOSSES 4
4.1.3 OILS, GREASES AND HYDRAULIC OILS 4
4.1.4 FILTERS 4
4.1.5 SEALS AND GASKETS 4
4.1.6 SEALING SURFACES 4
4.1.7 THREADED PIPE CONNECTORS; HOSES 4
4.1.8 GREASE LUBRICATION 4
4.1.9 GREASING 5
4.1.10 MARKING OF PARTS 5
4.1.11 REPLACEMENT UNITS 5
4.1.12 AFTER MAINTENANCE WORK 5
4.1.13 INSPECTION OF THE HOOK 5
4.1.14 ROPE - HOISTING AND LUFFING ROPES 6
4.1.15 ROPE - INSPECTION 8
4.1.16 MULTI-DISK BRAKES / MOTOR SHAFT DOG 9
4.1.17 SLEWING GEAR 10
4.1.17.1 GENERAL INFORMATION 11
4.1.17.1.1 MANUAL AIM 11
4.1.17.1.2 INFORMATION ON SAFETY 11
4.1.17.1.3 PRODUCT IDENTIFICATION 12
4.1.17.2 NOTES 13
4.1.17.2.1 DELIVERY CONDITIONS 13
4.1.17.2.2 TRANSPORT 13
4.1.17.2.3 STORAGE 14
4.1.17.3 LIFTING AND HANDLING 15
4.1.17.4 INSTALLATION 16
4.1.17.4.1 HYDRAULIC MOTOR INSTALLATION 16
4.1.17.4.2 INSTALLATION OF THE SLEW DRIVE ON THE MACHINE 17
4.1.17.4.3 CONNECTION OF THE BRAKE 18
4.1.17.4.4 CONNECTIN OF THE DRAINING PORT 19
4.1.17.4.5 REPLACING OF THE BREATHER VALVE AS LOOSE PART 19
4.1.17.5 LUBRICATION 20
4.1.17.5.1 GEARBOX LUBRICATION 20
4.1.17.5.2 OIL FILLING 21
4.1.17.5.3 OIL DRAINING AND REPLACEMENT 21
4.1.17.6 START UP AND RUNNING IN 22
4.1.17.7 MAINTENANCE 23
4.1.18 HOISTING AND LUFFING GEAR 24
4.1.18.1 WINCH DRIVE – 7C SERIES 25
4.1.18.1.1 MANUAL AIM 25
4.1.18.1.2 INFORMATION ON SAFETY 26
4.1.18.2 PRODUCT IDENTIFICATION 27
4.1.18.2.1 PRODUCT DESCRIPTION 28
4.1.18.3 NOTES 29
4.1.18.3.1 DELIVERY CONDITIONS 29
4.1.18.3.2 TRANSPORT 29
4.1.18.3.3 STORAGE 30
4.1.18.3.4 LIFTING AND HANDLING 30
4.1.18.4 INSTALLATION 31
4.1.18.4.1 DIRECTION OF ROTATION 31
4.1.18.4.2 CONSTRUKTION OF THE DRUM FRAME 32
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4.1.18.4.3 HYDRAULIC MOTOR INSTALLATION 33


4.1.18.4.4 INSTALLATION OF THE GEARBOX ON THE WINCH 36
4.1.18.4.5 CONNECTION OF THE BRAKE 37
4.1.18.5 LUBRICATION 38
4.1.18.5.1 GEARBOX LUBRICATION 38
4.1.18.5.2 OIL FILLING 39
4.1.18.5.3 OIL DRAINING AND REPLACEMENT 40
4.1.18.6 START UP AND RUNNING IN 41
4.1.18.7 MAINTENANCE 42
4.1.18.7.1 TROUBLE SHOOTINGS 43
4.1.19 GREASING POINTS – CRANE 46
4.1.20 OIL CHANGE 47
4.2 MAINTENANCE SCHEDULE 48
4.3 LUBRICANTS 50
4.4 ELECTRICAL EQUIPMENT 51
4.4.1 SAFETY DEVICES 51
4.4.2 LIGHTING 52
4.4.3 MOTORS 52
4.4.4 SLIPRING BODIES 52
4.4.5 CIRCUIT BREAKERS 52
4.5 HYDRAULIC EQUIPMENT 54
4.5.1 FUNCTIONAL DESCRIPTION 57
4.5.1.1 HOISTING GEAR CIRCUIT 1.0 57
4.5.1.2 LUFFING GEAR CIRCUIT 2.0 59
4.5.1.3 SLEWING GEAR CIRCUIT 3.0 59
4.5.1.4 BOOSTING AND CONTROL OIL CIRCUIT 4.0 60
4.5.1.5 OIL COOLING 5.0 63
4.5.1.6 HYDRAULIC OIL TANK 6.0 63
4.5.1.7 FILLING 7.0 63
4.5.1.8 EMERGENCY OPERATION 8.0 64
4.5.2 GENERAL REMARKS 66
4.5.2.1 PUTTING SYSTEMS INTO OPERATION (BY WORKS PERSONNEL) 68
4.5.2.2 INSPECTION AND MAINTENANCE 69
4.5.2.3 OPERATION AND MAINTENANCE OF HYDRAULIC PUMPS AND
MOTORS 72
4.5.2.3.1 GENERAL REMARKS 72
4.5.2.3.2 INSTALLATION 72
4.5.2.3.3 FIRST START 72
4.5.2.3.4 ROUTINE MAINTENANCE 73
4.5.2.4 TROUBLESHOOTING 73
4.5.2.5 TROUBLESHOOTING 74
4.6 ASSEMBLY AND DISMANTLING 79
4.6.1 GENERAL REMARKS 79
4.6.2 ROPE REPLACEMENT 82
4.6.3 HAND SIGNALS FOR CRANES 85
4.6.4 TIGHTENING TORQUES FOR HEXAGON BOLTS AND SPANNER BOLTS 86
4.6.5 INSTALLATION OF HOSES 87

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4.1 GENERAL REMARKS


The relevant official regulations, particularly those relating to accident prevention, must be observed during
repairs and maintenance work.

ATTENTION!
THE INSTRUCTIONS SAFETY REGULATIONS MUST ALSO BE OBSERVED DURING MAINTENANCE
WORK!

Crane maintenance work must be assigned only to suitable, reliable personnel who are familiar with the op-
eration of the crane and its mechanical and electrical assemblies.

The same personnel must also monitor the condition of the whole plant, ensure that it is adequately lubri-
cated and, in particular, regularly check the condition of the brakes and safety devices. In particular, these
persons must report all plant malfunctions to the supervisor concerned. They must immediately stop the
operation of the crane if brakes or safety devices fail.

Safe operation and the service life of the equipment depend greatly on standards of maintenance.

BEFORE STARTING MAINTENANCE WORK


Scrupulous cleanliness and reasonable planning are prerequisites for all successful maintenance work.

All units in the vicinity of the work area must be cleaned before work starts. The cleansing agent must be
chosen to suit the material of which the units are made.

Example: Solvents or a steam lance must not be used to clean


rubber or electrical components.

When dismantling equipment, blank off all open holes, connections, casings, etc., in a way suitable to pre-
vent dirt from entering them. All parts that have been removed must be protected from rust, dirt and damage
if work is interrupted for a considerable period. Use only lint-free cleaning rags, especially when working on
hydraulic systems.

Secure drives to prevent unauthorized or unintended starting.

ATTENTION
DO NOT ALTER THE NOMINAL PRESSURES OF PRESSURE LIMITING VALVES WITHOUT THE
EXPRESS AGREEMENT OF TTS - LMG.
DO NOT REMOVE SEALS FROM PRESSURE LIMITING VALVES.

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4.1.1 CHECKING OIL LEVELS, OIL CHANGES


Change oil while the equipment is still warm from operation because warm oil can be drained off more easily.
The suspended solids contained in warm oil, such as oil coke, wear particles, etc., settle to the bottom of the
sump if the equipment is not used for some time and do not flow out if the oil is cold. Use only lint-free rags
to wipe the dip-stick.

DANGER
Hot lubricating or hydraulic oil flowing out without control can cause serious scalds.

4.1.2 VISIBLE OIL LOSSES


lf lost oil is visible, check the oil level in the unit concerned at shorter intervals and add oil if necessary. Lo-
cate and rectify the cause of the loss.

4.1.3 OILS, GREASES AND HYDRAULIC OILS


lf oil or grease grades are changed for technical or other reasons, the qualities and viscosities of the re-
placements must be identical to those recommended.

4.1.4 FILTERS
All filters and filter cartridges must be changed at the specified intervals unless cleaning is expressly permit-
ted. All filters are carefully matched to the equipment they serve. Only the use of original parts from TTS-
LMG
will ensure trouble-free operation and a long service life.

4.1.5 SEALS AND GASKETS


Pay attention to seals and gaskets when removing items such as covers, screw plugs, etc.
Inspect all seals carefully before use, and use new ones if possible. Make sure they are correctly seated
when fitting them.

4.1.6 SEALING SURFACES


Clean sealing surfaces before assembling the parts.
Check that joints do not leak after assembly.

4.1.7 THREADED PIPE CONNECTORS; HOSES


Relieve the pressure before tightening leaking screw plugs. Replace hydraulic hoses at the first sign of dam-
age or oil penetration.
Repair leaks in piping systems at the earliest opportunity.
FASTENERS
Check all fasteners and their components (nuts, bolts, circlips, washers) before re-use. Replace them if
necessary.
BOLTED JOINTS
All mating surfaces must be flat and free from paint, grease, acids, dirt and rust.

4.1.8 GREASE LUBRICATION


Clean grease fittings before greasing according to schedule.

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4.1.9 GREASING
Grease all exposed metallic surfaces of machine components at regular intervals to prevent by rust.

4.1.10 MARKING OF PARTS


Replace defective parts in good time to avoid more serious damage. To facilitate reassembly, mark all parts
in the correct order during dissassembly.

4.1.11 REPLACEMENT UNITS


These must be serviced at the same intervals as the units they replace.

4.1.12 AFTER MAINTENANCE WORK


ATTENTION
REPLACE ALL GUARDS AFTER THE WORK IS FINISHED.

Check that the units function correctly.


Observe environmental protection regulations when disposing of oil, grease, cleaning fluids or oil-
contaminated components such as filter cartridges.

4.1.13 INSPECTION OF THE HOOK

The cargo hook must be checked by an appropriately trained and authorized engineer at once a year. The
measured values are to be entered in the crane record book.

1. The distances y1 and y2 are to be measured at the hook mouth.


Item 1 - punch mark
Item 2 - marking on cargo hook
2. Check the root of the thread, the shaft and the hook surface for cracks.
3. Welding work on cargo hooks, for instance to build up worn surfaces, is forbidden !

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4.1.14 ROPE - HOISTING AND LUFFING ROPES


The exterior of the wire rope must be cleaned and regreased every three months. The ropes must be in-
spected before this is done.

Always wear leather gloves when handling wire ropes.

To grease a whole rope, the whole length of the rope must be removed and laid out. However, it must not be
dragged along the ground because otherwise dirt and foreign bodies will adhere to it. This will increase the
rate of wear.

lf the whole length of the rope is not removed and laid out, the grease should be applied by brush where the
rope runs round the drum or a pulley and the strands are forced slightly apart. This will allow the grease to
penetrate into the rope more easily.

Care must be taken to handle the rope properly when removing a rope and when installing a new one.

UNLOADING STORING

Use web slings to unload steel wire Ropes should be stored in a clean,
ropes. The hook of a crane or the cool and dry place. They must be kept
prong of a fork-lift truck might damage clear of the floor. Ropes stored out-
the rope. side must be protected against rain.

UNCOILING UNREELING

Uncoil wire rope by using an uncoiling Unreel wire rope by using an un-
stand or by rolling the coil along the reeling stand.
ground. Make sure the ground is clean.

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AVOIDING KINKS COILING

Never unwind wire ropes without rotating The rope should travel from the
the coil or reel, otherwise the rope will top of the reel to the top of the
tend to form loops during installation or in drum or from the bottom of the
service. When pulled taut, the loops form reel to the bottom of the drum. A
kinks. reverse bend will create problems.

INSTALLATION BREAKING IN

Ropes should be installed under tension. The first operations with a new
rope should be carried out with
low loads.
INSPECTION LUBRICATION
IN SERVICE

Inspect steel wire ropes regularly. Keep record of Lubrication helps prevent
the rope diameter, the lay length, broken wires or corrosion and reduces
other defects. Discard the rope in time (while it is friction. Steel wire ropes
still safe). should be lubricated at
regular intervals.

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4.1.15 ROPE - INSPECTION


The ropes must be inspected every three months.

Rope inspection books must be kept for all ropes. The results of each inspection must be recorded in these
books, which must also contain the works certificates supplied by the rope manufacturer.

The supervisor entrusted with the inspection must ascertain the general condition of the rope by
inspecting its whole length.

THE FOLLOWING FINDINGS MUST BE RECORDED:


♦ wear of external wires
♦ rust
♦ loosening of the structure
♦ changes in shape
♦ crushed wires and strands
♦ damage to seizings.

The rope must be freed from grease and dirt in several places for the inspection.

During intermediate inspections, attention must be given especially to parts of the rope that run over
pulleys or are close to rope suspension or rope attachment points.
It broken wires are found, the rope must be compared with the values given in the tables "Readiness for
discarding of wire ropes on the basis of wire breaks" in DIN 15020, part 2, and scrapped if necessary.

ROPES MUST BE REJECTED IF THE FOLLOWING FORMS OF DAMAGE ARE FOUND :

Wire rope with corkscrew shaped deformation Wire rope with basket formation

Wire rope with loop formation of wires Wire rope with nodes

Wire rope with slackened wires due to corrosion and Wire rope with contraction
abrasive wear

Wire rope with knot Wire rope with kink

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4.1.16 MULTI-DISK BRAKES / MOTOR SHAFT DOG

1 Brake piston 2 Brake cylinder


3 Disk carrier 4 Internal disks
5 External disks 6 Sealing ring
7 Sealing ring

The brakes on the hoisting, luffing and slewing gears


are multi-disk brakes which are lifted hydraulically and
applied by spring tension. The hydraulic systems of
these brakes ensure that they are not applied until the
drive speed has dropped to zero.

The brakes are not intended to dissipate energy , but


only to apply a holding torque. The disks are not sub-
ject to wear under these conditions.However, they are
applied instantly in the event of power failures or if an
emergency OFF button is pressed, without having to
ramp the drive speed down to zero beforehand. Under
these circumstances they dissipate energy and are
subject to considerable wear. The brakes must be
checked after only a few such braking operations.
The brakes are designed to run "dry". Nevertheless,
small amounts of oil seep past the sealing ring (6) and
enter the disk space. In the case of slewing gears, the
see page oil must be drained off every three months.

The following procedure should be used to check the holding torque of the brakes:
♦ Luff the jib to its minimum outreach.
♦ Take any load off the hook - hook must be empty.
♦ Check the slewing gear at a heel of 5° with the jib parallel to the ship´s centreline.
♦ Pull the plug of the brake valve out to prevent the brake from lifting.
Activate the drives for about 5 sec. The maximum pressure corresponding to the maximum torque must be
built up within this time. The winches (or the slewing gear of the crane) must not move !
The holding torque should be checked every three month. Operation must be stopped after power failures
and emergency OFF actuation until brake torque has been checked.
After repair, fill the spring pressure actuated multi-disc brake of the slewing,hoisting and Luffing gear with
oil (AUTOMATIC TRANSMISSION FLUID) (cf. chapter 4.1.17 and 4.1.18).
The brakes must be overhauled annually.
The disk packs must be replaced if wear is excessive. Sealing rings 6 and 7 should be replaced if leaks
become apparent (e.g. excessive seepage oil is found).
When checking the brakes the spline profiles of motor and gear reducer should be checked for wear at the
same time. If the dog/motor is replaced or refitted, a suitable grease should be applied to prevent fretting
corrosion. We recommend to use Gleitmo 805 or similar.

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4.1.17 SLEWING GEAR

ATTENTION
Oil level must only be inspected with non-running
gear.

THE BRAKE MUST BE FILLED WITH APPROX.


0,2ltrs GEAR OIL ATF A PRIOR TO MOUNTING
THE MOTOR

1 Oil filling and breather valve (setting 0,35bar)


2 Oil level plug
3 Oil draining plug
4 Brake port

OIL CHANGE
First oil change after 200 crane operating hours. After every 1000 hours, oil should be changed again, but at
least once a year.

OIL CHANGE :
See instruction of manufacturers

OIL TYPE
Gear oil CLP 220 (see lubrication chart section 4.3)

OIL QUANTITY
2 gearboxes with abt. 12 l each – in total 24 l.

The hydraulically lifted disc brake has to be filled with 1 ltr. oil when fitting the engine. Suitable are above all
hydraulic oil scustomary in commerce relatively to friction, coking of the oil, foam formation, a.s.o.
Oil type (multi-disk brake): See instruction of manufacturers

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4.1.17.1 GENERAL INFORMATION

4.1.17.1.1 MANUAL AIM

This manual has been devised by the manufacturer to give necessary information to those
authorised to work on this product for example the design engineers,
installers, repair and maintenance technicians.

Besides helping one understand the rules of good manufacturing techniques used, the information given
must be read attentively and strictly put into action.

Failure to observe this information may lead to health and safety risks to persons as well as economic loss.

INFORMATION!
A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL
MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE.

Photographic documentation and drawings are supplied for educational purposes, so as to safely and prop-
erly carry out maintenance operations.
Minor deviations from pictures of this manual may appear on the actual gearbox. However, these
discrepancies are not relevant to the main parameters, or maintenance functions.

4.1.17.1.2 INFORMATION ON SAFETY


Carefully read the instructions given in this instruction manual as well as the ones attached to the product
and make sure to follow the information concerning safety.

Personnel, which perform any type of work on the product during its life span, must possess precise
technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do
so may lead to health and safety risks to persons.

It is recommended that when handling the product attention is paid to the information given in this
manual or simply follow the instructions given on the packaging (if present).

Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to
health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee
given by the manufacturer.

Keep the product in perfect working order by following the scheduled maintenance procedure set
out by the manufacturer. Good maintenance will ensure the best performances, a longer period of
operation and a constant safeguard towards security requirements.

To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is
important to follow adequate safety conditions for one self and for others in compliance with the rules and
regulations that govern safety in the workplace.

When replacing worn parts, use original spare parts. Use oils and greases recommended by the
manufacturer. Doing this, will ensure that the product works properly and that the safety level is "acceptable".

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4.1.17.1.3 PRODUCT IDENTIFICATION


The identification data of the unit are shown on a name plates put on it.

INFORMATION!
FOR ALL ENQUIRIES REGARDING GENERAL INFORMATION ON THE PRODUCT, SPARE PARTS,
ASSITANCE, ALWAYS GIVE THE IDENTIFICATION DATA STAMPED ON THE ID PLATE. THE PLATE
MUST BE REMOVED OR DAMAGED DURING THE LIFE OF THE PRODUCT.

The following illustration shows how the data is set out

For all requests for assistance please contact the manufacturer's sales network, directly.

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4.1.17.2 NOTES

4.1.17.2.1 DELIVERY CONDITIONS


Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions:
Ready for installation in the mounting position specified when ordering.

Factory filled with lubricanting oil at level:


oil type SHELL SPIRAX A 80W-90

All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants.
External surfaces are protected with an antioxidant water resistant grey color and painted with a
blue synthetic finish coat (painting data are shown on the installation drawing).

Machined surfaces are not painted.


Tested toin-house specifications.
Appropriately packaged to facilitate handling, transport and storage.

INFORMATION!
WHEN THE PRODUCT ARRIVES, ENSURE THAT IT MEETS THE INFORMATION CONTAINED IN THE
PURCHASE AGREEMENT AND THAT THERE ARE NO DAMAGES OR IRREGULARITIES. IF THERE
ARE ANY PROBLEMS CONTACT THE MANUFACTURERS' SALES NETWORK DIRECTLY.

4.1.17.2.2 TRANSPORT
We recommend that the box containing gearboxes is handled carefully in order to avoid damages during
transport. When removing gearboxes from their packaging, extra caution should be taken to avoid impacts,
which may damage sensitive parts. The illustrations show the more common types of packaging.

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4.1.17.2.3 STORAGE
OBSERVE THE FOLLOWING INSTRUCTIONS TO ENSURE CORRECT STORAGE OF DELIVERED
PRODUCTS:

1. Do not store outdoors, in areas exposed to weather or with excessive humidity.


2. Always place boards of wood or other material between floor and products, to avoid direct contact
with the floor.
3. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and cou-
plingsmust be protected with a suitable anti-oxidation product (SHELL ENSIS FLUID SDC or
equivalent product).

THE FOLLOWING MEASURES MUST BE TAKEN FOR PRODUCTS WHICH EXPECTED STORAGE
PERIOD EXCEEDS 6 MONTHS:

4. Cover outer machined parts and mating parts with grease to avoid oxidation.
5. At the slew drive installation on the machine frame replace the plug with breather valvesupplied as
loose part.

INFORMATION!
BEFORE USE, THE GEARBOXES SHOULD BE FILLED WITH THE PROPER AMOUNT OF LUBRICANT
OF THE RECOMMENDED TYPE.

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4.1.17.3 LIFTING AND HANDLING


If the handling occurs when the product is still packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.

WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.

TO LIFT AND HANDLE THE PRODUCT, AFTER HAVING OPENED THE PACKAGING, FOLLOW THE
INFORMATION GIVEN BELOW:

1. Unscrew the nos.4 screws and remove the closing plate from the motor adapror flange.
2. Tighten nos.2 eyebolts at 180° on the thread holes of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.

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4.1.17.4 INSTALLATION

4.1.17.4.1 HYDRAULIC MOTOR INSTALLATION


The mating areas and the pilot diameter of the gearbox where the motor is to be mounted must be clean and
without burrs.

1. Fit the O-ring seal, supplied with the gearbox, in its seat in the hydraulic motor, and assemble it to
the gearbox being careful not to damage the seal already fitted.
2. Assemble the hydraulic motor to the gearbox frame by using the screws shown in the following table

INFORMATION!
UNDER NO CIRCUMSTANCE REMOVE THE PLASTIC LID FROM THE POWER SUPPLY PORTS OF
THE HYDRAULIC MOTOR; THIS WILL HELP AVOID THE ACCIDENTAL INTRODUCTION OF FOREIGN
BODIES INTO THE MOTOR, UNTIL THE HOSES ARE ASSEMBLED.

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4.1.17.4.2 INSTALLATION OF THE SLEW DRIVE ON THE MACHINE


1. Move the slew drive in the mounting area applying lifting methods shown in section 3.4.
2. Clean the mating surfaces from oils or paint and fit the slew drive on the machine frame
(for the correct orientation refe to the installation drawing).
3. In case the pinion shaft-slew ring backlash has to be increased or decreased, turn the eccentric
gearbox housing on the machine frame (see installation drawing).
4. Fix the slew drive to the machine frame by using the screws shown in the following table

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4.1.17.4.3 CONNECTION OF THE BRAKE


The gearbox drive is supplied with a safety negative multidisc brake hydraulically driven
(parking brake). For information regarding the characteristics of the brake, port types and
dimensions, refer to the installation drawing.

1. To operate the brake, connect the brake pilot pipe to the brake port.

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4.1.17.4.4 CONNECTIN OF THE DRAINING PORT


INFORMATION!
IF THE FRAME OF THE MACHINE DOES NOT ALLOW THE ACCESS TO THE PLUG, IT IS
NECESSARY, DURING THE SLEW DRIVE INSTALLATION, TO FIT AN EXTENTION WHICH TAKES THE
OIL AWAY FROM THE MACHINE.

1. Remove the drain plug and screw on a pipe to the drain port(for hose size and dimension refer to
the installation drawing).

4.1.17.4.5 REPLACING OF THE BREATHER VALVE AS LOOSE PART


At the slew drive installation on the machine frame replace the plug with breather valve supplied
as loose part.

1. Tigthen the brather valve supplied as loose part(for size and dimension refer to the installation
drawing).

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4.1.17.5 LUBRICATION

4.1.17.5.1 GEARBOX LUBRICATION


The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing.
The gearbox is factory filled with lubricanting oil at level.
Oil type: SHELL SPIRAX A 80W-90 (specified when ordering).

Otherwise, the recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP
characteristics according to: MIL-L-2105 C & API GL5.

In the following table the most common brands of lubricant and the types recommended are shown.

INFORMATION!
DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

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4.1.17.5.2 OIL FILLING


1. Unscrew the FILLING LEVEL OIL PLUG (2) and add the lubricating oil which has the
characteristics given in section 5.1.
2. By using the dipstick, check that the oil level is somewhere between the
MIN and MAX notch and then screw the plug back on.
3. Operate the slew drive, after a few minutes, stop and check the oil level.
4. If necessary, refill with lubricant oil. Size and dimension of plugs are shown on the
installation drawing.

APROXIMATE OIL CAPACITY LITERS ARE: 12 L ±10%

4.1.17.5.3 OIL DRAINING AND REPLACEMENT


1. Unscrew the DRAINING PLUG and let the oil flow in a large enough container; in order to facilitate
the draining it is better to operate with the oil still warm.
2. Wait a few minutes until all the oil is drained and then proceed to screw on DRAINING PLUG.
3. Proceed with the oil fill-up following the procedures given (see Section 5.2).

WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.

WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

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4.1.17.6 START UP AND RUNNING IN


In this first stage it is advised to follow the measures given below:

1. Check the correctly lubrication of the unit.


2. Bleed air from every part of the hyraulic and add oil in the tank if necessary.

INFORMATION!
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.

3. Start the gearmotor at a low speed and gradually increase it after having verified that
it is functioning correctly without any noises or vibrations.

INFORMATION!
DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.

During the running-in stage follow the steps given below.

4. Check the correct revolution and direction of rotation.


5. Make sure that the functioning is regular and with-out any excessive noises and vibrations.
6. Make sure that the oil temperature does not exceed 85-90°C intermittent.

After having terminated this first running-in follow the steps given below.

7. Check that there are no oil leakages. If present, proceed to remove them.
8. Check the level of lubricating oil in the gearmotor.

It could happen that due to the presence of air, during the first start up, the opening action of the
brake could be slowed down. It is advised to repeat the opening and closing function of the brake.

Check that there are no other problems in general

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4.1.17.7 MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and
oil changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation. For a proper maintenance of the gearbox, the following
checks and operations have to be done.

INFORMATION!

IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE


SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.

DO NOT HESITATE TO CONTATCT THE GEARBOX DISTRIBUTOR OR MANUFACTURER IF FURTHER


INSTRUCTIONS ARE NECESSARY OR IN
CASE OF PARTICULAR PROBLEMS.

This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL res-
res the right to implement modifications without notice. This manual cannot be reproduced, even partially,
without prior written consent.

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4.1.18 HOISTING AND LUFFING GEAR

ATTENTION !

Oil level can only be inspected with non-running gear

CHECK OIL LEVEL (LUFFING AND HOISTING GEAR)


If oil is below the oil level mark, oil must be added

OIL CHANGES ( LUFFING AND HOISTING GEAR )

First oil change after 150 crane operating hours.


After 1500 crane operating hours but at least once a
year further oil change.
Crane must be shut down
Oil must be warm as in operation
Oil drainage - loosen drain screw 3, drain oil into a
receptacle which is kept in readiness are visable.
Clean gear - Flush the gears with some of the new oil
(temperature abt. 80ºC), so that most of the dirt drains
off.
Fill in oil - tighten drain screw 3 (with new sealing ring)
Unscrew ventscrew 1, fill oil into opening 1. Check oil
Level - when the correct oil level 2 is reached, close
opening 1.

Oil change :
See instruction of manufacturers

Oil type :
Gear oil Synthetic CLP PG 220 (see lubrication chart
of manufacturer)

OIL QUANTITY :
Luffing gear abt. 6,0 l , hoisting gear abt. 6,0 l

1 Oil filling and breather valve (setting 0,4bar)


2 Oil level plug
3 Oil draining plug
4 Brake port

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4.1.18.1 WINCH DRIVE – 7C SERIES

Installation and service manual

GENERAL information

4.1.18.1.1 MANUAL AIM


This manual has been devised by the manufacturer to give necessary information to those authorised to
work on this product for example the design engineers, installers, repair and maintenance technicians.

Besides helping one understand the rules of good manufacturing techniques used, the information given
must be read attentively and strictly put into action.

Failure to observe this information may lead to health and safety risks to persons as well as economic loss.

INFORMATION!

A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL


MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE.

Photographic documentation and drawings are supplied for educational purposes, so as to safely and
properly carry out maintenance operations. Minor deviations from pictures of this manual may appear on the
actual gearbox. However, these discrepancies are not relevant to the main parameters, or maintenance
functions.

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4.1.18.1.2 INFORMATION ON SAFETY


Carefully read the instructions given in this instruction manual as well as the ones attached to the product
and make sure to follow the information concerning safety.

Personnel, which perform any type of work on the product during its life span, must possess precise
technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do
so may lead to health and safety risks to persons.

It is recommended that when handling the product attention is paid to the information given in this
manual or simply follow the instructions given on the packaging (if present).

Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to
health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee
given by the manufacturer.

Keep the product in perfect working order by following the scheduled maintenance procedure set
out by the manufacturer. Good maintenance will ensure the best performances, a longer period of
operation and a constant safeguard towards security requirements.

To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is
important to follow adequate safety conditions for one self and for others in compliance with the rules and
regulations that govern safety in the workplace.

When replacing worn parts, use original spare parts. Use oils and greases recommended by the
manufacturer. Doing this, will ensure that the product works properly and that the safety level is
"acceptable".

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4.1.18.2 PRODUCT IDENTIFICATION


The data to identify the product are shown on the identification plate attached to it.
The gearmotor has two plates, one gives data on the gearbox and the other data on the hydraulic motor.
The following illustration shows how the data is set out.

INFORMATION!

For all enquiries regarding general information on the product, spare parts, assitance, always give the
identification data stamped on the ID plate. The plate must be removed or damaged during the
life of the product.

The following illustration shows how the data is set out

For all requests for assistance please contact the manufacturer's sales network, directly.

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4.1.18.2.1 PRODUCT DESCRIPTION

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4.1.18.3 NOTES

4.1.18.3.1 DELIVERY CONDITIONS

Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions:

· Ready for installation in the mounting position specified when ordering.

· To guarantee their reliability, the internal parts are properly lubricated with a layer of oil, the same as
the one used in the final test of the gearbox and compatible with the recommended oils (section 5.1).
Lubricating oil has not been added (as shown on the card).

· All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants.
· External surfaces are protected with an antioxidant water resistant grey color suitable for finish painting.
Machined surfaces are not painted. Finish coat to be applied by the customer.
· Tested to in-house specifications.
· Appropriately packaged to facilitate handling, transport and storage.

INFORMATION!
When the product arrives, ensure that it meets the information contained in the
purchase agreement and that there are no damages or irregularities. If there are any problems
contact the manufacturers' sales network directly.

4.1.18.3.2 TRANSPORT

We recommend that the box containing gearboxes is handled carefully in order to avoid damages
during transport. When removing gearboxes from their packaging, extra caution should be taken to
avoid impacts, which may damage sensitive parts.
The illustrations show the more common types of packaging.

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4.1.18.3.3 STORAGE

Observe the following instructions to ensure correct storage of delivered products:

1. Do not store outdoors, in areas exposed to weather or with excessive humidity.

2. Always place boards of wood or other material between floor and products, to avoid direct contact
with the floor.

3. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and couplings
must be protected with a suitable anti-oxidation product
(SHELL ENSIS FLUID SDC OR EQUIVALENT PRODUCT).

The following measures must be taken for products


which expected storage period exceeds 6 months:

4. Cover outer machined parts and mating parts with grease to avoid oxidation.

5. Fill completely the gearboxes with lubticant oil.

INFORMATION!
BEFORE USE, THE GEARBOXES SHOULD BE FILLED WITH THE PROPER AMOUNT OF LUBRICANT
OF THE RECOMMENDED TYPE.

4.1.18.3.4 LIFTING AND HANDLING

If the handling occurs when the product is still


packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.

WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.

Handling should be undertakenwith maximum caution avoiding impacts.

WARNING!
UNDER NO CIRCUMSTANCE REMOVE THE PLASTIC LID FROM THE POWER SUPPLY PORTS OF
THE HYDRAULIC MOTOR; THIS WILL HELP AVOID THE ACCIDENTAL INTRODUCTION OF FOREIGN
BODIES INTO THE MOTOR, UNTIL THE HOSES ARE ASSEMBLED.

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4.1.18.4 INSTALLATION

4.1.18.4.1 DIRECTION OF ROTATION

THE CORRECT DIRECTION OF ROTATION OF THE DRUM AND THE MOTOR SHAFT IS SHOWN IN
THE SKETCH HERE FOLLOW

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4.1.18.4.2 CONSTRUKTION OF THE DRUM FRAME

CORRECT CONSTRUCTION OF THE DRUM FRAME AND RELATIVE COUPLING INDICATIONS ARE
SHOWN HERE FOLLOW.

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4.1.18.4.3 HYDRAULIC MOTOR INSTALLATION

The mating areas and the pilot diameter of the gearbox where the hydraulic motor is to be mounted
must be clean and without burrs.

INFORMATION!
BEFORE ASSEMBLING THE HYDRAULIC MOTOR, VERIFY BY A DEPTH SLIDE GAUGE THE
CORRECT ASSEMBLY OF THE UNIT CHECKING THE AXIAL DISTANCE AS SHOWN IN THE SCHEME
BELOW.

1. ASSEMBLE THE HYDRAULIC MOTOR WITH ITS O-RING SEAL TO THE GEARBOX.

2. TIGHTEN THE MOTOR SCREWS AT A TORQUE SHOWN ON THE FOLLOWING TABLE:

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4.1.18.4.4 INSTALLATION OF THE GEARBOX ON THE WINCH


1. MOVE THE WINCH DRIVE IN THE MOUNTING AREA APPLYING LIFTING METHODS SHOWN IN
SECTION 3.4.

2. CLEAN THE MATING SURFACES FROM OILS OR PAINT AND FIT THE GEARBOX ON THE
MACHINE
(FOR THE CORRECT ORIENTATION REFE TO THE INSTALLATION DRAWING).

3. FIX THE GEARBOX TO THE WINCH FRAME BY USING THE SCREWS (A) TIGHTENED AT A
TORQUE SHOWN ON THE FOLLOWING TABLE:

4. FIX THE GEARBOX TO THE DRUM BY USING THE SCREWS (B) TIGHTENED AT A TORQUE
SHOWN ON THE
FOLLOWING TABLE:

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4.1.18.4.5 CONNECTION OF THE BRAKE


THE GEARBOX DRIVE CAN BE SUPPLIED WITH A SAFETY NEGATIVE MULTIDISC BRAKE
HYDRAULICALLY DRIVEN
(PARKING BRAKE).

FOR INFORMATION REGARDING THE CHARACTERISTICS OF THE BRAKE, PORT TYPES AND
DIMENSIONS, REFER TO THE INSTALLATION DRAWING.

1. TO OPERATE THE BRAKE, CONNECT THE BRAKE PILOT PIPE TO THE BRAKE PORT.

AS THE GEARBOX INSTALLATION HAS BEEN COMPLETED, A STATIC SEALING TEST HAS TO BE
CARRIED OUT ACCORDING TO THE WORKING CONDITIONS:

1. a load equal or higher than the max operating one has to be applied per 5 min. at least and check that
no drum rotation happened.

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4.1.18.5 LUBRICATION

4.1.18.5.1 GEARBOX LUBRICATION


The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing.

The recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP characteristics
according to MIL-L-2105 C & API GL5.

In the following table the most common brands of lubricant and the types recommended are shown.

INFORMATION!
DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

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4.1.18.5.2 OIL FILLING


WARNING!

The gearbox is supplied without oil; anyway it has filling, draining and oil level plugs. Before putting the gear-
box into operation,it is necessary to fill it with oil.

Unscrew the fill and level oil plugs (1-2).

3. Fill from the hole (1) until the lubricant oil (see Section 5.1) flows out from the hole (2).

4. Tighten the fill and level oil plugs (1-2) and let the gearbox run. After a few minutes, stop and check
the oil level.

5. If necessary, refill with lubricant oil.

(Size and dimension of plugs are shown on the installation drawing).

INFORMATION!

Check the correct oil level after filling through the appropriate plug

Oil quantity to fill the gearbox is indicated on the following table or on the product installation drawing (In-
dicative values).

Belove are reported the standard gearbox oil filling-draining sketche.

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4.1.18.5.3 OIL DRAINING AND REPLACEMENT


Unscrew the plugs and let the oil flow in a large enough container; in order to facilitate the draining must
be oil still warm.

3. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs.

4. Proceed with the oil fill-up following the procedures given (see Section 5.2).

WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.

WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

INFORMATION!
IN CASE THE GEARBOX IS FACTORY FILLED WITH LUBRICANT OIL AT LEVEL, FOLLOW THE
PROCEDURES GIVEN IN DETAIL AT SECTIONS 5.2-5.3 ONLY FOR THE OIL REPLACEMENTS
FOLLOWING THE START UP AND RUNNING IN.

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4.1.18.6 START UP AND RUNNING IN

In this first stage it is advised to follow the measures given below:

1. Bleed air from every part of the hyraulic and add oil in the tank if necessary.

INFORMATION!

THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.

2. Start the gearmotor at a low speed and gradually increase it after having verified that it is functioning
correctly without any noises or vibrations.

INFORMATION!

DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT. DURING THE RUNNING-IN STAGE
FOLLOW THE STEPS GIVEN BELOW.

3. Check the correct revolution and direction of rotation.

4. Make sure that the functioning is regular and with-out any excessive noises and vibrations.

5. Make sure that the oil temperature does not exceed 90°.

After having terminated this first running-in follow the steps given below.

6. Check that there are no oil leakages. If present, proceed to remove them.

7. Check the level of lubricating oil in the gearmotor.

8. It could happen that due to the presence of air, during the first start up, the opening action of the brake
could be slowed down. It is advised to repeat the opening and closing function of the brake.

9. Check that there are no other problems in general.

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4.1.18.7 MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and oil
changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation.

For a proper maintenance of the gearbox, the following checks and operations have to be done.

INFORMATION!

IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE


SPARE PART LISTS EXPLODED IEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.

Do not hesitate to contatct the gearbox distributor or manufacturer if further instructions are necessary or in
case of particular problems.

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4.1.18.7.1 TROUBLE SHOOTINGS


The following table is realized to localize troubles in winch drive gearboxes 700C SERIES.

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This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL re-
serves the right to implement modifications without notice. This manual cannot be reproduced,
even partially, without prior written consent.

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4.1.19 GREASING POINTS – CRANE

ITEM INTERVALS MAINTENANCE POINT NUMBER OF TYPE OF


LUBRICATION LUBRICANT *
POINTS
1 Hoisting gear - second journal bearing 1 nipple multi-purpose grease
2 Luffing gear - second journal bearing 1 nipple multi-purpose grease
3 Slewing ring 20 nipples multi-purpose grease
4 Gearing-slewing-ring 1 ring Lub. oil or gear grease
monthly
5 Jib bearing 2 × 1 nipple multi-purpose grease
6
7 Hook 1 nipple multi-purpose grease
8
9 quarterly Ropes Hoisting and luffing rope grease
ropes
10
11
12 see instruction Electr. motor
of manufactur-
ers
13

* Grease see 4.3 lubricants

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4.1.20 OIL CHANGE

CHECK OIL LEVEL CURRENTLY RESP. DAILY

Item Intervals Maintenance point No. Type of lubricant*) Lubricant tool and quantity
1 every 1500 h or Slewing gear 2 gears gear oil Oil can abt. 12 l
(3 x 24 l)
2 every 1500 h or Hoisting gear 1 gear gear oil Oil can abt. 6,0 l
3 every 1500 h or Luffing gear 1 gear gear oil Oil can abt. 6,0 l
6 2000 - 3000 hrs. Hydraulic tank Hydr. oil VG 46 total capacity 500 l
7 2000 - 3000 hrs. Hydraulic sytem Tank, Hydr. oil VG 46 total capacity 570 l
hoses etc.

*) Type of lubricants see section 4.3 and Manufacturer of gears

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4.2 MAINTENANCE SCHEDULE


Pos. Maintenance Maintenance points Nos. Of Lub- Lubricants Refilling and Sec-
Points Quantity tion
Intervalls Oil type ¹)
1 Oil level
2 Oil temperature
3 Check of filters with-
currently out clogging indica-
resp. tors
4 daily Outer leaks
5 Damages
6 Pressure valves /
Current valves
7
8 Condensed moisture
to be dropped
14 days resp.
9 Change of filters
after 250 hrs.
without clogging
indicators
10 Hoisting gear - 1 nipple Multi-purpose grease 4.1.19
counter bearing
11 Luffing gear – 1nipple Multi-purpose grease 4.1.19
counter bearing
12
13 monthly Slewing bearing 20 nipples Multi-purpose grease 4.1.19
14 Gearing of slewing Gearing Open-gear grease 4.1.19
bearing
15 Jib bearing 2 × 1 nipple Multi-purpose grease 4.1.19
16 Hook tackle block 1 nipple Multi-purpose grease 4.1.19
17
18 Oil condition / oil
samples
19 Ropes (hoisting and Hoisting and Rope grease 4.1.14
luffing ropes) luffing gear
rope
20 Cleaning of Breath-
ers
21 Hoisting gear rope 4.1.15
quarterly
22 Luffing gear rope 4.1.15
23 Slipring assembly
24 Multi-disk brake 4.1.16
25 Check of the con-
nections for fasten-
ing
26 Check for wear of Electr.
brushes equipment

¹) Type of lubricants see section 4.3and manufacturers of gears

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Item Maintenance Maintenance Nos. of Lub- Lubricants Refilling and Sectiont


Intervals Points Points Quantity
Oil Type ¹)
27 after 1000 Cleaning of
hrs. breathers
28 Slewing gear 2 gearboxes Gear oil Oil can abt. 12 l 4.1.17
(2×24 l) 4.1.22
29 Hoisting gear 1 gearbox Gear oil Oil can 4.1.18
abt. 6,0 l 4.1.22
30 Luffing gear 1 gearbox Gear oil Oil can 4.1.18
abt. 6,0 l 4.1.22
31
yearly
32
resp
33 Load hooks
after 1500
34 hrs. Power circuit contacts
breaker
35 Monitoring units Electr.
equipment
36 Terminals connection
37 Fuses
38 Hydraulic system 4.5.2.2
4.5.2.3
39 Hydraulic tank Hydr. oil VG 46 500 l
40 2000-3000 Hydraulic system Tank, hoses, Hydr. oil VG 46 Filling pump
hrs. etc. ca. 570 l
40 Oil change
41 yearly Measuring Instru-
ments (Pressure
gauges)
42 see instruc- Electr. motor
tion of manu-
facturers

¹) Type of lubricants see section 3.3 and manufacturers of gears

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4.3 LUBRICANTS
Lubricants Types of Lubr. perm. Equivalent types of other makes can also be used
Maker mainly tropical areas mainly moderate Hydraulic oil 46 Multi-Purpose- Lubricant for Lubricant for
areas Quality Grease gear rim ropes
1) HV 46 1) HLP
Gear Oil C-LP220 Gear Oil C-LP150 K-L2K
Aral Epona Z 220 Epona Z 150 Visga 46 Vitam GF 4 Epexa 2 Cardrexa DC 1 Cardrexa DC 1

Vitam BG 220 Vitam BG 150 Vitam HF 46 6 Aralub HLP 2 Aralub LFZ 1 Aralub LFZ 1
BP Enersyn HTX 220 Epona Z 150 Bartran Energol HLP46 Energrease MP Energrease MP Energrease MP

Energol GR-XP 220 Vitam BD 150 HV 46 Energol HLP46 MG 2 MG 2 MG 2


Chevron Non-Leaded Gear Non-Leaded Gear Mechanism Mechanism Dura-Lith Pinion Grease Pinion Grease

Compound 220 Compound 150 LPS 46 LPS 46 Grease EP2 250 CB 250 CB
Castrol Alphasyn HG 220 Alphasyn HG 220 Hyspin Hyspin Spheerol Spheerol Spheerol

Alpha SP 220 Alpha SP 150 AWH 46 AWS 46 SX 2 SX 2 SX 2


Esso Spartan EP 220 Spartan EP 150 UNIVIS N 46 NUTO H 46 Beacon 2 Surett Fluid 4K Surett Fluid 4K
Cazar K2
Unirex N2 Beacon EP 2
Mobil Mobilgear 630 Mobilgear 629 DTE 15 DTE 25 Mobilux 2 Mobiltac D Mobilarma 798
Hydr. Oel Mobiltac D
HLPD 46
Shell Shell Omala 220 Shell Omala 150 Tellus Oel Tellus Oe Alvania Fett R2 Cardium Fluid C Cardium Fluid
C
T46 46
DEA/Texaco Meropa 220 Meropa 150 Rando oil Rando oil Multifak EP 2 Texclad 2 Texclad 2

HDZ 46 HD 46
1) With considerably varying ambient temperatures we recommend the use of oil quality HV for the hydraulic system

Note: The oil types listed in the „List of Hydraulic Oils“ are interchangeable and can be mixed with each
other. It is not necessary to drain off the oil or flush the hydraulic pipes prior to refill with a different type
of oil.

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4.4 ELECTRICAL EQUIPMENT


ATTENTION!
♦ Maintenance work and repairs are to be performed only by suitably trained personnel and only after the
power supply has been switched off.
♦ The regulations applying to cranes and the accident prevention rules in the country concerned and in-
house instructions are to be followed.
♦ Care must be taken to observe the relevant labour safety regulations.
♦ Special attention must be given to switching off the power supply for the auxiliary power and lighting
services. These have a separate feeder.
♦ The insulation value of cables, motors and switch gear must be checked after prolonged periods of
idleness, and these items are to be cleaned and, if necessary, dried (formation of condensation). The
intervals at which this is necessary will depend on the region in which the equipment is used.
♦ All units must be kept clean at all times.
♦ After maintenance work has been performed, all covers must be replaced and the electrical equipment
closed in accordance with regulations.
♦ The feeders must be reconnected to prevent condensation after maintenance work has been
completed . This applies particularly to the feeders for the heating circuits.

4.4.1 SAFETY DEVICES


The electrical safety devices switch off the corresponding drives in the event of danger.
The safety devices must be checked regularly to ensure that they work properly and are in perfect
condition. Defective parts must be replaced immediately by spare parts from the original manufacturer.

THE MODIFICATION OF MONITORING DEVICES AND THE INSTALLATION OF OTHER DEVICES IS


PERMITTED ONLY AFTER CONSULTATION WITH AND APPROVAL BY
TTS-LMG MARINE CRANES GMBH.

Electrical safety devices may be removed, replaced or bridged only by authorised persons under
appropriate supervision when the crane is not in operation, and after all necessary safety precautions
have been taken. The satisfactory operation of the safety devices concerned must be checked after the
original state has been restored.

All monitoring devices such as limit switches, overload trips, pressure switches, etc., must be checked at
regular intervals to ensure that they are in good working order.
When checking equipment, make sure that all monitoring devices, especially safety switches and their
actuators, are firmly seated.

All safety devices must be rechecked after repairs or prolonged periods of idleness.

All monitoring devices should be checked after the crane or part of it has been cleaned. This should be
done regardless of the interval that has elapsed since the last check.
THE CHECKS MUST CONSIST OF AN INSPECTION AND A FUNCTION CHECK.

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4.4.2 LIGHTING
Adequate illumination is essential for safe access to the crane and for safe crane operation. Defective parts
of the lighting system should therefore be repaired or replaced immediately.
The emergency lighting accumulator must be replaced after five years.

4.4.3 MOTORS
All motors are equipped with antifriction bearings. These must be greased as specified by the manufacturers.
The lubricating properties of grease and oil deteriorate during long periods of inactivity. This can lead to
rusting in the bearings. The motor should therefore be run for about a minute every one or two months.

4.4.4 SLIPRING BODIES


CAUTION !
THE CRANE IS SUPPLIED FROM SEVERAL POINTS IN THE SHIP'S MAINS .
BEFORE WORKING ON SLIP-RING BODIES, MAKE SURE THAT THE POWER SUPPLY FROM THE
SHIP'S POWER SUPPLY SYSTEM IS SWITCHED OFF !

Work to be performed every three months


♦ Check the brushes for wear.
♦ Coat the slip rings with a thin film of contact grease to reduce wear.
♦ Grease the bearings.
♦ Check that all connections are firmly seated, mainly the terminals of the main switch and the power
contactors must be proper tighten.

4.4.5 CIRCUIT BREAKERS


The intervals at which all contacts should be checked for wear will depend on service conditions, but should
not exceed one year.

ANNUAL CHECKS OF THE WHOLE ELECTRICAL SYSTEM


The following checks and work must be performed :
♦ Check that the specified enclosure conditions are met.
♦ Check the fastenings of all units (especially safety devices, limit switches etc.).
♦ Check all terminals for firm connection.
♦ Check all protective earth connections.
♦ Replace damaged or worn units and parts (contacts).
♦ Check that all fuses are firmly seated.
♦ Clean all parts of the plants.

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4.5 HYDRAULIC EQUIPMENT

HYDRAULIC SYSTEM

A powerful electric motor drives the hydraulic pumps via a distribution gearbox with constant speed and al-
ways with the same direction of rotation:
The individual crane gears (hoisting-, luffing and slewing gear) will be driven electro-hydraulically. A three-
phase electro-motor with constant speed and invariable direction of rotation drives via a splitter gearbox
three independent hydraulic circuits.

ALL THREE CRANES GEARS ARE OPERATING IN „CLOSED CIRCUITS“.

During crane idling, i.e. no function (slewing, luffing, hoisting) is actuated by the crane operator, the pumps
are at their zero-position. The zero-position is adequate to zero stroke - the pumps do not deliver oil to the
motors.

MEANINGS
CLOSED CIRCUIT

„Closed circuit“ of a hydraulic system means that the oil returned from the consumer will be delivered directly
to the hydraulic pump.
HIGH-PRESSURE SIDE is such side on which the oil is delivered from the pump to the motor.
LOW-PRESSURE SIDE is such side on which the oil will be returned from motor to pump.
The pump is driven in an invariable direction of rotation.
Speed control and reversal of the hydraulic motor are effected by means of adjustment of the pump.
Internal loss of leak in the pumps, motors, and valves must be balanced out by an auxiliary pump, which is
feeding into the individual low-pressure side of the circuit via non-return valves.
Additionally, two pressure limiting valves are required in order to se-cure each individual high-pressure side.
In „closed circuits“ brake forces will be transmitted from motor to pump. The pump is supported by the elec-
tric drive motor which feeds reverse power into ship’s mains.
This will apply mainly for drives of winches, travel and slewing gears.

TYPICAL FEATURES OF „CLOSED CIRCUIT“ ARE:

„ Directional valves
Small sizes for pilot operation
„ Filters / coolers
Small openings to flow /small sizes
„ Tank size
Small-determined only by flow of auxiliary pumps and system flow
„ Speeds
High limits due to anti-cavitation
„ Arrangement /installation position
Any
„ Drive
Completely reversible through zero position
„ Support of loads
Via drive motor
„ Return of braking energy

DELIVERY FLOW

Delivery flow is the volume flow to be delivered by a pump.


- see „Volume Flow“
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DISPLACEMENT VOLUME (OF A MOTOR)

Displacement volume is the oil volume (hydraulic oil) taken up by the hydraulic motor during one rotation.
It can be fixed or variable, dependent on the type of motor.

Displacement volume is the oil volume (hydraulic oil) taken up by the hydraulic motor during one rotation
It can be fixed or variable, dependent on the type of motor.

OPEN CIRCUIT

„Open circuit“ means that - in general - the suction line of a pump is led below a oil level, the surface of which
is combined with the atmospheric pressure.
The pump draws oil from the opened reservoir (tank) and conveys it to the consumer (motor, cylinder). The
oil will be returned from the consumer to the reservoir.
The pump conveys only in one direction of flow. Modification of the direction of the consumer can be
achieved by installation of a direct-ional valve between pump and consumer.
Brake forces must be converted to thermal energy by means of installation of additional brake valves.
In the starting position shown, the oil flow circulates freely (without pressure).
Various pump adjustments will enable different control systems in „open circuit“.

TYPICAL FEATURES OF „OPEN CIRCUIT“ ARE:

„ Suction lines
Large diameters, small lengths
„ Directional valves
Sizes dependent on flow
„ Filters / coolers
Cross-sectional areas/sizes dependent on flow
„ Tank size
Multiple of max pump flow in litres
„ Pump arrangement
Next to or under the tank
„ Drive speeds
Limited by amount of suction
„ Unloading in the return line via valves

SWIVEL ANGLE (A2F-MOTOR)

The swivel angle of the fixed displacement unit is set by the housing and hence it is fixed. In a variable dis-
placement unit this angle may be smoothly adjusted between certain limits.
By changing the swivel angle a different piston stroke is obtained and hence an adjustable displacement
volume may be produced.

SLEWING ANGLE (A4VG-PUMP)

The swivel angle of the swash plate in the housing in the fixed displacement unit is fixed, In a variable dis-
placement unit the angle of the swash plate may be smoothly adjusted between specific limits. By changing
the angle of the swash plate it is possible to change the piston stroke and hence the displacement volume.

VOLUME FLOW

Volume flow is the fluid volume flowing through a cross-section area in a time unit.
The air flow is always indicated in an intake condition - referring to normal conditions.
In the hydraulics, the volume flow is normally mentioned in L/min; in the pneumatics in m³/min.

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4.5.1 FUNCTIONAL DESCRIPTION


Basis of this description is the enclosed hydraulic diagram. The items included in the diagram are divided
into 9 groups:

1. Hoisting gear circuit 1.0


2. Luffing gear circuit 2.0
3. Slewing gear circuit 3.0
4. Boosting and control oil circuit 4.0
5. Cooling system 5.0
6. Oil tank 6.0
7. Manuel filling pump 7.0
8. Manual pump for emergency operation 8.0
9.
10.
11.

HYDRAULIC PUMP SET

The distribution gearbox is equipped with hydraulic pumps for the following crane drives:

1 pump for the hoisting gear circuit (1.1)


1 pump for the luffing gear circuit (2.1)
1 pump for the slewing gear circuit (3.1)

Please find below the descriptions of these crane gears.

HYDRAULIC DIAGRAM SEE CHAPTER 6.0 ASSEMBLY GROUP 97.66.00

4.5.1.1 HOISTING GEAR CIRCUIT 1.0


The hoisting gear pump ( 1.1 ) delivers to the respective hoisting gear motor (1.5).
From the motor, the oil is returned to the pump.
This is the "closed circuit" shown in the diagram by heavier lines.
The hoisting gear pump is a variable displacement pump, type A4VG125EP.

The inclination of the swivel rocker determines the stroke of the piston and, therefore, the volume of
discharge.

25° inclination corresponds to maximum discharge


0° inclination: no discharge.

When the swash plate is passing the 0-position and inclining to the other side, the direction of delivery
changes while the direction of rotation of the pump remains the same.

Displacement control of the pumps is described in detail in section “Control Oil Circuit - Pump Control“.

The hoisting gear is equipped with a variable displacement motor (1.5) in addition to the variable displace-
ment pump ( 1.1 ). The type of the hoisting motor is A6VM 200 EP (TRIMOT is the name given to the motor
of this type by the maker).
In case of the pump, the volume of discharge - and therefore the speed of the drive - is always the higher
the greater the piston stroke.
However, in the case of the variable displacement motor (TRIMOT), the speed (rpm) is always the higher
the smaller the piston stroke.

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REMARK: If the variable displacement motor swashes back, i.e. the piston stroke decreases and the
rotation speed increase (hoisting speed increases), the pressure will increase while the load
remains the same.

The max. swash angle is 25°. To keep the max. rpm within certain limits, the minimum swash angle is limited
to abt. 10°. Displacement control is described in detail in Section "Control Oil Circuit" - Adjustment of Hoisting
Motors".

With this system, variable displacement pump + variable displacement motor, high operating speeds can
be attained in operation with partial loads or no load, while components are kept small. Hose lines are
also small.

LEAFLETS OF PUMPS AND MOTORS

Displacement of pump and motor are adjusted according to the diagram below:

A= pump adjusts from o-stroke to B= pump at max. piston stroke and


max. displacement. stays there. Motor swashes from
Motor starts with max. piston max. stroke back to smaller stroke
stroke and stays there. (not to 0) while the working pressure
rises with constant load.

The sequence (firstly displacement of pump and secondly displacement of motor) does not require any
measures from the crane operator who has one control lever only for the hoisting and lowering sequence.

FOR CRANE DRIVES EQUIPPED WITH WINCHES MUST BE NOTICED:


When hoisting the load, the pump delivers oil to the motor.
When lowering the load, the weight of the load pulls the winch. The motor delivers oil to the pump; the pump
turns the electric motor which then acts as generator and generates current which is feed back into the ship's
mains.
The line which is under high pressure during hoisting is also under high pressure when lowering; merely the
direction of oil flow in the lines has reversed. The load is supported by the pump.

DISPLACEMENT CONTROL OF THE HOISTING GEAR MOTOR (TRIMOT)


Displacement control of the hoisting gear motor is not connected with the control oil circuit. In this case
pressure is admitted to the control cylinder from the high pressure circuit via non-return valves. The control
cylinder is operated by a control valve which is controlled a solenoid valve. The displacement angle of the
variable displacement motor is proportional to the magnetic force.

HYDRAULIC DIAGRAM SEE CHAPTER 6.0 ASSEMBLY GROUP 97.66.00

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4.5.1.2 LUFFING GEAR CIRCUIT 2.0


The luffing gear pump ( 2.1 and 2.2 ) delivers to the luffing gear motor (2.5). From the motor, the oil flow
returns to the pumps. This closed circuit as well is shown in the diagram by heavy lines.
The luffing gear pump is also a variable displacement pump type A4VG125 EP

The luffing gear motor is a fixed displacement motor with fixed piston stroke. Its displacement in
cm³/revolution is constant.
The motor speed is solely dependent upon the variable pump discharge.

Section "control oil circuit - pump control" applies to the control of the pump, same as for the hoisting and
luffing gear.

4.5.1.3 SLEWING GEAR CIRCUIT 3.0


The slewing gear pump ( 3.1 ) delivers to the slewing gear motors (3.4).
From the motors, the oil flow is returned to the pump.

Here, too, this "closed circuit" is marked by heavy lines in the diagram.
The slewing pump also is a variable displacement pump type A4VG125 EP.

The slewing gear motors are fixed displacement motors, i.e. the piston stroke remains unchanged. The
consumption of cm³/revolution is constant.

The rotating speed is solely determined by the variable pump discharge volume.

For control of the pump of the slewing gear, please refer to section "Boosting and Control Oil Circuit - Pump
Control".

In the case of the slewing gear the high and the low pressure sides change, depending on the direction in
which the crane is required to slew against the heeling angle of the vessel.

This is the information concerning the "closed circuits" of the hoisting gear, the slewing gear and the
luffing gear. So far the drives are still incomplete. The leakage oil emerging from the pumps and motors
(broken lines in the diagram) flows to the tank and has to be replaced in the circuits being cooled and
filtered at the same time (boosting circuit).

Auxiliary equipment, such the brakes, have to be operated.

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4.5.1.4 BOOSTING AND CONTROL OIL CIRCUIT 4.0


The 3 "pump units" for the hoisting, slewing and luffing gear not only consist of the pumps themselves but
also include all valves required to feed into the circuits and to control the pressure. In addition, the
respective control devices to adjust the discharge rate and reverse the direction of discharge are flanged on

The first step of the twin pump (5.1) is a fly pump (PVH 98). It supplies the boosting and control oil circuit.

The fly pump draws the required oil from the tank and delivers it through the filter (4.9) to the three pump
connections Fa of pumps 1.1, 2.1, 3.1. Oil is delivered to the respective low pressure side
via non- return valves.

The discharge rate controller (4.1.1) keeps the feed oil pressure at a constant 28 bar.

THE CONTROL OIL CIRCUIT .

The control oil circuit maintains the control pressure needed for :
1. Pump displacement control (volume and direction of discharge)
2. Operation of holding brakes.

This control oil circuit is supplied by the same pump (5.1) as the boosting oil circuit, i.e. after filter (4.9),
the control oil is branched off from the boosting oil circuit, i.e. it is taken to the pump control units (1.1,
2.1, 3.1) after entering into the pump units (Fa).

The 28 bar pressure relief valve for the boosting circuit also ensures pressure relief for the control circuit.

The control oil circuit has the following functions:

PUMP CONTROL

(adjustment of discharge volume and change of the direction of flow)

The hydraulic control is designed to convert the electric signal quickly and precisely, i.e. current which can
very between abt. 200 to 600 mA coming from the master controller in the operator's cabin, into the
corresponding pump position within the swashing range of the pump.

The control device consists of the respective actuation devices 1.1.2, 2.1.2, 3.1.2 with the flange-connected
magnets a + b and the respective control cylinders. The actuation devices convert the
incoming electric signal into the corresponding control pressure. Depending on the direction of delivery, this
control pressure exists either in line X1 or X2.

In control line (X1) nozzle (V1) is fitted which throttles the incoming oil and thus determines the speed of the
control cylinder. The movement of the control cylinder is transferred to the actuating devices 1.1.2 or 2.1.2 or
3.1.2 via the return lever.

The return lever acts upon springs and the adjustment comes to a standstill when the magnetic force exerted
by the control magnet (a) is compensated by the force of the spring. In this way, the volume of pump
discharge adjusts itself in proportion to the magnetic force.

The direction of pump discharge is reversed when the other control


magnet (b) is actuated. Analogous to the procedure just described, pressure is admitted to the control piston,
so that the swash plate slews into the other direction through the 0-position.

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ACTUATION OF THE HYDRAULIC HOLDING BRAKES

The holding brakes for main hoisting, luffing, auxiliary hoisting and slewing gears which are hydraulically
lifted and engaged by spring force are supply with pressurefrom the control oil circuit.

Actuation of the slewing gear brakes in the simplest one. When operating the slewing gear in the cabin,
magnet 3.17 (on the valve panel) is excited.

The valve isolates the brake line from the tank line and connects with the control oil circuit. The brakes open.

AFTER SWITCHING OFF THE SLEWING MOVEMENT, THE BRAKES ENGAGE WITH TIME LAG. (THE
MOVEMENT HAS TO COME TO A COMPLETE STAND-STILL FIRST).

After switching off the slewing movement, the brakes engage with time lag. (The movement has to come to a
complete stand-still first).

This procedure also applies to the main hoisting gear via magnet 1.24, luffing gear via magnet 2.22,
but opening of the brakes is delayed until the level of pressure has been reached in the respective high
pressure lines after a pause with the brakes still engaged which had been there prior to engagement of the
brakes. This is effected by pressure value sensor 1.23 for the hoisting gear and 2.20
for the luffing gear.

SPECIAL EQUIPMENT

EQUIPMENT FOR JERKFREE STARTING

If a load is stopped, i.e. the brake engages in the hoisting gear, the high pressure line becomes
pressureless owing to leakage oil losses. If the brake would be released now, the load would drop into an
oil column without pressure and there would be hard knocks and corresponding pressure peaks. The
electric pressure sensor 1.23 prevents starting of the load with a jerk.

The brake is only lifted when the high pressure line has reached the respective load pressure stored in
the memory. The control stores the load pressure when the brake engages.

When switching to "lowering", the hoisting gear pump is switched to deliver in the opposite direction at the
beginning, until the equivalent pressure is built up.

When the pressure sensor 1.23 gives the signal to open brakes, the pump is also switched to deliver in
lowering direction.

The whole process of jerkfree starting is automatic.

PIPE BURST SAFETY DEVICES

Readiness for operation of the crane is monitored by several pressure switches, i.e. item nos. 1.27, 2.14,
3.12, 3.13.

Therefore, the pressure controls in the boosting circuit also act as pipe burst safety devices for the main
pipes, i.e. in case of a hose burst or a noticeable leakage, the boosting pressure in the low pressure line
collapses. Due to this, the pressure control automatically switches the crane off and the holding brakes
engage.

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FILTER CLOGGING INDICATOR

The filter is equipped with a protective valve. If the filter is very dirty, the protective valve for the filter at
the bypass opens at a certain pressure differential (abt. 1 bar) and thus prevents destruction of the filter
insert owing to further rise in pressure. To prevent such an occurrence which would allow unfiltered oil to
get into the circuit, the high pressure filter (4.9) in the boosting circuit is equipped with an electric clogging
indicator (differential pressure measuring device). When clogging is indicated, the filter cartridge 4.9.2
needs replacing.

If this is not done, the electric contact in the clogging indicator switches and the crane becomes
non-operational because the control voltage for the electrical equipment is switched off.

HYDRAULIC PRESSURE RELIEF

In the main lines of all three drives, pressure relief valves are installed which protect the drive as well as
the pipe and hose lines from overloads. Whereas the slewing gear has two high pressure valves (3.1.5
and 3.1.6) as the high pressure side changes, the hoisting and luffing gear are provided with only one
high pressure valve (1.1.6, and 2.1.6) and a low pressure valve (1.1.5, and 2.1.5).

ELECTRONIC AND HYDRAULIC CONSTANT PRESSURE CONTROL


(Power control)

The constant pressure control in the hoisting gear is a special type of power control acting only upon the
variable displacement motor. Actuation of the variable displacement motor (1.5) reduces the specific
volume of piston stroke. Owing to this, the power take-off speed or working speed as well as the working
pressure increase.

The output limit of the drive is reached at max. discharge volume of the pump and max. pressure set at
the pressure relief valves (1.1.3).

The constant pressure control has the effect that the variable displacement motors adjust to low working
volume only until the maximum pressure is almost reached. In this position which depends on the load,
the motor remains. This process is electronically controlled in the hoisting gear. The pressure sensor
(1.23) serve as pick-ups for the maximum pressure for the lowering and hoisting functions respectively.

The pressure sensor (1.23) gives also a signal when the working pressure is about to exceed the max. per-
missible pressure.

At that point, the working volume of the variable displacement motor (1.5) is increased again. The hydraulic
pressure control at the hoisting gear motor (1.5) is installed for safety reasons. The hydraulic control has the
same effect as the electronic control of the pressure sensor.

The hydraulic control is superimposed on the electronic control and operates only if the electronic control
is not functioning. By doubling the system in the hoisting gear, it is ensured that the motor (1.5) never adjust
to a working volume smaller than permissible and therefore will not open the pressure relief valve (1.1.6).

LEAKAGE OIL

The excess oil quantity of the pressure relief valves (items 1.1.4, 2.1.4, 3.1.4) as well as the quantity of
leakage oil from the pumps flow through connection T1 or T2 (main hoisting gear, luffing gear, and slewing
gear pumps) to the collecting block and then to the tank. In addition, the leakage oil from the motors and
brakes is returned to the tank.

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4.5.1.5 OIL COOLING 5.0


Circuit 5.0 cools the hydraulic oil. The second step of the twin pump (5.1) draws the oil from the tank, delivers
it through filter (5.3.1) and the cooling set to the pump housings (1.1, 2.1, 3.1, 10.1) and from there back
to the tank.

To avoid high pressures when starting with cold oil, a bypass valve (5.3.3) with a spring pretension of 3 bar is
fitted in the line.

The cooling set consists of an electric motor (5.8.2) with screwed-on fan and with a honeycomb radiator (5.8.3).

After passing through the honeycomb radiator, the air is discharged into the open through the exhaust flap. The
hydr. oil quickly warms up to suitable operating temperature, as the ventilator is only switched on by the
temperature sensor (5.5.1) when the oil temperature in the tank reaches abt. 50° C.

4.5.1.6 HYDRAULIC OIL TANK 6.0


The hydraulic oil tank has a maximum oil volume of ab. 500l. The oil level can visuelly be checked by two
sight glasses (6.1 - 1xmax; 1xmin) - the oil level should always be between the two sight glasses.

A double pump, complete with connecting piece on the suction side and hoses for the boosting and
control oil circuit (5.1) and for oil cooling (5.2) is installed the tank.

Besides this a breather filter (6.2) is provided that makes an air exchange possible when the oil level varies.

At the bottom of the tank a drain cock (6.3) is installed that is used to empty the tank partly or completely.

4.5.1.7 FILLING 7.0


The oil level in the tank is topped up through filling filter 6.4 and the closing coupling with non-return valve
6.5. Each ship's set of cranes is delivered with a manually operated filling pump (barrel pump) 7.0 together
with hose 7.2, suitable for closing coupling 7.4 at the pump on one side and for 6.5 on the other.

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4.5.1.8 EMERGENCY OPERATION 8.0


In case it should become necessary to carry out a crane movements without drive, each ship’s set of the
cranes is equipped with a hand pump for emergency operation in order to release the relevant brakes.

LOWERING OF A LOAD IN THE HOISTING GEARS RESP. OF THE JIB IN THE LUFFING
GEAR.

ATTENTION:
The emergency lowering by means of a hand pump is only allowed during emergency, i. e. failure
of the hydraulic system.

The brake is released by means of the hand pump. The load in the hook or the jib-weight is sup-
ported on the pump via the oil column in the hose line.
Lowering to be done via the existing leak oil in the pumps or motors.

PROCEDURE:
1. Hose line item 1.01 or 2.01 to be screwed off at the screw joint of the brake filter.

2. Hose line to be closed with plug and hose of the emergency hand pump to be connected to
screw joint of the brake filter.

3. Relief valve in the main hand pump to be closed by turning the handwheel.

4.Pressure to be built up by means of the lever of hand pump. The brake starts to release at abt.
10 bar (if necessary: air in the hose line to be vented by unscrewing the cap-nut).

NOTE:
Pay attention to the movement of the rope drum. In case rope drum gets to turn quicker, relief
valve to be opened with hand wheel.
The brake will become pressureless and engages.

5. Load to be lowered and hose Item 1.01 or 2.01 to be fitted again.

hand pump
hand lever

hand wheel relief valve

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TURNING OF CRANE TOWER

In case of emergency it should become necessary to turn the crane tower with-out
drive.

The procedure is on principle the same as lowering under emergency. How-ever, it


is necessary to turn the crane tower by means of external actuation, for instance
with a deck winch whereby a turn of a mooring rope will be put around the crane
tower.
The jib-bearing bolt can serve as a fixed point.
For lifting the slewing gear brakes the emergency hand pump must be connected to
the brake filter 3.18 instead of the hose line 3.01.

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4.5.2 GENERAL REMARKS


Strict adherence to the operating and maintenance manual published by the manufacturer is necessary
for trouble-free operation.
The work required to put hydraulic systems into operation and keep them in good working order is outlined

IN THE FOLLOWING.

COMMISSIONING MAINTENANCE
INSPECTION SERVICING TROUBLESHOOTING
Commissioning of a Condition and opera- Continued operation Pinpointing and rectifi-
new system or recom- tion Changing of spare cation of malfunctions
missioning of an exist- parts and damage
ing system
Fault-finding requires
Installation, filling with Observation, meas- Cleaning and replace- close and logical atten-
fluid, bleeding, basic urements, test run ment of components tion to detail
adjustment, running-in (fluid change, filter
inserts, seals) Repair of damage by
replacement of compo-
nents

Repair of components
by manufacturer

A hydraulic circuit diagram is indispensible when handling problems in hydraulic systems. Defective
hydraulic systems respond in different ways. Always find out when, under which conditions and how
often a problem occurs, e.g.

* after a relatively short period of operation,


* at regular intervals, or
* after long periods of trouble-free operation.

In case of a malfunction, first check whether the pressure is being build up.

GENERAL REMARKS

General instructions for work on hydraulic systems:


To avoid accidents, never slacken pipe couplings, hose connections or mechanisms as long as the
system is under pressure. Loads must be lowered to the ground and secured, and all pumps must must
be switched off beforehand.

DO NOT WORK WITH OILY HANDS !

Keep everything absolutely clean during all stages of the work because dirt is the greatest enemy of
hydraulic systems. Clean the surroundings of the place of work before slackening couplings. Blank off all
openings immediately to prevent dirt from entering the system. Do not use cotton waste for cleaning oil
tanks.

When filling the system, always pour in the oil through a filter.
When applying paint by spraying or by brush, make sure that all flexible seals and bearings are protected
from the paint, especially if it is based on nitrocellulose.

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INSTALLING HOSES

When selecting hoses and couplings/flanges, make sure you choose the right pattern (wall thickness,
material) for the pressure concered.

Do not use cotton waste for cleaning purposes.

The thread depths of components and connection plates are suitable for use with all conventional screwed
pipe couplings. The countersunk holes of casings are designed to permit the use of couplings with both
sealing edges and soft seals. They are not suitable for couplings using "O" rings as seals.

The thread must not butt against the bottom of the hole.

Sealing aids auch as hemp or sealing compound must not be used because they lead to dirt and therefore
cause malfunctions.

ATTENTION!

Damaged hoses must be replaced immediately!

When installing equipment, it is important to make sure that the mounting position, ambient temperature,
operating voltage etc. are correct.

Control valves and regulating devices must to be installed without stress to prevent jamming of the control
pistons. Mounting faces must be absolutely flat, and fixing bolts must be tightened uniformly with the
specified torque.

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4.5.2.1 PUTTING SYSTEMS INTO OPERATION (BY WORKS PERSONNEL)

Commissioning involves a number of procedures which should all receive careful attention :
♦ Visual inspection for damage and dirt picked up during transport;
♦ Installation and mounting of pump sets and assembly groups;
♦ Connection of hydraulic consumers in acc. with diagram. Flush long pipes and hoses.
♦ Electrical wiring for drives and controls after checking the supply ratings. Check the direction of rotation
of pumps before starting.
♦ Filling of fluid reservoir with the hydraulic fluid specified in the oil table through the filling filter or a
separate filter with a maximum mesh of 10µm .

ENSURE ABSOLUTE CLEANLINESS.


Clean the filter cap and the cap of the transport and storage vessel before opening. Check the fluid
reservoir for dirt and clean it if necessary. Check the hydraulic fluid for water. The contamination of
the hydraulic fluid must not exceed class 8 acc. to NAS 1638.
Do not fill up above the maximum level mark.

♦ Fill the pumps and motors with oil through oil return line.
♦ All valves must be in the zero or central position, i.e. circulation without pressure.
♦ Open the main pressure relief valve.
♦ Pull out electric plugs of solenoid valves at the variable displacement pumps.
♦ Check the direction of rotation of the pumps by starting the system for a moment (app. 1 - 3 seconds).
♦ Start the drive motor slowly.
Run the electric motor in inching mode.
♦ Let the pumps run in idling mode.
♦ Check for leakage.
♦ Bleed the system in the consumer lines, preferably at their highest points. Operate directional contol
valves and extend and retract consumers several times. Increase the load slowly. Increase the settings
of pressure valves and regulators. The system has been bled properly when foam is no longer present in
the reservoir, movement is smooth and no abnormal noise occurs.
♦ Check the fluid level and top up after bleeding, if necessary.
♦ Check the oil temperature and clogging indicator of the return filter continually.
♦ Monitor the final operating temperature after machine has been in full operation for several hours.
♦ Check coming-on of cooler
♦ Set the pressures for the different circuits and seal the pressure relief valves.
♦ Complete functional test
♦ Switch drives off
♦ Check oil levels
♦ Retighten unions
♦ Check all return filters and line filters for contamination and replace paper cartridges, if necessary.

After this preparatory work, it is advisable to run the system in for about 6 hours while keeping an eye on
the pressure. All hose connections and unions should then be tightened again (switch the motors off first).
Remove all external oil and grease from the hydraulic system by washing it with detergent and inspect for
leakage for about an hour.

Check once again and retighten all connections after operation at full load.

Replace all oil filters and clean all filters magnets after the trial run.

ATTENTION:

It is very important that the boosting pressure for the closed circuit (DMP 7) is maintained during the
pressure check and the operation of the main pumps.

If the boosting pressure drops to below 20 bar, the drive motor is switched off immediately because of the
danger of caviation involved.

During operation, the boosting oil pressure is monitored by pressure sensors.

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4.5.2.2 INSPECTION AND MAINTENANCE

TTS-LMG hydraulic components have been designed for long and trouble-free operation. They require very
little maintenance. However, the little attention they need absolutely necessary for trouble-free operation
as pratical experience has shown that up to 80% all malfunctions are due to dirt, poor maintenance and
unsuitable hydraulic fluid.
Inspection and maintenance intervals and the work involved are generally laid down by the manufacturer
of the machine in an appropriate schedule. The most important points for hydraulic systems are mentioned
in the following and summarized in a table.

FLUID LEVEL

This must be checked frequently, as rising operating temperatures, accumulation of undissolved air and
pump failure due to cavitation can result if the fluid surface drops below the minimum level mark.
Check the oil level before starting the hydraulic system.

FLUID TEMPERATURE

The operating temperature depends on several factors such as mode of operation, machine operating
cycle, circuitry etc. In practice, the temperatures are normally between 40ºC and 90ºC.
The oil temperature in the reservoir must be monitored continuously. Gradually increasing temperatures
may indicate contamination, clogging, or worn metal components or seals and should be seen as a reason
to examine the corresponding components.
Sudden rises in temperature are an alarm signal, and the system should be shut down immediately for in-
spection.

FLUID CONDITION

Ageing of the fluid depends on a number of factors such as temperature, dirty environment, operating pres-
sure, humidity, etc.

APPEARANCE CONTAMINANTS POSSIBLE CAUSES


Dark in colour Products of oxidation Overheating,fluid not changed in
time
(possible contamination by other
oils)
Milkiness Water or foam Ingress of water or air
Water segregation Water Ingress of water,

Air bubbles Air Ingress of air, e.g. due to


low fluid level or leaky
suction
Floating contaminants or Solids Wear, dirt, ageing products
sediment

Smell of burnt oil Ageing products Overheating

Laboratory analysis will provide further information.

CHANGING THE FLUID

♦ Oil changes should be carried out about every 2000 to 3000 hours if the fluid is not analysed regularly
in a laboratory.

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CAUTION
The cover of the hydraulic reservoir must be cleaned thoroughly before each oil change. Always clean
the hydraulic tank when changing the oil. Use no cotton waste, but only rags.
♦ Never run the motor(s) when the oil tank is empty. Perform oil change only at operating temperature.
♦ Stop the motor(s)
♦ Drain off the old oil completely into barrels or similar receptacles.Clean the tank, remove all cleaning
materials from the tank and close the tank, making sure that the
cover is air-tight.
♦ Close the drain cock .
♦ Use a barrel pump to fill the tank via the filler filter and filler coupling with cap.
After filling with fresh oil, start the pump for a moment. Repeat this several times while watching the oil
level.
After filling the hydraulic system, disconnect the system and fill the oil tank up to the prescribed max. oil
level.

CHECKING AND CHANGING FILTERS

Check the filters as specified in the maintenance schedule. The indicator moves into the red warning
sector as clogging becomes more severe. This means that the filter cartridge must be replaced at the
end of the shift or when the crane is not in operation. The filter cartridges must also be replaced after any
kind of damage to the hydraulic system.

NOTE !

Paper filter cartridges must not be washed or blown clean with compressed air.
USE ONLY NEW FILTER CARTRIDGES!
The pressure switch in the filter is an additional precaution against filter clogging. If the pressure exceeds
a certain value, an electrical system prevents pump adjustment to positive displacement.

CHECKING FOR CONDENSATION

(Dewatering the hydraulic oil tank)


Condensed water that has accumulated in the tank must be drained off through the drain cock once a
month and before the crane is put into operation after long periods of idleness.

PROTECTING HOSE COUPLINGS

Outside hose connections must receive special attention since they are exposed to the elements.

PREVENTING AND REPAIRING LEAKS

Check the hydraulic system regularly for leaks. Leaks can be located only if the external surfaces of the
hydraulic system are kept clean. Leaky hoses must be replaced immediately. Replace the "0" rings if
leaks are found at flanged or compression couplings using "0" rings as sealing elements.

OIL CHANGES

Oil changes must be carried out while the system is still warm from operation. The tank must be inspected
and cleaned if necessary (oil sludge) before refilling it, and the filter cartridge must be replaced at the same
time.
The old oil is drained out of the tank through the drain cock. If the oil grade is changed for technical or other
reasons, the new grade must be selected from among those recommended.
The required intervals between oil changes are stated in the maintenance schedule.
The recommended intervals between oil changes can be increased if oil samples are tested regularly by the
supplier and found to be in order.

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SETTING VALUES

Pressure control valves, flow control valves, pump controls and signalling devices such as limit switches,
pressure switches, thermostats etc. are adjusted during initial commissioning. These setting must be
monitored continuously during the initial phase; subsequent checks should be made at reasonable
intervals.

OIL COOLERS

Regular oil-air filter cleaning intervals depend on the amount of dirt collected from the surroundings.

OTHER CHECKS

With a little attention, most malfunctions can be identified before they become serious. This applies both
when running in and during subsequent operation.
Particular attention should be paid to the following :

♦ external leakage
♦ contamination
♦ damage, in particular to hoses
♦ noises from pumps, motors, couplings, mountings
♦ proper functioning of measuring instruments
HYDRAULIC VALVES - GENERAL REMARKS

All valves are sensitive to dirt. If a valve fails, it must be replaced by a new one. All valves can be removed
and installed without danger if the hoisting gear is not under load and the jib has been lowered onto its
support. In the case of large diameter pipes, drain off the oil first by opening the drain plugs at the lowest
points. Drain the oil into a receptacle and observe environmental protection rules. Clean the valves and the
adjacent parts of the piping with a detergent before starting work.

ATTENTION :

Do not forget to open the ball cocks again after the repairs

CHANGING THE GASKETS OF FLANGE CONNECTIONS

When changing the gaskets of flange connections, first wash the flange thoroughly with detergent. lf necessary,
drain the oil off into a receptacle at a lower point.

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4.5.2.3 OPERATION AND MAINTENANCE OF HYDRAULIC PUMPS AND MOTORS

4.5.2.3.1 GENERAL REMARKS


To make sure that hydraulic pumps and motors function satisfactorily, carefully read and follow:
♦ the operating instructions supplied with the unit,
♦ the technical data given in the catalogue,
♦ the general instructions for putting oil hydraulic systems into operation and
♦ the following installation and operating instructions.

4.5.2.3.2 INSTALLATION
FLUSHING
The oil in pumps that have been stored for some time may have resinified. The resin must be removed
with solvents, whereafter the lubrication film must be restored. Apart from this, no special action is needed
if fire-resistant fluid is to be used.

INSTALLATION
♦ Install as shown in drawings or as instructed.
♦ Avoid permanent stresses.
♦ Carefully align with the prime mover/driven unit (are foundations flat?)

PIPING AND CONNECTIONS


Suction lines
♦ are the suction lines tight?
♦ The flow rate in the suction line should not exceed 0.5 m/s.

4.5.2.3.3 FIRST START


ELECTRICAL CONTROL SYSTEMS
♦ Are the specified voltages and currents correct?

ARE THE DRIVING AND DRIVEN UNITS DESIGNED FOR THE SAME DIRECTION OF SHAFT
ROTATION?
♦ Take the direction of rotation into account.
♦ Fill the unit with fluid and check the direction of rotation. Switching on and immediately off again
avoids damage if the sense of rotation is wrong.

STARTING
♦ Pay attention to instructions referring to specific components.
♦ Open all valves, especially those on the suction or feed side.
♦ Switch the motor on and off again quickly several times to remove air. Do not operate at full load until
the pump is running smoothly and quietly.
♦ Bleed the delivery line when starting for the first time to fill the pump completely.
♦ Bleeding is unnecessary for pumps with automatic bleeding valves.
♦ Take care that the fluid surface in the reservoir does not drop below the minimum suction level when
starting the plant.

PRESSURE RELIEF VALVES


− Choose the lowest setting in each case.
− Gradually increase the pressure to the specified value, but not to an unnecesarily high pressure.
− Secure the final setting to prevent inadvertant misadjustment.

Temperature
− Check the fluid temperature under normal service conditions.
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4.5.2.3.4 ROUTINE MAINTENANCE


INTERVALS

♦ Maintenance should be performed at regular intervals which depend on the duty and service conditions.

MOUNTINGS

♦ Check the alignment of the pumps, motors, other actuators and piping at the normal service pressure
and after operation for normal periods of time.

FILTERS
♦ Watch the clogging indicators.

4.5.2.4 TROUBLESHOOTING
TROUBLESHOOTING INCLUDES

♦ fault-finding i.e. pinpointing of damage or malfunctions and ascertaining their causes.


♦ rectification i.e. repair or replacement of defective components to eliminate the primary causes of the
trouble.

HYDRAULIC TESTER

♦ A portable hydraulic tester makes it possible to measure pressures, volumes flow rates and temperatures.

REPAIR

♦ Most faults are repaired by replacing the defective components. In general, defective components are
repaired by the manufacturer or
♦ at the workshops of his agents. Provided the user has the know-how and equipment (such as test
benches), he can carry out the repairs himself. Spare parts lists and instructions for testing and repairing
the various components are available and provide valuable assistance.

FAULT FINDING

♦ If a fault occurs in the hydraulic system, use the hydraulic and electrical circuit diagrams to locate it by a
process of elimination
Leaks are a common source of trouble with hydraulic systems. If they occur at unions, they can often be
rectified by simply re-tightening. In the case of leaks from units, it is possible to replace seals and gaskets
(see spare parts lists).
Once the actual damage has been repaired, the primary cause must be eliminated. For example, if
equipment has failed due to dirt in the system, the fluid must be changed and the filters examined.

ELECTRO-HYDRAULIC SYSTEMS

♦ Stationary installations often have electro-hydraulic control systems. The combination of electrical with
hydraulic systems naturally makes fault-finding more difficult and requires good cooperation between
electricians and hydraulics engineers.

FAULT-FINDING CHART

There is no general recipe for finding faults owing to the huge variety of hydraulic systems. However, the
following chart provides a useful starting point.

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4.5.2.5 TROUBLESHOOTING

CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM


Source of the 1 2 3 4 5 6
Fault Mechn driving Intakte Pump Pressure line Return line Pressure
Consequence section conditions control valves
A Excessive 1. Coupling Resistance in 1. Pump speed 1. Pipe fixing As 4 A 1. Valve chat-
noise incorrectly Suction ine too too high missing or ters, worn
aligned Great because: 2. Maximum loose 1. Return line awing to
2. Coupling pump pres- 2. Not laid ends above fouled valve
loose 1. Cock insuc- sure ex- properly fluid level seat
tion line not ceeded 2. Return line 2. Insufficient
3. Coupling open or only 3. Cross-
faulty 3. Charge sections too filter clogged clamping
partly open (type not
4. Pumpor pump faulty small
2. Suction filter suitable)
motor clogged or 4. Shaft seal or 4. As 4 C
mouting packing on 3. Noise of flow
too small during statup
loose the suction
3. Suction line side faulty 4. Unfavour-
5. Other trans- clogged or
mission 5. Pump faulty able char-
leaking acteristic
component 6. Pressure
(V-belt, gear 4. Suction line 5. Incorrect
too small or and return
wheel) faulty lines re- design
oo many
6. Pump or bends in line versed
motor faulty 7. Regulating
5. Fluid level
7. Direction of too low system as-
rotation in- cillating
correct 8. As 1 A B
8. Confiuration
not optimal
for noise re-
duction
(elastic met-
als)

B Insufficient 1. Fault in As 2 A 1. Internal 1. Leaks 1. Excessive 1. Woking


force and Power leakage ow- 2. Excessive line resis- pressure set
torque at drives transmission ing to wear line resis- tance too low
(insufficient 2. V-belt or 2. Type unsuit- tance 2. Filter 2. Internal
pressure) Sprocke belt able 3. Pressure clogged leakage
slipping 3. Pump faulty filter clogged owing to
3. Incorrect wear
4. Governor
Direction of pressure set 3. Valve seat
rotation to low or fouled or
4. Motor faulty control de- damaged
5. Key on pump vice faulty 4. Spring
or motor broken
seared off. 5. Type unsuit-
able (setting
range too
low)

C Cylinder or As 1 A 1 - 7 As 2 A 1. Variable 1. Installation As 5 B As 6 A 1...2


motor capacity not com-
Movements pumps: pletely bled
Regulator 1. Excessively
jerky
fauty long un-
(fluctuations in
damped
pressure and 2. Pump faulty telecontrol
flow)
3. Feedback on line
pumps from 2. Unsuitable
the system tele-control
Regulators valve
(DMV; SRV)
4. Pilot valves
unsuitable

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM


Source of the 1 2 3 4 5 6
Fault Mechn driving Intakte Pump Pressure line Return line Pressure
Consequence section conditions control valves
D Drive fails to As 1 A 1 - 7 As 2 A 1. Internal As 4 B As 4 B As 6 B
turn or turns to leakage ow-
slowly ing to wear
(no delivery or
Sequence
2. Pump faulty
insuiffcient control:
delivery) 3. Supply and
1. Sequence
return lines
valve set too
reversed
high or faulty

E Operating . 1. Utilization 1. Line As 4 E 1. Excessive


temperature too coefficient crosssecton continuaus
high losses owign too smal delivery
to wear Conse- 2. Unsuitable
2. Variable quently fric- valve type
capacity tional resis- (cross-
pumps tance sections too
Regulator 2. Pressure small)
faulty filters 3. Pressure
3. Speed or clogged setting too
delivery too high
high 4. Resonse
time too long

F Pressure fluid 1. Leak in 1. Shaft seal or 1. Return line


foaming suction line packking on ends above
2. Fluid level intake side liquid level
too low faulty 2. Vortex effect
3. Tank design 2. Leakage line caused by
incorrect ot below oil poor routing
level

G Cylinder logs 1. Hoses too


elastic
2. Lines not
bled

H Lines hit during As 4 A Lines loose 1. Switches too


Switchng fault
1. Excessive 2. Throttles or
accumulator baffles dam-
capacity of ages
the pipe
sysem

I On/off switching 1. Pump faulty Sequence or


frequency of the 2. Accumulators cut off valve
pump to high system: incorrectly set
Pump too or faulty
smal

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM


Source of the 7 8 9 10 11
fault Flow control Control valves Pressure fluid Drive Other
Consequence valves (Motor, cyl.)
A Excessive noise 1. Valve oscillates 1. Valve chatters, 1. Problems with 1. Wear of bear-
and induces os- as solenoid fault intake, as ing surface
cillation in other or voltage too a) Fluid level to 2. As 3 A 7
regulators low low
2. Valve fauy b) Viscosity too
2. Noise of flow high
owing to wear
3. As 3 A 7 or dirt (temperature
to low)
3. Excessive
delivery 2. Fluid contami-
nated causing
4. Valves with damage and
adjustable clogging of de-
damping ad- vices
justment not
carried out 3. Fluid foaming
5. Check electrical
control system

B Insufficient force 1. Excessive 1. Incorrect 1. Viscosity too low 1. Internal leak- 1. Fault in control
and torque at pressure losses switching posi- thus leakage too age (e. g. cyl- or regulating
drives (insufficient tion (e. g. pres- great inder boolts cicuit of pres-
pressure) 2. Seltting incor- sureless circu- worn) sure (regulating
rect 2. Viscosity too
lation fails to high resistance 2. See 10 A control system)
3. As 3 A 7 switch off) to flow too great 2. Indicating in-
3. Excessive
2. Solenoid faulty 3. Fluid foams internal friction strument faulty
(poor effciently)
3. Internal leakage
owing to wear
4. Excessive
resistance to
flow
5. Spool sticks

C Jerky cylinder or 1. Valve fouled As 8 A 1. Pressure fluid 1. Stick slip ef- 1. Insfficient load
motor movements 2. As 7 A 1 fouled fect, as friction bracing on the
(fluctuations in 2. Pressure fluid of the cyinder rear of the out-
pressure and foamed boots too high. put (e. g. low-
delivery) Speed of hy- ering throttle,
draulic motor pressure drop
below mini- valve)
mum

D Output fals to turn 1. Delivery set too As 8 B As 9 B As 10 B Conditions for


or turns too slowly low 1. Output blocked starting not met
(no delivery or 1. Spool sticking (regulator faulty).
2. Unsuitable type (e. g. pistion
delivery too low) 2. Manually oper- seizure) Electrical control
(setting range line (plug-in con-
too low) ated valves
(cocks) not in nection) broken.
3. Valve clogged thriugh.Flow Signal elements (e.
(fouled) position g. pressure switch
set incorrectly or
faulty limit switch
not actuated)

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM


Source of the 7 8 9 10 11
fault Flow control Control valves Pressure fluid Drive Other
Effect valves (Motor, cyl.)
E Operating tem- 1. Set to exces- 1. Leakage losses As 9 B 1. Loss of effi- 1. Cooling capac-
perature too high sively low deliv- too high ciency owing to ity of the unit
ery (Pump de- 2. Pressureless wear (of the installa-
livers too much circulation fails 2. Excessive tion) too low n
through pres- to switch on internal friction relation to the
sure reliefvalve) (poor effiency) power rating or
3. Spool sticking the duty time
2. Valve faulty 3. Internal
leakeage 2. No pressureless
losses ciculation during
long breakes in
operation (with
pump running)
3. Insufficient
pressure fluid in
the installation
4. Coolant valve
fails to switch
5. Thermostat set
too high
6. No coolant or
fan failure
7. Coolant tem-
perature too
high
8. Ambiente tem-
perature too
high
9. Deposits in
cooler
10. Insufficient heat
emission ow-
ing to encap-
sulation

F Foaming of pres- 1. Unsuitable type


sure fluid
G Cylinder lags 1. Switching time 1. Internal leak- 1. Piloted check
setting too slow age valve dos not
2. Solenoid faulty 2. Inadequate close immedi-
leakage bleeding ately,as
a) slit fouled or
3. Valve fouled faulty
b) Circuit fault
2. Limit switch is
overrun

H Shocks during 1. Switching time 1. Pressure fluid 1. Masses and 1. No throttles


switching setting too fast foamed forces too high upstream of
2. Type unsuitable 2. No damping selector valves
(chane in orifice in accumulator
cross-section systems
too rapid)

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM


Source of the 7 8 9 10 11
fault Flow control Control valves Pressure fluid Drive Other
Effect valves (Motor, cyl.)
I On/off switching Installations with
frequency of the pressure accumu-
pump to high lators: Pre-set gas
pressure too low.
Bladder diaphragm
faulty:
Pressure switch
set incorrectly

TYPES OF FLUID

The satisfactory operation, long life and efficiency of a hydraulic system depend to a great extent on the
selection of a suitable fluid.

VISCOSITY

Pumps and hydraulic motors require suitable operating viscosity. Too high a viscosity (thick fluid) leads to
cavitation problems. Too low a viscosity causes higher leakage losses, higher temperatures with a
corresponding further drop in viscosity and ultimatey loss of the lubrication properties of the fluid.

For further information, please refer to the TTS-LMG oil table

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4.6 ASSEMBLY AND DISMANTLING


4.6.1 GENERAL REMARKS
This chapter describes procedures for fitting and removing ropes and other components. The descriptions
are provided for guidance only and do not preclude the use of other suitable methods.
The accident prevention regulations must be observed at all times.

SAFETY RULES

1. Observe accident prevention regulations and stipulated working procedures at all times.
2. Act in a responsible manner, and pay just as much attention to the safety of others as to your own safety.
3. Check all tools and safety equipment frequently to make sure they are safe to use.
4. Inform yourself and others about the dangers of the work and workplace, and about safe ways of
doing routine jobs.
5. Ask others about ways of doing unusual jobs. Getting on with a job without first considering all steps
can lead to expensive accidents.
6. Consider potential causes of accidents and injury before embarking on a project. Take suitable
precautions to protect yourself and others.
7. Warn others about potential causes of accidents and injury if they are seen working without taking
suitable precautions and thus creating potential hazards.
8. Increased attention is needed if working conditions and procedures change.
9. Inform your superiors immediately of dangerous actions or conditions. Do not leave it to others.
10. Keep your place of work tidy. Clear away all tools and materials, and make sure they are stored properly.

Before starting work, read the appropriate parts of the manual and study both the sectional views shown
in the spare parts catalogue and the corresponding drawings.

Use only new parts when replacing or repairing parts and assemblies.

WELDING

The earth connection must be located as close as possible to the welding point. Make sure that the welding
current is not conducted through rolling bearings, gears or similar assemblies.

SPARE PARTS CATALOGUE

The assemblies and subassemblies are listed in detail together with the quantities required and the cata-
logue number (order no.) of each part in the spare parts catalogue.

FITTING AND REMOVING PARTS

Recommendations for handling parts.


The following general precautions should be taken when handling parts:
♦ When lifting or removing parts, make sure that the hoists are adequate for the job.
♦ The weights of assemblies and parts are stated in the spare parts catalogue to help you choose the
right cranes, chain tackles, etc.
♦ Clean and lubricate all parts thoroughly, and check them carefully for damage and defects.

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MACHINED AND LOAD-CARRYING SURFACES

♦ Take special care to prevent damage to machined or load-carrying surfaces. Machined.


♦ and load-carrying surfaces must be protected by a coat of oil or rust inhibitor if they will be exposed to
the open air for a considerable period of time
♦ Machined surfaces must be placed on timbers or special supports NEVER place them on the bare
ground.

REMOVAL FROM STORAGE

Before reassembling parts, the Tust inhibitor must be removed from all surfaces by means of a suitable
solvent. Oil poured into spaces to prevent rust must be drained off completely. Complete flushing should
be unnecessary. Inspect all parts for signs of corrosion or damage that might impair the operation of
mechanical assemblies. All problems must be dealt with before the parts are installed or assembled.

SAFE FASTENING OF LOADS

1. The physical characteristics of a load (weight, size and shape) must be checked before it is lifted or
handled.
2. The weights of the main assemblies and the components are generally stated in the maintenance
manual. lf the weight of a part can not be found, the supervisor must be asked before attempting to
lift it.
3. The size and shape of a load govern the method used to secure it - i.e. slings, basket or sling with a
special cradle. The size and shape also determine the gear used to fasten it (wire rope, alloy steel
chain, hook eyes, shackle, etc.).
4. The correct size of the fastening gear can be selected after the weight of the load, the angle at which
it acts and the gear for fastening it have been ascertained.
5. lf the load to be lifted exceeds the permissible safe working load of a given sling size or the
corresponding fastening gear, the next larger size capable of carrying the load must be used. The
permissible safe working load of the fastening gear must not be exceeded.
6. lf there is any doubt regarding the best way to secure a load or conceming the type and size of gear
needed to secure it, the supervisor must be consulted.
7. The fastening gear must be carefully inspected when it is taken from the rack in the store. Damaged
gear must be excluded from use and must be reported to the supervisor.
8. Do not overload fastening gear. This will prolong its service life and enhance safety when using it.
lt must also be protected by sacking, iron edge protectors or timbers, etc., against sharp edges of the
load. Machined surfaces of the load must be protected against damage by the fastening gear.
Material used for protection should be secured to the load or sling to prevent it from falling when the
sling is slackened.
9. The sling can be hauled taut after the fastening gear has been correctly positioned. Pay attention to
the positions of fingers to prevent them from being squashed. See Fig. a and b

Fig. a: Position of hand when Fig. b: Position of hand when


hauling sling tight. guiding hook.

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10.The agreed crane signals shall be given to the crane driver clearly and in his view so that the load can
be moved as required. See the item
"Hand signals" at the end of this chapter.
11.Before the signal is given to lift the load, the person who has secured the load must make the following
checks:
There must be no loose material , tools, dirt, bolts, etc., lying on the load.
Unused ends of the sling must be secured by threading them through the main ring or fastening them
together with a shackle. Unused ends must not hang loose.
All persons must be outside the danger zone before the lifting operation starts.
12.After the sling has been hauled taut, check that the fastening gear is secure and symmetric at all points.
Check the fastening gear to ensure that it is still protected against sharp edges and that machined
surfaces are protected from the fastening gear. The load brake must be checked when the load has been
lifted a few centimetres from the ground and is being carried entirely by the hoisting gear. The fastening
gear must also be checked again in all places-
13.Do not move the load over the heads of people. lf this is unavoidable, adequate waming must be given
(signal horn).
14.Set the load down in a selected place. Sufficient shoring material must already be available there.
15.Stop the load just before setting it down on the ground so that the shoring can be readjusted to suit the
position of the load.
DANGER!
Keep hands and feet clear of squeezing points between the shoring and the load.
16. Correctly positioned shoring ensures that the load will lie in the desired stable position after it has been
set down on the ground. Take the following into account when arranging the piling:
Weight of the load: The piling must form a stable surface capable of supporting the whole weight of the
load.
Machined surfaces of the load: machined surfaces must be protected by wadding the supports and
fastening gear with sacking, firm cardboard, leather straps, etc.
Load size and shape: Shafts, forgings and rings must be wedged and supported Shorings of identical
dimensions ensure that the load will lie flat and evenly. Loads which can easily become unbalanced must
be adequately shored.
Working surfaces: The shoring must be arranged or adjusted to compensate for irregular surfaces-
Condition of the shoring: Shoring material must be in good condition and of a uniform size. Do not use
damaged shoring, e.g. shoring which has rounded edges, is rotten or broken, or contains large knots.

17. Lower the load slowly until its full weight is supported by the ground or shoring.

WARNING

Equipment used to protect the fastening gear such as iron edge protectors, leather straps or timbers
can fall out as the sling becomes slack. Personnel must therefore keep clear of these areas until the
se items have been removed.
18. After the lifting operation has been completed, remove the fastening gear and inspect it for damage. lf
it is no longer needed, it must be returned to the storage rack.

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4.6.2 ROPE REPLACEMENT


The rope reevings shown below are schematic representations !

1. Dismantle rope from locating point on crane tower, catch rope and put it down on deck.

2. Cut off wire rope socket.

3. Join cut-off old rope end to smooth new rope end using a chinese finger.

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4. Run the wire rope off the winch drum, and let the old rope run down in front of the crane tower until only
four windings of the old rope remain on the drum.

5. Unbolt wire rope clamps on drum.

6. Run the rope back on the winch drum – the four windings of the old rope which are still on the drum will
now run to the other drum end – let the rope that comes loose run off the winch to the rear.

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7. Guide the rope running off back to the start of the winch drum leaving the first four windings on the drum
free.

8. Run the rope off the drum until the windings on the end of the winchhave run off and at the same time,
four new windings of the old rope have run on the winch drum start.

9. Repeat this until the new rope has been pulled through the rope sheaves on the drum. Run abt. 4
windings of the new ropeon the winch drum, catch the rope and remove the chinese finger between
old and new ropes

10. Fasten end of new rope in the rope clamps of the drum.

11. Run off the four rope windings which have been run on the drum at random and start running the rope
on the drum normally, starting at the rope clamps.

12. Fasten rope socket to locating point on crane tower.

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4.6.3 HAND SIGNALS FOR CRANES

HOIST LOWER USE MAIN HOIST


With forearm vertical, forefinger With arm extended downward, Tap fist on head; then use regular
pointing uo, move in smal hori- forefinger pointing down, mowe singnals.
zontal circle. hand in small horizontal circles

SWING STOP EMERGENCY STOP


Arm extended point with finger in Arm extended, palm down, hold Arm extended, palm down move
direction of swing of boom. position rigidly. hand rapidly right and left.

USE WHIPLINE RAISE BOOM LOWER BOOM


(Auxiliary Hoist) Tap elbow with Arm extended, finger closed, Arm extended, fingers closed,
one hand; then use regular sig- thumb pointing upward. thumb pointing downward.
nals.

TRAVEL TRAVEL MOVE SLOWLY


Arm extended forward, hand (Both Tracks.) Use one hand to give any motion
open and slightly raised, make Use both fists in front of body, signal and place other hand mo-
pushing motion in direction of making a circular motion about tionless in front of hand giving the
travel. each other, indicating direction of motion signal. (Hoist slowly
travel; forward or backward. shown as an example.)

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4.6.4 TIGHTENING TORQUES FOR HEXAGON BOLTS AND


SPANNER BOLTS

Nominal Pre-load Torques


thread kp kpm
dia. Fv in Ma in
Nm Nm
Property Class Property Class
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M5 535 635 895 1 070 0,50 0,60 0,85 1,0
5 350 6 350 8 950 10 700 5,00 6,00 8,50 10,00
M6 755 900 1 260 1 510 0,85 1,0 1,4 1,7
7 550 9 000 12 600 15 100 8,50 10,0 14,0 17,0
M8 1 390 1 650 2 320 2 790 2,1 2,5 3,5 4,1
13 900 16 500 23 200 27 900 21,0 25,0 35,0 41,0
M 10 2 210 2 620 3 690 4 430 4,1 4,9 6,9 8,3
22 100 26 200 36 900 44 300 41,0 49,0 69,0 83,0
M 12 3 240 3 850 5 400 6 450 7,2 8,6 12,0 14,5
32 400 38 500 54 000 64 500 72,0 86,0 120 145
M 16 6 150 7 300 10 200 12 300 18,0 21,0 29,5 35,5
61 500 73 000 102 000 123 000 180 120 295 355
M 20 9 600 11 400 16 000 19 200 34,5 41 59,7 69
96 000 114 000 160 000 192 000 345 410 597 690
M 24 13 800 16 400 23 000 27 600 60 71 102 120
138 000 164 000 230 000 276 000 600 710 1020 1200
M 30 22 100 26 200 36 800 44 200 120 145 200 240
221 000 262 000 368 000 442 000 1 200 1 450 2 000 2 400
M 36 32 300 38 200 53 800 64 500 214 253 356 428
323 000 382 000 538 000 645 000 2 140 2 530 3 560 4 280

The tightening torques habe been calculated with the following frication coefficients:

µ tot. = 0.14 for oiled bolts


µ tot. = 0.16 for bolts secured with liquid (Loctite, Omnifit)

CHECK OF HSFG BOLT CONNECTIONS

Check HSFG bolt connections visually by examining state of paint work of components bolted together.
If paint appears cracked or flakes off this means that the bolt connection moves, and the bolts must be
replaced at once.
Use only perfect torque spanners for tightening the bolts.
Check to be carried out monthly.

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4.6.5 INSTALLATION OF HOSES

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5. SPECIFICATION OF THE ELECTRICAL


EQUIPMENT
SINGLE DECK CRANE

TABLE OF CONTENTS

5. SPECIFICATION OF THE ELECTRICAL EQUIPMENT 1


5.1 TECHNICAL DATA 3
5.2 GENERAL DESCRIPTION 4
5.2.1 SUPPLY SOURCES 4
5.2.2 GENERAL DRIVE SYSTEM REMARKS 5
5.2.3 CRANE OPERATION (NORMAL MODE) 6
5.3 DESCRIPTION OF ELECTRICAL COMPONENTS 7
5.3.1 SWITCH GEAR 7
5.3.2 SENSORS 8
5.3.3 LIMIT SWITCHES 9
5.3.3.1 GEARED LIMIT SWITCHES - SERIES 51 9
5.3.3.2 ASSEMBLY OF THE GEARED LIMIT SWITCH 10
5.3.3.3 CONTACT ADJUSTMENT (SEE FIG. 3) 11
5.3.3.4 BLOCK ADJUSTMENT (SEE FIG. 4) 12
5.3.4 PROGRAMMABLE LOGIC CONTROLLER (PLC) 13
5.3.4.1 COMPACT MODULE PWM 25
5.3.4.2 COMPACT MODULE DIGITAL / ANALOGE 37
5.3.4.3 CABINET-MODULE 49
5.3.4.4 INCLINOMETER ( SPECIAL EQUIPMENT ) 58
5.3.4.5 LCD-DISPLAY 65
5.4 DISPLAY AND INDICATORS 70
5.4.1 INDICATOR LIGHTS 70
5.4.2 DISPLAY OF CRANE INFORMATIONS 70
5.4.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT PANEL) 71
5.4.3.1 OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS 72
5.4.3.2 HOW TO ENTER MAIN MENU 72
5.5 COMMISSIONING AND ADJUSTMENTS 79
5.5.1 GENERAL DEFAULT SETTING 80
5.5.2 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER PUMP) 81
5.5.3 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT) 82
5.5.3.1 SETTING LAYER CHANGE POSITION 85
5.5.3.2 RESETTING OF REFERENCE POSITIONS 86
5.5.4 ADJUSTABLE WORKING RANGE LIMITATION 89
5.5.5 SPECIAL MODUS FOR ROPE CHANGE 92
5.5.6 CALIBRATION OF LOAD INDICATION 93
5.5.7 REPORT OF CHANGE 94
5.5.8 ZERO-SETTING OF POTENTIOMETERS 95
5.5.9 SETTING OF OPERATION HOURS 95
5.5.10 ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT) 95
5.6 INTERLOCKING FOR SEA VOYAGE (SPECIAL EQUIPMENT) 96
5.6.1 LOCKING 96
5.6.2 UNLOCKING 97
5.6.3 FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM 98
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5.6.3.1 SETTING THE PRESSURE LIMITING VALVE 101


5.6.3.2 LOCK / UNLOCK IN EMERGENCY OPERATION 102
5.7 PMS – POWER MANAGEMENT SYSTEM (SPECIAL EQUIPMENT) 103
5.7.1 FUNCTIONAL DESCRIPTION 103
5.8 SPECIAL OPERATION MODES 104
5.8.1 TEST OPERATION 104
5.8.2 POWER / SPEED REDUCTION 104
5.8.3 DISABLE TRIMOT 104
5.9 TROUBLE SHOOTING 105
5.9.1 GENERAL REMARKS 105
5.9.1.1 POWER SUPPLY AND CONTROL VOLTAGE 106
5.9.1.2 PLC STATUS INDICATORS 106
5.9.1.3 ADDITIONAL INDICATIONS 106
5.9.2 LIST OF FAULT MESSAGES 107
5.10 EMERGENCY OPERATION SYSTEM 160
5.11 SERVICE 162
5.11.1 MAINTENANCE INFORMATION FOR HYDRAULICAL 162
5.11.2 MAINTENANCE OF ELECTRICAL EQUIPMENT 163
5.11.3 SPARE PARTS 165
5.11.4 CIRCUIT DIAGRAMS 166

We reserve the right to make technical alterations without prior notice. Technische Änderungen behalten wir uns ohne
vorherige Ankündigung vor. • • Nous nous réservons le droit de modifier les données techniques sans préavis.

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5.1 TECHNICAL DATA

The electrical equipment of the crane conforms to the Rules of the classification societies.
It is designed for operation at ambient temperatures between -25 and +45 °C.

Supply voltages
Mains supply: 440 V AC, 60 Hz, 3-phase
Auxiliary supply: 220 V AC, 60 Hz, 2-phase
Control voltage: 24 V DC

List of motors
Pump drive main motor: 160 kW, duty cycle S1, 4 pole
Boost pump (control oil pump): 9 kW, duty cycle S1, 4 pole
Hydraulic oil cooler: 1,5 kW, duty cycle S1, 4 pole

Lighting and heating


Interior lighting: 3 x 20 W
Jib floodlight: 1000 W, halogen
Working floodlight below cabin: 2 x 1000 W, halogen
Warning light red: 1 x 60 W
Machinery space heating: 2000 W
Cabin heating: 1400 W

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5.2 GENERAL DESCRIPTION

5.2.1 SUPPLY SOURCES


Before starting work on the electrical system, switch off all supply sources to the crane and check that all
equipment is inactive.

Power is fed to the crane via a slip ring assembly containing


Main supply 4 rings (3 + earth) for 500 V, 600 A
Auxiliary supply and controls 10 rings for 250 V, 60 A

The main supply is taken from the slip ring body to the connection terminals of main switch =M01-S1.

To switch on power supply to the crane, shift the switch to the position "1". The switch must be reset to the
position "0" before leaving the crane.
The switch can be secured in the position "0" by means of a padlock to prevent unauthorised tampering.

The auxiliary supply leads from the slip ring body to terminals X3/1 and -2 in the control cabinet.
The auxiliary supply can be switched off by means of the master switch (=M01-S2) for repair and maintenance
work.
From master switch =M01-S2 the feeder branches to the automatic circuit breakers =M03-F31 to -F36 and the
various lighting and heating consumer circuits.

The auxiliary supply should be constantly connected so that


the anti-condensation heater is operational.

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5.2.2 GENERAL DRIVE SYSTEM REMARKS


All crane motions are powered by electro-hydraulically controlled hydraulic motors.
While the crane is in use, the main motor (=M02-M1) runs continuously at constant speed and drives the
hydraulic pumps via a multiple distribution gear. The hydraulic pumps supply oil independently to the
hoisting, luffing and slewing gear motors.
The pumps are electro-hydraulically controlled by means of control units with two proportional solenoid
valves each.
If they receive no control power, the pumps run with zero stroke and, therefore without oil delivery. The rate
and direction of pump delivery is governed by the current flowing through the solenoids of the proportional
valves.
Variation of the solenoid current thus permits infinitely variable control of the pump delivery and,
consequently, of the drive speeds. The solenoid current is about 200 to 600 mA.. This value depends on
the deflection of the control lever if no restrictions are given (e.g. speed limitation by rope length
measurement), at minimal deflection it is about 200 mA – at full about 600 mA..

The hoisting gear circuit incorporates a variable displacement hydraulic motor (TRIMOT) which permits
small loads or the empty hook to be handled at higher speeds. This motor is controlled by a proportional
solenoid valve drawing a current of 200 to 500 mA. The actual control current varies according to the load
on the hoisting gear, which is measured by pressure sensor.
Besides the pump adjustment arrangements, the control system also controls solenoid valves of brakes
used enable the various drives.

Further particulars are given in the specification of the hydraulic system.

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5.2.3 CRANE OPERATION (NORMAL MODE)


By turning the selector switch =M07-S06 <START> into ON-position, contactor =M02-K11 will be activated
and starts the booster (control oil) pump.
Additionally the crane system sends a POWER REQUEST SIGNAL to the ship´s control system.
When the crane system receives a POWER AVAILABLE SIGNAL from the ship´s control system the time
relay = M02-K4 switches on the contactors = M01-K2 and -K3 to start the main motor by means of a star-
delta circuit. The star/delta change is switched over after about 4 seconds.
If the POWER AVAILABLE SIGNAL is not given within 50 seconds, the starting procedure of the crane will
be stopped and must be repeated for a new start. <FAULT OF PMS-SYSTEM>
During the starting sequence <START UP OF DRIVES > is shown on the display.
After that the system will make an auto-calibration of the drives, displayed with <SELF ADJUSTMENT>.

If all systems are in good order, <READY FOR OPERATION> is shown and the crane can be operated by
shifting the joystick (control lever).
If the joystick (control lever) is shifted too soon, or the deadman switch (optional equipment) is actuated,
the status monitoring system C006 responds and prevents operation of the crane.

The crane is controlled by a programmable logic control (PLC). The PLC processes the digital input signals
it receives from the switches (contacts of contactors and the joystick (control lever), limit switches, etc.) and
the analogue values received from the controls (set-up values) and sensors (pressures, temperatures) in
the way defined by the algorithms of the stored programs (software), produces the output control signals
needed to switch the indicator lights, contactors or solenoid valves and generates the pulse-width
modulated (PWM) control current for the proportional solenoid valves controlling the delivery of the pumps.

In normal operation mode the main crane data (load, outreach etc.) are shown on the display.

When the crane operation is finished the drives will be stopped by turning the selector switch =M07-S06
into OFF-position and the drives will be shut down by the control system. < SYSTEM SHUT DOWN> is
now displayed.

Preheating the hydraulic oil


At sub-zero temperatures, the hydraulic oil should be preheated before the crane is put into operation. This
is done by turning on the crane control system by means of the main switch =M01-S1.
The oil temperature is measured by temperature sensor =M07-B01. If the temperature is below 5°C, the
feed oil (booster) pump will start and heat up the hydraulic oil until the temperature reaches 8°C.

Cooling
The hydraulic oil cooler is switched on and off automatically during crane operation when the temperature
exceeds 50°C depending on the oil temperature in the hoisting gear circuit (sensor =M07-B01).
If the pump drive is switched off while the cooling system is running, the main motor stops, but the booster
pump hydraulic oil cooler and (engine room fan) remain in operation to cool the oil down. It keeps running
until the oil temperature is below 50°C, but operation in this cooling mode ceases after 10 minutes at the
latest.

DO NOT STOP the drives by using the emergency button.

The crane drives must be stopped when the driver is leaving the cabin.

When the crane has stopped owing to a fault or a loss of power supply the
<START> switch must be turned to OFF-position before the crane can be started
again.

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5.3 DESCRIPTION OF ELECTRICAL COMPONENTS

5.3.1 SWITCH GEAR


The power switch gear consists of contactors =M02-K2 (star circuit contactor) and =M02-K3 (delta circuit
contactor).
The control voltage of these contactors is 440/400 V ):
Contactors =M02-K2 and -K3 are switched by timing relay =M02-K4.

The contactors =M02-K11 + -K12 both have a control voltage of 24 V and, like =M027-K4, are switched
directly by a PLC output.

The main motor is protected against overload by thermistors and additionally by monitoring the amperage
with the current-transformer =M02-T1.
The aux. drive motors =M02-M11 + -M12 are protected from overload by MCB´s.

The 24 V DC control voltage is produced by the three-phase rectifier bridge =M05-U1.

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5.3.2 SENSORS
The current-transformer =M02-T1 measures the amperage of the main motor.
The output signal is 0 – 20 mA DC, corresponding to the primary current 0 – 500 amp. AC.
The current-transformer is supplied with 220 V AC (auxiliary supply source / circuit breaker =M03-F34)

The pressure of the hoisting and luffing gear circuits is monitored by pressure sensors (=M07-B10 / -B20)
which convert the hydraulic pressure 0 – 600 bar into an analogue output signal 4-20 mA.

The oil temperature is monitored by a temperature sensors (=M07-B01) which convert the temperature
-50 to +150°C bar into an analogue output signal 4-20 mA.

The rope length will be measured by incremental encoders (=M06-IE16 / -IE26), they are mounted inside
the limit switches.

The control lever (joysticks) contain potentiometers, are permanently connected to 24 V supply, and their
output voltages vary, depending on joystick deflection, between 12 V in the zero or neutral position and 0
V respectively. 24 V at maximum joystick deflection.

A 2-axle-inclinometer (=M07-A8) is installed in the control cabinet for measuring the heeling of the crane
(ship).
The heeling angle is displayed in the right-hand control desk. (optional equipment)

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5.3.3 LIMIT SWITCHES


The travel route of the hoisting gear and also the luffing gear are limited by rope length measurement and
additionally by mechanical limit switches.
These limit switches are directly mounted on the winches of the corresponding drives.

Main-Hoisting gear - defines the highest and lowest hook positions:


Gear-driven cam actuated limit switch series 51, with incremental encoder.

Luffing gear - defines the maximum and minimum outreaches :


Gear-driven cam-actuated limit switch series 51, with incremental encoder.

5.3.3.1 GEARED LIMIT SWITCHES - SERIES 51


Construction, functioning, constructional male characteristics (see Fig.1)

The fitted maintenance-free planetary gears with or without spur gear pre-step down are made of
thermoplastic plastics.

Because of the applied modular technology the switching steps are equipped with the same parts as the
planetary gears. A cam disc and an adjusting worm are added.

The planetary and switching steps as well as the spur gear pre-step down (not necessary for certain
reductions) are mounted into a glass-fibre reinforced modular housing of synthetic material.

The contacts are actuated by the cam discs of the switching steps.

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5.3.3.2 ASSEMBLY OF THE GEARED LIMIT SWITCH


Caution!
Every person involved in operating, maintaining and repairing the limit switch must be authorised,
adequately trained and instructed.
Each operator must have read and understood this instruction manual and must have been instructed in
particular regarding to possible danger.
Mounting position of the geared limit switch with or without protective housing as required. The drive shall
be transmitted by a flexible connection, e.g. a flexible diaphragm coupling. With chain or synchronous belt
drive, etc. the admissible radial force Fmax must not be exceeded (see Fig. 2)., With the exception of
compact aluminium housings, a grooved ball bearing is fitted to protective housings in addition to the plain
bearing. When using these housings, the admissible graphical values can be doubled.
Avoid axial forces onto the input shaft.
The ideal drive is transmitted by a torsionally stiff flexible coupling with low axial and radial restoring forces.
Thereby misalignment and axial displacement are balanced.
After adjustment of the switching point on commissioning, the limit switch shall immediately be re-locked by
the cap in order to prevent penetrating dust or water from affecting the switching-off safety.
Accidents caused by touching live parts are thereby avoided too.
When fitting the cap, make sure that all screws are tightened uniformly in order to avoid tilting of the cap
and a bad pressuring of the sealing.
The used PG-glands comply with protection directive IP 68.
When fitting the cable, pay particular attention that after insertion of the cable the tightening nut is carefully
tightened. The wrench torque shall be between 2 and 3 Nm to the type of cable.
As a permanent deformation of the plastic sheath of some cables can occur at the contact point in the
cable gland because of contraction, it is recommended to retighten the tightening nut by 1/2 revolution after
3 to 4 days.
The cable conduct to the limit switch shall always be executed to prevent the cable from conducting water
to the gland.

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5.3.3.3 CONTACT ADJUSTMENT (SEE FIG. 3)


For contact adjustment, remove the cap of the limit switch.
Thereby the live contact connections are laid bare.
Danger !
Do not touch live parts!

An infinitely adjustable cam disc is provided for each contact. Independent of each other, the cam discs (1)
can be set with the adjusting worm (2). lt is not necessary to loosen any parts for the adjustment. The
worm is self-locking. The worm can be turned by means of a screwdriver of 1 0 mm or 4 mm or by means
of a hexagon socket screw key of 4mm. mm or with a 4 mm hexagonal internal key.

When turning the worm through one clockwise revolution (360º), the cam disc is turned clockwise as well
through 2,464º (view of the rear part, the B-side of the switch).

The standard cam discs are designed to dispose of a max. useful travel and a max. overtravel Cam discs
with other useful travels can be fitted as special discs.

When exceeding the overtravel, the switch is not damaged. The contact, however, is opened or closed
again.

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5.3.3.4 BLOCK ADJUSTMENT (SEE FIG. 4)

Functioning
The planetary gear construction allows a block adjustment in addition to the individual contact adjustment
from the usable revolution 17.5. The final gear stage is also provided with an adjusting worm, coloured
black. All cam discs (1) can be commonly adjusted by means of this adjusting worm (2). The relative
adjustments of the individual contacts to each other are not modified.

When turning the black worm clockwise through one revolution (360°), the cam discs are also turned
clockwise by 0.575° (view of the rear part, the B-side of the switch).

Accessories for block adjustment


By means of an indicating plate (3), located on the rear side (B-side) of the switch, the adjustment can be
read on a rough scale (4) (5º-graduation) at the rear panel. The indicating plate shows the position of the
last cam disc. After adjustment of the last cam disc, the indicator (5) shall be set to zero. The disc is
seated and can be turned manually.

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5.3.4 PROGRAMMABLE LOGIC CONTROLLER (PLC)


Hardware description
Most of the work involved in crane control is performed by the PLC, which receives all control signals,
processes them as foreseen by the stored program and generates appropriate control signals for the final
control units.
The 24 V supply for the PLC is fed across fuses =M05-F21 and -F22.
The control unit consists of a Controller R360 (PLC), three Compact modules, a Cabinet module and a
LCD-Display.

All components are networked over CAN-BUS interface and located as follow:

ITEM located
Controller R360 Electrical control cabinet
Cabinet Module r-h Control desk in crane cabin
Compact Module PWM Nearby the hydraulic pumps
Compact Module Analogue Nearby the hydraulic pumps
Compact Module Digital Nearby the hydraulic pumps
LCD-Display r-h Control desk in crane cabin

The modules must be plugged in at the specified locations and nowhere else.

For more detailed information please refer to the unit specification supplied by ifm electronic.

The PLC (Programmable Logic Controller) controls and monitors the electro hydraulic system of the crane.
The status of current signals and operating data are continuously fed to the PLC where they are processed in
accordance with the control program (software) and stored. If the control system malfunctions, the fault should
first be sought outside the PLC as experience has shown that faults are much more common in the PLC
periphery than in the PLC itself.

In any case, PLC should be replaced only as a last resort to eliminate a fault as it leads to loss of stored
information and all setting work has to be repeated.

Before replacing these modules, the status of the operating hour counters must also be noted down as they
are all reset to "000" during the setting work.

General information about the CAN-BUS ( CAN –open )


All components are networked over CAN-BUS. This is 2-wire-system, called CAN_H and CAN_L..
When the network system is operational on all components the green LED is blinking with 2 Hz.

All components are connected in serial, that means whenever the control line is physically interrupted, the
complete system will not work.
Both ends of the network must be provided with a 120Ω resistor, in the crane network these resistors are
located at the compact module =M07-A2 and the terminal strip X72 in the right control desk console.
When the bus network is physically OK, you must measure a resistance of 60Ω.

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NOTES

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CONTROLLER R360

Mounting - and installation instructions

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Safety instructions

This description is part of the unit. It contains texts and drawings


concerning the correct handling of the controller and must be read
before installation or use.

Observe the information of the description. Non-observance of the notes,


operation which is not in accordance with use as prescribed below, wrong
installation or handling can result in serious harm concerning the safety of
persons and plant.
The instructions are for authorised persons in accordance with the EMC
and low voltage guidelines. The controllers must be installed and
commissioned by a skilled electrician (programmer or service technician).
If the unit is not supplied by the mobile on-board system (12/24 V battery
operation) it must be ensured that the external voltage is generated and
supplied according to the criteria for safety extra-low voltage (SELV) as
supplied without further measures to the connected controller, the sensors,
and the actuators.
The wiring of all signals in connection with the SELV circuit of the unit must
also comply with the SELV criteria (safe extra-low voltage, safe electrical
separation from other electric circuits).
If the supplied SELV voltage has an external connection to ground (SELV
becomes PELV) the responsibility lies with the user and the respective
national regulations for installation must be complied with. All statements in
these operating instructions refer to the unit the SELV voltage of which is
not grounded.
The terminals may only be supplied with the signals indicated in the
technical data or on the unit label and only the approved accessories of Ifm
Electronic GmbH may be connected.
The unit can be operated within a wide temperature range according to the
technical specifications indicated below. Due to the additional self-heating
the housing walls can have high perceptible temperatures when touched in
hot environments.
In case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the unit can lead to considerable risks for the safety of
persons and plant. It is not permitted and leads to the exclusion of any
liability and warranty claims.

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CLASSICCONTROLLER

Function and features


The freely programmable controllers of the "ClassicController R 360" series are rated for use under difficult
conditions (e.g. extended temperature range, strong vibration, intensive EMC interference).
They are thus suitable for direct mounting into machines in mobile and rugged applications. Due to their
specification the inputs and outputs are especially rated for this use. Integrated hardware and software
functions (operating system) offer high protection of the machine.

The controllers can be used as CANopen master. The controllers


"ClassicController R 360" are not approved for safety-relevant tasks in the
field of personal safety.

Programming
The application software can be easily created by the user with the Ifm programming system "ecolog 100
plus" according to IEC 61131-3.
In addition to the programming system the complete system manual is required to program the controller.
If this manual is not available, please contact one of the Ifm branch offices overleaf for your free copy. The
system manual (pdf format) can also be downloaded from the web (www.ifm-electronic.com)..

System manual R 360; English (order no. EC2041)


Data sheet direct CR0505 Additional data

The user is responsible for the safe functioning of the application


programs which he creates himself. If necessary, he must additionally
obtain approval according to the corresponding national regulations
issued by the corresponding testing and supervisory organisations.
NGLISH

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CLASSICCONTROLLER

Mounting
In order to expose the controller to the minimum mechanical stress it should preferably be mounted
horizontally or vertically on the mounting panel. The module must be fixed with four screws to DIN 7500 or
DIN 7984 (M5 x L).
If possible, the controller should be mounted in such a way that the cable entry of the plug points
downwards.
As the self-heating of the electronics of the unit is dissipated via the housing, sufficient cooling must be
ensured in case of "sandwich-mounting" of controllers.

Electrical connection
To guarantee the electrical interference protection of the controller, the housing must be
connected to GND (e.g. to the ground of the vehicle). To protect the whole system (wiring and
controller) the individual electric circuits must be protected.

Designation Potential Pin no. Fuse


supply voltage sensors/module VBB S 23 max. 1 A
supply voltage outputs VBB O 05 max. 15 A
supply voltage via relays VBB R 34 max. 15 A

Interaction between the inputs and outputs within one group of connections
In the application, the following must be observed as regards the use of the terminals as input and output:
Within one output group inputs and outputs should not be mixed. One output group is marked by a
common VBBX potential.
The background is a possible internal cross-connection of the outputs from the externally supplied inputs.
This may occur unexpectedly if the supply to the outputs is switched off externally.
Should a mixture still be carried out for reasons of optimising the terminals, please read in detail about the
situation described in the system manual and the restrictions resulting from this. Follow these instructions
for your application and keep records of this.

Maintenance, repair and disposal


As the Controller does not contain any components which must be maintained by the user, the housing
must not be opened. The repair of the controller may only be carried out by the manufacturer. The disposal
must be carried out according to the corresponding national environmental regulations.

Declaration of conformity
The CE-marking is applied on the basis of the EMC guideline EMC 89/336/EEC implemented in the
standards EN 61000-6-4 (2001) and EN 61000-6-2 (2001) as well as the low voltage guideline
NS73/23/EEC implemented in the standard EN 61010-1 (2001). ENGLISH

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CLASSICCONTROLLER

NOTES

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5.3.4.1 COMPACT MODULE PWM

Mounting - and installation instructions


DEUTSCH E

COMPACTMODUL METAL CR2031

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Safety instructions
This description is part of the unit. It contains texts and
drawings concerning the correct handling of the module and
must be read before installation or use.
Observe the information of the description. Non-observance of the notes,
operation which is not in accordance with use as prescribed below, wrong
installation or handling can result in serious harm concerning the safety of
persons and plant.
The instructions are for authorised persons in accordance with the EMC and
low voltage guidelines. The unit must be installed and commissioned by a
skilled electrician (programmer or service technician). The device may only
be installed, connected and commissioned by qualified personnel.
Disconnect the device externally before doing any work on it. If necessary,
also disconnect separately supplied output load circuits.
If the unit is not supplied with the mobile on-board system (12/24 V battery
operation) it must be ensured that the external voltage is generated and
supplied according to the criteria for safety extra-low voltage (SELV) as this
is supplied without further measures to the connected controller, the
sensors, and the actuators.
The wiring of all signals in connection with the SELV circuit of the unit must
also comply with the SELV criteria (safe extra-low voltage, safe electrical
separation from other electric circuits).
If the supplied SELV voltage has an external connection to ground (SELV
becomes PELV) the responsibility lies with the user and the respective
national regulations for installation must be complied with. All statements in
these operating instructions refer to the unit the SELV voltage of which is not
grounded.
The terminals may only be supplied with the signals indicated in the
technical data or on the unit label and only the approved accessories of Ifm
Electronic GmbH may be connected.
The unit can be operated within a wide temperature range according to the
technical specifications indicated below. Due to the additional self-heating
the housing walls can have high perceptible temperatures when touched in
hot environments.
In case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the unit can lead to considerable risks for the safety of
persons and plant. It is not permitted and leads to the exclusion of any
liability and warranty claims.

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COMPACTMODUL METAL CR2031

Function and features

The CR2031 I/O module enables decentralised triggering of actuators and proportional valves. The coil
current can be monitored and controlled via the integrated current measurement.

• The module supports binary/analogue outputs and is therefore classified in the device profile "I/O
module" to CiA DS 401.

• As regards the output functions, the module can be configured and it supports the following functions:
- binary outputs with/without current detection; up to 4 A
- PWM outputs with/without current detection; up to 4 A
- current-controlled PWM outputs, up to 4 A
- selectable current measuring range 0...1 A or 0...4 A.

• There are 1 server SDO and the 3 default PDOs to CiA DS 401.
The PDO mapping cannot be changed (static PDO mapping). The default identifiers are assigned
according to the "predefined connection set".

• The COB IDs of the PDOs as well as the transmission type (synch / asynch) of the individual PDOs
can be configured.

• The module expects a synch object.


The CAN identifier of the synch object can be configured.

• • The module supports "node guarding" and "heartbeat".


The "guard time", the "life time factor" and the "heartbeat time" can be configured.

• • The module generates an emergency object. The COB ID of the EMCY object can be configured.

• • The module stores the last error.


The error code of the corresponding emergency object is stored.

• • The module supports a reset function, i.e. assignment of the parameters to the factory default values*
upon request.

The CR2031 I/O module is not approved for safety-relevant tasks in the
field of personal safety.

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COMPACTMODUL METAL CR2031


CR2031 Wiring
Parameters and EMCY object overview

Automatic saving of the communication and unit parameters can be activated or deactivated by means of
the "save all parameters" entry (see object directory, index 1010). When the value 0x02 is entered into SIdx
01, all parameters are automatically saved if changes were made.

With the value 0x00 there is no automatic saving, i.e. changed parameters will only be valid until the unit is
switched off or until the next reset is made.

With the function "restore" (see object directory, index 1011) the parameters (except the baud rate and the
node ID) can be assigned to the factory default values. With the next power on they become valid.

Control characteristics (index 2004...7)

The current control behaviour can be parameterised separately for each channel pair in the P and I values.
For each of the 4 output pairs the max. load current [mA] has to be indicated. By means of this value the
respective measuring range (1 A or 4 A) is automatically selected.

Explanation of the abbreviations:


0x... = hexadecimal number
0d = decimal numerical value
str = string
rw = read-write
ro = read only
u8 = unsigned 8 bit
u16 = unsigned 16 bit

COMPACTMODUL METAL CR2031

Maintenance, repair and disposal

As the module does not contain any components which must be maintained by the user, the housing must
not be opened.
The maintenance of the module may only be carried out by the manufacturer.
The disposal must be carried out according to the corresponding national environmental regulations.

Declaration of conformity

The CE marking is applied on the basis of the EMC Directive EMC 89/336/EEC as well as the Low Voltage
Directive NS73/23/EEC, implemented in the standard DIN EN 61326.
ENGLISH

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COMPACTMODUL METAL CR2031


NOTES

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5.3.4.2 COMPACT MODULE DIGITAL / ANALOGE

Mounting - and installation instructions

COMPACTMODULE METAL CR2033

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COMPACTMODULE METAL CR2033

Safety instructions

This description is part of the unit. It contains texts and drawings


concerning the correct handling of the module and must be read before
installation or use.

Observe the information of the description. Non-observance of the notes, operation which
is not in accordance with use as prescribed below, wrong installation or handling can
result in serious harm concerning the safety of persons and plant.
The instructions are for authorised persons in accordance with the EMC and low voltage
guidelines. The unit must be installed and commissioned by a skilled electrician
(programmer or service technician). The device may only be installed, connected and
commissioned by qualified personnel.
Disconnect the device externally before doing any work on it. If necessary, also
disconnect separately supplied output load circuits.
If the unit is not supplied with the mobile on-board system (12/24 V battery operation) it
must be ensured that the external voltage is generated and supplied according to the
criteria for safety extra-low voltage (SELV) as this is supplied without further measures to
the connected controller, the sensors, and the actuators.
The wiring of all signals in connection with the SELV circuit of the unit must also comply
with the SELV criteria (safe extra-low voltage, safe electrical separation from other
electric circuits).
If the supplied SELV voltage has an external connection to ground (SELV becomes
PELV) the responsibility lies with the user and the respective national regulations for
installation must be complied with. All statements in these operating instructions refer to
the unit the SELV voltage of which is not grounded.
The terminals may only be supplied with the signals indicated in the technical data or on
the unit label and only the approved accessories of Ifm Electronic GmbH may be
connected.
The unit can be operated within a wide temperature range according to the technical
specification indicated below. Due to the additional self-heating the housing walls can
have high perceptible temperatures when touched in hot environments.
In case of malfunctions or uncertainties please contact the manufacturer. Tampering with
the unit can lead to considerable risks for the safety of persons and plant. It is not
permitted and leads to the exclusion of any liability and warranty claims.

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COMPACTMODULE METAL CR2033

Function and features

The CR2033 I/O module enables decentralised evaluation of sensor signals and decentralised triggering of
actuators and proportional valves.

• The module supports binary/analogue inputs/outputs and is therefore classified in the device profile
"I/O module" to CiA DS 401.
• As regards the input/output functions, the module can be configured and it supports the following
functions:
- analogue inputs
(0...10/32 V, 0...20 mA, ratiometric, binary and binary with diagnosis)
- binary inputs
- binary outputs
- PWM outputs up to 4 A
• There are 1 server SDO and the 4 default PDOs to CiA DS 401.
The PDO mapping cannot be changed (static PDO mapping). The default identifiers are assigned
according to the "predefined connection set".
• The COB IDs of the PDOs as well as the transmission type (synch / asynch) of the individual PDOs
can be configured.
• The module expects a synch object.
The CAN identifier of the synch object can be configured.
• The module supports "node guarding" and "heartbeat".
The "guard time", the "life time factor" and the "heartbeat time" can be configured.
• The module generates an emergency object. The COB ID of the EMCY object
can be configured.
• The module stores the last error.
The error code of the corresponding emergency object is stored.
• The module supports a reset function, i.e. assignment of the parameters to the factory default values*
upon request.

The CR2033 I/O module is not approved for safety-relevant tasks in the field
of personal safety.

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COMPACTMODULE METAL CR2033

Maintenance, repair and disposal

As the module does not contain any components which must be maintained by the user, the
housing must not be opened.
The maintenance of the module may only be carried out by the manufacturer.
The disposal must be carried out according to the corresponding national environmental
regulations.

Declaration of conformity

The CE marking is applied on the basis of the EMC Directive EMC 89/336/EEC as well as the
Low Voltage Directive NS73/23/EEC, implemented in the standard DIN EN 61326.
ENGLISH

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COMPACTMODUL METAL CR2033


NOTES

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5.3.4.3 CABINET-MODULE

Mounting - and installation instructions


DEUTSCH ENGLISH

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INPUT/OUTPUT MODULE CR2012

Safety instructions

This description is part of the unit. It contains texts and


drawings concerning the correct handling of the controller
and must be read before installation or use.

Observe the information of the description. Non-observance of the notes,


operation which is not in accordance with use as prescribed below, wrong
installation or handling can result in serious harm concerning the safety of
people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
Disconnect the device externally before doing any work on it. If necessary,
also disconnect separately supplied output load circuits.
In the case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the device can lead to considerable risks for the safety of
people and plant. It is not permitted and leads to an exclusion of any liability
and warranty claims.

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INPUT/OUTPUT MODULE CR2012

Function and features

The CR2012 input/output module is used for connection of controls and indicators in driver's cabs, control
panels or control boxes to CAN bus.
• The module supports binary/analogue inputs and binary outputs and is therefore classified in the
device profile "I/O module" to CiA DS 401.
• As regards the input/output functions the module can be configured.
• The input/output module supports the following I/O configurations:
8 binary inputs
+ 4 binary/analogue inputs
+ 4 binary inputs/outputs
• There are 1 server SDO and the 3 default PDOs to CiA DS 401.
The PDO mapping cannot be changed (static PDO mapping). The default identifiers are assigned
according to the "predefined connection set".
• The COB IDs of the PDOs as well as the transmission type (synch / asynch) of the individual PDOs
can be configured. The transmission type is non-volatile stored. Changed PDOs (PDO linking) are
volatile stored.
• The module expects a synch object.
The CAN identifier of the synch object can be configured. After a change the ID is automatically non-
volatile stored.
• The module supports "node guarding".
The "guard time", "life time factor" and the CAN identifier of the guard object can be configured and are
non-volatile stored.
• The module generates an emergency object.
The COB ID of the EMCY object can be configured.
• The module stores the last 4 errors.
The error code of the corresponding emergency object is stored.
• The module supports a reset function, i.e. assignment of the parameters to the
factory default values* upon request.

ENGLISH

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INPUT/OUTPUT MODULE CR2012

Maintenance, repair and disposal


As the input/output module does not contain any components which must be maintained by the user, the
housing must not be opened.
The maintenance of the module may only be carried out by the manufacturer.
The disposal must be carried out according to the corresponding national environmental regulations.

Declaration of conformity

The CE marking is applied on the basis of the EMC guideline EMC 89/336/EEC, implemented in the
standards EN 500 81-1 and EN 500 82-2 as well as the low voltage guideline NS73/23/EEC, implemented
in the standard EN 61010.

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COMPACTMODUL METAL CR2012


NOTES

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5.3.4.4 INCLINOMETER ( SPECIAL EQUIPMENT )

Mounting - and installation instructions

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COMPACTMODUL METAL CR2101

Safety instructions

This description is part of the unit. It contains texts and


drawings concerning the correct handling of the controller
and must be read before installation or use.

Observe the information of the description. Non-observance of the notes,


operation which is not in accordance with use as prescribed below, wrong
installation or handling can result in serious harm concerning the safety of
people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
Disconnect the device externally before doing any work on it. If necessary,
also disconnect separately supplied output load circuits.
In the case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the device can lead to considerable risks for the safety of
people and plant. It is not permitted and leads to an exclusion of any liability
and warranty claims.

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COMPACTMODUL METAL CR2101

Function and features

The 2-axis inclination sensor enables zero point levelling and position detection of mobile machines.
Typical applications are, for example, the position detection of access platforms, levelling of mobile cranes
and mobile machines.

Operating principle:
Two measuring cells which operate to the conductometric principle evaluate the change in conductivity of a
liquid.
By applying an alternating voltage between the electrodes, a current flows through the liquid and generates
an electric field.
When the sensor is inclined the electric field changes and thus the conductivity of the liquid depending on
the level. Arranging the electrodes in pairs results in a signed angle of inclination.

• Parameter setting of the sensor resolution and the 2-axis zero point is possible.
• 1 server SDO and 2 Transmit PDOs conforming to CiA DS 401 are available. The PDO mapping
cannot be changed (static PDO mapping). Default identifiers have been assigned according to the
"predefined connection set".
• The COB IDs of the PDOs as well as the type of transmission (synch/asynch) of the individual PDOs
can be configured. The type of transmission is non volatile stored. Changed PDOs (PDO linking) are
volatile stored.
• The inclination sensor expects a synch object. The CAN identifier of the synch object can be
configured. After a change the ID is automatically non volatile stored.
• The inclination sensor supports "node guarding".
The "guard time", the lifetime factor" and the CAN identifier of the guard object can be configured and
are stored non volatilely.
• The inclination sensor generates an emergency object. The COB ID of the EMCY object can be
configured.
• The inclination sensor stores the last 4 errors occurred. The error code of the respective emergency
object is stored.
• The inclination sensor supports a reset function, i.e. upon request the parameters are assigned to the
factory default values*.

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INCLINATION SENSOR CR2101

Maintenance, repair and disposal

As the inclination sensor does not contain any components which must be maintained by the user, the
housing must not be opened.
The sensor may only be repaired by the manufacturer.
The disposal must be carried out according to the corresponding national environmental regulations.

Declaration of conformity

The CE marking is applied on the basis of the EMC directive EMC 89/336/EEC, implemented in the
standards EN 500 81-1 and EN 500 82-2 as well as the low voltage directive NS73/23/EEC, implemented
in the standard EN 61010.
ENGLISH

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COMPACTMODUL METAL CR2101


NOTES

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5.3.4.5 LCD-DISPLAY

Mounting - and installation instructions

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LCDDisplay CR1031

Contrast and brightness adjustment


Independently of the device type, contrast and brightness are adjusted via the ESC key and the cursor
keys. This description therefore applies for all LCD device ranges.

You have to call up the "LCD service page" at the Dialogue Module menu.
How to do, see chapter “ Operation of the Dialogue Module over the function keys”.
Then, you can adjust the contrast and brightness at least for this page.

Proceed as follows to modify the settings:

1. Press the ESC key and keep it pressed during the following steps.
2. Wait for approx. 2 seconds.
3. Adjust (with the ESC key pressed) brightness and contrast via the cursor keys.

The key mapping is as follows:

Reduce brightness
Increase brightness
Reduce contrast
Increase contrast

Please observe:
If you switch off the crane after the contrast and brightness adjustment the new settings will be
automatically saved.

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LCDDisplay CR1031
NOTES

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5.4 DISPLAY AND INDICATORS


A horn (=M05-H1) is attached to the cabin for giving danger signals and can be activated by pressing the
button in the left joystick.
The horn operates with a voltage of 24 V.

5.4.1 INDICATOR LIGHTS


=M07-H06 "READY FOR OPERATION" is inside the selector switch <START> and lights up when the
crane is <READY FOR OPERATION>; i.e. when the main motor is running in the delta circuit and all
systems are in order.
During start up procedure this pilot signal blinks until the self adjustment is finished.

=M07-H07 "FAULT" is in the right control desk and lights up as a collective signal when the status
monitoring system signals a fault.

This indicator lights are installed additionally to the crane information system on the display, located on the
right hand control desk. Normally all relevant fault indications and operation conditions are shown on the
display.
Only if the display itself is defective is the main information indicated by these lights.

5.4.2 DISPLAY OF CRANE INFORMATIONS


Normally on the display the operation manual shows the indications of
SWL – LOAD
ACTUAL LOAD
OUTREACH
HOOK HEIGHT
By pressing the soft-key button MENUE an additional menu page is called up and
CRANE INFORMATION can be selected, the following information is displayed now:
CRANE NUMBER (software identification number)
TEMPERATURE (actual oil temperature)
OPERATION HOURS M01 (elapsed working time of the main motor)
SELECTED CRANE No. (crane 1 is front crane, the highest number is the rearmost crane)

For safety reasons the operational hours should be written down every 2-3
months.
If the PLC system (main processor) becomes defective and must be renewed, the
stored operational hour value is lost and must be manually entered into the new
PLC.

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5.4.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT


PANEL)
A LCD Display with 8 plunger-operated buttons and status LEDs is installed in the right hand control
desk of the crane cabin.

The dialogue module communicates via CAN bus with the control system ecomat 100 type R 360
interactively and sends or receives operational status information of the crane. The following
information of the dialogue module can be handled at the menu structure
− Fault / Condition messages
− Operating states messages
− Additional messages.
− Service inputs

Operational state messages Under normal conditions, the indications shown by the dialogue module
is SWL – LOAD, ACTUAL LOAD, OUTREACH and HOOK HEIGHT to signify normal, trouble-free
operation or, if the temperature of the hydraulic oil is below 0 °C, " TEMPERATURE < 5° PRE-
HEATING ACTIVE" to show that the booster pump is working in the oil pre-heating mode.

Fault messages are indicated by a separate fault picture with the "FAULT CODE" and the respective
cleartext of this fault.
Fault messages have the highest priority and therefore overwrite existing operating conditions or
special messages.
A fault message can be cleared by pressing the RESET button F2.

Condition messages are indicated by a separate condition picture with the "CONDITION CODE" and
the respective clear text of this condition. e.g. " Condition 2214" with clear text „LUFFNG OUT PRE-
LIMITATION “, is a typical operating condition message, for instance, and indicates that the luffing
direction is approaching the maximum of luffing gear out direction.

Additional messages do not appear on the display during normal operation. They must be called
separately.
Additional messages are suppressed when the detailed points are selected over the menu.
Button „BACK“ must be pressed to return from the additional message page to the normal mode.
Faults and conditions not eliminated during the menu are selected.

Service inputs could be entered over a separate secured Password area. In this special area e.g. the
system values could be reset to default settings, Emergency Codes could be activated or some values
could be displayed.

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5.4.3.1 OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS

Normal operation is basically done using the following 6 function keys:

ESC key

Cursor keys

Enter key

Special keys are:

Function key F1 ENTER Main Menu, anytime at call.

Function key F2 single Quit of displayed Fault

5.4.3.2 HOW TO ENTER MAIN MENU

After crane is started above picture is normally displayed.


Now you can press to enter main menu, because the display shows you in this picture an
allocation above this key to “MENU”. This will be the same for selection and enter.
In the next picture you will find “BACK” allocated to key .
This key takes you back to the previous picture.

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Menu structure
Is divided into sections.

• The normal and free available area: display values and operational state

• The secured password area: Service Menu / set values

Enter a menu item

The menu structure and meaning of keys are self-explanatory.


We will in any case explain the function in detail on the basis of some examples.

EXAMPLE: Display of detail “ACTUAL LOAD” ( capital letters )

After crane is started above picture is normally displayed.


Press to activate the menu. The first item is now reversible.
Using the keys, you can now change between the available menu items. Select now
„ACTUAL LOAD“ and press to change the display.

The “BACK” key takes you back to the previous picture.

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EXAMPLE: Display of crane information: Operating hours

At the given picture press key to enter the main menu.

Then select with the “CRANE INFORMATION” item and press Enter to display.

Now you will have the information displayed.


The “BACK” key takes you back to the previous picture.

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EXAMPLE: SERVICE INPUT: RESET TO DEFAULT SETTINGS

At the given picture press key to enter the main menu.

After that select with the “SECURED AREA” item and press Enter to display.

Now you must press Enter to select “YES” and press again Enter to confirm this message.
Otherwise press key to go “BACK”.

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EXAMPLE: ... SERVICE INPUT: RESET TO DEFAULT SETTINGS

After conformity you have the following picture (KEY-CODE IS ON DEMAND). The security code is
written in capture(capitals?) GENERAL DEFAULT SETTING

To insert the Security Code press Enter. Now the code column will be displayed in reverse. Now
press Enter again. and the first digit of security code blinks. With you modify the value
and with you can go to the next digit. When you have inserted everything press Enter to
confirm the insert security code of your entry.

If the code is invalid a message will inform you “NOT ACCEPTED TRY AGAIN”. Please do so as
described above.

If the code is valid go to next picture

To insert the crane number press Enter. Now the value will be displayed in reverse. Now press
Enter again and the digit blinks. With you modify the value . If you have selected the right
number press Enter to confirm your entry. Now the selected crane number is displayed and you
can go further press “NEXT” or “BACK” takes you to previous picture.

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EXAMPLE: ... SERVICE INPUT: RESET TO DEFAULT SETTINGS

You are now in the Service menu

With you can go to the next range of service points.

With you can select the menu item “SET DEFAULT SETTINGS”. Press Enter to confirm
your entry

Now you must press Enter to select “YES” and press again Enter to confirm this message.
Otherwise press key to go “BACK”.

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Now you must press Enter to set the system back to default settings. Otherwise press key to
go “BACK”.

EXAMPLE: ... SERVICE INPUT: RESET TO DEFAULT SETTINGS

Finally the system informs you that the settings now reset to factor default.

press key to go “BACK”. to main service menu.

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5.5 COMMISSIONING AND ADJUSTMENTS


( CODE SECURED AREA )

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

This member of the crew is responsible for explaining the changed situation to the crane operator
and must report it to the management of the ship.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (accepted must be entered)
• Select SECURITY CODE must be set and entered ( CODE NUMBER = 257377 )
• Select SET CRANE NUMBER (corresponding crane number must be entered)
now the menu for the secured area modes is opened and the intended mode must be
selected

If you want to leave this secured area and especially before you leave the crane:
Switch off the power to de-activate all emergency codes.
(Emergency Operation System = EOS-Codes)

If the EOS system has been activated an information will be written into the flash memory.
The status of the EOS codes can be called up under
INDICATIONS
EOS STATUS MEMORY

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5.5.1 GENERAL DEFAULT SETTING


During the first start i.e. when activating the control system for the first time and after replacing the
main controller R 360 (located in the control cabinet), the internal memory of the PLC must be
formated and paramaterized with the default operational values.
If this default setting is carried out all previous personnel adjustments of the control system will be
overwritten.

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET DEFAULT SETTINGS
follow the instruction displayed

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5.5.2 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER


PUMP)
This special mode will have to be activated in order to adjust the control oil pressure without starting the
main drive motor – only the motor =M02-M11 for the booster pump (control oil supply pump) will be started
/ stopped by the <START> switch.
During this special mode possible low-pressure-alarm is suppressed, the technician must take care that
there is oil in the system and the pump is running with the right sense of rotation.
On the display is shown the average pressure measured in the hoisting gear circuit.

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select CONTROL PRESSURE ADJUSTMENT
press ENTER and SELECTION
to set = TRUE or reset = FALSE this special mode

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5.5.3 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)


Work on the electrical equipment of the crane is to be performed only by well trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

This member of the crew is responsible for explaining the changed situation to the crane operator
and must report it to the management of the ship.

The luffing- and hoisting gear travel way is limited by mechanical limit switch contacts and additionally by
measurement of the rope length. This rope length measurement is carried out by incremental encoders
which are mounted inside the limit switches.
(see also the technical description of the limit switches under item: „DESCRIPTION OF ELECTRICAL
COMPONENTS“)

Only on the first start of the crane or after exchange of the limit switch (also when a rope change is not
carried out corresponding to the instruction „SPECIAL MODUS FOR ROPE CHANGE“ the mechanical limit
switch contact have to be adjusted..

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET LIMIT SWITCHES
• Select LUFFING GEAR or MAIN HOISTING GEAR or AUXILIARY HOISTING GEAR
(OPTIONAL)
follow the instruction displayed

If another fault is indicated during the limit switch adjustment procedure, the reason for this fault
must be eliminated prior to any further action.

ATTENTION: all limit switches are by-passed, the drive will not stop in the limit position,
only a STOP command is shown on the display when this position is reached.
ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib
could be damaged, or the wire could unreel completely from the drum.

The following runs have to be done at slow speed.

The order of the adjustment steps must be kept strictly and exactly in the described manner.

Start with the adjustment of the luffing gear limit switch.

STEP 1:
Luff the jib in completely in the most upright position (the gap between the jib and rubber buffer should be 5
– 10 cm). Stop the drive.
STEP 2:
In this jib position the limit switch contact for minimum outreach, contact no.1 (seen from the drive shaft)
must be adjusted by turning the adjusting worm in counter-clockwise direction. The contact must switch
over from closed position into opened position. If the contact has been opened while driving with the jib into
the most upright position (precedent adjustment) the contact must be closed and opened again by means
of the adjusting worm. See also the description “GEARED LIMIT SWITCHES - Series 51”.

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STEP 3:
Luff out the jib until Step 4 is shown on the display. Step 4 will be displayed when the limit switch contact is
closing again.
If not Step 4 but Step 1 is displayed again during this procedure, it is the information that the limit switch
contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange.
Steps 1 and 2 must be repeated. (The contact must open by turning the adjusting worm in counter-
clockwise direction)
STEP 4:
Luff in the jib until the STOP command is displayed. This command is given in the moment when the limit
switch contact is opening again.
Now the adjustment of the minimum outreach position is completed and you can drive with the jib to the
maximal outreach position. During this procedure the actual outreach (in meters) is shown on the display.
The drive will stop automatically at the maximal outreach position with speed slow down the before
reaching it.
STEP 5:
In this position the limit switch contact for maximal outreach, contact no.2 (seen from the drive shaft) must
be adjusted by turning the adjusting worm in clockwise direction. The contact must switch over from closed
position into opened position. If the contact has been opened while driving with the jib into the maximal
outreach position (precedent adjustment) the contact must be closed and opened again by means of the
adjusting worm.
STEP 6:
Luff in the jib until Step 7 is displayed. Step 7 will be displayed when the limit switch contact is closing
again.
If not Step 7 but Step 5 is displayed during this procedure, it is the information that the limit switch contact
is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange. (The
contact must open by turning the adjusting worm in clockwise direction). Step 5 must be repeated.
STEP 7:
Luff out again the jib until the STOP command is displayed. This command is given in the moment when
the limit switch contact is opening again.
Now the adjustment of the luffing gear limit switch is completed.

Leave the adjustment procedure by pressing EXIT on the display.

Adjustment of the hoisting gear limit switch.

Before starting with the hook adjustment, the jib must be in the maximal outreach position (this is the
reference position for the jib and also the position to adjust the highest hook position).
STEP 1:
Lift the hook into the highest position (the gap between the hook and the jib head should be approx. 1
meter).
STEP 2:
In this hook position the limit switch contact for highest hook position, contact no.1 (seen from the drive
shaft) must be adjusted by turning the adjusting worm in counter-clockwise direction. The contact must
switch over from closed position into opened position. If the contact has been opened while driving with the
hook into the highest position (precedent adjustment) the contact must be closed and opened again by
means of the adjusting worm. See also the description “GEARED LIMIT SWITCHES - Series 51”.
STEP 3:
Lower the hook until the Step 4 is displayed. Step 4 will be displayed when the limit switch contact is
closing again.
If not Step 4 but Step 1 is displayed again during this procedure, it is the information that the limit switch
contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange.
Steps 1 and 2 must be repeated. (The contact must open by turning the adjusting worm in counter-
clockwise direction)

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STEP 4:
Lift up the hook until the STOP command is displayed. This command is given in the moment when the
limit switch contact is opening again.
Now the adjustment of the highest position is completed and you can drive with the hook to the deepest
hook position. During this procedure the actual hook height (below highest position in meters) is shown on
the display.
STEP 5:
There is no automatic stop during lowering, the hook should be stopped when the position is approx. 1
meter above the ground. In this position press the DONE key on the display.
In this position the limit switch contact for the deepest position, contact no.2 (seen from the drive shaft)
must be adjusted by turning the adjusting worm in clockwise direction. The contact must switch over from
closed position into opened position. If the contact has been opened while driving with the jib into the
maximal outreach position (precedent adjustment) the contact must be closed and opened again by means
of the adjusting worm.
STEP 6:
Lift up the hook until the step 7 is displayed. Step 7 will be displayed when the limit switch contact is closing
again.
If not Step 7 but Step 5 is displayed during this procedure, it is the information that the limit switch contact
is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange. (The
contact must open by turning the adjusting worm in clockwise direction). Step 5 must be repeated.
STEP 7:
Lower again the hook until the STOP command is displayed. This command is given in the moment when
the limit switch contact is opening again and the adjustment of the hoisting gear limit switch is completed.

Leave the adjustment procedure by pressing EXIT on the display.

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5.5.3.1 SETTING LAYER CHANGE POSITION


If the hoisting rope is wheeled up on the winch in 2 layers, the layer change position must be checked or
set when this position is not displayed correctly.

Procedure:
• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES

When the indication of counter values is activated on the dialogue module the actual hoisting position
counter value and also the layer (1 or 2) is indicated. This layer indication must change from 1 to 2 before
the rope will turn in the 2nd layer.
If this layer change indication is not properly adjusted the layer changing position must be set by selection
of the setting mode in the secured area.
Turn the winch into the right position before the rope begins to shift over.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET LAYERCHANGE POSITION
LAYER2 must be selected on TRUE and entered

Now the limit switches are adjusted and the settings stored in the PLC memory.
Switch off the controls in order to deactivate the limit switch setting system.

Finally check all limit switch cut-out positions.

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5.5.3.2 RESETTING OF REFERENCE POSITIONS


The rope length measuring system is carried out by means of incremental encoders inside the limit switches.
The fault indication F1312 or F2312 will be displayed, if a previous failure of the rope length measuring
system has stopped the corresponding drive.
To reset this alarm and to restore the system, the corresponding drive must be driven into its
reference position.
• Jib to the maximum outreach (max. working range)
• Hook / both hooks (if the crane has this equipment) into highest hook position (approx. 1 m below the
jib-head or 0,5 m below the chain limiter)
• Jib in max. outreach and hook(s) in highest position is the crane reference/default position –

Procedure: The function and how to operate the function-buttons of the display is described in the
specification of the electrical equipment under item:
Operation of the dialogue module over the function keys

• Set MAIN MENU (by pressing button F1)

• Select SECURED AREA and press ENTER


• (KEY-CODE IS ON DEMAND that means the code number must be entered into the
system)
• Read the information about the emergency system in the specification of the electrical
equipment under item:
COMMISSIONING AND ADJUSTMENTS

• Jump over the next pages by pressing NEXT

• Select RESET OF REFERENCE POSITIONS and press ENTER

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YES must be selected and entered and the information must be confirmed
by pressing ENTER again
(If this mode is activated the contents of the counter values for luffing and hoisting drive are
displayed.)

Do not activate the emergency system EOS-codes when the reference positions shall be reset,
because these codes will oppress possible system failures. In case EOS-codes had been entered
into the PLC before, the power must be switched off to de-activate the emergency codes, and the
previous procedure must be repeated.

ATTENTION: Now all limit switches are by-passed, the drive will not stop in the limit position, only
LIMIT SWITCH CONTACT HAS OPENED will be displayed, when this position is reached.

ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be
damaged, or the wire could unreel completely from the drum.
The following runs have to be done at slow speed.

Restorage luffing gear reference position:


The jib position must be in the normal working area, not beyond the maximum outreach limitation (by-
passed with JIB-RESTING switch.
Luff out the jib to the maximum outreach position (maximum working area), the signal
LIMIT SWITCH CONTACT HAS OPENED will be shown on the display when this position is reached, stop
the drive.
Lift up the jib until LIMIT SWITCH CONTACT HAS OPENED extinguishes, then lower the jib again, until
the signal LIMIT SWITCH CONTACT HAS OPENED is shown on the display again.

Restorage main hoisting gear reference position:


Drive the jib to the maximum outreach position (maximum working area), ), the signal
LIMIT SWITCH CONTACT HAS OPENED will be shown on the display. When this position is reached, stop
the drive. (The jib should be driven into this position first, it is easier to find the right reference position for
the hook, because this is now close to the jib head – approx. 1 m below.)
Lift up the main hook, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display
when this position is reached, stop the drive. Lower the hook until
LIMIT SWITCH CONTACT HAS OPENED is deleted.
Lift up the main hook again, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the
display when this position is reached, stop the drive and then lower the hook approx. 2 m.

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Restorage auxiliary hoisting gear reference position: (if the crane has an aux. Hoisting gear)
The procedure corresponds to the main hoisting gear, using the aux. hook.

Restorage slewing gear reference position:


The fault indication F3312 will be displayed, if a failure of the slewing ring counting system has stopped the
drive.
To reset this alarm and to restore the system, the slewing drive must be driven into the reference position.
The reference position is the interlocking position of the tower for sea voyage
( jib in direction forward ). When the right position is reached LIMIT SWITCH CONTACT HAS OPENED will
be displayed.

If during this procedure another fault is indicated, the reason for this fault must be eliminated prior
to any further action.

When the reference positions have been reset by the described procedure it is
very important to de-activate this reference setting system before the power of the crane is
switched off.
Otherwise the reference position data will not be stored in the retain memory and this procedure must be
repeated when the power is switched on again.

Press EXIT to leave page P184, page P149 now will be displayed

Press BACK several times until one of the following pages will be displayed

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5.5.4 ADJUSTABLE WORKING RANGE LIMITATION


( SPECIAL EQUIPMENT )

slewing gear
reference position

restricted area

circle chord

actual outreach
chord distance

crane

max. working radius

The crane is equipped with an adjustable working range limitation, whereby the area of working range
limitation is forming a segment of the circle.
For adjusting you must first define the reference position of the slewing gear.
A steel plate which activates the proximity switch =M06-B802 must be screwed to the relevant threaded
bolts of the slewing ring.
The other two proximity switches =M06-B810/-B811 count the gear teeth of the slewing ring and define the
slewing angle.

The WORKING RANGE LIMITATION will be activated / de-activated by means of the dialogue module
(display).
Press <F1> to enter the main menu

Select WORKING RANGE SETTINGS and press ENTER.

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In the following menu the security code for the activation must be entered
by using the keys ←→↑↓ the security code is 887564.
Keep the code numbers secret for activating the secured area.

Now you can activate / de-activate the working range limitation

To de-activate the working range limitation press the “OFF” key and leave the working range settings with
EXIT.
When the working range limitation has been activated the slewing gear must slowly be driven into the
reference position (zero position of the slewing angle) and the drive must be stopped when the reference
position is reached (the menu will change and REFERENCE POSITION IS SET is blinking).

On this menu the actual distance of the circle chord from the centre of the crane radius is displayed.
If the chord distance shall not be changed press the NEXT key.
Menu P72 will be called up again, the status of the working range limitation is now “ON” you can now leave
the working range settings by pressing EXIT.

If the chord distance shall be changed press the ADJUST key and follow the instruction on this menu.

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On this menu the changed chord value is displayed now.


If EXIT is pressed menu P72 will be called up again, the status of the working range limitation is now “ON”.
You can now leave the working range settings by pressing EXIT.

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5.5.5 SPECIAL MODUS FOR ROPE CHANGE


Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

When a rope has to be exchanged a special mode will support this procedure.
If this special mode is activated the rope length measuring system and also the limit switches are by-
passed.

• Drive with the corresponding drive into a definite position (e.g. the jib into the jib resting position, or the
hook is touching the deck).
• In this position activate the rope change mode and then remove the limit switch from the winch. (Take
care that the shaft of the limit switch will not be turned.)
• Now the rope can be paid out completely from the winch and the new rope can be installed. (Drive
carefully – no limitation is active.)
• When the new rope is installed and the hook/jib is in the same position where limit switch has been
removed, at this position the limit switch must be fixed to the winch again.
• De-activate the rope change mode.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select ROPE CHANGE MODUS
• Select L_ROPE_CHANGE or H_ROPE_CHANGE
• Select FALSE or TRUE and ENTER

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5.5.6 CALIBRATION OF LOAD INDICATION


Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

The crane load will be calculated as a function of the hoisting pressure. The oil pressure in the hoisting
circuit consists of the idle running pressure + losses through floating resistances + working pressure. This
working pressure always depends on the lifted load.
The default load data for the calculation of the load weight are stored in the memory-module.
These data can be overwritten if the displayed load weight is not similar to the lifted test weight.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select LOAD ADJUSTMENT

Lift up the test weight with slow speed approx. 1 meter.


When the drive has stopped on the display you can see the measured and calculated load,
in the 2nd line the actual value for the load calculation
in the 3rd line you can select a new calculation value (a higher one would increase the load)
by entering this value, the 2nd line actual value for the load calculation and also the displayed load will
change.
If the load displayed corresponds to the lifted weight, you can leave this program.

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5.5.7 REPORT OF CHANGE


If during the adjustments some PLC-values have been changed, please report the new values to our
electrical design department so that we can renew the default data of the PLC program corresponding to
these changes.
In case of any spare part delivery the new actual values will be delivered and set automatically, otherwise
the personally changed values will be overwritten by the default (old) data.

e-mail: info@tts-lmg.de

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5.5.8 ZERO-SETTING OF POTENTIOMETERS


The potentiometers of the control levers set the direction and the speed of the corresponding drive.
They are supplied by 24 V DC (not a fixed/regulated voltage) and in neutral position of the control lever the
output of this potentiometer shall be ½ of the supply voltage.
If this potentiometer is not exactly adjusted or the potentiometer resistance is non-linear, it is possible to set
the potentiometer output level to zero. (Offset value)
(This is only possible when the potentiometer is more or less correctly adjusted, otherwise a fault indication
will result.)

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select ZERO-SET OF POTENTIOMETERS
PRESS ENTER TO CALIBRATE

5.5.9 SETTING OF OPERATION HOURS


When the PLC has been changed and the system has been set back to default data the contents of the
operation hours counter is set to zero.
It is possible to override the zero-value with the actual counter value (should be written down every 2-3
months).

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET OPERATION HOURS
Press ACCEPT to select by the keys ↑↓←→ and put in the required value
and then press ACCEPT again to store this value as actual operation counter value.

5.5.10 ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT)


A feature of the crane control equipment is a heeling monitoring system.
The heeling angle is shown on the display. If the angle exceeds 5° a pre-warning signal is given, and if the
angle exceeds 8° the hoisting-, luffing out- and slewing operation is blocked.

At even keel an angle of 0° should be displayed. If this value does not corresponds the output of the
inclinometer can be set to zero.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select ZERO-SETTING OF INCLINOMETER
Select YES and ENTER

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5.6 INTERLOCKING FOR SEA VOYAGE (SPECIAL


EQUIPMENT)

5.6.1 LOCKING
The operating system must be in order before the system for locking is switched on.
During normal operation when the crane is not near the locking area the status of all signals from the
monitoring proximity switches must be "TRUE":
=M06-B804 - =M06-B809 cylinder position control
=M06-B802 - =M06-B803 slewing gear position control
The locking mode is selected by the key-operated switch on the right control desk. One of the two proximity
switches monitoring the slewing gear position must be depressed? when this is done (signal-status = FALSE),
i.e. the crane must have been slewed into the approximate locking position.
The display shows the information that the locking system is been activated.
The crane can now be slewed into the exact locking position only; motion in the opposite direction is blocked.
Once the locking position has been reached (both slewing gear proximity switches must be depressed) the
slewing gear is switched off automatically and the locking cylinders extended.
If, due to the heel of the ship, the crane drifts out of the exact locking position, i.e. if either of the slewing gear
proximity switches is no longer depressed, the slewing gear will be automatically returned to the correct
position.
To extend the locking cylinders, the luffing gear pump powers and the locking gear directional control valve is
set to the position for locking. The display shows the progress of the locking procedure.
When all locking cylinders are completely extended the corresponding signal-status of the proximity switches
must be FALSE. The luffing gear pump and directional control valve are switched off, and the display shows
the information that the crane tower is locked..
While locking , the pressure is limited to about 150 bar by sensor =M07-B20.
A semi-automatic luffing gear positioning system is activated in the locking mode and automatically stops the
jib from being lowered further when the locking position is reached.
If the locking position lies outside the working range, the luffing gear stops at maximum outreach. In this case,
actuate the key-operated switch JIB RESTING to continue luffing out until the jib stops automatically at the
locking point.
Caution: When using the JIB RESTING switch to leave the working range the hook block may be drawn
against the jib head.
If the jib is to be moved again by renewed movement of the control lever (joystick) after the luffing gear has
been switched off automatically, the luffing gear positioning system must be reactivated by briefly switching the
key-operated switch for the sea locking system OFF and ON. The semi-automatic luffing gear positioning
system works only in the direction for luffing out.

Once the slewing gear is locked and the jib is in the locking position, the lashing rope can be attached.
The hook is now hoisted and slowly (carefully) roved into the hook block carrier. The hoisting gear is further run
slowly in the hoisting direction until the lashing rope is taut, the jib being lifted slightly by the hook block at the
same time. When the tension in the lashing rope is sufficient, the hoisting gear is automatically stopped and the
luffing gear automatically activated to take up the slack in the luffing gear rope.

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5.6.2 UNLOCKING
The operating system must be in order before the system for locking for sea is switched on.
During normal operation when the crane is locked, the status of all signals from the monitoring proximity
switches must be "FALSE":
=M06-B804 - =M06-B809 cylinder position control
=M06-B802 - =M06-B803 slewing gear position control
To unlock the crane, the hook must first be lowered and the lashing rope disconnected, and then the key-
actuated switch of the sea locking system must be turned to the zero position.
To retract the locking cylinders, the luffing gear pump powers and the locking gear, the directional control valve
is set to the position for unlocking. The display shows the progress of the locking procedure.
When all locking cylinders are completely retracted the corresponding signal-status of the proximity switches
must be TRUE. The luffing gear pump and directional control valve are switched off, and the display shows the
information that the crane tower is unlocked..

While unlocking , the pressure is limited to about 210 bar by sensor =M07-B20.
As a rule, unlocking takes about 10 ... 15 seconds. If it has not been completed by this time, the slewing gear is
activated briefly in both directions to ease the jammed locking pin free. The slewing gear pressure is limited to
80 bar by pressure switch =M07-S82 during this.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

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5.6.3 FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM


The following fault messages are generated by the interlocking system:
F 4301 CYLINDER NOT IN UNLOCK POSITION
F 4302 STATUS FAILURE OF PROXIMITY SWITCHES
F 4303 CRANE REMOVED FROM LOCKING POSITION
F 4304 LOCKING TIME LIMITATION EXCEEDED
F 4305 UNLOCKING TIME LIMITATION EXCEEDED

F 4301 CYLINDER NOT IN UNLOCK POSITION

Proximity switches =M06-B804 to B809 monitor the upper positions of the locking cylinders during normal
crane operation. The status signals from the monitoring proximity switches must be "TRUE":
=M06-B804 - =M06-B809 cylinder position control

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the positions of the locking cylinders.
− Check proximity switches =M06-B804 to B809.
− Check the power supply and leads to the proximity switches.
− Check the wiring.
− Replace PLC.

Attention by activation of emergency code EOS4301:


Should the cylinder monitoring system be by-passed by emergency code, it must first be checked that all
cylinders are completely retracted. If any cylinder extends, a damage of the slewing gear (slewing ring) is
possible.

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F 4302 STATUS FAILURE OF PROXIMITY SWITCHES


The position of the locking cylinders is monitored by proximity switches.
This fault will be announced if the signalled condition is not logical.

The actual input status can be displayed:

• Set MAIN MENU


• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the conditions signalled by the proximity switches. When
the locking cylinders are completely retracted proximity switches
=M06-B804 to B809 must be TRUE, when these cylinders are fully
extended, the same signals must be FALSE.
− Check the proximity switches and their fastenings
− Check the leads
− Check the wiring.
− Replace PLC.

Attention by activation of emergency code EOS4302:


If the cylinder monitoring system is by-passed by emergency code, at first it must be checked that all cylinders
are completely retracted. If any cylinder extends, a damage of the slewing gear (slewing ring) is possible.

F 4303 CRANE REMOVED FROM LOCKING POSITION


When locking, the slewing gear is stopped in the locking position and, if it leaves that position owing to heel,
etc., is automatically returned to the locking position.
This fault message is generated if this does not work and the crane has not returned to the locking position
within 8 seconds.
The position is monitored by proximity switches = M06-B802 - B803.
When the crane is in "at-interlocking" position, the proximity switches must signal "FALSE".

The actual input status can be displayed:

• Set MAIN MENU


• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
- Check the proximity switches
- Check the pilot markers (both proximity switches must be half covered)
− Check the leads
− Check the wiring.
− Replace PLC.

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F 4304 LOCKING TIME LIMITATION EXCEEDED


F 4305 UNLOCKING TIME LIMITATION EXCEEDED

Locking or unlocking procedures should take no longer than approx.15 sec.


The above fault announcement will appear if locking or unlocking procedures are not finished within 30 sec.

Remedial action
- Check the electrical and hydraulic locking controls.
- The additional pump (luffing gear pump) must have power for locking and unlocking.
- The directional valve for locking or unlocking and the release valve must be actuated.
- The cylinders should be unlocked with approx. 210 bar pressure, they should be locked with approx.
150 bar pressure. The pressure (luffing gear pressure) can be read on the display or measured with a
pressure gauge.

The actual sensor output value can be displayed:

• Set MAIN MENU


• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

If the interlocking system is not working properly an emergency system can be activated for overriding and
direct control of the interlocking cylinder.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select EOS INTERLOCKING SYSTEM

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5.6.3.1 SETTING THE PRESSURE LIMITING VALVE


Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

This member of the crew is responsible for explaining the changed situation to the crane operator
and must report it to the management of the ship.

The pressure is limited to 150/210 bar by sensor =M07-B20 during locking and unlocking.
For higher safety level it is advisable to set the pressure limiting valve in the switching block of the sea locking
system to 240 bar.
This setting should be undertaken only at nominal voltage (e.g. 440 V, 60 Hz, i.e. at the shipyard using the
ship's mains fed by the ship's generators) with hydraulic oil that is operationally warm (>40 °C).
When the operating system is activated for the setting operation, the locked or unlocked status is not switched
off if the cylinders are in their end positions and the electronic pressure limitation is not in effect.
Procedure:
Turn the crane into the sea locking position and, using the normal operating system, lock it and unlock it again
to check that the locking system is in order.

Select EOS INTERLOCKING SYSTEM


Set PRESSURE ADJUSTMENTS on TRUE: The pressure will be shown automatically on the display.
Lock / Unlock the crane by SET OPERATION. The pump delivery increases slightly when the cylinders are
fully extended. The hydraulic pressure setting can be adjusted at this point.
By activating the emergency operating system the locking cylinders can be extended and retracted even when
the proximity switches and pressure sensors are out of order.
In such cases care must be taken that the slewing gear is exactly in the locking position because all monitoring
facilities are overridden.

Explanation in the case of locking:


The locking pressure then appears automatically on the display; if the sensor is defective the pressure must be
checked by pressure gauge.
When the LOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the locking position and the luffing gear pump is started at low (minimum) current.
The current, and therefore the delivery of the pump, is increased by ramp function and must be observed to
prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is locked (cylinder completely extended) the procedure is ended by releasing the soft-
key.

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5.6.3.2 LOCK / UNLOCK IN EMERGENCY OPERATION


Work on the electrical equipment of the crane is to be performed only by well trained personnel.

All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.

This member of the crew is responsible for explaining the changed situation to the crane operator
and must report it to the management of the ship.

If the interlocking system is not working properly an emergency system can be activated for overriding and
direct control of the interlocking cylinder.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select EOS INTERLOCKING SYSTEM

Procedure:
By activating the emergency operating system, the locking cylinders can be extended and retracted even when
the proximity switches and pressure sensors are out of order.
Turn the crane into the sea locking position. Care must be taken that the slewing gear is exactly in the locking
position because all monitoring facilities are overridden

Lock / Unlock procedure will be carried out by SET OPERATION.


The locking pressure then appears automatically on the display. If the sensor is defective the pressure must be
checked by pressure gauge.

Locking procedure:
When the LOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the locking position and the luffing gear pump is started at low (minimum) current.
The current, and therefore the delivery of the pump, is increased by ramp function and must be observed to
prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is locked (cylinder completely extended) the procedure is ended by releasing the soft-
key.
Take care that all locking cylinders are completely extended and than set the status of the interlocking system
on LOCKED by selection of CRANE IS LOCKED and entering TRUE.

Unlocking procedure:
When the UNLOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the unlocking position and the luffing gear pump is started at low (minimum)
current. The current, and therefore the delivery of the pump, is increased by ramp function and must be
observed to prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is unlocked (cylinder completely retracted) the procedure is ended by releasing the soft-
key.
Take care that all locking cylinders are completely retracted and than set the status of the interlocking system
on UNLOCKED by selection of CRANE IS UNLOCKED and entering TRUE.

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5.7 PMS – POWER MANAGEMENT SYSTEM (SPECIAL


EQUIPMENT)
5.7.1 FUNCTIONAL DESCRIPTION

The crane drives will be started by activating the START - switch. At first, the feed oil pump motor (9 kW)
starts while simultaneously the POWER-REQUEST signal (potential-free N.O. contact) will be given to the
ship control system of the ECR (engine control room) via the slip ring body.
In case of sufficient power supply of the generator, the crane control system will get a POWER-AVAILABLE
signal (potential-free N.O.contact) from the ECR. The main motor (160-kW-motor) will start only if the
POWER-AVAILABLE signal is available.

If the POWER-AVAILABLE signal will not be received within 30 sec after START (= POWER-REQUEST),
the feed oil pump motor will be stopped and the starting procedure must be repeated.
Display: FAULT OF PMS-SYSTEM

If the POWER-AVAILABLE signal drops out (e.g. in case of power outage / generator failure) during crane
operation, the crane drives will run down and the motors will be switched-off.
Display: FAULT OF PMS-SYSTEM

Within 10 min after normal termination of the crane operation, the POWER-REQUEST signal will be cut off.

The following status signals can be seen on the display:

FAULT OF PMS-SYSTEM
: POWER-REQUEST
POWER-AVAILABLE

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5.8 SPECIAL OPERATION MODES


5.8.1 TEST OPERATION
This special mode allows to check all solenoid valve circuits without running pump motors.
Therefore the crane control will be set into operable and all relevant limitations will be by-passed.
When the test operation mode is activated it is not possible to start the pump drive motors.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET / RESET TEST OPERATION
TEST OPERATION can now be activated = TRUE / deactivated = FALSE
by selection and entering

5.8.2 POWER / SPEED REDUCTION


This special mode will limit the speed of all drives at about 50 percent of it’s maximal speed.
This mode can be used to reduce the power consumption of the crane in case of problems with the supply
source (shore connection / generator failure), or when the drive speeds shall be reduced to prevent
collision conflicts etc.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE
by selection and entering

5.8.3 DISABLE TRIMOT


This special mode will limit the speed of the hoisting drive by switching off the control of the variable
displacement motor (TRIMOT).

Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select DISABLE TRIMOT
T_DISABLE: can now be activated = TRUE / deactivated = FALSE
by selection and entering

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5.9 TROUBLE SHOOTING


5.9.1 GENERAL REMARKS
The electronic assemblies include ICs in C-MOS Technology, the assemblies should never be extracted or
plugged in while the power is connected.
While designing the electrical equipment, great value was attached to providing a status monitoring system
that would monitor as many operating criteria as possible and would generate an appropriate message in
the event of malfunctions on the display.
If a malfunction occurs, the red collective fault indicator light in the control console lights up.

After the part of the system concerned has been checked and, if necessary, repaired, the crane can be put
into operation again by pressing the button < F2 >.
The following text describes the messages given by the status monitoring system in more detail.

The status monitoring system consists of several subsystems handling various criteria.
The first distinction has to be made between fault messages and condition status messages.
"FAULT" signalises malfunctions or faults which interrupt crane operation or certain functions and must be
RESET after repair.
"CONDITIONS", in contrast, are intentional interruptions or limits set on the basis of monitoring criteria (e.g.
hoisting gear limit switches or excessive hook loads). "CONDITION" displays that a limiting device has
responded, but not that there is a fault in the system.

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5.9.1.1 POWER SUPPLY AND CONTROL VOLTAGE


The power supply is feed from the ship's mains to the crane main switch across slip ring body.
If the main switch cannot be turned on, check the following points :
1. Is the power feeder from the ship's supply switched on?
2. Is an EMERGENCY OFF button being pressed?
3. Is the breaker =M01-Q1 in the OFF position.

The 24 V DC control voltage is produced by the three-phase rectifier bridge =M01-U1.

The 24 V control voltage is distributed into different circuits which are protected by fuses =M01-F11 to –
F18. If one of these fuses is out of order (for instance, blown owing to a short circuit), the fault is indicated
by the LED in the fuse terminal.

5.9.1.2 PLC STATUS INDICATORS


The main status of the PLC-system is indicated by LED’s on the main controller and on the input and
output Compact Modules.
When the system is running in good order the green LED is blinking with a 2 Hz signal.
Detailed information about the status indication is given in the hardware description of the PLC
components.

The signal status of each input and output on the Compact Modules is also indicated by a LED.

5.9.1.3 ADDITIONAL INDICATIONS

Detailed information about the input- output-status or value will be displayed, if the corresponding indication
sheet is selected, e.g.:
DRIVE VALUES potentiometer value, setup value, nominal / actual speed value
SENSOR VALUES digital inputs and outputs (TRUE / FALSE)
analogue inputs (current or voltage)
current outputs (PWM value in mA)
COUNTER VALUES position of the drive and drive speed

By calls of this information you are able to check a lot of relevant system data, e.g. it is possible to check
the status of an input or a sensor value (output current) will be read into the PLC.

Procedure:
• Set MAIN MENU
• Select INDICATIONS
Choose the required information

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5.9.2 LIST OF FAULT MESSAGES


and fault identification instructions

F 0010 STATUS FAILURE DELTA CONTACTOR

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture)
or that the corresponding PLC input itself is defective.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the contact of the displayed circuit line, e.g. F0015
indicates voltage at input IX4.01, although the contact of the
pressure switch =M07-S10 must be open.
− Eliminate the extraneous voltage, if present.
− Exchange the PLC or the corresponding Compact Module.

F 0011 STATUS FAILURE LIMIT SWITCH LUFFING IN


F 0012 STATUS FAILURE LIMIT SWITCH LUFFING OUT
F 0013 STATUS FAILURE LIMIT SWITCH HOISTING
F 0014 STATUS FAILURE LIMIT SWITCH LOWERING

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture)
or that the corresponding PLC input itself is defective.
Additional the status the limit switch contacts will be monitored:
Each contact block contains a NC and NO contact that means the voltage on the corresponding PLC inputs
must alternate. If both inputs have an identical signal level at the same time the corresponding fault will be
set.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the contact of the displayed circuit line, e.g. F0015
indicates voltage at input IX4.01, although the contact of the
pressure switch =M07-S10 must be open.
− Eliminate the extraneous voltage, if present.
− Exchange the PLC or the corresponding Compact Module.

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F 0015 STATUS FAILURE PRESS. SWITCH HOISTING


F 0016 STATUS FAILURE PRESS. SWITCH LUFFING
F 0017 STATUS FAILURE PRESS. SWITCH SLEWING
F 0018 STATUS FAILURE PRESS. SWITCH SLEWING

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture)
or that the corresponding PLC input itself is defective.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the contact of the displayed circuit line, e.g. F0015
indicates voltage at input IX4.01, although the contact of the
pressure switch =M07-S10 must be open.
− Eliminate the extraneous voltage, if present.
− Exchange the PLC or the corresponding Compact Module.

F 003 MAIN SWITCH CONTROL

Appears if main switch is switched off while pump drive motors are still running.
Press <F2> button to eliminate.
The crane shall not be stopped by pressing the emergency stop button.

Remedial action:
− Check the auxiliary contact of the main switch, this contact must
be opened when the main switch is ON.

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F 004 FAULT OF PMS-SYSTEM

For further information see functional description of the PMS-System.


This message appears if the power available signal is not given within 30 sec. after starting of the electrical
drives of the crane or when the signal drops out (e.g. in case of power outage / generator failure) during
crane operation).

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the relay =M06-KRQ, this relay must be switched on
during run time of the crane.
− Check the relay =M06-KEN, this relay will be activated by the
power available signal from ECR.
− Check the wiring and the connections via slipring assembly
− Check the control system of the ship controls in the engine
control room (ECR)

C 0041 PMS POWER REQUEST

This signal will be displayed if the starting procedure of the main motor is delayed because there is no
start enable by the power available signal.

C 0042 PMS POWER AVAILABLE

The PMS-System has received the start enable signal and will start the main motor.

F 005 DRIVE CONTACTOR NOT IN DELTA

The motor of the main pump is switched from the star to the delta circuit by means of timing relay =M02-
K4. This is intended to happen after about four seconds.
This message appears if the switch-over has not taken place after 10 seconds.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Set the switching time on the star/delta timing relay to 4 seconds.
− Replace the timing relay if defective.
− Repair the contactor for the delta circuit if necessary.
− Check the wiring.
− Replace the PLC.

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C 006 CONTROL LEVER NOT IN NEUTRAL POSITION

The control levers are not to be operated until <READY FOR OPERATION> is displayed.
This is checked by means of the contacts in the control levers.
This message appears if one or more contacts are closed before <READY FOR OPERATION> is
displayed.
This message appears also if the dead man switch is actuated before <READY FOR OPERATION> is
displayed. (optional equipment)

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Set the control levers to the neutral (zero) position (check the
return springs and replace if necessary).
− Check the control lever contacts and replace them if necessary.
− Replace the Cabinet Module in the right control desk.

F 007 OPERATION HOURS COUNTER

Memory contents of the operation hours counter is not correct. This occurs only if the processor module is
defective or if the PLC main controller has been changed.

Remedial action:

− Set the operation hours counter back to zero or to the relevant


counter value.

• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET OPERATING HOURS
SET NEW OPERATION HOURS M01:by corresponding data input

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F 0110 CONTROL OIL PRESSURE <15bar

The minimum permissible control pressure for the hydraulic system is 15 bar (normal operating pressure:
26 bar). Fault message F011 appears on the display if the pressure measured by the two pressure sensors
(=M07-B10 and -B20) is lower than this value.

The actual sensor output values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The values of the sensors are displayed in µA and bar.

Remedial action:
− Check the hydraulic oil circuit.
(cf. specification of the hydraulic system.)
− Measure the pressure with a pressure gauge and compare this
value with the displayed one.
− Check the power supply DC 24V of the Compact Module.
− Exchange the PLC or the corresponding Compact Module.

F 0160 OIL OVERTEMPERATURE

The hydraulic oil temperature is monitored by the temperature sensor =M07-B01. Fault message F016
appears on the display if the maximum permissible temperature of 90°C is exceeded.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and °C.

Remedial action:
− Check the hydraulic oil cooling circuit.
(cf. specification of the hydraulic system.)
− Check temperature sensor =M07-B01.
− Exchange the PLC or the corresponding Compact Module.

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F 0161 TEMPERATURE SENSOR OUTPUT <4mA


F 0162 TEMPERATURE SENSOR OUTPUT >18mA

This fault message appears if the temperature signal from the temperature sensor =M07-B01. The output
current from the temperature measurement must be between 4 and 18 mA (cf. specification of the
temperature sensor). Messages are generated if the measured value is outside.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and °C.

Remedial action:
− Check temperature sensor =M07-B01.
− e.g. connect a pressure sensor to the input of the temperature
sensor, if a value of >/= 4 mA is now displayed, then the
temperature sensor itself or the connector cable is defective.
− Exchange the PLC or the corresponding Compact Module.

F 0210 FILTER OVERPRESSURE

This fault message appears if the pressure switch (=M07-S08) of the filter clogging indicator has tripped.
The switch trips when the pressure dropped across the filter exceeds 5 bar (cf. specification of the
hydraulic system).

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Replace the filter cartridge.
− Check the pressure switch characteristics (the contact must be
closed).
− Check the wiring.
− Exchange the PLC or the corresponding Compact Module.

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F 0220 OVERLOAD FEED OIL PUMP

This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q11 for the control oil /
booster pump has tripped.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Reset the MCB.
− Check the power supply for phase failure.
− Compare the current set on the MCB with the specified nominal
motor current.
− Measure the motor amperage. If it is too high, the cause must be
sought in the booster pump or hydraulic system.
− Check the wiring.
− Replace the PLC.

F 0230 OVERLOAD OIL COOLER

This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q12 for the hydraulic oil
cooler has tripped.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Reset the MCB.
− Check the power supply for phase failure.
− Compare the current set on the MCB with the specified nominal
motor current.
− Measure the motor amperage. If it is too high, the cause must be
sought in the booster pump or hydraulic system.
− Check the wiring.
− Replace the PLC.

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F 0240 OVERLOAD MAIN MOTOR (THERMISTOR)

This fault message appears when the overload protection circuit for the main motor (=M02-M1) trips. The
protection circuit consists of a thermistor controlled relay (=M02-F4). The thermistor controlled relay will trip
if the pump drive is overloaded or the motor is not being adequately cooled.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the air circulation in the machinery space (air supply via
the crane column, exhaust via the hydraulic oil cooler).
− Check the thermistors in the motor.
− The thermistor resistance is normally 250 to 700 ohms, but
exceeds 3.5 kilo ohm if the temperature is too high.
BE CAREFUL WHEN CHECKING THERMISTORS!
They are extremely sensitive and will be destroyed if a voltage
exceeding 2 V is applied.
− Check that the thermistor-controlled relay is working properly.
− Check the wiring.
− Replace the PLC.

F 0251 OVERCURRENT MAIN MOTOR

The current drawn by the main motor is monitored in addition to the winding temperature. This is done by
current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is
proportional to the current.
Fault message appears if the drawn current exceeds 2.3 times the nominal current.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and the calculated motor amperage A.
(A=I(v1-v2) * 1,73

Remedial action:
− Check the voltage and the current drawn by the motor.
− Check the power supply and output signal of the sensor (about 4
mA output current per 100 A drawn).
− Replace the PLC.

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F 0252 NO AMPERAGE MAIN MOTOR

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line.
The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
Fault message appears if the current drawn is lower than that normally drawn under no-load conditions
(protection against phase failure).

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and the calculated motor amperage A.
(A=I(v1-v2) * 1,73

Remedial action:
− The sensor works with 220 V, i.e. the supply for lighting and
heating must be switched on via fuse =M03-F34.
− Check the voltage and the current drawn by the motor.
− Check the power supply and output signal of the sensor (about 4
mA output current per 100 A drawn).
− Replace the PLC.

F 0253 IDLE RUNNING AMPERAGE MAIN MOTOR

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line.
The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
Fault message appears if the current drawn is higher than that normally drawn under no-load conditions
(protection against phase failure).

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and the calculated motor amperage A.
(A=I(v1-v2) * 1,73

Remedial action:
− Check the voltage and the current drawn by the motor.
− Check the power supply and output signal of the sensor (about 4
mA output current per 100 A drawn).
− Replace the PLC.

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C 0711 POWER REDUCTION (MAIN MOTOR AMPERAGE)

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line.
The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
This message appears if the hoisting speed is reduced because current drawn by the main motor is too
high.
This can happen if all three crane motions are activated at full speed simultaneously under full load.
If the message appears while working at part load, the power supply to the motor should be checked.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and the calculated motor amperage A.
(A=I(v1-v2) * 1,73

Remedial action:
− Check the voltage and the current drawn by the motor.
− Check the power supply and output signal of the sensor (about 4
mA output current per 100 A drawn).
− Replace the PLC.

C 0713 SPEED REDUCTION (SPEC. OPERATION MODE)

This message indicates that the speed reduction mode has been activated.

Remedial action:
− De-activate this mode.
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be
activated = TRUE / deactivated = FALSE
by selection and entering

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F 1010 HOISTING PRESSURE <7bar

The pressure in the hoisting gear hydraulic circuit is monitored by switch =M07-S10. Fault signal appears
on the display if the pressure drops below 7 bar.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the hydraulic pressure by measuring it with a pressure
gauge. (cf. specification of the hydraulic system.)
− Measure the characteristics of the switch and replace as
necessary.
− Check the wiring.
− Exchange the PLC or the corresponding Compact Module.
− (Status must be <TRUE> when the pump drive is running.)

F 1020 HOISTING PRESSURE <>15bar

This fault message appears if pressure sensor =M07-B10 (hoisting gear) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is activated, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf.
specification of the pressure sensor.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Check pressure sensor =M07-B10.
− e.g. interchange the hoisting pressure sensor against the luffing
pressure sensor, if the failure is now displayed in the luffing
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

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F 1031 HOISTING SENSOR OUTPUT <4mA


F 1032 HOISTING SENSOR OUTPUT >18mA

This fault message appears if pressure sensor =M07-B10 (hoisting gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the
pressure sensor.

The actual sensor output value can be displayed:


• Set MAIN MENUE
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Check pressure sensor =M07-B10.
− e.g. interchange the hoisting pressure sensor against the luffing
pressure sensor, if the failure is now displayed in the luffing
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

F 1033 AUX. HOISTING SENSOR OUTPUT <4mA


F 1034 AUX. HOISTING SENSOR OUTPUT >18mA

The reason for this message corresponds to F 1031 / F.1032; it is created by malfunction of the auxiliary
pressure sensor =M07-B11.

F 1040 HOISTING PRESSURE TEST FAILURE

The hydraulic pump is tested after starting the pumps and every time before a new lifting/lowering cycle is
started with a gradually increasing electrical control current for the high-side pressure proportional solenoid
valve „B“ until the pressure reaches 50 bar (or the memorised pressure value from the previous hoisting
cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Compare the pressure displayed with a measurement carried out
by a pressure gauge.
− If no pressure build-up can be noticed, press the emergency
button of the solenoid valve directly for functional test of the
pump.
− Check pressure sensor =M07-B10.
− e.g. interchange the hoisting pressure sensor against the luffing
pressure sensor, if the failure is now displayed in the luffing
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.
− Exchange the PLC or the corresponding Compact Module.

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F 1050 HOISTING PRESSURE >40 bar

If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil
pressure). This message appears if the pressure remains at a level >40 bar.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Compare the pressure displayed with a measurement carried out
by a pressure gauge.
− Check the control unit of the hydraulic pump, maybe the pump
control unit is not shifting back into neutral position
− (see description of the hydraulic plant).
− Check pressure sensor =M07-B10.
− e.g. interchange the hoisting pressure sensor against the luffing
pressure sensor, if the failure is now displayed in the luffing
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.
− Exchange the PLC or the corresponding Compact Module.

F 1060 HOISTING CONTROL LEVER (OFFSET)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 10% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the
contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Check the contacts of the control lever.
− Re-adjust the potentiometer.
− Check the wiring.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 1060:
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.

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If one of the contacts is defective, the drive can be controlled by


the potentiometer only, this will be activated by the EOS-code.
Now the drive will be started and stopped by the potentiometer in
the control lever without safety control-check.
This is a dangerous condition: if now the potentiometer or
the analogue input becomes defective the drive will start
without driver command and can be stopped by emergency
stop only.

F 1070 HOISTING CONTROL LEVER (SUPPLY)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the
contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Check the wiring and the supply connections of the
potentiometer.
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Most of time it is a supply failure or the potentiometer itself is
defective.
− Check the contacts of the control lever.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 1070.
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If the potentiometer is defective, the drive can be controlled by
the control lever contacts only, this will be activated by the EOS-
code.
In normal conditions the contacts of the control lever are
connected in parallel, it does not matter in which direction the
control lever is actuated. For control with the EOS 1070-code it is
necessary to remove the bridge which is connecting the contacts
(the bridge on the supply side must remain), and now the contact
which will close in lowering direction must be connected to the
terminal for the EOS-input (IX5.01).
Now the drive will be started and stopped by the contacts in the
control lever without potentiometer speed control. For safety
reasons the drive speed is limited to half of its maximum.

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F 1080 HOISTING PWM-OUTPUT FAILURE =M07-A3


F 1081 HOISTING PWM-OUTPUT FAILURE =M07-A7

The control current for the proportional solenoid vales of the pump is generated in the Compact Module by
Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is
taken although the corresponding PWM output is activated by the nominal value .

The drive condition can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select DRIVE VALUES

Remedial action:
− Check the wiring to the solenoid valve.
− Check the resistance of the solenoid coil. (approx. 24-30Ω)
− Replace the PLC or the Cabinet Module.

F 1090 HOISTING WINCH OVERTEMPERATURE

The maximum temperature of the winch gear box is controlled by a temperature switch, the contact will
open when the temperature is exceeding the maximum value.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the winch temperature.
− Check the temperature switch
− Check the wiring between switch and PLC
− Replace the PLC.

F 1091 SECURITY CHECK WINCH OVERTEMPERATURE

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that
the PLC input itself is defective.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Eliminate the extraneous voltage, if present.
− Exchange the PLC.
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C 1210 LIFTING LIMIT (SAFETY LIMIT-SWITCH)

Additional to the electronic limit protection, there are 2 mechanical limit switches installed for collision
protection between hook and jib (anti-two-block).
One of these limit switches is actuated.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Lower the hook or luff in the jib.
− Check the limit switches, mounted at the jib head.
− Check the wiring to the limit switches.
− Check the relays =M06-K1S, -K2S.

− It is not possible to override this fault by the emergency system.

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C 1211 LIFTING LIMIT (MECHANICAL SWITCH)

The lifting distance of the crane is limited by the hoisting gear limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the following checks should be
carried out:

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the mechanism of the limit switch (connection to the
hoisting gear drum, limit switch coupling, limit switch gear, cam
shaft)
− Check the switching contacts.
− Check the wiring.
− Replace the PLC.

C 1212 LIFTING LIMIT (ROPE LENGHT)

The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out
by means of incremental encoders, mounted inside of the limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 1214 LIFTING PRE-LIMITATION

The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out
by means of incremental encoders, mounted inside of the limit switch =M06-S16.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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C 1216 LOWERING LIMIT (MECHANICAL SWITCH)

The lowering distance of the crane is limited by the hoisting gear limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the following checks should be
carried out:

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the mechanism of the limit switch (connection to the
hoisting gear drum, limit switch coupling, limit switch gear, cam
shaft)
− Check the switching contacts.
− Check the wiring.
− Replace the PLC.

C 1217 LOWERING PRE-LIMITATION

The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S16.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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C 1220 SLACK ROPE

The slack rope monitoring system of the hoisting gear has responded and blocked the motion. Haul the rope
taut by cautious operation in the opposite direction.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the contact rail; the contact rail is connected to a 24 V output
channel of the PLC. If the lifting gear rope is slack, it will touch the
rail, thereby earthing it so that the output voltage will drop down.
In other words, the lifting gear rope must not touch the contact rail,
and the contact rail must also be free from any dirt that might cause
an earth fault.
− Check the wiring.
− Replace the PLC.

C 1221 LOWERING LIMIT (ROPE LENGTH)

The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 1222 DEADMAN SWITCH NOT ACTUATED

The control leaver is equipped with a deadman switch. This switch must be actuated before the leaver is
moved from neutral position.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the mechanism of the control leaver (automatic return into
zero position; in zero position the directional contacts must be
open)
− Check the deadman switching contact.
− Check the wiring.
− Replace the cabinet module.

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F 1301 HOISTING COUNTER EQUALITY FAILURE

This fault is an internal fault in the PLC.


The output pulses from the incremental encoder are counted to ascertain the position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are
compared. It is also necessary to make sure that the correct position information is stored if an emergency
cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

− The fault should have vanished when the plant is switched on


again. If it has not, or if the fault occurs often, the PLC must be
replaced.

F 1302 HOISTING COUNTER OUT OF RANGE

The output pulses from the incremental encoder are counted to ascertain the position of the drive.
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter contents is not inside its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

− The fault should have vanished when the plant is switched on


again. If it has not, or if the fault occurs often, the PLC must be
replaced.

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F 1303 HOISTING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by
electronic measurement of rope length. This fault message is generated when mechanical and electronic
limitation of length are not carried out simultaneously (the drive has passed the limit position without
opening of the contact).
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the limit switch contacts (function and adjustment)
− Check the counter value of the position counter

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

F 1304 HOISTING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by
electronic measurement of rope length. This fault message is generated when mechanical and electronic
limitation of length are not carried out simultaneously (the contact has opened before the drive has reached
the electronic measured limit position).
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the limit switch contacts (function and adjustment)
− Check the counter value of the position counter
− Replace the PLC.

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

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F 1305 HOISTING GEAR IS BLOCKED

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the
outputs must constantly change. This fault message is generated if the pulse train fails.
• The winch does not move although the drive command is given (- the brake is not released; - or the
gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective).

Remedial action:
− Check the electrical power of the brake valve (the LED on the
valve connector plug should light up).
− Check the hydraulic control pressure for the brake at the
respective pressure measuring point.
− Press the emergency button on the solenoid valve of the brake,
the pressure must increase up to 25-28 bar
− Press the emergency button on the solenoid valve of the pump
control unit, the pressure must increase up to 300 bar
− Replace the PLC, or digital input/output module

F 1306 HOISTING ENCODER OUTPUTS EXCHANGED

The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses
generated by the encoder are phase-shifted with respect to each other (see illustration below) .

If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed
around.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− interchange the outputs of the encoder
− Replace the encoder
− Replace the PLC.

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

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F 1307 HOISTING NO COUNTING PULSES

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the
outputs must constantly change. This fault message is generated if the pulse train fails.
• The electrical encoder system fails
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− Check the hydraulic working pressure of the pump, if the drive is
set for lifting run the pressure on the high pressure side of the
pump must increase from 40 bar up to 300 bar
− Press the emergency button on the solenoid valve of the pump
control unit, the pump must increase up to 300 bar
− Check the encoder power supply.
− Check the encoder installation (coupling) inside the limit switch
− Check the wiring
− Replace the encoder
− Replace the PLC, or the PWM module

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

F 1308 HOISTING WRONG ROTARY MOTION

The winch monitoring system has indicated that the winch is turning in the paying out direction although the
control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
− interchange the outputs of the encoder
− Replace the encoder
− Replace the PLC

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F 1309 HOISTING STANDSTILL DRUM MONITORING

If the drive is not activated (brake applied), the winch monitoring system must not signal any motion.

The actual output status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the brake concerned.
− Check the electrical controls of the brake valves; if necessary,
replace the Compact Module.

F 1310 HOISTING OVERSPEED (FULL LOAD)

The speed of the winch is monitored by an incremental encoder.


This maximum drum speed has been exceeded.

The drive speed can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor
(see specification of the hydraulic system).
− Check the electrical power of the TRIMOT control. There must be
no output signal when a full load is to be lifted / lowered.

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F 1311 HOISTING OVERSPEED (EMPTY HOOK)

The speed of the winch is monitored by an incremental encoder.


This maximum drum speed has been exceeded.

The drive speed can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor
(see specification of the hydraulic system).
− Check the minimum displacement angle of the TRIMOT.
(see specification of the hydraulic system).

F 1312 HOISTING MUST RUN INTO REF. POSITION

This fault indication appears as a result of a previous failure.


The previous failure which has caused this indication is also displayed as ORIGIN FAULT.
This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according
to the corresponding fault description.
It is necessary to drive into the reference position for reset and confirmation of the counter system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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F 1330 TRIMOT OVERPRESSURE HOISTING


F 1331 TRIMOT OVERPRESSURE LOWERING

This fault message appears when the safety cut-out of the variable displacement hydraulic motor
(TRIMOT) for the hoisting gear trips.
This fault could be caused by a driver mistake, when he starts lifting a load with full speed, although the
load is not lifted up from the ground (slack rope).

The current output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
Select CURRENT OUTPUTS
The actual amperage is displayed

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

The following action should be taken if this fault occurs frequently :


− Check pressure hoisting pressure on the display and with a
gauge.
− Check the current drawn by the solenoid valve.
(Set the controls to the test mode, shift the hoisting gear control
lever to maximum deflection. In this state, the current drawn by
the solenoid valve should rise from about 200 to about 500 mA
within about 4 seconds.)
− If the measured currents are within limits, check the hydraulic
controls.
− If the current is outside of the limits, replace the PLC.
− Check the wiring.

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F 2010 LUFFING PRESSURE <7bar

The pressure in the luffing gear hydraulic circuit is monitored by switch =M07-S20. Fault signal appears on
the display if the pressure drops below 7 bar.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the hydraulic pressure by measuring it with a pressure
gauge. (Cf. specification of the hydraulic system.)
− Measure the characteristics of the switch and replace as
necessary.
− Check the wiring.
− Exchange the PLC or the corresponding Compact Module.
− (Status must be <TRUE> while the pump drive is running.)

F 2020 LUFFING PRESSURE <>15bar

This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is activated, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf.
specification of the pressure sensor.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Check pressure sensor =M07-B20.
− e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

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F 2031 LUFFING SENSOR OUTPUT <4mA


F 2032 LUFFING SENSOR OUTPUT >18mA

This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the
pressure sensor.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Check pressure sensor =M07-B10.
− e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

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F 2040 LUFFING PRESSURE TEST FAILURE

The hydraulic pump is tested after starting the pumps and every time before a new luffing cycle is to be
started with a gradually increasing electrical control current for the high-side pressure proportional solenoid
valve „B“ until the pressure reaches 50 bar (or the memorised pressure value from the previous luffing
cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Compare the pressure displayed with a measurement carried out
by a pressure gauge.
− If no pressure build-up can be noticed, press the emergency
button of the solenoid valve directly for functional test of the
pump.
− Check pressure sensor =M07-B20.
− e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

F 2050 LUFFING PRESSURE >40 bar

If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil
pressure). This message appears if the pressure remains at a level >40 bar.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Compare the pressure displayed with a measurement carried out
by a pressure gauge.
− Check the control unit of the hydraulic pump, maybe the pump
control unit is not shifting back into neutral position
− (see description of the hydraulic plant).
− Check pressure sensor =M07-B20.
− e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
circuit, then the pressure sensor itself or the connector cable is
defective.
− Exchange the PLC or the corresponding Compact Module.

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F 2060 LUFFING CONTROL LEVER (OFFSET)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 10% from the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and
the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Check the contacts of the control lever.
− Re-adjust the potentiometer.
− Check the wiring.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 2060:
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If one of the contacts is defective, the drive can be controlled by
the potentiometer only, this will be activated by the EOS-code.
Now the drive will be started and stopped by the potentiometer in
the control lever without safety control-check.
This is a dangerous condition: if the potentiometer or the
analogue input now becomes defective the drive will start
without driver command and can be stopped by emergency
stop only.

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F 2070 LUFFING CONTROL LEVER (SUPPLY)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and
the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Check the wiring and the supply connections of the
potentiometer.
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Most of time it is a supply failure or the potentiometer itself is
defective.
− Check the contacts of the control lever.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 2070.
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If the potentiometer is defective, the drive can be controlled by
the control lever contacts only, this will be activated by the EOS-
code.
In normal conditions the contacts of the control lever are
connected in parallel, it does not matter in which direction the
control lever is to be actuated. For control with the EOS 2070 -
code it is necessary to remove the bridge which is connecting the
contacts (the bridge on the supply side must remain), and now
the contact which will close in luffing out direction must be
connected to the terminal for the EOS-input (IX5.01).
Now the drive will be started and stopped by the contacts in the
control lever without potentiometer speed control. For safety
reasons the drive speed is limited to half of its maximum.

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F 2080 LUFFING PWM-OUTPUT FAILURE =M07-A3


F 2081 LUFFING PWM-OUTPUT FAILURE =M07-A7

The control current for the proportional solenoid values of the pump is generated in the Compact Module by
Pulse Width Modulation. A fault message appears when no control current measurement (actual value) is
taken although the corresponding PWM output is activated by the nominal value .

The drive condition can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select DRIVE VALUES

Remedial action:
− Check the wiring to the solenoid valve.
− Check the resistance of the solenoid coil. (approx. 24-30Ω)
− Replace the PLC or the Cabinet Module.

F 2090 LUFFING WINCH OVERTEMPERATURE

The maximum temperature of the winch gear box is controlled by a temperature switch, the contact will
open when the temperature is exceeding the maximum value.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the winch temperature.
− Check the temperature switch
− Check the wiring between switch and PLC
− Replace the PLC.

F 2091 SECURITY CHECK WINCH OVERTEMPERATURE

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that
the PLC input itself is defective.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Eliminate the extraneous voltage, if present.
− Exchange the PLC.
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C 2210 LUFF. OUT LIMIT (SAFETY LIMIT-SWITCH)

Additional to the electronic limit protection there are 2 mechanical limit switches installed for collision
protection between hook and jib (anti-two-block).
One of these limit switches is actuated.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Lower the hook or luff in the jib.
− Check the limit switches, mounted at the jib head.
− Check the wiring to the limit switches.
− Check the relays =M06-K1S, -K2S.

− It is not possible to override this fault by the emergency system.

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C 2211 LUFF. OUT LIMIT (MECHANICAL SWITCH)

The maximum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be
carried out:

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the mechanism of the limit switch (connection to the luffing
gear drum, limit switch coupling, limit switch gear, cam shaft)
− Check the switching contacts.
− Check the wiring.
− Replace the PLC.

C 2212 LUFF. OUT LIMIT (ROPE LENGHT)

The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 2214 LUFF. OUT PRE-LIMITATION

The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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C 2216 LUFF. IN LIMIT (MECHANICAL SWITCH)

The minimum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be
carried out:

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the mechanism of the limit switch (connection to the luffing
gear drum, limit switch coupling, limit switch gear, cam shaft)
− Check the switching contacts.
− Check the wiring.
− Replace the PLC.

C 2217 LUFF. IN PRE-LIMITATION

The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 2218 LUFF. IN (ROPE LENGTH)

The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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F 2219 LUFF. OUT FINAL SAFETY POSITION

The final (maximum) outreach of the crane is limited by the luffing gear rope length measurement system,
carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.

ATTENTION: If this limitation is to be by-passed


RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be damaged, or
the wire could unreel completely from the drum.

C 2222 DEADMAN SWITCH NOT ACTUATED

The control leaver is equipped with a deadman switch. This switch must be actuated before the leaver is
moved from neutral position.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the mechanism of the control leaver (automatic return into
zero position; in zero position the directional contacts must be
open)
− Check the deadman switching contact.
− Check the wiring.
− Replace the cabinet module.

F 2301 LUFFING COUNTER EQUALITY FAILURE

This fault is an internal fault in the PLC.


The output pulses from the incremental encoder are counted to ascertain the position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are
compared. It is also necessary to make sure that the correct position information is stored if an emergency
cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

− The fault should have vanished when the plant is switched on


again. If it has not, or if the fault occurs often, the PLC must be
replaced.

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F 2302 LUFFING COUNTER OUT OF RANGE

The output pulses from the incremental encoder are counted to ascertain the position of the drive.
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter content is not within its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

− The fault should have vanished when the plant is switched on


again. If it has not, or if the fault occurs often, the PLC must be
replaced.

F 2303 LUFFING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by
electronic measurement of rope length. This fault message is generated when mechanical and electronic
limitation of length are not carried out simultaneously (the drive has passed the limit position without
opening of the contact).
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the limit switch contacts (function and adjustment)
− Check the counter value of the position counter

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

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F 2304 LUFFING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by
electronic measurement of rope length. This fault message is generated when mechanical and electronic
limitation of length are not carried out simultaneously (the contact has opened before the drive has reached
the electronic measured limit position).
When this fault has been reset, <LUFFTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The counter values can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the limit switch contacts (function and adjustment)
− Check the counter value of the position counter
− Replace the PLC.

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

F 2305 LUFFING GEAR HAS BLOCKED

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the
outputs must constantly change. This fault message is generated if the pulse train fails.
• The winch does not move although the drive command is given (- the brake is not released; - or the
gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective).

Remedial action:
− Check the electrical power of the brake valve (the LED on the
valve connector plug should light up).
− Check the hydraulic control pressure for the brake at the
respective pressure measuring point.
− Press the emergency button on the solenoid valve of the brake,
the pressure must increase up to 25-28 bar
− Press the emergency button on the solenoid valve of the pump
control unit, the pressure must increase up to 300 bar
− Replace the PLC, or digital input/output module

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F 2306 LUFFFING ENCODER OUTPUTS EXCHANGED

The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses
generated by the encoder are phase-shifted with respect to each other (see illustration below) .

If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed
around.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− interchange the outputs of the encoder
− Replace the encoder
− Replace the PLC.

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

F 2307 LUFFING NO COUNTING PULSES

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the
outputs must constantly change. This fault message is generated if the pulse train fails.
• The electrical encoder system fails
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− Check the hydraulic working pressure of the pump, if the drive is
set for luffing in run the pressure on the high pressure side of the
pump must increase from 40 bar up to 300 bar
− Press the emergency button on the solenoid valve of the pump
control unit, the pump must increase up to 300 bar
− Check the encoder power supply.
− Check the encoder installation (coupling) inside the limit switch
− Check the wiring
− Replace the encoder
− Replace the PLC, or the PWM module

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

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F 2308 LUFFING WRONG ROTARY MOTION

The winch monitoring system has indicated that the winch is turning in the paying out direction although the
control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
− interchange the outputs of the encoder
− Replace the encoder
− Replace the PLC

F 2309 LUFFING STANDSTILL DRUM MONITORING

If the drive is not activated (brake applied), the winch monitoring system must not signal any motion.

The actual output status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the brake concerned.
− Check the electrical controls of the brake valves; if necessary,
replace the Compact Module.

F 2310 LUFFING OVERSPEED

The speed of the winch is monitored by an incremental encoder.


This maximum drum speed has been exceeded.

The drive speed can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

Remedial action:
− Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor
(see specification of the hydraulic system).

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F 2312 LUFFING MUST RUN INTO REF. POSITION

This fault indication appears as a result of a previous failure.


The previous failure which has caused this indication is also displayed as ORIGIN FAULT.
This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according
to the corresponding fault description.

It is necessary to drive into the reference position for reset and confirmation of the counter system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

F 3010 SLEWING PRESSURE <7bar

The pressure in the slewing gear hydraulic circuit is monitored by switches =M07-S20 and –S31. Fault
signal appears on the display if the pressure drops below 7 bar.

The actual input status can be displayed:


• Set MAIN MENUE
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the hydraulic pressure by measuring it with a pressure
gauge. (Cf. specification of the hydraulic system.)
− Measure the characteristics of the switches and replace as
necessary.
− Check the wiring.
− Exchange the PLC or the corresponding Compact Module.
− (Status must be <TRUE> while the pump drive is running.)

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F 3060 SLEWING CONTROL LEVER (OFFSET)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
A fault message is generated if the output voltage deviates more than 10% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the
contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Check the contacts of the control lever.
− Re-adjust the potentiometer .
− Check the wiring.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 3060:
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If one of the contacts is defective, the drive can be controlled by
the potentiometer only, this will be activated by the EOS-code.
Now the drive will be started and stopped by the potentiometer in
the control lever without safety control-check.
This is a dangerous condition: if the potentiometer or the
analogue input now become defective the drive will start
without driver command and can be stopped by emergency
stop only.

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F 3070 SLEWING CONTROL LEVER (SUPPLY)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).

The actual control lever conditions can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and
the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.

Remedial action:
− Check the wiring and the supply connections of the
potentiometer.
− Measure the output voltage of the potentiometer (control lever in
neutral position).
− Most of time it is a supply failure or the potentiometer itself is
defective.
− Check the contacts of the control lever.
− Replace the PLC or the Cabinet Module.
− Additional information regarding EOS 3070.
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If the potentiometer is defective, the drive can be controlled by
the control lever contacts only. This will be activated by the EOS-
code.
In normal condition the contacts of the control lever are
connected in parallel, it does not matter in which direction the
control lever will be actuated. For control with the EOS 3070 -
code it is necessary to remove the bridge which is connecting the
contacts (the bridge on the supply side must remain), and now
the contact which will close in slewing left direction must be
connected to the terminal for the EOS-input (IX5.01).
Now the drive will be started and stopped by the contacts in the
control lever without potentiometer speed control. For safety
reasons the drive speed is limited to half of its maximum.

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F 3080 SLEWING PWM-OUTPUT FAILURE =M07-A3


F 3081 SLEWING PWM-OUTPUT FAILURE =M07-A7

The control current for the proportional solenoid values of the pump is generated in the Compact Module by
Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is
taken although the corresponding PWM output is activated by the nominal value .

The drive condition can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select DRIVE VALUES

Remedial action:
− Check the wiring to the solenoid valve.
− Check the resistance of the solenoid coil. (approx. 24-30Ω)
− Replace the PLC or the Cabinet Module.

C 3211 RIGHT LIMIT (WORKING RANGE)

The maximum slewing range of the crane is limited by the slewing angle measurement system, carried out
by means of 2 proximity switches, mounted at the slewing rim, these proximity switches are counting the
teeth.
If this message appears although the slewing and luffing gear are in the "free" range, the measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 3214 RIGHT PRE-LIMITATION

Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
The maximum slewing range of the crane is limited by the slewing angle measurement system, carried out
by means of 2 proximity switches, mounted at the slewing rim, these proximity switches are counting the
teeth.
If this message appears although the slewing and luffing gear are in the "free" range, the measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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C 3216 LEFT LIMIT (WORKING RANGE)

The maximum slewing range of the crane is limited by the slewing angle measurement system, carried out
by means of 2 proximity switches, mounted at the slewing rim, these proximity switches are counting the
teeth.
If this message appears although the slewing and luffing gear are in the "free" range, the measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 3217 LEFT PRE-LIMITATION

Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
The maximum slewing range of the crane is limited by the slewing angle measurement system, carried out
by means of 2 proximity switches, mounted at the slewing rim, these proximity switches are counting the
teeth.
If this message appears although the slewing and luffing gear are in the "free" range, the measurement
system must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 3218 SLEW. LIMIT (JIB RESTING MODE)

When the jib resting mode has been activated it is not possible to turn the crane tower in any direction
without actuation of the key-operated switch <JIB RESTING>.

C 3222 DEADMAN SWITCH NOT ACTUATED

The control leaver is equipped with a deadman switch. This switch must be actuated before the leaver is
moved from neutral position.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action
− Check the mechanism of the control leaver (automatic return into
zero position; in zero position the directional contacts must be
open)
− Check the deadman switching contact.
− Check the wiring.
− Replace the cabinet module.

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F 3301 SLEWING COUNTER EQUALITY FAILURE

This fault is an internal fault in the PLC.


The teeth of the slewing rim are counted by 2 proximity switches (=M06-B810/B811) to ascertain the
position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are
compared. It is also necessary to make sure that the correct position information is stored if an emergency
cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <SLEWING MUST RUN INTO REF.-POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

− The fault should have vanished when the plant is switched on


again. If it has not, or if the fault occurs often, the PLC must be
replaced.

F 3302 SLEWING COUNTER OUT OF RANGE

The teeth of the slewing rim are counted by 2 proximity switches (=M06-B810/B811) to ascertain the
position of the drive.
Every time when the slewing drive is passing the reference/zero position (interlocking position for sea
voyage) the slewing position counter will be reset.
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter contents is not inside its limits.
When this fault has been reset, <SLEWING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

The actual input status can be displayed:


• Set MAIN MENUE
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the proximity switches (=M06-B802/B803) of the
interlocking system, the output signal of both switches must be
<FALSE>) when the crane is in the interlocking position.
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“
− The fault should have vanished when the plant is switched on
again. If it has not, or if the fault occurs often, the PLC must be
replaced.

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F 3306 PROXIMITY SWITCHES EXCHANGED

The sense of rotation and speed of the tower is monitored by proximity switches (pulsors). The pulses
generated are phase-shifted with respect to each other (see illustration below) .

If this fault message appears (for instance after replacing the pulsors), the pulsors must be changed
around.
When this fault has been reset, <SLEWING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− interchange the proximity switches (pulsors)
− Replace the proximity switches (pulsors)
− Replace the PLC.

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

F 3307 SLEWING NO COUNTING PULSES

The outputs of the proximity switches (pulsors) are monitored while the tower is turning, the signal status at
the outputs must constantly change. This fault message is generated if the pulse train fails.
There are two possibilities for activation of this fault:
• The tower does not move although the drive command is given (- the brake is not released; - or the
gear of the slewing is broken and blocks the drive, - or the hydraulic pump is defective).
• The electrical proximity switches (pulsors) system fails
When this fault has been reset, <SLEWING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system.

Remedial action:
− Check the electrical power of the brake valve (the LED on the
valve connector plug should light up).
− Check the hydraulic control pressure for the brake at the
respective pressure measuring point.
− Check the hydraulic working pressure of the pump, if the drive is
set the pressure of the pump must increase up to 300 bar
− Press the emergency button on the solenoid valve of the pump
control unit, the pump must increase up to 300 bar
− Check the proximity switches (pulsors) power supply.
− Check the proximity switches (pulsors) installation at the slewing
ring
− Check the wiring
− Replace the proximity switches (pulsors)
− Replace the PLC

− follow up the procedure, described under item


„RESET OF REFERENCE POSITIONS“

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F 3312 SLEWING MUST RUN INTO REF. POSITION

This fault indication appears as a result of a previous failure.


The previous failure which has caused this indication is also displayed as ORIGIN FAULT.
This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according
to the corresponding fault description.

It is necessary to drive into the reference position for reset and confirmation of the counter system.

Remedial action:
− follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 4101 OVERLOAD

The crane is protected against overload by a load measuring system.


The lifted load is calculated as a function of the hydraulic pressure.
If this message appears, check whether the load being lifted exceeds the maximum allowed load (SWL) for
the outreach range currently in use.

The actual sensor output value can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in µA and bar.

Remedial action:
− Reduce the load or outreach.
− Check the hydraulic oil pressure in the hoisting gear circuits.
(Compare the value measured with a pressure gauge with the
displayed value given.)
− Replace the hoisting gear pressure sensor (=M07-B10).
− Check the wiring.
− Replace the PLC or the corresponding Compact Module.

C 4103 OVERLOAD HOOK LASHING

The pull of the hook is reduced to a level for lashing the hook if the maximum outreach is exceeded by the
jib resting mode.
This message indicates that this pull has been reached or exceeded. After the crane controls have been
switched on (main switch ON), the hook must first be lowered a little in order to reset the pull limiting
system.

Remedial action :
− Briefly operate the hoisting gear in the direction "lowering".
− Check the hydraulic oil pressure in the hoisting gear circuits.
(Compare the value measured with a pressure gauge with the
displayed value given.)
− Replace the hoisting gear pressure sensor (=M07-B10).
− Check the wiring.
− Replace the PLC or the corresponding Compact Module.

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C 4203 OVERLOAD JIB RESTING

When the maximum outreach shall be exceeded by activation of the jib resting mode, the crane must not
have any load in the hook.
This message appears when the monitoring system has detected a load in the hook.

F 4301 CYLINDER NOT IN UNLOCK POSITION


F 4302 STATUS FAILURE OF PROXIMITY SWITCHES
F 4303 CRANE REMOVED FROM LOCKING POSITION
F 4304 LOCKING TIME LIMITATION EXCEEDED
F 4305 UNLOCKING TIME LIMITATION EXCEEDED

These failures are generated by the interlocking system (special equipment).


For explanation and trouble shooting see item: Interlocking for sea voyage.

C 4310 COLLISION ALARM - JIB IN REST POSITION

When the jib of the other crane is parked in the rest position and this jib shall be lowered below the
maximal outreach position (jib resting mode) than this alarm will occur to warn the crane driver that he must
drive carefully and pay attention for the parked jib of the other crane.
If this alarm occur although the jib of the other crane is not parked in the rest position than the control
device must be checked.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the proximity switch on the rest position (supply voltage
and output signal
− Check the cable connection (especially the slip ring connection
− Check the PLC input status (must be TRUE)
− Exchange the PLC

C 4311 JIB IS MOVED FROM REST POSITION

The parked jib of the other crane is moving out of the rest position.
This alarm will occur to warn the crane driver that he must drive carefully and pay attention for the jib of the
other crane.

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F 5010 PRESSURE FAULT CARGO GEAR

The pressure of the cargo gear is monitored by switch =M07-S82. A fault signal appears on the display if
the pressure drops below 20 bar.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the hydraulic pressure by measuring it with a pressure
gauge. (Cf. specification of the hydraulic system.)
− Measure the characteristics of the switch and replace as
necessary.
− Check the wiring.
− Exchange the PLC or the corresponding Compact Module.
− (Status must be <TRUE> when the main pump drive is running.)

F 5011 FAULT IN CARGO GEAR CONTROL

The cargo gear equipment (Grab) is protected by thermal overload relay =M80-Q81.
This message appears when the contact of these relay has opened.

The actual input status can be displayed:


• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal

Remedial action:
− Check the thermal overload relay =M80-Q81 (Status must be
<TRUE>)
− Measure the motor amperage of the grab motor.
− Check the wiring.
− Exchange the PLC.

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C 5020 HEELING ANGLE >5°


C 5021 HEELING ANGLE >8°

The heeling angle of the crane is monitored by an inclinometer inside the control cabinet.
The actual heeling value is displayed on the operation menu and when heeling exceeds 5° an additional
warning signal is given.
When heeling exceeds 8° the slewing gear, luffing out and lifting, is blocked.

Remedial action:
− Reduce the load or outreach.
− Replace the inclinometer (=M07-A8).
− Check the wiring.
− Replace the PLC.
− Re-adjust the heeling level, see description under item
<ZERO-SET OF INCLINOMETER>

F 5124 GRAB OPERATION MUST BE ACTIVATED

The analysis from the working process results that the hoisting gear is equipped with a grab.
Therefore the GRAB OPERATION must be activated with the key-switch in the right hand control desk.
If the analysis result is wrong this fault must be bypassed with the emergency operation system.

C 5125 LOWERING BLOCKAGE BY LOW PRESSURE

When the GRAB OPERATION is activated the hoisting gear pressure will be monitored and the lowering of
the grab is switched off by dropping down of the pressure when the grab is put on the ground.
After the control leaver has been set back to neutral it is possible to lower the grab again.

If this message appears when the grab is hanging free (not put on the ground) this feature can be
bypassed with the emergency operation system, or easier by pressing the <F2> key when C5125 is shown
on the display.

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C 5310 WORKING RANGE-LIMITATION

The working area of the crane is limited to prevent a collision.


This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit
position is reached the drive speed will be ramped down (pre-limitation).
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

C 5311 WORKING RANGE-PRE-LIMITATION

The working area of the crane is limited to prevent a collision.


This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit
position is reached the drive speed will be ramped down.
If this message appears although the luffing gear is in the "free" range, the rope length measurement
system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted.

Remedial action:
follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“

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F 810 Compact Module DIGITAL not initiated

The compact module =M07-A2 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 820 Compact Module PWM not initiated

The compact module =M07-A3 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 830 Compact Module ANALOG not initiated

The compact module =M07-A4 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 840 Cabinet Module not initiated

The cabinet module =M07-A5 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 0850 Compact Module PWM_2 not initiated

The compact module =M07-A3 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 0880 Inclinometer not initiated

The compact module =M07-A8 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 0886 Large LED display not initiated

The compact module =M07-A11 is defective and must be renewed.


If this message appears at first check the CAN-BUS system, described under item
Programmable logic controller.

F 0888 FAILURE OF CRANE IDENTIFICATION

If a new PLC is installed or the system is generally reset to DEFAULT data the corresponding crane
number must be entered into the system.

Procedure:
• Set MAIN MENU
• Select SECURED AREA (accepted must be entered)
• Select SECURITY CODE must be set and entered
• Select SET CRANE NUMBER (corresponding crane number must be entered)

ELECTRICAL EQUIPMENT 7/3165-3168 2-571-7/365-7/3168 Ind. 00 /02-2008 5-159


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

5.10 EMERGENCY OPERATION SYSTEM


Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.

Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override messages in the emergency operating mode and must take the
instructions given here into account.
This member of the crew is responsible for explaining the changed situation to the crane operator.

The identification and elimination of malfunctions are greatly simplified by the circuit diagrams, units
specifications and manufacturer's documentation, the list of fault status messages and the explanation of
the reason for the failures with recommended trouble shooting hints are described under item TROUBLE
SHOOTING.

If a fault can not be remedied immediately, for instance because the appropriate spare part is not available,
it should be remembered that the causes of many faults can be remedied temporarily by means of an
emergency operating system.

ATTENTION!
Before overriding a fault message by means of the emergency operating system, always check that the
corresponding monitored criterion, which is intended to protect the machinery against overload and
damage, is faulty and that the plant itself has not failed.
The emergency control system only overrides the fault message. It does not eliminate the cause!
The cause of the fault must be identified and eliminated as quickly as possible in order to avoid danger.

The crane is never to be operated by the emergency operating system for normal crane operations.

To de-activate the emergency operation system and set back the control into normal condition the
control power must be switched off completely (main switch).

Example 1 :
Status message
C 2211 LUFF. OUT LIMIT (MECHANICAL SWITCH)
blocks the luffing gear in the direction for luffing out. The message is caused by a faulty switch contact in
the luffing gear limit switch.
The maximum outreach is limited by the mechanical switch and additionally by the rope length
measurement system.
No replacement contact is available, and the status message is therefore overridden by means of the
emergency operating system until a replacement has been obtained.
Under these conditions, the luffing range is now restricted to the maximum permissible outreach by the
rope length measurement system only so that there is a higher risk of exceeding the maximum outreach
and overload.

Example 2 :
Fault message
F 1031 HOISTING SENSOR OUTPUT <4mA
blocks the hoisting gear. The message is caused by a fault in the pressure sensor and is overridden by the
emergency operating system until a replacement sensor is available.
This means that the hoisting gear is being used without the hydraulic pressure being checked
automatically. In other words, the hydraulic oil is under no pressure when a lifting operation is initiated.
Overload protection and tension limiters will not work and must be by-passed, if necessary. The use of the
Trimot is blocked. Prolonged operation without pressure checking will lead to damage in the drive systems.

5-160 Ind. 00 / 02-2008 2-571-7/3165-7/3168 ELECTRICAL EQUIPMENT 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

Example 3 :
Fault message
F 2010 LUFFING PRESSURE <7bar
blocks the complete crane operation. The message is caused by a faulty pressure switch contact in the
luffing gear hydraulic circuit.
No replacement pressure switch is available, and the fault message is therefore overridden by means of
the emergency operating system until a replacement has been obtained.
Normally if a hose bursts, the pressure will drop down and the corresponding pressure switch will shut
down immediately all drives and the brakes will engage.
Under emergency operation condition, the luffing circuit is no longer controlled against hose bursting,
the jib could fall down with the risk of damage and loss of life of personnel.

Overriding fault messages by means of the emergency operating system :

• Set MAIN MENU


• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET EMERGENCY OPERATION SYSTEM
now the Emergency Operation System CODE can be selected and entered, the EOS
CODE corresponds always to the fault or condition message number,
e.g. F2010 LUFFING PRESSURE <7bar will be overridden by the EOS CODE 2010.
e.g. F1301 HOISTING SENSOR OUTPUT <4mA will be overridden by the EOS CODE
1301.

ELECTRICAL EQUIPMENT 7/3165-3168 2-571-7/365-7/3168 Ind. 00 /02-2008 5-161


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

5.11 SERVICE
5.11.1 MAINTENANCE INFORMATION FOR HYDRAULICAL
The PLC monitors the crane equipment and will report a recommended maintenance instruction on the
display. If maintenance works are necessary this information is displayed after switching on the crane
control and can be reset by pressing the QUIT – button (F2).
If the maintenance work has been carried out, the maintenance instruction can be reset durable:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select MAINTENANCE
• Select ACKNOWLEDGE

M 901 MAINTENANCE CHECK HYDRAULIC OIL

Every 500 operational hours the hydraulic oil should be checked by taking of an oil sample.
A certain evidencing diagnostics of an oil sample depends decisively on the method of sample taking.
The taking of the sample always has to be made in the same manner. In principle, the oil should be at least
hand warm when taking it. If possible the oil to be analysed has to be taken from about the middle of the oil
level.
At winch gear where it is not possible to have access to the oil level, the oil to be analysed has to be taken
from the oil drain line. About 1-2L oil have to be drained into a container and an oil sample has to be taken
from the draining oil.
The access to a good oil level at the slewing gears is also difficult. Here too we recommend having a part
of the oil drained by removing the accessible oil draining screw and taking an oil sample from the draining
oil.

M 911 MAINTENANCE CHECK MAIN HOISTING GEAR


M 912 MAINTENANCE CHECK AUX. HOISTING GEAR
M 921 MAINTENANCE CHECK LUFFING GEAR
M 931 MAINTENANCE CHECK SLEWING GEAR

The control system checks that the corresponding drive speed is below 80% of the nominal rated speed.
This points to a higher oil leakage in the drive circuit, caused by wear of the pump and/or motor.
For further information, see the hydraulic manuals.

5-162 Ind. 00 / 02-2008 2-571-7/3165-7/3168 ELECTRICAL EQUIPMENT 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

5.11.2 MAINTENANCE OF ELECTRICAL EQUIPMENT


Safety regulations
All maintenance and repair work is to be carried out exclusively by trained electricians and only
after the whole plant is dead. Care must be taken that current labour safety regulations are
observed. In addition, all rules and regulations issued by local authorities concerning cranes and
accident prevention and works' regulations are to be followed.
Special care must be taken to ensure that the feeders for auxiliary equipment and deck illumination
are switched off (separate feeders).

If the crane has not been used for a considerable time, depending on conditions at the place of use, the
wiring, motors and switch gear for the low voltage installations are to be checked for satisfactory insulation,
cleaned and, if necessary, dried (condensation).
The whole equipment is always to be kept clean.
The electrical equipment belonging to the plant should be inspected at regular intervals. Defects such as
loose terminals or singed cables should be rectified immediately.
Use only fuses from the same manufacturer as the original fuses, and make sure that their ratings are as
specified. Switch the plant off immediately if faults develop in the power supply system.
After completion of maintenance work, all covers that have been removed must be replaced and the
electrical units closed as specified in the corresponding regulations. The feeders, especially those serving
the heating circuits, must be switched on again to prevent condensation when maintenance work has been
completed.

Tightness of all terminals


4 weeks after commissioning of the crane the terminals of the power circuits, especially main switch, main
contactors, main motor and slipring body must be checked for tight seating and fastened if necessary.

Motors
All motors are fitted with anti-friction bearings. These must be re-greased as specified by the corresponding
manufacturers.
The lubricating properties of grease and oil deteriorate during long periods of inactivity. This can lead to
rusting in the bearings. The motor should therefore be started for a short period every one or two months.

Slipring body
Caution!
Make absolutely sure that all feeders from the ship are switched off before work commences on the slip
ring body!
Power may be fed to the slip ring body via several independent feeders from the ship.

ELECTRICAL EQUIPMENT 7/3165-3168 2-571-7/365-7/3168 Ind. 00 /02-2008 5-163


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

Safety devices
All monitoring equipment such as limit switches, overload protection devices, pressure switches, etc.,
should be checked regularly to ensure that they are in perfect working order.
All monitoring equipment, and especially safety switches and their actuating mechanisms, must be checked
for tight seating whenever they are inspected.
The modification of safety equipment and the installation of other units is permissible only after consultation
and after approval has been given by TTS-LMG.
All safety equipment must be tested once again after repairs and after the crane has not been used for a
considerable time.

For safety reasons the operational hours should be noted every 2-3 month.
If the PLC system becomes defective and must be renewed the stored operation hours value is lost
and must be manually entered into the new PLC.

Annual checks of the entire electrical equipment


Attention is to be paid to the following items:
− Fastening of the units, especially of monitoring equipment, limit
switches, etc.
− Conformity to the specified enclosure requirements
− Tightness of all terminals
− Integrity of protective conductor connections
− Replacement of all damaged or worn units and parts (e.g.
contacts)
− Firm seating of fuses
− Cleaning of all parts of the plant

5-164 Ind. 00 / 02-2008 2-571-7/3165-7/3168 ELECTRICAL EQUIPMENT 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

5.11.3 SPARE PARTS


The spare parts documentation of the electrical equipment is located in a separate folder.
This folder is categorised corresponding to the assembly groups.

Additionally in the electrical circuit diagram you can find the part number of the device directly below
the electrical identification (mark of the unit).

Example:

The part number of the main switch –S1 is 2502406


The 3-pole fuse –F1 is divided into 2 part numbers: 1608376 for fuse switch-disconnector
1608405 for fuse cartridge

ELECTRICAL EQUIPMENT 7/3165-3168 2-571-7/365-7/3168 Ind. 00 /02-2008 5-165


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ELECTRICAL EQUIPMENT

5.11.4 CIRCUIT DIAGRAMS

5-166 Ind. 00 / 02-2008 2-571-7/3165-7/3168 ELECTRICAL EQUIPMENT 3165-3168


0 1 2 3 4 5 6 7 8 9

TTS-LMG Marine Cranes GmbH

SYSTEM's COVER PAGE


OBSERVE COPYRIGHT AS PER DIN 34

PLANT DESIGNATION :
____________________ TECHNICAL DATAS :
__________________

SINGLE DECK CRANE


CLASSIFICATION SOCIETY : LR
KL30t - 28m YEAR OF CONSTRUCTION : 2007

PLC SYSTEM : ifm R 360

MAIN POWER SUPPLY : 440V


CRANE-No.:3165-3180
Schutzvermerk nach DIN 34 beachten

AUX. POWER SUPPLY : 220V AC

FREQUENCE : 60Hz
MANUFACTURER
____________ :
RATED CURRENTS : 240A, 32A
TTS-LMG Marine Crane GmbH
CONTROL VOLTAGES : 440V , 24V DC
Einsiedelstrasse 6
23554 Lbeck

PROJECT ENGINEER : Mr. SCHMAHL


DEPARTMENT : TTS-LMG-K5

TELEPHONE : 0451 / 4501-725


TELEFAX : 0451 / 4501-392

=GEN/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
COVER PAGE Typ Bl.
7/3165 97.25 50 1
letzte Žnd./last mod. 22.05.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = COV


0 1 2 3 4 5 6 7 8 9

Seite / Seitenbenennung / letzte Bearbeitung/ Bemerkungen /


PAGE PAGE NAME LAST CHANGE REMARKS
Datum / Name
DATE / NAME

=COV/1 COVER PAGE 22.05.07 Schmahl

=GEN/1 TABLE OF CONTENTS 08.02.08 Schmahl

=GEN/2 TABLE OF CONTENTS 08.02.08 Schmahl

=GEN/3 TABLE OF CONTENTS 08.02.08 Schmahl

=GEN/4 GENERAL MARKINGS 15.05.07 Schmahl

=GEN/5 MARKS OF THE TERMINAL BLOCKS 28.11.07 Schmahl


OBSERVE COPYRIGHT AS PER DIN 34

=GEN/6 CONTROL CABINET 1800x600x300 DESIGN VIEW 25.05.07 Schmahl

=GEN/6.1 CONTROL CABINET 1800x600x300 DESIGN VIEW 15.05.07 Schmahl

=GEN/7 CONTROL DESK LEFT VIEW 08.02.08 Schmahl

=GEN/8 CONTROL DESK RIGHT VIEW 15.05.07 Schmahl

=GEN/9 OVERVIEW PLC INPUTS/OUTPUTS 28.11.07 ASC

=GEN/10 OVERVIEW PLC INPUTS/OUTPUTS 31.05.07 ASC

=GEN/11 OVERVIEW PLC INPUTS/OUTPUTS 31.05.07 ASC

=GEN/12 OVERVIEW PLC INPUTS/OUTPUTS 30.05.07 ASC

=GEN/13 OVERVIEW PLC INPUTS/OUTPUTS 31.05.07 ASC


Schutzvermerk nach DIN 34 beachten

=GEN/14 OVERVIEW PLC INPUTS/OUTPUTS 31.05.07 ASC

=SRK/1 SLIP RING CONNECTION 29.05.07 Schmahl

=SL/1 SINGLE LINE DIAGRAM MAIN POWER SUPPLY 25.05.07 Schmahl

=SL/2 SINGLE LINE DIAGRAM LIGHT AND HEATER 25.05.07 Schmahl

=SL/3 PLC OVERVIEW 29.05.07 Schmahl

=SL/4 PLC OVERVIEW 15.05.07 Schmahl

=SL/5 PLC OVERVIEW 29.05.07 Schmahl

=M01/1 POWER SUPPLY CIRCUIT DIAGRAM 21.08.07 Schmahl

=M01/2 CONTROL VOLTAGE SUPPLY CIRCUIT DIAGRAM 16.10.07 Schmahl

=M01/3 24 V DC CONTROL VOLTAGE SUPPLY 30.05.07 Schmahl

=M02/1 MAIN MOTOR CIRCUIT DIAGRAM 30.05.07 Schmahl

=M02/2 AUXILIARY DRIVES CIRCUIT DIAGRAM 15.05.07 Schmahl


=COV/1 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TABLE OF CONTENTS Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 08.02.08 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

Seite / Seitenbenennung / letzte Bearbeitung/ Bemerkungen /


PAGE PAGE NAME LAST CHANGE REMARKS
Datum / Name
DATE / NAME

=M02/3 STAR/DELTA CONTROL MAINMOTOR CIRCIUT DIAGRAM 30.05.07 Schmahl

=M03/1 LIGHT CIRCUIT DIAGRAM 29.05.07 Schmahl

=M03/2 LIGHT CIRCUIT DIAGRAM 21.08.07 Schmahl

=M03/3 LIGHT CIRCUIT DIAGRAM 30.05.07 Schmahl

=M03/4 HEATERS CIRCUIT DIAGRAM 29.05.07 Schmahl

=M03/5 DECK LIGHT CIRCUIT DIAGRAM 21.08.07 Schmahl


OBSERVE COPYRIGHT AS PER DIN 34

=M05/1 AUXILIARY 24V-DC CONSUMERS CIRCUIT DIAGRAM 22.05.07 Schmahl

=M06/1 PLC SUPPLY 24V DC CIRCUIT DIAGRAM 28.11.07 Schmahl

=M06/2 PLC INPUTS CIRCUIT DIAGRAM 28.11.07 Schmahl

=M06/3 PLC INPUTS CIRCUIT DIAGRAM 28.11.07 Schmahl

=M06/4 PLC INPUTS CIRCUIT DIAGRAM 28.11.07 Schmahl

=M06/5 PLC OUTPUTS CIRCUIT DIAGRAM 28.11.07 Schmahl

=M07/1 COMPACT MODULE PWM-OUTPUTS CIRCUIT DIAGRAM 29.05.07 Schmahl

=M07/2 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 31.05.07 Schmahl

=M07/3 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 31.05.07 Schmahl


Schutzvermerk nach DIN 34 beachten

=M07/4 CABIN MODULE INPUTS CIRCUIT DIAGRAM 31.05.07 Schmahl

=M07/5 CABIN MODULE INPUTS CIRCUIT DIAGRAM 31.05.07 Schmahl

=M07/6 CABIN MODULE OUTPUTS CIRCUIT DIAGRAM 31.05.07 Schmahl

=M07/7 DISPLAY CONNECTION DIAGRAM 22.05.07 Schmahl

=PE/1 PE CIRCUIT DIAGRAM 29.05.07 Schmahl

=TERMINALS/1 SLIP RING ASSEMBLY 29.05.07 ASC

=TERMINALS/2 TERMINAL BLOCK X3 220V CONTROL CABINET 21.08.07 ASC

=TERMINALS/2.1 TERMINAL BLOCK X3 220V CONTROL CABINET 21.08.07 ASC

=TERMINALS/2.2 TERMINAL BLOCK X3 220V CONTROL CABINET 21.08.07 ASC

=TERMINALS/3 TERMINAL BLOCK X4 380/440V CONTROL CABINET 29.05.07 ASC

=TERMINALS/4 TERMINAL BLOCK X5 24V CONTROL CABINET 28.11.07 ASC

=TERMINALS/4.1 TERMINAL BLOCK X5 24V CONTROL CABINET 28.11.07 ASC


1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TABLE OF CONTENTS Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 08.02.08 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

Seite / Seitenbenennung / letzte Bearbeitung/ Bemerkungen /


PAGE PAGE NAME LAST CHANGE REMARKS
Datum / Name
DATE / NAME

=TERMINALS/4.2 TERMINAL BLOCK X5 24V CONTROL CABINET 28.11.07 ASC

=TERMINALS/5 TERMINAL BLOCK X11 TERMINAL BOX OIL COOLER 29.05.07 ASC

=TERMINALS/6 TERMINAL BLOCK X12 TERMINAL BOX JIB-BEARING 29.05.07 ASC

=TERMINALS/7 TERMINAL BLOCK X13 TERMINAL BOX JIB TOP 29.05.07 ASC

=TERMINALS/8 TERMINAL BLOCK X39 TERMINAL BOX DECK LIGHTING 29.05.07 ASC

=TERMINALS/9 TERMINAL BLOCK X60 CONTROL DESK LEFT CABIN 21.08.07 ASC
OBSERVE COPYRIGHT AS PER DIN 34

=TERMINALS/10 TERMINAL BLOCK X62 CONTROL DESK LEFT CABIN 29.05.07 ASC

=TERMINALS/11 TERMINAL BLOCK X70 CONTROL DESK RIGHT CABIN 29.05.07 ASC

=TERMINALS/12 TERMINAL BLOCK X72 CONTROL DESK RIGHT CABIN 29.05.07 ASC

=TERMINALS/13 PLUG CONNECTOR X75 380/440V CONTROL DESK RIGHT 29.05.07 ASC

=TERMINALS/14 PLUG CONNECTOR XM50 WINDSCREEN WIPER 29.05.07 ASC

=TERMINALS/15 -XA1 24V PLC CABINET 29.05.07 ASC

=TERMINALS/15.1 -XA1 24V PLC CABINET 29.05.07 ASC

=TERMINALS/16 -X1A5 24V CAN NODE CABIN 29.05.07 ASC

=TERMINALS/17 -X2A5 24V CAN NODE CABIN 29.05.07 ASC


Schutzvermerk nach DIN 34 beachten

=TERMINALS/18 -X3A5 24V CAN NODE CABIN 29.05.07 ASC

=CABLES/1 CABLE OVERVIEW 21.08.07 ASC

=CABLES/1.1 CABLE OVERVIEW 21.08.07 ASC

=CABLES/1.2 CABLE OVERVIEW 21.08.07 ASC

2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TABLE OF CONTENTS Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 08.02.08 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

MARKS OF THE LOCATION MARKS OF THE UNIT MARKS OF THE EQUIPMENT PART

+A1 OUTSIDE EQUIPMENT GENERAL -A SYSTEM GROUPS 01 POWER SUPPLY

+A1.J JIB -B TRANSFORMERS ELECTRIC <-> NOT-ELECTRIC 02 3~AC MOTOR DRIVES

+A1.S COLUMN (SLIP RING ASSEMBLY) -C CAPACITORS 03 LIGHT AND HEATER

+A1.W WINCH PLATFORM -D STORAGE DEVICES

-E LIGHT/HEATERS 05 24V-AUXILIARY CONSUMERS

+F1 CABIN -F PROTECTION DEVICES 06 PLC - IN-/OUTPUTS

+F1.PR CONTROL DESK RIGHT CABIN -G GENERATORS, POWER SUPPLIES 07 PLC - CAN-KNOTS

+F1.PL CONTROL DESK LEFT CABIN -H SIGNALING DEVICES 08 PE


OBSERVE COPYRIGHT AS PER DIN 34

-K RELAYS/CONTACTORS
+P1 POWER MODULE
-L INDUCTORS
+P1.P PUMP UNIT
-M MOTORS
+P1.V VALVE BOARD
-N AMPLIFIERS/REGULATORS
+P1.H CONTROL CABINET
-P MEASURING/TESTING EQUIPMENT
+P1.M CONTROL CABINET MC
-Q MECHANICAL SWITCHING DEVICES FOR POWER CIRCUITS
+P1.C CONTROL CABINET PLC
-R RESISTORS

-S SWITCHES/SELECTORS
Schutzvermerk nach DIN 34 beachten

+T1.O CRANE TOWER TOP


-T TRANSFORMERS
+T1.U CRANE TOWER BELOW
-U MODULATORS/TRANSFORMERS
+T1.W WINCH MODULE
-V TUBES/SEMICONDUCTORS

-W TRANSMISSION PATHS/WAVEGUIDES/AERIALS

-X TERMINALS/PLUGS/SOCKETS

-Y ELECTRIC OPERATED MECHANICAL DEVICES

ADDITIONAL TO THE MARKS OF UNIT

IS A NUMBERCODING AS CROSS REFERENCE

TO IDENTIFICATION THE UNIT IN THE SPARE PART LIST

3 5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
GENERAL MARKINGS Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 15.05.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

PLUG CONNECTORS TERMINAL BLOCKS CONDUCTOR COLOURS /


CROSS-SECTIONAL AREAS
-X65 220V HEATING CONTROL DESK LEFT X1 TERMINAL BOX COLUMN (OPTIONAL)

-X66 220V LIGHTING CONTROL DESK LEFT X2 SUPPLY TERMINALS CONTROL CABINET
- DELAYED TO VDE 0113 -
-X67 24V CONTROL DESK LEFT X3 220V CONTROL CABINET
THE FOLLOWING COLOURS AND
X4 380/440V CONTROL CABINET
CROSS-SECTIONS ARE VALID,
-X75 380/440V CONTROL DESK RIGHT X5 24V CONTROL CABINET
IF NO FURTHER INSTRUCTIONS ARE MADE:

-X76 220V HEATING CONTROL DESK RIGHT


X60 220V CONTROL DESK LEFT CABIN
-X77 220V LIGHTING CONTROL DESK RIGHT
X61 220V CONTROL DESK LEFT CABIN - MAIN CIRCUITS AWG-16 BLACK
OBSERVE COPYRIGHT AS PER DIN 34

-X78 24V CONTROL DESK RIGHT


X62 24V CONTROL DESK LEFT CABIN - AC CONTROL CIRCUITS AWG-16 RED

-X82 LOAD TURNING DEVICE X70 220V CONTROL DESK RIGHT CABIN - DC CONTROL CIRCUITS AWG-20 BLUE
SPREADER (OPTIONAL)
X72 24V CONTROL DESK RIGHT CABIN
-XM11 440V FEED OIL PUMP
X75 380/440V CONTROL DESK RIGHT # = SHORT CIRCLE PROOF
-XM50 24V WINDSCREEN WIPER
X11 TERMINAL BOX OIL COOLER

X12 TERMINAL BOX JIB-BEARING


- NOTE TO THE CONDUCTOR COLOURS:
X13 TERMINAL BOX JIB TOP SHORTENING DELAYED TO DIN IEC 60757

X39 TERMINAL BOX DECK LIGHTING BK = BLACK


Schutzvermerk nach DIN 34 beachten

-XA1 24V PLC-CABINET BU = BLUE


X41 TERMINAL BOX DECK LIGHTING BN = BROWN
-XA2 24V CAN NODE I/O OR = ORANGE
X81 TERMINAL BOX PROX. SWITCHES RD = RED
-XA2C CAN BUS SEA LASHING WH = WHITE

-XA3 24V CAN NODE PWM X82 CARGO GEAR (OPTIONAL) PE = GNYE (PROTECTIVE EARTH)

-XA3C CAN BUS X83 CABLE REEL (OPTIONAL) SH / SC = SHIELD / SCREEN

-XA4 24V CAN NODE IDA XS16 TERMINAL BLOCK LIMIT


SWITCH HOISTING GEAR
-XA4C CAN BUS
XS26 TERMINAL BLOCK LIMIT
-X1A5 24V CAN NODE CABIN SWITCH LUFFING GEAR

-X2A5 24V CAN NODE CABIN XSR SLIP RING ASSEMBLY

-X3A5 24V CAN NODE CABIN XM1 MOTOR TERMINALS

-XA6 24V CAN DISPLAY XA2T 24V CAN NODE I/O

-XA8 24V CAN INCLINOMETER XA3T 24V CAN NODE PWM

4 6

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
MARKS OF THE TERMINAL BLOCKS Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

-S35
=M03
POWER UNIT

=M02-K3
CONTACTOR
DELTA
=MO1-U1

=M01-S1
MAIN SWITCH

-F30-F37
=M03
CABLE TUNNEL 35x75

CABLE TUNNEL 35x75

CABLE TUNNEL 35x75

CABLE TUNNEL 35x75


CABLE TUNNEL 50x75

-Q1
=M01 =M01 =M02 =M02
-T1
=M02

-F1
=M01

X5
-Q2
=M02-K2
CONTACTOR
STAR
=M02-F4

-Q11 -Q12
OBSERVE COPYRIGHT AS PER DIN 34

=M02-K4

-K11 -K12 -K32


=M02 =M02 =M03
CABLE TUNNEL 50x75

=M03

CLAMPS
SHIELD
-XSAPI
-K33

X4
=M03

X3
-K34 =M01
-F11-F17
1-4

CABLE TUNNEL 75x75


Schutzvermerk nach DIN 34 beachten

4-
3-
2-
1-
=M03-K32
=M03-K31
=M06-KEN
=M06-KRQ
5 6.1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
6
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CONTROL CABINET 1800x600x300 Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 25.05.07 Schmahl
Marine Cranes GmbH DESIGN VIEW
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

CONTROL CABINET CONTROL CABINET


DOOR VIEW (OUTSIDE) DOOR VIEW (INSIDE)

FILTERFAN

PLC - CABLE CONNECTION


OBSERVE COPYRIGHT AS PER DIN 34

PLC - R360
MAIN SWITCH
LIGHTING +
HEATING

MAIN SWITCH
POWER SUPPLY
Schutzvermerk nach DIN 34 beachten

CABINET HEATER

6 7

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
6.1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CONTROL CABINET 1800x600x300 Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 15.05.07 Schmahl
Marine Cranes GmbH DESIGN VIEW
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

1
OBSERVE COPYRIGHT AS PER DIN 34

1A 1 = CONTROL LEVER =M06-S21 SLEWING / LUFFING GEAR

=M05-S21H HORN
H

1A = CONTROL LEVER NAME PLATE

10 = SELECTOR SWITCH =M05-S1 WINDSCREEN WIPER


Schutzvermerk nach DIN 34 beachten

11 = SELECTOR SWITCH =M03-S35 DECKS LIGHT

12 = SELECTOR SWITCH =M03-S34 CABIN HEATER

13 = SELECTOR SWITCH =M03-S33 WARNING LIGHT RED

10 11 12 14 = SELECTOR SWITCH =M03-S32 WORKING LIGHT

15 = SELECTOR SWITCH =M03-S31 CABIN LIGHT

13 14 15

BP = BLIND CAP FOR ADDITIONAL INSTALLATION

6.1 8

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
7
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CONTROL Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 08.02.08 Schmahl
Marine Cranes GmbH DESK LEFT VIEW
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

DISPLAY

2 = CONTROL LEVER =M07-S12 HOISTING GEAR


OBSERVE COPYRIGHT AS PER DIN 34

2A
2A = CONTROL LEVER NAME PLATE
2

20 20 = EMERG. - OFF BUTTON =M01-S4 EMERG. - OFF


Schutzvermerk nach DIN 34 beachten

BP BP BP 26 = ILL. SWITCH =M07-S06/H06 START/STOP


READY FOR OPERATION

28 28 = INDICATION LAMP RED =M07-H07 FAULT


BP 30

30 = KEY OPERATED BUTTON =M07-S07 JIB RESTING

26 BP BP

BP = BLIND CAP FOR ADDITIONAL INSTALLATION

7 9

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
8
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CONTROL Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 15.05.07 Schmahl
Marine Cranes GmbH DESK RIGHT VIEW
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M06
-A1
=M06/1.1

CR 0505/0020
PLC MAIN BOARD

INPUTS OUTPUTS

-XA1
08
=M06/2.1 IW03
27
LOWERING =M06/4.3 IX0.01
09
HOISTING =M06/4.2 IX0.02
28
MAIN SWITCH =M06/2.4 IX0.03
10
FEED OIL PUMP =M06/2.5 IX0.04
29
HYDRAULIC OIL COOLER =M06/2.6 IX0.05
11
DELTA CONTACTOR =M06/2.7 IX0.06
30
MAIN MOTOR THERMISTOR RELAY =M06/2.8 IX0.07 I/O's depending on
hardware configuration
-XA1
OBSERVE COPYRIGHT AS PER DIN 34

44 44
IX0.08 QX0.00 =M06/5.7 TRIMOT
45 45
IX0.09 QX0.01 =M06/5.4 PMS-SYSTEM START REQUEST
46 46
SAFETY CONTACT HG =M06/4.4 IX0.10 QX0.02
47 47
SAFETY CONTACT LG =M06/3.4 IX0.11 QX0.03
20
LG INCREMENTAL ENCODER "B" =M06/3.5 IX0.12
02
LG INCREMENTAL ENCODER "A" =M06/3.5 IX0.13
21
HG INCREMENTAL ENCODER "B" =M06/4.5 IX0.14
38
HG INCREMENTAL ENCODER "A" =M06/4.5 IX0.15 I/O's depending on
hardware configuration
36 36
IX0.16 QX0.04 =M06/5.1 MAIN MOTOR TIME RELAY
54 54
IX0.17 QX0.05 =M06/5.2 FEED OIL PUMP
17 17
IX0.18 QX0.06 =M06/5.3 HYDRAULIC OIL COOLER
53 53
IX0.19 QX0.07 =M06/5.8 SUPPLY SAFETY CIRCUITS
19
LUFFING IN =M06/3.2 IX0.20
55
LUFFING OUT =M06/3.3 IX0.21
18
SLACK ROPE SW. HOISTING GEAR =M06/2.2 IX0.22
37
Schutzvermerk nach DIN 34 beachten

PMS-SYSTEM START ENABLE =M06/4.7 IX0.23 I/O's depending on


hardware configuration
39 39
IX0.24 QX0.08
03 03
IX0.25 QX0.09
40 40
IX0.26 QX0.10
22 22
IX0.27 QX0.11
41 41
IX0.28 QX0.12
42 42
IX0.29 QX0.13
43 43
IX0.30 QX0.14
04 04
IX0.31 QX0.15

48 48
IX0.32 QX0.16
49 49
IX0.33 QX0.17
31 31
IX0.34 QX0.18
50 50
IX0.35 QX0.19
51 51
IX0.36 QX0.20
52 52
IX0.37 QX0.21
16 16
IX0.38 QX0.22
35 35
IX0.39 QX0.23

14
CAN 1H =M06/1.5
32
CAN 1L =M06/1.5

8 10

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
9
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 28.11.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M07
-A2
=M07/3.1

CR 2033
MODULE DIGITAL

-XA2T
03
MODULE SUPPLY GND =M07/3.1 GND

05
24VDC SUPPLY
MODULE SUPPLY +24VDC =M07/3.2 +VBB

INPUTS OUTPUTS

-XA2 -XA2
1.4 2.4
FILTER OVERPRESSURE =M07/3.4 IX2.01 QX2.02 =M07/3.4 MAIN HOISTING GEAR BRAKE

CHANNEL 1 CHANNEL 2
OBSERVE COPYRIGHT AS PER DIN 34

1.1 2.3
FILTER OVERPRESSURE =M07/3.4 +24V_CH1 GND_CH2 =M07/3.4

3.4 4.4
RESERVE =M07/3.5 IX2.03 QX2.04 =M07/3.5 LUFFING GEAR BRAKE

CHANNEL 3 CHANNEL 4
3.1 4.3
RESERVE =M07/3.6 +24V_CH3 GND_CH4 =M07/3.6
Schutzvermerk nach DIN 34 beachten

5.4 6.4
RESERVE =M07/3.7 IX2.05 QX2.06 =M07/3.7 SLEWING GEAR BRAKE

CHANNEL 5 CHANNEL 6
5.1 6.3
RESERVE =M07/3.7 +24V_CH5 GND_CH6 =M07/3.7

7.4 8.4
RESERVE =M07/3.8 IX2.07 QX2.08 =M07/3.8 PRE HEATING

CHANNEL 7 CHANNEL 8
7.1 8.3
RESERVE =M07/3.9 +24V_CH7 GND_CH8 =M07/3.9

CAN IN CAN OUT


-XA2C -XA2C
1.4 2.4
CAN_H IN =M07/3.3 CAN_H CAN_H =M07/3.3 TERMINATION
1.5 2.5
CAN_L IN =M07/3.3 CAN_L CAN_L =M07/3.3

9 11

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
10
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 31.05.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M07
-A3
=M07/1.0

CR 2031
MODULE PWM I

-XA3T
03
MODULE SUPPLY GND =M07/1.1 GND

05
24VDC SUPPLY
MODULE SUPPLY +24VDC =M07/1.1 +VBB

OUTPUTS OUTPUTS

-XA3 -XA3
1.4 2.4
HOISTING GEAR HOISTING =M07/1.3 +24V_CH1 +24V_CH2 =M07/1.3 HOISTING GEAR LOWERING

CHANNEL 1 CHANNEL 2
OBSERVE COPYRIGHT AS PER DIN 34

1.2 2.2
=M07/1.4 CURRENT 1 CURRENT 2 =M07/1.4

3.4 4.4
LUFFING GEAR LUFFING IN =M07/1.5 +24V_CH3 +24V_CH4 =M07/1.5 LUFFING GEAR LUFFING OUT

CHANNEL 3 CHANNEL 4
3.2 4.2
=M07/1.5 CURRENT 3 CURRENT 4 =M07/1.6
Schutzvermerk nach DIN 34 beachten

5.4 6.4
SLEWING GEAR CLKW (RIGHT) =M07/1.7 +24V_CH5 +24V_CH6 =M07/1.7 SLEWING GEAR C-CLKW (LEFT)

CHANNEL 5 CHANNEL 6
5.2 6.2
=M07/1.7 CURRENT 5 CURRENT 6 =M07/1.7

7.4 8.4
RESERVE =M07/1.8 +24V_CH7 +24V_CH8 =M07/1.8 RESERVE

CHANNEL 7 CHANNEL 8
7.2 8.2
=M07/1.9 CURRENT 7 CURRENT 8 =M07/1.9

CAN IN CAN OUT


-XA3T -XA3C
01 2.4
CAN_H IN =M07/1.2 CAN_H CAN_H =M07/1.2 CAN_H OUT
02 2.5
CAN_L IN =M07/1.3 CAN_L CAN_L =M07/1.3 CAN_L OUT

10 12

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
11
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 31.05.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M07
-A4
=M07/2.0

CR 2033
MODULE ANALOG

DIG. INPUTS ANA. INPUTS

-XA4 -XA4
1.4 2.1
MAIN HOIST. GEAR PRESSURE (7 bar) =M07/2.4 IX4.01 +24V_CH2 =M07/2.4 MAIN HOIST. GEAR PRESSURE (0-600 bar)

CHANNEL 1 CHANNEL 2
1.1 2.2
MAIN HOIST. GEAR PRESSURE (7 bar) =M07/2.4 +24V_CH1 IW4.02 =M07/2.4 MAIN HOIST. GEAR PRESSURE (0-600 bar)
OBSERVE COPYRIGHT AS PER DIN 34

2.5
GND_CH2

3.4 4.1
LUFFING GEAR PRESSURE (7 bar) =M07/2.5 IX4.03 +24V_CH4 =M07/2.5 LUFFING GEAR PRESSURE (0-600 bar)

CHANNEL 3 CHANNEL 4
3.1 4.2
LUFFING GEAR PRESSURE (7 bar) =M07/2.6 +24V_CH3 IW4.04 =M07/2.6 LUFFING GEAR PRESSURE (0-600 bar)

4.5
GND_CH4 =M07/2.6

5.4 6.1
SLEWING GEAR PRESSURE (7 bar) =M07/2.7 IX4.05 +24V_CH6 =M07/2.7 RESERVE
Schutzvermerk nach DIN 34 beachten

CHANNEL 5 CHANNEL 6
5.1 6.2
SLEWING GEAR PRESSURE (7 bar) =M07/2.7 +24V_CH5 IW4.06 =M07/2.7 RESERVE

6.5
GND_CH6 =M07/2.7 RESERVE

7.4 8.1
SLEWING GEAR PRESSURE (7 bar) =M07/2.8 IX4.07 +24V_CH8 =M07/2.8 OIL TEMPERATURE -50-150 DEGREES)

CHANNEL 7 CHANNEL 8
7.1 8.2
SLEWING GEAR PRESSURE (7 bar) =M07/2.9 +24V_CH7 IW4.08 =M07/2.9 OIL TEMPERATURE -50-150 DEGREES)

8.5
GND_CH8 =M07/2.9

CAN IN CAN OUT


-XA4C -XA4C
1.4 2.4
CAN_H IN =M07/2.2 CAN_H CAN_H =M07/2.2 CAN_H OUT
1.5 2.5
CAN_L IN =M07/2.3 CAN_L CAN_L =M07/2.3 CAN_L OUT

11 13

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
12
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 30.05.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M07
-A5
=M07/4.0

CR 2012
CABINET MODULE 1/2

-X1A5
18
MODULE SUPPLY GND =M07/4.2 GND_CH8

2
24VDC SUPPLY
MODULE SUPPLY +24V =M07/4.2 +UB_CH1

DIG. INPUTS ANA. INPUT

-X1A5 -X1A5
1 5
EOS =M07/4.3 IX5.01 +UB_CH5 =M07/4.8

CHANNEL 1 CHANNEL 5
OBSERVE COPYRIGHT AS PER DIN 34

11
IW5.05 =M07/4.8 SET VALUE HOISTING GEAR

13
GND_CH5 =M07/4.8

14
GND_SH5 =M07/4.9

3
SWITCH PUMPS START/STOP =M07/4.4 IX5.02

CHANNEL 2 12
IX5.06
4
+UB_CH2

CHANNEL 6

DIG. OUTPUT
Schutzvermerk nach DIN 34 beachten

5 15
KEY BUTTON JIB RESTING =M07/4.5 IX5.03 QX5.07 =M07/6.1 READY FOR OPERATION

CHANNEL 3 CHANNEL 7
6 16
+UB_CH3 GND_CH7 =M07/6.3

7 17
=M07/4.6 IX5.04 QX5.08 =M07/6.2 FAULT

CHANNEL 4 CHANNEL 8
8 18
+UB_CH4 GND_CH8

CAN IN
-X3A5
6
CAN_H IN =M07/4.1 CAN_H
5
CAN_L IN =M07/4.1 CAN_L

12 14

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
13
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 31.05.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

=M07
-A5
=M07/4.0

CR 2012
CABINET MODULE 2/2

-X2A5
18
=M07/5.8 GND_CH16

2
24VDC SUPPLY
+UB_CH9

DIG. INPUTS ANA. INPUT

-X2A5 -X2A5
1 11
LUFFING IN =M07/5.1 IX5.09 IW5.13 =M07/5.3 SET VALUE LUFFING GEAR

CHANNEL 9 CHANNEL 13
OBSERVE COPYRIGHT AS PER DIN 34

9
+UB_CH13

13
GND_CH13 =M07/5.2 SET VALUE LUFFING GEAR

3 12
SLEWING CLKW (RIGHT) =M07/5.5 IX5.10 IW5.14 =M07/5.6 SET VALUE SLEWING GEAR

CHANNEL 10 CHANNEL 14
4 14
+UB_CH10 GND_SH14

DIG. INPUTS
Schutzvermerk nach DIN 34 beachten

5 15
RESERVE =M07/5.7 IX5.11 IX5.15

CHANNEL 11 CHANNEL 15
6 16
+UB_CH11 GND_CH15

7 17
RESERVE =M07/6.4 IX5.12 IX5.16 =M07/6.6 RESERVE

CHANNEL 12 CHANNEL 16
8 18
+UB_CH12 GND_CH16

13 =SRK/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
14
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
OVERVIEW Typ Bl.
7/3165 97.25 50 14
letzte Žnd./last mod. 31.05.07 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = GEN


0 1 2 3 4 5 6 7 8 9

SUPPLY FROM SHIP MAINS

POWER MANAGEMENT SYSTEM

EMERGENCY STOP

FOR DECKS LIGHTING


CONTROL LINE

EMERGENCY LIGHTING

LIGHT + HEATER

3PE

MAIN SUPPLY
(PMS)

~
(1N

(1N

~
60Hz 440V
~

~)
) 60Hz 220V

60Hz 220V
OBSERVE COPYRIGHT AS PER DIN 34

ON SHIP
L12-15

L10-11

L8-9

L6-7

L4-5

L3

L2

L1

PE
L3

L2

L1

PE
(L)M2X4 - 70mmý
Schutzvermerk nach DIN 34 beachten

L1

TO CONTROL CABINET +P1.H


L2
(L)M2X4 - 3x2x70mmý

ON CRANE
L3

TO CONTROL CABINET +P1.H


1 2 3 4 5 6 7 8 9 10 11 12

L4-L5
(L)M2X4 - 2x6mmý
L6-L7

L8-L9
TO CONTROL CABINET +P1.H
(L)M2X4 - 2x1,5mmý
L10-L11

L12-L15 TO CONTROL CABINET +P1.H


(L)M2X4 - 5x1,5mmý
16A

16A

16A

16A

16A

16A

16A

16A

16A

16A

60A

60A

600A

600A

600A

600A

=GEN/14 =SL/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
SLIP RING CONNECTION Typ Bl.
7/3165 97.25 50 1
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = SRK


0 1 2 3 4 5 6 7 8 9

*) TECHNICAL DATAS
----------------
440V # BK 6mmý DATA FOR SUPPLY CABLE RATING :

3x1 MEAN EFFECTIVE POWER CONSUMPTION : 185 kVA


x50mmý

DATA FOR GENERATOR LOADS :

SHORT TIME LOAD (10% DUTY CYCLE): 380 kVA

PEAK LOAD (2-3S): 430 kVA


3

-S1 3 -K3 -K2 -F1 REVERSE POWER WHEN LOWERING FULL LOAD: 100 kW
400A 35A

STARTING CURRENT OF EL. MOTOR : 610 A


3x1
x50mmý NOTE:
OBSERVE COPYRIGHT AS PER DIN 34

IMPORTANT FOR CIRCUIT BREAKER WITH ELECTRONIC


SHORT CIRCUIT DETECTION !

BY SWITCHING THE MAIN MOTOR FROM STAR TO DELTA


A CURRENT PEAK (RUSH - EFFECT) IS ORIGINATE.

THIS CURRENT OCCURS ONLY A SHORT TIME (<10MS)


AND CAN RISE UP TO 4.500 A.

BUS BAR

PE

BK 3x2
x70mmý 1x70mmý
-Q11 3
-Q12 3
-Q1 3
20-25A 2,4-4A 2,4-4A
Schutzvermerk nach DIN 34 beachten

-XSR

S S S
L PE PE -K11 -K12 -U1
R R R 380/440V
--------
24V, 20A

4x2,5mmý 4x1,5mmý

3+PE 3+PE 3+PE

L1-3 PE L10-11
-M1 -M11 -M12
160kW 9KW 1,5KW CTRL
3

MAIN EMERGENCY STOP MAIN FEED OIL HYDRAULIC OIL CONTROL


POWER FROM DECK AREA MOTOR PUMP COOLER VOLTAGE
SUPPLY 3PE 440V 24V DC
AC 60Hz

=SRK/1 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
SINGLE LINE DIAGRAM Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 25.05.07 Schmahl
Marine Cranes GmbH MAIN POWER SUPPLY
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = SL


0 1 2 3 4 5 6 7 8 9

220V AWG 10 BUS BAR

-S2 2 -F35 2 -F30 2 -F31 2 -F32 2 -F33 2 -F34 2 -F36 2 -F37 2

10A 10A 10A 10A 10A 10A 10A 10A


OBSERVE COPYRIGHT AS PER DIN 34

K32 -S03 -S31 -S32 -S33 -K34 -K34

-XSR

S S S
R R R
Schutzvermerk nach DIN 34 beachten

L4-5 L6-7 L8-9

E2
-E31 -E5
-E36 -E37 -E38 E3 -E6 -E39 -E40
-E32 M31
40W 1000W 60W E8 2KW 1000W 1000W
3x20W 0,55 kW
1,5kW

SUPPLIES 220V AC, 60Hz

AUX. EMERGENCY DECKS


POWER SUPPLY LIGHTING
SUPPLY FOR LIGHT CONTROL

LIGHT LIGHT WORKING WARNING DESK HEATER CONTROL DECK LIGHT DECK LIGHT
CRANE CABIN LIGHT LIGHT HEATER, CRANE CABINET UNDER CABIN UNDER CABIN
TOWER BELOW/TOP AT JIB AT JIB HEATING FAN TOWER HEATER,
TOP CABIN FAN

1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
SINGLE LINE DIAGRAM Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 25.05.07 Schmahl
Marine Cranes GmbH LIGHT AND HEATER
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = SL


0 1 2 3 4 5 6 7 8 9

MAIN CONTROL CABINET

MAIN MOTOR
CURRENT
24V DC
K Kx
Q BX

6 4
OBSERVE COPYRIGHT AS PER DIN 34

CR0505 / 0020
VIQ IX QX IW

IX = 9 (14)
IxC = 4 (6)
A1
1.8
IW = 1 (2)

CR 0505 / CR 0020 QX = 4 (5)


QX(PWM) = 1 (2)
QX
PWM IX IX IX (C) IX IX (C) IX (C) C1

1(2)
Schutzvermerk nach DIN 34 beachten

-YT -SL -S16 -S26 -XSR


2.2

L12-15 CR2012 /5.0


TRIMOT
PROP. VALVE

SWITCHES
LIMIT

CR2031 /4.0
SWITCHES
LIMIT

ENCODER
INCREMENTAL

SWITCHES
LIMIT

ENCODER
INCREMENTAL

SYSTEM
MANAGEMENT
POWER
2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC OVERVIEW Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = SL


Bl.
Sh.
5

SOL. VALVES
5
QD3

Bl.
Sh.
9

HOIST. GEAR BRAKE


-Y1

5002556

SOL. VALVES
QD2

PRESSURE LUFF. GEAR BRAKE


ID

-Y2

SWITCHES
PS
8

Sach-Nr.

SOL. VALVES
QD1

PRESSURE SLEW. GEAR BRAKE


ID

-Y3

SWITCHES
CR 2033

= SL
Typ
PS

SOL. VALVES
QD1

PRE-HEATING
-Y11
7

VBB

24VDC-V
C1

SINGLE DECK CRANE


A2
6

C2

IA4

PLC OVERVIEW
PRESSURE
D4

SWITCHES
PS

PRESS./TEMP.
IA3

PRESSURE TRANSMITTER
D3

SWITCHES
5

-B01
PS

PRESSURE PRESS./TEMP.
IA2

Marine Cranes GmbH


D2

CR 2033

SWITCHES TRANSMITTER
-B20
PS

PRESSURE
D1

PRESS./TEMP.
4

SWITCHES
IA1

TRANSMITTER
PS

-B10

TTS-LMG
C1

A4
3

C2

Name/name

Schmahl

Schmahl
PROP. VALVES PROP. VALVES
4B

4A
PUMP CONTROL PUMP CONTROL
-4B

4A

Datum/date

08.02.08

15.05.07

15.05.07
2

PROP. VALVES PROP. VALVES

3B

3A
PUMP CONTROL PUMP CONTROL
-3B

3A

letzte Žnd./last mod.

erstellt/designed
CR 2031
PROP. VALVES PROP. VALVES

geprft/checked
2B

2A
PUMP CONTROL PUMP CONTROL
-2B

2A
1

PROP. VALVES PROP. VALVES

1B

1A
PUMP CONTROL PUMP CONTROL

Ch.

50
-1B

1A

ass.-gr.

-K5
Baugr./

97.25

Abt./departm.:
VBB
CR2031 24VDC-P

C1
3.9/
0

Bau-Nr./

7/3165
A3

Com-No
3
OBSERVE COPYRIGHT AS PER DIN 34 Schutzvermerk nach DIN 34 beachten
0 1 2 3 4 5 6 7 8 9

CONTROL DESK
DRIVERS CABIN

COMMANDS
CONTROL

CONTROL
LEVER

LAMPS
PILOT
TDM MONITOR COM CL H
OBSERVE COPYRIGHT AS PER DIN 34

4 3 3

ID IA QD

A6 CR 1031 A5 CR 2012

RS CAN CAN
Schutzvermerk nach DIN 34 beachten

3.9/ CR2012

4 =M01/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC OVERVIEW Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = SL


0 1 2 3 4 5 6 7 8 9

SLIP RING ASSEMBLY MAIN SWITCH AUXILIARY MAIN SWITCH


MAIN POWER AUX. POWER SUPPLY DRIVES POWER SUPPLY
SUPPLY POWER SUPPLY
EMERGENCY OFF
220V AC AWG 10 BK
L4.1 /=M03/2.0
L5.1 /=M03/2.0
440V AC # 2,5mmý BK

#6mmýBK
L1.2 /=M02/1.1
L2.2 /=M02/1.1
L3.2 /=M02/1.1
1 3 5

1 3 5
2 4

-S2 1 3 5 -Q1
1 3 -S1 0,6-1A
11KW -F1
3x2x70mmý

32A .8 2 4 6
63A PN 2544253 2 4 6
OBSERVE COPYRIGHT AS PER DIN 34

PN 2381873 400A ---


U< 2 4 6
35A 1,5mmý
RD
PN 2502406 PN 1608376
70mmýBK PN 1608405 D1 313

-S1.H
314
X3 1 2

6mmýBK
-S1
.4 D2

PE
X4 1

70mmý

X75 1

21

-S4
Schutzvermerk nach DIN 34 beachten

22
PN 2502563

XSR X75 2
PN 5002356
+F1.PR
L1 L2 L3 PE L4 L5

X4 2

X4 15 16

XSR
PN 5002356 L10 L11

+A1.S
L1.1

L2.1

L3.1

M1-U1

M1-V1

M1-W1

L1.11

L2.11

L3.11
Emergency Stop button -S41
to be supplied

3PE 440V 220V as loose part


=M02/1.1/

=M02/1.1/

=M02/1.1/

AC 60Hz AC 60Hz 21
=M02/1.1/

=M02/1.1/

=M02/1.1/

2.1/

2.1/

2.1/
-S41
22
PN 5002584
DECK
AREA

+A1.S
=SL/5 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
POWER SUPPLY Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 21.08.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M01 +P1.H


0 1 2 3 4 5 6 7 8 9

440V AC
1.6/ L1.11 L1.11 /=M02/2.1
1.6/ L2.11 L2.11 /=M02/2.1
1.6/ L3.11 L3.11 /=M02/2.1

1 3 5

-Q2
2,4-4A
(3A)
2 4 6

PN 2544252

CV.L2 /=M02/3.1
OBSERVE COPYRIGHT AS PER DIN 34

CV.L3 /=M02/3.1

Power Unit
L1 L2 L3
DIP-SWITCH

-U1 settings
400-500VAC
50/60Hz
ON A = OFF
- +
24VDC
20A
OFF B = ON
A B
PN 5002582
Schutzvermerk nach DIN 34 beachten

2,5mmý BU

2,5mmý BU

PE

PE

PE

24VN 24VP
3.1 3.1

1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CONTROL VOLTAGE SUPPLY Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 16.10.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M01 +P1.H


0 1 2 3 4 5 6 7 8 9

24 V DC FUSE SEPARATION
PLC PLC PLC INTERNAL EXTERNAL EXTERNAL AUXILIARY
MODULE SUPPLY SUPPLY CONSUMERS CONSUMERS CONSUMERS CONSUMERS
SUPPLY OUTPUTS OUTPUTS

2,5mmý BU
2.2/ 24VP

-F11 -F12 -F13 -F14 -F15 -F16 -F17


3A 7,5A 7,5A 3A 7,5A 7,5A 7,5A

PN 2535436
PN 2533904
PN 4510378
OBSERVE COPYRIGHT AS PER DIN 34

2,5mmý BU 24N2(GND) /=M02/1.6


2.2/ 24VN 24N1(GND) /=M05/1.1
Schutzvermerk nach DIN 34 beachten

X5 1 2 3 4

X5 20 21 22 23 24
24V-PLC-VBB

24V-PLC-OUT05

24V-PLC-OUT34

24V-INT.

24V-P1.P

GND-P1.P

24V-P1.V

GND-P1.V

24V-CAB

GND-CAB

24V-AUX
=M07/4.1/

=M07/4.1/

=M05/1.1/
=M02/3.1/

=M07/1.1/

=M07/1.1/

=M07/3.1/

=M07/3.1/
=M06/1.1/

=M06/1.1/

=M06/1.1/

2 =M02/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
24 V DC Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 30.05.07 Schmahl
Marine Cranes GmbH CONTROL VOLTAGE SUPPLY
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M01 +P1.H


0 1 2 3 4 5 6 7 8 9

MAIN MOTOR DELTA CONTACTOR STAR CONTACTOR STANDSTILL THERMISTOR


HEATER

440V AC 70mmý BK
=M01/1.4/ L1.1
=M01/1.4/ L2.1
=M01/1.4/ L3.1

=M01/1.9/ L1.2
=M01/1.9/ L2.2
=M01/1.9/ L3.2
1 3 5 2 4 6
-K3 -K2
3.3 2 4 6 3.2 1 3 5

=M01/1.4/ M1-U1
=M01/1.5/ M1-V1
=M01/1.5/ M1-W1
OBSERVE COPYRIGHT AS PER DIN 34

SMB 500/0,02
CURRENT MEASURING DEVICE
-T1
PN 2368074

=M01/3.8/ 24N2(GND) 24N2(GND) /3.1

+
I-MAIN /=M06/2.1
3x1x70mmý

3x1x70mmý

UH
UH /=M03/4.6
UH
VH /=M03/4.6

M1-L /=M03/4.7
M1-N /=M03/4.7
Schutzvermerk nach DIN 34 beachten

AWG 16 WH
M1/1 /3.1
M1/2 /3.1

X5 33 34

PE PE

PE

M1 XM1 U1 V1 W1 W2 U2 V2 L N T1 T2
160KW

PN 5002027

+P1.P

=M01/3 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
MAIN MOTOR Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 30.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M02 +P1.H


0 1 2 3 4 5 6 7 8 9

FEED OIL PUMP HYDRAULIC OIL COOLER


MOTOR MOTOR

BUS BAR
=M01/2.8/ L1.11
=M01/2.8/ L2.11
=M01/2.8/ L3.11

1 3 5 1 3 5
13 13

-Q11 14
-Q12 14

=M06/2.5

=M06/2.6
16-20A 2,4-4A
(In=18,5A) (In=3,8A)
2 4 6 2 4 6
OBSERVE COPYRIGHT AS PER DIN 34

PN 2546542 PN 2544252
PN 2544250 PN 2544250
BK AWG 10

1 3 5 1 3 5
-K11 -K12
=M06/5.2 2 4 6 =M06/5.3 2 4 6

PE PE PE

PE
Schutzvermerk nach DIN 34 beachten

X4 7 8 9 10PE 11 12 13 14PE

X11 1 2 3 4PE

V1 W1 U1 W1 V1 U1

-M11 -M12
9 kW 1,75kW
(In=3,8A)
PE PE

+P1 +T1.O

1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
AUXILIARY DRIVES Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 15.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M02 +P1.H


0 1 2 3 4 5 6 7 8 9

MAIN MOTOR CONTROL


STAR DELTA THERMISTOR RELAY

24V DC
=M01/3.4/ 24V-INT. 24V-INT /=M06/2.1
1.8/ 24N2(GND) 24N2(GND) /=M06/5.1

1.8/ M1/1
1.8/ M1/2

=M01/2.8/ CV.L2 A1 T1 T2 11 A2

-F4
OBSERVE COPYRIGHT AS PER DIN 34

PN 2094520

12 14

F4/14 /=M06/2.8

17

-K4
Schutzvermerk nach DIN 34 beachten

=M06/5.1 18 28

21 21
-K3 -K2
.3 22 .2 22

A1 A1

-K2 -K3
A2 A2
PN 4226207 PN 4226329
PN 2532326 PN 4226210

=M01/2.8/ CV.L3

1 2 1.4 1 2 1.2
3 4 1.4 3 4 1.3
5 6 1.4 5 6 1.3
21 22 .3 21 22 .2
31 32 =M03/4.7 31 32 =M03/4.7
43 44 =M06/2.7
2 =M03/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
STAR/DELTA CONTROL Typ Bl.
7/3165 97.25 50 3
letzte Žnd./last mod. 30.05.07 Schmahl
Marine Cranes GmbH MAINMOTOR
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl CIRCIUT DIAGRAM = M02 +P1.H


0 1 2 3 4 5 6 7 8 9

EMERGENCY SUPPLY LIGHTING LIGHT LIGHT


220V AC SWITCH CRANE POWER
TOWER BELOW MODULE

220V AC

1 3

-F30
B 10A
2 4
PN 5002000
OBSERVE COPYRIGHT AS PER DIN 34

PE1 PE PE PE PE PE

PE

X3 3 4 5PE 6 7 8PE 9 10 11PE 12 13 14PE 15 16 17PE


Schutzvermerk nach DIN 34 beachten

XSR
PN 5002356 L N PE L N PE

L6 L7
1 3 PE
-E31 -E32
20W 2x20W
-S03
2 4
PN 1608349 PN 2010837 PN 5002079
PN 0058132 PN 0058132

+A1.S +A1.S +T1.U +P1

220V
AC 60Hz

POWER SUPPLY ON SHIP


FROM THE EMERGENCY SWITCH BOARD

=M02/3 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
LIGHT Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M03 +P1.H


0 1 2 3 4 5 6 7 8 9

POWER SUPPLY 220V AC DECKS WORKING WARNING LIGHT RESERVE


CONTROL DESK LEFT, LIGHT LIGHT RED
CABIN LIGHT

220V AC BUS BAR


=M01/1.9/ L4.1 L4.1 /3.0
=M01/1.9/ L5.1 PE L5.1 /3.0

1 3

-F31
B 10A

PN 5002000 2 4

AWG 14

X3 21 22 23PE
OBSERVE COPYRIGHT AS PER DIN 34

X60 1 2 3PE

13 33 13 33 13 33 13 33

-S31 -S35 -S32 -S33


14 34 14 34 14 34 14 34
PN 2502557 PN 2502556 PN 2502556 PN 2502555

PE1 PE2 PE1

PE2

PE
+F1.PL X60 7 8 9PE 23 24 25PE 10 11 12 13

X3 24 25 26PE
Schutzvermerk nach DIN 34 beachten

PE PE PE

PE

PE
X3 27 28 29PE 30 31 32PE 51 52 53PE

+A1 X12 1 2 3 4 5PE

A1

-K31
A2
PN 2535422 X13 1 2 5PE 3 4 6PE

L N PE L N PE L N PE

-E36 -E37 -E38


40W 1000W 60W

PN 2532329 PN 1627792 PN 1624721


PN 0146181 PN 0625145 PN 1624722
PN 1660212
14 5.1
11 12 5.1

+F1 +A1.J
1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
LIGHT Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 21.08.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M03 +P1.H


0 1 2 3 4 5 6 7 8 9

HEATING FAN DESK HEATER DESK HEATER


CABIN CONTROL DESK CONTROL DESK
RIGHT LEFT

220V AC BUS BARBUS BAR


2.9/ L4.1 L4.1 /4.0
2.9/ L5.1 PE L5.1 /4.0

1 3
PE

-F32
B 10A
2 4
PN 5002000

X3 33 34 35PE
OBSERVE COPYRIGHT AS PER DIN 34

X60 4 5 6PE

L N
13 33

-S34 -E3
14 34 10W
PN 2502627
PN 1636863

PE4 PE5

PE2

+F1.PL X60 14 15 16PE 17 18 19PE


Schutzvermerk nach DIN 34 beachten

X70 1 2 3PE

L N PE

-E8 L N PE

1,4kW -E2
PN 4228061 10W

PN 1636863

+F1 +F1-PR

2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
LIGHT Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 30.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M03 +P1.H


0 1 2 3 4 5 6 7 8 9

HEATER HEATER FAN SUPPLY FOR STANDSTILL- PMS-SYSTEM


CRANE TOWER CONTROL CABINET CONTROL CABINET AMPERAGE HEATER START
MONITOR MAIN MOTOR ENABLE

220V AC BUS BAR


3.9/ L4.1 L4.1 /5.0
3.9/ L5.1 L5.1 /5.0

1 3 1 3

-F33 -F34
B 10A B 10A
2 4 2 4
PN 5002000 PN 5002000

AWG 14

5 31 A1
OBSERVE COPYRIGHT AS PER DIN 34

=M02
-S35 =M06-KEN
3 4 -K2 32 A2
40øC PN 5002352
=M02/3.2
PN 1740773
31
=M02
-K3 32

=M02/3.3

PE PE PE PE PE PE PE
Schutzvermerk nach DIN 34 beachten

X3 36 37 38PE 39 40 41PE 42 43 44PE 45 46 47PE 48 49 50PE 66 67 68PE

PE

XSR
PN 5002356
L12 L13

UH

VH

M1-L

M1-N
L N PE L N PE L N PE
+A1.S

=M02/1.8/

=M02/1.8/
-E6 -E5 -M31
2kW 400W 35W

=M02/1.8/

=M02/1.8/
PN 2535250 PN 2094564 PN 2532331
X PMS PMS

PMS-SYSTEM 13

POWER AVAILABLE -K
14

FROM SHIPS ECR


13 14 =M06/4.7

+T1.U
=ECR

3 5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
HEATERS Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M03 +P1.H


0 1 2 3 4 5 6 7 8 9

DECKS LIGHT DECKS LIGHTING CONTROL DECK LIGHT 1 DECK LIGHT 2


CONTROL FROM SHIPS ECR

220V AC BUS BAR


4.9/ L4.1
4.9/ L5.1

1 3 1 3 1 3

-F35 -F36 -F37


B 10A B 10A B 10A
2 4 2 4 2 4
PN 5002000 PN 5002000 PN 5002000

AWG 14 AWG 14 AWG 14

13 23 33 43
-K33 -K33
.1 14 24 .1 34 44
OBSERVE COPYRIGHT AS PER DIN 34

A2

-K32
A1
PN 5002352

11
-K31
2.3 12 14

12
-K32
PE PE PE PE
.5 14 11

PE
X3 54 55 56PE 57 58 59PE 60 61 62PE
Schutzvermerk nach DIN 34 beachten

A1

-K33 XSR
A2 PN 5002356
PN 2535422
L8 L9 X39 1 2 3PE 1.1 2.1 3.1PE

PN 1367472

L N PE L N PE

-E39 -E40
DECKS LIGHTING CONTROL
1000W 1000W
FROM SHIPS ECR
+A1.S PN 1627792 PN 1627792
PN 0625145 PN 0625145

13 14 .6 14 .1
23 24 .7 11 12 .1
33 34 .8
43 44 .8
+T1.U

4 =M05/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
DECK LIGHT Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 21.08.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M03 +P1.H


0 1 2 3 4 5 6 7 8 9

WINDSCREEN WIPER FAN HORN

=M01/3.8/ 24N1(GND) 24N1(GND) /=M06/1.1


=M01/3.8/ 24V-AUX

X5 25 5

X62 11 12

OFF
ON
OBSERVE COPYRIGHT AS PER DIN 34

21 33

-S8
22 34
PN 2502558

13

=M07-S22H PE
PE PE
14 PE Schiene
PN 2078899

X62 13 14 15 17 16 18 20 19 21PE
Schutzvermerk nach DIN 34 beachten

+F1.PL

1 2 PE

-XM50 4 3 1 5 -H50
BK/WH
53 31b 53a PN 1096359

-M50 -M51 +

PN 2532317

31 -

BK

+F1

31 53 31b 53a

PLUG CONNECTOR
1 5 FOR WIPER

=M03/5 =M06/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
AUXILIARY 24V-DC CONSUMERS Typ Bl.
7/3165 97.25 50 1
letzte Žnd./last mod. 22.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M05 +P1.H


0 1 2 3 4 5 6 7 8 9

PLC MAIN BOARD


=M01/3.3/ 24V-PLC-OUT34
=M01/3.2/ 24V-PLC-OUT05

A1 -XA1 05 34
=GEN/9.4
PN 5002194
+24V +24V

CR 0505
CAN 1L
OBSERVE COPYRIGHT AS PER DIN 34

GND GND GND +24V TEST TxD RxD CAN CAN 1H


GND

-XA1 12 15 01 23 24 07 06 33 14 32
2,5mmý GN/YE

X5 6 7 8 26 16 17 18 27 28 29 30 31 32
Schutzvermerk nach DIN 34 beachten

-XSAPI
1 2 3 4 5 6 7 8 9

SUB-D

API
APPLICATION PROGRAMMING INTERFACE

PE PN 4228649

PE
CAN-L1 /=M07/1.1

PE CAN-H1 /=M07/1.1

CAN-L4 /=M07/4.1
CAN-H4 /=M07/4.1

=M01/3.1/ 24V-PLC-VBB

=M05/1.8/ 24N1(GND) 24N1(GND) /3.1

=M05/1 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC SUPPLY 24V DC Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M06 +P1.H


0 1 2 3 4 5 6 7 8 9

AUXILIARY CONTACTS
MAIN MOTOR SLACK ROPE SW. MAIN FEED OIL HYDRAULIC DELTA MAIN MOTOR
AMPERAGE HOISTING GEAR SWITCH PUMP OIL CONTACTOR THERMISTOR
COOLER RELAY
24V DC
SECQ
5.8/ SECQ. /3.1
=M02/3.8/ 24V-INT 24V-INT /4.1

1.X1 13 13 43
=M01 =M02 =M02 =M02
-S1 1.X2 -Q11 14 -Q12 14 -K3 44

=M01/1.4 =M02/2.3 =M02/2.6 =M02/3.3

-S19
SLACK ROPE SWITCH
OBSERVE COPYRIGHT AS PER DIN 34

13 13
=M02-K11 =M02-K12
5.2 14 5.3 14

HG-ROPE
METAL-BAR
+P1 INSULATING MATERIAL

=M02/3.8
Schutzvermerk nach DIN 34 beachten

F4/14
=M02/1.8/ I-MAIN

X5 35 36

A1 -XA1 08 18 28 10 29 11 30
1.1
PN 5002194 IW03 IX0.22 IX0.03 IX0.04 IX0.05 IX0.06 IX0.07

-BH

CR 0505

1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC INPUTS Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M06 +P1.H


0 1 2 3 4 5 6 7 8 9

LIMIT SWITCH LUFFING GEAR


LUFFING LUFFING SAFETY INCREMENTAL
IN OUT CONTACT ENCODER

24V DC
SECQ.
2.9/ SECQ. /4.1
1.8/ 24N1(GND) 24N1(GND) /4.1

X5 37 9 10
OBSERVE COPYRIGHT AS PER DIN 34

48BM-299G+IMP1000

-S26 XS26 2 1
48BM
PN 5002244

L+ L-

-IE26
1000ppr
11 21

-S26.1 -S26.2
12 14 22 24

B A
Schutzvermerk nach DIN 34 beachten

XS26 4 3

+T1.W

X5 41 42 43 44 45

A1 -XA1 19 55 47 20 02
1.1
PN 5002194 IX0.20 IX0.21 IX0.11 IX0.12 IX0.13

CR 0505

2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC INPUTS Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M06 +P1.H


0 1 2 3 4 5 6 7 8 9

LIMIT SWITCH HOISTING GEAR PMS-SYSTEM


START
HOISTING LOWERING SAFETY INCREMENTAL RESERVE
ENABLE
CONTACT ENCODER
24V DC
2.9/ 24V-INT
3.8/ SECQ.
3.8/ 24N1(GND) 24N1(GND) /5.1

X5 38 11 12 39 13 40
OBSERVE COPYRIGHT AS PER DIN 34

48BM-299G+IMP1000

13
-KEN
-S16 XS16 2 1 =M03/4.8 14

48BM
PN 5002244

L+ L-

-IE16
1000ppr
11 21

-S16.1 -S16.2
12 14 22 24

B A
Schutzvermerk nach DIN 34 beachten

XS16 4 3

+T1.W

X5 46 47 48 49 50

A1 -XA1 09 27 46 21 38 37
1.1
PN 5002194 IX0.02 IX0.01 IX0.10 IX0.14 IX0.15 IX0.23

CR 0505

3 5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC INPUTS Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M06 +P1.H


0 1 2 3 4 5 6 7 8 9

MAIN MOTOR FEED OIL PUMP HYDRAULIC PMS-SYSTEM TRIMOT SUPPLY SAFETY
TIME RELAY OIL COOLER START (PWM-OUTPUT) CIRCUITS
REQUEST

24V DC

A1

PN 5002194
1.1
CR 0505

QX0.04 QX0.05 QX0.06 QX0.01 QX0.00 QX0.07

-XA1 36 54 17 45 44 53
OBSERVE COPYRIGHT AS PER DIN 34

X5 51

A1 13 SECQ
2.1
-KRQ
A2 14
PN 4236676
1,5mmý
1,5mmý OR
OR

X5 60 61
Schutzvermerk nach DIN 34 beachten

-XY1T 1
XSR 1
PN 5002356
-Y1T
L14 L15 2
B 24ê

-XY1T 2

+T1.W

X PMS PMS

A1 A1 A1

=M02-K4 =M02-K11 =M02-K12 +A1.S


A2 A2 A2
PN 2088712 PN 5002085 PN 5002084

X5 14 15

=M02/3.8/ 24N2(GND)
4.8/ 24N1(GND)

28 =M02/3.3 1 2 =M02/2.2 1 2 =M02/2.5 13 14 .5 PMS-SYSTEM


3 4 =M02/2.2 3 4 =M02/2.5
18 =M02/3.2 5 6 =M02/2.2 5 6 =M02/2.5
START REQUEST SIGNAL
13 14 2.5 13 14 2.6 TO SHIPS ECR

4 =M07/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLC OUTPUTS Typ Bl.
7/3165 97.25 50 5
letzte Žnd./last mod. 28.11.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M06 +P1.H


0 1 2 3 4 5 6 7 8 9

SOLENOID VALVES
=M06/1.8/ CAN-L1 HOISTING GEAR LUFFING GEAR SLEWING GEAR RESERVE
=M06/1.8/ CAN-H1
HOISTING LUFFING IN CLKW (RIGHT)
=M01/3.5/ 24V-P1.P
=M01/3.5/ GND-P1.P

-XY1B 2 -XY2B 2 -XY3B 2

2 2 2

-Y1B -Y2B -Y3B


1 1 1
24ê 24ê 24ê

-XY1B 1 -XY2B 1 -XY3B 1


OBSERVE COPYRIGHT AS PER DIN 34

-A3 XA3T 03 04 05 06 07 -XA3C 1.4 1.5 -XA3 1.4 1.2 3.4 3.2 5.4 5.2 7.4 7.2
=GEN/11.4
PN 5002197 GND +VBB CAN_H CAN_L +24V_CH1 CURRENT 1 +24V_CH3 CURRENT 3 +24V_CH5 CURRENT 5 +24V_CH7 CURRENT 7

CAN IN CHANNEL 1 CHANNEL 3 CHANNEL 5 CHANNEL 7

COMPACT MODULE CR2031 // PWM I

CAN OUT CHANNEL 2 CHANNEL 4 CHANNEL 6 CHANNEL 8

CAN_H CAN_L +24V_CH2 CURRENT 2 +24V_CH4 CURRENT 4 +24V_CH6 CURRENT 6 +24V_CH8 CURRENT 8
Schutzvermerk nach DIN 34 beachten

-XA3C 2.4 2.5 -XA3 2.4 2.2 4.4 4.2 6.4 6.2 8.4 8.2

-XY1A 1 -XY2A 1 -XY3A 1

1 1 1

-Y1A -Y2A -Y3A


2 2 2
24ê 24ê 24ê

-XY1A 2 -XY2A 2 -XY3A 2

2.1/ CAN-H2
2.1/ CAN-L2
HOISTING GEAR LUFFING GEAR SLEWING GEAR RESERVE
LOWERING LUFFING OUT C-CLKW (LEFT)

=M06/5 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
COMPACT MODULE Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH PWM-OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl CIRCUIT DIAGRAM = M07 +P1.P


0 1 2 3 4 5 6 7 8 9

PRESSURE SWITCHES
1.1/ CAN-L2 HOISTING LUFFING SLEWING SLEWING
1.1/ CAN-H2
GEAR GEAR GEAR GEAR

1 1 1 1

-S10 -S20 -S30 -S31


3 3 3 3
7 bar 7 bar 7 bar 7 bar

BK BN BK BN BK BN BK BN
OBSERVE COPYRIGHT AS PER DIN 34

-A4 -XA4C 1.4 1.5 -XA4 1.4 1.1 3.4 3.1 5.4 5.1 7.4 7.1
=GEN/12.4
PN 5002204 CAN_H CAN_L IX4.01 +24V_CH1 IX4.03 +24V_CH3 IX4.05 +24V_CH5 IX4.07 +24V_CH7

CAN IN CHANNEL 1 CHANNEL 3 CHANNEL 5 CHANNEL 7

COMPACT MODULE CR2033 // MODULE ANALOG

CAN OUT CHANNEL 2 CHANNEL 4 CHANNEL 6 CHANNEL 8

CAN_H CAN_L +24V_CH2 IW4.02 GND_CH2 +24V_CH4 IW4.04 GND_CH4 +24V_CH6 IW4.06 GND_CH6 +24V_CH8 IW4.08 GND_CH8
Schutzvermerk nach DIN 34 beachten

-XA4C 2.4 2.5 -XA4 2.1 2.2 2.5 4.1 4.2 4.5 6.1 6.2 6.5 8.1 8.2 8.5

3.1/ CAN-L3
3.1/ CAN-H3 -XB10 3 1 -XB20 3 1 -XB01 3 1
+Ub OUT +Ub OUT +Ub OUT

0 - 600 BAR 0 - 600 BAR -50 - +150 DEGREES

P <= P <= <=


4 - 20 mA 4 - 20 mA 4 - 20 mA

-B10 -B20 -B01


PN 5002117 PN 5002117 PN 5002118

HOISTING GEAR LUFFING GEAR OIL


PRESSURE PRESSURE TEMPERATURE

ANALOGUE SENSORS
1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
COMPACT MODULE Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 31.05.07 Schmahl
Marine Cranes GmbH IN-/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl CIRCUIT DIAGRAM = M07 +P1.P


0 1 2 3 4 5 6 7 8 9

FILTER RESERVE RESERVE RESERVE


2.1/CAN-L3
OVERPRESSURE
2.1/CAN-H3
=M01/3.6/ 24V-P1.V

terminal 6+7 to be removed


=M01/3.6/ GND-P1.V

* jumper header between


-XS08 1

-S08
2
5 bar

-XS08 2

BK BN
OBSERVE COPYRIGHT AS PER DIN 34

-A2 XA2T 03 04 05 06 07 -XA2C 1.4 1.5 -XA2 1.4 1.1 3.4 3.1 5.4 5.1 7.4 7.1
=GEN/10.4
PN 5002203 GND +VBB CAN_H CAN_L IX2.01 +24V_CH1 IX2.03 +24V_CH3 IX2.05 +24V_CH5 IX2.07 +24V_CH7

CAN IN CHANNEL 1 CHANNEL 3 CHANNEL 5 CHANNEL 7

COMPACT MODULE CR2033 // MODULE DIGITAL

CAN OUT CHANNEL 2 CHANNEL 4 CHANNEL 6 CHANNEL 8


CAN_H CAN_L QX2.02 GND_CH2 QX2.04 GND_CH4 QX2.06 GND_CH6 QX2.08 GND_CH8
Schutzvermerk nach DIN 34 beachten

-XA2C 2.4 2.5 -XA2 2.4 2.3 4.4 4.3 6.4 6.3 8.4 8.3

120R
PN 4243112 -XY1 1 -XY2 1 -XY3 1 -XY11 1

1 1 1 1

-Y1 -Y2 -Y3 -Y11


2 2 2 2
24ê 24ê 24ê 24ê

-XY1 2 -XY2 2 -XY3 2 -XY11 2

HOISTING GEAR LUFFING GEAR SLEWING GEAR PRE HEATING


BRAKE BRAKE BRAKE

SOLENOID VALVES
2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
COMPACT MODULE Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 31.05.07 Schmahl
Marine Cranes GmbH IN-/OUTPUTS
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl CIRCUIT DIAGRAM = M07 +P1.V


0 1 2 3 4 5 6 7 8 9

CONTROL LEVER
CAN-BUS MODULE EOS SWITCH KEY BUTTON HOISTING LOWERING SET VALUE
SUPPLY SUPPLY PUMPS JIB HOISTING GEAR
START/STOP RESTING
=M01/3.7/ 24V-CAB A5UB /5.0
=M01/3.7/ GND-CAB A5GND /5.0

=M06/1.8/ CAN-H4 CAN-H4 /7.1


=M06/1.8/ CAN-L4 CAN-L4 /7.1

X72 1 3 5 6 2 4 7 9 11
OBSERVE COPYRIGHT AS PER DIN 34

13 13 5.3 5.5
-S12
-S06 -S07
14 14 PN 2078890 5.03 5.05
R1 PN 2502564 PN 2502566
120ê A S

TERMINATING
RESISTOR
Schutzvermerk nach DIN 34 beachten

A5 -X3A5 6 5 -X1A5 2 18 1 4 3 5 7 8 11 13 14
=GEN/13.4
PN 4243438 CAN_H CAN_L +UB_CH1 IX5.01 IX5.02 IX5.04 IW5.05 GND_SH5
GND_CH8 +UB_CH2 IX5.03 +UB_CH5 GND_CH5
+24V +24V

CR2012
+24V

3 5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABIN MODULE INPUTS Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 31.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M07 +F1.PR


0 1 2 3 4 5 6 7 8 9

CONTROL LEVER
LUFFING LUFFING SET VALUE SLEWING SLEWING SET VALUE
IN OUT LUFFING GEAR C-CLKW CLKW SLEWING GEAR
(LEFT) (RIGHT)
4.9/ A5UB A5UB /7.1
4.9/ A5GND A6GND /7.1
A6CAN-GND /7.1

E E

4.3 3.5 2.3 1.5


-S22 -S32
PN 2078899 4.03 3.05 PN 2078899 2.03 1.05
OBSERVE COPYRIGHT AS PER DIN 34

A S A S

X62 1 2 3 4 5 6 7 8 9

+F1.PL
Schutzvermerk nach DIN 34 beachten

X72 12 13 14 15 16 17 18 19 20 8 10

A5 -X2A5 1 13 11 3 14 12 4 5 16 6 18
4.0
PN 4243438 IX5.09 IW5.13 GND_CH14 +UB_CH10 GND_CH15 GND_CH16
GND_CH13 IX5.10 IW5.14 IX5.11 +UB_CH11
+24V +24V

CR2012

4 6

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABIN MODULE INPUTS Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 31.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M07 +F1.PR


0 1 2 3 4 5 6 7 8 9

INDIC. LIGHTS
READY FOR FAULT RESERVE RESERVE RESERVE
OPERATION

X2 X2

-H06 -H07
OBSERVE COPYRIGHT AS PER DIN 34

X1 X1
PN 2502564 PN 2502565
Schutzvermerk nach DIN 34 beachten

A5 -X1A5 15 17 16 -X2A5 15 7 17
4.0
PN 4243438 QX5.07 QX5.08 GND_CH7 QX5.15 IX5.12 IX5.16

CR2012

5 7

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
6
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABIN MODULE OUTPUTS Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 31.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M07 +F1.PR


0 1 2 3 4 5 6 7 8 9

CAN-BUS MONITOR DISPLAY


SUPPLY

A5UB
5.9/
A6GND
5.9/
5.9/ A6CAN-GND

4.9/ CAN-H4
4.9/ CAN-L4
OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

A6 -XA6 5 1 3 6 2
PN 4243440
CAN_H CAN_L CAN_GND +24V GND

TDM DISPLAY CR1001


2,5mmý GN/YE

PE

PE

PE

6 =PE/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
7
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
DISPLAY Typ Bl.
7/3165 97.25 50 7
letzte Žnd./last mod. 22.05.07 Schmahl
Marine Cranes GmbH CONNECTION DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = M07 +F1.PR


0 1 2 3 4 5 6 7 8 9

POWER
SUPPLY

SLIP RING
ASSEMBLY
XSRK PE

+A1.S

(L)M2XH
70mmý

PE

CRANE TOWER CRANE TOWER


OBSERVE COPYRIGHT AS PER DIN 34

PE PE

PE PE
+T1.U

(L)M2XH NSGA
70mmý 70mmý

PE
ye/gn
PUMP MODULE 16mmý
PE

PE PE
JIB
Schutzvermerk nach DIN 34 beachten

PE
PE
(L)M2XH (L)M2XH
70mmý 70mmý

ye/gn ye/gn
4mmý 4mmý

PE

CABINET
M1 PE PULT_L PE PULT_R PE
CONTROL
=M02-M1
CABINET

+P1.H +M1 +F1-PL +F1-PR

+P1 +F1 +A1.J

=M07/7 =TERMINALS/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PE Typ Bl.
7/3165 97.25 50 1
letzte Žnd./last mod. 29.05.07 Schmahl
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = PE +P1.H


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-PMS
(L)M2XH-J
W-X1_ESTOP
(L)M2XH-J
W-ESTOP_XSR
(L)M2XH-J
W-SRL10
(L)M2XH-J
W-ELIGHTSUPPLY
(L)M2XH
W-SUPPLY220VL4/L5
(L)M2XH-PE
W-SUPPLYPE
(L)M2XH
W-SUPPLYL3
(L)M2XH
W-SUPPLYL2
(L)M2XH
W-SUPPLYL1

(L)M2XH-J
W-X1_ESTOP
(L)M2XH-J
W-ESTOP_XSR

WX/XSR
TERMINAL BLOCK XSR

5x1.5mmý

3x1.5mmý

3x1.5mmý

3x1.5mmý

3x1.5mmý

2x6mmý

1x70mmý

2x1x70mmý

2x1x70mmý

2x1x70mmý

3x1.5mmý

3x1.5mmý

4x
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

POWER SUPPLY 02 BK =M01-S1 1 L1 =M01/1.1

POWER SUPPLY 02 BK =M01-S1 3 L2 =M01/1.1

POWER SUPPLY L3 BK =M01-S1 5 L3 =M01/1.2

POWER SUPPLY PE BK =M01-PE PE =M01/1.2


OBSERVE COPYRIGHT AS PER DIN 34

POWER SUPPLY L4 BK X3 1 L4 =M01/1.2

POWER SUPPLY L5 BU X3 2 L5 =M01/1.3

POWER SUPPLY L6 BK X3 3 L6 =M03/1.1

POWER SUPPLY L7 BU X3 4 L7 =M03/1.1

DECKS LIGHTING CTRL BK X3 54 L8 =M03/5.4

DECKS LIGHTING CTRL BU X3 55 L9 =M03/5.5

EMERGENCY STOP BK X4 15 L10 =M01-S41 21 BK =M01/1.8

EMERGENCY STOP BU =M01-S41 22 L11 X4 16 BU =M01/1.8


Schutzvermerk nach DIN 34 beachten

PMS-START ENABLE 1 X3 66 L12 X PMS 1 =M03/4.8

PMS-START ENABLE 2 X3 67 L13 X PMS 2 =M03/4.8

PMS START REQUEST 3 X5 60 L14 X PMS 3 =M06/5.5

PMS START REQUEST 4 X5 61 L15 X PMS 4 =M06/5.6

=PE/1 2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
SLIP RING ASSEMBLY Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-Jú
W-S31/X3
(L)M2XH-J
W-E32
(L)M2XH-J
W-E31
(L)M2XH-Jú
W-S03/LIGHTING
(L)M2XH-J
W-ELIGHTSUPPLY
(L)M2XH
W-SUPPLY220VL4/L5

(L)M2XH-Jú
W-X3/X12
(L)M2XH-J
W-S34_K31
TERMINAL BLOCK X3

7x1.5mmý

3x1.5mmý

3x1.5mmý

5x1.5mmý

3x1.5mmý

2x6mmý

5x1.5mmý

3x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

AUX. POWER SUPPLY BK XSR L4 1 =M01-S2 1 =M01/1.2

AUX. POWER SUPPLY BU XSR L5 2 =M01-S2 3 =M01/1.3

EMERGENCY SUPPLY 220V AC BK XSR L6 3 =M03-F30 2 =M03/1.1

EMERGENCY SUPPLY 220V AC BU XSR L7 4 =M03-F30 4 =M03/1.1


OBSERVE COPYRIGHT AS PER DIN 34

PE 5PE =M03-PE1 =M03/1.2

LIGHTING SWITCH 1 =M03-S03 1 6 =M03-F30 1 =M03/1.3

LIGHTING SWITCH 2 =M03-S03 3 7 =M03-F30 3 =M03/1.4

PE 8PE =M03-PE =M03/1.4

LIGHTING SWITCH 3 =M03-S03 2 9 =M03/1.4

LIGHTING SWITCH 4 =M03-S03 4 10 =M03/1.4

PE PE =M03-S03 PE 11PE =M03-PE =M03/1.5

LIGHT CRANE TOWER BELOW BK =M03-E31 L 12 =M03/1.6


Schutzvermerk nach DIN 34 beachten

LIGHT CRANE TOWER BELOW BU =M03-E31 N 13 =M03/1.6

PE PE =M03-E31 PE 14PE =M03-PE =M03/1.6

LIGHT POWER MODULE BK =M03-E32 L 15 =M03/1.8

LIGHT POWER MODULE BU =M03-E32 N 16 =M03/1.8

PE PE =M03-E32 PE 17PE =M03-PE =M03/1.8

SUPPLY CONTROL DESK RIGHT 220V 1 X60 1 21 =M03-F31 2 =M03/2.1

SUPPLY CONTROL DESK RIGHT 220V 2 X60 2 22 =M03-F31 4 =M03/2.1

SUPPLY CONTROL DESK LEFT PE PE X60 3PE 23PE =M03-PE =M03/2.2

WORKING LIGHT 3 X60 10 24 X12 1 1 =M03/2.5

WORKING LIGHT 4 X60 11 25 X12 2 2 =M03/2.5

PE =M03-PE 26PE =M03/2.5

DECKS LIGHT =M03-K31 A1 27 X60 23 BK =M03/2.3

1 DECKS LIGHT =M03-K31 A2 28 X60 24 BU 2.1


=M03/2.3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X3 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH 220V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-M1/HEATER
(L)M2XH-J
W-E6
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-S31/X3

(L)M2XH-J
W-S34_K31
(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK X3

3x1.5mmý

3x1.5mmý

3x1.5mmý

7x1.5mmý

3x1.5mmý

5x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

DECKS LIGHT 29PE X60 25PE PE =M03/2.3

WARNING LIGHT RED 5 X60 12 30 X12 3 3 =M03/2.6

WARNING LIGHT RED 6 X60 13 31 X12 4 4 =M03/2.7

PE =M03-PE 32PE X12 5PE PE =M03/2.7


OBSERVE COPYRIGHT AS PER DIN 34

SUPPLY CONTROL DESK LEFT 220V BK X60 4 33 =M03-F32 2 =M03/3.1

SUPPLY CONTROL DESK LEFT 220V BU X60 5 34 =M03-F32 4 =M03/3.1

SUPPLY CONTROL DESK LEFT PE PE X60 6PE 35PE =M03-PE =M03/3.2

HEATER CRANE TOWER BK =M03-E6 L 36 =M03-F33 2 =M03/4.1

HEATER CRANE TOWER BU =M03-E6 N 37 =M03-F33 4 =M03/4.1

HEATER CRANE TOWER PE PE =M03-E6 PE 38PE =M03-PE =M03/4.1

HEATER CONTROL CABINET =M03-E5 L 39 =M03-S35 3 =M03/4.3

HEATER CONTROL CABINET =M03-E5 N 40 =M03/4.3


Schutzvermerk nach DIN 34 beachten

HEATER CONTROL CABINET PE =M03-E5 PE 41PE =M03-PE =M03/4.3

FAN CONTROL CABINET =M03-M31 L 42 =M03-S35 4 =M03/4.4

FAN CONTROL CABINET =M03-M31 N 43 =M03/4.5

FAN CONTROL CABINET PE =M03-M31 PE 44PE =M03-PE =M03/4.5

SUPPLY FOR AMPERAGE MONITOR =M02-T1 UH 45 =M02-K2 31 =M03/4.6

SUPPLY FOR AMPERAGE MONITOR =M02-T1 UH 46 =M03/4.6

FAN CONTROL CABINET PE 47PE =M03-PE =M03/4.6

STANDSTILLHEATER MAIN MOTOR BK XM1 L 48 =M02-K3 32 =M03/4.7

STANDSTILLHEATER MAIN MOTOR BU XM1 N 49 =M03/4.7

RESERVE PE PE 85PE 50PE =M03-PE =M03/4.7

RESERVE 51 =M03/2.8

RESERVE 52 =M03/2.8

2 RESERVE PE 53PE =M03-PE 2.2


=M03/2.9

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2.1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X3 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH 220V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-PMS
(L)M2XH-J
W-X39
(L)M2XH-J
W-SRL10
TERMINAL BLOCK X3

5x1.5mmý

5x1.5mmý

3x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

DECKS LIGHTING CONTROL FROM BK XSR L8 54 =M03-F35 2 =M03/5.4

SHIPS ECR

DECKS LIGHTING CONTROL FROM BU XSR L9 55 =M03-K32 A1 =M03/5.5

SHIPS ECR
OBSERVE COPYRIGHT AS PER DIN 34

DECKS LIGHTING CONTROL FROM 56PE =M03-PE =M03/5.5

SHIPS ECR

DECK LIGHT L 1 X39 1 57 =M03-K33 14 =M03/5.6

DECK LIGHT N 2 X39 2 58 =M03-K33 24 =M03/5.7

DECK LIGHT PE PE X39 3PE 59PE =M03-PE =M03/5.7

DECK LIGHT L 3 X39 1.1 60 =M03-K33 34 =M03/5.8

DECK LIGHT N 4 X39 2.1 61 =M03-K33 44 =M03/5.8

DECK LIGHT PE 62PE =M03-PE =M03/5.8


Schutzvermerk nach DIN 34 beachten

PMS-SYSTEM START ENABLE 1 XSR L12 66 =M06-KEN A2 =M03/4.8

PMS-SYSTEM START ENABLE 2 XSR L13 67 =M03-F34 4 =M03/4.8

PMS-SYSTEM START ENABLE PE =M03-XSR 68PE =M03-PE =M03/4.9

2.1 3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
2.2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X3 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH 220V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-ESTOP_XSR
(L)M2XH-J
W-X4/X11
(L)M2XH-J
W-M11
(L)M2XH-J
W-S04
TERMINAL BLOCK X4

3x1.5mmý

4x2.5mmý

4x2.5mmý

3x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

EMERGENCY STOP BK X75 1 1 =M01-S1 D2 =M01/1.8

EMERGENCY STOP BU X75 2 2 =M01/1.8

FEED OIL PUMP MOTOR BK =M02-M11 V1 7 =M02-K11 2 =M02/2.2

FEED OIL PUMP MOTOR BU =M02-M11 W1 8 =M02-K11 4 =M02/2.2


OBSERVE COPYRIGHT AS PER DIN 34

FEED OIL PUMP MOTOR BN =M02-M11 U1 9 =M02-K11 6 =M02/2.2

FEED OIL PUMP MOTOR PE PE =M02-M11 PE 10PE =M02-PE =M02/2.3

HYDRAULIC OIL COOLER MOTOR BK X11 1 11 =M02-K12 2 =M02/2.5

HYDRAULIC OIL COOLER MOTOR BU X11 2 12 =M02-K12 4 =M02/2.5

HYDRAULIC OIL COOLER MOTOR BN X11 3 13 =M02-K12 6 =M02/2.5

HYDRAULIC OIL COOLER MOTOR PE PE X11 4PE 14PE =M02-PE =M02/2.6

EMERGENCY STOP BK XSR L10 15 =M01/1.8

EMERGENCY STOP BU XSR L11 16 =M01-S1.H 314 =M01/1.8


Schutzvermerk nach DIN 34 beachten

2.2 4

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
3
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X4 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH 380/440V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

Quattro
W-Y1T
LYCY
W-S16
LYCY
W-S26
Quattro
WS8C/X5
CAN_4x0,75
W-CAN4
QUATTRO-O
W-P1Q
CAN_4x0,75
W-CAN1
TERMINAL BLOCK X5

3x1mmý

12x0.5mmý

12x0.5mmý

3x1mm

4x0.75mmý

2x1.5mmý

4x
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

24N (GND) YE XA3T 03 1 =M01-U1 - =M01/3.5

24N (GND) 2 XA2T 03 2 =M01/3.6

24N (GND) YE X72 9 3 =M01/3.7

24N (GND) 4 =M02-T1 - =M01/3.8


OBSERVE COPYRIGHT AS PER DIN 34

24N (GND) 2 X62 12 5 =M05/1.7

24N (GND) 6 -XA1 12 =M06/1.1

24N (GND) 7 -XA1 15 =M06/1.2

24N (GND) 8 -XA1 01 =M06/1.2

24N (GND) 2 XS26 1 9 =M06/3.5

24N (GND) SH W-S26 S 10 =M06/3.6

24N (GND) 2 XS16 1 11 =M06/4.5

24N (GND) SH W-S16 S 12 =M06/4.6


Schutzvermerk nach DIN 34 beachten

24N (GND) 13 =M06/4.8

24N (GND) 2 -XY1T 2 14 =M06/5.7

24N (GND) 15 =M06/5.8

24N (GND) SH W-CAN1 S 16 -XA1 33 =M06/1.6

24N (GND) S 17 =M06/1.6

24N (GND) 18 =M06/1.7

INTERNAL CONSUMERS 20 =M01-F15 =M01/3.5

EXTERNAL CONSUMERS GN XA3T 05 21 =M01/3.5

EXTERNAL CONSUMERS 1 XA2T 05 22 =M01/3.6

EXTERNAL CONSUMERS GN X72 7 23 =M01-F16 =M01/3.7

EXTERNAL CONSUMERS 24 =M01/3.7

SUPPLY AUX. CONSUMERS 1 X62 11 25 =M01-F17 =M05/1.6

3 +24V =M01-F11 26 -XA1 23 4.1


=M06/1.3

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X5 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 28.11.07 ASC
Marine Cranes GmbH 24V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

Quattro
W-Y1T
LYCY
W-S16
LYCY
W-S26
Quattro
W-S19
Quattro
W-M1/THERM
CAN_4x0,75
W-CAN1
CAN_4x0,75
W-CAN4
TERMINAL BLOCK X5

3x1mmý

12x0.5mmý

12x0.5mmý

3x1mmý

3x1mmý

4x

4x0.75mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

CAN BUS WH X72 1 27 -XA1 14 =M06/1.7

CAN BUS WH -XA3C 1.4 28 =M06/1.7

CAN BUS 29 =M06/1.7

CAN BUS BN X72 3 30 -XA1 32 =M06/1.8


OBSERVE COPYRIGHT AS PER DIN 34

CAN BUS BN -XA3C 1.5 31 =M06/1.8

CAN BUS 32 =M06/1.8

THERMISTOR MAIN MOTOR 1 XM1 T1 33 =M02-F4 T1 =M02/1.6

THERMISTOR MAIN MOTOR 2 XM1 T2 34 =M02-F4 T2 =M02/1.7

SLACK ROPE SW. HOISTING GEAR 1 =M06-S19 35 -XA1 18 =M06/2.2

SLACK ROPE SW. HOISTING GEAR 36 =M06/2.3

LIMIT SW. LUFFING GEAR 24V DC 1 =M06-S26.1 11 37 =M02-K3 43 =M06/3.2

LIMIT SW. HOISTING GEAR 24VDC 1 =M06-S16.1 11 38 =M06/4.2


Schutzvermerk nach DIN 34 beachten

RESERVE 39 =M06/4.7

RESERVE 40 =M06/4.8

LIM. SW. LG LUFFING IN 3 =M06-S26.1 12 41 -XA1 19 =M06/3.2

LIM. SW. LG LUFFING OUT 4 =M06-S26.2 22 42 -XA1 55 =M06/3.3

SAFETY CONTACT 5 =M06-S26.2 24 43 -XA1 47 =M06/3.4

INCREMENTAL ENCODER 6 XS26 4 44 -XA1 20 =M06/3.5

INCREMENTAL ENCODER 7 XS26 3 45 -XA1 02 =M06/3.5

HOISTING 3 =M06-S16.1 12 46 -XA1 09 =M06/4.2

LOWERING 4 =M06-S16.2 22 47 -XA1 27 =M06/4.3

SAFETY CONTACT 5 =M06-S16.2 24 48 -XA1 46 =M06/4.4

INCREMENTAL ENCODER 6 XS16 4 49 -XA1 21 =M06/4.5

INCREMENTAL ENCODER 7 XS16 3 50 -XA1 38 =M06/4.5

4 TRIMOT 1 -XY1T 1 51 -XA1 44 4.2


=M06/5.7

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4.1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X5 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 28.11.07 ASC
Marine Cranes GmbH 24V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-PMS
TERMINAL BLOCK X5

5x1.5mmý

1.5mmý OR
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

PMS-REQUEST 3 XSR L14 60 =M06-KRQ 14 X =M06/5.5

PMS-REQUEST 4 XSR L15 61 =M06-KRQ 13 X =M06/5.6


OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

4.1 5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
4.2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X5 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 28.11.07 ASC
Marine Cranes GmbH 24V CONTROL CABINET
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

H07RN
W-M12

(L)M2XH-J
W-X4/X11
TERMINAL BLOCK X11

4x1.5mmý

4x2.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

HYDRAULIC OIL COOLER MOTOR BK =M02-M12 W1 1 X4 11 BK =M02/2.5

HYDRAULIC OIL COOLER MOTOR BN =M02-M12 V1 2 X4 12 BU =M02/2.5

HYDRAULIC OIL COOLER MOTOR GY =M02-M12 U1 3 X4 13 BN =M02/2.5

HYDRAULIC OIL COOLER MOTOR PE =M02-M12 PE 4PE X4 14PE PE =M02/2.6


OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

4.2 6

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
5
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X11 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH TERMINAL BOX OIL COOLER
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

H07RN
W-X12/X13

(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK X12

5x1.5mmý

5x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

WORKING LIGHT BK X13 1 1 X3 24 1 =M03/2.5

WORKING LIGHT GY X13 2 2 X3 25 2 =M03/2.5

WARNING LIGHT RED BN X13 3 3 X3 30 3 =M03/2.6

WARNING LIGHT RED BU X13 4 4 X3 31 4 =M03/2.7


OBSERVE COPYRIGHT AS PER DIN 34

WORKING/WARNING LIGHT RED PE PE X13 6PE 5PE X3 32PE PE =M03/2.7


Schutzvermerk nach DIN 34 beachten

5 7

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
6
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X12 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH TERMINAL BOX JIB-BEARING
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

H07RN
W-E38
H07RN
W-E37

H07RN
W-X12/X13
TERMINAL BLOCK X13

3x1.5mmý

3x1.5mmý

5x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

WORKING LIGHT BN =M03-E37 L 1 X12 1 BK =M03/2.5

WORKING LIGHT BU =M03-E37 N 2 X12 2 GY =M03/2.5

WARNING LIGHT RED BN =M03-E38 L 3 X12 3 BN =M03/2.6

WARNING LIGHT RED BU =M03-E38 N 4 X12 4 BU =M03/2.7


OBSERVE COPYRIGHT AS PER DIN 34

WORKING LIGHT PE PE =M03-E37 PE 5PE =M03/2.5

WARNING LIGHT RED PE PE =M03-E38 PE 6PE X12 5PE PE =M03/2.7


Schutzvermerk nach DIN 34 beachten

6 8

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
7
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X13 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH TERMINAL BOX JIB TOP
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-E40
(L)M2XH-J
W-E39

(L)M2XH-J
W-X39
TERMINAL BLOCK X39

3x1.5mmý

3x1.5mmý

5x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

DECK LIGHT 1 BK =M03-E39 L 1 X3 57 1 =M03/5.6

DECK LIGHT 1 BU =M03-E39 N 2 X3 58 2 =M03/5.7

DECK LIGHT 1 PE =M03-E39 PE 3PE X3 59PE PE =M03/5.7

DECK LIGHT 2 BK =M03-E40 L 1.1 X3 60 3 =M03/5.8


OBSERVE COPYRIGHT AS PER DIN 34

DECK LIGHT 2 BU =M03-E40 N 2.1 X3 61 4 =M03/5.8

DECK LIGHT 2 PE =M03-E40 PE 3.1PE =M03/5.8


Schutzvermerk nach DIN 34 beachten

7 9

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
8
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X39 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH TERMINAL BOX DECK LIGHTING
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-S34_K31

WX60/X70
H07RN
W-HEATERCABLE
(L)M2XH-J
W-E36
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-S31/X3
TERMINAL BLOCK X60

3x1.5mmý

3x

3x1mmý

3x1.5mmý

3x1.5mmý

7x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

220V DESK SUPPLY 1 X3 21 1 =M03-S31 13 =M03/2.1

220V DESK SUPPLY 2 X3 22 2 =M03-S31 33 =M03/2.1

220V DESK SUPPLY PE PE X3 23PE 3PE =M03-PE1 PE2 =M03/2.2

HEATING FAN CABIN BK X3 33 4 =M03/3.1


OBSERVE COPYRIGHT AS PER DIN 34

HEATING FAN CABIN BU X3 34 5 =M03/3.1

PE PE X3 35PE 6PE =M03-PE1 PE2 =M03/3.2

LIGHT CABIN BK =M03-E36 L 7 =M03-S31 14 =M03/2.1

LIGHT CABIN BU =M03-E36 N 8 =M03-S31 34 =M03/2.1

LIGHT CABIN PE PE =M03-E36 PE 9PE =M03-PE1 PE2 =M03/2.2

WORKING LIGHT 3 X3 24 10 =M03-S32 14 =M03/2.5

WORKING LIGHT 4 X3 25 11 =M03-S32 34 =M03/2.5

WARNING LIGHT RED 5 X3 30 12 =M03-S33 14 =M03/2.6


Schutzvermerk nach DIN 34 beachten

WARNING LIGHT RED 6 X3 31 13 =M03-S33 34 =M03/2.7

HEATING FAN CABIN BN =M03-E8 L 14 =M03-S34 14 =M03/3.1

HEATING FAN CABIN BU =M03-E8 N 15 =M03-S34 34 =M03/3.1

PE 16PE =M03-PE1 PE4 =M03/3.1

DESK HEATER CONTROL DESK RIGHT 1 X70 1 17 =M03-S34 13 =M03/3.3

DESK HEATER CONTROL DESK RIGHT 2 X70 2 18 =M03-S34 33 =M03/3.3

PE PE X70 3PE 19PE =M03-PE1 PE5 =M03/3.3

DECKS LIGHT BK X3 27 23 =M03-S35 14 =M03/2.3

DECKS LIGHT BU X3 28 24 =M03-S35 34 =M03/2.3

P19 PE X3 29PE 25PE =M03-PE1 PE1 =M03/2.3

8 10

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
9
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X60 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH CONTROL DESK LEFT CABIN
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

Quattro
W-HORN
Quattro
W-FAN
Quattro
W-SWIPER
Quattro
WS8C/X5
LYCY
W-S22V

LYCY
W-S22
TERMINAL BLOCK X62

3x1mmý

3x1mm

5x1mmý

3x1mm

12x0.5mmý

12x0.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

LUFFING IN 1 X72 12 1 =M07-S22 4.03 1 =M07/5.1

SET VALUE LUFFING GEAR 2 X72 13 2 =M07-S22 A 2 =M07/5.2

SET VALUE LUFFING GEAR 3 X72 14 3 =M07-S22 S 3 =M07/5.3

SLEWING CLKW (RIGHT) 4 X72 15 4 =M07-S32 1.05 4 =M07/5.5


OBSERVE COPYRIGHT AS PER DIN 34

SET VALUE SLEWING GEAR 5 X72 16 5 =M07-S32 A 5 =M07/5.5

SET VALUE SLEWING GEAR 6 X72 17 6 =M07-S32 S 6 =M07/5.6

SET VALUE SLEWING GEAR 7 X72 18 7 =M07-S32 E 7 =M07/5.6

SET VALUE SLEWING GEAR 8 X72 19 8 =M07/5.7

SET VALUE SLEWING GEAR SH X72 20 9 W-S22 S SH =M07/5.7

CABIN SUPPLY 24V+ 1 X5 25 11 =M07-S22H 13 =M05/1.6

CABIN SUPPLY 24V GND 2 X5 5 12 =M05/1.7

WINDSCREEN WIPER 24V DC 4 -XM50 4 13 =M05-S8 21 =M05/1.2


Schutzvermerk nach DIN 34 beachten

WINDSCREEN WIPER 24V DC 3 -XM50 3 14 =M05-S8 22 =M05/1.3

WINDSCREEN WIPER 24V DC 1 -XM50 1 15 =M05/1.3

FAN 24V DC 1 =M05-M51 + 16 =M05-S8 34 =M05/1.5

WINDSCREEN WIPER 0V DC 2 -XM50 5 17 =M05/1.3

FAN 0V DC 2 =M05-M51 - 18 =M05/1.5

HORN 0V DC 2 =M05-H50 2 19 =M05/1.7

HORN 24V DC 1 =M05-H50 1 20 =M07-S22H 14 =M05/1.6

HORN PE PE =M05-H50 PE 21PE =M05-PE PE =M05/1.7

9 11

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
10
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X62 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH CONTROL DESK LEFT CABIN
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

TERMINAL BLOCK X70


EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

DESK HEATER CONTROL DESK RIGHT X60 17 1 =M03-E2 L =M03/3.3

DESK HEATER CONTROL DESK RIGHT X60 18 2 =M03-E2 N =M03/3.3

DESK HEATER CONTROL DESK RIGHT X60 19PE 3PE =M03-E2 PE =M03/3.3
OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

10 12

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
11
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X70 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH CONTROL DESK RIGHT CABIN
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

LYCY
W-S22V
LYCY
W-X72A5
LYCY
W-X72A6
CAN_4x0,75
W-CAN4

LYCY
W-X72A5
CAN_4x0,75
W-CAN4
LYCY
W-X72A6.1
LYCY
W-X72A6
TERMINAL BLOCK X72

12x0.5mmý

12x0.5mmý

4x0.5mmý

4x0.75mmý

12x0.5mmý

4x0.75mmý

4x0.5mmý

4x0.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

WH X5 27 1 -X3A5 6 2 =M07/4.1

CAN-BUS SUPPLY 4 -XA6 5 2 =M07-R1 =M07/4.2

CAN-BUS SUPPLY BN X5 30 3 -X3A5 5 1 =M07/4.1

CAN-BUS SUPPLY 1 -XA6 1 4 =M07-R1 =M07/4.2


OBSERVE COPYRIGHT AS PER DIN 34

CAN-BUS SUPPLY SH W-X72A5 S 5 W-X72A5 S SH =M07/4.1

CAN-BUS SUPPLY SH W-X72A6 S 6 =M07/4.1

MODULE SUPPLY -X1A5 2 7 X5 23 GN =M07/4.2

SET VALUE SLEWING GEAR -X2A5 6 8 -XA6 6 1 =M07/5.8

MODULE SUPPLY -X1A5 18 9 X5 3 YE =M07/4.2

SET VALUE SLEWING GEAR -X2A5 18 10 -XA6 2 2 =M07/5.8

EOS 11 -X1A5 1 =M07/4.3

LUFFING IN 1 X62 1 12 -X2A5 1 =M07/5.1


Schutzvermerk nach DIN 34 beachten

SET VALUE LUFFING GEAR 2 X62 2 13 -X2A5 13 =M07/5.2

SET VALUE LUFFING GEAR 3 X62 3 14 -X2A5 11 =M07/5.3

SLEWING CLKW (RIGHT) 4 X62 4 15 -X2A5 3 =M07/5.5

SET VALUE SLEWING GEAR 5 X62 5 16 -X2A5 14 =M07/5.5

SET VALUE SLEWING GEAR 6 X62 6 17 -X2A5 12 =M07/5.6

SET VALUE SLEWING GEAR 7 X62 7 18 -X2A5 4 =M07/5.6

SET VALUE SLEWING GEAR 8 X62 8 19 -X2A5 5 =M07/5.7

SET VALUE SLEWING GEAR SH X62 9 20 -X2A5 16 =M07/5.7

11 13

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
12
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
TERMINAL BLOCK X72 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH CONTROL DESK RIGHT CABIN
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

(L)M2XH-J
W-S04
TERMINAL BLOCK X75

3x1.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

EMERGENCY STOP BK X4 1 1 =M01-S4 21 =M01/1.8

EMERGENCY STOP BU X4 2 2 =M01-S4 22 =M01/1.8


OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

12 14

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
13
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLUG CONNECTOR X75 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH 380/440V CONTROL DESK RIGHT
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

Quattro
W-SWIPER
TERMINAL BLOCK -XM50

5x1mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

WINDSCREEN WIPER =M05-M50 53a 1 X62 15 1 =M05/1.3

WINDSCREEN WIPER =M05-M50 31b 3 X62 14 3 =M05/1.3

WINDSCREEN WIPER =M05-M50 53 4 X62 13 4 =M05/1.2

WINDSCREEN WIPER =M05-M50 31 5 X62 17 2 =M05/1.3


OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

13 15

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
14
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
PLUG CONNECTOR XM50 Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH WINDSCREEN WIPER
Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

TERMINAL BLOCK -XA1


EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

24N(GND) X5 8 01 =M06/1.2

INCREMENTAL ENCODER X5 45 02 =M06-A1 IX0.13 =M06/3.5

+24V =M01-F12 05 =M06/1.1

RS232 =M06-SUB-D 3 06 =M06/1.4


OBSERVE COPYRIGHT AS PER DIN 34

RS232 =M06-SUB-D 2 07 =M06/1.4

MAIN MOTOR AMPERAGE =M02-T1 + 08 =M06-A1 IW03 =M06/2.1

HOISTING X5 46 09 =M06-A1 IX0.02 =M06/4.2

FEED OIL PUMP =M02-K11 14 10 =M06-A1 IX0.04 =M06/2.5

DELTA CONTACTOR =M02-K3 44 11 =M06-A1 IX0.06 =M06/2.7

24N(GND) X5 6 12 =M06/1.1

X5 27 14 =M06-A1 CAN1H =M06/1.5

24N(GND) X5 7 15 =M06/1.2
Schutzvermerk nach DIN 34 beachten

HYDRAULIC OIL COOLER =M02-K12 A1 17 =M06-A1 QX0.06 =M06/5.3

SLACK ROPE SW. HOISTING GEAR X5 35 18 =M06-A1 IX0.22 =M06/2.2

LUFFING IN X5 41 19 =M06-A1 IX0.20 =M06/3.2

INCREMENTAL ENCODER X5 44 20 =M06-A1 IX0.12 =M06/3.5

INCREMENTAL ENCODER X5 49 21 =M06-A1 IX0.14 =M06/4.5

+24V X5 26 23 =M06/1.3

24N(GND) =M06-SUB-D 1 24 =M06/1.3

LOWERING X5 47 27 =M06-A1 IX0.01 =M06/4.3

MAIN SWITCH ON =M01-S1 1.X2 28 =M06-A1 IX0.03 =M06/2.4

HYDRAULIC OIL COOLER =M02-K12 14 29 =M06-A1 IX0.05 =M06/2.6

MAIN MOTOR THERMISTOR RELAY =M02-F4 14 30 =M06-A1 IX0.07 =M06/2.8

PMS-SYSTEM START ENABLE =M06-KEN 14 31 =M06-A1 IX0.34 =M06/4.7

14 X5 30 32 =M06-A1 CAN1L 15.1


=M06/1.5

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
15
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
-XA1 24V PLC CABINET Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

TERMINAL BLOCK -XA1


EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

CAN 1H X5 16 33 =M06/1.4

+24V =M01-F13 34 =M06/1.2

MAIN MOTOR TIME RELAY =M02-K4 A1 36 =M06-A1 QX0.04 =M06/5.1

FAULT IN GRAB CONTROL X5 36 37 =M06-A1 IX0.23 =M06/2.3


OBSERVE COPYRIGHT AS PER DIN 34

INCREMENTAL ENCODER X5 50 38 =M06-A1 IX0.15 =M06/4.5

TRIMOT X5 51 44 =M06-A1 QX0.00 =M06/5.7

PMS-SYSTEM START REQUEST =M06-KRQ A1 45 =M06-A1 QX0.01 =M06/5.4

SAFETY CONTACT X5 48 49 =M06-A1 IX0.33 =M06/4.4

SAFETY CONTACT X5 43 50 =M06-A1 IX0.35 =M06/3.4

INCREMENTAL ENCODER 51 =M06-A1 IX0.36 =M06/3.6

SUPPLY SAFETY CIRCUITS X5 37 53 =M06-A1 QX0.07 =M06/5.8

FEED OIL PUMP =M02-K11 A1 54 =M06-A1 QX0.05 =M06/5.2


Schutzvermerk nach DIN 34 beachten

LUFFING OUT X5 42 55 =M06-A1 IX0.21 =M06/3.3

15 16

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
15.1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
-XA1 24V PLC CABINET Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

LYCY
W-A5S12
TERMINAL BLOCK -X1A5

12x0.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

EOS X72 11 1 =M07-A5 IX5.01 =M07/4.3

MODULE SUPPLY X72 7 2 =M07-A5 +UB_CH1 =M07/4.2

SWITCH PUMPS START/STOP =M07-S06 14 3 =M07-A5 IX5.02 =M07/4.4

EOS =M07-S06 13 4 =M07-A5 IXS5.02\+UB_CH =M07/4.3


OBSERVE COPYRIGHT AS PER DIN 34

KEY BUTTON JIB RESTING =M07-S07 14 5 =M07-A5 IX5.03 =M07/4.5

KEY BUTTON JIB RESTING =M07-S12 5.03 7 =M07-A5 IX5.04 =M07/4.6

LOWERING 1 =M07-S12 A 8 =M07-A5 IW5.05\+UB_CH5 =M07/4.8

SET VALUE HOISTING GEAR 2 =M07-S12 S 11 =M07-A5 IW5.05 =M07/4.8

SET VALUE HOISTING GEAR 3 =M07-S12 E 13 =M07-A5 IW5.05\GND_CH5 =M07/4.8

SET VALUE HOISTING GEAR S 14 =M07-A5 IW5.05\GND_SH5 =M07/4.9

READY FOR OPERATION =M07-H06 X1 15 =M07-A5 QX5.07 =M07/6.1

FAULT =M07-H06 X2 16 =M07-A5 QX5.07\GND_CH7 =M07/6.3


Schutzvermerk nach DIN 34 beachten

FAULT =M07-H07 X1 17 =M07-A5 QX5.08 =M07/6.2

MODULE SUPPLY X72 9 18 =M07-A5 GND_CH8 =M07/4.2

15.1 17

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
16
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
-X1A5 24V CAN NODE CABIN Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

TERMINAL BLOCK -X2A5


EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

LUFFING IN X72 12 1 =M07-A5 IX5.09 =M07/5.1

SLEWING CLKW (RIGHT) X72 15 3 =M07-A5 IX5.10 =M07/5.5

SET VALUE SLEWING GEAR X72 18 4 =M07-A5 IW5.14\+UB_CH1 =M07/5.6

SET VALUE SLEWING GEAR X72 19 5 =M07-A5 IX5.11 =M07/5.7


OBSERVE COPYRIGHT AS PER DIN 34

SET VALUE SLEWING GEAR X72 8 6 =M07-A5 +UB_CH11 =M07/5.8

RESERVE 7 =M07-A5 IX5.12 =M07/6.4

SET VALUE LUFFING GEAR X72 14 11 =M07-A5 IW5.13 =M07/5.3

SET VALUE SLEWING GEAR X72 17 12 =M07-A5 IW5.14 =M07/5.6

SET VALUE LUFFING GEAR X72 13 13 =M07-A5 IW5.13\GND_CH1 =M07/5.2

SET VALUE SLEWING GEAR X72 16 14 =M07-A5 IW5.14\GND_CH1 =M07/5.5

RESERVE 15 =M07-A5 QX5.15 =M07/6.4

SET VALUE SLEWING GEAR X72 20 16 =M07-A5 IW5.14\GND_CH1 =M07/5.7


Schutzvermerk nach DIN 34 beachten

RESERVE 17 =M07-A5 IX5.16 =M07/6.6

SET VALUE SLEWING GEAR X72 10 18 =M07-A5 GND_CH16 =M07/5.8

16 18

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
17
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
-X2A5 24V CAN NODE CABIN Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

LYCY
W-X72A5
TERMINAL BLOCK -X3A5

12x0.5mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH

CAN-BUS SUPPLY 1 X72 3 5 =M07-A5 CAN_L =M07/4.1

2 X72 1 6 =M07-A5 CAN_H =M07/4.1


OBSERVE COPYRIGHT AS PER DIN 34
Schutzvermerk nach DIN 34 beachten

17 =CABLES/1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
18
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
-X3A5 24V CAN NODE CABIN Typ Bl.
7/3165 97.25 50 18
letzte Žnd./last mod. 29.05.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = TERMINALS


0 1 2 3 4 5 6 7 8 9

Cable overview WUPS001 22.04.96

Cable name Source Target used Cross-section Length Graphics -

Cable designations from to Cable type Cores Cores mmý m Remark Page

W-A5S12 -X1A5 =M07-S12 LYCY 12+S 3 0.5 1.5 CONTROL LEVER HOISTING

W-B01 -XA4 -XB01 Sensor 4+S 2+S 0.3 2 TEMPERATURE SENSOR

W-B10 -XA4 -XB10 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR HOISTING

W-B20 -XA4 -XB20 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR LUFFING

W-CAN1 X5 XA3T CAN_4x0,75 4+S 4+S - 5 CAN BUS CABLE MODULE CR2031

W-CAN2 -XA2C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION

W-CAN3 -XA3C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION

W-CAN4 X5 X72 CAN_4x0,75 4+S 4 0.75 6 CAN BUS CABLE CONNEC. CTRL DESK

W-E31 X3 =M03-E31 (L)M2XH-J 3/PE 3/PE 1.5 4 LIGHT CRANE TOWER BELOW
OBSERVE COPYRIGHT AS PER DIN 34

W-E32 X3 =M03-E32 (L)M2XH-J 3/PE 3/PE 1.5 6 LIGHT POWER MODULE

W-E36 X60 =M03-E36 (L)M2XH-J 3/PE 3/PE 1.5 3.5 LIGHT CABIN

W-E37 X13 =M03-E37 H07RN 3/PE 3/PE 1.5 2 WORKING LIGHT

W-E38 X13 =M03-E38 H07RN 3/PE 3/PE 1.5 1.5 WARNING LIGHT RED

W-E39 X39 =M03-E39 (L)M2XH-J 3/PE 3 1.5 1.5 DECK LIGHT 1

W-E40 X39 =M03-E40 (L)M2XH-J 3/PE 3 1.5 1.5 DECK LIGHT 2

W-E6 X3 =M03-E6 (L)M2XH-J 3/PE 3/PE 1.5 6 HEATER CRANE TOWER

W-ELIGHTSUPPLY X3 XSR (L)M2XH-J 3/PE 2 1.5 10 LIGHT CRANE TOWER SWITCH

W-ESTOP_XSR X4 XSR (L)M2XH-J 3/PE 2 1.5 10 EMERGENCY STOP VIA SRA

W-FAN X62 =M05-M51 Quattro 3/PE 2 1 4 WINDSCREEN FAN

W-HEATERCABLE X60 =M03-E8 H07RN 3/PE 2 1 1 HEATING FAN CABIN


Schutzvermerk nach DIN 34 beachten

W-HORN X62 =M05-H50 Quattro 3/PE 3/PE 1 3.5 HORN

W-M1/HEATER X3 XM1 (L)M2XH-J 3/PE 3/PE 1.5 4 MOTOR HEATER

W-M1/PE =M02-M1 =M02-PE (L)M2XH 1 1 70 2 MAIN MOTOR PE

W-M1/THERM X5 XM1 Quattro 3/PE 2 1 4 THERMISTOR

W-M1/U1 XM1 =M01-S1 (L)M2XH 1 1 70 3 MAIN MOTOR U1

W-M1/U2 XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR U2

W-M1/V1 XM1 =M01-S1 (L)M2XH 1 1 70 3 MAIN MOTOR V1

W-M1/V2 XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR V2

W-M1/W1 XM1 =M01-S1 (L)M2XH 1 1 70 3 MAIN MOTOR W1

W-M1/W2 XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR W2

W-M11 X4 =M02-M11 (L)M2XH-J 4/PE 4/PE 2.5 5 FEED OIL PUMP

W-M12 X11 =M02-M12 H07RN 4/PE 4/PE 1.5 3 HYDRAULIC OIL COOLER

W-P1Q X5 XA2T QUATTRO-O 2 2 1.5 6 SUPPLY COMPACT MODULE

W-PE170 =PE-CRANETOWER =PE-PUMPMODULE (L)M2XH-PE 1/PE 1/PE 70 4 GROUNDING MODULE PE

W-PE270 =PE-CABINET =PE-PUMPMODULE (L)M2XH-PE 1/PE 1/PE 70 1 CABINET PE

=TERMINALS/18 1.1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABLE OVERVIEW Typ Bl.
7/3165 97.25 50 1.2
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = CABLES


0 1 2 3 4 5 6 7 8 9

Cable overview WUPS001 22.04.96

Cable name Source Target used Cross-section Length Graphics -

Cable designations from to Cable type Cores Cores mmý m Remark Page

W-PE470 =PE-CRANETOWER =PE-JIB NSGA-PE 1/PE 1/PE 70 1.5 JIB PE

W-PE4L PULT_L =PE-PE SZ2564 1 1 4 0.5 CONTROL DESK LEFT PE

W-PE4R PULT_R =PE-PE SZ2564 1 1 4 0.5 CONTROL DESK RIGHT PE

W-PMS X3 XSR (L)M2XH-J 5/PE 5/PE 1.5 10 PMS-SYSTEM

W-S03/LIGHTING X3 =M03-S03 (L)M2XH-Jú 5/PE 5/PE 1.5 9 LIGHTING SWITCH

W-S04 X4 X75 (L)M2XH-J 3/PE 2 1.5 6 EMERGENCY STOP IN CONTROL DESK

W-S08 -XA2 -XS08 IFM 3 2 0.3 2 PRESSURE SWITCH FILTER

W-S10 -XA4 =M07-S10 IFM 3 2 0.3 2 PRESSURE SWITCH HOISTING GEAR

W-S16 X5 =M06-S16.1 LYCY 12+S 7+S 0.5 7.5 LIMIT SWITCH HOISTING WINCH
OBSERVE COPYRIGHT AS PER DIN 34

W-S19 X5 =M06-S19 Quattro 3/PE 1 1 6 CONN. SLACK ROPE SWITCH HG

W-S20 -XA4 =M07-S20 IFM 3 2 0.3 2 PRESSURE SWITCH LUFFING GEAR

W-S22 X62 =M07-S22 LYCY 12+S 7+S 0.5 1.5 CONTROL LEVER LEFT

W-S22V X62 X72 LYCY 12+S 8+S 0.5 3.5 CONTROL LEVER LEFT

W-S26 X5 =M06-S26.1 LYCY 12+S 7+S 0.5 6.5 LIMIT SWITCH LUFFING WINCH

W-S30 -XA4 =M07-S30 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR

W-S31 -XA4 =M07-S31 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR

W-S31/X3 X3 X60 (L)M2XH-Jú 7/PE 7/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V

W-S34/X3 X3 X60 (L)M2XH-J 3/PE 3/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V

W-S34_K31 X3 X60 (L)M2XH-J 3/PE 3/PE 1.5 6 DECKS LIGHT SWITCH

W-SRL10 X3 XSR (L)M2XH-J 3/PE 2 1.5 10 DECK LIGHT CTRL


Schutzvermerk nach DIN 34 beachten

W-SUPPLY220VL4/L5 X3 XSR (L)M2XH 2 2 6 10 AUX. POWER SUPPLY L4/L5

W-SUPPLYL1 XSR =M01-S1 (L)M2XH 2x1 1 70 10 MAIN POWER SUPPLY L1

W-SUPPLYL2 XSR =M01-S1 (L)M2XH 2x1 1 70 10 MAIN POWER SUPPLY L2

W-SUPPLYL3 XSR =M01-S1 (L)M2XH 2x1 1 70 10 MAIN POWER SUPPLY L3

W-SUPPLYPE XSR =M01-PE (L)M2XH-PE 1/PE 1/PE 70 6.5 MAIN POWER SUPPLY PE

W-SWIPER X62 -XM50 Quattro 5/PE 4 1 5.5 WINDSCREEN WIPER

W-X12/X13 X12 X13 H07RN 5/PE 5/PE 1.5 32 CONNECTION ON JIB

W-X1_ESTOP XSR =M01-S41 (L)M2XH-J 3/PE 2 1.5 5 EMERGENCY STOP VIA SRA

W-X3/X12 X3 X12 (L)M2XH-Jú 5/PE 5/PE 1.5 5.5 CONNECTION TO JIB

W-X39 X3 X39 (L)M2XH-J 5/PE 5/PE 1.5 12.5 DECK LIGHT 1

W-X4/X11 X4 X11 (L)M2XH-J 4/PE 4/PE 2.5 10.5 HYDRAULIC OIL COOLER

W-X72A5 X72 -X3A5 LYCY 12+S 2+S 0.5 1.5 CAN BUS CABLE X72/CR2012

W-X72A6 X72 S LYCY 4+S 4+S 0.5 1.5 CAN BUS CONNECTION X72/CR1031

W-X72A6.1 X72 -XA6 LYCY 4+S 1 0.5 1.5 CAN BUS CONNECTION X72/CR1031

W-Y1 -XA2 -XY1 IFM M12/DINA 3 2 0.5 1 HOISTING GEAR BRAKE

1 1.2

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1.1
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABLE OVERVIEW Typ Bl.
7/3165 97.25 50 1.2
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = CABLES


0 1 2 3 4 5 6 7 8 9

Cable overview WUPS001 22.04.96

Cable name Source Target used Cross-section Length Graphics -

Cable designations from to Cable type Cores Cores mmý m Remark Page

W-Y11 -XA2 -XY11 IFM M12/DINA 3 2 0.5 1 PRE HEATING

W-Y1A -XA3 -XY1A IFM M12/DINA 2 2 0.75 2 SN 4243444

W-Y1B -XA3 -XY1B IFM M12/DINA 2 2 0.75 2 SN 4243444

W-Y1T X5 -XY1T Quattro 3/PE 2 1 11.5 TRIMOT

W-Y2 -XA2 -XY2 IFM M12/DINA 3 2 0.5 1 LUFFING GEAR BRAKE

W-Y2A -XA3 -XY2A IFM M12/DINA 2 2 0.75 2 SN 4243444

W-Y2B -XA3 -XY2B IFM M12/DINA 2 2 0.75 2 SN 4243444

W-Y3 -XA2 -XY3 IFM M12/DINA 3 2 0.5 1 SLEWING GEAR BRAKE

W-Y3A -XA3 -XY3A IFM M12/DINA 2 2 0.75 2 SN 4243444


OBSERVE COPYRIGHT AS PER DIN 34

W-Y3B -XA3 -XY3B IFM M12/DINA 2 2 0.75 2 SN 4243444

WS8C/X5 X5 X62 Quattro 3/PE 2 1 6 CONN. CONTROL DESK RIGHT 24V

WX/XSR X XSR 4 4 - -

WX60/X70 X60 X70 3/PE 3/PE - -


Schutzvermerk nach DIN 34 beachten

1.1

Bau-Nr./ Baugr./ Datum/date Name/name Bl.


Ch.
SINGLE DECK CRANE Sach-Nr. 5002556 Sh.
1.2
Com-No ass.-gr.
geprft/checked 08.02.08 TTS-LMG
CABLE OVERVIEW Typ Bl.
7/3165 97.25 50 1.2
letzte Žnd./last mod. 21.08.07 ASC
Marine Cranes GmbH Sh.

Abt./departm.: -K5 erstellt/designed 15.05.07 Schmahl = CABLES


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

6 SPARE PARTS LISTS CRANES

ASSEMBLY GROUP 00.00.00 DECK CRANE COMPL.

ASSEMBLY GROUP 01.00.00 SLEWING TOWER

ASSEMBLY GROUP 02.00.00 JIB COMPL.

ASSEMBLY GROUP 05.00.00 ROPE PLAN

ASSEMBLY GROUP 07.00.00 CARGO BLOCKS COMPL.

ASSEMBLY GROUP 12.00.00 PANEL LIST

ASSEMBLY GROUP 14.00.00 PART WITHOUT ATTACH IN WORKS

ASSEMBLY GROUP 15.00.00 AGGREGATE MODULE COMPL.

ASSEMBLY GROUP 18.00.00 DRIVING HOUSE COMPL.

ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.

ASSEMBLY GROUP 97.00.00 TECHNICAL DOKUMENTS


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 003 165-00
DESCRIPTION: DECK CRANE KL 30T – 28M

CRANE COMPL. ONLY CRANE NO. 1 : LMG YARD NO.: 2-571-73165 ORDER NO.: 5 003 165

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

00.00.00.00.00 1 ST DECK CRANE COMPL. 5003165 5003165

01.00.00.00.00 1 ST CRANE TOWER COMPL. 5005186 500186


02.00.00.00.00 1 ST JIB COMPL. 5005255 5005255
05.00.00.00.00 1 ST ROPE PLAN 5005402 5005402
07.00.00.00.00 1 ST CARGO BLOCKS COMPL. 5005277 5005277
12.00.00.00.00 1 ST PANEL LIST 5004095 5004095
14.00.00.00.00 1 ST PARTS WITHOUT ATTECH IN WORK 5005678
15.00.00.00.00 1 ST AGGREGATE MODULE 5005282
18.00.00.00.00 1 ST DRIVERS CABIN COMPL. 5005422 2389487
19.00.00.00.00 1 ST WINCH MODULE 5005166 5005166
97.00.00.00.00 1 ST TECHNICAL DPKUMENTS 5005694

ASSEMBLY GROUP 00.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 003 166-00
DESCRIPTION: DECK CRANE KL 30T – 28M

CRANE COMPL. ONLY CRANE NO. 2 : LMG YARD NO.: 2-571-73166 ORDER NO.: 5 003 166

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

00.00.00.00.00 1 ST DECK CRANE COMPL. 5003166 5003165

01.00.00.00.00 1 ST CRANE TOWER COMPL. 5005186 500186


02.00.00.00.00 1 ST JIB COMPL. 5005365 5005255
05.00.00.00.00 1 ST ROPE PLAN 5005402 5005402
07.00.00.00.00 1 ST CARGO BLOCKS COMPL. 5005277 5005277
12.00.00.00.00 1 ST PANEL LIST 5004095 5004095
14.00.00.00.00 1 ST PARTS WITHOUT ATTECH IN WORK 5005678
15.00.00.00.00 1 ST AGGREGATE MODULE 5005282
18.00.00.00.00 1 ST DRIVERS CABIN COMPL. 5005422 2389487
19.00.00.00.00 1 ST WINCH MODULE 5005166 5005166
97.00.00.00.00 1 ST TECHNICAL DPKUMENTS 5005694

ASSEMBLY GROUP 00.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 003 167-00
DESCRIPTION: DECK CRANE KL 30T – 28M

CRANE COMPL. ONLY CRANE NO. 3 : LMG YARD NO.: 2-571-73167 ORDER NO.: 5 003 167

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

00.00.00.00.00 1 ST DECK CRANE COMPL. 5003167 5003165

01.00.00.00.00 1 ST CRANE TOWER COMPL. 5005186 500186


02.00.00.00.00 1 ST JIB COMPL. 5005366 5005255
05.00.00.00.00 1 ST ROPE PLAN 5005402 5005402
07.00.00.00.00 1 ST CARGO BLOCKS COMPL. 5005277 5005277
12.00.00.00.00 1 ST PANEL LIST 5004095 5004095
14.00.00.00.00 1 ST PARTS WITHOUT ATTECH IN WORK 5005678
15.00.00.00.00 1 ST AGGREGATE MODULE 5005282
18.00.00.00.00 1 ST DRIVERS CABIN COMPL. 5005422 2389487
19.00.00.00.00 1 ST WINCH MODULE 5005166 5005166
97.00.00.00.00 1 ST TECHNICAL DPKUMENTS 5005694

ASSEMBLY GROUP 00.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 003 168-00
DESCRIPTION: DECK CRANE KL 30T – 28M

CRANE COMPL. ONLY CRANE NO. 4 : LMG YARD NO.: 2-571-73168 ORDER NO.: 5 003 168

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

00.00.00.00.00 1 ST DECK CRANE COMPL. 5003168 5003165

01.00.00.00.00 1 ST CRANE TOWER COMPL. 5005186 500186


02.00.00.00.00 1 ST JIB COMPL. 5005367 5005255
05.00.00.00.00 1 ST ROPE PLAN 5005402 5005402
07.00.00.00.00 1 ST CARGO BLOCKS COMPL. 5005277 5005277
12.00.00.00.00 1 ST PANEL LIST 5004095 5004095
14.00.00.00.00 1 ST PARTS WITHOUT ATTECH IN WORK 5005678
15.00.00.00.00 1 ST AGGREGATE MODULE 5005282
18.00.00.00.00 1 ST DRIVERS CABIN COMPL. 5005422 2389487
19.00.00.00.00 1 ST WINCH MODULE 5005166 5005166
97.00.00.00.00 1 ST TECHNICAL DPKUMENTS 5005694

ASSEMBLY GROUP 00.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 186-00
DESCRIPTION: SLEWING TOWER COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.00.00.00.00 1 ST SLEWING TOWER COMPL. 5005186 5005186

01.10.00.00.00 1 ST PROTECTION FOR CABIN 2067984 2067984


01.12.00.00.00 1 ST ROPE PULLEYS RIGHT HAND COMPL. 5005098 5005098
01.15.00.00.00 1 ST ROPE PULLEYS COMPL. 5005091 5005091
01.16.00.00.00 2 ST JIB BEARING DIA 160 5005087 5005087
01.17.00.00.00 1 ST SLEWING GEAR COMPL. 5005181 5005181
01.18.00.00.00 1 ST ROLLER BEARING COMPL. 5005113 5005113
01.23.00.00.00 1 ST FLAP COOLER CAP COMPL. 5005207 5005207
01.25.00.00.00 1 ST E-PART SLEWING TOWER 5002138
01.31.00.00.00 1 ST ROPE PULLEYS LEFT HAND COMPL, 5005094 5005094
01.66.00.00.00 1 ST HYDRAULIC SYSTEM SLEWING TOWER 5005259

ASSEMBLY GROUP 01.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 098-00
DESCRIPTION: ROPE PULLEYS DIA 630 COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.12.00.00.00 1 ST ROPR PULLEYS DIA 630 COMPL. 5005098 5005098

01.12.01.00.00 3 ST ROPE PULLRY DIA 630 3327643 3327643


01.12.02.00.00 3 ST ROLLER BEARIN 1350987
01.12.03.00.00 6 ST SPR-SPACER 1656791
01.12.04.00.00 1 ST AXLE 5005097 5005097
01.12.05.00.00 1 ST WASHER 0173102 0173102
01.12.06.00.00 1 ST THRUST PLATE 2370674
01.12.06.00.00 1 ST PLATE WASHER 5001811
01.12.06.00.00 6 ST RIPPSCREW 2361684

ASSEMBLY GROUP 01.12.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 091-00
DESCRIPTION: ROPE PULLEYS DIA 630 COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.15.00.00.00 1 ST ROPR PULLEYS DIA 630 COMPL. 5005091 5005091

01.15.01.00.00 2 ST ROPE PULLRY DIA 630 3327643 3327643


01.15.02.00.00 2 ST ROLLER BEARIN 1350987
01.15.03.00.00 4 ST SPR-SPACER 1656791
01.15.04.00.00 1 ST AXLE 5005092 5005092
01.15.05.00.00 1 ST WASHER 0173102 0173102
01.15.06.00.00 3 ST RIPPSCREW 2361684

ASSEMBLY GROUP 01.15.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 087-00
DESCRIPTION: JIB BEARING DIA 160

ASSEMBLY GROUP 01.16.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 087-00
DESCRIPTION: JIB BEARING DIA 160

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.16.00.00.00 2 ST JIB BEARING DIA 160 5005087 5005087

01.16.01.00.00 1 ST BAERING HOUSING 2389246 2389246


01.16.02.00.00 1 ST AXLE 5005088 5005088
01.16.03.00.00 1 ST PRESSURE DISC 5001771 5001771
01.16.04.00.00 2 ST BEARING COVER 2389367 2389367
01.16.05.00.00 1 ST DISTANCE BUSH 5005089 5005089
01.16.06.00.00 1 ST JOURNAL 2389251 2389251
01.16.07.00.00 1 ST JOINT BEARING 1657952
01.16.08.00.00 2 ST SHAFT SEAL 0422109
01.16.09.00.00 3 ST HEXAGON SCREW 0057076
01.16.10.00.00 16 ST HEXAGON SCREW 0035035
01.16.13.00.00 4 ST HEXAGON SCREW 0152618
01.16.14.00.00 4 ST WASHER 2479256
01.16.19.00.00 1 ST FLAT GREASE NIPPLE 0155286
01.16.20.00.00 16 ST WASHER 8408962
01.16.21.00.00 8 ST PROTECTIVE PLUG 1609235

ASSEMBLY GROUP 01.16.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 181-00
DESCRIPTION: SLEWING GAER COMPL.

The brake must be filled with GEAR OIL prior to mounting the motor

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.17.00.00.00 1 ST SLEWING GEAR COMPL. 5005181 5005181

01.17.02.00.00 2 ST SLEWING GEAR 5005146


SUBSUPPLIER SEE
ASSEMBLY GROUP 01.17.02.00
01.17.05.00.00 48 ST HEXAGON SCREW 1637385
01.17.06.00.00 48 ST WASHER 3343769
01.17.07.00.00 2 ST WASHER 5005143 5005143

ASSEMBLY GROUP 01.17.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

SLEWING GEAR
i= 125

PART-NO.: 5 005 146

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 146-00
DESCRIPTION: SLEWING GEAR

TYPE AGGREGAT-NO. DESCRIPTION SERIAL-NO

5005146 SLEWING GEAR i= 125

ORDER-NO.: DESCRIPTION

56170890* INSTALLATION DRAWING

190000800* INSTALLATION INSTRUCTION


190000234* MAINTENANCE INSTRUCTION
190000315* RECOMMENDATION FOR LUBRICANTS
190000781* GEARBOX INSPECTION
190000159* TIGHTENING TORQUES

WEIGHT: 300,0 KG OIL QUANTITY:: 12,0 LTR.

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 146-00
DESCRIPTION: SLEWING GEAR

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 6630070500* PIMION SHAFT 1 ST
2 6662005120* SPACER 1 ST
3 0712710128A* NILOS RING 1 ST
4 0712758094* BEARING 1 ST
5 6650009960* GEARBOX HOUSING 1 ST
6 710301024A* SEAL RING 1 ST
8 0712758046* BEARING 1 ST
9 6662003530* SPACER 1 ST
10 6660000270* NUT 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 0715303258* O-RING 2 ST
2 6641020300* TOOTHER RING 1 ST
3 2T235346100* REDUCTION ASSEMBLY 1 ST L
4 6643021150* SUN GERA 1 ST
5 6653501530* COVER 1 ST
6 0720967023* SCREW 24 ST
7 0715303410* O-RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 2T235334030* REDUCTION ASSEMBLY 1 ST L
2 0715303410* O-RING 2 ST
3 6641010030* TOOTHED RING 1 ST
4 6643010070* SUN GEAR 1 ST
5 2T235634030* REDUCTION ASSEMBLY 1 ST L
6 6653500920* COVER 1 ST
7 0720955031* SCREW 12 ST
8 0720955030* SCREW 4 ST
9 715303268A* O-RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 715303268A* O-RING 2 ST
2 2T235332030* REDUCTION ASSEMBLY 1 ST L
3 6641000360* TOOTHED RING 1 ST
4 6643000190* SUN GEAR 1 ST
5 2T235332030* REDUCTION STAGE 1 ST L

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 0718299106* CIRCLIP 2 ST
2 6660300500* SPRING RETAINER 1 ST
3 6633030481* BRAKE SHAFT 1 ST
4 6680700040* STEEL RING 5 ST
5 6680900040* SINTERED DISC 6 ST
6 6652500452* BREAKE HOUSING 1 ST
7 0718416007* PLUG 1 ST
8 6682500271* OIL LEVEL PLUG 1 ST
9 0722369001* BACKUP RING 2 ST
10 0715307255* O-RING 2 ST
11 6662050090* SPACER 1 ST
12 0722369002* BACKUP RING 1 ST
13 0715307250* O-RING 1 ST
14 6635050140* PISTON 1 ST
15 6680300070* SPRING 10 ST
16 6660300240* SPRING RETAINER 1 ST
17 715303245A* O-RING 1 ST
18 0720954115* SCREW 12 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 ST L
1 6654503850* FLANGE 1 ST
2 0715303287* O-RING 1 ST
3 0718298752* CIRCLIP 2 ST
4 712753055A* EARING 1 ST
5 6646001580* COUPLING 1 ST
6 718299076A* CIRCLIP 1 ST
7 720955005A* SCREW 4 ST
8 0720971006* SCREW 8 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.17.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

GENERAL INFORMATION
Manual aim

This manual has been devised by the manufacturer to give necessary information to those
authorised to work on this product for example the design engineers,
installers, repair and maintenance technicians.

Besides helping one understand the rules of good manufacturing techniques used, the information given
must be read attentively and strictly put into action.

Failure to observe this information may lead to health and safety risks to persons as well as economic loss.

INFORMATION!
A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL
MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE.

Photographic documentation and drawings are supplied for educational purposes, so as to safely and pro-
perly carry out maintenance operations.
Minor deviations from pictures of this manual may appear on the actual gearbox. However, these
discrepancies are not relevant to the main parameters, or maintenance functions.

INFORMATION ON SAFETY
Carefully read the instructions given in this instruction manual as well as the ones attached to the product
and make sure to follow the information concerning safety.

Personnel, which perform any type of work on the product during its life span, must possess precise
technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do
so may lead to health and safety risks to persons.

It is recommended that when handling the product attention is paid to the information given in this
manual or simply follow the instructions given on the packaging (if present).

Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to
health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee
given by the manufacturer.

Keep the product in perfect working order by following the scheduled maintenance procedure set
out by the manufacturer. Good maintenance will ensure the best performances, a longer period of
operation and a constant safeguard towards security requirements.

To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is
important to follow adequate safety conditions for one self and for others in compliance with the rules and
regulations that govern safety in the workplace.

When replacing worn parts, use original spare parts. Use oils and greases recommended by the
manufacturer. Doing this, will ensure that the product works properly and that the safety level is "acceptable".

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PRODUCT IDENTIFICATION
The identification data of the unit are shown on a name plates put on it.

INFORMATION!
FOR ALL ENQUIRIES REGARDING GENERAL INFORMATION ON THE PRODUCT, SPARE PARTS,
ASSITANCE, ALWAYS GIVE THE IDENTIFICATION DATA STAMPED ON THE ID PLATE. THE PLATE
MUST BE REMOVED OR DAMAGED DURING THE LIFE OF THE PRODUCT.

The following illustration shows how the data is set out

For all requests for assistance please contact the manufacturer's sales network, directly.

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Notes
DELIVERY CONDITIONS
Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions:
Ready for installation in the mounting position specified when ordering.

Factory filled with lubricanting oil at level:


oil type SHELL SPIRAX A 80W-90

All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants.
External surfaces are protected with an antioxidant water resistant grey color and painted with a
blue synthetic finish coat (painting data are shown on the installation drawing).

Machined surfaces are not painted.


Tested toin-house specifications.
Appropriately packaged to facilitate handling, transport and storage.

INFORMATION!
WHEN THE PRODUCT ARRIVES, ENSURE THAT IT MEETS THE INFORMATION CONTAINED IN THE
PURCHASE AGREEMENT AND THAT THERE ARE NO DAMAGES OR IRREGULARITIES. IF THERE
ARE ANY PROBLEMS CONTACT THE MANUFACTURERS' SALES NETWORK DIRECTLY.

TRANSPORT
We recommend that the box containing gearboxes is handled carefully in order to avoid damages during
transport. When removing gearboxes from their packaging, extra caution should be taken to avoid impacts,
which may damage sensitive parts. The illustrations show the more common types of packaging.

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STORAGE
OBSERVE THE FOLLOWING INSTRUCTIONS TO ENSURE CORRECT STORAGE OF DELIVERED
PRODUCTS:

1. Do not store outdoors, in areas exposed to weather or with excessive humidity.


2. Always place boards of wood or other material between floor and products, to avoid direct contact
with the floor.
3. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and couplings-
must be protected with a suitable anti-oxidation product (SHELL ENSIS FLUID SDC or equivalent
product).

THE FOLLOWING MEASURES MUST BE TAKEN FOR PRODUCTS WHICH EXPECTED STORAGE
PERIOD EXCEEDS 6 MONTHS:

4. Cover outer machined parts and mating parts with grease to avoid oxidation.
5. At the slew drive installation on the machine frame replace the plug with breather valvesupplied as
loose part.

INFORMATION!
BEFORE USE, THE GEARBOXES SHOULD BE FILLED WITH THE PROPER AMOUNT OF LUBRICANT
OF THE RECOMMENDED TYPE.

ASSEMBLY GROUP 01.17.01.00.00


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LIFTING AND HANDLING


If the handling occurs when the product is still packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.

WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.

TO LIFT AND HANDLE THE PRODUCT, AFTER HAVING OPENED THE PACKAGING, FOLLOW THE
INFORMATION GIVEN BELOW:

1. Unscrew the nos.4 screws and remove the closing plate from the motor adapror flange.
2. Tighten nos.2 eyebolts at 180° on the thread holes of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.

ASSEMBLY GROUP 01.17.01.00.00


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INSTALLATION
HYDRAULIC MOTOR INSTALLATION
The mating areas and the pilot diameter of the gearbox where the motor is to be mounted must be clean and
without burrs.

1. Fit the O-ring seal, supplied with the gearbox, in its seat in the hydraulic motor, and assemble it to
the gearbox being careful not to damage the seal already fitted.
2. Assemble the hydraulic motor to the gearbox frame by using the screws shown in the following table

INFORMATION!
UNDER NO CIRCUMSTANCE REMOVE THE PLASTIC LID FROM THE POWER SUPPLY PORTS OF
THE HYDRAULIC MOTOR; THIS WILL HELP AVOID THE ACCIDENTAL INTRODUCTION OF FOREIGN
BODIES INTO THE MOTOR, UNTIL THE HOSES ARE ASSEMBLED.

ASSEMBLY GROUP 01.17.01.00.00


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INSTALLATION OF THE SLEW DRIVE ON THE MACHINE


1. Move the slew drive in the mounting area applying lifting methods shown in section 3.4.
2. Clean the mating surfaces from oils or paint and fit the slew drive on the machine frame
(for the correct orientation refe to the installation drawing).
3. In case the pinion shaft-slew ring backlash has to be increased or decreased, turn the eccentric ge-
arbox housing on the machine frame (see installation drawing).
4. Fix the slew drive to the machine frame by using the screws shown in the following table

ASSEMBLY GROUP 01.17.01.00.00


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CONNECTION OF THE BRAKE


The gearbox drive is supplied with a safety negative multidisc brake hydraulically driven
(parking brake). For information regarding the characteristics of the brake, port types and
dimensions, refer to the installation drawing.

1. To operate the brake, connect the brake pilot pipe to the brake port.

ASSEMBLY GROUP 01.17.01.00.00


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CONNECTIN OF THE DRAINING PORT


INFORMATION!
IF THE FRAME OF THE MACHINE DOES NOT ALLOW THE ACCESS TO THE PLUG, IT IS
NECESSARY, DURING THE SLEW DRIVE INSTALLATION, TO FIT AN EXTENTION WHICH TAKES THE
OIL AWAY FROM THE MACHINE.

1. Remove the drain plug and screw on a pipe to the drain port(for hose size and dimension refer to
the installation drawing).

REPLACING OF THE BREATHER VALVE AS LOOSE PART


At the slew drive installation on the machine frame replace the plug with breather valve supplied
as loose part.

1. Tigthen the brather valve supplied as loose part(for size and dimension refer to the installation
drawing).

ASSEMBLY GROUP 01.17.01.00.00


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LUBRICATION
GEARBOX LUBRICATION
The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing.
The gearbox is factory filled with lubricanting oil at level.
Oil type: SHELL SPIRAX A 80W-90 (specified when ordering).

Otherwise, the recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP
characteristics according to: MIL-L-2105 C & API GL5.

In the following table the most common brands of lubricant and the types recommended are shown.

INFORMATION!
DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

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OIL FILLING
1. Unscrew the FILLING LEVEL OIL PLUG (2) and add the lubricating oil which has the
characteristics given in section 5.1.
2. By using the dipstick, check that the oil level is somewhere between the
MIN and MAX notch and then screw the plug back on.
3. Operate the slew drive, after a few minutes, stop and check the oil level.
4. If necessary, refill with lubricant oil. Size and dimension of plugs are shown on the
installation drawing.

APROXIMATE OIL CAPACITY LITERS ARE: 12 L ±10%

OIL DRAINING AND REPLACEMENT


1. Unscrew the DRAINING PLUG and let the oil flow in a large enough container; in order to facilitate
the draining it is better to operate with the oil still warm.
2. Wait a few minutes until all the oil is drained and then proceed to screw on DRAINING PLUG.
3. Proceed with the oil fill-up following the procedures given (see Section 5.2).

WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.

WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

ASSEMBLY GROUP 01.17.01.00.00


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START UP AND RUNNING IN


In this first stage it is advised to follow the measures given below:

1. Check the correctly lubrication of the unit.


2. Bleed air from every part of the hyraulic and add oil in the tank if necessary.

INFORMATION!
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.

3. Start the gearmotor at a low speed and gradually increase it after having verified that
it is functioning correctly without any noises or vibrations.

INFORMATION!
DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.

During the running-in stage follow the steps given below.

4. Check the correct revolution and direction of rotation.


5. Make sure that the functioning is regular and with-out any excessive noises and vibrations.
6. Make sure that the oil temperature does not exceed 85-90°C intermittent.

After having terminated this first running-in follow the steps given below.

7. Check that there are no oil leakages. If present, proceed to remove them.
8. Check the level of lubricating oil in the gearmotor.

It could happen that due to the presence of air, during the first start up, the opening action of the
brake could be slowed down. It is advised to repeat the opening and closing function of the brake.

Check that there are no other problems in general

ASSEMBLY GROUP 01.17.01.00.00


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MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and
oil changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation. For a proper maintenance of the gearbox, the following
checks and operations have to be done.

INFORMATION!

IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE


SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.

DO NOT HESITATE TO CONTATCT THE GEARBOX DISTRIBUTOR OR MANUFACTURER IF FURTHER


INSTRUCTIONS ARE NECESSARY OR IN
CASE OF PARTICULAR PROBLEMS.

This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL res-
res the right to implement modifications without notice. This manual cannot be reproduced, even partially,
without prior written consent.

ASSEMBLY GROUP 01.17.01.00.00


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TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 113-00
DESCRIPTION: ROLLER BEARING COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.18.00.00.00 1 ST ROLLER BEARING COMPL. 5005113 5005113

01.18.01.00.00 1 ST ROLLER BEARING 5004951 5004951


01.18.02.00.00 119 ST WASHER 5005115 5005115
01.18.03.00.00 239 ST HEXAGON NUT 2028445 2028445
01.18.04.00.00 239 ST STUD BOLT 2370718 2370718
01.18.05.00.00 120 ST WASHER 1601526 1601226

ASSEMBLY GROUP 01.18.00.00.00


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SPARE PARTS LIST


ORDER NO. 5 005 207-00
DESCRIPTION: FLAP COOLER CAP COMPL.

ASSEMBLY GROUP 01.23.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 207-00
DESCRIPTION: FLAP COOLER CAP COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.23.00.00.00 1 ST FLAP COOLER CAP COMPL. 5005207 5005207

01.23.01.00.00 1 ST FLAP COOLER CAP 5005208 5005208

01.23.01.06.00 1 ST FLAT
01.23.01.07.00 1 ST FLAT
01.23.01.09.00 1 ST ROUND
01.23.01.10.00 1 ST ROUND
01.23.01.14.00 2 ST RING

01.23.02.00.00 4 ST PART OF JOINT 5004079


01.23.03.00.00 6 ST PIN 0583196
01.23.04.00.00 6 ST SPLIT-PIN 0119814
01.23.05.00.00 6 ST HEXAGON NUT 0057127
01.23.06.00.00 3 M SEALING PROFILE 5005147
01.23.07.00.00 2 ST HEXAGON SCREW 2533314
01.23.08.00.00 2 ST CLEVIS HEAD 5004451
01.23.09.00.00 1 ST SPRING PIN 0013825
01.23.11.00.00 3 ST HEXAGON NUT 0057130
01.23.14.00.00 2 ST SET-SCREW 0576549
01.23.15.00.00 2 ST PART OF JOINT 5005145
01.23.16.00.00 4 ST HEXAGON NUT 0057133
01.23.22.00.00 1 ST HOLE COVER 0490348

ASSEMBLY GROUP 01.23.00.00.00


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SPARE PARTS LIST


ORDER NO. 5 002 138-00
DESCRIPTION: E-PART SLEWING TOWER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.25.00.00.00 1 ST E-PART SLEWING TOWER 5002138

01.25.03.00.00 1 ST LIGHTING AND HEATING 5002074


01.25.60.00.00 1 ST MOUNTING IN WORKSHOP 5002137

ASSEMBLY GROUP 01.25.00.00.00

SPARE PARTS LIST


ORDER NO. 5 002 074-01
DESCRIPTION: LIGHTING AND HEATING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.25.03.00.00 1 ST LIGHTING AND HEATING 5002074

01.25.03.01.00 1 ST LAMP 5002079


01.25.03.03.00 2 ST FLUORESCENT LAMP 0058132
01.25.03.05.00 1 ST SCREW BUSH 1624414
01.25.03.07.00 1 ST ROOM HEATER 2535250
01.25.03.11.00 2 ST HEXAGON NUT 0650234
01.25.03.12.00 2 ST CNTACT WASHER 2079808
01.25.03.13.00 2 ST HEXAGON SCREW 1683943
01.25.03.14.00 4 ST HEXAGON SCREW 1683937
01.25.0315.00 4 ST SLIT WASHER 0511788
01.25.03.16.00 4 ST WASHER 1684578
01.25.03.17.00 4 ST SCREW PLUG 1627280

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SPARE PARTS LIST


ORDER NO. 5 002 137-02
DESCRIPTION: MOUNTING IN WORKSHOP

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.25.60.00.00 1 ST MOUNTING IN WORKSHOP 5002137

01.25.60.01.00 1 ST PROTECTION EARTHING OF JIB 5002078

01.25.60.03.00 8 M CABLE TRAY 1627349


01.25.60.04.00 30 ST CABLE TRAY NUT 2012404 2012404
01.25.60.05.00 6 ST BOLTED CONNECTION FOR CABLE GUIDE 1624652
01.25.60.06.00 1 ST DISTRIBUTION BOX 1627768
01.25.60.07.00 3 ST SCREW BUSH 1624414
01.25.60.08.00 2 ST INSIDE FOR CABLE GUIDE 1627506
01.25.60.09.00 5 ST SCREW PLUG 1627280
01.25.60.10.00 2 ST HEXAGON SCREW 0842417
01.25.60.11.00 2 ST SPRING RING 3398003
01.25.60.12.00 2 ST WASHER 3330214
01.25.60.13.00 2 ST CARRIER RAIL NUT 3398455
01.25.60.20.00 2 ST CONDUIT BUSHING 1360534
01.25.60.21.00 2 M EDGE PROTECTION 0597527
01.25.60.22.00 2 M EDGE PROTECTION 0153957 0153957

ASSEMBLY GROUP 01.25.60.00.00

SPARE PARTS LIST


ORDER NO. 5 002 078-00
DESCRIPTION: PROTECTION EARTHING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.25.60.01.00 1 ST PROTECTION EARTHING 5002078

01.25.60.01.01 1,5 M CABLE 1637432


01.25.60.01.02 2 ST CABLE SHOE 0216411
01.25.60.01.03 4 ST HEXAGON NUT 1683742
01.25.60.01.04 4 ST CONTACT WASHER 2079810

ASSEMBLY GROUP 01.25.60.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 094-00
DESCRIPTION: ROPE PULLEYS DIA 630 COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.31.00.00.00 1 ST ROPR PULLEYS DIA 630 COMPL. 5005094 5005094

01.31.01.00.00 1 ST ROPE PULLRY DIA 630 3327643 3327643


01.31.02.00.00 1 ST ROLLER BEARIN 1350987
01.31.03.00.00 2 ST SPR-SPACER 1656791
01.31.04.00.00 1 ST AXLE 5005095 5005095
01.31.05.00.00 1 ST WASHER 0173102 0173102
01.31.06.00.00 3 ST RIPPSCREW 2361684

ASSEMBLY GROUP 01.31.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 259-00
DESCRIPTION: HYDRAULIC SYSTEM SLEWING TOWER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.66.00.00.00 1 ST HYDRAULIC SYSTEM SLEWING TOWER 5005259

01.66.02.00.00 1 ST COMPONENTS HYDRAULIC SYSTEM 5005251 5005251


01.66.13.00.00 1 ST HYDR.MOTOR SLEWING GEAR COMPL. 5005249

ASSEMBLY GROUP 01.66.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 251-00
DESCRIPTION: COMPONENTS HYDRAULIC SYSTEM

ASSEMBLY GROUP 01.66.02.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 251-00
DESCRIPTION: COMPONENTS HYDRAULIC SYSTEM

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.66.02.00.00 1 ST COMPONENTS HYDRAULIC SYSTEM 5005251 5005251

01.66.02.01.00 1 ST COOL SYSTEM OIL-AIR 5005192 5005192


SEE SUBSUPPLIER
ASSEMBLY GROUP 01.66.02.01

01.66.02.02.00 2 ST UNION 1331028


01.66.02.03.00 2 ST UNION 1636008
01.66.02.04.00 8 ST SELF-LOCKING 0146559
01.66.02.05.00 8 ST WASHER 0063677
01.66.02.06.00 8 ST THRUST WASHER 0153211
01.66.02.10.00 3,2 M SEALING - ADHESIVE TAPE 2548028
01.66.02.12.00 1 ST BRAKE FILTER 1637770
01.66.02.13.00 6 ST SEALING RING 1725417
01.66.02.14.00 12 ST SEALING RING 1725419
01.66.02.18.00 2 ST UNION 1338218
01.66.02.19.00 2 ST UNION 1636027
01.66.02.20.00 1 ST UNION 1636004
01.66.02.21.00 1 ST UNION 1665705
01.66.02.22.00 1 ST TRANSIT.MUFF CONNECT.PIECE 0665861
01.66.02.23.00 1 ST UNION 1665742

ASSEMBLY GROUP 01.66.02.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 249-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.66.13.00.00 1 ST HYDR.MOTOR SLEWING GEAR COMPL. 5005249


01.66.13.01.00 1 ST HYDR. MOTOR SLEWING GEAR COMPL 5005155 5005155
01.66.13.03.00 1 ST HYDR. MOTOR SLEWING GEAR COMPL. 5005157 5005157

ASSEMBLY GROUP 01.66.13.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 155-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.66.13.01.00 1 ST HYDR.MOTOR SLEWING GEAR 5005155 5005155

01.66.13.01.01 1 ST HYDR. MOTOR 2010753


SEE SUBSUPPLIER
ASSEMBYL 01.66.13.01.01

01.66.13.01.02 1 ST SOCKET PIECE 0625708


01.66.13.01.03 1 ST LOCK SCREW 1009480
01.66.13.01.04 4 ST SAE-FLANGE 0727077
01.66.13.01.05 1 ST SCREWING 0070277
01.66.13.01.06 8 ST SAE-FLANGE HALF 0625571
01.66.13.01.07 2 ST SEAL RING 1725417
01.66.13.01.08 8 ST CAP-SCREW 0939137
01.66.13.01.09 8 ST CYL.SCREW 1758053
01.66.13.01.12 16 ST CAP-SCREW 0861764
01.66.13.01.13 4 ST CYL.SCREW 0119724
01.66.13.01.14 2 ST T-PIECE 2072544 2072544
01.66.13.01.15 2 ST ADAPTER 1397738 1397738
01.66.13.01.16 2 ST SEALING RING 1725419
01.66.13.01.17 4 ST THRUST WASHER 1005866
01.66.13.01.18 1 ST UNION 1665715
01.66.13.01.19 1 ST PIPE FILTER 0986373
01.66.13.01.20 1 ST CLOSING COUPLING 1335578
01.66.13.01.21 1 ST SEAL.RING 0029263

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TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

AXIAL PISTON UNIT

PART-NO.: 2 010 753

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7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 010 753
DESCRIPTION: AXIAL PISTON UNIT

POS. ORDER-NO. DESCRIPTION QUANTITY


2 010 753 AXIAL PISTON UNIT A2FM56/61 ( R909422129*) 1 ST L
1 R902031626* ROTARY GROUP 1 ST L
3 R902040495* HOUSING 1 ST
4 R909421620* PORT PLATE 1 ST
5 R909084150* CYLINDER PIN 1 ST
6 R909085571* O-RING 1 ST D
7 R909083060* SOCKET-HEAD SCREW 51NM 2 ST
10 R909083068* SOCKET-HEAD SCREW 51NM 4 ST
19 R909156651* LOCKING SCREW 60NM 1 ST D
98 R902002217* SEALING SET COMPL: 1 ST L

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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SPARE PARTS LIST


ORDER NO. R902031626*
DESCRIPTION: ROTARY GROUP

POS. ORDER-NO. DESCRIPTION QUANTITY


R902031626* ROTARY GROUP 1 ST L
1 R902028933* ROTARY GROUP; HYDR. SECTION 1 ST L
2 R902030594* DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 R909119566* COVER 1 ST LD
12 R909154528* RETAINING RING 1 ST
15 R909154986* O-RING 1 ST D
17 R909152831* SHIM 2 ST
18 R909084592* SHIM 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.66.13.01.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902028933*
DESCRIPTION: ROTARY GROUP, HYDR . SECTION

POS. ORDER-NO. DESCRIPTION QUANTITY


R902028933* ROTARY GROUP, HYDR . SECTION 1 ST L
1 R909421305* CYLINDER 1 ST
2 R909650831* CONTROL PLATE 1 ST
3 R902028565* CENTER PIN 1 ST
4 R902031674* PISTON WITH PISTON RINGS 7 ST L
5 R909409994* WASHER 1 ST
6 R902028559* ADJUSTMENT SHIM 1 ST
6 R902028560* ADJUSTMENT SHIM 1 ST
6 R902028561* ADJUSTMENT SHIM 1 ST
6 R902028562* ADJUSTMENT SHIM 1 ST
6 R902028563* ADJUSTMENT SHIM 1 ST
7 R902028810* PRESSURE SPRING 1 ST
11 R909444063* RETAINING PLATE 1 ST
12 R902602493* PAN HEAD SCREW W. TORX 7 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.66.13.01.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902030594*
DESCRIPTION: DRIVE SHAFT WITH BEARING ASSY

POS. ORDER-NO. DESCRIPTION QUANTITY


R902030594* DRIVE SHAFT WITH BEARING ASSY 1 ST L
2 R902028564* DRIVE SHAFT 1 ST
3 R909430338* BEARIMG RING 1 ST
6 R902030518* BACK-UP PLATE 1 ST L
7 R90908363* RETAINING RING 1 ST
10 R909156194* TAPERED-ROLLER BEARING 1 ST
11 R909154608* TAPERED-ROLLER BEARING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.66.13.01.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902030518*
DESCRIPTION: BACK-UP PLATE

POS. ORDER-NO. DESCRIPTION QUANTITY


R902030518* BACK-UP PLATE 1 ST L
1 R902028800* BACK-UP PLATE 1 ST
2 R902028801* BACK-UP PLATE 1 ST
3 R902028802* BACK-UP PLATE 1 ST
4 R902028803* BACK-UP PLATE 1 ST
5 R902028804* BACK-UP PLATE 1 ST
6 R902028805* BACK-UP PLATE 1 ST
7 R902028806* BACK-UP PLATE 1 ST
8 R902028807* BACK-UP PLATE 1 ST
9 R902028808* BACK-UP PLATE 1 ST
10 R902028809* BACK-UP PLATE 1 ST
12 R909084737* BACK-UP PLATE 1 ST

SPARE PARTS LIST


ORDER NO. R902119566*
DESCRIPTION: COVER WITH SHAFT SEAL RING

POS. ORDER-NO. DESCRIPTION QUANTITY


R902119566* COVER WITH SEAL RING 1 ST L
1 COVER 1 ST D
2 R909830383* SHAFT SEALING RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 01.66.13.01.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 157-00
DESCRIPTION: HYDR. MOTOR SLEWING GEAR COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

01.66.13.03.00 1 ST HYDR. MOTOR SLEWING GEAR COMPL. 5005157 5005157

01.66.13.03.01 1 ST HYDR. MOTOR 2010753


SUBSUPPLIER SEE
ASSEMBLY GROUP 01.66.13.01.00
01.66.13.03.02 1 ST SOCKET PIECE 0625708
01.66.13.03.03 1 ST LOCK SCREW 1009480
01.66.13.03.04 8 ST SAE-FLANGE 0727077
01.66.13.03.05 1 ST SCREWING 0070277
01.66.13.03.08 16 ST CAP-SCREW 0939137
01.66.13.03.09 2 ST ADAPTER 1627448 1627448
01.66.13.03.10 2 ST SEAL RING 1725417
01.66.13.03.11 4 ST THRUST WASHER 1005866
01.66.13.03.13 4 ST CAP SCREW 0119724

ASSEMBLY GROUP 01.66.13.03.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 255-00
DESCRIPTION: JIB COMPL.

JIB COMPL. ONLY CRANE NO. 1 : LMG YARD NO.: 2-571-73165 ORDER NO.: 5 005 255

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.00.00.00.00 1 ST JIB COMPL. 5005255 5005255

02.01.00.00.00 1 ST JIB STEEL STRUCTURE COMPL. 5005357 5005255


02.04.00.00.00 1 ST ROPE PULLEYS COMPL: 5005111 5005111
02.09.00.00.00 1 ST LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 ST BUFFER STOP 2389406
02.25.00.00.00 1 ST E-SYSTEM JIB 2350938

ASSEMBLY GROUP 02.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 365-00
DESCRIPTION: JIB COMPL.

JIB COMPL. ONLY CRANE NO. 2 : LMG YARD NO.: 2-571-73166 ORDER NO.: 5 005 365

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.00.00.00.00 1 ST JIB COMPL. 5005365 5005255

02.01.00.00.00 1 ST JIB STEEL STRUCTURE COMPL. 5005355 5005255


02.04.00.00.00 1 ST ROPE PULLEYS COMPL: 5005111 5005111
02.09.00.00.00 1 ST LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 ST BUFFER STOP 2389406
02.25.00.00.00 1 ST E-SYSTEM JIB 2350938

ASSEMBLY GROUP 02.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 366-00
DESCRIPTION: JIB COMPL.

JIB COMPL. ONLY CRANE NO. 3 : LMG YARD NO.: 2-571-73167 ORDER NO.: 5 005 366

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.00.00.00.00 1 ST JIB COMPL. 5005366 5005255

02.01.00.00.00 1 ST JIB STEEL STRUCTURE COMPL. 5005356 5005255


02.04.00.00.00 1 ST ROPE PULLEYS COMPL: 5005111 5005111
02.09.00.00.00 1 ST LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 ST BUFFER STOP 2389406
02.25.00.00.00 1 ST E-SYSTEM JIB 2350938

ASSEMBLY GROUP 02.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 367-00
DESCRIPTION: JIB COMPL.

JIB COMPL. ONLY CRANE NO. 4 : LMG YARD NO.: 2-571-73168 ORDER NO.: 5 005 367

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.00.00.00.00 1 ST JIB COMPL. 5005367 5005255

02.01.00.00.00 1 ST JIB STEEL STRUCTURE COMPL. 5005357 5005255


02.04.00.00.00 1 ST ROPE PULLEYS COMPL: 5005111 5005111
02.09.00.00.00 1 ST LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 ST BUFFER STOP 2389406
02.25.00.00.00 1 ST E-SYSTEM JIB 2350938

ASSEMBLY GROUP 02.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 111-00
DESCRIPTION: ROPE PULLEYS JIB HEAD COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.04.00.00.00 1 ST ROPR PULLEYS JIB HEAD COMPL. 5005111 5005111

02.04.01.00.00 7 ST ROPE PULLRY DIA 630 COMPL. 3327643 3327643


02.04.02.00.00 7 ST ROLLER BEARING 1350987
02.04.03.00.00 14 ST SPR-SPACER 1656791
02.04.04.00.00 1 ST AXLE 5005109 5005109
02.04.05.00.00 1 ST AXLE 5005112 5005112
02.04.06.00.00 4 ST WASHER 0173102 0173102
02.04.07.00.00 12 ST RIPPSCREW 2361684

ASSEMBLY GROUP 02.04.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 067 941-04
DESCRIPTION: LAMP BRACKET L.H

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.09.00.00.00 1 ST LAMP BRACKET L.H 2067941 2067941

02.09.06.00.00 1 ST WASHER 0841470 0841470


02.09.07.00.00 2 ST HEXAGON. NUT 0057130
02.09.08.00.00 1 ST HEXAGON. NUT 0057125
02.09.09.00.00 1 ST SLIT WASHER 0511788
02.09.10.00.00 1 ST WASHER 0053741
02.09.11.00.00 6 ST HEXAGON SCREW 0056659
02.09.12.00.00 6 ST SPRING LOCK WASHER 0249845
02.09.13.00.00 1 ST RUBBER-MET.COBBECTION 2063050
02.09.14.00.00 1 ST BUSH 2067164 2067164

ASSEMBLY GROUP 02.09.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 389 406-01
DESCRIPTION: BUFFER STOP

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.20.00.00.00 1 ST BUFFER STOP 2389406 2389406

02.20.01.00.00 1 ST STOP-RAIL 1636914


02.20.02.00.00 4 ST HEXAGON NUT 0057130
02.20.03.00.00 4 ST CURVED SPRING LOCK WASHER 0249845

ASSEMBLY GROUP 02.20.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 350 938-04
DESCRIPTION: E-SYSTEM JIB

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

02.25.00.00.00 1 ST E-SYSTEM JIB 2350938

02.25.01.00.00 1 ST HNA-STANDARD FITTING 1624721


02.25.02.00.00 1 ST TWO-BASE BULB 1624722
02.25.03.00.00 1 ST INCANDESCENT LAMP 1660212
02.25.05.00.00 1 ST HNA-JUNCTION BOX 1624723
02.25.06.00.00 4 ST SCREW BUSH 1624414
02.25.07.00.00 4 ST HEXAGON SCREW 842417
02.25.08.00.00 4 ST SPRING RING 3398003
02.25.09.00.00 4 ST CARRIER RAIL NUT 3398455
02.25.10.00.00 1 M CABLE 505898
02.25.11.00.00 1 M CABLE 505897
02.25.12.00.00 14 ST CONDUIT BUSHING 1360534
02.25.13.00.00 3 ST INNERPARTS FOR CABLE INLET 1627507

SSEMBLY GROUP 02.25.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 402-00
DESCRIPTION: ROPE PLAN 30T – 28M

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

05.00.00.00.00 1 ST ROPE PLAN KL 30T – 28M 5005402 5005402

05.01.00.00.00 1 ST ROPE 30 262M ( HOISTING ROPE ) 5005427 5005427


05.02.00.00.00 1 ST ROPE 30 209M ( LUFFING ROPE ) 5005428 5005428
05.03.00.00.00 2 ST BUSH 2094863
05.04.00.00.00 2 ST ADJUSTING-RING 0033190
05.05.00.00.00 2 ST HEXAGON SCREW 7120053
05.06.00.00.00 2 ST EXAGON-NUT 0146559

ASSEMBLY GROUP 05.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 402-00
DESCRIPTION: ROPE PLAN 30T – 28M

ASSEMBLY GROUP 05.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 277-00
DESCRIPTION: CARGO GEAR

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

07.00.00.00.00 1 ST CARGO GEAR 5005277

07.01.00.00.00 1 ST HOOK BOTTLE 5005073 5005073


07.02.00.00.00 1 ST GRAB MOUNTING 5005267 5005267

ASSEMBLY GROUP 07.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 273-00
DESCRIPTION: CARGO BLOCK SWL 35T COMPL.

ASSEMBLY GROUP 07.01.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 273-00
DESCRIPTION: CARGO BLOCK SWL 35T COMPL.

ASSEMBLY GROUP 07.01.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 273-00
DESCRIPTION: CARGO BLOCK SWL 35T COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

07.01.00.00.00 1 ST CARGO BLOCK SWL 35T COMPL. 5005273 5005273

07.01.01.00 1 ST BEARING PLATE F. CARGO BLOCK 5005149 5005149


07.01.02.00 1 ST SWIVEL EYE 5005152 5005152
07.01.03.00 1 ST PIN 5005136 5005136
07.01.04.00 1 ST THRUST WASHER 5005137 5005137
07.01.05.00 1 ST PIN 5005139 5005139
07.01.06.00 1 ST THRUST WASHER 5005148 5005148
07.01.07.00 2 ST WASHER 5001927 5001927
07.01.08.00 1 ST ROPE PULLEY 5005138 5005138
07.01.09.00 1 ST CYLINDER ROLLER BEARING 1382156
07.01.10.00 2 ST RETAINING RING 065ß844
07.01.11.00 1 ST RAMSHORN SHANK HOOK 5005162 5005162
07.01.12.00 1 ST LIFTING HOOK NUT 5005153 5005153
07.01.13.00 1 ST SAFETY LUG 5005169 5005169
07.01.14.00 1 ST BUSHING 2094863
07.01.15.00 1 ST SUSPENSION 5005171 5005171
07.01.16.00 6 ST DISTANCE TUBE 5005161 5005161
07.01.17.00 6 ST SELF-LOCKING-NUT 0589418
07.01.18.00 6 ST HEXAGON SCREW 0013217
07.01.19.00 3 ST HEXAGON SCREW 0013046
07.01.20.00 3 ST RIPP-SCREW 0012913
07.01.21.00 2 ST HEXAGON SCREW 0054405
07.01.22.00 2 ST HEXAGON SCREW 0056668
07.01.23.00 2 ST WASHER 0952012
07.01.24.00 1 ST AXIAL-CYLINDER ROLLER BEARING 5001630
07.01.25.00 1 ST GREASE NIPPLR 0010528
07.01.26.00 1 ST V-RING 0750868
07.01.27.00 2 ST HEXAGON SCREW 0840133
07.01.28.00 1 ST BUSH 5005263 5005263

ASSEMBLY GROUP 07.01.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 267-00
DESCRIPTION: GRAB MOUNTING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

07.02.00.00.00 1 ST GRAB MOUNTING 5005267 5005267

07.02.01.00.00 1 ST WEAR RING 5001277 5001277

ASSEMBLY GROUP 07.02.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 004 095-00
DESCRIPTION: PANEL LIST SLEWING TOWER

ASSEMBLY GROUP 12.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 004 095-00
DESCRIPTION: PANEL LIST SLEWING TOWER

ASSEMBLY GROUP 12.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 004 095-00
DESCRIPTION: PANEL LIST SLEWING TOWER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

12.00.00.00.00 1 ST PANEL LIST SLEWING TOWER 5004095 5004095

12.02.00.00.00 1 ST TYPE PLATE 5001168 5001168


12.04.00.00.00 1 ST PLATE "DANGER" 3337851 3337851
12.05.00.00.00 1 ST PLATE "MOUNTING HATCH" 3337852 3337852
12.06.00.00.00 1 ST PLATE "OPERATING" 3337853 3337853
12.08.00.00.00 1 ST BLADE EMERGENCY EXIT 2008698 2008698
12.09.00.00.00 1 ST EMERGENCY EXIT 2389652 2389652
12.10.00.00.00 1 ST LABEL 1604793 1604793
12.11.00.00.00 1 ST PLATE "SEAT BELT" 3337855 3337855
12.12.00.00.00 1 ST PLATE "DANGER" 3337856 3337856
12.13.00.00.00 1 ST PLATE 3337857 3337857
12.14.00.00.00 1 ST PALTE “OPERATING INSTRUCTION” 5001164 5001164
12.15.00.00.00 6 ST ST-SCREW 1520120
12.16.00.00.00 6 ST WASHER 2372234
12.17.00.00.00 1 ST BLADE VENTILATION 2509888 2509888
12.18.00.00.00 1 ST PLATE "DOOR OPEN" 3396157 3396157
12.19.00.00.00 2 ST NAME PLATE TTS 5001397
12.20.00.00.00 4 ST ROUND HEAD GROVED PIN 0040708
12.21.00.00.00 1 ST PLATE VENTILATOR COVER CLOSE 5004094
12.22.00.00.00 1 ST PLATE VENTILATOR COVER OPEN 5004093

ASSEMBLY GROUP 12.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 678-00
DESCRIPTION: PARTS WITHOUT ATTACH IN WORK

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.00.00.00.00 1 ST PARTS WITHOUT ATTACH IN WORK 5005678

14.02.00.00.00 1 ST EXTINGUISHER 3330836

14.03.00.00.00 1 ST ROPE DOWN DEVICE 2544045 2544045

14.25.00.00.00 1 ST E - PARTS FOR ASSEMBLY 14.00 5002590

ASSEMBLY GROUP 14.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 590-00
DESCRIPTION: E - PARTS WITHOUT ATTACH IN WORK

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.25.00.00.00 1 ST E - PARTS WITHOUT ATTACH IN WORK 5002590

14.25.20.00.00 1 ST SLIP RING BODY 5002356


SEE SUBSUPPLIER
ASSEMBLY GROUP 14.25.20
14.25.21.00.00 1 ST ACCESSORIES FOR SLIP RING 5002369
14.25.30.00.00 1 ST WORKING LIGHT 1x 500W 2350939
14.25.31.00.00 2 ST DECKS LIGHTING 1x1000W-HAL 5002591
14.25.50.00.00 1 ST EMERGENCY STOP FROM DECK AERA 5002602

ASSEMBLY GROUP 14.25.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

SLIPRING BODY

PART-NO.: 5 002 356

ASSEMBLY GROUP 14.25.20.00.0


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 356
DESCRIPTION: SLIPRING BODY

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 14.25.20.00.0


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 356
DESCRIPTION: SLIPRING BODY

POS. ORDER-NO. DESCRIPTION QUANTITY


5 002 356 SLIPRING BODY 1 ST L
1 A 100.9306-4* FLANGE 1 ST
2 100:9382-4* SPACER RING 1 ST
3 N 100.47-2* BEARING SUPPORT 1 ST
5 SLIPRING; Ø200x24 3 ST
6 THREADED ROD 3 ST
7 100.07-4 REDUCTION RING 1 ST
8 PIPE 4 ST
9 PIPE 1 ST
10 A 100.422-4* INTERMEDIATE WASHER 1 ST
11 HGW 2375.12* GFK-PIPE 12.6x16 2 ST
12 THREADED ROD 4 ST
13 100.11-2* BEARING FLANGE 1 ST
14 100.47-2* MOUNTING PLATE 1 ST
15 THREADED ROD 2 ST
16 1206E* SELF-ALIGNING BALL BEARING 1 ST
17 CAP SCREW 1 ST
18 HEXAGON NUT 10 ST
19 100.21-4* BEARING RING 30/100 1 ST
20 100.998-4* CAP 1 ST
21 300.02-3* INSULATING RING 7 ST
22 A 300.03-4* SLIPRING Ø125x3 6 ST
23 THREADED ROD 3 ST
24 400.4.0.09.1-4* SPACER SLEEVE 3 ST
25 HGW2375.21x30-4* GFK-PIPE 21.2x30 3 ST
26 3 343 623 GFK-PIPE 21.2x30 9 ST
27 HGW2375.14x20-4* GFK-PIPE 14.2x20 2 ST
28 120.31-3* EARTHING RING Ø200X24 1 ST
29 A 490.01-4* EARTHING SLEEVE 20x3 2 ST
30 A 100.38-4* BEARING RING 1 ST
31 CAP SCREW 6 ST
32 HEXAGON SCREW 31 ST
33 100.9467-4* FOLLOWER 1 ST
34 HEXAGON NUT 9 ST
36 E 100.6150-1* HOOD 1 ST
37 SEEGER RING 1 ST
38 HGW2375.8x18-4* GFK-PIPE 8.2x18 1 ST
39 HGW2375.25x14-4* GFK-PIPE 25x14 2 ST
40 A 100.927-3* BEARING RING 1 ST
41 100.960-3* BRUSH HOLDER 60A 6 ST
42 142.02-3* BRUSH HOLDER 60A 8 ST
43 THREADED ROD 2 ST
44 HGW2375.14x20-4* GFK-PIPE 8.2x18 3 ST
45 LOCK WASHER 2 ST

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 14.25.20.00.0


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 356
DESCRIPTION: SLIPRING BODY

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 14.25.20.00.0


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 356
DESCRIPTION: SLIPRING BODY

POS. ORDER-NO. DESCRIPTION QUANTITY


46 LOCK WASHER 11 ST
47 LOCK WASHER 12 ST
48 LOCK WASHER 5 ST
49 HEXAGON NUT 14 ST
50 HEXAGON SCREW 12 ST
51 WASHER 12 ST
52 HP2061.25x12-4* HP-WASHER 16 ST
53 E 100.12.2-4* FELT WASHER 1 ST
54 E 100.12.1-4* WASHER 1 ST
55 WASHER 1 ST
56 LOCK WASHER 1 ST
57 LOCK WASHER 1 ST
58 LOCK WASHER 3 ST
59 COUNTER-SUNK SCREW 2 ST
60 HGW2375.8x10-4* GFK-PIPE 82.x10 3 ST
61 HEXAGON NUT 2 ST
62 WASER 2 ST
63 B 100.75-3* CURRENT COLLECTOR. 600A 4 ST
64 K 100.9391-4* PLATE 2 ST
66 CAP SCREW 2 ST
67 LOCK WASHER 2 ST
69 RK 6-10 PA* INE-UP TERMINAL 6 ST
70 EW 35* SIDE ANGLE 2 ST
71 TW 2.5-10 PA* SEPARATING WALL 1 ST

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 14.25.20.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 369-00
DESCRIPTION: ACCESSORIES FOR SLIP-RING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.25.21.00.00 1 ST ACCESSORIES FOR SLIP-RING 5002369

14.25.21.01.00 4 ST PIPE 0051328


14.25.21.02.00 4 ST HEXAGON SCREW 0955986
14.25.21.03.00 4 ST HEXAGON NUT 2507318
14.25.21.05.00 4 ST CABLE UNION 4236260
14.25.21.06.00 8 ST CABLE UNION 4236259
14.25.21.07.00 4 ST NUT 4236264
14.25.21.08.00 8 ST NUT 4236263
14.25.21.10.00 1 ST SIKAFLEX 4228427
14.25.21.11.00 8 ST CABLE THIMBLE 5002355
14.25.21.12.00 8 ST CABLE THIMBLE 0215244
14.25.21.13.00 2 ST CABLE THIMBLE 1709720
14.25.21.14.00 12 ST CABLE THIMBLE 0057925

ASSEMBLY GROUP 14.25.21.00.00

SPARE PARTS LIST


ORDER NO. 2 350 939-02
DESCRIPTION: LIGHTING FOR JIB

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.25.30.00.00 1 ST LIGHTING FOR JIB 2350939

14.25.30.01.00 1 ST FLOOD LIGHT 1627792


14.25.30.02.00 1 ST SCREW BUSH 1624414
14.25.30.03.00 1 ST HALOGEN-LAMP 0625145
14.25.30.04.00 2 ST HEXAGON SCREW 1683991
14.25.30.05.00 2 ST HEXAGON NUT 1683743
14.25.30.06.00 2 ST CONTACT WASHER 2079812
14.25.30.07.00 10 ST CABLE STRAP 1660206
14.25.30.08.00 1 ST INNERPARTS FOR CABLE INLET 1627507
14.25.30.09.00 1 ST SIKAFLEX 3398165

ASSEMBLY GROUP 14.25.30.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 591-00
DESCRIPTION: DECKS LIGHTING 1x1000W-HAL

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.25.31.00.00 1 ST DECKS LIGHTING 1x1000W-HAL 5002591

14.25.31.02.00 1 ST FLOOD LIGHT 1627792


14.25.31.03.00 1 ST HALOGENLAMP 0625145
14.25.31.05.00 2 ST SCREW BUSH 1624414
14.25.31.06.00 2 ST GASKET FOR CABLE GLAND 5002076
14.25.31.08.00 2 ST HEXAGON SCREW 1683991
14.25.31.09.00 2 ST HEXAGON NUT 1683743
14.25.31.10.00 2 ST CONTACT WASHER 2079812

ASSEMBLY GROUP 14.25.31.00.00

SPARE PARTS LIST


ORDER NO. 5 002 602-00
DESCRIPTION: EMERGENCY STOP FROM DECK AREA

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

14.25.50.00.00 1 ST EMERGENCY STOP FROM DECK AREA 5002602

14.25.50.01.00 1 ST EMERGENCY SWITCH 5002584


14.25.50.02.00 2 ST CAP-SCREW 0064152
14.25.50.03.00 2 ST HEXAGON NUT 0084669
14.25.50.04.00 1 ST CABLE UNIT 4236260

ASSEMBLY GROUP 14.25.50.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 282-00
DESCRIPTION: AGGREGATE MODULE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.00.00.00.00 1 ST AGGREGATE MODULE 5005282

15.01.00.00.00 1 ST INSTALL.SCAFFOLD INCL.TANK COMPL. 5005150


15.25.00.00.00 1 ST E-SYSTEM AGGREGATE MODULE 5002592
15.66.00.00.00 1 ST HYDR. SYSTEM AGGREGATE MODULE 5005281

ASSEMBLY GROUP 15.00.00.00.00

SPARE PARTS LIST


ORDER NO. 5 002 592-00
DESCRIPTION: E-SYSTEM AGGREGATE MODULE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.00.00.00 1 ST E-SYSTEM AGGREGATE MODULE 5002592

15.25.03.00.00 1 ST LIGHTING 220V/60HZ 5002109


15.25.10.00.00 1 ST PUMP DRIVE UNIT 5002593
15.25.15.00.00 1 ST LIMIT SWITCH FOR WINCHES 5002495
15.25.50.00.00 1 ST CONTROL CABINET 5002595
15.25.60.00.00 1 ST WORKSHOP INSTALLATION 5002598

ASSEMBLY GROUP 15.25.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 109-01
DESCRIPTION: LIGHTING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.03.00.00 1 ST LIGHTING 220V / 60Hz 5002109

15.25.03.01.00 1 ST LAMP 2010837


15.25.03.03.00 1 ST FLUORESCENT LAMP 0058132
15.25.03.04.00 1 ST CONTACT BREAKER 1608349
15.25.03.05.00 2 ST SCREW BUSH 1624414
15.25.03.16.00 2 ST HEX.NUT 0650234
15.25.03.17.00 2 ST CONTACT WASHER 2079808
15.25.03.18.00 2 ST HEX-SCREW 1683943
15.25.03.19.00 1 ST PLUG 1627280

ASSEMBLY GROUP 15.25.03.00.00

SPARE PARTS LIST


ORDER NO. 5 002 593-00
DESCRIPTION: PUMP DRIVE UNIT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.10.00.00 1 ST PUMP DRIVE UNIT 5002593

15.25.10.01.00 1 ST DS-MOTOR 160KW 5002027


SEE SUBSUPPLIER
ASSEMBLY GROUP 15.15.10.01
15.25.10.60.00 1 ST INSTALLATION POWER PACK 5002594

ASSEMBLY GROUP 15.25.10.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

E-MOTOR

PART-NO.: 5 002 027

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR

L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 594-00
DESCRIPTION: INSTALLATION POWER PACK

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.10.60.00 1 ST INSTALLATION POWER PACK 5002594

15.25.10.60.01 1 ST COMPACTMODULE CR203 – ID01 5002203


15.25.10.60.02 1 ST ANALOG MODULE CR2033 – ID03 5002204
15.25.10.60.03 1 ST COMPACT MODULE PWM – ID02 5002256
15.25.10.60.04 2 ST CABLE CAN-BUS M12/M12-0,3m 4243111
15.25.10.60.05 1 ST PLUG-RESISTOR M12-120R 4243112
15.25.10.60.06 4 ST CABLE 5002038
15.25.10.60.07 6 ST CABLE M12/DIN A - CURRENT 4243444
15.25.10.60.08 5 ST CABLE PLUG M12-2m 4243115
15.25.10.60.09 3 ST CONNECT CABLE 5002116 5002116
15.25.10.60.10 2 ST PRESSURE TRANSMITTER TYP HT-PD 5002117
15.25.10.60.11 2 ST UNIT 0625701
15.25.10.60.12 1 ST TEMPERATURETRANSMITTER - 5002118
50/+200°C
15.25.10.60.13 1 ST ADAPTOR ISO 228-G 1/4 5002119
15.25.10.60.14 10 ST FLACHSTECKHUELSE 6,3-1 NR 2079546
15.25.10.60.15 40 ST CABLE STRAP 1660206
15.25.10.60.20 12 ST CYLINDRICAL SCREW 1350451
15.25.10.60.21 12 ST NUT 1676821
15.25.10.60.22 12 ST SL-WASHER 0725726

ASSEMBLY GROUP 15.25.10.60.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 495-00
DESCRIPTION: LIMIT SWITCH FOR WINCHES

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.15.00.00 1 ST LIMIT SWITCH FOR WINCHES 5002495

15.25.15.01.00 2 ST LIMIT SWITCH 5002244


15.25.15.10.00 14 M LTG.-OELFLEX 140 CY D=16,1 5002412
15.25.15.11.00 6 ST HEXAGON-SCREW 0840883
15.25.15.12.00 6 ST SPRING RING 3398003
15.25.15.13.00 2 ST BLIND GASKET 4236998

ASSEMBLY GROUP 15.25.15.00.00

SPARE PARTS LIST


ORDER NO. 5 002 595-00
DESCRIPTION: CONTROLL CABINET

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.01.00 1 PC CABINET 5002595

15.25.50.01.00 1 PC CABINET 5002052


15.25.50.02.00 1 PC EQUIPMENT PART = M01 5002596
15.25.50.03.00 1 PC EQUIPMENT PART = MO2 5002693
15.25.50.04.00 1 PC EQUIPMENT PART = MO3 5002597
15.25.50.05.00 1 PC EQUIPMENT PART = MO6 5002373
15.25.50.06.00 1 PC STANDARD INSTALLATION 5002379
15.25.50.80.00 1 PC PMS – SYSTEM 5002353

ASSEMBLY GROUP 15.25.50.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 052-01
DESCRIPTION: CABINET

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.01.00 1 ST CABINET 1800x600x300 5002052

15.25.50.01.01 1 ST CABINET SERIE 5002053


15.25.50.01.02 1 ST LOCK LINK 5002054
15.25.50.01.03 1 ST DOOR CATCH 5002055
15.25.50.01.05 10 ST SREW 5002057

ASSEMBLY GROUP 15.25.50.01.00

SPARE PARTS LIST


ORDER NO. 5 002 596-00
DESCRIPTION: EQUIPMENT PART =M01

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.02.00 1 ST EQUIPMENT PART =M01 5002596

15.25.50.02.01 1 PC LOAD BREAKER 5002251


15.25.50.02.02 1 PC LOAD BREAK SWITCH T3-1 2381873
15.25.50.02.03 1 PC CAP 2381874
15.25.50.02.10 1 PC TRIPLE POLE FUSED ISOLATOR 1608376
15.25.50.02.11 3 PC FUSE LINK 1608405
15.25.50.02.12 3 PC FITTING SLEEVE D02/35 1608403
15.25.50.02.13 2 PC MOTOR OVERLOAD PROTECTOR 2544253
15.25.50.02.14 1 PC MOTOR CIRCUIT BREAKER 2544252
15.25.50.02.15 6 M WIRE 1608435
15.25.50.02.16 3 M CABLE 5002431
15.25.50.02.17 2 PC TERMINAL PROTECTIVE COND 1791281
15.25.50.02.18 1 PC TERMINAL PROTECTIVE COND 1791283
15.25.50.02.30 1 PC CONTACTOR 5002582
15.25.50.02.31 7 PC FUSE TERMINAL W.LED 2535436
15.25.50.02.32 1 PC PLATE 2535437
15.25.50.02.33 4 PC SIDE ANGLE 1791302
15.25.50.02.34 6 PC TERMINAL CLIP 1791285
15.25.50.02.35 1 PC TITLE CARD 1667814
15.25.50.02.36 2 PC FUSE CARTRIDGE C 3 2533904
15.25.50.02.37 5 PC FUSE CARTRIDGE C 7,5 4510378
15.25.50.02.40 1 PC PLATE 2350685
15.25.50.02.41 1 PC PLATE 2350684

ASSEMBLY GROUP 15.25.50.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 693-00
DESCRIPTION: EQUIPMENT PART =M02

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.03.00 1 ST EQUIPMENT PART =M02 5002693

15.25.50.03.01 1 ST CONNECTOR 4226209


15.25.50.03.03 2 ST CLEMPINGBLOCK 4236664
15.25.50.03.05 1 ST CONNECTOR DILM150-22 RAC 440 5002377
15.25.50.03.07 1 ST STARPOINT BAR DILM150-XS1 284768 5002378
15.25.50.03.08 1 ST CURRENT-CONVERTER 2368074
15.25.50.03.09 2 M CABLE NSGAF 1637432
15.25.50.03.10 1 ST CONTACTOR DIL9-10 5002084
15.25.50.03.11 1 ST CONTACTOR DIL25-10 5002085
15.25.50.03.19 1 ST SUPPLY TERMINAL BK25/3-PKZ0 5002517
15.25.50.03.20 1 ST PROTECTION SWITCH PKZM 0-6,3 2546539
15.25.50.03.21 1 ST PROTECTION SWITCH PKZM 0-20 2546542
15.25.50.03.22 1 ST 3-PHASE BAND 2544249
15.25.50.03.23 2 ST AUXILIARY SWITCH NH/11-PKZM0 2544250
15.25.50.03.24 1 ST TIME RELAY-DELTA STAR TE 2088712
15.25.50.03.25 1 ST THERMAL RELAY MS 220 2094520
15.25.50.03.30 6 ST TERMINAL GR. 282-601 1791281
15.25.50.03.31 2 ST TERMINAL PROTECTIVE COND. 1791283
15.25.50.03.32 1 ST SIDE PLATE 1791284
15.25.50.03.33 2 ST SIDE ANGL 1791302
15.25.50.03.34 1 ST PLATE HOLDER 1667815

ASSEMBLY GROUP 15.25.50.03.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 597-00
DESCRIPTION: EQUIPMEMT PART =M03

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.04.00 1 ST EQUIPMENT PART =M03 5002597

15.25.50.04.01 8 ST CIRCUIT BREAKER 5002000


15.25.50.04.03 1 ST BUS BAR PS2/12 5002008
15.25.50.04.04 2 ST END CAP PS-END 5002010
15.25.50.04.05 1 ST CONTACTOR 5002010
15.25.50.04.06 2 ST FIELD RELAY 5002352
15.25.50.04.11 20 ST FILTER VENTILATOR 2532331
15.25.50.04.13 1 ST TEMPERATURE CONTROLLER 1740773
15.25.50.04.14 1 ST HEATING FLH 2094564
15.25.50.04.20 2 ST PC TERMINAL 1666904
15.25.50.04.21 1 ST FINAL PLATE 1666905
15.25.50.04.22 23 ST TERMINAL 1666916
15.25.50.04.23 1 ST FINAL PLATE 1666917
15.25.50.04.24 20 ST TERMINAL CLIP 1791265
15.25.50.04.25 4 ST WIRE CLIP 1676951
15.25.50.04.26 1 ST PLATE HOLDER 1667815
15.25.50.04.28 30 M LINE UL 1015-AWG16SW 1656359
15.25.50.04.29 2 ST CABLE THIMBLE 1637542

ASSEMBLY GROUP 15.25.50.04.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 373-00
DESCRIPTION: EQUIPMENT PART =M06

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.05.00 1 ST EQUIPMENT PART =M06 5002373

15.25.50.05.01 1 ST CONTROLLER R360 5002196


15.25.50.05.02 1 ST CABLE CONNECTOR 4243437
15.25.50.05.03. 1 ST BUSH STRIP 4228649
15.25.50.05.10. 75 ST TERMINAL GR. 3 LADDER 280-641 1791266
15.25.50.05.11. 1 ST SIDE PLATE GR. 280-312 1791269
15.25.50.05.12. 30 ST TERMINAL CLIP 1791265
15.25.50.05.14. 2 ST SIDE ANGLE 209-101 1791302
15.25.50.05.15. 1 ST PLATE HOLDER 209-112 1667815
15.25.50.05.17. 1 ST BAR FOR SCREEN CLAMP 790-115 5002088
15.25.50.05.18. 3 ST SCREEN-CLAMP 790-108 5002089
15.25.50.05.19. 1 ST SCREEN-CLAMP 790-116 5002090

ASSEMBLY GROUP 15.25.50.05.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 379-00
DESCRIPTION: STANDARD INSTALLATIONS
ASSEMBLY MATERIAL DRAWING
GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.06.00. 1 ST STANDARD INSTALLATIONS 5002379

15.25.50.06.01 4 ST HEX-SCREW 7121363


15.25.50.06.02 4 ST CONTACT WASHER 8 2079808
15.25.50.06.04 4 ST CYL-SCREW 1683926
15.25.50.06.05 4 ST HEX.SCREW 1683940
15.25.50.06.06 4 ST HEX-SCREW 7121112
15.25.50.06.07 10 ST HEX-SCREW 1683937
15.25.50.06.08 40 ST COUNTER SUNK SCREW 6705038
15.25.50.06.10 8 ST HEX.NUT 1683741
15.25.50.06.11 12 ST WASHER 1684578
15.25.50.06.12 30 ST CONTACT WASHER 2079806
15.25.50.06.15 30 ST HEX.-SCREW 1652159
15.25.50.06.16 4 ST CAP.SCREW 1059010
15.25.50.06.17 6 ST HEX-SCREW 0063275
15.25.50.06.18 8 ST CONTACT WASHER 2079805
15.25.50.06.19 6 ST NUT 1652515
15.25.50.06.20 4 ST SUNK SCREW 1683729
15.25.50.06.21 8 ST CYL-SCREW 1683913
15.25.50.06.24 8 ST HEX-NUT 1683740
15.25.50.06.25 12 ST SL-WASHER 0725726
15.25.50.06.26 12 ST WASHER 1684548
15.25.50.06.30 20 ST SCREW 2088718
15.25.50.06.31 1 M CABLE HOSE 2031738
15.25.50.06.32 1 ST HOLDER CABLE HOSE 2031739
15.25.50.06.33 1 M CABLE HOSE 1676983
15.25.50.06.34 1 ST HOLDER CABLE HOSE 1676984
15.25.50.06.36 1 ST PLATE-CONTRO 2078572 2078572
15.25.50.06.37 1 ST PLATE - WARNING 1686093 1686093
15.25.50.06.40 2 M PROFILRAIL 1652510
15.25.50.06.41 4 M CARRIER RAIL 1080033
15.25.50.06.42 2 M CABLE DUCT 1657271
15.25.50.06.43 1 M CABLE DUCT 1657370
15.25.50.06.44 2 M CABLE DUCT 1657369
15.25.50.06.45 1 M CABLE DUCT 2079527
15.25.50.06.50 1 ST EARTHING STRIP 1652483
15.25.50.06.51 5 M LINE H07V-K4-GNGE 0337832
15.25.50.06.52 10 M LINE 1654809
15.25.50.06.53 10 M ISO. WIRE 2010796
15.25.50.06.54 20 M LINE UL 1656359
15.25.50.06.55 5 M LINE UL 1654810
15.25.50.06.56 5 M LINE UL 1656358
15.25.50.06.57 3 M LINE UL 1657410
15.25.50.06.58 50 M LINE UL 1656357
15.25.50.06.60 2 ST TITLE CARD 1666929
15.25.50.06.61 1 ST TITLE CARD 1666930

ASSEMBLY GROUP 18.25.50.06.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 353-00
DESCRIPTION: PMS - SYSTEM

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.50.80.00 1 ST PMS - SYSTEM 5002353

15.25.50.80.01 1 ST FIELED RELAY 4236676


15.25.50.80.02 1 ST FIELED RELAY 5002352
15.25.50.80.03 4 ST TERMINAL 1791266
15.25.50.80.04 5 M LINE 1656357
15.25.50.80.05 2 M LINE 1656359

ASSEMBLY GROUP 15.25.50.80.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 598-00
DESCRIPTION: WORKSHOP INSTALLATION

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.25.60.00.00 1 ST WORKSHOP INSTALLATION 5002598

15.25.60.01.00 100 M CABLE IEC 60092 (L)M2XH 1x70 5002063


15.25.60.02.00 10 M CABLE IEC 60092 (L)M2XH 2x6 5002065
15.25.60.03.00 18 M CABLE IEC 60092 (L)M2XH-J 4x2,5 5002068
15.25.60.05.00 100 M CABLE IEC 60092 (L)M2XH-J 3x1,5 5002066
15.25.60.06.00 26 M CABLE IEC 60092 (L)M2XH-J 5x1,5 5002069
15.25.60.07.00 7 M CABLE IEC 60092 (L)M2XH-J 7x1,5 5002070
15.25.60.08.00 6 M CABLE H07V-K16-GNGE 0625070
15.25.60.10.00 7 M CABLE-QUATTRO 2X1,5 5002121
15.25.60.11.00 14 M CABLE UNITRONIC BUS CAN 2x2x0,75 5002413
D=12,
15.25.60.12.00 40 M CABLE 3X1,0 1655148
15.25.60.13.00 3 M CABLE H07RN-F4G1,5 0725174
15.25.60.20.00 3 M SHRINK TUBE 5002128
15.25.60.22.00 1 ST SHRINK HOSE BLACK -HSB 1000-0 1655414
15.25.60.23.00 1 ST CABLE UNIT 4236259
15.25.60.24.00 2 ST CABLE UNIT 4236260
15.25.60.25.00 2 ST CONDUIT BUSHING 1360536
15.25.60.26.00 1 M EDGE PROTECTION 4610027 0597527
15.25.60.30.00 7 ST CABLE THIMBLE 0215244
15.25.60.31.00 9 ST CABLE SHOE 10-70 0216411
15.25.60.32.00 2 ST CABLE THIMBLE 10-16 0511001
15.25.60.33.00 1 ST CABLE THIMBLE 12-16 0146964
15.25.60.34.00 1 ST CABLE THIMBLE 6-16 0771645
15.25.60.35.00 8 ST CABLE SHOE 6-2,5 0038663
15.25.60.36.00 5 ST CABLE SHOE 5-2,5 0039087
15.25.60.40.00 2 M CABLE TRAM TYP 20 920/15/100 NR 0158339
15.25.60.41.00 4 M CABLE RAIL 1660239
15.25.60.42.00 20 ST CABLE TRAY NUT M10 NR. 110199 2012404 2012404
15.25.60.50.00 2 ST HEXAGON - NUT 1683743
15.25.60.51.00 2 ST CONTACT WASHER 2079812
15.25.60.52.00 1 ST HEXAGON SCREW 1683949
15.25.60.53.00 5 ST HEXAGON - NUT 1683742
15.25.60.54.00 4 ST CONTACT WASHER 2079810
15.25.60.55.00 1 ST CYLINDRICAL SCREW 1683921
15.25.60.56.00 2 ST HEXAGON - NUT 8476065
15.25.60.57.00 2 ST CONTACT WASHER 2079805
15.25.60.60.00 5 ST CABLE JOINT 5002310
15.25.60.61.00 8 ST STEEL CABLE JOINT 5002309
15.25.60.62.00 50 ST CABLE TIE 1624720
15.25.60.63.00 40 ST CABLE STRAP 1660206

ASSEMBLY GROUP 15.25.60.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 281-00
DESCRIPTION: HYDRAULIC SYSTEM AGGREGATE MODULE

DRAWIN
ASSEMBLY MATERIAL G
GROUP QTY QC DESCRIPTION NO. NO.

15.66.00.00.00 1 ST HYDRAULIC SYSTEM AGGREGATE MODULE 5005281

15.66.01.00.00 1 ST HYDRAULIC AGGREGATE COMPL 5005266


15.66.20.00.00 1 ST HYDRAULICTANK EQUIPMENT 5005657 5005657
15.66.21.00.00 1 ST PUMPAGGREGAT 5001106 5001106

ASSEMBLY GROUP 15.66.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 266-00
DESCRIPTION: HYDRAULIC AGGREGATE COMPL

DRAWIN
ASSEMBLY MATERIAL G
GROUP QTY QC DESCRIPTION NO. NO.

15.66.01.00.00 1 ST HYDRAULIC AGGREGATE COMPL. 5005266

15.66.01.01.00 1 ST DISTRIBUTION GEAR I = 0,65 5005266 5005266


15.66.01.02.00 1 ST FASTENING PARTS F. DISTRIBUTION GEAR 2093380 2093380
15.66.01.03.00 3 ST DAMPER 2067961 2067961
15.66.01.04.00 1 ST HYDRAULIC POWER UNIT 5004001 5004001

ASSEMBLY GROUP 15.66.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 264-00
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

ASSEMBLY GROUP 15.66.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SARE PARTS LIST


ORDER NO. 5 005 264-00
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.01.01.00 1 ST DISTRIBUTION GEAR I=0,65(440V-60HZ) 5005264 5005264

15.66.01.01.01 1 ST GEAR BOX 4221626 4221626


15.66.01.01.02 1 ST COVER 4221628 4221628
15.66.01.01.03 1 ST SPUR WHEEL Z-66 MN-3,5 Z-66 Mn-3,5 4221591 4221591
15.66.01.01.04 3 ST SPUR WHEEL Z-43 MN-3,5 Z-43 Mn-3,5 4221593 4221593
15.66.01.01.05 3 ST HOLLOW SHAFT 4221598 4221598
15.66.01.01.06 3 ST WAVE DISK 4221595 4221595
15.66.01.01.07 1 ST WAVE DISK 4221594 4221594
15.66.01.01.08 3 ST CENTER BUSHING 4221596 4221596
15.66.01.01.09 1 ST SPACER 4221597 4221597
15.66.01.01.10 1 ST O-RING 4228224
15.66.01.01.11 3 ST O-RING 4228223
15.66.01.01.12 1 ST O-RING 4228240
15.66.01.01.13 1 ST O-RING 0460685
15.66.01.01.14 3 ST O-RING 0830401
15.66.01.01.15 1 ST V-RING 0750367
15.66.01.01.16 1 ST OIL SIGHT GLAS 1655840
15.66.01.01.17 9 ST STUD BOLT 4221684 4221684
15.66.01.01.18 12 ST STUD BOLT 4221685 4221685
15.66.01.01.19 1 ST HEXAGON SCREW 0074188
15.66.01.01.20 3 ST HEXAGON SCREW 0056638
15.66.01.01.21 21 ST HEXAGON NUT 0011597
15.66.01.01.22 21 ST WASHER 0305773
15.66.01.01.23 1 ST LOCKING BOLT DISK 4228235
15.66.01.01.24 3 ST LOCKING BOLT DISK 2535252
15.66.01.01.25 4 ST SPRING-PIN 0054166

ASSEMBLY GROUP 15.66.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 093 380-00
DESCRIPTION: FASTENING PARTS F. DISTRIBUTION GEAR

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.01.02.00 1 ST FASTENING PARTS F. DISTRIBUTION GEAR 2093380 2093380

15.66.01.02.01 1 ST AIR FILTER 0029493


15.66.01.02.02 1 ST UNION 0982729
15.66.01.02.03 1 ST SCREWING 0033589
15.66.01.02.04 1 M PIPE 0065184
15.66.01.02.06 8 ST WASHER 0056993
15.66.01.02.07 8 ST HEXAGON SCREW 0056683

ASSEMBLY GROUP 15.66.01.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 067 961-01
DESCRIPTION: DAMPER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.01.03.00 3 ST DAMPER 2067961 2067961

15.66.01.03.02 2 ST BUFFER 65SHORE 2067983 2067983


15.66.01.03.09 1 ST HEXAGON SCREW 7120794
15.66.01.03.10 1 ST HEXAGON NUT 0032975
15.66.01.03.11 1 ST HEXAGON NUT 1673943
15.66.01.03.12 2 ST WASHER 0152174
15.66.01.03.14 1 ST WASHER 0034624

ASSEMBLY GROUP 15.66.01.03.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 004 001-00
DESCRIPTION: HYDRAULIC-AGGREGATE

ASSEMBLY GROUP 15.66.01.04.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 004 001-00
DESCRIPTION: HYDRAULIC-AGGREGATE

ASSEMBLY QTY QC DESCRIPTION MATERIAL DRAWING


GROUP NO. NO.

15.66.01.04.00 1 ST HYDRAULIC AGGREGATE 5004001 5004001

15.66.01.04.01 2 ST VARIABLE DISPLACEMENT PUMP 2376155


A4V G125
SEE SUBSUPPLIER
ASSEMBLY 15.66.01.04.01
15.66.01.04.03 1 ST VARIABLE DISPLACEMENT PUMP 2376174
A4V G125
SEE SUBSUPPLIER
ASSEMBLY 01.66.04.04.03
15.66.01.04.04 4 ST PRESSURE SWITCH 1652151
15.66.01.04.16 9 ST SHEET STEEL SIGN 0303742
15.66.01.04.19 3 ST MEASURING CONNECTION 1709799
15.66.01.04.30 6 ST TRANSITION PIECE 1665757
15.66.01.04.31 6 ST UNION 1636006
15.66.01.04.34 6 ST UNION 8411057
15.66.01.04.35 1 ST UNION 1665749
15.66.01.04.36 1 ST UNION 0304986
15.66.01.04.38 2 ST UNION 1637351
15.66.01.04.41 3 ST UNION 1331029
15.66.01.04.42 9 ST CABLE CLAMP 0661868
15.66.01.04.53 4 ST RUBBER CAP 0625431
15.66.01.04.55 24 ST SAE-FLANGE HALF 0625571
15.66.01.04.63 6 ST SEALING RING 1725419
15.66.01.04.64 6 ST MEASURING SOCKE 0310324 310324
15.66.01.04.65 1 ST UNION 1331028
15.66.01.04.81 48 ST CAP – SCREW 0861764
15.66.01.04.82 2 ST UNION 0153812
15.66.01.04.85 6 ST LOCK SCREW 1406392
15.66.01.04.87 6 ST SAE-ELBOW 2072550 2072550

ASSEMBLY GROUP 15.66.01.04.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

VAR. DISPL. PUMP


A4VG 125

PART-NO.: 2 376 155

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 2 376 155
DESCRIPTION: VAR. DISPL. PUMP A4VG125

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 2 376 155
DESCRIPTION: VAR. DISPL. PUMP A4VG125

POS. ORDER-NO. DESCRIPTION QUANTITY

2 376 155 VAR. DIPL. PUMP A4VG125 ( 02061001* ) 1 ST L

1 09607937* ROTARY GROUP 1 ST L


2 02012015* CONTROL HYDR. 1 ST L
3 09609518* PORT PLATE WITH VALVES 1 ST L
4 02006333* PUMP CARRIER 1 ST L
5 02052862* CONTROL MODULE 1 ST L
10 02015532* HOUSING 1 ST
13 09435016* JOINT PIN 2 ST
14 09405732* DOWEL ÜIN 1 ST
20 01408251 LOCKING SCREW 140NM 1 ST D
21 01412651 LOCKING SCREW 40NM 1 ST D
22 01403308 LOCKING SCREW 35NM 3 ST D
24 09083229* LOCKING SCREW 1 ST D
25 08476823 O-RING 1 ST D
26 00031484 LOCKING SCREW 3NM 1 ST D
28 09426700* ORIFICE 12NM 2 ST D
31 09154427* CLAMPING PIN 2 ST
32 00970659 LOCKING SCREW 20NM 4 ST D
33 01408251 LOCKING SCREW 140NM 3 ST D
35 01637351 LOCKING SCREW 10NM 2 ST D
37 09156570* LOCKING SCREW 26NM 1 ST
39 09153459* LOCKING SCREW 300NM 1 ST D
46 09154982* THREADED PIN 1 ST D
47 09087405* SEAL-LOCK-NUT 1 ST D
48 00945328 LOCKING SCREW 60NM 1 ST D
49 09426707* ORIFICE 12NM 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09607937*
DESCRIPTION: ROTARY GROUP

POS. ORDER-NO. DESCRIPTION QUANTITY

09607927* ROTARY GROUP 1 ST L

1 02040556* CYLINDER WITH CONTROL PLATE 1 ST


2 09428131* PISTON-SLIPPER PAD 9 ST
11 09921720* CUP-SPRING STACK 1 ST
12 09445122* CRADLE 1 ST
13 09449034* SLIDE RING 1 ST
14 09921000* DRIVE SHAFT 1 ST
17 09421418* WIRE 2 ST
20 09432505* SHIM 1 ST
20 09432506* SHIM 1 ST
20 09432507* SHIM 1 ST
20 09432508* SHIM 1 ST
24 09921719* RETAINING RING 1 ST
25 09432264* RETAINING BALL 1 ST
26 02066594* BEARING LINER ( PAIR ) 1 ST
27 09921717* WASHER 2 ST
29 09435465* PRESSURE SPRING 1 ST
31 09156269* PLAIN ROLLER BEARING 1 ST
32 09830578* CRADLE BEARING ASSEMBLY ( SET ) 1 ST
36 00012491 RETAINING RING 1 ST
37 02600002* RETAINING RING 2 ST
38 01476328 SHAFT SEAL RING 1 ST D
41 09083405* RETAINING RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02012015*
DESCRIPTION: CONTROL HYDRAULIC

POS. ORDER-NO. DESCRIPTION QUANTITY

02012015* CONTROL HYDRAULIC 1 ST L

1 02025586* POSITIONING PISTON 1 ST L


3 02010745* COVER 1 ST
4 02010746* COVER 1 ST
16 09157477* HEXAGON NUT 1 ST
17 00515285 SOCKET HEAD SCREW 25NM 8 ST
20 09085360* O-RING 2 ST D
21 09432790* THREADED PIN 2 ST
22 01401644 SEAL-LOCK-NUT 69NM 2 ST D
30 02600839* GUIDE RING 2 ST
31 02600272* TURCON-GLYD-RING 2 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02025586*
DESCRIPTION: CONTROL HYDRAULIC

POS. ORDER-NO. DESCRIPTION QUANTITY

02025586* CONTROL HYDRAULIC 1 ST L

1 02010570* POSITIONING PISTON 1 ST


2 09449241* ROD 1 ST
5 02020493* RING 2 ST
5 02020494* RING 2 ST
5 02020495* RING 2 ST
5 02020496* RING 2 ST
5 02020497* RING 2 ST
5 02020498* RING 2 ST
5 02029756* RING 2 ST
5 02029757* RING 2 ST
5 02043149* RING 2 ST
6 02600767* ASSEMBLY RING 2 ST
7 09652048* SPRING COLLAR 2 ST
9 09435004* PRESSURE SPRING 2 ST
10 09435005* PRESSURE SPRING 2 ST
15 00012517 RETAINING RING 2 ST
19 01402905 O-RING 1 ST D
23 09449252* SPRING COLLAR 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09609518*
DESCRIPTION: PORT PLATE WITH VALVES

POS. ORDER-NO. DESCRIPTION QUANTITY

09609518* PORT PLATE WITH VALVES 1 ST L

1 02601879* MHDBN32K2 1 ST L
2 09434856* PRESSURE RELIEF VALVE 1 ST L
3 09433834* PRESSURE OVERRIDE VALVE 1 ST L
4 02019663* PRESSURE RELIEF VALVE 1 ST L
5 09651090* PORT PLATE 1 ST
7 00945233 SOCKET HEAD SCREW 310NM 4 ST
9 09830217* O-RING 1 ST D
11 09831320* DOUBLE BREAK-OFF PIN 1 ST D
13 09154024* LOCKING SCREW 5NM 4 ST D
26 01402905 O-RING 2 ST D
35 00970659 LOCKING SCREW 20NM 3 ST D
43 09432774* BUSH 1 ST
44 09432773* BEARING BUSH 1 ST
48 09831319* DOUBLE BREAK-OFF PIN 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02601879*
DESCRIPTION: MHDBN32K2

POS. ORDER-NO. DESCRIPTION QUANTITY

02601879* MHDBN32K2 1 ST L

1 02600124* SEAL KIT 1 ST D


2 09157895* CAP 1 ST D

SPARE PARTS LIST


ORDER NO.: 09434856*
DESCRIPTION: PRESSURE RELIEF VALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

09434856* PRESSURE RELIEF VALVE 1 ST L

1 09436167* LOCKING SCREW 1 ST


2 09449622* ADJUSTING SCREW 1 ST
3 09435899* VALVE PISTON 1 ST
4 02010336* SPRING COLLAR 1 ST
5 09440765* PRESSURE SPRING 1 ST
8 00971901 O-RING 1 ST D
9 01412648 SEAL-LOCK-NUT 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09433834*
DESCRIPTION: PRESSURE OVERRIDE VALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

09433834* PRESSURE OVERRIDE VALVE 1 ST L

1 09432376* LOCKING SCREW 1 ST


2 09426552* VALVE BUSHING 1 ST
3 09432301* CONTROL PISTON 1 ST
4 09432163* PISTON 1 ST
5 09432164* VALVE PISTON 1 ST
6 09432775* POPPET SEAT 1 ST
7 02009402* PRESSURE SPRING 1 ST
8 02043092* SPRING COLLAR 2 ST
9 09432167* ADJUSTING SCREW 1 ST
10 00200485 O-RING 1 ST D
14 00764416 SEAL-LOCK-NUT 22NM 1 ST D
15 00146186 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02019663*
DESCRIPTION: PRESSURE RELÖIEFVALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

02019663* PRESSURE RELÖIEFVALVE 1 ST L

1 09436266* VALVE BUSHING 1 ST


2 09409929* PISTON 1 ST
3 09409818* VALVE PISTON 1 ST
4 09409819* GUIDE BUSHING 1 ST
5 09002455* PLUG 1 ST
6 09424759* SPRING COLLAR 1 ST
7 09409821* SPRING COLLAR 1 ST
8 09409822* LOCKING BOLT 1 ST
9 09409930* LOCKING SREW 1 ST
11 09150369* SHIM 1 ST
11 09153402* SHIM 1 ST
12 02019623* PRESSURE SPRING 1 ST
13 09409931* PRESSURE SPRING 1 ST
17 00950467 O-RING 1 ST D
18 00950467 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09606333*
DESCRIPTION: PUMP COVER

POS. ORDER-NO. DESCRIPTION QUANTITY

09606333* PUMP COVER 1 ST L

1 09434017* PUMP COVER 1 ST L


2 09650693* WEAR PLATE 1 ST L

SPARE PARTS LIST


ORDER NO.: 09434017*
DESCRIPTION: PUMP COVER

POS. ORDER-NO. DESCRIPTION QUANTITY

09434017* PUMP VOVER 1 ST L

1 09650695* PUMP COVER 1 ST


6 09083206* SOCKET HEAD SREW 4 ST
7 04226837 O-RING 1 ST D
8 01435609 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09650693*
DESCRIPTION: WEAR PLATE

POS. ORDER-NO. DESCRIPTION QUANTITY

09650693* WEAR PLATE 1 ST L

1 09650692* WEAR PLATE 1 ST


2 04226837 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02052862*
DESCRIPTION: CONTROL MODULE

POS. ORDER-NO. DESCRIPTION QUANTITY

02052862* CONTROL MODULE 1 ST L

1 02048768* CONTROL MODULE 1 ST L


3 09443201* COVER 1 ST
4 02063327* DRAW SPRING 1 ST
5 09651478* GASKET 1 ST D
6 02046037* PICKUP RING 2 ST
8 09083183* SOCKET HAED SCREW 8 ST
9 09085831* SOCKET HEAD SCREW 10,4NM 4 ST
10 02600641* O-RING 1 ST D
12 01437359 O-RING 3 ST D
13 02601860* SOLENOID VALVE 2 ST L
15 01402905 O-RING 2 ST
16 00146186 O-RING 1 ST D
17 09083764* O-RING 2 ST D
18 02601640* SPRING COLLAR 2 ST D
19 00765885 PLUG BOX 1 ST
20 01412646 PLUG BOX 1 ST
30 09087338* CYLINDRICAL PIN 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02048768*
DESCRIPTION: CONTROL MODULE

POS. ORDER-NO. DESCRIPTION QUANTITY

02048768* CONTROL MODULE 1 ST L

1 02067240* CONTROL HOUSING WITH ACCESSOR. 1 ST L


5 02061843* TUNER 1 ST
6 02067213* WASHER 1 ST
6 02067214* WASHER 1 ST
6 02067215* WASHER 1 ST
6 02067216* WASHER 1 ST
6 02067217* WASHER 1 ST
6 02067218* WASHER 1 ST
6 02067219* WASHER 1 ST
6 02067220* WASHER 1 ST
6 02070232* WASHER 1 ST
22 09087453* NEEDLE ROLLER 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02067240*
DESCRIPTION: CONTROL HOUSING WITH ACCESSOR.

POS. ORDER-NO. DESCRIPTION QUANTITY

02067240* CONTROL HOUSING WITH ACCESSOR. 1 ST L

1 02068232* HOUSING 1 ST
3 02067221* CONTROL PISTON WITH CYLINDRICAL PIN 1 ST
4 02050396* LEVER 2 ST
6 02067212* EXENTRIC PIN 1 ST
8 02044854* WASHER 1 ST
21 00219041 SOCKET HEAD SCREW 10,4NM 2 ST D
24 02601243* SOCKET HEAD SCREW 6,1NM 1 ST D
28 09831320* DOUBLE BREAK-OFF PIN 1 ST D
29 09153668* O-RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

VAR. DISPL. PUMP


A4VG 125

PART-NO.: 2 376 174

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 2 376 174
DESCRIPTION: VAR. DISPL. PUMP A4VG125

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 2 376 174
DESCRIPTION: VAR. DISPL. PUMP A4VG125

POS. ORDER-NO. DESCRIPTION QUANTITY


2 376 174 VAR. DISPL. PUMP A4VG 125 ( 02059896* ) 1 STL
1 09607937* ROTARY GROUP 1 STL
2 02012015* CONTROL HYDR.. 1 STL
3 09609517* PORT PLATE WITH VALVES 1 STL
4 02006333* PUMP CARRIER 1 STL
5 02052862* CONTROL MODULE 1 STL
10 02015532* HOUSING 1 ST
13 09435016* JOINT PIN 2 ST
14 09405732* DOWEL PIN 1 ST
20 01408251 LOCKING SCREW 140NM 1 STD
21 01412651 LOCKING SCREW 40NM 1 STD
22 01403308 LOCKING SCREW 35NM 3 STD
24 09083229* LOCKING SCREW 1 STD
25 08476823 O-RING 1 STD
26 00031484 LOCKING SCREW 3NM 1 STD
28 09426700* ORIFICE 12NM 2 STD
31 09154427* CLAMPING PIN 2 ST
32 00970659 LOCKING SCREW 20NM 4 STD
33 01408251 LOCKING SCREW 140NM 3 STD
35 01637351 LOCKING SCREW 10NM 2 STD
37 09156570* LOCKING SCREW 26NM 1 ST
39 09153459* LOCKING SCREW 300NM 1 STD
46 09154982* THREADED PIN 1 STD
47 09087405* SEAL-LOCK-NUT 1 STD
48 00945328 LOCKING SCREW 60NM 1 STD
49 09426707* ORIFICE 12NM 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09607937*
DESCRIPTION: ROTARY GROUP

POS. ORDER-NO. DESCRIPTION QUANTITY

09607937* ROTARY GROUP 1 ST L

1 02040556* CYLINDER WITH CONTROL PLATE 1 ST


2 09428131* PISTON-SLIPPER PAD 9 ST
11 09921720* CUP-SPRING STACK 1 ST
12 09445122* CRADLE 1 ST
13 09449034* SLIDE RING 1 ST
14 09921000* DRIVE SHAFT 1 ST
17 09421418* WIRE 2 ST
20 09432505* SHIM 1 ST
20 09432506* SHIM 1 ST
20 09432507* SHIM 1 ST
20 09432508* SHIM 1 ST
24 09921719* RETAINING RING 1 ST
25 09432264* RETAINING BALL 1 ST
26 02066594* BEARING LINER (PAIR) 1 ST
27 09921717* WASHER 2 ST
29 09435465* PRESSURE SPRING 1 ST
31 09156269* PLAIN ROLLER BEARING 1 ST
32 09830578* CRADLE BEARING ASSEMBLY ( SET ) 1 ST
36 00012491 RETAINING RING 1 ST
37 02600002* RETAINING RING 2 ST
38 01476328 SHAFT SEAK RING 1 ST D
41 09083405* RETAINING RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02012015*
DESCRIPTION: CONTROL HYDRAULIC

POS. ORDER-NO. DESCRIPTION QUANTITY

02012015* CONTROL HYDRAULIC 1 ST L

1 02025586* POSITIONING PISTON 1 ST L


3 02010745* COVER 1 ST
4 02010746* COVER 1 ST
16 09157477* HEXAGON NUT 1 ST
17 00515285 SOCKET HEAD SCREW 25NM 8 ST
20 09085360* O-RING 2 ST D
21 09432790* THREADED PIN 2 ST
22 01401644 SEAL-LOCK-NUT 69NM 2 ST D
30 02600839* GUIDE RING 2 ST
31 02600272* TURCON-GLYD-RING 2 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02025586*
DESCRIPTION: PORT PLATE WITH VALVES

POS. ORDER-NO. DESCRIPTION QUANTITY

02025586* PORT PLATE WITH VALVES 1 ST L

1 02010570* POSITIONING PISTON 1 ST


2 09449241* ROD 1 ST
5 02020493* RING 2 ST
5 02020494* RING 2 ST
5 02020495* RING 2 ST
5 02020496* RING 2 ST
5 02020497* RING 2 ST
5 02020498* RING 2 ST
5 02029756* RING 2 ST
5 02029757* RING 2 ST
5 02043149* RING 2 ST
6 02600767* ASSEMBLY RING 2 ST
7 09652048* SPRING COLLAR 2 ST
9 09435004* PRESSURE SPRING 2 ST
10 09435005* PRESSURE SPRING 2 ST
15 00012517 RETAINING RING 2 ST
19 01402905 O-RING 1 ST D
23 09449252* SPRING COLLAR 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09609517*
DESCRIPTION: PORT PLATE WITH VALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

09609517* PORT PLATE WITH VALVE 1 ST L

1 02601879* MHDBN32K2 200NM 1 ST L


2 09434856* PRESSURE RELIEFVALVE 1 ST L
3 09433834* PRESSURE OVERRIDE VALVE 1 ST L
5 09651090* PORT PLATE 1 ST
7 00945233 SOCKETHEAD SCREW 310NM 4 ST
9 09830217* O-RING 1 ST D
11 09831320* DOUBLE BREAK-OFF PIN 1 ST D
13 09154024* LOCKING SCREW 5NM 4 ST D
26 01402905 O-RING 2 ST D
35 00970659 LOCKING SCREW 20NM 3 ST D
43 09432774* BUSH 1 ST
44 09432773* BEARING BUSH 1 ST
48 09831319* DOUBLE BREAK-OFF PIN 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02601879*
DESCRIPTION: MHDBN32K2

POS. ORDER-NO. DESCRIPTION QUANTITY

02601879* MHDBN32K2 1 ST L

1 02600124* SEAL KIT 1 ST D


2 09157895* CAP 1 ST D

SPARE PARTS LIST


ORDER NO.: 09434856*
DESCRIPTION: PRESSURE RELIEF VALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

09434856* PRESSURE RELIEF VALVE 1 ST L

1 09436167* LOCKING SCREW 1 ST


2 09449622* ADJUSTING SCREW 1 ST
3 09435899* VALVE PISTON 1 ST
4 02010336* SPRING COLLAR 1 ST
5 09440765* PRESSURE SPRING 1 ST
8 00971901 O-RING 1 ST D
9 01412648 SEAL-LOCK-NUT 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09433834*
DESCRIPTION: PRESSURE OVERRIDE VALVE

POS. ORDER-NO. DESCRIPTION QUANTITY

09433834* PRESSURE OVERRIDE VALVE 1 ST L

1 09432376* LOCKING SCREW 1 ST


2 09426552* VALVE BUSHING 1 ST
3 09432301* CONTROL PISTON 1 ST
4 09432163* PISTON 1 ST
5 09432164* VALVE PISTON 1 ST
6 09432775* POPPET SEAT 1 ST
7 02009402* PRESSURE SPRING 1 ST
8 02043092* SPRING COLLAR 2 ST
9 09432167* ADJUSTING SCREW 1 ST
10 00200485 O-RING 1 ST D
14 00764416 SEAL-LOCK-NUT 22NM 1 ST D
15 00146186 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09606333*
DESCRIPTION: PUMP COVER

POS. ORDER-NO. DESCRIPTION QUANTITY

09606333* PUMP COVER 1 ST L

1 09434017* PUMP COVER 1 ST L


2 09650693* WEAR PLATE 1 ST L

SPARE PARTS LIST


ORDER NO.: 09434017*
DESCRIPTION: PUMP VOVER

POS. ORDER-NO. DESCRIPTION QUANTITY

09434017* PUMP VOVER 1 ST L

1 09650695* PUMPENDECKEL 1 ST
6 09083206* SOCKET HEAD SCREW 4 ST
7 04226837 O-RING 1 ST D
8 09086378* O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 09650693*
DESCRIPTION: WEAR PLATE

POS. ORDER-NO. DESCRIPTION QUANTITY

09650693* WEAR PLATE 1 ST L

1 09650692* WEAR PLATE 1 ST


2 04226837 O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02052862*
DESCRIPTION: CONTROL MODULE

POS. ORDER-NO. DESCRIPTION QUANTITY

02052862* CONTROL MODULE 1 ST L

1 02048768* CONTROL MODULE 1 ST L


3 09443201* COVER 1 ST
4 02063327* DRAW SPRING 1 ST
5 09651478* GASKET 1 ST D
6 02046037* PICKUP RING 2 ST
8 09083183* SOCKET HEAD SCREW 6,1NM 8 ST
9 09085831* SOCKET HEAD SCREW 10,4NM 4 ST
10 02600641* O-RING 1 ST D
12 01437359 O-RING 3 ST D
13 02601860* SOLENOID VALVE 19NM / 5NM 2 ST L
15 01402905 O-RING 2 ST D
16 00146186 O-RING 1 ST D
17 00750466 O-RING 2 ST D
18 02601640* SPRING COLLAR 2 ST D
19 00765885 PLUG BOX 1 ST
20 00141264 PLUG BOX 1 ST
30 09087338 CYLINDRICAL PIN 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02048768*
DESCRIPTION: CONTROL MODULE

POS. ORDER-NO. DESCRIPTION QUANTITY

02048768* CONTROL MODULE 1 ST L

1 02067240* CONTROL HOUSING WITH ACCESSOR. 1 ST L


5 02061843* TUNER 1 ST
6 02067213* WASHER 1 ST
6 02067214* WASHER 1 ST
6 02067215* WASHER 1 ST
6 02067216* WASHER 1 ST
6 02067217* WASHER 1 ST
6 02067218* WASHER 1 ST
6 02067219* WASHER 1 ST
6 02067220* WASHER 1 ST
6 02070232* WASHER 1 ST
22 09087453* NEEDLE ROLLER 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO.: 02067240*
DESCRIPTION: CONTROL HOUSING WITH ACCESSOR.

POS. ORDER-NO. DESCRIPTION QUANTITY

02067240* : CONTROL HOUSING WITH ACCESSOR. 1 ST L

1 02068232* HOUSING 1 ST
3 02067221* CONTROL PISTON WITH CYLINDRICAL PIN 1 ST L
4 02050396* LEVER 2 ST
6 02067212* EXCENTRIC PIN 1 ST
8 02044854* SCHEIBE 1 ST D
21 00219041 SOCKET HEAD SCREW 10,4NM 2 ST D
24 02061243* SOCKET HEAD SCREW 6,1NM 1 ST D
28 09831320* DOUBLE BREAK-OFF PIN 1 ST D
29 09153668* O-RING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.01.04.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 657-01
DESCRIPTION: HYDRAULIC TANK COMPONENTS

ASSEMBLY GROUP 15.66.20.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 657-01
DESCRIPTION: HYDRAULIC TANK COMPONENTS

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.20.00.00 1 ST HYDRAULIC TANK COMPONENTS 5005657 5005657

15.66.20.01.00 1 ST FILTER A.LEACK OIL BLOCK 5001120


SEE SUBSUPPLIER
ASSEMBLY 16.66.20.01.00

15.66.20.03.00 1 ST CONTROL STATION FILTER 5001119


SEE SUBSUPPLIER
ASSEMBLY 15.66.20.03.00

15.66.20.05.00 1 ST VENTILATION FILTER 0156729


15.66.20.06.00 1 ST BALL VALVE 1367718
15.66.20.07.00 1 ST BALL COCK 0830538
15.66.20.08.00 2 ST OIL SIGHT GLAS 1655840
15.66.20.09.00 1 ST SUCTION FILTER 2547561
15.66.20.10.00 6 ST UNION 0835058
15.66.20.13.00 2 ST SEAL RING 1725421
15.66.20.14.00 1 ST SEALING RING 1725418
15.66.20.16.00 2 ST SAE-FLANGE 0440207
15.66.20.18.00 1 ST THREAD FLANGE 1656521
15.66.20.19.00 4 ST HEXAGON SCREW 0056672
15.66.20.20.00 4 ST HEXAGON NUT 0011569

ASSEMBLY GROUP 15.66.20.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 657-01
DESCRIPTION: HYDRAULIC TANK COMPONENTS

ASSEMBLY GROUP 15.66.20.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 657-01
DESCRIPTION: HYDRAULIC TANK COMPONENTS

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.20.22.00 4 ST CYLINDRICAL-SCREW 0056714


15.66.20.23.00 2 ST CYLINDRICAL -SCREW 2168573
15.66.20.28.00 4 ST HEXAGON SCREW 3398122
15.66.20.29.00 8 ST HEXAGON SCREW 2533314
15.66.20.30.00 8 ST WASHER 0056992
15.66.20.33.00 2 ST HEXAGON NUT 0057127
15.66.20.34.00 8 ST HEXAGON NU 0057133
15.66.20.38.00 8 ST WASHER 0063701
15.66.20.39.00 2 ST RETAINER-WASHER 0552981
15.66.20.42.00 1 ST UNION 8411057
15.66.20.44.00 1 ST UNION 1768309
15.66.20.47.00 1 ST FITTING 1636028
15.66.20.51.00 2 ST UNION 1367719
15.66.20.52.00 1 ST UNION 2371476
15.66.20.53.00 1 ST UNION 1307804
15.66.20.56.00 3 ST UNION 1636008
15.66.20.64.00 1 ST UNION 0304990
15.66.20.66.00 1 ST BOLT 0773596
15.66.20.67.00 1 ST PLUG FOR COUPLING 0785169
15.66.20.69.00 1 ST PLUG FOR COUPLING 0785169
15.66.20.70.00 1 ST CONN.-NUT 0010731
15.66.20.80.00 2 ST SHEET STEEL SIGN 0303742
15.66.20.81.00 2 ST CABLE CLAMP 0661868
15.66.20.85.00 1 ST UNION 1360742

ASSEMBLY GROUP 15.66.20.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

FILTER A.LEACK OIL COLLECTING


BLOCK

PART-NO.: 5 001 120

ASSEMBLY GROUP 15.66.20.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 120
DESCRIPTION: FILTER A.LEACK OIL COLLECTING BLOCK

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.20.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 120
DESCRIPTION: FILTER A.LEACK OIL COLLECTING BLOCK

POS. ORDER-NO. DESCRIPTION QUANTITY


5 001 120 FILTER A.LEACK OIL COLLECTING BLOCK 1 ST L
LT 35D38.0
1 1245655* BLOCK LT 35D38.0 1 ST
2 1231384* HIGH PRESSURE HYDRAULIC-FILTER GR. 2 1 ST
3 1233627* CHECK VALVE 1 ST
4 1233628* CHECK VALVE 1 ST
5 1233630* CHECK VALVE 1 ST
6 1239322* FIXING BUSH 3 ST
7 1241442* THERMOMETER 1 ST
8 1240026* FLANGE HALF 2 ST
9 1241447* FLANGE HALF 2 ST
10 1135719* FITTING 5 ST
11 1239370* FITTING 4 ST
12 1135715* FITTING 1 ST
13 1241173* CYLINDER HEAD SCREW 4 ST
14 1241193* CYLINDER HEAD SCREW 4 ST
15 1241165* CYLINDER HEAD SCREW 4 ST
16 1238560* O-RING 1 ST
17 1240958* LOCKING SCREW 1 ST
18 1421589* REDUCTION ADAPTER 1 ST
19 1241604* MEASURING PORT 2 ST
20 1421592* SEALING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.20.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

FILTER AND CONTROL STATION

SACH-NR.: 5 001 119

ASSEMBLY GROUP 15.66.20.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 119
DESCRIPTION: FILTER AND CONTROL STATION

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.20.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 119
DESCRIPTION: FILTER AND CONTROL STATION

POS. ORDER-NO. DESCRIPTION QUANTITY


5 001 119 CONTROL BLOCK COMPL. ( LT-10-88.0-K ) 1 ST L
1 1421627* CONTROL BLOCK 1 ST
2 1421628* 2/2 WAY SOLENOID VALVE 4 ST
3 1250067* SOLENOID COIL 4 ST
4 1421629* HAND BUTTON 4 ST
5 1420427* NOZZLE 1 ST
6 1280559* THROTTLE CHECK VALVE 1 ST
7 1231466* HIGH PRESSURE HYDRAULIC-FILTER GR. 3 1 ST
8 1238578* O-RING 1 ST
9 1241181* CYLINDER HEAD SCREW 4 ST
10 1240762* RESOPAL SIGN-BOARD SET 5 ST
11 1240763* RESOPAL SIGN-BOARD SET 6 ST
12 1241604* MEASURING CONNECTOR 5 ST
13 1239370* UNION 4 ST
14 1239371* UNION 4 ST
15 1240956* SCREW PLUG 1 ST
16 1240987* SIDEX-EXPANDER 9 ST

L = ASSEMBLY GROUP
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.20.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 106-00
DESCRIPTION: PUMP AGGREGAT COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.21.00.00 1 ST PUMP AGGREGAT COMPL. 5001106 5001106

15.66.21.01.00 1 ST TANK COVER 5001105 5001105


15.66.21.02.00 1 ST PUMP UNIT 5001110 5001110
SEE SUBSUPPLIER
ASSEMBLY GROUP 15.66.21.02
15.66.21.03.00 1 ST SEAL 5001115 5001115
15.66.21.04.00 1 ST SEAL 5001114 5001104
15.66.21.05.00 4 ST STUD BOD 0301702
15.66.21.06.00 10 ST HEXAGON NUT 0057130
15.66.21.07.00 10 ST WASHER 0063701
15.66.21.08.00 18 ST HEXAGON SCREW 0057127
15.66.21.09.00 18 ST WASHER 0056988
15.66.21.10.00 1 ST O-RING 0936425
15.66.21.11.00 6 ST STUD BOLD 0303774
15.66.21.12.00 6 ST HEXAGON SCREW 0056672

ASSEMBLY GROUP 15.66.21.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 105-00
DESCRIPTION: TANK COVER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

15.66.21.01.00 1 ST TANK COVER WITH PUMP CARRIER 5001105 5001105

15.66.21.01.01 1 ST PLATE
15.6.21.01.02 1 ST PLATE
15.66.21.01.03 1 ST UNION 0215051
15.66.21.01.04 1 ST UNION 0304890
15.66.21.01.05 1 ST UNION 0924291

ASSEMBLY GROUP 15.66.21.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

FUEL FEED AND CONTROL PUMP

PART-NO.: 5 001 110

ASSEMBLY GROUP 15.66.21.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 110-00
DESCRIPTION: FUEL FFED AND CONTROL PUMP

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.21.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 110-00
DESCRIPTION: FUEL FFED AND CONTROL PUMP

POS. ORDER-NO. DESCRIPTION QUANTITY


5 001 110 FUEL FEED AND CONTROL PUMP 1 ST L
1 1238311* THREE PHASE MOTOR 1 ST
2 1421506* AXIAL PISTON PUMP K3VL80 1 ST
3 1421507* GEAR PUMPALP3A 1 ST
4 1421508* PUMP CARRIER 1 ST
5 1421509* COUPLING 1 ST
6 1421510* COUPLING 1 ST
7 1421511 COUPLING RING 1 ST
8 1241164* CYLINDRICAL SCREW 6 ST
9 1421512* CYLINDRICAL SCREW 2 ST
10 1239900* CHECK VALVE 1 ST
11 1240026* HALF-FLANGE 4 ST
12 1421632* HYDR. HOSE 1 ST
SEE LIST OF LMG HYDRAULIC HOSES
13 1241145* CYLINDRICAL SCREW 4 ST
14 1421562* UNION 1 ST
15 1054529* HYDR. PIPE 1M
16 1239873* UNION 1 ST
17 1421634* HYDR. HOSE 1 ST
SEE LIST OF LMG HYDRAULIC HOSES
18 1421563* TANK UNION 1 ST
19 1421565* TANK UNION 1 ST
20 1414464* CYLINDRICAL SCREW 4 ST
21 1241173* CYLINDRICAL SCREW 4 ST
22 1421633* HYDR. HOSE 1 ST
SEE LIST OF LMG HYDRAULIC HOSES
23 1421132* SEALING 1 ST
24 1240785* USITRING 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 15.66.21.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 422-00
DESCRIPTION: DRIVING HOUS COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.00.00.00.00 1 ST DRIVING HOUS COMPL. 5005422 2389487

18.01.00.00.00 1 ST CABIN STEEL NO.3 2509643


18.02.00.00.00 1 ST CABIN COMPONENTS 2544087
18.25.00.00.00 1 ST E-SYSTEM ASSEMBLY GROUP 18.00 5002599

ASSEMBLY GROUP 18.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 544 087-03
DESCRIPTION: CABIN COMPONENTS

ASSEMBLY GROUP 18.02.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 544 087-02
DESCRIPTION: CABIN COMPONENTS

ASSEMBLY GROUP 18.02.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 544 087-02
DESCRIPTION: CABIN COMPONENTS

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.02.00.00.00 1 ST CABIN COMPONENTS 2544087

18.02.03.00.00 1 ST MOTOR VEHICLE WANDHOLDER 2537979


18.02.04.00.00 3 ST SHOCK ABSORBING ELEM. 1355813
18.02.05.00.00 1 ST DOUBLE TAPE OF RUBBER 1627721
18.02.07.00.00 7,5 M OWA-TAPE 1636997
18.02.08.00.00 2 ST CAP-SCREW 0490263
18.02.09.00.00 1 ST CAP-SCREW 1636423
18.02.10.00.00. 3 ST DISK 1885320
18.02.11.00.00 4 ST CAP-SCREW 0153331
18.02.12.00.00 1 ST DOOR LATCH 1608569
18.02.13.00.00 3 ST CONTERS: SCREW 0599714
18.02.14.00.00 3 ST HEXAGON NUT 0421223
18.02.15.00.00 9 ST WASHER 0063713
18.02.17.00.00 12 ST WASHER 2381601
18.02.18.00.00 12 ST HEX-SCREW 0063317
18.02.19.00.00. 12 ST HEX. NUT 0057130
18.02.21.00.00 1 ST WIPER BLADE 5004897
18.02.22.00.00 1 ST GUIDE ARM 4510072
18.02.23.00.00 1 ST WIPER ARM 4510071
18.02.24.00.00 1 ST BRACKET 0750219
18.02.25.00.00 1 ST HEXAGON SCREW 0784494
18.02.26.00.00 1 ST OPERATOR'S SEAT 5001336
18.02.27.00.00 1 ST GLAS PANE 3330512
18.02.28.00.00 1 ST GLAS PANE 3330513
18.02.29.00.00 1 ST GLAS PANE 3330514
18.02.30.00.00 2 ST GLAS PANE 3330515
18.02.31.00.00 1 ST GLAS PANE 2549770
18.02.32.00.00 1 ST HANDLE SUITE DS COMPL. 2 549771 2392097
18.02.33.00.00 1 ST PROFILE CYLINDER 2549772 2392097
18.02.34.00.00 3 ST NIRO-RIBBON 2549773
18.02.35.00.00 2 M WINDOW RIBBON 2549774
18.02.36.00.00 2 M WINDOW RIBBON 2549775
18.02.37.00.00 4 ST HINGE 2549776
18.02.38.00.00 38 ST SELF CUTTING SCREW 3330510
18.02.39.00.00 1 ST NEOPRENE 3330511
18.02.40.00.00 1 ST DOOR RUBBER SEALING 2549779
18.02.41.00.00 1 ST GISTA PROFILE 2549780
18.02.42.00.00 1 ST LEVER PLUG 2549781
18.02.44.00.00 1 ST WINDOW PLUG 2549783
18.02.45.00.00 1 ST WINDOW PLUG 2549784
18.02.46.00.00 1 ST TELESCOPE COVER 2549785
18.02.47.00.00 3 ST HEXAGON SCREW 0054379
18.02.48.00.00 3 ST WASHER 1684578
18.02.51.00.00 4 ST HEXGON SCREW 1683942
18.02.52.00.00 4 ST HEXAGON NUT 2095060
18.02.53.00.00 4 ST WASHER 0063704

ASSEMBLY GROUP 18.02.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 599-00
DESCRIPTION: ELECTRICAL EQUIPMENT CABIN

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.00.00.00 1 ST ELECTRICAL EQUIPMENT CABIN 5002599

18.25.02.00.00 1 ST CABINE BUILT-IN 5002102


18.25.10.00.00 1 ST CONTROL DESK LEFT CPL. 5002600
18.25.20.00.00 1 ST CONTROL DESK RIGHT CPL. 5002286
18.25.60.00.00 1 ST WORKSHOP INSTALLATION 5002178

ASSEMBLY GROUP 18.25.00.00.00

SPARE PARTS LIST


ORDER NO. 5 002 102-00
DESCRIPTION: CABIN BUILT IN

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.02.00.00 1 ST CABINE BUILT-IN 5002102

18.25.02.01.00 1 ST LAMP 2532329


18.25.02.02.00 1 ST BULB 0146181
18.25.02.11.00 1 ST VENTILATOR 2532317
18.25.02.20.00 1 ST SOUND-GENERATOR 1096359

ASSEMBLY GROUP 18.25.02.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 600-00
DESCRIPTION: CONTROL DESK LEFT COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.00.00 1 ST CONTROL DESK LEFT CPL. 5002600

18.25.10.01.00 1 ST HOUSINGS 5002096


18.25.10.02.00 1 ST HEATER 4228061
18.25.10.03.00 1 ST CONTROL EQUIPMENT 5002601

ASSEMBLY GROUP 18.25.10.00.00

SPARE PARTS LIST


ORDER NO. 5 002 096-00
DESCRIPTION: HOUSING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.01.00 1 ST HOUSING 5002096

18.25.10.01.01 1 ST DESK LEFT 5002031 5002031


18.25.10.01.02 1 ST SWITCH CABINET 2350251 2350251
18.25.10.01.10 4 ST HEX.SCREW 1683942
18.25.10.01.11 4 ST HEX.NUT 0650234
18.25.10.01.12 4 ST CONTACT WASHER 2079808
18.25.10.01.13 3 ST CYL-SCREW 1683913
18.25.10.01.14 3 ST HEX-NUT 1683740
18.25.10.01.15 3 ST CONTACT WASHER 2079804
18.25.10.01.16 1 ST CABLE GLAND 5002062
18.25.10.01.17 1 ST NUT 4236264

ASSEMBLY GROUP 18.25.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 601-00
DESCRIPTION: CONTROL EQUIPMENT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.00 1 ST CONTROL EQUIPMENT 5002601

18.25.10.03.01 1 ST CONTROL LEVER SLEW./LUFF. 2078899


18.25.10.03.02 1 ST SELECTOR SWITCH WORKING LIGHT 2502556
18.25.10.03.03 1 ST SELECTOR SWITCH CABIN LIGHT 2502557
18.25.10.03.04 1 ST SELECTOR SWITCH RED WARNING 2502555
LIGHT
18.25.10.03.05 1 ST SELECTOR SWITCH CABIN HEATER 2502627
18.25.10.03.06 1 ST SELCTOR SWITCH SREEN WIPER 2502558
18.25.10.03.09 1 ST SELCTOR SWITCH DECKS LIGHT 5002385
18.25.10.03.10 1 ST HEATER 1636863
18.25.10.03.11 1 M CARRIER RAIL 1080033
18.25.10.03.12 1 M CABLE DUCT 1657369
18.25.10.03.14 6 ST COUNTER SUNK SCREW 6705038
18.25.10.03.15 6 ST HEX.-SCREW 1652159
18.25.10.03.16 6 ST HEX-SCREW 1683937
18.25.10.03.17 6 ST CONTACT WASHER 2079806
18.25.10.03.20 40 ST TERMINAL 1791266
18.25.10.03.21 8 ST PROTECTIVE COND.CLAMP 1791268
18.25.10.03.22 3 ST SIDE PLATE 1791269
18.25.10.03.23 3 ST SIDE ANGLE 1791302
18.25.10.03.24 2 ST PLATE HOLDER 1667815
18.25.10.03.25 1 ST TITLE CARD 1666929
18.25.10.03.30 2 M LTG.-OELFLEX 1657707
18.25.10.03.31 10 M LINE 1656357
18.25.10.03.32 12 M LINE 1656359
18.25.10.03.33 10 ST CABLE STRAP 0840069
18.25.10.03.34 1 ST EARTHING STRIP 1660053
18.25.10.03.35 1 ST PLATE 1653236
18.25.10.03.36 1 ST PLATE 1608442

ASSEMBLY GROUP 18.25.10.03.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 502 556-00
DESCRIPTION: SELECTOR SWITCH WORKING LIGHT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.02.00 1 ST SEL. SWITCH WORKING LIGHT 2502556

18.25.10.03.02.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.02.02 1 ST CONTACT HOLDER 4228101
18.25.10.03.02.03 1 ST CONTACT SEGMENT 4228102
18.25.10.03.02.04 1 ST PLATE HOLDER 4228103
18.25.10.03.02.05 1 ST PLATEWORKING LIGHT 4228105

ASSEMBLY GROUP 18.25.10.03.02

SPARE PARTS LIST


ORDER NO. 2 502 557-00
DESCRIPTION: SELECTOR SWITCH CABIN LIGHT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.03.00 1 ST SELECTOR SWITCH CABIN LIGHT 2502557

18.25.10.03.03.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.03.02 1 ST SWITCH CONTACT 4228101
18.25.10.03.03.03 1 ST CONTACT SEGMENT 4228102
18.25.10.03.03.04 1 ST PLATE HOLDER 4228103
18.25.10.03.03.05 1 ST PLATE 4228106

ASSEMBLY GROUP 18.25.10.03.03


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 502 555-00
DESCRIPTION: SELECTOR SWITCH RED WARNING LIGHT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.04.00 1 ST SELECTOR SWITCH RED WARNING 2502555


LIGHT

18.25.10.03.04.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.04.02 1 ST SWITCH CONTACT 4228101
18.25.10.03.04.03 1 ST CONTACT SEGMENT 4228102
18.25.10.03.04.04 1 ST PLATE HOLDER 4228103
18.25.10.03.04.05 1 ST PLATE 4228104

ASSEMBLY GROUP 18.25.10.03.04

SPARE PARTS LIST


ORDER NO. 2 502 627-00
DESCRIPTION: SELECTOR SWITCH CABIN HEATING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.05.00 1 ST SELECTOR SWITCH CABIN HEATING 2502627

18.25.10.03.05.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.05.02 1 ST SWITCH CONTACT 4228101
18.25.10.03.05.03 1 ST CONTACT SEGMENT 4228102
18.25.10.03.05.04 1 ST PLATE HOLDER 4228103
18.25.10.03.05.05 1 ST PLATE 4228650

ASSEMBLY GROUP 18.25.10.03.05


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 502 558-00
DESCRIPTION: SELECTOR SWITCH SCREEN WIPER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.06.00 1 ST SELCTOR SWITCH SREEN WIPER 2502558

18.25.10.03.06.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.06.02 1 ST CONTACT SEGMENT 4228107
18.25.10.03.06.03 1 ST CONTACT SEGMENT 4228102
18.25.10.03.06.04 1 ST PLATE HOLDER 4228103
18.25.10.03.06.05 1 ST PLATE 4228108

ASSEMBLY GROUP 18.25.10.03.06

SPARE PARTS LIST


ORDER NO. 5 002 385-00
DESCRIPTION: SELECTOR SWITCH DECKS LIGHT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.10.03.09.00 1 ST SELECTOR SWITCH DECKS LIGHT 5002385

18.25.10.03.09.01 1 ST SELECTOR SWITCH 4228100


18.25.10.03.09.02 1 ST SWITCH CONTACT 4228101
18.25.10.03.09.04 1 ST PLATE HOLDER 4228103
18.25.10.03.09.05 1 ST PLATE 5002386

ASSEMBLY GROUP 18.25.10.03.09


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 286-01
DESCRIPTION: CONTROL DESK RIGHT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.00.00 1 ST CONTROL DESK RIGHT 5002286

18.25.20.01.00 1 ST HOUSING 5002097


18.25.20.02.00 1 ST CONTROL EQUIPMENT 5002174
18.25.20.80.00 1 ST SPECIAL EQUIPMENT 5002101

ASSEMBLY GROUP 18.25.20.00.00

SPARE PARTS LIST


ORDER NO. 5 002 097-00
DESCRIPTION: HOUSING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.01.00.00 1 ST HOUSING 5002097

18.25.20.01.01.00 1 ST CONTROL DESK RIGHT 5002032 5002032


18.25.20.01.02.00 1 ST SWITCH CABINET 2350252 2350252
18.25.20.01.10.00 4 ST HEX.SCREW 1683942
18.25.20.01.11.00 4 ST HEX.NUT 0650234
18.25.20.01.12.00 4 ST CONTACT WASHER 2079808

ASSEMBLY GROUP 18.25.20.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 174-00
DESCRIPTION: CONTROL EQUIPMENTN

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.02.00.00 1 ST CONTROL EQUIPMENT 5002174

18.25.20.02.01.00 1 ST CONTROL LEVER HOIST 2078900


18.25.20.02.02.00 1 ST LCD-DISPLAY 4243440
18.25.20.02.03.00 1 ST CONNECTOR SET FOR DISPLAY 4243441
18.25.20.02.04.00 1 ST CABINETMODULE 4243438
18.25.20.02.05.00 1 ST CONNECTOR SET FOR CM 4243439
18.25.20.02.06.00 1 ST RESISTOR 5002107
18.25.20.02.10.00 1 ST EMERG-STOP BUTTON 2502563
18.25.20.02.11.00 1 ST KEY-OPERATED BUTTON JIB RESTING 2502566
18.25.20.02.12.00 1 ST PILOT LIGHT FAULT 2502565
18.25.20.02.13.00 1 ST SELECTOR SWITCH OFF/ON 2502564
18.25.20.02.14.00 6 ST DUMMY COVER RB22S 1652429
18.25.20.02.20.00 1 ST HEATER 1636863
18.25.20.02.21.00 1 M CARRIER RAIL 1080033
18.25.20.02.22.00 1 M CABLE DUCT 1657369
18.25.20.02.23.00 6 ST COUNTER SUNK SCREW 6705038
18.25.20.02.24.00 6 ST HEX.-SCREW 1652159
18.25.20.02.25.00 6 ST HEX-SCREW 1683937
18.25.20.02.26.00 6 ST CONTACT WASHER 2079806
18.25.20.02.27.00 2 ST CAP SCREW 1683914
18.25.20.02.28.00 2 ST SL-WASHER 0725726
18.25.20.02.29.00 2 ST WASHER 1684548
18.25.20.02.40.00 25 ST TERMINAL GR. 3 LADDER 1791266
18.25.20.02.41.00 2 ST PROTECTIVE COND.CLAMP 1791268
18.25.20.02.42.00 3 ST SIDE PLATE 1791269
18.25.20.02.43.00 4 ST SIDE ANGLE 1791302
18.25.20.02.44.00 3 ST PLATE HOLDER 1667815
18.25.20.02.45.00 1 ST TITLE CARD 1666929
18.25.20.02.50.00 2 M LTG.-OELFLEX 1657707
18.25.20.02.51.00 20 M LINE 1656357
18.25.20.02.52.00 3 M LINE 1656358
18.25.20.02.53.00 10 ST CABLE STRAP 0840069
18.25.20.02.54.00 1 ST EARTHING STRIP 1660053
18.25.20.02.55.00 1 ST PLATE 1653236
18.25.20.02.56.00 1 ST PLATE 1608442

ASSEMBLY GROUP 18.25.20.02.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 502 563-00
DESCRIPTION: EMERGENCY STOP BUTTON

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.02.10.00 1 ST EMERGENCY-STOP BUTTON 2502563

18.25.20.02.10.01 1 ST EMERG-PUSH BUTTON 4228110


18.25.20.02.10.02 1 ST CONTACT SEGMENT 4228107
18.25.20.02.10.03 1 ST PROTECTION SHIELD 4228111

ASSEMBLY GROUP 18.25.20.02.10

SPARE PARTS LIST


ORDER NO. 2 502 566-00
DESCRIPTION: KEY-OPERATED BUTTON JIB RESTING

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.02.11.00 1 ST KEY-OPERATED BUTTON JIB RESTING 2502566

18.25.20.02.11.01 1 ST KEY-OPERATED BUTTON 4228116


18.25.20.02.11.02 1 ST SWITCH CONTACT 4228101
18.25.20.02.11.03 1 ST PLATE HOLDER 4228103
18.25.20.02.11.04 1 ST PLATE 4228117

ASSEMBLY GROUP 18.25.20.02.11.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 502 565-00
DESCRIPTION: PILOT LIGHT FAULT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.02.12.00 1 ST PILOT LIGHT FAULT 2502565

18.25.20.02.12.01 1 ST PILOT LIGHT 4228112


18.25.20.02.12.02 1 ST FASTENER 4228113
18.25.20.02.12.03 1 ST LED-INSERT 4228114
18.25.20.02.12.04 1 ST PLATE FAULT 4228115

ASSEMBLY GROUP 18.25.20.02.12

SPARE PARTS LIST


ORDER NO. 2 502 564-00
DESCRIPTION: SELECTOR SWITCH OFF/ON

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.02.13.00 1 ST SELECTOR SWITCH OFF/ON 2502564

18.25.20.02.13.01 1 ST ILLUMINATED SELECTOR SWITCH 4228118


18.25.20.02.13.02 1 ST SWITCH CONTACT 4228101
18.25.20.02.13.03 1 ST LED-INSERT 4228114
18.25.20.02.13.04 1 ST PLATE 4228119

ASSEMBLY GROUP 18.25.20.02.13


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 101-00
DESCRIPTION: SPECIAL EQUIPMENT

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.80.00.00 1 ST SPECIAL EQUIPMENT 5002101

18.25.20.80.01.00 1 ST SELECTOR SWITCH GRAB OPERATION 2502766


18.25.20.80.02.00 1 M LINE 1656357

ASSEMBLY GROUP 18.25.20.03.00

SPARE PARTS LIST


ORDER NO. 2 502 766-00
DESCRIPTION: SELECTOR SWITCH GRAB OPERATION

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.20.80.01.00 1 ST SELECTOR SWITCH GRAB OPERATION 2502766

18.25.20.80.01.01 1 ST SELECTOR SWITCH 4236696


18.25.20.80.01.02 1 ST SWITCH CONTAC 4228101
18.25.20.80.01.04 1 ST PLATE HOLDER 4228103
18.25.20.80.01.05 1 ST SCHILD 4236701

ASSEMBLY GROUP 18.25.20.80.01


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 002 178-00
DESCRIPTION: WORKSHOP INSTALLATION

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

18.25.60.00.00 1 ST WORKSHOP INSTALLATION 5002178

18.25.60.01.00 4 M CABLE 5002066


18.25.60.02.00 5 M CABLE 1608342
18.25.60.03.00 3 M CABLE 0337832
18.25.60.04.00 8,5 M CABLE 1655148
18.25.60.05.00 4 M LTG.-OELFLEX 1657707
18.25.60.10.00 1 ST SOCKET CASING 4228204
18.25.60.11.00 4 ST FLAT PLUG CASING 4228205
18.25.60.12.00 4 ST CABLE THIMBLE 0145829
18.25.60.13.00 1 ST INTERIOR PART 1654680
18.25.60.20.00 4 ST CYL-SCREW 1683913
18.25.60.21.00 4 ST CONTACT WASHER 2079804
18.25.60.22.00 2 ST ZYL.SCREW 1683919
18.25.60.23.00 2 ST CONTACT WASHER 2079805
18.25.60.25.00 4 ST HOLDER 2062983 2062983
18.25.60.26.00 8 ST HEX.SCREW 1683992
18.25.60.27.00 8 ST WASHER 1684581
18.25.60.28.00 8 ST CURVED SPRING LOCK WASHER 0249845

ASSEMBLY GROUP 18.25.60.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 166-00
DESCRIPTION: WINCH MODULE COMPL.

ASSEMBLY GROUP 19.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 166-00
DESCRIPTION: WINCH MODULE COMPL.

ASSEMBLY GROUP 19.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 166-00
DESCRIPTION: WINCH MODULE COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.00.00.00.00 1 ST WINCH MODULE COMPL. 5005166 5005166

19.01.00.00.00 1 ST WINCH MODULE 5005274 5005274


19.32.00.00.00 1 ST LIMIT SWITCH SLACK ROPE 5001059 5001059
19.66.00.00.00 1 ST HYDR.SYSTEM WINCH MODULE 5005672
19.100.00.00.00 1 ST PIN 5001075 5001075
19.101.00.00.00 1 ST THRUST PLATE 5001074 5001074
19.102.00.00.00 1 ST DISTANCE BUSHING 5001080 5001080
19.103.00.00.00 4 ST WASHER 2067451 2067451
19.104.00.00.00 4 ST WASHER 2067452 2067452
19.105.00.00.00 3 ST RIPPSCREW 2361684
19.107.00.00.00 2 ST PROTECTIVE PLUG 1609236
19.108.00.00.00 1 ST PIN 5001079 5001079
19.109.00.00.00 1 ST WASHER 2049788
19.110.00.00.00 1 ST SPLIT PIN 2049787
19.112.00.00.00 2 ST HEXAGON SCREW 0650775
19.114.00.00.00 2 ST HEXAGON NUT 0053502
19.115.00.00.00 3 ST WASHER 2392782 2392782
19.116.00.00.00 6 ST WASHER 0152895
19.117.00.00.00 6 ST HEXAGON SCREW 0054379

ASSEMBLY GROUP 19.00.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 274-00
DESCRIPTION: WINCH MODULE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.01.00.00.00 1 ST WINCH MODULE 5005274 5005274

19.01.01.00.00 1 ST LUFFING GEAR WINCH COMPL. 5005289 5005289


19.01.02.00.00 1 ST HOISTING GEAR WINCH COMPL. 5005290 5005290
19.01.08.00.00 1 ST PRESSURE ROLLER 5005292 5005292
19.01.17.00.00 1 ST WINCH UNIT STEEL COMPL. 5005228 5005228

ASSEMBLY GROUP 19.01.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 289-00
DESCRIPTION: LUFFING GEAR WINCH COMPL.

ASSEMBLY GROUP 19.01.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SARE PARTS LIST


ORDER NO. 5 005 289-00
DESCRIPTION: LUFFING GEAR WINCH COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.01.01.00.00 1 ST LUFFING GEAR WINCH COMPL. 5005289 5005289

19.01.01.01.00 1 ST WINCHGEAR 5005199 5005199


SEE SUBSUPPLIER
ASSEMBLY 19.01.01.01.00
19.01.01.02.00 1 ST ROPE DRUM DIA 600 5005280 5005280
19.01.01.03.00 1 ST BEARING COVER 5005217 5005217
19.01.01.04.00 1 ST SPACER DISK 5005219 5005219
19.01.01.05.00 1 ST BEARING FLANGE 5005206 5005206
19.01.01.06.00 1 ST CANSHAFT 5005218 5005218
19.01.01.07.00 1 ST ROPE WEDGE 5005303 5005303
19.01.01.08.00 1 ST SPACER RING 5005278 5005278
19.01.01.10.00 1 ST ROLLER – BEARING 0011418
19.01.01.11.00 3 ST DOWEL PIN 0013807
19.01.01.12.00 1 ST SPRING PIN 0054147
19.01.01.13.00 1 ST FELTRING 5005291
19.01.01.14.00 1 ST RETAINING RING 0012564
19.01.01.15.00 1 ST CYLINDRICAL SCREW 1758053
19.01.01.16.00 3 ST HEXAGON SCREW 0054379
19.01.01.17.00 6 ST HEXAGON SCREW 0518173
19.01.01.18.00 1 ST GREASE NIPPLE 0010528
19.01.01.19.00 1 ST SET-SCREW 0219019
19.01.01.20.00 6 ST CYLINDRICAL SCREW 1608749
19.01.01.21.00 24 ST CYLINDRICAL SCREW 2168722
19.01.01.22.00 24 ST HEXAGON SCREW 1637385
19.01.01.23.00 24 ST WASHER 2115513

ASSEMBLY GROUP 19.01.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

WINCH GEAR
i= 108,1

PART-NO.: 5 005 199

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 199-00
DESCRIPTION: WNCH GEAR

TYPE AGGREGAT-NO. DESCRIPTION SERIAL-NO

5005199 WINCH GEAR 715 i= 108,1

ORDER-NO.: DESCRIPTION

56481360* INSTALLATION DRAWING

INSTALLATION INSTRUCTION

WEIGHT: 350,0 KG OIL QUANTITY:: 6,0 LTR.

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 199-00
DESCRIPTION: WINCH GEAR 715 i=108,1

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T264801082*
DESCRIPTION: WINCH GEAR 7 15 C 3 B 15 A0 108 I7 6WHY U26 CC

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2T264801082*
DESCRIPTION: WINCH GEAR 7 15 C 3 B 15 A0 108 I7 6WHY U26 CC

POS. ORDER-NO. DESCRIPTION QUANTITY


2T264801082* WINCH GEAR 7 15 C 3 B 15 A0 108 I7 6WHY U26 CC 1 ST L
1 0720968010* SCREW 16 ST
2 6682500640* OIL BREATHER PLUG 2 ST
3 0718006008* WASHER 2 ST
4 0715303276* O-RING 1 ST
5 6663350310* PAD 1 ST
6 2T237179022* COVER ASSEMBLY 1 ST
7 6643010430* SUN GEAR 1 ST
8 2T235379050* 1. REDUCTION ASSEMLY 1 ST
9 6643020590* SUN GEAR 1 ST
10 2T235379030* 2. REDUCTION ASSEMLY 1 ST
11 6643040150* SUN GEAR 1 ST
12 0720965816* SCREW 4 ST
13 2T2352379013* REDUCTION ASSEMBLY 1 ST
14 6661000441* BUSH 4 ST
15 2T237470830* HOUSING AND BEARING 1 ST
16 0710317016* LIFTIME SEAL 1 ST
17 6660300411* DISCS RETAINER 1 ST
18 6632592820* HUB 1 ST
19 6633032670* BRAKE SHAFT 1 ST
20 6680900150* SINTERED DISC 7 ST
21 6680700060* STEEL DISC 6 ST
22 0722369044* BACKUP RING 1 ST
23 0715307367* O-RING 1 ST
24 0715307371* O-RING 1 ST
25 0722369045* SPIRAL RING 1 ST
26 6635060153* BRAKE PISTON 1 ST
27 6680000100* SPRING 21 ST
28 6660300420* SPRING RETAINER PLAT 1 ST
29 0718299136* CIRCLIP 1 ST
30 0715303257* O-RING 1 ST
31 6654509210* MOTOR ADAPTOR 1 ST
32 720956001A* SCREW 8 ST
33 715303253A* O-RING 1 ST
35 0718006008* WASHER 5 ST
36 6668200590* EXTENSION 3 ST
37 0718401048* BREATHER PLUG 1 ST
38 6668200121* ELBOW 1 ST
39 0722366103* PLUG 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

Winch drive – 7c series

Installation and service manual

GENERAL information

MANUAL AIM
This manual has been devised by the manufacturer to give necessary information to those authorised to
work on this product for example the design engineers, installers, repair and maintenance technicians.

Besides helping one understand the rules of good manufacturing techniques used, the information given
must be read attentively and strictly put into action.

Failure to observe this information may lead to health and safety risks to persons as well as economic loss.

INFORMATION!

A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL


MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE.

Photographic documentation and drawings are supplied for educational purposes, so as to safely and
properly carry out maintenance operations. Minor deviations from pictures of this manual may appear on the
actual gearbox. However, these discrepancies are not relevant to the main parameters, or maintenance
functions.

ASSEMBLY GROUP 19.01.01.01.00


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INFORMATION ON SAFETY
Carefully read the instructions given in this instruction manual as well as the ones attached to the product
and make sure to follow the information concerning safety.

Personnel, which perform any type of work on the product during its life span, must possess precise
technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do
so may lead to health and safety risks to persons.

It is recommended that when handling the product attention is paid to the information given in this
manual or simply follow the instructions given on the packaging (if present).

Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to
health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee
given by the manufacturer.

Keep the product in perfect working order by following the scheduled maintenance procedure set
out by the manufacturer. Good maintenance will ensure the best performances, a longer period of
operation and a constant safeguard towards security requirements.

To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is
important to follow adequate safety conditions for one self and for others in compliance with the rules and
regulations that govern safety in the workplace.

When replacing worn parts, use original spare parts. Use oils and greases recommended by the
manufacturer. Doing this, will ensure that the product works properly and that the safety level is
"acceptable".

ASSEMBLY GROUP 19.01.01.01.00


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PRODUCT IDENTIFICATION
The data to identify the product are shown on the identification plate attached to it.
The gearmotor has two plates, one gives data on the gearbox and the other data on the hydraulic motor.
The following illustration shows how the data is set out.

INFORMATION!

For all enquiries regarding general information on the product, spare parts, assitance, always give the
identification data stamped on the ID plate. The plate must be removed or damaged during the
life of the product.

The following illustration shows how the data is set out

For all requests for assistance please contact the manufacturer's sales network, directly.

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

PRODUCT DESCRIPTION

ASSEMBLY GROUP 19.01.01.01.00


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NOTES
DELIVERY CONDITIONS

Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions:

· Ready for installation in the mounting position specified when ordering.

· To guarantee their reliability, the internal parts are properly lubricated with a layer of oil, the same as
the one used in the final test of the gearbox and compatible with the recommended oils (section 5.1).
Lubricating oil has not been added (as shown on the card).

· All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants.
· External surfaces are protected with an antioxidant water resistant grey color suitable for finish painting.
Machined surfaces are not painted. Finish coat to be applied by the customer.
· Tested to in-house specifications.
· Appropriately packaged to facilitate handling, transport and storage.

INFORMATION!
When the product arrives, ensure that it meets the information contained in the
purchase agreement and that there are no damages or irregularities. If there are any problems
contact the manufacturers' sales network directly.

TRANSPORT

We recommend that the box containing gearboxes is handled carefully in order to avoid damages
during transport. When removing gearboxes from their packaging, extra caution should be taken to
avoid impacts, which may damage sensitive parts.
The illustrations show the more common types of packaging.

ASSEMBLY GROUP 19.01.01.01.00


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STORAGE

Observe the following instructions to ensure correct storage of delivered products:

1. Do not store outdoors, in areas exposed to weather or with excessive humidity.

2. Always place boards of wood or other material between floor and products, to avoid direct contact
with the floor.

3. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and couplings
must be protected with a suitable anti-oxidation product
(SHELL ENSIS FLUID SDC OR EQUIVALENT PRODUCT).

The following measures must be taken for products


which expected storage period exceeds 6 months:

4. Cover outer machined parts and mating parts with grease to avoid oxidation.

5. Fill completely the gearboxes with lubticant oil.

INFORMATION!
BEFORE USE, THE GEARBOXES SHOULD BE FILLED WITH THE PROPER AMOUNT OF LUBRICANT
OF THE RECOMMENDED TYPE.

LIFTING AND HANDLING

If the handling occurs when the product is still


packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.

WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.

Handling should be undertakenwith maximum caution avoiding impacts.

WARNING!
UNDER NO CIRCUMSTANCE REMOVE THE PLASTIC LID FROM THE POWER SUPPLY PORTS OF
THE HYDRAULIC MOTOR; THIS WILL HELP AVOID THE ACCIDENTAL INTRODUCTION OF FOREIGN
BODIES INTO THE MOTOR, UNTIL THE HOSES ARE ASSEMBLED.

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

INSTALLATION
DIRECTION OF ROTATION

THE CORRECT DIRECTION OF ROTATION OF THE DRUM AND THE MOTOR SHAFT IS SHOWN IN
THE SKETCH HERE FOLLOW

ASSEMBLY GROUP 19.01.01.01.00


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CONSTRUKTION OF THE DRUM FRAME

CORRECT CONSTRUCTION OF THE DRUM FRAME AND RELATIVE COUPLING INDICATIONS ARE
SHOWN HERE FOLLOW.

ASSEMBLY GROUP 19.01.01.01.00


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HYDRAULIC MOTOR INSTALLATION

The mating areas and the pilot diameter of the gearbox where the hydraulic motor is to be mounted
must be clean and without burrs.

INFORMATION!
BEFORE ASSEMBLING THE HYDRAULIC MOTOR, VERIFY BY A DEPTH SLIDE GAUGE THE
CORRECT ASSEMBLY OF THE UNIT CHECKING THE AXIAL DISTANCE AS SHOWN IN THE SCHEME
BELOW.

1. ASSEMBLE THE HYDRAULIC MOTOR WITH ITS O-RING SEAL TO THE GEARBOX.

2. TIGHTEN THE MOTOR SCREWS AT A TORQUE SHOWN ON THE FOLLOWING TABLE:

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 19.01.01.01.00


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INSTALLATION OF THE GEARBOX ON THE WINCH


1. MOVE THE WINCH DRIVE IN THE MOUNTING AREA APPLYING LIFTING METHODS SHOWN IN
SECTION 3.4.

2. CLEAN THE MATING SURFACES FROM OILS OR PAINT AND FIT THE GEARBOX ON THE
MACHINE
(FOR THE CORRECT ORIENTATION REFE TO THE INSTALLATION DRAWING).

3. FIX THE GEARBOX TO THE WINCH FRAME BY USING THE SCREWS (A) TIGHTENED AT A
TORQUE SHOWN ON THE FOLLOWING TABLE:

4. FIX THE GEARBOX TO THE DRUM BY USING THE SCREWS (B) TIGHTENED AT A TORQUE
SHOWN ON THE
FOLLOWING TABLE:

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

CONNECTION OF THE BRAKE


THE GEARBOX DRIVE CAN BE SUPPLIED WITH A SAFETY NEGATIVE MULTIDISC BRAKE
HYDRAULICALLY DRIVEN
(PARKING BRAKE).

FOR INFORMATION REGARDING THE CHARACTERISTICS OF THE BRAKE, PORT TYPES AND
DIMENSIONS, REFER TO THE INSTALLATION DRAWING.

1. TO OPERATE THE BRAKE, CONNECT THE BRAKE PILOT PIPE TO THE BRAKE PORT.

AS THE GEARBOX INSTALLATION HAS BEEN COMPLETED, A STATIC SEALING TEST HAS TO BE
CARRIED OUT ACCORDING TO THE WORKING CONDITIONS:

1. a load equal or higher than the max operating one has to be applied per 5 min. at least and check that
no drum rotation happened.

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

LUBRICATION
GEARBOX LUBRICATION
The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing.

The recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP characteristics
according to MIL-L-2105 C & API GL5.

In the following table the most common brands of lubricant and the types recommended are shown.

INFORMATION!
DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

OIL FILLING
WARNING!

The gearbox is supplied without oil; anyway it has filling, draining and oil level plugs. Before putting the gear-
box into operation,it is necessary to fill it with oil.

Unscrew the fill and level oil plugs (1-2).

3. Fill from the hole (1) until the lubricant oil (see Section 5.1) flows out from the hole (2).

4. Tighten the fill and level oil plugs (1-2) and let the gearbox run. After a few minutes, stop and check
the oil level.

5. If necessary, refill with lubricant oil.

(Size and dimension of plugs are shown on the installation drawing).

INFORMATION!

Check the correct oil level after filling through the appropriate plug

Oil quantity to fill the gearbox is indicated on the following table or on the product installation drawing (In-
dicative values).

Belove are reported the standard gearbox oil filling-draining sketche.

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

OIL DRAINING AND REPLACEMENT


Unscrew the plugs and let the oil flow in a large enough container; in order to facilitate the draining must
be oil still warm.

3. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs.

4. Proceed with the oil fill-up following the procedures given (see Section 5.2).

WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.

WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

INFORMATION!
IN CASE THE GEARBOX IS FACTORY FILLED WITH LUBRICANT OIL AT LEVEL, FOLLOW THE
PROCEDURES GIVEN IN DETAIL AT SECTIONS 5.2-5.3 ONLY FOR THE OIL REPLACEMENTS
FOLLOWING THE START UP AND RUNNING IN.

ASSEMBLY GROUP 19.01.01.01.00


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START UP AND RUNNING IN


In this first stage it is advised to follow the measures given below:

1. Bleed air from every part of the hyraulic and add oil in the tank if necessary.

INFORMATION!

THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.

2. Start the gearmotor at a low speed and gradually increase it after having verified that it is functioning
correctly without any noises or vibrations.

INFORMATION!

DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT. DURING THE RUNNING-IN STAGE
FOLLOW THE STEPS GIVEN BELOW.

3. Check the correct revolution and direction of rotation.

4. Make sure that the functioning is regular and with-out any excessive noises and vibrations.

5. Make sure that the oil temperature does not exceed 90°.

After having terminated this first running-in follow the steps given below.

6. Check that there are no oil leakages. If present, proceed to remove them.

7. Check the level of lubricating oil in the gearmotor.

8. It could happen that due to the presence of air, during the first start up, the opening action of the brake
could be slowed down. It is advised to repeat the opening and closing function of the brake.

9. Check that there are no other problems in general.

ASSEMBLY GROUP 19.01.01.01.00


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MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and oil
changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation.

For a proper maintenance of the gearbox, the following checks and operations have to be done.

INFORMATION!

IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE


SPARE PART LISTS EXPLODED IEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.

Do not hesitate to contatct the gearbox distributor or manufacturer if further instructions are necessary or in
case of particular problems.

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

TROUBLE SHOOTINGS
The following table is realized to localize troubles in winch drive gearboxes 700C SERIES.

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 19.01.01.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL re-
serves the right to implement modifications without notice. This manual cannot be reproduced,
even partially, without prior written consent.

ASSEMBLY GROUP 19.01.01.01.00


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7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 290-00
DESCRIPTION: HOISTING GEAR WINCH COMPL.

ASSEMBLY GROUP 19.01.02.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SARE PARTS LIST


ORDER NO. 5 005 290-00
DESCRIPTION: HOISTING GEAR WINCH COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.01.02.00.00 1 ST HOISTING GEAR WINCH COMPL. 5005290 5005290

19.01.02.01.00 1 ST WINCHGEAR 5005198 5005198


SEE SUBSUPPLIER
ASSEMBLY 19.01.02.01.00
19.01.02.02.00 1 ST ROPE DRUM DIA 600 5005195 5005195
19.01.02.03.00 1 ST BEARING COVER 5005217 5005217
19.01.02.04.00 1 ST SPACER DISK 5005219 5005219
19.01.02.05.00 1 ST BEARING FLANGE 5005206 5005206
19.01.02.06.00 1 ST CANSHAFT 5005218 5005218
19.01.02.07.00 1 ST ROPE WEDGE 5005303 5005303
19.01.02.10.00 1 ST ROLLER – BEARING 0011418
19.01.02.11.00 3 ST DOWEL PIN 0013807
19.01.02.12.00 1 ST SPRING PIN 0054147
19.01.02.13.00 1 ST FELTRING 5005291
19.01.02.14.00 1 ST RETAINING RING 0012564
19.01.02.15.00 1 ST CYLINDRICAL SCREW 1758053
19.01.02.16.00 3 ST HEXAGON SCREW 0054379
19.01.02.17.00 6 ST HEXAGON SCREW 0518173
19.01.02.18.00 1 ST GREASE NIPPLE 0010528
19.01.02.19.00 1 ST SET-SCREW 0219019
19.01.02.20.00 6 ST CYLINDRICAL SCREW 1608749
19.01.02.21.00 36 ST CYLINDRICAL SCREW 2168722
19.01.02.22.00 24 ST HEXAGON SCREW 0072005
19.01.02.23.00 24 ST WASHER 0784905

ASSEMBLY GROUP 19.01.02.00.00


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TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

WINCH GEAR
i= 83,3

PART-NO.: 5 005 198

ASSEMBLY GROUP 19.01.02.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

ASSEMBLY GROUP 19.01.02.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 198-00
DESCRIPTION: WNCH GEAR

TYPE AGGREGAT-NO. DESCRIPTION SERIAL-NO

5005198 WINCH GEAR 716 i= 83,3

ORDER-NO.: DESCRIPTION

I7160C002400* INSTALLATION DRAWING

INSTALLATION INSTRUCTION

WEIGHT: 400,0 KG OIL QUANTITY:: 6,0 LTR.

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.02.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 198-00
DESCRIPTION: WINCH GEAR 716 i=83,3

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.02.01.00


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SPARE PARTS LIST


ORDER NO. 2T716C3083001*
DESCRIPTION: WINCH GEAR 7 C 16 3 B 10 A0 83 J9 6W1A145 U26

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.02.01.00


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SPARE PARTS LIST


ORDER NO. 2T716C3083001*
DESCRIPTION: WINCH GEAR 7 C 16 3 B 10 A0 83 J9 6W1A145 U26

POS. ORDER-NO. DESCRIPTION QUANTITY


2T716C3083001* WINCH GEAR 7 C 16 3 B 10 A0 83 J9 6W1A145 U26 1 ST L
1 720968004A* SCREW 17 ST
2 2T237179250* COVER ASSEMBLY 1 ST
3 0718006008* WASHER 2 ST
4 6682500640* OIL BREATHER PLUG 2 ST
5 6663350310* O-RING 1 ST
6 6663350310* PAD 1 ST
7 6643011200* SUN GEAR 1 ST
8 2T235369340* 1. REDUCTION ASSEMLY 1 ST
9 6643021110* SUN GEAR 1 ST
10 2T235369310* REDUCTION ASSEMLY 1 ST
11 6643040330* SUN GEAR 1 ST
12 0718298055* CIRCLIP 5 ST
13 2T235569300* PLANETARY ASSEMBLY 5 ST
14 6662005710* SPACER 5 ST
15 6660000700* NUT 1 ST
16 2T237470890* GEARBOX HOUSING 1 ST
17 0710317016* LIFTIME SEAL 1 ST
18 0718299199* CIRCLIP 1 ST
19 6660300411* DISCS RETAINER 1 ST
20 6632592310* HUB 1 ST
21 0715303026* O-RING 1 ST
22 6633031730* BRAKE SHAFT 1 ST
23 6680700060* STEEL DISC 6 ST
24 6680900150* SINTERED DISC 7 ST
25 0722369044* BACKUP RING 1 ST
26 0715307367* O-RING 1 ST
27 0715307371* O-RING 1 ST
28 0722369045* SPIRAL RING 1 ST
29 6635060153* BRAKE PISTON 1 ST
30 6680000100* SPRING 30 ST
31 6660301020* SPRING RETAINER PLAT 1 ST
32 0718299136* CIRCLIP 1 ST
33 0715303257* O-RING 1 ST
34 6654507511* MOTOR ADAPTOR 1 ST
35 0715303300* O-RING 1 ST
36 0711397006* SCREW 4 ST
37 0720956102* SCREW 8 ST
38 0718401048* BREATHER PLUG 1 ST
39 6668200121* ELBOW 1 ST
40 6668200620* ETENSION 3 ST
41 0722366103* PLUG 3 ST
42 0718006008* WASHER 6 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.01.02.01.00


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INSTALLATION INSTRUCTION FOR WINCH GERA ASSEMBLY GROUP


01.19.01.02.01 SEE UNDER ASSEMBLY GROUP 01.19.01.01.01
TTS-LMG Marine Cranes GmbH

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SPARE PARTS LIST


ORDER NO. 5 005 292-00
DESCRIPTION: PRESSURE ROLLER

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.01.08.00.00 1 ST PRESSURE ROLLER 5005292 5005292

19.01.08.01.00 2 ST CLAMPING PIECE 5005293 5005293


19.01.08.02.00 1 ST AXLE 5005294 5005294
19.01.08.03.00 2 ST BEARING RING 5005295 5005295
19.01.08.04.00 1 ST PIPE 5005296 5005296
19.01.08.05.00 1 ST ROLLER 5005297 5005297
19.01.08.06.00 4 ST SPACER 5005298 5005298
19.01.08.07.00 1 ST WASHER 5005506 5005506
19.01.08.10.00 3 ST ROLLER – BEARING 0308496
19.01.08.11.00 3 ST RETAINING RING 0012459
19.01.08.12.00 1 ST CIRCLIP 0012506
19.01.08.13.00 1 ST HEXAGON SCREW 0054399
19.01.08.14.00 2 ST HEXAGON SCREW 0056677
19.01.08.15.00 2 ST WASHER 0056992
19.01.08.16.00 2 ST SPRING PIN 0218766

ASSEMBLY GROUP 19.01.01.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 228-00
DESCRIPTION: WINCH UNIT STEEL COMPL,

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.01.17.00.00 1 ST WINCH UNIT STEEL COMPL. 5005228 5005228

19.01.17.01.00 1 ST WINCH UNIT STEEL 5005230 5005230


19.01.17.02.00 1 ST SAFETY DUARD 5005211 5005211
19.01.17.03.00 1 ST GUARD PLATE 5005210 5005210
19.01.17.04.00 8 ST HEXAGON SCREW 0057013
19.01.17.05.00 8 ST SL-WASHER 0118704
19.01.17.06.00 8 ST HEXAGON SCREW 0118372
19.01.17.07.00 16 ST WASHER 0012796
19.01.17.08.00 8 ST HEXAGON NUT 0057127

ASSEMBLY GROUP 19.01.17.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 001 059-01
DESCRIPTION: LIMIT SWITCH SLACK ROPE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.32.00.00.00 1 ST LIMIT SWITCH SLACK ROPE 2389281 2389281

19.32.01.00.00 1 M PIPE 2535203


19.32.02.00.00 2 ST CLAMP 1444367
19.32.03.00.00 2 ST CARRIER RAIL NUT 3398455

ASSEMBLY GROUP 19.32.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 672-00
DESCRIPTION: HYDR.SYSTEM WINCH MODULE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.66.00.00.00 1 ST HYDR.SYSTEM WINCH MODULE 5005672

19.66.02.00.00 1 ST COMPONENTS HYDR. WINCH MODULE 5005165 2389310


19.66.10.00.00 1 ST HYDR. MOTOR HOISTING GEAR COMPL. 2389311 2389311
19.66.11.00.00 1 ST HYDR.MOTOR LUFFING GEAR COMPL. 4243255 4243255

ASSEMBLY GROUP 19.66.00.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 165-00
DESCRIPTION: COMPONENTS HYDR.SYSTEM WINCH MODULE

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.66.02.00.00 1 ST COMPONENTS HYDR. WINCH MODULE 5005165 2389310

19.66.02.01.00 2 ST UNION 1665712


19.66.02.02.00 2 ST UNION 1636004
19.66.02.03.00 2 ST UNION 1338218
19.66.02.04.00 2 ST TRANSIT.MUFF CONNECT.PIECE 0665861
19.66.02.05.00 2 ST UNION 1665742
19.66.02.06.00 2 ST BRAKE FILTER 1637770

ASSEMBLY GROUP 19.66.02.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 389 311-02
DESCRIPTION: HYDRAULIC MOTOR HOISTING GEAR COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

HYDRAULIC MOTOR HOISTING GEAR


19.66.10.00.00 1 ST COMPL. 2389311 2389311

19.66.10.01.00 1 ST ADJUSTABLE MOTOR 2532117


SEE SUBSUPPLIER
ASSEMBLY GROUP 19.66.10.01
19.66.10.02.00 1 ST SOCKET 1665744
19.66.10.03.00 1 ST UNION 1636031
19.66.10.04.00 8 ST SAE-FLANGE HALF 0625571
19.66.10.05.00 16 ST CAP-SCREW 0861764
19.66.10.06.00 4 ST CAP-SCREW 1570492
19.66.10.07.00 4 ST RETAINER-WASHER 0153213
19.66.10.08.00 1 ST ADAPTER 90GR 1397693
19.66.10.09.00 2 ST SEALING RING 1725419
19.66.10.11.00 1 ST PLUG A2L VSTI 0271803
19.66.10.12.00 1 ST SAE-ELBOW 2072550 2072550
19.66.10.13.00 1 ST LOCK SCREW 1406392
19.66.10.14.00 1 ST THREAD JOINT VSTI 0986982
19.66.10.15.00 1 ST UNION VSTI 1637351
19.66.10.16.00 1 ST CHAK VALVE 1636493
19.66.10.17.00 1 ST ADAPTER SOCKET SLEEVE 0986672
19.66.10.18.00 1 ST PLUG 8411033
19.66.10.19.00 1 ST PLUG 1636005

ASSEMBLY GROUP 19.66.10.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

ADJUSTABLE OIL MOTOR


A6VM 200

PART-NO: 2 532 117

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 2 532 117
DESCRIPTION: ADJUSTABLE OIL MOTOR A6VM 200/63

POS. ORDER-NO. DESCRIPTION QUANTITY


1 4 532 117 ADJUSTABLE OIL MOTOR A6VM 200/63 ( 09604650* ) 1 ST L
1 09603916* ROTARY GROUP 1 ST L
2 09604644* CONTROL 1 ST L
5 09921682* HOUSING 1 ST
8 01466223 LOCKING SCREW 1 ST D
9 00012532 RETAINING RING 1 ST
10 09831663* SHAFT SEAL RING 1 ST D
11 09832084* BACK-UP PLATE 1 ST
12 09157314* O-RING 1 ST D
13 09156989* LOCKING SCREW 1 ST D
17 09446862* THREADED PIN 2 ST
18 01401644 SEAL-LOCK-NUT 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09603916*
DESCRIPTION: ROTARY GROUP

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09603992* ROTARY GROUP, HYDR. SECTION 1 ST L
2 09921774* DRIVE SHAFT 1 ST
3 09651659* SHIM 1 ST
6 09921766* BACK-UP PLATE 1 ST
6 09921767* BACK-UP PLATE 0 ST
6 09921768* BACK-UP PLATE 0 ST
6 09921769* BACK-UP PLATE 0 ST
6 09921770* BACK-UP PLATE 0 ST
6 09921771* BACK-UP PLATE 0 ST
6 09921772* BACK-UP PLATE 0 ST
6 09921773* BACK-UP PLATE 0 ST
7 09086744* RETAINING RING 1 ST
10 09157196* TAPERED-ROLLER BEARING 1 ST
11 09157197* TAPERED-ROLLER BEARING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09603992*
DESCRIPTION: ROTARY GROUP, HYDR. SECTION

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09430072* CYLINDER 1 ST
2 09921791* CONTROL LENS 1 ST
3 09921781* CENTER PIN 1 ST
4 02021906* PISTON WITH PISTON RINGS 7 ST L
6 09921775* ADJUSTMENT SHIM 1 ST
6 09921776* ADJUSTMENT SHIM 0 ST
6 09921777* ADJUSTMENT SHIM 0 ST
6 09921778* ADJUSTMENT SHIM 0 ST
6 09921779* ADJUSTMENT SHIM 0 ST
6 09921780* ADJUSTMENT SHIM 0 ST
7 09921782* PRESSURESPRING 1 ST
11 02033027* RETAINING PLATE 1 ST
12 09831108* PAN HEAD SCREW WITH TROX 15,8NM 14 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 02021906*
DESCRIPTION: PISTON WITH PISTON RINGS

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09430104* PISTON 1 ST
2 09831898* STEEL SEALING RING 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09604644*
DESCRIPTION: CONTROL

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09604634* CONTROL PART 1 ST L
2 09603769* COVER 1 ST L
3 09921414* PORT PLATE 1 ST
4 09921435* POSITIONING PISTON 1 ST
5 09424057* POSITIONING TRUNNION 1 ST
7 09652204* PISTON 1 ST
8 09445016* THREADED PIN 1 ST
10 09422894* VALVE GUIDE 2 ST
11 09426662* BOLT 2 ST
13 09412756* BUSH 2 ST
15 09083131* SOCKET-HEAD SCREW 215NM 8 ST
19 09830726* O-RING 2 ST D
20 09085577* O-RING 6 ST D
21 09086487* O-RING 2 ST D
23 09831057* SOCKET-HEAD SCREW E 150NM 1 ST
24 09832146* SQUARE RING 3 ST D
26 00218305 CYLINDER PIN 2 ST
28 09831318* DOUBLE BREAK-OFF PIN 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09604634*
DESCRIPTION: CONTROL PART

POS. ORDER-NO. DESCRIPTION QUANTITY


1 02000313* CONTROL HOUSING 1 ST
2 09412246* CONTROL BUSH 1 ST
3 09921942* CONTROL PISTONV 1 ST
4 09651119* ADJUSTING BUSHING 1 ST
5 09921351* SPRING COLLAR 1 ST
6 09420874* SPRING COLLAR 1 ST
7 09921421* PRESSURE SPRING 1 ST
8 09440508* PRESSURE SPRING 1 ST
9 09921342* PRESSURE SPRING 1 ST
14 09085560* O-RING 1 ST D
15 00013445 SOCKET-HEAD SCREW 25NM 4 ST
16 09153930 LOCKING SCREW 30NM 1 ST D
17 00032071 RETAINING RING 1 ST
19 09152427* THREADED PIN 1 ST
20 00591375 CYLINDER PIN 1 ST
21 00900778 SEAL-LOCK-NUT 10NM 1 ST D
22 09831317 DOUBLE BREAK-OFF PIN 5 ST
25 02600646* O-RING 1 ST D
27 09441694* PROPORTIONAL SOLENOID 1 ST L
28 00765885 PLUG BOX 1 ST
40 09440571* CONTROL PISTON 1 ST
41 02000492* CONTROL BUSH 1 ST
43 09075975* SPRING COLLAR 2 ST
44 02057206* LOCKING SCREW 1 ST
46 09420239* PRESSURE SPRING 1 ST
47 02052249* THREADED PIN 1 ST
48 09152686* O-RING 1 ST D
49 09157764* SEAL-LOCK-NUT 11NM 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09441694*
DESCRIPTION: PROPORTIONAL SOLENOID

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09830752* SOLENOID 1 ST
2 09086070* SOCKET-HEAD SCREW 3,1NM 4 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09603769*
DESCRIPTION: COVER

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09445990* COVER 1 ST
2 09400263* THROTTLE SCREW 1 ST
3 09446625* THROTTLE PIN 1 ST L
4 09400264* THROTTLE SCREW 1 ST
10 09831592* SOCKET-HEAD SCREW 4 ST
11 09154053* O-RING 1 ST D
12 09153930* LOCKING SCREW 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 09446625*
DESCRIPTION: THROTTLE PIN

POS. ORDER-NO. DESCRIPTION QUANTITY


3 09400262* THROTTLE PIN 1 ST D
4 09411019* THROTTLE PIN 1 ST
5 09410814* THROTTLE PIN 1 ST
6 09410142* THROTTLE PIN 1 ST
8 09410278* THROTTLE PIN 1 ST
12 09651337* THROTTLE PIN 1 ST
13 09417118* THROTTLE PIN 1 ST
14 09425867* THROTTLE PIN 1 ST
15 09425868* THROTTLE PIN 1 ST
16 09425869* THROTTLE PIN 1 ST
18 09425870* THROTTLE PIN 1 ST D
19 09432572* THROTTLE PIN 1 ST
20 09439272* THROTTLE PIN 1 ST
21 09444305* THROTTLE PIN 1 ST
22 09921168* THROTTLE PIN 1 ST
23 09650161* THROTTLE PIN 1 ST
24 09651078* THROTTLE PIN 1 ST
25 09651166* THROTTLE PIN 1 ST
26 09651165* THROTTLE PIN 1 ST
27 09651195* THROTTLE PIN 1 ST
28 02000453* THROTTLE PIN 0 ST
29 02009841* THROTTLE PIN 1 ST

SPARE PARTS LIST


ORDER NO. 09446862*
DESCRIPTION: THREADED PIN

POS. ORDER-NO. DESCRIPTION QUANTITY


1 09086120* THREADED PIN 1 ST
2 09083530* THREADED PIN 1 ST
3 09085976* THREADED PIN 1 ST
4 09153075* THREADED PIN 1 ST
5 09154041* THREADED PIN 1 ST
6 09153975* THREADED PIN 1 ST
7 09154212* THREADED PIN 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.10.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 4 243 255-00
DESCRIPTION: HYDR.MOTOR LUFFING GEAR COMPL.

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

19.66.11.00.00 1 ST HYDR.MOTOR LUFFING GEAR COMPL. 4243255 4243255

19.66.11.01.00 1 ST AXIAL PISTON UNIT 1601518


SEE SUBSUPPLIER
ASSEMBLY 19.66.11.01
19.66.11.02.00 1 ST SOCKET PIECE 625708
19.66.11.03.00 1 ST LOCK SCREW 1009480
19.66.11.04.00 6 ST SAE-FLANGE HALF 0625571
19.66.11.05.00 1 ST THREAD JOINT VSTI 0986982
19.66.11.06.00 1 ST SCREWING 0070277
19.66.11.07.00 12 ST CAP-SCREW 0861764
19.66.11.08.00 4 ST HEXAGON SCREW 0056679
19.66.11.09.00 4 ST THRUST WASHER 0153212
19.66.11.10.00 2 ST ADAPTER 90GR 1627452
19.66.11.11.00 3 ST SEALING RING 1725419
19.66.11.12.00 1 ST SAE-ELBOW 2072550 2072550
19.66.11.13.00 1 ST LOCK SCREW 1406392
19.66.11.14.00 1 ST UNION 1312318
19.66.11.15.00 1 ST UNION VSTI 1637351
19.66.11.16.00 1 ST CHAK VALVE 1636493

ASSEMBLY GROUP 19.66.11.00.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST

AXIAL PISTON UNIT

PART-NO.: 1 601 518

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 1 601 518
DESCRIPTION: AXIAL PISTON UNIT

POS. ORDER-NO. DESCRIPTION QUANTITY


1 601 518 AXIAL PISTON UNIT A2FM107 ( R909409691*) 1 ST L
1 R902030550* ROTARY GROUP 1 ST L
3 R902038551* HOUSING 1 ST
4 R909409692* PORT PLATE 1 ST
5 R909084163* CYLINDER PIN 1 ST
6 R909154986* O-RING 1 ST D
7 R909083087* SOCKET-HEAD SCREW 87NM 2 ST
10 R909083104* SOCKET-HEAD SCREW 87NM 4 ST
19 R909156651* LOCKING SCREW 40NM 1 ST D
98 R902002219* SEALING SET COMPL: 1 ST L

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902030550*
DESCRIPTION: ROTARY GROUP

POS. ORDER-NO. DESCRIPTION QUANTITY


1 R902028911* ROTARY GROUP; HYDR. SECTION 1 ST L
2 R902030596* DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 R909409482* COVER 1 ST D
12 R909152143* RETAINING RING 1 ST
14 R909831178* SHAFT SEALING RING 1 ST D
15 R909086636* O-RING 1 ST D
17 R909154359* SHIM 2 ST
18 R909154360* SHIM 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902028911*
DESCRIPTION: ROTARY GROUP, HYDR . SECTION

POS. ORDER-NO. DESCRIPTION QUANTITY


1 R909421309* CYLINDER 1 ST
2 R909650835* CONTROL PLATE 1 ST
3 R902027352* CENTER PIN 1 ST
4 R902031678* PISTON WITH PISTON RINGS 7 ST L
5 R909409612* WASHER 1 ST
6 R902027329* ADJUSTMENT SHIM 1 ST
6 R902027330* ADJUSTMENT SHIM 1 ST
6 R902027331* ADJUSTMENT SHIM 1 ST
6 R902027332* ADJUSTMENT SHIM 1 ST
6 R902027333* ADJUSTMENT SHIM 1 ST
7 R902027353* PRESSURE SPRING 1 ST
11 R909444064* RETAINING PLATE 1 ST
12 R902602395* PAN HEAD SCREW W. TORX 7 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902031678*
DESCRIPTION: PISTON WITH PISTON RINGS

POS. ORDER-NO. DESCRIPTION QUANTITY


1 R902028624* PISTON 1 ST
2 R909831891* STEEL SEALING RING 2 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902030596*
DESCRIPTION: DRIVE SHAFT WITH BEARING ASSY

POS. ORDER-NO. DESCRIPTION QUANTITY


2 R902028923* DRIVE SHAFT 1 ST
3 R909430091* BEARIMG RING 1 ST
6 R902027403* BACK-UP PLATE 1 ST L
7 R909083365* RETAINING RING 1 ST
10 R909154382* TAPERED-ROLLER BEARING 1 ST
11 R909154293* TAPERED-ROLLER BEARING 1 ST

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 – 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. R902027403*
DESCRIPTION: BACK-UP PLATE

POS. ORDER-NO. DESCRIPTION QUANTITY


1 R909921494* BACK-UP PLATE 1 ST
2 R909921493* BACK-UP PLATE 1 ST
3 R909921492* BACK-UP PLATE 1 ST
4 R909921491* BACK-UP PLATE 1 ST
5 R909921490* BACK-UP PLATE 1 ST
6 R909921489* BACK-UP PLATE 1 ST
7 R909921488* BACK-UP PLATE 1 ST
8 R902027334* BACK-UP PLATE 1 ST
9 R902027335* BACK-UP PLATE 1 ST
10 R902027336* BACK-UP PLATE 1 ST
11 R902027337* BACK-UP PLATE 1 ST
12 R909085045* BACK-UP PLATE 1 ST

SPARE PARTS LIST


ORDER NO. R902027403*
DESCRIPTION: BACK-UP PLATE

POS. ORDER-NO. DESCRIPTION QUANTITY


1 R909831178* SHAFT SEAL RING 1 ST D
2 R909086636* O-RING 1 ST D
3 R909154986* O-RING 1 ST D
4 R909087891* O-RING 2 ST D
5 R909087938* O-RING 1 ST D
6 R909152688* O-RING 2 ST D
7 R909086765* O-RING 1 ST D

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

ASSEMBLY GROUP 19.66.11.01.00


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 SPARE PARTS LIST

SPARE PARTS LIST


ORDER NO. 5 005 694
DESCRIPTION: TECHNICAL DOKUMENTS

ASSEMBLY MATERIAL DRAWING


GROUP QTY QC DESCRIPTION NO. NO.

97.00.00.00.00 1 ST TECHNICAL DOKUMENTS 5005694

97.01.00.00.00 1 ST TECHNICAL DOKUMENTATION 5005695

97.01.01.00.00 1 ST DECK-CRANE 3327669 3327669


97.01.0200.00 1 ST CRANE ARRANGEMENT 3327672 3327672
97.01.03.00.00 1 ST ASSEMBLY INSTRUCTION 5005051 5005051

97.25.00.00.00 1 ST ELECTRIC DOKUMENTATION 5005696

97.25.01.00.00 1 ST ELECTRIC DIAGRAM 5002556 5002556

97.66.00.00.00 1 ST HYDRAULIC DOKUMENTATION 5005697

97.66.01.00.00 1 ST HYDRAULIC DIAGRAM 5005050 5005050


97.66.02.00.00 1 ST LIST OF PARTS FOR HYDR. DIAGRAM 5005257 5005257
97.66.03.00.00 1 ST LIST OF HOSES 5005258 5005258

ASSEMBLY GROUP 97.00.00.00.00


TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01

AUFLISTUNG
LIST OF PARTS
zum
for

HYDRAULIKSCHEMA
HYDRAULIC DIAGRAM
SACH - NR. : / PART - NO. : 5 005 257

KRAN - TYP : / CRANE TYPE : KL 30T – 25M


BAU - NR. : / COMM. NO. : 7/3165 - 7/3180

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 1/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
1.0 Hubwerk
Hoisting gear
2.0 Wippwerk
Luffing gear
3.0 Drehwerk
Slewing gear
4.0 Speiseölkreis
Feed oil circuit
5.0 Ölkühler-Kreislauf
Oil cooler circuit
6.0 Hydrauliköltank
Hydraulicoiltank
7.0 Füllhandpumpe
filling pump
8.0 Handpumpe für Notbetrieb
Manual pump for emergency operation

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 2/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
1.0 1 Hubwerk
Hoisting gear)
1.1 1 Verstellpumpe 2 376 155 A4VG 125 EP2DM1 / 32R
Var. displacement pump
1.5 1 Verstellmotor 2 532 117 A6VM 200 EP2D/63W
Var. displacement motor
1.15 1 Filter 1 637 770 14300-40299
Filter
1.16 1 Rückschlagventil 1 636 493 RHZ 16
Check valve
1.23 1 Drucksensor 5 002 117 HT-PD
Pressure sensor
1.24 1 3/2 Wegeventil Item in GS04-30-10N
3/2 Way valve 5 001 119
1.27 1 Druckschalter 1 652 151 0163-407-01-1-025 7 bar
Pressure switch
1.28 1 Schutzkappe 625 431 1166 621 010
Rubber cap

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 3/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
2.0 1 Wippwerk
Luffing gear
2.1 1 Verstellpumpe 2 376 155 A4VG 125 EP2DM1 / 32R
Var. displacement pump
2.5 1 Axialkolbeneinheit 1 601 518 A2FM107 / 63W
Axial piston unit
2.15 1 Filter 1 637 770 14300-40299
Filter
2.16 1 Rückschlagventil 1 636 493 RHZ 16
Check valve
2.23 1 Drucksensor 5 002 117 HT-PD
Pressure sensor
2.24 1 3/2 Wegeventil Item in GS04-30-10N
3/2 Way valve 5 001 119
2.27 1 Druckschalter 1 652 151 0163-407-01-1-025 (7 bar)
Pressure switch
2.28 1 Schutzkappe 625 431 1166621010
Rubber cap

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 4/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
3.0 1 Drehwerk
Slewing gear
3.1 1 Verstellpumpe 2 376 174 A4VG 125 EP2DM1 / 32R
Var. displacement pump
3.4 2 Axialkolbeneinheit 2 010 753 A2FM 56
Axial piston unit
3.12 1 Druckschalter 1 652 151 0163-407-01-1-025; 7bar
Pressure switch
3.13 1 Schutzkappe 625 431 1166621010
Rubber cap
3.15 1 Filter 1 637 770 14300-40299
Filter
3.24 1 3/2 Wegeventil Item in GS04-30-10N
3/2 Way valve 5 001 119
3.27 1 Druckschalter 1 652 151 0163-407-01-1-025 (7 bar)
Pressure switch
3.28 1 Schutzkappe 625 431 1166621010
Rubber cap

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 5/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
4.0 1 Speiseölkreislauf
Feed oil circuit
4.1 1 Speiseöl- und Steuerölpumpe Pump 1 in K3VL80
Feed and control oil pump 5 001 110
4.2 1 Drehstrommotor Motor in 9 kW, 440 V - 60Hz
three phase motor 5 001 110
4.3 1 E-Motor 5 002 572 160 kW 440V - 60Hz
Elect. motor
4.9 1 Steuerstation Filter 5 001 119 LT-10-88.0-K
control station filter.
4.9.1 1 Filter Item in 374A-3E50-TL110/123
Filter 5 001 119
4.9.1.1 1 Wartungsanzeige 1 654 621 FF 3468
Maintenance indicator
4.9.1.2 1 Filtereinsatz 0 690 443 370-L-123A
Filter cartridge
4.9.2 1 Drosselventil NV08-20A-O-N
Throttle valve
4.24 1 3/2 Wegeventil 5 001 137
3/2 Way valve (Item in 5 001 119)

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 6/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
5.0 1 Ölkühler-Kreislauf
Oil cooler circuit
5.1 1 Kühlölpumpe Pump 2 in ALP3 A-D-94-S1-A
Cooling oil pump 5 001 110
5.3 1 Filter-Leckölblock 5 001 120 LT-35D38.1-K
Filter-leak oil block
5.3.1 1 Filter 274A – 2N35 – TL110/123
Filter
5.3.1.1 1 Filtereinsatz 2 548 583 270 – L –123A
Filter cartridge
5.3.2 1 Rückschlagventil Hy5300034 1 bar
Check valve
5.3.3 1 Rückschlagventil Hy5300036 3 bar
Check valve
5.3.4 1 Rückschlagventil Hy5300035 2 bar
Check valve
5.5 1 Temperatursensor 5 002 118
Temperature sensor
5.8 1 Ölkühler kompl. 5 005 192
Oil cooler compl.
5.8.2 1 E-Motor IMB14C140-90L
Elect.-motor

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 7/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
5.8.3 1 Ölkühler 2.7809.2.14-51.19.00
oil cooler

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 8/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
6.0 1 Hydrauliktank
Hydraulictank
6.1 2 Ölstansanzeige 1 655 840 R1“ - 530
Oil gauge
6.2 1 Belüftungsfilter 0 156 729 BF 25 S130 – F00
Venting filter
6.3 1 Kugelhahn 1 367 718 KN 25.225 B1
Ball cock
6.4 1 Leitungsfilter 0 986 373 7SL45/21 P10 R-00P
Line filter
6.4.1 1 Filtereinsatz 0 303 628 8.7SL45/21 P10 P
Filter cartridge
6.5 1 Verschlußkupplung 1 335 578 DN19 Nr.. 05014
Locking coupling LP-019-0-WR 026
6.8 1 Kugelhahn 0 830 538 KN 25.312-B1
Ball cock

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 9/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
7.0 1 Füllhandpumpe 0 478 065
Manual filling pump

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 10/11
TTS-LMG Marine Cranes GmbH

HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 005 257 Index 01
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
8.0 1 Handpumpe für Notbetrieb 5 001 738
Manual pump
(Lagerung im Store)
(To be kept in store)

Auflistung z. Hydraulikschema Ident No. : 5 005 050


Bau 7/3165 – 7/3180 20.08.2007 11/11
TTS-LMG Marine Cranes GmbH

Anschlußform der Schlaucharmatur


nach DIN 20078

Sach.-Nr.:
Part.-No.: 5 005 258 SCHLAUCHLISTE FÜR
HYDRAULIKSCHEMA Blatt:
List of hoses Hydraulic diagram

CH 90 1 von 3
TTS-LMG Marine Cranes GmbH

Pos im Gegenstand / für / Ident Nr. /


Schema Object for Ident No
1.01 DN08x5350 -N/N90 -1SN TOWER 2 536 028

1.03 DN12x950 -P/P90 -1SN TOWER 2 072 987

1.05 DN16x1600 -N/N90 -1SN SCAFFOLD 2 548 358

1.06 DN16x1200 -N/N90 -1SN SCAFFOLD 2 536 147

1.07 DN20x1200 -N/N90 -1SN TOWER 2 028 319

1.08 DN25x1600 -N/N -1SN SCAFFOLD 5 005 919

1.09 DN32x7050 -S/S90 -4SH TOWER 5 006 429

1.10 DN32x6750 -S/S90 -4SH TOWER 5 006 422

1.11 DN10x5000 -N/N90 -1SN TOWER 2 536 127

2.01 DN08x4150 -N/N90 -1SN TOWER 2 072 985

2.03 DN12x1700 -P/P90 -1SN TOWER 2 072 988

2.05 DN16x1400 -N/N90 -1SN SCAFFOLD 2 536 013

2.06 DN16x1050 -N/N90 -1SN SCAFFOLD 1 604 741

2.07 DN20x1700 -N/N90 -1SN TOWER 4 221 028

2.08 DN25x900 -N/N90 -1SN SCAFFOLD 1 612 829

2.09 DN32x7750 -S/S90 -4SH TOWER 5 006 423

2.10 DN32x7600 -S/S90 -4SH TOWER 5 006 424

3.01 DN08x5550 -N/N90 -1SN TOWER 2 072 986

3.02 DN06x1300 -N/N90 -1SN TOWER 2 072 984

3.05 DN16x1500 -N/N90 -1SN SCAFFOLD 2 536 140

Sach.-Nr.:
Part.-No.: 5 005 258 SCHLAUCHLISTE FÜR
HYDRAULIKSCHEMA Blatt:
List of hoses Hydraulic diagram

CH 90 2 von 3
TTS-LMG Marine Cranes GmbH

Pos im Gegenstand / für / Ident Nr. /


Schema Object for Ident No
3.06 DN16x1100 -N/N -1SN SCAFFOLD 5 004 820

3.09 DN20x1100 -N/N90 -1SN TOWER 2 072 990

3.10 DN20x700 -N/N90 -1SN TOWER 2 072 989

3.14 DN25x750 -N/N90 -1SN SCAFFOLD 3 335 055

3.15 DN32x5200 -S/S45 -4SH TOWER 5 006 425

3.16 DN32x4650 -S/S90 -4SH TOWER 5 005 118

3.19 DN20x900 -S/S90 -4SH TOWER 2 072 993

3.20 DN20x900 -S/S90 -4SH TOWER 2 072 993

4.01 DN08x1100 -N/N -1SN TANK 2 536 827

4.03 DN08x700 -N/N90 -1SN SCAFFOLD 5 004 826

4.04 DN06x1150 -N/N90 -1SN SCAFFOLD 1 604 954

4.05 DN16x450 -N/N90 -1SN SCAFFOLD 5 005 821

4.06 DN25x600 -N/N90 -1SN SCAFFOLD 3 335 311

4.10 DN32x850 -N/N90 -1SN SCAFFOLD 4 221 530

4.12 DN25x1700 -R/N90 -1SN SCAFFOLD 4 236 369

4.13 DN25x2800 -N/N90 -1SN TOWER 5 005 180

4.14 DN25x3000 -N/N90 -1SN TOWER 2 536 509

4.17 DN50x1000 -R/R90 -1SN SCAFFOLD 2 536 022

4.20 DN25x2000 -N/N90 -1SN TANK 2 536 023

4.22 DN32x1050 -R90/N -1SN TANK 2 536 025

Sach.-Nr.:
Part.-No.: 5 005 258 SCHLAUCHLISTE FÜR
HYDRAULIKSCHEMA Blatt:
List of hoses Hydraulic diagram

CH 90 3 von 3
TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7. ASSEMBLY INSTRUCTION
Crane type: KL 30 T – 28 M
Crane No.: 7/3165 - 7/3180

Date: 06.2008

TTS-LMG Marine Cranes GmbH


Marine Crane Division
Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
E-mail: info@tts-lmg.de
Internet: www.tts-marine.com

Please state the crane no. and type (see data plate) with all enquiries. PART – NO.: 5 005 051

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-1


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.1 ASSEMBLY INSTRUCTION

INDEX
7. ASSEMBLY INSTRUCTION 1
7.1 ASSEMBLY INSTRUCTION 2
7.2 ASSEMBLY AND PUTTING INTO SERVICE OF THE CRANE 3
7.3 PREPARATION OF FOUNDATION COLUMN 5
7.4 UNLOADING AND PUTTING UP CRANE TOWER 7
7.4.1 UNLOADING OF CRANE TOWER 7
7.4.2 PUTTING THE CRANE UPRIGHT 8
7.5 FILLING OF THE GEAR REDUCERS AND THE HYDRAULIC 9
7.6 MOUNTING OF CRANE TOWER 10
7.7 FITTING THE ACCESS LADDER INTO THE FOUNDATION COLUMN/CRANE
TOWER 11
7.8 SCHEMATIC DIAGRAM OF CONNECTION 11
7.9 FITTING THE JIB 12
7.10 REEVING OF ROPES AND CABLE 13
7.10.1 ROPE LAYOUT FOR LUFFING GEAR: 14
7.10.2 ROPE LAYOUT FOR MAIN HOISTING GEAR: 14
7.10.3 HOISTING AND LUFFING ROPE END FASTENINGS ON THE WINCHES: 15
7.10.4 HOISTING AND LUFFING ROPE END FASTENINGS ON CRANE AND JIB 15
7.11 FITTING THE REMAINING PLATES 16
7.12 INSTALLATION OF REMAINING COMPONENTS 16
7.13 LUBRICANTS RECOMMENDATION 17
7.14 TERMINAL CONNECTING PLAN 18

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7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.2 ASSEMBLY AND PUTTING INTO SERVICE OF THE


CRANE
The following instructions will enable the yard personnel to erect the crane and prepare it for commissioning.

The duration and the scope of work to be performed by TTS-LMG Marine Cranes GmbH personnel are
defined in the supply contract. Any extra cost exceeding the contract provisions shall be borne by the con-
tract partner having incurred such cost.

It is therefore in the yard’s own interest to ensure that erection and commissioning of the crane proceed
smoothly and make the respective preparations beforehand.

FOR THE ERECTION, THESE PREPARATIONS ARE:

7.2.1 The foundation column upper part to be welded to the foundation column lower part following the
weld seam preparation and in accordance with the actualfoundation column drawing.
Execution and testing of all weld seams in conformity with the rules and regulations of the respective
classification society, and to the satisfaction and with the approval of the local inspector of that
society.

7.2.2 It is imperative to keep the planeness specified in chapter 7.3 when welding the foundation column
upper part. Check that planeness is correct.

7.2.3 0,6 Mpa (6bar) air supply shall be available for the erection tools.

7.2.4 Crane capacities to cope with the loads mentioned in the erection instructions shall be available.

7.2.5 A horizontal support must be provided for the jib.

7.2.6 Work platforms for tightening the fastening screws should be prepared.

7.2.7 A trestle or a rotary plate for picking up the rope spools and a auxiliary rope (200m) as well as a rope
stocking shall be provided.

7.2.8 The ship’s mains for uninterrupted current supply to the crane is operative.

7.2.9 The ship can be ballasted if necessary, in order to allow mounting the crane on an even keel.

FOR PUTTING THE CRANE INTO SERVICE AND FOR THE ACCEPTANCE TESTS, IT SHOULD BE
ENSURED THAT:

7.2.10 The ship’s mains for uninterrupted current supply to the crane is operative.

7.2.11 The ship can be ballasted if necessary, in order to allow mounting the crane on an even keel.

7.2.12 The hatch covers can be opened if requested, in order to be able to set the bottom position of the
hook.

ATTENTION:
It should be ensured that no current is led over the slewing assembly or other bearings when welding.
The ground connection is to be made immediately next to the point of welding in order to avoid any damage
to the electronic components.

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-3


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.2.13 YARD SCOPE OF WORK

- Putting the crane tower upright - raising it from the horizontal into the vertical position
- Assembling the slipring body including making of all electrical connections to the ship and the
crane tower
- Fitting the venting mushrooms to the gear reducers and the hydraulic oil tank, filling in oil if
necessary
- Putting the crane (crane tower) on the foundation column
- Bolted connection between crane tower and foundation column
- Bolted connection between crane tower and jib
- Assembly of access ladder
- Assembly and electrical connection of jib light, switch, inside lighting and possible further deck
lights and additional lanterns
- Reeving the hoisting and the luffing ropes
- Making ready of test weight acc. to test programme
- Lubricating work acc. to lubrication plan (see operating manual)
- Preparation of vessel for functional and overload tests
- Acceptance by classification society
- The cable inlets at the slipring body have to be sealed

7.2.14 TTS-LMG MARINE CRANES GMBH SCOPE OF WORK

- General erection supervision


- Commissioning of the crane
- Setting the limit switches
- Carrying out functional tests in accordance with test program

CONTACT TTS-LMG MARINE CRANES GMBH WELL AHEAD OF TIME TO REQUEST


DELEGATION OF TTS-LMG PERSONNEL.:

TTS-LMG Marine Cranes GmbH


Marine Crane Division
Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
E-mail: info@tts-lmg.de
Internet: www.tts-marine.com

Please state the crane no. and type (see data plate) with all enquiries.

7-4 Ind. 02 / 06-2008 2-571-7/3165-7/3168 ASSEMBLY INSTRUCTION 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.3 PREPARATION OF FOUNDATION COLUMN


- Clean and degrease contact surfaces (fig. 2) (free from grease, rust and paint residues).
The contact surface for the slewing assembly must be cleaned over the entire circumference.
On the bottom, only the contact surfaces for washers need to be cleaned.

Fig. 2

- Check evenness with ruler over the entire diameter. Inform TTS-LMG if the
evenness indicated in fig. 3 is not kept.
- Fit slip - ring body and connect to ship’s system and to the crane tower.See.
terminal connecting plan ref. no. 5002556 in Appendix. Holes for entering the
cables for connection to the ship’s mains will have to be made in the bottom
locking plates of the slipring body(cable inlets are not TTS-LMG supply). The
diameters of the bore holes depend on the cable diameters and
consequently, the cable gland diameters. The number of cables to be
connected can be seen on the connecting plan in the annex. Glue plates on
the slipring body (cf. fig.3) before connecting it. The slipring body is best
positioned by lowering it through the access hatch in the foundation column
intermediate floor before the crane is erected. It is then bolted to the
intermediate floor from below (fig. 4).
- Put access ladder (fig. 3) and fastening material for erection of the crane into
the foundation column before the crane tower is put on. The ladder is fitted
after the deck crane has been mounted on the foundation column.

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-5


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

Fig. 3

Fig. 4

Fig. 5

7-6 Ind. 02 / 06-2008 2-571-7/3165-7/3168 ASSEMBLY INSTRUCTION 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.4 UNLOADING AND PUTTING UP CRANE TOWER


Timbers for unloading the crane tower and putting it upright should be adequately dimensioned.
Timbers should provide an even surface when the tower is put upright so that contact is close.

7.4.1 UNLOADING OF CRANE TOWER

ABT.13,0t

Fig. 6

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-7


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.4.2 PUTTING THE CRANE UPRIGHT

ABT.24t

ABT.24t Fig. 7

Fig. 8

7-8 Ind. 02 / 06-2008 2-571-7/3165-7/3168 ASSEMBLY INSTRUCTION 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.5 FILLING OF THE GEAR REDUCERS AND THE


HYDRAULIC
Remove blind plugs from gear reducers (hoisting, luffing and slewing gear reducer) and from hydraulic tank.
Replace by respective venting mushrooms (fig.9). Check the fillings and top up, if necessary.

Fillings: Main hoisting gear winch: 1x 6 Litres


Luffing gear winch: 1x 6 Litres
Slewing gear reducer 2 pces a12 Ltr. 24 Litres
Hydraulic tank 1x 550 Litres
remaining hydr. equipment 1x 70 Litres

Fig. 9

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-9


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.6 MOUNTING OF CRANE TOWER


♦ Lift the crane tower above the foundation column, distance abt. 5-10mm. Position bore holes on top
of one another with the help of guide mandrils and screw in the stud bolts. All stud bolts must have
been screwed in before the crane tower is put on fully.

♦ Set the dimension for screwing-in the stud bolts acc. to fig. 11.

♦ Before unslinging the crane tower from the erection crane, all stud bolts must be screwed in, and
each stud bolt on the circumference must have been tightened with an impact screw driver.

♦ After the tower has been taken from the erection crane, the bolts are lengthened with the specified
pre-stress crosswise (see fig. 11).

♦ After completion of the erection the pre-stressing force on all the bolts is checked once again and
re-tightened if necessary.

NOTE:
Place down crane tower in a way to allow jib to be put into the support.

WEIGHT OF TOWER ABT. 24t

Fig. 10 Fig. 11

7-10 Ind. 02 / 06-2008 2-571-7/3165-7/3168 ASSEMBLY INSTRUCTION 3165-3168


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.7 FITTING THE ACCESS LADDER INTO THE FOUNDATION


COLUMN/CRANE TOWER
Weld the ladder with the fastening plates to the bottom of the crane tower base plate.
Weld the pin for driving the slipring body after adjusting it.

Fig. 12

7.8 SCHEMATIC DIAGRAM OF CONNECTION


After the crane tower and the ladder have been fitted, the supply cables having come up into the tower are
led to the slipring body and the light switch over the ladder string piece (fig.12). The cables are then cut to
the correct size and connected to the slipring body fitted with cables lugs. (Connecting diagram ref. no.
5002556 in the annex). After erection work has been completed and tests have been successfully conclu-
ded, the slipring body must be sealed by grouting it in.

Fig. 13

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-11


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.9 FITTING THE JIB


Before mounting the jib, the jib and alarm lamps must be installed and electrically connected. If there is no jib
rest on board the ship, a provisional support must be made.
The jib bearings have already been fastened on the crane tower, therefore the jib will only have to be fitted to
the bearings (fig.14). The contact surfaces (fig. 15) must be cleaned and degreased (free from grease, rust,
and paint residues). The thread and the contact surfaces of the fastening screw heads must be greased
with MOS2.

Fig. 14

Fig. 15

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TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

After jib has been fitted, electrical connections must be made. The cables on the jib must all be guided to the
distributor boxes near the jib bearing on the crane tower (fig. 16) and connected there. Earthing must also be
installed between jib and crane tower. See connecting diagram ref. no. 5002556 in the annex.

Fig. 15

7.10 REEVING OF ROPES AND CABLE


Use a thin auxiliary rope (abt. 200 m) attached to the hoisting and luffing ropes for reeving the ropes in. Pull
at the auxiliary rope until the hoisting or luffing rope reaches the rope drum, starting with the luffing rope. The
hook block should be in upright position when the hoisting rope is reeved in.

Luffing rope ∅30x209m long

Hoisting rope ∅30x262m long

ATTENTION!
Pull ropes off the reel, otherwise they might twist.

Fig. 16

ASSEMBLY INSTRUCTION 3165-3168 2-571-7/3165-7/3168 Ind. 02 / 06-2008 7-13


TTS-LMG Marine Cranes GmbH

7/3165 - 7/3168 ASSEMBLY INSTRUCTION

7.10.1 ROPE LAYOUT FOR LUFFING GEAR:

Fig. 17

7.10.2 ROPE LAYOUT FOR MAIN HOISTING GEAR:

Fig. 18

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7.10.3 HOISTING AND LUFFING ROPE END FASTENINGS ON THE WINCHES:


After the ropes have been reeved in and fastened acc. to fig. 20, fit screw retention (retention wire through
screw heads).

6 hex. Socket head cap srews M16-8.8


distributed over circumference Z
tightening torque Ma = 210Nm

Fig. 20

7.10.4 HOISTING AND LUFFING ROPE END FASTENINGS ON CRANE AND JIB
Beat sleeves into rope thimbles before fitting thimbles on the pin

Fig. 21

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7.11 FITTING THE REMAINING PLATES


Plates installed at the inside door foundation column

Fig. 22

Plate installed the wall closed by


hatchcover

Fig. 23

7.12 INSTALLATION OF REMAINING COMPONENTS


The fire extinguisher and the rope-down device will be installed in the crane driver’s cabin right at the end of
the erection.

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7.13 LUBRICANTS RECOMMENDATION

Fig. 24

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7.14 TERMINAL CONNECTING PLAN

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