Tts Deck Crane 458884920

TTS Marine Cargo Cranes
O P E R AT I O N I N S T RU C TI O N
AN D
S P AR E P AR T S LI S T
SINGLE DECK CRANE KL 30T – 25M
TTS YARD-NO. : 2-571-7/3945 – 7/3948

YEAR OF CONSTRUCTION : 2009
CLASSIFICATION SOCIETY : GL
DATE : AUGUST 2009
TAEKWANG SHIPYARD H003
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

7/3945-7/3948 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 18.00.00 DRIVING HOUSE COMPL.
ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.
ASSEMBLY GROUP 25.00.00 ELECTRICAL EQUIPMENT COMPL.
ASSEMBLY GROUP 66.00.00 HYDRAULIC SYSTEM COMPL.
ASSEMBLY GROUP 97.00.00 TECHNICAL DOKUMENTS
7. ASSEMBLY INSTRUCTION
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7/3945-7/3948 PREFACE
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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7/3945-7/3948 PREFACE
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:

Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
Please state the crane no. and type (see data plate) with all enquiries.
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7/3945-7/3948 PREFACE
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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7/3945-7/3948 PREFACE
1.3.4 RESCUE SIGNS
First aid Fire extinguisher
Doctor
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7/3945-7/3948 PREFACE
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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7/3945-7/3948 PREFACE
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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7/3945-7/3948 PREFACE
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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7/3945-7/3948 PREFACE
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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7/3945 - 7/3948 DESCRIPTION
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 9
DESCRIPTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 2-1

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.: 7/3945 – 7/3948
Calculation of carrying steel structure in accordance with FEM

and Classification Society
hook operation 30t
The Crane as a whole
Appliance group A4
Load spectrum class Q2
Utilisation class U4
Number of loading cycles during lifetime max.250.000
Calculation of drive in accordance with FEM
HOISTING GEAR
Mechanism group M5
Class of load spectrum L2
Class of utilization T5
LUFFING GEAR
Mechanism group M5
SLEWING GEAR
Mechanism group M5
DESCRIPTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 2-3

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 25 m, it is limited by the luffing gear limit switch.
At an outreach of 3,6 – 25 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 3,6 – 25 m, loads of up to 24 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.
DESCRIPTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 2-5

2.2.4 PRINCIPAL DATA

Crane type KL 30t-25m
Type of drive electro – hydraulic

Ambient temperature -20ºC to +45ºC
Lifting capacity 30 t – 25 m Hook opeartion
24 t – 25 m Grab operation
Min. outreach 3,6 m
Max. lifting height 37,0 m
Slewing speed * 1,22 rpm
Hoisting speed * full load 21,0 m/min
no load 43,0 m/min
Luffing time * from max. in min. outreach 56 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 1x170 kW (hoisting)
1x147 kW (luffing)
1x142 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 125,1
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
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 42 / 86 m/min
Hydraulic motor A6VM200EP2D/63 VAB 02 B
LUFFING GEAR
Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically

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 A2FM107/61 W-PZB02
2.2.12 ROPES
HOISTING ROPE
Rope diameter (mm) 30

Rope length (m) 199
Wire breaking strength (N/mm²) 1960
Operation force (kN) 165,9
Min. breaking strength (kN) 763,1
Rope design Left hand regular lay
Thimble DIN 3091-36GTW
LUFFING ROPE
Rope diameter (mm) 30

Rope length (m) 192
Wire breaking strength (N/mm²) 1770
Operation force (kN) 116,8
Min. breaking strength (kN) 537,3
Rope design Left hand regular lay
Thimble DIN 3091-36GTW
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2.2.13 WEIGHTS
Slewing tower compl 22 910 kg

Jib compl. 11 320 kg
Hoisting rope 880 kg
Luffing rope 740 kg
Tackle block 1 040 kg
Crane compl. approx. 36 890 kg
DESCRIPTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 2-9

7/3945 - 7/3948 OPERATION INSTRUCTION
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
OPERATION INSTRUTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 3-1

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 24 tons.

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 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.

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 20 Emerg.-off button Emergency off
11 Selector switch Cabin Heater 26 illuminated switch Start / Stop
Ready for operation
13 Selector switch Warning light red 29 Indication lamp ( red ) Fault
14 Selector switch Working light 31 Key operated button Jib resting
15 Selector switch Cabin light 32 Arlarm Buzzer Fault
Bp Blind cap for additional Installation 34 Key operated switch Grab operation
Bp Blind cap for additional Installation

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.

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.

FAULT – Indication signal lamp
Signal lamp 29 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.

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.
LIFTING AND LOWERING OF LOAD
Push control lever in r.h. control desk either forward or backward.

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
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
SLEWING STOPPED AUTOMATICALLY

IF WORKING RANGE LIMITATION IS ACTIVATED.

LUFFING IN AND OUT

Excursion angle forward = jib lowering

Excursion angle to the back = jib lifting

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

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

CRANE HOOK STOPPED AUTOMATICALLY
CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.
The limit position will be indicated on the display.

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

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
electrical 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

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.

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 24 tons.

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.

STARTING

will start up.
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.

SLEWING
Excursion angle to the left = slewing to the left

Excursion angle to the right = slewing to the right

SLEWING STOPPED AUTOMATICALLY

IF WORKING RANGE LIMITATION IS ACTIVATED.
LUFFING IN AND OUT

Excursion angle forward = jib lowering

Excursion angle to the back = jib lifting


JIB STOPPED AUTOMATICALLY
LIFTING OR LOWERING STOPPED AUTOMATICALLY.
The limit position will be indicated on the DISPLAY.
LIFTING AND LOWERING

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


CRANE HOOK STOPPED AUTOMATICALLY
CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.
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 24 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.

FAULT - INDICATION SIGNAL LAMP (SIGNAL LAMP 29)
Signal lamp 29 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

 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.

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 !)

3.3.4 CLOSING DOWN
(SEE “CRANE OPERATION“ FOR SAFETY REGULATIONS)

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

will start up.
 Bring crane into sea voyage position - luff-down jib ( bridge limit switch with key-operated button 31 )
 Crane hook must be empty.
ATTENTION :
BRIDGING-OVER WITH KEY-OPERATED SWITCH 31 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.


STOP

 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.

7/3945-7/3948 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
4.1.17.2 LIFTING AND HANDLING 12
4.1.17.3 INSTALLATION 13
4.1.17.3.1 HYDRAULIC MOTOR INSTALLATION 13
4.1.17.3.2 INSTALLATION OF THE SLEW DRIVE ON THE MACHINE 14
4.1.17.3.3 CONNECTION OF THE BRAKE 15
4.1.17.3.4 CONNECTIN OF THE DRAINING PORT 16
4.1.17.3.5 REPLACING OF THE BREATHER VALVE AS LOOSE PART 16
4.1.17.4 LUBRICATION 17
4.1.17.4.1 GEARBOX LUBRICATION 17
4.1.17.4.2 OIL FILLING 18
4.1.17.4.3 OIL DRAINING AND REPLACEMENT 18
4.1.17.5 START UP AND RUNNING IN 19
4.1.17.6 MAINTENANCE 20
4.1.18 HOISTING AND LUFFING GEAR 21
4.1.18.1 WINCH DRIVE – 7C SERIES 22
4.1.18.1.1 MANUAL AIM 22
4.1.18.1.2 INFORMATION ON SAFETY 23
4.1.18.2 INSTALLATION 24
4.1.18.2.1 DIRECTION OF ROTATION 24
4.1.18.2.2 CONSTRUKTION OF THE DRUM FRAME 25
4.1.18.2.3 HYDRAULIC MOTOR INSTALLATION 26
4.1.18.2.4 INSTALLATION OF THE GEARBOX ON THE WINCH 29
4.1.18.2.5 CONNECTION OF THE BRAKE 30
4.1.18.3 LUBRICATION 31
4.1.18.3.1 GEARBOX LUBRICATION 31
4.1.18.3.2 OIL FILLING 32
4.1.18.3.3 OIL DRAINING AND REPLACEMENT 33
4.1.18.4 START UP AND RUNNING IN 34
4.1.18.5 MAINTENANCE 35
4.1.18.5.1 TROUBLE SHOOTINGS 36
4.1.19 GREASING POINTS – CRANE 39
4.1.20 OIL CHANGE 40
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4.2 MAINTENANCE SCHEDULE 41

4.3 LUBRICANTS 43
4.4 ELECTRICAL EQUIPMENT 44
4.4.1 SAFETY DEVICES 44
4.4.2 LIGHTING 45
4.4.3 MOTORS 45
4.4.4 SLIPRING BODIES 45
4.4.5 CIRCUIT BREAKERS 45
4.5 HYDRAULIC EQUIPMENT 47
4.5.1 FUNCTIONAL DESCRIPTION 50
4.5.1.1 HOISTING GEAR CIRCUIT 1.0 50
4.5.1.2 LUFFING GEAR CIRCUIT 2.0 52
4.5.1.3 SLEWING GEAR CIRCUIT 3.0 52
4.5.1.4 BOOSTING AND CONTROL OIL CIRCUIT 4.0 53
4.5.1.5 OIL COOLING 5.0 56
4.5.1.6 HYDRAULIC OIL TANK 6.0 56
4.5.1.7 FILLING 7.0 56
4.5.1.8 EMERGENCY OPERATION 8.0 57
4.5.2 GENERAL REMARKS 59
4.5.2.1 PUTTING SYSTEMS INTO OPERATION (BY WORKS PERSONNEL) 61
4.5.2.2 INSPECTION AND MAINTENANCE 62
4.5.2.3 OPERATION AND MAINTENANCE OF HYDRAULIC PUMPS AND
MOTORS 65
4.5.2.3.1 GENERAL REMARKS 65
4.5.2.3.2 INSTALLATION 65
4.5.2.3.3 FIRST START 65
4.5.2.3.4 ROUTINE MAINTENANCE 66
4.5.2.4 TROUBLESHOOTING 66
4.5.2.5 TROUBLESHOOTING 67
4.6 ASSEMBLY AND DISMANTLING 72
4.6.2 ROPE REPLACEMENT 75
4.6.3 HAND SIGNALS FOR CRANES 78
4.6.4 TIGHTENING TORQUES FOR HEXAGON BOLTS AND SPANNER BOLTS 79
4.6.5 INSTALLATION OF HOSES 80
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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
4-8 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

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 ji b 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.
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.
4-10 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

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".
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-11

4.1.17.2 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 hole s of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.
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4.1.17.3 INSTALLATION
4.1.17.3.1 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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-13

4.1.17.3.2 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
4-14 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

4.1.17.3.3 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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-15

4.1.17.3.4 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).
4.1.17.3.5 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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4.1.17.4 LUBRICATION
4.1.17.4.1 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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-17

4.1.17.4.2 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%
4.1.17.4.3 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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4.1.17.5 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
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-19

4.1.17.6 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
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-21

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.
INFORMATION!

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.
4-22 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

4.1.18.1.2 INFORMATION ON SAFETY

manufacturer. Doing this, will ensure that the product works properly and that the safety level is
"acceptable".
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-23

4.1.18.2 INSTALLATION
4.1.18.2.1 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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4.1.18.2.2 CONSTRUKTION OF THE DRUM FRAME
CORRECT CONSTRUCTION OF THE DRUM FRAME AND RELATIVE COUPLING INDICATIONS ARE
SHOWN HERE FOLLOW.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-25

4.1.18.2.3 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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4.1.18.2.4 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:
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-29

4.1.18.2.5 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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4.1.18.3 LUBRICATION
4.1.18.3.1 GEARBOX LUBRICATION

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.
INFORMATION!
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-31

4.1.18.3.2 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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4.1.18.3.3 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.
WARNING!
WARNING!
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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-33

4.1.18.4 START UP AND RUNNING IN
INFORMATION!
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!
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT. DURING THE RUNNING-IN STAGE
FOLLOW THE STEPS GIVEN BELOW.
5. Make sure that the oil temperature does not exceed 90°.
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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4.1.18.5 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!

SPARE PART LISTS EXPLODED IEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
Do not hesitate to contatct the gearbox distributor or manufacturer if further instructions are necessary or in
case of particular problems.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-35

4.1.18.5.1 TROUBLE SHOOTINGS

The following table is realized to localize troubles in winch drive gearboxes 700C SERIES.
4-36 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-37

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
(2 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
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-41

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
(2×36 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
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 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 w ithin certain limits, the minimum swash angle is limited
to abt. 10°. Displacement control is described in d etail 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 ) 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 (4.1) is a fly pump (K3VL80). 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 (4.1) 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 2.23
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, 2.27,
3.12, 3.27.
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) 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 resistance 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
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-67


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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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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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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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

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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-73

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.
4-74 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-75

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.
4-76 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-77

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.)
4-78 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

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.
MAINTENANCE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 4-79

4.6.5 INSTALLATION OF HOSES
4-80 Ind. 00 / 08-2009 2-571-7/3945-7/3948 MAINTENANCE 3945-3948

7/3945 - 7/3948 ECTRICAL EQUIPMENT
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 MAIN SWITCH 5
5.2.4 CRANE OPERATION (NORMAL MODE) 6
5.2.5 SWITCH GEAR 7
5.2.6 SENSORS 8
5.2.7 LIMIT SWITCHES 9
5.2.8 PROGRAMMABLE LOGIC CONTROLLER (PLC) 10
5.3 DISPLAY AND INDICATORS 11
5.3.1 INDICATOR LIGHTS 11
5.3.2 DISPLAY OF CRANE INFORMATIONS 11
5.3.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT PANEL) 12
5.3.3.1 OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS 13
5.3.3.2 HOW TO ENTER MAIN MENU 13
5.4 COMMISSIONING AND ADJUSTMENTS 20
5.4.1 GENERAL DEFAULT SETTING 21
5.4.2 PLC CHANGE 22
5.4.3 SETTING THE MINIMUM CURRENT FOR SLEWING GEAR 23
5.4.4 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER PUMP) 24
5.4.5 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT) 25
5.4.5.1 SETTING LAYER CHANGE POSITION 28
5.4.5.2 RESETTING OF REFERENCE POSITIONS 29
5.4.5.3 FORCING OF REFERENCE POSITIONS 33
5.4.6 ADJUSTABLE WORKING RANGE LIMITATION 34
5.4.7 SPECIAL MODUS FOR ROPE CHANGE 37
5.4.8 CALIBRATION OF LOAD INDICATION 38
5.4.9 REPORT OF CHANGE 41
5.4.10 ZERO-SETTING OF POTENTIOMETERS 42
5.4.11 SETTING OF OPERATION HOURS 42
5.4.12 ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT) 42
5.5 CRANE OPERATION MODES 43
5.5.1 GRAB OPERATION 43
5.6 INTERLOCKING FOR SEA VOYAGE (SPECIAL EQUIPMENT) 45
5.6.1 LOCKING 45
5.6.2 UNLOCKING 46
5.6.3 FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM 47
5.6.3.1 SETTING THE PRESSURE LIMITING VALVE 50
5.6.3.2 LOCK / UNLOCK IN EMERGENCY OPERATION 51
5.7 PMS – POWER MANAGEMENT SYSTEM (SPECIAL EQUIPMENT) 52
5.7.1 FUNCTIONAL DESCRIPTION 52
ELECTRICAL EQUIPMENT 7/3945 - 7/3948 2-571-7/3945 - 7/3948 Ind. 00 /08-2009 5-1
7/3945 - 7/3948 ELECTRICAL EQUIPMENT
5.8 SPECIAL OPERATION MODES 53

5.8.1 TEST OPERATION 53
5.8.2 POWER / SPEED REDUCTION 53
5.8.3 DISABLE TRIMOT 53
5.9 TROUBLE SHOOTING 54
5.9.1.1 FAULT INDICATIONS 54
5.9.1.2 CONDITION INDICATIONS 54
5.9.1.3 PLC STATUS INDICATORS 55
5.9.1.4 ADDITIONAL INDICATIONS 55
5.9.2 LIST OF FAULT MESSAGES 56
5.10 EMERGENCY OPERATION SYSTEM 116
5.11 SERVICE 118
5.11.1 MAINTENANCE INFORMATION FOR HYDRAULICAL 118
5.11.2 MAINTENANCE OF ELECTRICAL EQUIPMENT 119
5.11.3 SPARE PARTS 121
5.12 APPENDIX 122
5.12.1 DESCRIPTION OF THE ELECTRICAL COMPONENTS 122
5.12.1.1 MAIN SWITCH (LOAD BREAKER) 122
5.12.1.2 GEARED LIMIT SWITCHES - SERIES 51 129
5.12.1.3 PROGRAMMABLE LOGIC CONTROLLER (PLC) 133
5.12.1.4 COMPACT MODULE PWM 142
5.12.1.5 COMPACT MODULE DIGITAL / ANALOGE 150
5.12.1.6 CABINET-MODULE 158
5.12.1.7 INCLINOMETER ( SPECIAL EQUIPMENT ) 165
5.12.1.8 LCD-DISPLAY 170
5.12.2 CIRCUIT DIAGRAMS 174
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.
5-2 Ind. 00 / 08-2009 2-571-7/3945 - 7/3948 ELECTRICAL EQUIPMENT 7/3945 - 7/3948

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): 11.5 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: (optional) 2 x 1000 W, halogen
Warning light red: 1 x 60 W
Machinery space heating: 2000 W
Cabin heating: 1400 W

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 2 rings for 250 V, 60 A
Auxiliary supply and controls up to 13 rings for 250 V, 16 A
The main supply is taken from the slip ring assembly 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 assembly to terminals X3-1 and -2 in the control cabinet.
The auxiliary supply can be switched off by means of the main switch (=M01-S2) for repair and maintenance
work.
From main 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 heating is operational.

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 electrical 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 450 mA. The actual control current varies according to the load
on the hoisting gear, which is measured by a 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.
5.2.3 MAIN SWITCH

The crane will be switched on and off with the main switch =M01-S1.
The main switch is a load breaker acc. IEC/EN 60204 with an emergency release.
This emergency function will be actuated by an under voltage release connected in line to the emergency
stop button in the right hand control desk and on deck area (optional equipment).
The main switch can be switched on only when there is power at this under voltage release.
If the main switch cannot be switched on please check the emergency stop buttons are not actuated, check
the voltage of the main power supply, and check that the circuit breaker =M01-Q1 is on.
Remark: If the under voltage release unit of the main switch itself is defective the main switch can be
switched on when this under voltage release unit will be removed from the main switch.
This should be done only in case of emergency when no spare is available. Without under voltage
release unit no emergency stop (cut off) is given. This is a very dangerous situation – no normal
crane operation is allowed without emergency stop function of the main switch.
See also DESCRIPTION OF ELECTRICAL COMPONENTS (APPENDIX)

5.2.4 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 control system.
When the crane system receives a POWER AVAILABLE SIGNAL from the ship 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 procedure. 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>
The PMS POWER MANAGEMENT SYSREM is an optional equipment without this the main motor will start
with a delay of 8 seconds after starting the booster pump.
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 dead man 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 15°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 measured with the 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 and pumps 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 into OFF-position before the crane can be started
again.

5.2.5 SWITCH GEAR

The crane control will be switched on and off with the main switch =M01-S1.
This main switch has an under voltage release connected to the emergency stop button in the r.h. control
desk and on deck area (special equipment).
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 =M02-K4, are switched
directly by a PLC output.
The main motor is protected against overload by thermistor and additionally by monitoring the amperage
with the current-transformer =M02-T1.
The aux. drive motors =M02-M11 + -M12 are protected against overload by motor circuit breakers.
The 24 V DC control voltage is produced by the three-phase power unit =M01-U1.

5.2.6 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 (slewing left, luffing out, hook lowering) respectively 24 V at maximum joystick deflection (slewing right,
luffing in, hook lifting).
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)

5.2.7 LIMIT SWITCHES

The travel route of the hoisting gear(s) 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.

5.2.8 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 =M01-F21 / -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 in appendix
DESCRIPTION OF ELECTRICAL COMPONENTS.
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.

5.3 DISPLAY AND INDICATORS

A horn (=M05-H50) 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.
In the r-h control desk a small buzzer is installed which sounds short signals in case of condition and fault
status.
5.3.1 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.
5.3.2 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 (bow) 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.

5.3.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT

PANEL)
A LCD Display with 8 plunger-operated buttons and status LED´s 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
clear text 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.

5.3.3.1 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
5.3.3.2 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.

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.

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.

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”.

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.

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”.

Now you must press Enter to set the system back to default settings. Otherwise press key to
go “BACK”.
Finally the system informs you that the settings now reset to factor default.
press key to go “BACK” to main service menu.

5.4 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

5.4.1 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
formatted and parameterised with the default operational values.
If this default setting is carried out all previous personnel adjustments of the control system will be
overwritten.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET DEFAULT SETTINGS
follow the instruction displayed

5.4.2 PLC CHANGE

After replacing the main controller R 360 (located in the control cabinet) the internal memory of the
PLC must be formatted and parameterised with the default operational values.
If this default setting is carried out all previous personnel adjustments of the control system will be
overwritten.
Before replacing the PLC please do the following steps:

1. Switch POWER ON
2. Check the load-adjustment on the display MENU SECURED AREA LOAD ADJUSTMENT
(security code needed!) and write down the „CALCULATION VALUE“
3. Check on the display MENU CRANE INFORMATION the OPERATION HOURS and write them
down
4. Switch POWER OFF
5. Replace PLC
After replacing the PLC please do the following steps:

1. Switch POWER ON
2. Check the crane number and ship number on the display, if it is correct, continue with step 4.
3. Set the crane and ship number MENU SECURED AREA
4. Set the PLC to factory default MENU SECURED AREA SET DEFAULT SETTINGS
5. Switch POWER OFF and ON to restart PLC
6. Check the LOAD CALCULATION VALUE: MENU SECURED AREA LOAD ADJUSTMENT, if
necessary overwrite it with the one from the old PLC
7. Set the operation hours MENU SECURED AREA SET OPERATION HOURS
8. Set the reference positions, it could be necessary to adjust the limit switches of hoisting and luffing
gear. MENU SECURED AREA RESET OF POSITIONING SYSTEMRESET OF
REFERENCE POSITIONS
Normally all the reference positions of the crane must be reset by driving with the corresponding drive
into these positions:
for the hoisting drive(s) = highest and deepest hook position
for the luffing drive = maximum and minimum outreach.
Sometimes it is not possible to drive into the deepest position because the hatch is not empty.
For that reason the outstanding reference positions can be forced.
MENU SECURED AREA FORCING OF REFERENCE POSITIONS >.
9. Set the layer-change position MENU SECURED AREA SET LAYER CHANGE POSITION
For detailed information please refer to the relevant operating instructions.

5.4.3 SETTING THE MINIMUM CURRENT FOR SLEWING GEAR

During the first start i.e. when activating the control system for the first time and after replacing the
Main controller R 360 (located inside the control cabinet) the minimum current for the slewing gear
pump control should be checked and if necessary adjusted.
General remark:
The start of oil delivery of the pumps will be determined by the minimum current value.
This value has a tolerance of ±10% and depending on the maker of the pumps this value can be different.
The default value for the minimum current is 200mA.
To reach an optimal slewing gear speed control the minimum current for the slewing gear pump control should
be checked and if necessary adjusted.
(For the hoisting and luffing gear an automatic self-adjustment will be carried out by the PLC.)
Procedure:
Before starting the pump adjustment the slewing drive should have run for a while to bleed out possible air in
the hydraulic circuit and to warm up the system.
• Connect a 400 bar pressure gauge to the measuring point DMP1 on the pump (high pressure side for
slewing clockwise).
• Start the crane motors.
• Select on the display the mode for the pump adjustment.
• Set MAIN MENU
• Select SET SLEWING GEAR MINIMUM CURRENT
When this menu is selected the pump control current for slewing clockwise will be set on the ACTUAL VALUE.
Observe the pressure displayed on the gauge.
The pressure should not increase above 30bar if it is higher then the pump control current shall be decreased
by pressing the button -10mA so often until the pressure is dropping down below 30bar. The change of the
pump control current is indicated as NEW VALUE.
If the pressure is below 30bar then press the button +10mA and wait about 2 seconds. The change of the
pump control current is indicated as NEW VALUE.
If in this time the pressure is not increasing then press the button +10mA again and wait another 2 seconds.
Repeat this procedure until the pressure is increasing. Now press the button SET and the ACTUAL VALUE will
be overridden by the NEW VALUE.
The new pump adjustment now is stored in the PLC memory; leave the adjustment mode by pressing the
BACK button.

5.4.4 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.
Procedure:
• Set MAIN MENU
• Select CONTROL PRESSURE ADJUSTMENT
press ENTER and SELECTION
to set = TRUE or reset = FALSE this special mode

5.4.5 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)

Work on the electrical equipment of the crane is to be performed only by well trained personnel.
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 SET LIMIT SWITCHES
• Select LUFFING GEAR or MAIN HOISTING GEAR or AUXILIARY HOISTING GEAR
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 in the jib 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”

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)

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.
After the basic adjustment of the limit switches the LAYER CHANGE POSITION (next chapter) has to be
checked respectively set.

5.4.5.1 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
nd
the rope will turn in the 2 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 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.

5.4.5.2 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 or F3312 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 chapter:
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

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 hoisting and slewing
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.
Normally all the indications for the reference values must be TRUE. If any value is on FALSE the
corresponding drive fault has been reset the reference value.
For example a failure in the positioning system of the hoisting drive will reset the reference value for
highest hook position (indication HIGH changes to FALSE).
The reference value for deepest hook position (indication DEEP) will be reset only when the complete PLC
program is set on DEFAULT, or the positioning system is reset by procedure POSITIONING SYSTEM TO
DEFAULT SETTING, or the positioning system is reset by procedure SET LIMIT SWITCHES.
Restoring 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.
If the reference value for IN is FALSE the minimum outreach reference value must also be set accordingly
to the procedure for the maximum.
The reference value for the maximum outreach must be set absolutely first.

Restoring 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.
If the reference value for DEEP is FALSE the deepest position reference value must also be set
accordingly to the procedure for the highest.
The reference value for the highest hook position must be set absolutely first.
Restoring 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.
Restoring 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 parking/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.
Normally the reference positions of the crane will be reset by driving with the corresponding drive into these
positions:
For the hoisting drive(s) = highest hook position
For the luffing drive = maximum outreach.
It could happen that the crane control also has lost the data for the deepest hook position and minimum
outreach. This will happen if the codes <SET DEFAULT SETTINGS> or <POSITIONING SYSTEM TO
DEFAULT SETTINGS> or <SET LIMIT SWITCHES> has been activated before.
Now it is necessary to drive into all the reference positions:
For the hoisting drive(s) = highest and deepest hook position
For the luffing drive = maximum and minimum outreach.
Therefore it is possible to reset all reference positions together; this is called FORCING OF REFERENCE
POSITIONS.
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

5.4.5.3 FORCING OF REFERENCE POSITIONS

Normally the reference positions of the crane will be reset by driving with the corresponding drive into these
positions:
For the hoisting drive(s) = highest hook position
For the luffing drive = maximum outreach.
It could happen that the crane control also has lost the data for the deepest hook position and minimum
outreach. This will happen if the codes <SET DEFAULT SETTINGS> or <POSITIONING SYSTEM TO
DEFAULT SETTINGS> or <SET LIMIT SWITCHES> has been activated before.
Now it is necessary to drive into all the reference positions:
For the hoisting drive(s) = highest and deepest hook position
For the luffing drive = maximum and minimum outreach.
Therefore it is possible to reset all reference positions together; this is called FORCING OF REFERENCE
POSITIONS.
Procedure:
• Set MAIN MENU
• Select FORCE REFERENCE POSITIONS
The command FORCING OF REFERENCE POSITIONS only must be carried out if it is

sure that the mechanical limit switch contacts have not been re-adjusted and the reference
positions for the highest hook and maximum outreach are <TRUE>.
When the status of all reference positions is <TRUE> leave the program by pressing BACK.
Switch off the main switch and after switching on again check the limit switches for
highest hook position and maximum outreach.

5.4.6 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.

In the following menu the security code for the activation must be entered
by using the keys ←→↑↓ the security code is 887564.
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.

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.

5.4.7 SPECIAL MODUS FOR ROPE CHANGE

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 ROPE CHANGE MODUS
• Select L_ROPE_CHANGE or H_ROPE_CHANGE
• Select FALSE or TRUE and ENTER

5.4.8 CALIBRATION OF LOAD INDICATION

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:
• In Main Page select MENUE
• In MAIN MENU select SECURED AREA (KEY-CODE IS ON DEMAND)
• In SECURED AREA press NEXT until Page 152 appears

• NEXT
• In Page 152 select LOAD ADJUSTMENT

On Page 205 LOAD ADJUSTMENT the actual load is shown. Lift up the test weight with slow speed
approx. 1 meter. The test weight should have a weight near by the SWL-Load of the crane. When the drive
nd
has stopped, on the display you can see the measured and calculated load, in the 2 line the actual value
rd
for the load calculation, in the 3 line you can select a new calculation value (a higher one would increase
the load). To overwrite the calculated value choose the Item OVERWRITE CALC_VALUE and press
ENTER. Page 207 will appear. To store the new value press ENTER and go back to the load adjustment
settings page with the BACK button. If the load displayed corresponds now to the lifted weight, you can
leave the load adjustment settings with the BACK button until the MAIN MENUE page will appear.
• Page 207 to store the new value in the PLC

5.4.9 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.
Email: info@tts-lmg.de

5.4.10 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 ZERO-SET OF POTENTIOMETERS
PRESS ENTER TO CALIBRATE
5.4.11 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 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.
5.4.12 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 sl ewing 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 ZERO-SETTING OF INCLINOMETER
Select YES and ENTER

5.5 CRANE OPERATION MODES

The normal operation mode is the hook operation.
If the crane is equipped with an optional grab operation the crane control system must be set into
grab operation mode if a grab is connected to the crane.
5.5.1 GRAB OPERATION

When the grab operation will be switched on for the first time with the key-operated switch <GRAB
OPERATION> in the right control desk the following menu will be displayed.
It is also possible to call up this menu by manual selection when it is necessary to change the operation
mode or when another grab type has been connected to the crane:
• Set MAIN MENU

• Select GRAB OPERATION SELECTION
Now it is possible to select between the stated modes by pressing the corresponding display button.
The status indication will change from FALSE to TRUE.
If no grab is connected to the crane the button <NO GRAB> must be pressed.
If the single rope grab has been selected the display changes to the menu
Now the rope way which is necessary to close the grab must be entered for <NEW ROPE WAY>.
Insert the corresponding length into the space after NEW ROPE WAY then select OVERWRITE OLD
VALUE and press ENTER. Now the same (right) value shall stay for NEW ROPE WAY and OLD ROPE
WAY.
Press BACK to leave this menu.

Remark:
The default value for the rope way is 6.0 (m). The right rope way must be checked and if necessary
be changed because the hoisting speed will be automatically reduced before the grab is completely
closed to prevent hard shocks from the crane equipment.
If the speed reduction occurs to early (the hoisting speed is increasing again before the grab is
closed) than this ROPE WAY value must be decreased). When the reduction is to late (the hoisting
speed is too high or is still ramping down when the grab is completely closed or the speed will be
reduced when the grab has already lifted from the ground) than the ROPE WAY value must be
increased to achieve an optimize result.
If the grab operation is switched on in the main operation menu the following condition indications will be
shown in the top line on the display:
C5121 SPEED LIMITATION BY GRAB CONTROL
C5122 SPEED LIMITATION BY GRAB CONTROL
C5125 GRAB ON GROUND

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 hand control desk. One of the two
proximity switches monitoring the slewing gear position must be covered by the control plate. 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.

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-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 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

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
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":

• Set MAIN MENU
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.


The position of the locking cylinders is monitored by proximity switches.
This fault will be announced if the signalled condition is not logical.
• Set MAIN MENU

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
− 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.

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".
• Set MAIN MENU

Remedial action:
- Check the proximity switches
- Check the pilot markers (both proximity switches must be half covered)
− Check the leads
− Replace PLC.


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 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 EOS INTERLOCKING SYSTEM

5.6.3.1 SETTING THE PRESSURE LIMITING VALVE

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.

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.
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 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.

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 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 assembly.
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 50 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

5.8 SPECIAL OPERATION MODES

5.8.1 TEST OPERATION
This special mode allows checking 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 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 its 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 SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE
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 DISABLE TRIMOT
T_DISABLE: can now be activated = TRUE / deactivated = FALSE

5.9 TROUBLE SHOOTING

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.
5.9.1.1 FAULT INDICATIONS

"FAULT" signalises malfunctions or faults which interrupt crane operation or certain functions and must be
RESET after repair; or to set the system by into normal.
For FAULT–reset please press the <F2> button on the display.
5.9.1.2 CONDITION INDICATIONS

"CONDITIONS" 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.
CONDITIONS will be reset automatically when the drive is actuated in the opposite direction.

POWER SUPPLY AND CONTROL VOLTAGE
The power supply is feed from the ship's mains to the crane main switch via slip rings.
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-primary switcher unit =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.
5.9.1.3 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.
5.9.1.4 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
Choose the required information

5.9.2 LIST OF FAULT MESSAGES

and fault identification instructions
F 003 MAIN SWITCH CONTROL
Appears if main switch trips while pump drive motors are 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.
F 0004 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).

• Set MAIN MENU
The status of the inputs is displayed with <TRUE> or <FALSE>.
Remedial action:
− Check the relay =M06-KRQ, this relay must be switched on
during run time of the crane.
− Check the relay =M06-KEN, it will be activated by the power
available signal from ECR. This relay is supplied with 220V via
the circuit breaker =M03-F34; check the supply voltage.
− Check the wiring and the connections via slip ring assembly
− Check the control system of the ship controls in the engine
control room (ECR)

F 0005 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.

• Set MAIN MENU
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.
− Replace the PLC.
C 0006 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)

• Set MAIN MENU
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 0007 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 SET OPERATING HOURS
SET NEW OPERATION HOURS M01:by corresponding data input
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.

• Set MAIN MENU
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
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.

• Set MAIN MENU
Remedial action:

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

• Set MAIN MENU
Remedial action:
For example:
On the crane the fault F0017 is displayed that means there is an input signal on channel 5 or
channel 7 of the analogue input module =M07-A4.
Please check which LED indication for channel 5 or channel 7 is lighting (normally the LED´s must
be off).
Then check the corresponding pressure switch M07-S30 or -S31. Maybe the connecting pins are
bended so that the plugs will contact or the pressure switch itself is defective (the contact must be
open).
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 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
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.
F 0140 OIL LEVEL MINIMUM
The level in the hydraulic oil tank will be controlled by an oil level switch.
Fault message F0140 appears on the display if oil level is below the minimum permissible stand.

• Set MAIN MENU
Remedial action:
− Check the oil level in the tank (there are control eyes on the side
wall of the tank).
− Check the function of the oil level indicator switch.
− Check the connection (wiring) between switch and module input.

F 0160 OIL OVERTEMPERATURE

C 0165 PRE-WARNING OIL OVERTEMPERATURE
The hydraulic oil temperature is monitored by the temperature sensor =M07-B01.

Fault message F0160 appears on the display if the maximum permissible temperature of 90°C is
exceeded. This fault will stop all drives.
Condition message C0165 appears on the display if the temperature exceeds 87°C, in this case the speed
of the hoisting drive will be reduced until the temperature is falling down below 86°C.

• Set MAIN MENU
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.
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.

• Set MAIN MENU
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.

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).

• Set MAIN MENU
Remedial action:
− Replace the filter cartridge.
− Check the pressure switch characteristics (the contact must be
closed).
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.

• Set MAIN MENU
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.

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.

• Set MAIN MENU
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.
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.

• Set MAIN MENU
Remedial action:
− Check the air circulation in the machinery space (air supply via
the crane column, exhaust via the hydraulic oil cooler).
− Check the thermistor 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.

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.

• Set MAIN MENU
The value of the sensor is displayed in µA and the calculated motor amperage A.
(v1-v2)
(A=I * 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).
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).

• Set MAIN MENU
(v1-v2)
(A=I * 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.

F 0253 IDLE RUNNING AMPERAGE MAIN MOTOR
Fault message appears if the current drawn is higher than that normally drawn under no-load conditions
(protection against phase failure).

• Set MAIN MENU
(v1-v2)
(A=I * 1,73
Remedial action:
C 0711 POWER REDUCTION (MAIN MOTOR AMPERAGE)
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.

• Set MAIN MENU
(v1-v2)
(A=I * 1,73
Remedial action:

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 SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be
activated = TRUE / deactivated = FALSE
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 bars.

• Set MAIN MENU
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 if
necessary.
− (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.

• Set MAIN MENU
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.
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.

• Set MAIN MENUE
Remedial action:
− E.g. interchange the hoisting pressure sensor against the luffing
defective.
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 bars (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.

• Set MAIN MENU
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.
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.

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 bars.

• Set MAIN MENU
Remedial action:
− 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).
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.

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 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.
− 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.
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)
lever deflection.

• Set MAIN MENU
The potentiometer value must be below 100 when the contact condition is false.
Remedial action:
− Check the wiring and the supply connections of the
potentiometer.
neutral position).
− Most of time it is a supply failure or the potentiometer itself is
defective.
− Additional information regarding EOS 1070.
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.

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 DRIVE VALUES
Remedial action:
− Check the wiring to the solenoid valve.
− Check the resistance of the solenoid coil. (approx. 24-30Ω)
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.

• Set MAIN MENU
Remedial action:
− Check the winch temperature.
− Check the temperature switch
− Check the wiring between switch and PLC

F 1091 SECURITY CHECK WINCH OVERTEMPERATURE
reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that
the PLC input itself is defective.

• Set MAIN MENU
Remedial action:
− Exchange the PLC.
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.

• Set MAIN MENU
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.

C 1211 LIFTING LIMIT (MECHANICAL SWITCH)
The lifting height 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:

• Set MAIN MENU
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.
REMARK: Only when the jib is in the maximal outreach position (maximal working range) and the
hook is in the highest position there is a distance of approx. 1 meter between jib head and hook
block.
When the jib is luffed in (lifted up) the distance between jib head and hook block will increase
because the hook is moving in a horizontal way.
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“
block.

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.
Remedial action:
block.
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:

• Set MAIN MENU
Remedial action:
− Check the mechanism of the limit switch (connection to the
hoisting gear drum, limit switch coupling, limit switch gear, cam
shaft)
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.
measurement.
Remedial action:

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.

• Set MAIN MENU
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
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 earthen 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.
C 1221 LOWERING LIMIT (ROPE LENGTH)
The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried
Remedial action:
C 1222 DEAD MAN SWITCH NOT ACTUATED
The control leaver is equipped with a dead man switch. This switch must be actuated before the leaver is
moved from neutral position.

• Set MAIN MENU
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 dead man switching contact.
− Replace the cabinet module.

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
− 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
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.
system.
The counter values can be displayed:

• Set MAIN MENU
<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:

replaced.

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).
system.

• Set MAIN MENU
Remedial action:
− Check the limit switch contacts (function and adjustment)
− Check the counter value of the position counter

F 1304 HOISTING COUNTER MONITORING (HP)
The limit position is monitored by the mechanical limit switch contact 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).
system.

• Set MAIN MENU
Remedial action:


F 1305 HOISTING GEAR IS BLOCKED
The outputs of the incremental encoder are monitored while the winch is running, the counter value 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).
The counter value can be displayed:

• Set MAIN MENU
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 bars
− Press the emergency button on the solenoid valve of the pump
control unit, the pressure must increase up to 300 bars
− 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.
system.
Remedial action:
− interchange the outputs of the encoder
− Replace the encoder


F 1307 HOISTING NO COUNTING PULSES
The outputs of the incremental encoder are monitored while the winch is running; the counter value must
system.

• Set MAIN MENU
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
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 PLC, or the PWM module

F 1308 HOISTING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the unwind 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.
system.
Remedial action:
− Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
− Replace the PLC

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 DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
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
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.

F 1311 HOISTING OVERSPEED (EMPTY HOOK)


• Set MAIN MENU
Remedial action:
− Check the minimum displacement angle of the TRIMOT.
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.
Until the system has not been reset the drive speed is restricted and the crane load is limited to the SWL
value which the crane can lift at maximal outreach range.
For resetting the system the luffing and hoisting gear must be driven to the following positions:
• 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 maximal outreach and hook(s) in highest position is the crane reference/default position.
The drives will stop at this limit positions and in this position the fault F1312 automatically will be reset.
Remedial action:

F 1313 HOISTING COUNTER MONITORING (DP)
system.

• Set MAIN MENU
Remedial action:


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 CURRENT OUTPUTS
The actual amperage is displayed

• Set MAIN MENU
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.

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.

• Set MAIN MENU
Remedial action:
gauge. (Cf. specification of the hydraulic system.)
− Measure the characteristics of the switch and replace if
necessary.
− (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.

• Set MAIN MENU
Remedial action:
− e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
defective.

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.

• Set MAIN MENU
Remedial action:
defective.

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.

• Set MAIN MENU
Remedial action:
− If no pressure build-up can be noticed, press the emergency
button of the solenoid valve directly for functional test of the
pump.
defective.
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.

• Set MAIN MENU
Remedial action:
− 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).
− E.g. interchange the luffing pressure sensor against the hoisting
defective.

F 2060 LUFFING CONTROL LEVER (OFFSET)
lever deflection.
Fault message is generated if the output voltage deviates more than 10% from the rated value when the

• Set MAIN MENU
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and
the contact condition is displayed false/true.
Remedial action:
neutral position).
This is a dangerous condition: if the potentiometer or the
analogue input now becomes defective the drive will start
stop only.

F 2070 LUFFING CONTROL LEVER (SUPPLY)
lever deflection.

• Set MAIN MENU
Remedial action:
potentiometer.
neutral position).
defective.
the control lever contacts only, this will be activated by the EOS-
code.
In normal conditions the contacts of the control lever are
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).

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.

• Set MAIN MENU
Remedial action:
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.

• Set MAIN MENU
Remedial action:
− Check the winch temperature.
− Check the temperature switch
− Check the wiring between switch and PLC
F 2091 SECURITY CHECK WINCH OVERTEMPERATURE
reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that
the PLC input itself is defective.

• Set MAIN MENU
Remedial action:
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.

• Set MAIN MENU
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.

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:

• Set MAIN MENU
Remedial action:
− Check the mechanism of the limit switch (connection to the luffing
gear drum, limit switch coupling, limit switch gear, cam shaft)
C 2212 LUFF. OUT LIMIT (ROPE LENGHT)
The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried
If this message appears although the luffing gear is in the "free" range, the rope length measurement
Remedial action:
C 2214 LUFF. OUT PRE-LIMITATION
The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried
measurement.
Remedial action:

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:

• Set MAIN MENU
Remedial action:
− Check the mechanism of the limit switch (connection to the luffing
gear drum, limit switch coupling, limit switch gear, cam shaft)
C 2217 LUFF. IN PRE-LIMITATION
The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried
measurement.
Remedial action:
C 2218 LUFF. IN (ROPE LENGTH)
The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried
measurement.
Remedial action:

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.

• Set MAIN MENU
Remedial action
open)
F 2301 LUFFING COUNTER EQUALITY FAILURE

cut-out is tripped.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed
system.
Remedial action:

replaced.

F 2302 LUFFING COUNTER OUT OF RANGE
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.
system.

• Set MAIN MENU
Remedial action:

replaced.
F 2303 LUFFING COUNTER MONITORING
The limit switches 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).
system.

• Set MAIN MENU
Remedial action:


F 2304 LUFFING COUNTER MONITORING (MAX)
When this fault has been reset, <LUFFTING MUST RUN INTO REF. POSITION> will be displayed
system.

• Set MAIN MENU
Remedial action:

F 2305 LUFFING GEAR HAS BLOCKED
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).

• Set MAIN MENU
Remedial action:
− Press the emergency button on the solenoid valve of the brake,
the pressure must increase up to 24-28 bar
control unit, the pressure must increase up to 300 bar
− Replace the PLC, or digital input/output module

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.
system.
Remedial action:

F 2307 LUFFING NO COUNTING PULSES
system.

• Set MAIN MENU
Remedial action:
set for luffing in run the pressure on the high pressure side of the
pump must increase from 40 bar up to 300 bar
− Check the encoder power supply.
− Check the encoder installation (coupling) inside the limit switch
− Replace the PLC, or the PWM module


F 2308 LUFFING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the unwind 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.
system.
Remedial action:
− Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
− Replace the PLC
F 2309 LUFFING STANDSTILL DRUM MONITORING
If the drive is not activated (brake applied), the winch monitoring system will not signal any motion.
The actual output status can be displayed:

• Set MAIN MENU
• Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
Remedial action:
− Check the brake concerned.
− Check the electrical controls of the brake valves; if necessary,
replace the Compact Module.
F 2310 LUFFING OVERSPEED


• Set MAIN MENU
Remedial action:

F 2312 LUFFING MUST RUN INTO REF. POSITION

Until the system has not been reset the drive speed is restricted, the luffing out movement is blocked when
the hook is in the highest position, and the crane load is limited to the SWL value which the crane can lift at
maximal outreach range.
For resetting the system the luffing gear must be driven to the reference position:
• Jib to the maximum outreach (max. working range).
The drive will stop at this limit position and in this position the fault F1312 automatically will be reset.
Remedial action:
F 2313 LUFFING COUNTER MONITORING (MIN)
When this fault has been reset, <LUFFTING MUST RUN INTO REF. POSITION> will be displayed
system.

• Set MAIN MENU
Remedial action:


F 3010 SLEWING PRESSURE <7bar
The pressure in the slewing gear hydraulic circuit is monitored by switches =M07-S30 and –S31. Fault
signal appears on the display if the pressure drops below 7 bars.

• Set MAIN MENUE
Remedial action:
− Measure the characteristics of the switches and replace if
necessary.
− (Status must be <TRUE> while the pump drive is running.)

F 3060 SLEWING CONTROL LEVER (OFFSET)
lever deflection.
A fault message is generated if the output voltage deviates more than 10% of the rated value when the

• Set MAIN MENU
Remedial action:
neutral position).
This is a dangerous condition: if the potentiometer or the
analogue input now becomes defective the drive will start
stop only.

F 3070 SLEWING CONTROL LEVER (SUPPLY)
lever deflection.

• Set MAIN MENU
Remedial action:
potentiometer.
neutral position).
defective.
the control lever contacts only. This will be activated by the EOS-
code.
In normal condition the contacts of the control lever are
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).

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.

• Set MAIN MENU
Remedial action:
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
Remedial action:
C 3214 RIGHT PRE-LIMITATION
Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
by means of 2 proximity switches, mounted at the slewing rim; these proximity switches are counting the
teeth.
Remedial action:

C 3216 LEFT LIMIT (WORKING RANGE)
teeth.
Remedial action:
C 3217 LEFT PRE-LIMITATION
Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
teeth.
Remedial action:
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>.

• Set MAIN MENU
Remedial action
open)

F 3301 SLEWING COUNTER EQUALITY FAILURE

The teeth of the slewing rim are counted by 2 proximity switches (=M06-B810/B811) to ascertain the
position of the drive.
cut-out is tripped.
When this fault has been reset, <SLEWING MUST RUN INTO REF.-POSITION> will be displayed
system.
Remedial action:

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 fault message is generated if the counter content is not inside its limits.
When this fault has been reset, <SLEWING MUST RUN INTO REF. POSITION> will be displayed
system.

• Set MAIN MENUE
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.
replaced.

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.
system.
Remedial action:
− interchange the proximity switches (pulsors)
− Replace the proximity switches (pulsors)

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
system.
Remedial action:
set the pressure of 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
− Replace the proximity switches (pulsors)
− Replace the PLC


F 3312 SLEWING MUST RUN INTO REF. POSITION

Remedial action:
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 overload will be reset by the system when the load is lowered.

• Set MAIN MENU
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).
− Replace the PLC or the corresponding Compact Module.

C 4102 OVERLOAD 110%
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
more than 10% depending on the outreach range currently in use.
The overload could also be displayed when the driver will lift up the load with too high speed (rough
operation by driver). The overload will be reset by the system when the load is lowered.

• Set MAIN MENU
Remedial action:
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".

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.

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.

• Set MAIN MENU
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.

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 bars.

• Set MAIN MENU
Remedial action:
− Measure the characteristics of the switch and replace as
necessary.
− (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.

• Set MAIN MENU
Remedial action:
− Check the thermal overload relay =M80-Q81 (Status must be
<TRUE>)
− Measure the motor amperage of the grab motor.

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 o ut and lifting, is blocked.
Remedial action:
− Replace the inclinometer (=M07-A8).
− Re-adjust the heeling level, see description under item
<ZERO-SET OF INCLINOMETER>
C 5030 SPEED REDUCTION BY REVERSE POWER CTRL
The power management system of the crane is signalling a too high reverse power of the crane. Therefore
the speed for lowering the hook and luffing out the jib will be reduced to minimize the reverse power.
The reverse power signal will be set by the ship control system (ECR) and the power available signal relay
=M06-KEN (PMS START ENABLE) will trip.

• Set MAIN MENU
Remedial action:
− Check the relay =M06-KEN, normally this relay must be switched
on during crane operation.
− Check the reverse power control relay in the ship control system
(ECR)
− Check the wiring between ECR and crane control cabinet.

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 can be eliminated by entering <NO GRAB> into the PLC.
Explanation sees under Item GRAB OPERATION.
C 5121 SPEED LIMITATION BY GRAB CONTROL

C 5122 SPEED LIMITATION BY GRAB CONTROL
The hoisting speed is reduced by the crane control to prevent hard shocks from the crane equipment
during pick up the grab from the ground or closing procedure of the grab.
C 5125 GRAB ON GROUND
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.
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).
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
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.
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

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

F 830 Compact Module ANALOG not initiated

F 840 Cabinet Module not initiated
The cabinet module =M07-A5 is defective and must be renewed.

F 0850 Compact Module PWM_2 not initiated

F 0880 Inclinometer not initiated

F 0886 Large LED display not initiated
The display =M07-A11 is defective and must be renewed.


F 0887 SHIPS SERIAL NUMBER NOT VALID
If a new PLC is installed or the system is generally reset to DEFAULT data the corresponding ship number
must be entered into the system. This message appears when no ship number of a wrong ship number has
been entered into the system
Procedure:
• Set MAIN MENU
• Select SECURITY CODE must be set and entered
• Select SET SHIP NUMBER (corresponding crane number must be entered)
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 SECURITY CODE must be set and entered
• Select SET CRANE NUMBER (corresponding crane number must be entered)

5.10 EMERGENCY OPERATION SYSTEM

should be allowed to override messages in the emergency operating mode and must take the
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, unit’s
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.

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.
How to activate the Emergency Operation System (key code) see the description under
Overriding fault messages by means of the emergency operating system :
• Set MAIN MENU

• 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.
How to activate the Emergency Operation System (key code) see the description under

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 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.

5.11.2 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 slip ring assembly 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.
Slip ring assembly

Caution!
Make absolutely sure that all feeders from the ship are switched off before work commences on the slip
ring assembly!
Power may be fed to the slip ring body via several independent feeders from the ship.

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
−

5.11.3 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-breaker
1608405 for fuse cartridge

5.12 APPENDIX
5.12.1 DESCRIPTION OF THE ELECTRICAL COMPONENTS

5.12.1.1 MAIN SWITCH (LOAD BREAKER)







5.12.1.2 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.

5.12.1.2.1 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.

5.12.1.2.2 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.

5.12.1.2.3 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-s ide 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.

5.12.1.3 PROGRAMMABLE LOGIC CONTROLLER (PLC)
CONTROLLER R360
Mounting - and installation instructions

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.

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

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






5.12.1.4 COMPACT MODULE PWM

DEUTSCH E
COMPACTMODUL METAL CR2031

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.
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.

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.






5.12.1.5 COMPACT MODULE DIGITAL / ANALOGE
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.

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
can be configured.
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 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.






5.12.1.6 CABINET-MODULE

DEUTSCH ENGLISH

INPUT/OUTPUT MODULE CR2012
Safety instructions

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

people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
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.

INPUT/OUTPUT MODULE CR2012
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
can be configured. The transmission type is non-volatile stored. Changed PDOs (PDO linking) are
volatile stored.
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 module supports a reset function, i.e. assignment of the parameters to the
factory default values* upon request.
ENGLISH





5.12.1.7 INCLINOMETER ( SPECIAL EQUIPMENT )

Safety instructions

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

people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
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.

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*.



5.12.1.8 LCD-DISPLAY



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.

5.12.2 CIRCUIT DIAGRAMS

0 1 2 3 4 5 6 7 8 9
SYSTEM's COVER PAGE

OBSERVE COPYRIGHT AS PER DIN 34
PLANT DESIGNATION :
____________________ TECHNICAL DATAS :
__________________
SINGLE DECK CRANE

CLASSIFICATION SOCIETY : GL
KL30t - 25m YEAR OF CONSTRUCTION : 2008
KL(G)24t - 25m
PLC SYSTEM : ifm R 360, CPU 0505
MAIN POWER SUPPLY : 440V

CRANE-No.:3945-76
Schutzvermerk nach DIN 34 beachten
AUX. POWER SUPPLY : 220V AC
FREQUENCY : 60Hz
MANUFACTURER
____________ :
RATED CURRENTS : 240A, 30A
TTS-LMG Marine Crane GmbH
CONTROL VOLTAGES : 440V , 24V DC
Einsiedelstrasse 6
23554 Lbeck
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. 5002997 Sh.
1
Com-No ass.-gr.
geprft/checked 24.09.08 TTS-LMG
COVER PAGE Typ Bl.
7/3945 97.25 50 1
letzte nd./last mod. 07.07.08 Alpers
Marine Cranes GmbH Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 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 07.07.08 Alpers
=GEN/1 TABLE OF CONTENTS 08.07.08 ALP
=GEN/4 GENERAL MARKINGS 11.07.07 Alpers
=GEN/5 MARKS OF THE TERMINAL BLOCKS 08.07.08 Alpers

=GEN/6 CONTROL CABINET 1800x600x300 DESIGN VIEW 07.07.08 ALP
=GEN/6.1 CONTROL CABINET 1800x600x300 DESIGN VIEW 04.04.08 ALP
=GEN/7 CONTROL DESK LEFT VIEW 07.07.08 Alpers
=GEN/8 CONTROL DESK RIGHT VIEW 07.07.08 Alpers
=GEN/9 OVERVIEW PLC INPUTS/OUTPUTS 08.07.08 ASC

=SRK/1 SLIP RING CONNECTION 07.07.08 Alpers
=SL/1 SINGLE LINE DIAGRAM MAIN POWER SUPPLY 07.07.08 Alpers
=SL/2 SINGLE LINE DIAGRAM LIGHT AND HEATER 07.07.08 Alpers
=SL/3 PLC OVERVIEW 07.07.08 ALP
=M01/1 POWER SUPPLY CIRCUIT DIAGRAM 07.07.08 Alpers
=M01/2 CONTROL VOLTAGE SUPPLY CIRCUIT DIAGRAM 04.04.08 ALP
=M01/3 24 V DC CONTROL VOLTAGE SUPPLY 21.02.08 ALP
=M02/1 MAIN MOTOR CIRCUIT DIAGRAM 07.07.08 Alpers
=M02/2 AUXILIARY DRIVES CIRCUIT DIAGRAM 21.02.08 Alpers

=COV/1 2

Ch.
1
Com-No ass.-gr.
TABLE OF CONTENTS Typ Bl.
7/3945 97.25 50 14
letzte nd./last mod. 08.07.08 ALP
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = GEN

0 1 2 3 4 5 6 7 8 9

Datum / Name
DATE / NAME
=M02/3 STAR/DELTA CONTROL MAINMOTOR CIRCIUT DIAGRAM 16.10.07 Alpers
=M03/1 LIGHT CIRCUIT DIAGRAM 18.10.07 Alpers
=M03/4 HEATERS CIRCUIT DIAGRAM 08.07.08 Alpers
=M03/5 DECK LIGHT CIRCUIT DIAGRAM 07.07.08 Schmahl

=M05/1 AUXILIARY 24V-DC CONSUMERS CIRCUIT DIAGRAM 21.02.08 Alpers
=M06/1 PLC SUPPLY 24V DC CIRCUIT DIAGRAM 08.07.08 Alpers
=M06/2 PLC INPUTS CIRCUIT DIAGRAM 07.07.08 Alpers
=M06/5 PLC INPUTS CIRCUIT DIAGRAM 21.02.08 ALP
=M06/7 PLC OUTPUTS CIRCUIT DIAGRAM 07.07.08 Alpers
=M06/8 PLC OUTPUTS CIRCUIT DIAGRAM 29.01.08 ALP
=M07/1 COMPACT MODULE PWM-OUTPUTS CIRCUIT DIAGRAM 21.02.08 ALP

=M07/2 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 08.07.08 ALP
=M07/3 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 21.02.08 ALP
=M07/4 CABIN MODULE INPUTS CIRCUIT DIAGRAM 21.02.08 Alpers
=M07/5 CABIN MODULE INPUTS CIRCUIT DIAGRAM 07.07.08 Alpers
=M07/6 CABIN MODULE OUTPUTS CIRCUIT DIAGRAM 21.02.08 Alpers
=M07/7 DISPLAY CONNECTION DIAGRAM 16.10.07 Alpers
=PE/1 PE CIRCUIT DIAGRAM 22.02.08 Schmahl
=TERMINALS/1 -XSR SLIP RING ASSEMBLY 07.07.08 ASC
=TERMINALS/2 TERMINAL BLOCK -X3 220V CONTROL CABINET 07.07.08 ASC
=TERMINALS/2.1 TERMINAL BLOCK -X3 220V CONTROL CABINET 07.07.08 ASC
=TERMINALS/3 TERMINAL BLOCK -X4 380/440V CONTROL CABINET 07.07.08 ASC

1 3

Ch.
2
Com-No ass.-gr.
7/3945 97.25 50 14

0 1 2 3 4 5 6 7 8 9

Datum / Name
DATE / NAME
=TERMINALS/4 TERMINAL BLOCK -X5 24V CONTROL CABINET 07.07.08 ASC
=TERMINALS/5 TERMINAL BLOCK -X11 TERMINAL BOX OIL COOLER 07.07.08 ASC
=TERMINALS/6 TERMINAL BLOCK -X12 TERMINAL BOX JIB-BEARING 07.07.08 ASC
=TERMINALS/7 TERMINAL BLOCK -X13 TERMINAL BOX JIB TOP 07.07.08 ASC
=TERMINALS/8 TERMINAL BLOCK -X60 CONTROL DESK LEFT CABIN 07.07.08 ASC
=TERMINALS/9 TERMINAL BLOCK -X62 CONTROL DESK LEFT CABIN 07.07.08 ASC
=TERMINALS/10 TERMINAL BLOCK -X70 CONTROL DESK RIGHT CABIN 07.07.08 ASC
=TERMINALS/11 TERMINAL BLOCK -X72 CONTROL DESK RIGHT CABIN 07.07.08 ASC
=TERMINALS/12 PLUG CONNECTOR -X75 380/440V CONTROL DESK RIGHT 07.07.08 ASC
=TERMINALS/13 -XA1 24V PLC CABINET 07.07.08 ASC
=TERMINALS/13.1 -XA1 24V PLC CABINET 07.07.08 ASC
=TERMINALS/13.2 -XA1 24V PLC CABINET 07.07.08 ASC
=TERMINALS/14 -X1A5 24V CAN NODE CABIN 07.07.08 ASC

=TERMINALS/17 -XA6 24V CAN NODE DISPLAY 07.07.08 ASC
=TERMINALS/18 PLUG CONNECTOR XM50 WINDSCREEN WIPER 07.07.08 ASC
=CABLES/1 CABLE OVERVIEW 07.07.08 ASC
=CABLES/1.1 CABLE OVERVIEW 07.07.08 ASC
=CABLES/1.2 CABLE OVERVIEW 07.07.08 ASC
2 4

Ch.
3
Com-No ass.-gr.
7/3945 97.25 50 14

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

-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
+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

Ch.
4
Com-No ass.-gr.
GENERAL MARKINGS Typ Bl.
7/3945 97.25 50 14

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
-X3.1 TERMINAL BOX DECK LIGHTS
CROSS-SECTIONS ARE VALID,
-X75 380/440V CONTROL DESK RIGHT -X4 380/440V CONTROL CABINET
IF NO FURTHER INSTRUCTIONS ARE MADE:
-X5 24V CONTROL CABINET
-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
-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 - PLC CIRCUITS 24VDC AWG-20 WHITE
-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

-X12.1 TERMINAL BOX JIB-MIDDLE - NOTE TO THE CONDUCTOR COLOURS:
-X13 TERMINAL BOX JIB TOP SHORTENING DELAYED TO DIN IEC 60757
-X39 TERMINAL BOX DECK LIGHTING BK = BLACK

-XA1 24V PLC-CABINET BU = BLUE

-X41 TERMINAL BOX DECK LIGHTING BN = BROWN
-XA2 24V CAN NODE I/O OR = ORANGE
-X81 -X81 TERMINAL BOX PROX. SWITCHES RD = RED
-XA2C CAN BUS SLEWING GEAR 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

Ch.
5
Com-No ass.-gr.
MARKS OF THE TERMINAL BLOCKS Typ Bl.
7/3945 97.25 50 14

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-F36
=M03
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75

CABLE TUNNEL 50x75
-Q1
=M01 =M01 =M02 =M02
-F1
=M01
-T1
=M02
X5
-Q2
=M02-F4
=M02-K2
CONTACTOR
STAR
=M02-K4
-Q11 -Q12
1-2
-K11 -K12 -K33

=M02 =M02 =M03
CABLE TUNNEL 50x75
CLAMPS
SHIELD
-XSAPI
-F2
=M01
X4
X3
=M01
-F11-F17
CABLE TUNNEL 75x75

2- =M06-KEN
1- =M06-KRQ
5 6.1

Ch.
6
Com-No ass.-gr.
CONTROL CABINET 1800x600x300 Typ Bl.
7/3945 97.25 50 14
Marine Cranes GmbH DESIGN VIEW
Sh.

0 1 2 3 4 5 6 7 8 9
CONTROL CABINET CONTROL CABINET

DOOR VIEW (OUTSIDE) DOOR VIEW (INSIDE)
FILTERFAN
PLC - CABLE CONNECTION

MAIN SUPPLY ON
AUX. SUPPLY ON
PLC - R360
MAIN SWITCH
LIGHTING +
HEATING
MAIN SWITCH
POWER SUPPLY
CABINET HEATER
6 7

Ch.
6.1
Com-No ass.-gr.
CONTROL CABINET 1800x600x300 Typ Bl.
7/3945 97.25 50 14
Marine Cranes GmbH DESIGN VIEW
Sh.

0 1 2 3 4 5 6 7 8 9
1
1A 1 = CONTROL LEVER =M06-S22 SLEWING / LUFFING GEAR

=M05-S21H HORN
H
1A = CONTROL LEVER NAME PLATE
10 = SELECTOR SWITCH =M05-S1 WINDSCREEN WIPER

11 = SELECTOR SWITCH =M03-S34 CABIN HEATER
13 = SELECTOR SWITCH =M03-S33 WARNING LIGHT RED
14 = SELECTOR SWITCH =M03-S32 WORKING LIGHT
10 11 15 = SELECTOR SWITCH =M03-S31 CABIN LIGHT

BP
13 14 15
BP = BLIND CAP FOR ADDITIONAL INSTALLATION
6.1 8

Ch.
7
Com-No ass.-gr.
CONTROL Typ Bl.
7/3945 97.25 50 14
Marine Cranes GmbH DESK LEFT VIEW
Sh.

0 1 2 3 4 5 6 7 8 9
DISPLAY
2 = CONTROL LEVER =M07-S12 HOISTING GEAR

2A
2A = CONTROL LEVER NAME PLATE
2
20 20 = EMERG. - OFF BUTTON =M01-S4 EMERG. - OFF

32 BP 34 26 = ILL. SWITCH =M07-S06/H06 START/STOP

READY FOR OPERATION
29 29 = INDICATION LAMP RED =M07-H07 FAULT

BP 31
31 = KEY OPERATED BUTTON =M07-S07 JIB RESTING
26 BP BP 32 = ALARM BUZZER =M07-H08 FAULT
34 = KEY OPERATED SWITCH =M07-S85 GRAB OPERATION

BP = BLIND CAP FOR ADDITIONAL INSTALLATION
7 9

Ch.
8
Com-No ass.-gr.
CONTROL Typ Bl.
7/3945 97.25 50 14
Marine Cranes GmbH DESK RIGHT VIEW
Sh.

0 1 2 3 4 5 6 7 8 9
=M06
-A1
=M06/1.1
CR 0505/0020
PLC MAIN BOARD
INPUTS CAN BUS

AND SERIAL
-XA1
CONNECTIONS
08 14
MAIN MOTOR AMPERAGE =M06/2.1 IW03 CAN 1H =M06/1.5 CAN 1H
27 32
PMS START ENABLE OPTIONAL =M06/2.3 IX0.01 CAN 1L =M06/1.5 CAN 1L
09 33
LIMIT SWITCH CHECK CONTACT =M06/3.3 IX0.02 CAN GND =M06/1.4 CAN GND
28 06
MAIN SWITCH =M06/2.4 IX0.03 RXD =M06/1.4 RXD
10 07
FEED OIL PUMP =M06/2.5 IX0.04 TXD =M06/1.4 TXD
29 24
HYDRAULIC OIL COOLER =M06/2.6 IX0.05 TEST =M06/1.3 TEST
11
DELTA CONTACTOR =M06/2.7 IX0.06 OUTPUTS
30
MAIN MOTOR THERMISTOR RELAY =M06/2.8 IX0.07 I/O's depending on
-XA1
-XA1
hardware configuration
44
IX0.08 QX0.00
44
=M06/7.1 TRIMOT (PWM-OUTPUT) 55-PIN PLUG CONNECTOR
45 45
IX0.09 QX0.01 =M06/7.2 PMS START REQUEST OPTIONAL
LIMIT LUFFING IN =M06/3.1
46
IX0.10 QX0.02
46 PLC
47 47
LIMIT LUFFING OUT =M06/3.3 IX0.11 QX0.03
20
LG INCREMENTAL ENCODER "B" =M06/3.4 IX0.12
02
LG INCREMENTAL ENCODER "A" =M06/3.5 IX0.13
21
HG INCREMENTAL ENCODER "B" =M06/4.4 IX0.14
38
HG INCREMENTAL ENCODER "A" =M06/4.5 IX0.15 I/O's depending on
36 36
IX0.16 QX0.04 =M06/7.3 MAIN MOTOR TIME RELAY
54 54
IX0.17 QX0.05 =M06/7.4 FEED OIL PUMP
17 17
IX0.18 QX0.06 =M06/7.5 HYDRAULIC OIL COOLER
53 53
IX0.19 QX0.07 =M06/7.6 SUPPLY SAFETY CIRCUITS
19
LIMIT HOISTING =M06/4.1 IX0.20
55
LIMIT LOWERING =M06/4.3 IX0.21
18
SLACK ROPE SW. HOISTING GEAR =M06/2.2 IX0.22
37
LIMIT SWITCH CHECK CONTACT =M06/4.3 IX0.23 I/O's below the line
only available on CR 0020
and depending on
39 39
=M06/5.1 IX0.24 QX0.08
03 03
SPARE =M06/5.2 IX0.25 QX0.09
40 40
SPARE =M06/5.3 IX0.26 QX0.10
22 22
SPARE =M06/5.4 IX0.27 QX0.11
41 41
SPARE =M06/5.5 IX0.28 QX0.12
42 42
SPARE =M06/5.6 IX0.29 QX0.13
43 43
SPARE =M06/4.7 IX0.30 QX0.14
04 04
SPARE =M06/5.7 IX0.31 QX0.15
48 48
IX0.32 QX0.16 =M06/8.6 SPARE
49 49
IX0.33 QX0.17 =M06/8.7 SPARE
31 31
IX0.34 QX0.18 =M06/8.8 SPARE
50 50
IX0.35 QX0.19 =M06/8.9 SPARE
51 51
IX0.36 QX0.20 =M06/8.1 SPARE
52 52
IX0.37 QX0.21 =M06/8.3 SPARE
16 16
IX0.38 QX0.22 =M06/8.4 SPARE
35 35
IX0.39 QX0.23 =M06/8.5 SPARE
8 10

Ch.
9
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
letzte nd./last mod. 09.07.08 ASC
Marine Cranes GmbH PLC INPUTS/OUTPUTS
Sh.

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 HOISTING GEAR BRAKE
CHANNEL 1 CHANNEL 2
1.1 2.3
FILTER OVERPRESSURE =M07/3.4 +24V_CH1 GND_CH2 =M07/3.4 HOISTING GEAR BRAKE
3.4 4.4
OIL LEVEL =M07/3.5 IX2.03 QX2.04 =M07/3.5 LUFFING GEAR BRAKE
CHANNEL 3 CHANNEL 4
3.1 4.3
OIL LEVEL =M07/3.6 +24V_CH3 GND_CH4 =M07/3.6 LUFFING GEAR BRAKE
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 SLEWING GEAR BRAKE
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 PRE HEATING
CAN IN CAN OUT

-XA2C -XA2C
1.4 2.4
CAN_H IN =M07/3.3 CAN_H CAN_H =M07/3.3 CAN_H OUT
1.5 2.5
CAN_L IN =M07/3.3 CAN_L CAN_L =M07/3.3 CAN_L OUT
9 11

Ch.
10
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
Sh.

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 =M07/1.4 +24V_CH1 +24V_CH2 =M07/1.4 HOISTING GEAR LOWERING
CHANNEL 1 CHANNEL 2
1.2 2.2
HOISTING GEAR HOISTING =M07/1.5 CURRENT 1 CURRENT 2 =M07/1.5 HOISTING GEAR LOWERING
3.4 4.4
LUFFING GEAR LUFF. IN MAIN =M07/1.5 +24V_CH3 +24V_CH4 =M07/1.5 LUFFING GEAR LUFF. OUT MAIN
CHANNEL 3 CHANNEL 4
3.2 4.2
LUFFING GEAR LUFF. IN MAIN =M07/1.6 CURRENT 3 CURRENT 4 =M07/1.6 LUFFING GEAR LUFF. OUT MAIN
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
SLEWING GEAR CLKW (RIGHT) =M07/1.8 CURRENT 5 CURRENT 6 =M07/1.8 SLEWING GEAR C-CLKW (LEFT)
7.4 8.4
RESERVE =M07/1.9 +24V_CH7 +24V_CH8 =M07/1.9 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
02 2.5
10 12

Ch.
11
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
Sh.

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
HOIST. GEAR PRESSURE (7 bar) =M07/2.4 IX4.01 +24V_CH2 =M07/2.3 HOIST. GEAR PRESSURE (0-600 bar)
CHANNEL 1 CHANNEL 2
1.1 2.2
HOIST. GEAR PRESSURE (7 bar) =M07/2.4 +24V_CH1 IW4.02 =M07/2.4 HOIST. GEAR PRESSURE (0-600 bar)
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
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 =M07/2.8 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
1.5 2.5
11 13

Ch.
12
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
Sh.

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
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
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 =M07/6.4
7 17
CONTROL LEVER HOISTING =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

Ch.
13
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
Sh.

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
CONTROL LEVER LUFFING IN =M07/5.1 IX5.09 IW5.13 =M07/5.3 SET VALUE LUFFING GEAR
CHANNEL 9 CHANNEL 13
2 9
+UB_CH9 +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
4 14
+UB_CH10 GND_SH14
DIG. OUTPUTS
5 15
SPARE =M07/5.7 IX5.11 QX5.15 =M07/6.3 BUZZER FAULT
6 16
+UB_CH11 GND_CH15
DIG. INPUTS
7 17
SPARE =M07/6.5 IX5.12 IX5.16 =M07/6.6 GRAB OPERATION ON
8 18
+UB_CH12 GND_CH16
13 =SRK/1

Ch.
14
Com-No ass.-gr.
OVERVIEW Typ Bl.
7/3945 97.25 50 14
Sh.

0 1 2 3 4 5 6 7 8 9
*) MUST BE SUPPLIED FROM
SPARE
3PE
MAIN SUPPLY
2
EMERGENCY LIGHTING
LIGHT + HEATER
ON SHIP
EMERGENCY SWITCHBOARD OF MCR
~
(1N
(1N
~
60Hz 440V
~
~)
) 60Hz 220V
60Hz 220V
ON CRANE
*)
L3
L2
L1
(L)M2X4 - 70mmý
L9
L8
L7
L6
L5
L4
L3
L2
L1
PE
L1
L2 TO CONTROL CABINET +P1.H (L)M2X4 - 3x2x70mmý
L3
1 2 3 4 5 6
L4-L5 TO CONTROL CABINET +P1.H (L)M2X4 - 2x6mmý
L6-L7 TO CONTROL CABINET +P1.H (L)M2X4 - 2x1,5mmý
L8-L11 SPARE
16A
16A
16A
16A
60A
60A
400A
400A
400A
400A
SLIP RING ASSEMBLY

=GEN/14 =SL/1

Ch.
1
Com-No ass.-gr.
SLIP RING CONNECTION Typ Bl.
7/3945 97.25 50 1
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = SRK

0 1 2 3 4 5 6 7 8 9
*) TECHNICAL DATAS
----------------
440V BK 70mmý DATA FOR SUPPLY CABLE RATING :
3x1 MEAN EFFECTIVE POWER CONSUMPTION : 185 kVA

x70mmý
DATA FOR GENERATOR LOADS :
SHORT TIME LOAD (10% DUTY CYCLE): 380 kVA
PEAK LOAD (2-3S): 430 kVA

3
-S1 3 -K3 -K2 -F2 -F1 REVERSE POWER WHEN LOWERING FULL LOAD: 100 kW
400A 100A 35A
STARTING CURRENT OF EL. MOTOR : 610 A

3x1
x70mmý NOTE:
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
10-16A 4-6,3A 2,4-4A
-XSR
S S
L1-L3 PE -K11 -K12 -U1
R R 400-500V
--------
24V, 20A
4x2,5mmý 4x1,5mmý
3+PE 3+PE 3+PE
L1-3 PE L1-L3
-M1 -M11 -M12
160kW 9KW 1,8KW CTRL
3
MAIN MAIN POWER SUPPLY FEED OIL HYDRAULIC OIL CONTROL

POWER MOTOR GRAB CONTROL PUMP COOLER VOLTAGE
SUPPLY 3PE 440V 24V DC
AC 60Hz
=SRK/1 2

Ch.
1
Com-No ass.-gr.
SINGLE LINE DIAGRAM Typ Bl.
7/3945 97.25 50 5
Marine Cranes GmbH MAIN POWER SUPPLY
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = SL

0 1 2 3 4 5 6 7 8 9
220V AWG 10 BUS BAR
-S2 2 -F30 2 -F31 2 -F32 2 -F33 2 -F34 2 -F35 2
10A 10A 10A 10A 10A 16A

-S03 -S31 -S32 -S33 -K33
-XSR
S S
R R
-K33
L4-5 L6-7
-E31
-E36 -E37 -E38 E2/E3 -E8 -E6 -E7 -E39 -E40
-E32
40W 1000W 60W 20W 1,4KW 2KW 0,55 kW 500W 500W
3x20W
SUPPLIES 220V AC, 60Hz
AUX. EMERGENCY
POWER SUPPLY
SUPPLY FOR LIGHT
LIGHT LIGHT WORKING WARNING DESK HEATER HEATER CONTROL DECK LIGHT
CRANE CABIN LIGHT LIGHT HEATER, CABIN CRANE CABINET BELOW CABIN
TOWER BELOW/TOP AT JIB AT JIB CABIN TOWER HEATER,
FAN
1 3

Ch.
2
Com-No ass.-gr.
SINGLE LINE DIAGRAM Typ Bl.
7/3945 97.25 50 5
Marine Cranes GmbH LIGHT AND HEATER
Sh.

0 1 2 3 4 5 6 7 8 9
MAIN CONTROL CABINET
MAIN MOTOR
CURRENT
24V DC
K Kx
Q BX
6 4
VIQ IX QX IW
CR0505 / 0020
IX = 9 (14)
A1
1.8
IxC = 4 (6)
IW = 1 (2)
CR 0505 / CR 0020
QX = 4 (5)
QX
PWM IX IX IX (C) IX IX (C) QX IX C1 QX(PWM) = 1 (2)
1(2)
-KX
-YT -SL -S16 -S26 PMS

AB AB OPTIONAL
SR8-11
CR2012 /5.0
TRIMOT
PROP. VALVE
SWITCHES
LIMIT
CR2031 /4.0
SWITCHES
LIMIT
ENCODER
INCREMENTAL
SWITCHES
LIMIT
ENCODER
INCREMENTAL
SYSTEM
MANAGEMENT
POWER
2 4

Ch.
3
Com-No ass.-gr.
PLC OVERVIEW Typ Bl.
7/3945 97.25 50 5

Bl.
Sh.
5
SOL. VALVES
5
QD3
Bl.
Sh.
9
HOIST. GEAR BRAKE

-Y1
5002997
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
PROP. VALVES PROP. VALVES
4B
4A
PUMP CONTROL PUMP CONTROL
ALP
-4B
4A
Datum/date
24.09.08
04.07.05
07.07.08
2
3B
3A
-3B
3A
letzte nd./last mod.
erstellt/designed
CR 2031
geprft/checked
2B
2A
-2B
2A
1
1B
1A
Ch.
50
-1B
1A
ass.-gr.
-K5
Baugr./
97.25
Abt./departm.:
VBB
CR2031 24VDC-P
C1
3.8/
0
Bau-Nr./
7/3945
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
4 3 3
ID IA QD
A6 AT6200C A5 CR 2012
RS CAN CAN
3.8/ CR2012
4 =M01/1

Ch.
5
Com-No ass.-gr.
PLC OVERVIEW Typ Bl.
7/3945 97.25 50 5

0 1 2 3 4 5 6 7 8 9
SLIP RING ASSEMBLY MAIN SWITCH POWER SUPPLY AUXILIARY MAIN SWITCH MAIN
MAIN POWER AUX. POWER SUPPLY GRAB CONTROL DRIVES POWER SUPPLY SUPPLY
SUPPLY POWER SUPPLY ON
EMERGENCY OFF
220V AC AWG 10 BK
L4.1 /=M03/2.0
L5.1 /=M03/2.0
440V AC # 2,5mmý BK
70mmý BK
L1.2 /=M02/1.1
L2.2 /=M02/1.1
L3.2 /=M02/1.1
1 3 5
1 3 5
2 4
-S2 -Q1
PN 2381873
1 3 -S1 0,6-1A
3x2x70mmý
.8
2 4 6
PN 2544253
400A
U< 2 4 6
1,5mmý
RD
PN 5002251
70mmýBK #6mmý BK
-H1
-X3 1 2 440VAC
D1 313 white 1
-S1.H PN 5002044 -R1

314 2
1
-S1
PE R2
.4 D2 2
CRANE
TOWER
70mmý 1 3 5 1 3 5
-X4 1
-F2 -F1 X1
2 4 6 2 4 6
100A 63A -H1
--- --- X2
100A 35A 230VAC
-X75 1 white
PN 2535438 PN 1608376
PN 0058095 PN 1608405
21
-S4
-XSR PN 2502563
22
25mmýBK 6mmýBK
PN 5002738
L1 L2 L3 PE L4 L5 -X75 2 3PE
+F1.PR
-X4 2 3PE
-X4 4 5
PE
GL1 GL2 GL3
L1.1
L2.1
L3.1
M1-U1
M1-V1
M1-W1
L1.11
L2.11
L3.11
+A1.S
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
2.1/
2.1/
2.1/
3PE 440V 220V
AC 60Hz AC 60Hz
=SL/5 2

Ch.
1
Com-No ass.-gr.
POWER SUPPLY Typ Bl.
7/3945 97.25 50 3
Marine Cranes GmbH CIRCUIT DIAGRAM
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = M01 +P1.H

0 1 2 3 4 5 6 7 8 9
24VDC
POWER SUPPLY
CONTROL CIRCUITS
440V AC
1.6/ L1.11 L1.11 /=M02/2.1
1.7/ L2.11 L2.11 /=M02/2.1
1.7/ 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
CV.L3 /=M02/3.1
Power Unit
DIP-SWITCH
L1 L2 L3
settings
-U1 ON A = OFF
400-500VAC
50/60Hz
24VDC - +
OFF B = ON
20A
A B
PN 5002582
2,5mmý BU
2,5mmý BU
PE
PE
PE
24VN 24VP
3.1 3.1
1 3

Ch.
2
Com-No ass.-gr.
CONTROL VOLTAGE SUPPLY Typ Bl.
7/3945 97.25 50 3
Sh.

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
2,5mmý BU 24N_INT /=M02/3.1

2.2/ 24VN 24N_EXT /=M05/1.1
-X5 10 11 12 13
-X5 1 2 3 4 5 6 7
24V-PLC-VBB
24V-PLC-OUT05
24V-PLC-OUT34
24V_INT
24V-P1.P
24V-P1.V
24V-CAB
GND-P1.P
GND-P1.V
GND-CAB
24V-AUX
=M02/3.1/
=M07/4.1/
=M07/4.1/
=M05/1.1/
=M07/1.1/
=M07/3.1/
=M07/1.1/
=M07/3.1/
=M06/1.1/
=M06/1.1/
=M06/1.1/
2 =M02/1

Ch.
3
Com-No ass.-gr.
24 V DC Typ Bl.
7/3945 97.25 50 3
Marine Cranes GmbH CONTROL VOLTAGE SUPPLY
Sh.

0 1 2 3 4 5 6 7 8 9
MAIN MOTOR DELTA STAR STANDSTILL THERMISTOR

CONTACTOR CONTACTOR 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
=M01/1.4/ M1-U1 -K3 -K2

3.3 2 4 6 3.2 1 3 5
=M01/1.4/ M1-V1
=M01/1.5/ M1-W1
SMB 500/0,02
CURRENT MEASURING DEVICE

-T1
PN 2368074
a - 24N_INT /=M06/7.6
+ I-MAIN /=M06/2.1
UH UH /=M03/4.5
UH VH /=M03/4.5
3x1x70mmý
3x1x70mmý
b
M1-L /=M03/4.6
M1-N /=M03/4.6
AWG 16 WH
M1/1 /3.1
M1/2 /3.1
-X5 75 76
PE PE
PE
-M1 -XM1 U1 V1 W1 W2 U2 V2 L N T1 T2
160KW U1 V1 W1
PN 2502253
W2 U2 V2
+P1.P
=M01/3 2

Ch.
1
Com-No ass.-gr.
MAIN MOTOR Typ Bl.
7/3945 97.25 50 3
Sh.

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 4-6,3A
(In=18,0A) (In=4,7A)
2 4 6 2 4 6
PN 2546542 PN 2546539
PN 2544250 PN 2544250
BK AWG 10
1 3 5 1 3 5
-K11 -K12
=M06/7.4 2 4 6 =M06/7.5 2 4 6
PE PE PE
PE
-X4 6 7 8 9PE 10 11 12 13PE
-X11 1 2 3 4PE
PN 1627768
W1 V1 U1 W1 V1 U1
-M11 -M12
10,5 kW 1,8kW
(In=10,0A) (In=4,7A)
PE PE
+P1 +T1.O
1 3

Ch.
2
Com-No ass.-gr.
AUXILIARY DRIVES Typ Bl.
7/3945 97.25 50 3
Sh.

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
=M01/3.8/ 24N_INT 24N_INT /=M06/1.1
1.8/ M1/1
1.8/ M1/2
=M01/2.8/ CV.L2 A1 T1 T2 11 A2
-F4
PN 2094520
12 14
F4/14 /=M06/2.8
17
-K4
=M06/7.3 18 28
21 21
-K3 -K2
.3 22 .2 22
A1 A1
-K2 -K3
A2 A2
PN 5002377 PN 4226209
PN 2532378 PN 4236664
=M01/2.8/ CV.L3
1 2 1.5 1 2 1.5
3 4 1.6 3 4 1.5
5 6 1.6 5 6 1.5
21 22 .3 21 22 .2
31 32 =M03/4.6 31 32 =M03/4.6
43 44 =M06/2.7
2 =M03/1

Ch.
3
Com-No ass.-gr.
STAR/DELTA CONTROL Typ Bl.
7/3945 97.25 50 3
Marine Cranes GmbH MAINMOTOR
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 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
PE1 PE PE PE PE PE
PE
-X3 3 4 5PE 6 7 8PE 9 10 11PE 12 13 14PE 15 16 17PE

-XSR
PN 5002738 L N PE L N PE
L6 L7
1 3 PE
-E31 -E32
20W 2x20W
-S03
2 4
PN 1608349 PN 2045221 PN 5002080
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

Ch.
1
Com-No ass.-gr.
LIGHT Typ Bl.
7/3945 97.25 50 5
Sh.

0 1 2 3 4 5 6 7 8 9
POWER SUPPLY 220V AC WARNING LIGHT WORKING

CONTROL DESK LEFT, RED LIGHT
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
-X60 1 2 3PE
13 33 13 33 13 33 5 13
-K33
-S31 -S32 -S33
14 34 14 34 14 34 .3 6 14
PN 2502557 PN 2502556 PN 2502555
PE1 PE2
PE2
PE
+F1.PL -X60 7 8 9PE 10 11 12 13
PE PE PE PE
-X3 27 28 29PE -X3 24 25 26PE 30 31 32PE

PE
+A1 -X12 1 2 3 4 5PE
+A1.J -X12.1 1 2 3 4 5PE
A1
-K33
A2
PN 5002735 -X13 1 2 5PE 3 4 6PE
L N PE L N PE L N PE
-E36 -E38 -E37

40W 60W 1000W
PN 2532329 PN 1624721 PN 1627792

PN 0146181 PN 1624722 PN 0625145
PN 1660212
1 2 5.6
3 4 5.7
5 6 .6
13 14 .7
+F1 +A1.J
1 3

Ch.
2
Com-No ass.-gr.
LIGHT Typ Bl.
7/3945 97.25 50 5
Sh.

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 PE L5.1 /4.0
1 3
PE
-F32
B 10A
2 4
PN 5002000
-X3 33 34 35PE
-X60 4 5 6PE
L N
13 33
-S34 -E3
14 34 10W
PN 2502627
PN 5002902
PE5 PE5
PE2
+F1.PL -X60 14 15 16PE -X60 17 18 19PE

-X70 1 2 3PE
L N PE L N PE
-E8 -E2
1,4kW 10W
PN 4228061 PN 5002902
+F1 +F1-PR
2 4

Ch.
3
Com-No ass.-gr.
LIGHT Typ Bl.
7/3945 97.25 50 5
Sh.

0 1 2 3 4 5 6 7 8 9
HEATER HEATER FAN SUPPLY FOR STANDSTILL- PMS-SYSTEM AUX.

CRANE TOWER CONTROL CABINET CONTROL AMPERAGE HEATER START ENABLE SUPPLY
CABINET MONITOR MAIN MOTOR OPTIONAL ON
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
-H2
=M02 230VAC
-S35 =M06-KEN white
3 4 -K2 32 A2
PN 5002045
40øC PN 5002352
=M02/3.2
PN 5002903
31
=M02
-K3 32
=M02/3.3
X1
-H2
X2
230VAC
white
PE PE PE PE PE PE PE
-X3 36 37 38PE 39 40 41PE 42 43 44PE 45 46 47PE 48 49 50PE 67 68 69PE
PE
UH
VH
M1-L
M1-N
L N PE L N PE L N PE
=M02/1.4/
=M02/1.4/
-E6 -E5 -M31
2kW 400W 35W
=M02/1.8/
=M02/1.8/
PN 2535250 PN 2094564 PN 5002904
11 14 =M06/2.3
+T1.U
3 5

Ch.
4
Com-No ass.-gr.
HEATERS Typ Bl.
7/3945 97.25 50 5
Sh.

0 1 2 3 4 5 6 7 8 9
DECK LIGHT 1 DECK LIGHT 2
220V AC BUS BAR

4.9/ L4.1
4.9/ L5.1
1 3
-F35
B 10A
2 4
PN 5002000
AWG 14
1 3
-K33
2.3 2 4
AWG 14 AWG 14
PE PE PE PE
PE
-X3 51 52 53PE 60 61 64PE 65 62 63 66PE
L N PE L N PE
-E39 -E40
500W 500W
PN 1637159 PN 1637159
PN 1673957 PN 1673957
+A1
4 =M05/1

Ch.
5
Com-No ass.-gr.
DECK LIGHT Typ Bl.
7/3945 97.25 50 5
letzte nd./last mod. 24.09.08 Schmahl
Sh.

0 1 2 3 4 5 6 7 8 9
WINDSCREEN WIPER FAN HORN
=M01/3.8/ 24N_EXT 24N_EXT /=M06/3.1

=M01/3.8/ 24V-AUX
-X5 9 14
-X62 11 12
OFF
ON
21 33
-S8
22 34
PN 2502558
=M07-S22H PE
PE PE
4 PE Schiene
PN 2078899
-X62 13 14 15 17 16 18 19 20 21PE
+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

Ch.
1
Com-No ass.-gr.
AUXILIARY 24V-DC CONSUMERS Typ Bl.
7/3945 97.25 50 1
Sh.

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 5002196
+24V +24V
CR 0505/0020
GND GND GND +24V CAN 1L
TEST TXD RXD CAN GND CAN 1H
-XA1 12 15 01 23 24 07 06 33 14 32
2,5mmý GN/YE
SCREEN CLAMP
-X5 22 23 24 8 30 31 32 35 36 37 40 41 42
PE
-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
=M02/3.8/ 24N_INT 24N_INT /7.1
=M05/1 2

Ch.
1
Com-No ass.-gr.
PLC SUPPLY 24V DC Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
AUXILIARY CONTACTS
MAIN MOTOR SLACK ROPE SW. PMS START MAIN FEED OIL HYDRAULIC DELTA MAIN MOTOR
AMPERAGE HOISTING GEAR ENABLE SWITCH PUMP OIL CONTACTOR THERMISTOR
OPTIONAL COOLER RELAY
24V DC
SECQ
7.6/ SECQ /3.1
=M02/3.8/ 24V_INT
11 1.X1 13 13 43
-KEN =M01 =M02 =M02 =M02
=M03/4.8 14 -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 13 13
=M02-K11 =M02-K12
7.4 14 7.5 14
HG-ROPE
METAL-BAR
+P1 INSULATING MATERIAL
=M02/3.8
F4/14
=M02/1.4/ I-MAIN
-X5 50
-A1 -XA1 08 18 27 28 10 29 11 30
1.1
PN 5002196 IW03 IX0.22 IX0.01 IX0.03 IX0.04 IX0.05 IX0.06 IX0.07
CR 0505/0020 // PLC MAINBOARD INPUTS
1 3

Ch.
2
Com-No ass.-gr.
PLC INPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
LIMIT SWITCH LUFFING GEAR

LIMIT LIMIT LIMIT SWITCH INCREMENTAL
LUFFING IN LUFFING OUT CHECK CONTACT ENCODER
24V DC
SECQ
2.9/ SECQ /4.1
=M05/1.8/ 24N_EXT 24N_EXT /4.1
SCREEN CLAMP
-X5 45 15
PE
48BM-299G+IMP1000
-S26 -XS26 2 1
PN 5002244
L+ L-
-IE26
1000ppr
11
-S26.2 21
-S26.1
12 14 22 24
B A
-XS26 4 3
+T1.W
-X5 51 52 53 54 55
-A1 -XA1 46 47 09 20 02
1.1
PN 5002194 IX0.10 IX0.11 IX0.02 IX0.12 IX0.13
2 4

Ch.
3
Com-No ass.-gr.
PLC INPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
LIMIT SWITCH HOISTING GEAR

LIMIT LIMIT LIMIT SWITCH INCREMENTAL SPARE
HOISTING LOWERING CHECK CONTACT ENCODER
24V DC
4.8/ 24V_EXT 24V_EXT /4.1
3.8/ SECQ
3.8/ 24N_EXT 24N_EXT /7.1
SCREEN CLAMP
-X5 46 16
PE
48BM-299G+IMP1000
-S16 -XS16 2 1
PN 5002244
L+ L-
-IE16
1000ppr
11
-S16.2 21
-S16.1
12 14 22 24
B A
-XS16 4 3
+T1.W
-X5 56 57 58 59 60 82
-A1 -XA1 19 55 37 21 38 43
1.1
PN 5002194 IX0.20 IX0.21 IX0.23 IX0.14 IX0.15 IX0.30
-BH
3 5

Ch.
4
Com-No ass.-gr.
PLC INPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
SPARE SPARE SPARE SPARE SPARE SPARE SPARE

-X5 61 62 63 64 65 66
-A1 -XA1 39 03 40 22 41 42 04
1.1
PN 5002194 IX0.24 IX0.25 IX0.26 IX0.27 IX0.28 IX0.29 IX0.31
CR 0020 // PLC MAINBOARD INPUTS
4 7

Ch.
5
Com-No ass.-gr.
PLC INPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
TRIMOT PMS MAIN MOTOR FEED OIL PUMP HYDRAULIC SUPPLY SAFETY
(PWM-OUTPUT) START TIME RELAY OIL COOLER CIRCUITS
REQUEST
OPTIONAL
24V DC
-A1
1.1
PN 5002196
CR 0505/0020 // PLC MAINBOARD OUTPUTS
QX0.00 QX0.01 QX0.04 QX0.05 QX0.06 QX0.07
-XA1 44 45 36 54 17 53
PMS
START
-X5 67 REQUEST
SECQ OPTIONAL
2.1
11
-KRQ
.2 14
1,5mmý
OR
-X5 80 81
-XY1T 1
1
-Y1T
2
B 24ê
-XY1T 2
+T1.W
A1 A1 A1 A1
=M02 =M02 =M02
-KRQ
A2 -K4 A2 -K11 A2 -K12 A2
PN 4236676
PN 2088712 PN 5002085 PN 5002084
-X5 18 19
1.8/ 24N_INT 24N_INT /=M02/1.4

4.8/ 24N_EXT 24N_EXT /8.1
11 14 .8 28 =M02/3.3 1 2 =M02/2.2 1 2 =M02/2.5

3 4 =M02/2.2 3 4 =M02/2.5
18 =M02/3.2 5 6 =M02/2.2 5 6 =M02/2.5
13 14 2.5 13 14 2.6
5 8

Ch.
7
Com-No ass.-gr.
PLC OUTPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

0 1 2 3 4 5 6 7 8 9
SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE
24V DC
A1
1.1
PN 5002194
CR 0020 // PLC MAINBOARD OUTPUTS
QX0.20 QX0.21 QX0.22 QX0.23 QX0.16 QX0.17 QX0.18 QX0.19
-XA1 51 52 16 35 48 49 31 50
-X5 70 71 72 73
-X5 20 21
7.9/ 24N_EXT
7 =M07/1

Ch.
8
Com-No ass.-gr.
PLC OUTPUTS Typ Bl.
7/3945 97.25 50 8
Sh.

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
=M01/3.7/ 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

-A3 XA3T 03 04 05 06 07 01 02 -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 1
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
-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)
=M06/8 2

Ch.
1
Com-No ass.-gr.
COMPACT MODULE Typ Bl.
7/3945 97.25 50 7
Marine Cranes GmbH PWM-OUTPUTS
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 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
-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
COMPACT MODULE CR2033 ANALOG
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
-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
-B10 +Ub OUT -B20 +Ub OUT -B01 +Ub OUT
PN 5002899 PN 5002899 PN 5002900

0 - 600 BAR 0 - 600 BAR -50 - +150 DEGREES
P <= P <= <=

4 - 20 mA 4 - 20 mA 4 - 20 mA
HOISTING GEAR LUFFING GEAR RESERVE OIL

PRESSURE PRESSURE TEMPERATURE
ANALOG SENSORS
1 3

Ch.
2
Com-No ass.-gr.
7/3945 97.25 50 7
Marine Cranes GmbH IN-/OUTPUTS
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl CIRCUIT DIAGRAM = M07 +P1.P

0 1 2 3 4 5 6 7 8 9
FILTER OIL RESERVE RESERVE

2.1/CAN-L3
OVERPRESSURE LEVEL
2.1/CAN-H3
=M01/3.6/ 24V-P1.V
terminal 6+7 to be removed

=M01/3.7/ GND-P1.V
* jumper header between

1 21
-S08 -S09
2 22
5 bar
+P1.P
BK BN BK BN
-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
COMPACT MODULE CR2033 DIGITAL
CAN_H CAN_L QX2.02 GND_CH2 QX2.04 GND_CH4 QX2.06 GND_CH6 QX2.08 GND_CH8
-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

Ch.
3
Com-No ass.-gr.
7/3945 97.25 50 7
Marine Cranes GmbH IN-/OUTPUTS
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl CIRCUIT DIAGRAM = M07 +P1.V

0 1 2 3 4 5 6 7 8 9
CAN-BUS MODULE EOS SWITCH KEY BUTTON CONTROL LEVER SET VALUE
SUPPLY SUPPLY PUMPS JIB HOISTING LOWERING HOISTING GEAR
START/STOP RESTING
=M01/3.6/ 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
S12T /6.1
-X72 1 3 5 6 2 4 7 9 11
13 13 -S12 3 5
-S06 -S07
14 14 03 05
R1 PN 2502564 PN 2502566 PN 2078900
120ê A S
TERMINATING
RESISTOR
-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
3 5

Ch.
4
Com-No ass.-gr.
CABIN MODULE INPUTS Typ Bl.
7/3945 97.25 50 7
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = M07 +F1.PR

0 1 2 3 4 5 6 7 8 9
CONTROL LEVER SET VALUE CONTROL LEVER

LUFFING LUFFING LUFFING GEAR SLEWING SLEWING SET VALUE SPARE
IN OUT 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
-S22 3 5 -S32 3 5
03 05 03 05
PN 2078899 PN 2078899
A S A S
-X62 1 2 3 4 5 6 7 8 9
+F1.PL
-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

Ch.
5
Com-No ass.-gr.
CABIN MODULE INPUTS Typ Bl.
7/3945 97.25 50 7
Sh.

0 1 2 3 4 5 6 7 8 9
INDIC. LIGHTS
READY FOR FAULT BUZZER SPARE GRAB
OPERATION FAULT OPERATION
ON
4.9/ S12T
X2 X2 X2 13
-H06 -H07 -H08 -S85

X1 X1 X1 14
PN 2502564 PN 2502565 PN 5002661 PN 2502766
PN 5002662
-A5 -X1A5 15 17 -X2A5 15 -X1A5 16 -X2A5 7 17

4.0
PN 4243438 QX5.07 QX5.08 QX5.15 GND_CH7 IX5.12 IX5.16
CR2012 CABINET MODULE
5 7

Ch.
6
Com-No ass.-gr.
CABIN MODULE OUTPUTS Typ Bl.
7/3945 97.25 50 7
Sh.

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
-A6 -XA6 5 1 3 6 2
PN 4243440
CAN_H CAN_L CAN_GND +24V GND
LCD DISPLAY AT6200C

2,5mmý GN/YE
PE
PE
PE
6 =PE/1

Ch.
7
Com-No ass.-gr.
DISPLAY Typ Bl.
7/3945 97.25 50 7
Marine Cranes GmbH CONNECTION DIAGRAM
Sh.

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

PE PE
PE PE
+T1.U
(L)M2XH NSGA
70mmý 70mmý
PE
ye/gn
PUMP MODULE 16mmý
PE
PE P1:PE
JIB
PE
F1 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

Ch.
1
Com-No ass.-gr.
PE Typ Bl.
7/3945 97.25 50 1
letzte nd./last mod. 22.02.08 Schmahl
Sh.
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = PE +P1.H

0 1 2 3 4 5 6 7 8 9
(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
TERMINAL BLOCK -XSR
3x1.5mmý
2x6mmý
1x70mmý
2x1x70mmý
2x1x70mmý
2x1x70mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH
POWER SUPPLY L1 BK =M01-S1 1 L1 =M01/1.1
POWER SUPPLY PE BK =M01-PE PE =M01/1.2

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

=PE/1 2

Ch.
1
Com-No ass.-gr.
-XSR SLIP RING ASSEMBLY Typ Bl.
7/3945 97.25 50 18
Abt./departm.: -K5 erstellt/designed 07.07.08 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
TERMINAL BLOCK -X3
7x1.5mmý
3x1.5mmý
3x1.5mmý
5x1.5mmý
3x1.5mmý
2x6mmý
5x1.5mmý
SIDE/
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

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

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
WARNING LIGHT RED 3 -X60 12 24 -X12 1 1 =M03/2.5
WARNING LIGHT RED 4 -X60 13 25 -X12 2 2 =M03/2.5
PE =M03-PE 26PE =M03/2.5
SPARE 5 -X60 10 27 =M03-K33 A1 =M03/2.3
1 SPARE 6 -X60 11 28 =M03-K33 A2 2.1

=M03/2.3

Ch.
2
Com-No ass.-gr.
TERMINAL BLOCK -X3 Typ Bl.
7/3945 97.25 50 18
Marine Cranes GmbH 220V CONTROL CABINET
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E39
(L)M2XH-J
W-M1/HEATER
(L)M2XH-J
W-E6
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK -X3
3x1.5mmý
3x1.5mmý
3x1.5mmý
3x1.5mmý
5x1.5mmý
SIDE/
SPARE PE 29PE =M03-PE =M03/2.4
WORKING LIGHT 3 -X12 3 30 =M03-K33 6 =M03/2.6
WORKING LIGHT 4 -X12 4 31 =M03-K33 14 =M03/2.7
PE PE -X12 5PE 32PE =M03-PE =M03/2.7

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

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 =M03/4.4
FAN CONTROL CABINET PE =M03-M31 PE 44PE =M03-PE =M03/4.5
SUPPLY FOR AMPERAGE MONITOR =M02-T1 UH 45 =M03-F34 2 =M03/4.5
SUPPLY FOR AMPERAGE MONITOR =M02-T1 UH 46 =M03/4.5
FAN CONTROL CABINET PE 47PE =M03-PE =M03/4.5
STANDSTILLHEATER MAIN MOTOR BK -XM1 L 48 =M02-K3 32 =M03/4.6
STANDSTILLHEATER MAIN MOTOR BU -XM1 N 49 =M03/4.6
RESERVE PE 85PE 50PE =M03-PE =M03/4.6
53PE =M03-PE =M03/5.5
51 =M03/5.5
2 DECK LIGHT L BK =M03-E39 L 60 =M03-K33 2 2.2

=M03/5.6

Ch.
2.1
Com-No ass.-gr.
7/3945 97.25 50 18
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E40
(L)M2XH-J
W-E39
TERMINAL BLOCK -X3
3x1.5mmý
3x1.5mmý
SIDE/
52 =M03/5.5
DECK LIGHT N BU =M03-E39 N 61 =M03-K33 4 =M03/5.7
DECK LIGHT L BK =M03-E40 L 62 =M03-K33 2 =M03/5.8
DECK LIGHT N BU =M03-E40 N 63 =M03-K33 4 =M03/5.8

DECK LIGHT PE PE =M03-E39 PE 64PE =M03-PE =M03/5.7
DECK LIGHT L 65 =M03/5.8
DECK LIGHT PE PE =M03-E40 PE 66PE =M03-PE =M03/5.8
PMS-SYSTEM START ENABLE 67 =M06-KEN A2 =M03/4.8
OPTIONAL
PMS-SYSTEM START ENABLE 68 =M03-F34 4 =M03/4.8
OPTIONAL
PMS-SYSTEM START ENABLE 69PE =M03-PE =M03/4.8

OPTIONAL
2.1 3

Ch.
2.2
Com-No ass.-gr.
7/3945 97.25 50 18
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH_J_1 4x2.5mmý
W-X4/X11
W-M11
(L)M2XH-J
W-S4
TERMINAL BLOCK -X4
3x1.5mmý
SIDE/
EMERGENCY STOP BK -X75 1 1 =M01-S1 D2 =M01/1.8
EMERGENCY STOP BU -X75 2 2 =M01/1.8
EMERGENCY STOP PE PE -X75 3PE 3PE =M01-PE =M01/1.8
EMERGENCY STOP 4 =M01/1.8

EMERGENCY STOP 5 =M01-S1.H 314 =M01/1.9
FEED OIL PUMP MOTOR BK =M02-M11 W1 6 =M02-K11 2 =M02/2.2
FEED OIL PUMP MOTOR BN =M02-M11 V1 7 =M02-K11 4 =M02/2.2
FEED OIL PUMP MOTOR GY =M02-M11 U1 8 =M02-K11 6 =M02/2.2
FEED OIL PUMP MOTOR PE GNYE =M02-M11 PE 9PE =M02-PE =M02/2.3
HYDRAULIC OIL COOLER MOTOR BK -X11 1 10 =M02-K12 2 =M02/2.5
HYDRAULIC OIL COOLER MOTOR BN -X11 2 11 =M02-K12 4 =M02/2.5
HYDRAULIC OIL COOLER MOTOR GY -X11 3 12 =M02-K12 6 =M02/2.5

HYDRAULIC OIL COOLER MOTOR PE GNYE -X11 4PE 13PE =M02-PE =M02/2.6
2.2 4

Ch.
3
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH 380/440V CONTROL CABINET
Sh.

0 1 2 3 4 5 6 7 8 9
Quattro
W-Y1T
Oelflex 110CY
W-S16
Oelflex 110CY
W-S26
Quattro
W-X62_24V
CAN_4x0,75
W-CAN4
QUATTRO-O
W-P1Q
CAN_4x0,75
W-CAN1
TERMINAL BLOCK -X5
3x1mmý
7x0.5mmý
7x0.5mmý
3x1mm
4x0.75mmý
2x1.5mmý
4x0.75mmý
SIDE/
EXTERNAL CONSUMERS GN XA3T 05 1 =M01-F15 =M01/3.5
EXTERNAL CONSUMERS 2 =M01/3.5

EXTERNAL CONSUMERS 1 XA2T 05 5 =M01/3.6
EXTERNAL CONSUMERS GN -X72 7 6 =M01-F16 =M01/3.6
+24V =M01-F11 8 -XA1 23 =M06/1.3
SUPPLY AUX. CONSUMERS 1 -X62 11 9 =M01-F17 =M05/1.6
24N (GND) YE XA3T 03 10 =M01-U1 - =M01/3.7
24N (GND) 2 XA2T 03 11 =M01/3.7
24N (GND) YE -X72 9 12 =M01/3.7

24N (GND) 13 =M01/3.8
24N_EXT 2 -X62 12 14 =M05/1.7
24N_EXT 2 -XS26 1 15 =M06/3.5
24N_EXT 2 -XS16 1 16 =M06/4.5
24N_EXT 2 -XY1T 2 18 =M06/7.1
24N_EXT 19 =M06/7.6
24N_EXT 20 =M06/8.1
24N_EXT 21 =M06/8.5
24N_INT =M02-F4 A2 22 -XA1 12 =M06/1.1
24N_INT 23 -XA1 15 =M06/1.2
24N_INT =M06-KRQ A2 24 -XA1 01 =M06/1.2
24N (GND) 30 -XA1 33 =M06/1.6
3 24N (GND) 31 4.1

=M06/1.6

Ch.
4
Com-No ass.-gr.
7/3945 97.25 50 18
Sh.

0 1 2 3 4 5 6 7 8 9
Quattro
W-S19
Oelflex 110CY
W-S16
Oelflex 110CY
W-S26
CAN_4x0,75
W-CAN1
CAN_4x0,75
W-CAN4
TERMINAL BLOCK -X5
3x1mmý
7x0.5mmý
7x0.5mmý
4x0.75mmý
4x0.75mmý
SIDE/
24N (GND) 32 =M06/1.7
CAN BUS WH -X72 1 35 -XA1 14 =M06/1.7
CAN BUS WH XA3T 01 36 =M06/1.7
CAN BUS 37 =M06/1.8

CAN BUS BN -X72 3 40 -XA1 32 =M06/1.8
CAN BUS BN XA3T 02 41 =M06/1.8
CAN BUS 42 =M06/1.8
LIMIT SW. LUFFING GEAR 24V DC 1 =M06-S26.1 11 45 -XA1 53 =M06/3.1
LIMIT SW. HOISTING GEAR 24V DC 1 =M06-S16.1 11 46 =M06/4.1
SLACK ROPE SW. HOISTING GEAR 1 =M06-S19 50 -XA1 18 =M06/2.2
LIM. SW. LG LUFFING IN 3 =M06-S26.1 12 51 -XA1 46 =M06/3.1
LIM. SW. LG LUFFING OUT 4 =M06-S26.2 22 52 -XA1 47 =M06/3.3

LIMIT SWITCH CHECK CONTACT 5 =M06-S26.2 24 53 -XA1 09 =M06/3.3
INCREMENTAL ENCODER 6 -XS26 4 54 -XA1 20 =M06/3.4
INCREMENTAL ENCODER LUFFING 7 -XS26 3 55 -XA1 02 =M06/3.5
GEAR
LIMIT HOISTING 3 =M06-S16.1 12 56 -XA1 19 =M06/4.1
LIMIT LOWERING 4 =M06-S16.2 22 57 -XA1 55 =M06/4.3
LIMIT SWITCH CHECK CONTACT 5 =M06-S16.2 24 58 -XA1 37 =M06/4.3
INCREMENTAL ENCODER 6 -XS16 4 59 -XA1 21 =M06/4.4
INCREMENTAL ENCODER HOIST. 7 -XS16 3 60 -XA1 38 =M06/4.5
GEAR
SPARE 61 -XA1 39 =M06/5.1
SPARE 62 -XA1 03 =M06/5.2
4 SPARE 63 -XA1 40 4.2

=M06/5.3

Ch.
4.1
Com-No ass.-gr.
7/3945 97.25 50 18
Sh.

0 1 2 3 4 5 6 7 8 9
Quattro
W-M1/THERM
Quattro
W-Y1T
TERMINAL BLOCK -X5
3x1mmý
3x1mmý
1.5mmý OR
SIDE/
SPARE 64 -XA1 22 =M06/5.4
SPARE 65 -XA1 41 =M06/5.5
SPARE 66 -XA1 42 =M06/5.6
TRIMOT (PWM-OUTPUT) 1 -XY1T 1 67 -XA1 44 =M06/7.1

SPARE 70 -XA1 51 =M06/8.1
SPARE 71 -XA1 52 =M06/8.3
SPARE 72 -XA1 16 =M06/8.4
SPARE 73 -XA1 35 =M06/8.5
THERMISTOR MAIN MOTOR 1 -XM1 T1 75 =M02-F4 T1 =M02/1.7
THERMISTOR MAIN MOTOR 2 -XM1 T2 76 =M02-F4 T2 =M02/1.8
PMS-START REQUEST 80 =M06-KRQ 14 X =M06/7.8
PMS-START REQUEST 81 =M06-KRQ 11 X =M06/7.8

SPARE -XA1 43 82 =M06/4.7
4.1 5

Ch.
4.2
Com-No ass.-gr.
7/3945 97.25 50 18
Sh.

0 1 2 3 4 5 6 7 8 9
H07RN
W-M12
W-X4/X11
TERMINAL BLOCK -X11
4x1.5mmý
SIDE/
HYDRAULIC OIL COOLER MOTOR BK =M02-M12 W1 1 -X4 10 BK =M02/2.5
HYDRAULIC OIL COOLER MOTOR BN =M02-M12 V1 2 -X4 11 BN =M02/2.5
HYDRAULIC OIL COOLER MOTOR GY =M02-M12 U1 3 -X4 12 GY =M02/2.5
HYDRAULIC OIL COOLER MOTOR PE =M02-M12 PE 4PE -X4 13PE GNYE =M02/2.6
4.2 6

Ch.
5
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH TERMINAL BOX OIL COOLER
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-Jú
W-X12/X12.1
(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK -X12
5x1.5mmý
5x1.5mmý
SIDE/
WORKING LIGHT 1 -X12.1 1 1 -X3 24 1 =M03/2.5
WORKING LIGHT 2 -X12.1 2 2 -X3 25 2 =M03/2.5
WARNING LIGHT RED 3 -X12.1 3 3 -X3 30 3 =M03/2.6
WARNING LIGHT RED 4 -X12.1 4 4 -X3 31 4 =M03/2.7

WORKING/WARNING LIGHT RED PE PE -X12.1 5PE 5PE -X3 32PE PE =M03/2.7

5 7

Ch.
6
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH TERMINAL BOX JIB-BEARING
Sh.

0 1 2 3 4 5 6 7 8 9
H07RN
W-E37
H07RN
W-E38
H07RN
W-X12.1/X13
TERMINAL BLOCK -X13
3x1.5mmý
3x1.5mmý
5x1.5mmý
SIDE/
WORKING LIGHT BN =M03-E38 L 1 -X12.1 1 BK =M03/2.5
WORKING LIGHT BU =M03-E38 N 2 -X12.1 2 GY =M03/2.5
WARNING LIGHT RED BN =M03-E37 L 3 -X12.1 3 BN =M03/2.6
WARNING LIGHT RED BU =M03-E37 N 4 -X12.1 4 BU =M03/2.7

WORKING LIGHT PE PE =M03-E38 PE 5PE =M03/2.5
WARNING LIGHT RED PE PE =M03-E37 PE 6PE -X12.1 5PE PE =M03/2.7

6 8

Ch.
7
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH TERMINAL BOX JIB TOP
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E2
H07RN
W-X60/E8
(L)M2XH-J
W-E36
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-S31/X3
TERMINAL BLOCK -X60
3x1.5mmý
3x1mmý
3x1.5mmý
3x1.5mmý
7x1.5mmý
SIDE/
DESK HEATER 1 -X3 21 1 =M03-S31 13 =M03/2.1
DESK HEATER 2 -X3 22 2 =M03-S31 33 =M03/2.1
LIGHT CABIN PE PE -X3 23PE 3PE =M03-PE1 PE2 =M03/2.2
HEATING FAN CABIN BK -X3 33 4 =M03-S34 13 =M03/3.1

HEATING FAN CABIN BU -X3 34 5 =M03-S34 33 =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
POWER SUPPLY 220V AC CONTROL 5 -X3 27 10 =M03-S32 14 =M03/2.3
DESK LEFT, CABIN LIGHT
POWER SUPPLY 220V AC CONTROL 6 -X3 28 11 =M03-S32 34 =M03/2.3

DESK LEFT, CABIN LIGHT
WARNING LIGHT RED 3 -X3 24 12 =M03-S33 14 =M03/2.5
WARNING LIGHT RED 4 -X3 25 13 =M03-S33 34 =M03/2.5
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 PE =M03-E8 PE 16PE =M03-PE1 PE5 =M03/3.1
DESK HEATER CONTROL DESK RIGHT BK -X70 1 17 =M03-S34 13 =M03/3.3
DESK HEATER CONTROL DESK RIGHT BU -X70 2 18 =M03-S34 33 =M03/3.3
PE PE -X70 3PE 19PE =M03-PE1 PE5 =M03/3.3
7 9

Ch.
8
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH CONTROL DESK LEFT CABIN
Sh.

0 1 2 3 4 5 6 7 8 9
Quattro
W-HORN
Quattro
W-FAN
Quattro
W-SWIPER
Quattro
W-X62_24V
LYCY
W-S22V
LIYCY
W-S22
TERMINAL BLOCK -X62
3x1mmý
3x1mm
5x1mmý
3x1mm
12x0.5mmý
12x0.34mmý
SIDE/
CONTROL LEVER LUFFING IN 1 -X72 12 1 =M07-S22 03 BK =M07/5.1
SET VALUE LUFFING GEAR 2 -X72 13 2 =M07-S22 A RD =M07/5.2
SET VALUE LUFFING GEAR 3 -X72 14 3 =M07-S22 S BU =M07/5.3
SLEWING CLKW (RIGHT) 4 -X72 15 4 =M07-S32 05 PK =M07/5.5

SET VALUE SLEWING GEAR 5 -X72 16 5 =M07-S32 A GN =M07/5.5
SET VALUE SLEWING GEAR 6 -X72 17 6 =M07-S32 S YE =M07/5.6
SET VALUE SLEWING GEAR 7 -X72 18 7 =M07-S32 E GY =M07/5.6
SPARE 8 -X72 19 8 =M07/5.7
SPARE SH -X72 20 9 W-S22 S SH =M07/5.7
SUPPLY 24V CONTR.DESK RIGHT 1 -X5 9 11 =M07-S22H 3 =M05/1.6
SUPPLY 24V CONTR.DESK RIGHT 2 -X5 14 12 =M05/1.7
WINDSCREEN WIPER 24V DC 3 -XM50 4 13 =M05-S8 21 =M05/1.2

WINDSCREEN WIPER 24V DC 2 -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 4 -XM50 5 17 =M05/1.3
FAN 0V DC 2 =M05-M51 - 18 =M05/1.5
HORN 24V DC 1 =M05-H50 1 19 =M07-S22H 4 =M05/1.6
HORN 0V DC 2 =M05-H50 2 20 =M05/1.7
HORN PE PE =M05-H50 PE 21PE =M05-PE PE =M05/1.7
8 10

Ch.
9
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH CONTROL DESK LEFT CABIN
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E2
TERMINAL BLOCK -X70
3x1.5mmý
SIDE/
DESK HEATER CONTROL DESK RIGHT BK -X60 17 1 =M03-E2 L =M03/3.3
DESK HEATER CONTROL DESK RIGHT BU -X60 18 2 =M03-E2 N =M03/3.3
DESK HEATER CONTROL DESK RIGHT PE -X60 19PE 3PE =M03-E2 PE =M03/3.3
9 11

Ch.
10
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH CONTROL DESK RIGHT CABIN
Sh.

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
TERMINAL BLOCK -X72
12x0.5mmý
12x0.5mmý
4x0.5mmý
4x0.75mmý
12x0.5mmý
SIDE/
CAN-BUS SUPPLY WH -X5 35 1 -X3A5 6 2 =M07/4.1
CAN-BUS SUPPLY 3 -XA6 5 2 =M07-R1 =M07/4.2
CAN-BUS SUPPLY BN -X5 40 3 -X3A5 5 1 =M07/4.1
CAN-BUS SUPPLY 1 -XA6 1 4 =M07-R1 =M07/4.2

CAN-BUS SUPPLY SH W-X72A5 S 5 W-X72A5 S SH =M07/4.1
CAN-BUS SUPPLY S 6 =M07/4.1
MODULE SUPPLY GN -X5 6 7 -X1A5 2 =M07/4.2
SPARE -X2A5 6 8 -XA6 6 =M07/5.8
MODULE SUPPLY YE -X5 12 9 -X1A5 18 =M07/4.2
SPARE 2 -XA6 2 10 -X2A5 18 =M07/5.8
EOS 11 -X1A5 1 =M07/4.3
CONTROL LEVER LUFFING IN 1 -X62 1 12 -X2A5 1 =M07/5.1

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
SPARE 8 -X62 8 19 -X2A5 5 =M07/5.7
SPARE SH -X62 9 20 -X2A5 16 =M07/5.7
10 12

Ch.
11
Com-No ass.-gr.
7/3945 97.25 50 18
Marine Cranes GmbH CONTROL DESK RIGHT CABIN
Sh.

0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-S4
(L)M2XH-J
W-S4
TERMINAL BLOCK -X75
3x1.5mmý
3x1.5mmý
SIDE/
EMERGENCY STOP BK -X4 1 1 =M01-S4 21 =M01/1.8
EMERGENCY STOP BU -X4 2 2 =M01-S4 22 =M01/1.8
EMERGENCY STOP PE 3PE -X4 3PE PE =M01/1.8

11 13

Ch.
12
Com-No ass.-gr.
PLUG CONNECTOR -X75 Typ Bl.
7/3945 97.25 50 18
Marine Cranes GmbH 380/440V CONTROL DESK RIGHT
Sh.

0 1 2 3 4 5 6 7 8 9
TERMINAL BLOCK -XA1

SIDE/
24N(GND) -X5 24 01 =M06/1.2
INCREMENTAL ENCODER LUFFING -X5 55 02 =M06-A1 IX0.13 =M06/3.5
GEAR
SPARE -X5 62 03 =M06-A1 IX0.25 =M06/5.2

SPARE 04 =M06-A1 IX0.31 =M06/5.7
+24V =M01-F12 05 =M06/1.1
RS232 =M06-SUB-D 3 06 =M06/1.4
RS232 =M06-SUB-D 2 07 =M06/1.4
MAIN MOTOR AMPERAGE =M02-T1 + 08 =M06-A1 IW03 =M06/2.1
LIMIT SWITCH CHECK CONTACT -X5 53 09 =M06-A1 IX0.02 =M06/3.3
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 22 12 =M06/1.1
CAN 1H -X5 35 14 =M06-A1 CAN1H =M06/1.5
24N(GND) -X5 23 15 =M06/1.2
SPARE -X5 72 16 =M06-A1 QX0.22 =M06/8.4
HYDRAULIC OIL COOLER =M02-K12 A1 17 =M06-A1 QX0.06 =M06/7.5
SLACK ROPE SW. HOISTING GEAR -X5 50 18 =M06-A1 IX0.22 =M06/2.2
LIMIT HOISTING -X5 56 19 =M06-A1 IX0.20 =M06/4.1
INCREMENTAL ENCODER -X5 54 20 =M06-A1 IX0.12 =M06/3.4
INCREMENTAL ENCODER -X5 59 21 =M06-A1 IX0.14 =M06/4.4
SPARE -X5 64 22 =M06-A1 IX0.27 =M06/5.4
+24V -X5 8 23 =M06/1.3
24N(GND) =M06-SUB-D 1 24 =M06/1.3
12PMS START ENABLE OPTIONAL =M06-KEN 14 27 =M06-A1 IX0.01 13.1

=M06/2.3

Ch.
13
Com-No ass.-gr.
-XA1 24V PLC CABINET Typ Bl.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
TERMINAL BLOCK -XA1

SIDE/
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
SPARE 31 =M06-A1 QX0.18 =M06/8.8

CAN 1L -X5 40 32 =M06-A1 CAN1L =M06/1.5
CAN 1H -X5 30 33 =M06/1.4
+24V =M01-F13 34 =M06/1.2
SPARE -X5 73 35 =M06-A1 QX0.23 =M06/8.5
MAIN MOTOR TIME RELAY =M02-K4 A1 36 =M06-A1 QX0.04 =M06/7.3
LIMIT SWITCH CHECK CONTACT -X5 58 37 =M06-A1 IX0.23 =M06/4.3
INCREMENTAL ENCODER HOIST. -X5 60 38 =M06-A1 IX0.15 =M06/4.5
GEAR
SPARE -X5 61 39 =M06-A1 IX0.24 =M06/5.1
SPARE -X5 63 40 =M06-A1 IX0.26 =M06/5.3
SPARE -X5 65 41 =M06-A1 IX0.28 =M06/5.5
SPARE -X5 66 42 =M06-A1 IX0.29 =M06/5.6
SPARE -X5 82 43 =M06-A1 IX0.30 =M06/4.7
TRIMOT (PWM-OUTPUT) -X5 67 44 =M06-A1 QX0.00 =M06/7.1
PMS START REQUEST OPTIONAL =M06-KRQ A1 45 =M06-A1 QX0.01 =M06/7.2
LIMIT LUFFING IN -X5 51 46 =M06-A1 IX0.10 =M06/3.1
LIMIT LUFFING OUT -X5 52 47 =M06-A1 IX0.11 =M06/3.3
SPARE 48 =M06-A1 QX0.16 =M06/8.6
SPARE 49 =M06-A1 QX0.17 =M06/8.7
SPARE 50 =M06-A1 QX0.19 =M06/8.9
13SPARE -X5 70 51 =M06-A1 QX0.20 13.2

=M06/8.1

Ch.
13.1
Com-No ass.-gr.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
TERMINAL BLOCK -XA1

SIDE/
SPARE -X5 71 52 =M06-A1 QX0.21 =M06/8.3
SUPPLY SAFETY CIRCUITS -X5 45 53 =M06-A1 QX0.07 =M06/7.6
FEED OIL PUMP =M02-K11 A1 54 =M06-A1 QX0.05 =M06/7.4
LIMIT LOWERING -X5 57 55 =M06-A1 IX0.21 =M06/4.3

13.1 14

Ch.
13.2
Com-No ass.-gr.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
LYCY
W-A4A5
TERMINAL BLOCK -X1A5
12x0.5mmý
SIDE/
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_CH2 =M07/4.3

KEY BUTTON JIB RESTING =M07-S07 14 5 =M07-A5 IX5.03 =M07/4.5
CONTROL LEVER HOISTING =M07-S12 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
BUZZER FAULT =M07-H08 X2 16 =M07-A5 QX5.07\GND_CH7 =M07/6.4

FAULT =M07-H07 X1 17 =M07-A5 QX5.08 =M07/6.2
MODULE SUPPLY -X72 9 18 =M07-A5 GND_CH8 =M07/4.2
13.2 15

Ch.
14
Com-No ass.-gr.
-X1A5 24V CAN NODE CABIN Typ Bl.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9

SIDE/
CONTROL LEVER 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_CH10 =M07/5.6
SPARE -X72 19 5 =M07-A5 IX5.11 =M07/5.7

SPARE -X72 8 6 =M07-A5 +UB_CH11 =M07/5.8
SPARE 7 =M07-A5 IX5.12 =M07/6.5
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_CH13 =M07/5.2
SET VALUE SLEWING GEAR -X72 16 14 =M07-A5 IW5.14\GND_CH14 =M07/5.5
BUZZER FAULT =M07-H08 X1 15 =M07-A5 QX5.15 =M07/6.3
SPARE -X72 20 16 =M07-A5 IW5.14\GND_CH15 =M07/5.7

GRAB OPERATION ON =M07-S85 14 17 =M07-A5 IX5.16 =M07/6.6
SPARE -X72 10 18 =M07-A5 GND_CH16 =M07/5.8
14 16

Ch.
15
Com-No ass.-gr.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
LYCY
W-X72A5
12x0.5mmý
SIDE/
CAN-BUS SUPPLY 1 -X72 3 5 =M07-A5 CAN_L =M07/4.1
CAN-BUS SUPPLY 2 -X72 1 6 =M07-A5 CAN_H =M07/4.1

15 17

Ch.
16
Com-No ass.-gr.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
LYCY
W-X72A6
TERMINAL BLOCK -XA6
4x0.5mmý
SIDE/
CAN-BUS SUPPLY 1 -X72 4 1 =M07/7.2
CAN-BUS SUPPLY -X72 10 3 =M07/7.2

CAN-BUS SUPPLY -X72 8 6 =M07/7.3

16 18

Ch.
17
Com-No ass.-gr.
-XA6 24V CAN NODE DISPLAY Typ Bl.
7/3945 97.25 50 18

0 1 2 3 4 5 6 7 8 9
Quattro
W-SWIPER
TERMINAL BLOCK -XM50
5x1mmý
SIDE/
WINDSCREEN WIPER =M05-M50 53a 1 -X62 15 1 =M05/1.3
WINDSCREEN WIPER =M05-M50 31b 3 -X62 14 2 =M05/1.3
WINDSCREEN WIPER =M05-M50 53 4 -X62 13 3 =M05/1.2
WINDSCREEN WIPER =M05-M50 31 5 -X62 17 4 =M05/1.3

17 =CABLES/1

Ch.
18
Com-No ass.-gr.
PLUG CONNECTOR XM50 Typ Bl.
7/3945 97.25 50 18
Marine Cranes GmbH WINDSCREEN WIPER
Sh.

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
SOURCE/ TARGET/ LENGHT
CABLE NAME FROM TO CABLE TYPE CORES USED í IN MMý M REMARKS PAGE
W-A4A5 -X1A5 =M07-S12 LYCY 12+S 3 0.5 1.5 CAN BUS CABLE CR2012/CR1001 =M07/4.7
W-B01 Sensor 4+S 2+S 0.3 2 TEMPERATURE SENSOR
XB01 -XA4 4+S 2 0.3 TEMPERATURE SENSOR =M07/2.8
S -XA4 4+S 0+S 0.3 TEMPERATURE SENSOR =M07/2.8
W-B10 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR HOISTING
XB10 -XA4 4+S 2 0.3 PRESSURE SENSOR HOISTING =M07/2.3
S -XA4 4+S 0+S 0.3 PRESSURE SENSOR HOISTING =M07/2.3
W-B20 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR LUFFING
XB20 -XA4 4+S 2 0.3 PRESSURE SENSOR LUFFING =M07/2.5

S -XA4 4+S 0+S 0.3 PRESSURE SENSOR LUFFING =M07/2.5
W-CAN1 XA3T -X5 CAN_4x0,75 4+S 4 0.75 5 CAN BUS CABLE MODULE CR2031 =M01/3.5
W-CAN2 -XA2C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION =M07/3.2
W-CAN3 -XA3C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION =M07/1.2
W-CAN4 -X5 -X72 CAN_4x0,75 4+S 4 0.75 6 CAN BUS CABLE CONNEC. CTRL DESK =M01/3.6
W-E2 -X60 -X70 (L)M2XH-J 3/PE 3/PE 1.5 3.5 DESK HEATER LEFT =M03/3.3
W-E31 -X3 =M03-E31 (L)M2XH-J 3/PE 3/PE 1.5 4 LIGHT CRANE TOWER BELOW =M03/1.6
W-E32 -X3 =M03-E32 (L)M2XH-J 3/PE 3/PE 1.5 6 LIGHT POWER MODULE =M03/1.8
W-E36 -X60 =M03-E36 (L)M2XH-J 3/PE 3/PE 1.5 3.5 LIGHT CABIN =M03/2.1
W-E37 -X13 =M03-E37 H07RN 3/PE 3/PE 1.5 2 WORKING LIGHT =M03/2.6
W-E38 -X13 =M03-E38 H07RN 3/PE 3/PE 1.5 1.5 WARNING LIGHT RED =M03/2.4
W-E39 -X3 =M03-E39 (L)M2XH-J 3/PE 3/PE 1.5 6 DECK LIGHT 1 =M03/5.6
W-E40 -X3 =M03-E40 (L)M2XH-J 3/PE 3/PE 1.5 6 DECK LIGHT 2 =M03/5.8
W-E6 -X3 =M03-E6 (L)M2XH-J 3/PE 3/PE 1.5 6 HEATER CRANE TOWER =M03/4.0
W-ELIGHTSUPPLY -X3 -XSR (L)M2XH-J 3/PE 2 1.5 10 LIGHT CRANE TOWER SWITCH =M03/1.1
W-FAN -X62 =M05-M51 Quattro 3/PE 2 1 4 WINDSCREEN FAN =M05/1.4
W-HORN -X62 =M05-H50 Quattro 3/PE 3/PE 1 3.5 HORN =M05/1.6
W-M1/HEATER -X3 -XM1 (L)M2XH-J 3/PE 2 1.5 4 MOTOR HEATER =M02/1.7
W-M1/PE =M02-M1 =M02-PE (L)M2XH 1 1 70 2 MAIN MOTOR PE =M02/1.2
W-M1/THERM -X5 -XM1 Quattro 3/PE 2 1 4 THERMISTOR =M02/1.7
W-M1/U1 -XM1 =M01-S1 (L)M2XH 1 1 70 3 MAIN MOTOR U1 =M02/1.1
W-M1/U2 -XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR U2 =M02/1.5
W-M1/V1 -XM1 =M01-S1 (L)M2XH 1 1 70 3 MAIN MOTOR V1 =M02/1.1
W-M1/V2 -XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR V2 =M02/1.5
W-M1/W1 -XM1 =M02-T1 (L)M2XH 1 1 70 3 MAIN MOTOR W1 =M02/1.2
W-M1/W2 -XM1 =M02-K3 (L)M2XH 1 1 70 3 MAIN MOTOR W2 =M02/1.4
=TERMINALS/18 1.1

Ch.
1
Com-No ass.-gr.
CABLE OVERVIEW Typ Bl.
7/3945 97.25 50 1.2
Abt./departm.: -K5 erstellt/designed 07.07.08 Schmahl = CABLES

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
W-M11 -X4 =M02-M11 (L)M2XH_J_1 4/PE 4/PE 2.5 5 FEED OIL PUMP =M02/2.1
W-M12 -X11 =M02-M12 H07RN 4/PE 4/PE 1.5 3 HYDRAULIC OIL COOLER =M02/2.5
W-P1Q XA2T -X5 QUATTRO-O 2 2 1.5 6 SUPPLY COMPACT MODULE =M01/3.6
W-PE16 F1 P1 H07VK 1/PE 1 16 5 CABIN PE =PE/1.5
W-PE170 =PE-CRANETOWER =PE-PUMPMODULE (L)M2XH-PE 1/PE 1/PE 70 5.5 MODULE PE =PE/1.3
W-PE270 =PE-CABINET =PE-PUMPMODULE (L)M2XH-PE 1/PE 1/PE 70 1 CABINET PE =PE/1.1
W-PE470 =PE-CRANETOWER =PE-JIB NSGA-PE 1/PE 1/PE 70 1.5 JIB PE =PE/1.8
W-PE4L F1 PULT_L SZ2564 1 1 4 0.5 DESK LEFT PE =PE/1.5
W-PE4R F1 PULT_R SZ2564 1 1 4 0.5 DESK RIGHT PE =PE/1.6

W-S03/LIGHTING -X3 =M03-S03 (L)M2XH-Jú 5/PE 5/PE 1.5 9 LIGHTING SWITCH =M03/1.3
W-S08 -XA2 =M07-S08 IFM 3 2 0.3 2 PRESSURE SWITCH FILTER =M07/3.4
W-S09 -XA2 =M07-S09 IFM 3 2 0.3 5 OIL LEVEL =M07/3.5
W-S10 -XA4 =M07-S10 IFM 3 2 0.3 2 PRESSURE SWITCH HOISTING GEAR =M07/2.4
W-S16 Oelflex 110CY 7+S 7 0.5 8.5 LIMIT SWITCH MAIN HOISTING WINCH
-X5 =M06-S16.1 7+S 2 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
-X5 =M06-S16.2 7+S 2 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
-X5 -XS16 7+S 3 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
W-S19 -X5 =M06-S19 Quattro 3/PE 1 1 6 CONN. SLACK ROPE SWITCH HG =M06/2.1
W-S20 -XA4 =M07-S20 IFM 3 2 0.3 2 PRESSURE SWITCH LUFFING GEAR =M07/2.5
W-S22 LIYCY 12+S 7+S 0.34 1.5 CONTROL LEVER LEFT

-X62 =M07-S22 12+S 3 0.34 CONTROL LEVER LEFT =M07/5.0
-X62 =M07-S32 12+S 4 0.34 CONTROL LEVER LEFT =M07/5.0
-X62 S 12+S 0+S 0.34 CONTROL LEVER LEFT =M07/5.0
W-S22V LYCY 12+S 8+S 0.5 3.5 CONTROL LEVER LEFT
-X62 -X72 12+S 8+S 0.5 CONTROL LEVER LEFT =M07/5.0
S -X72 12+S 0 0.5 CONTROL LEVER LEFT =M07/5.0
W-S26 Oelflex 110CY 7+S 7 0.5 7.5 LIMIT SWITCH LUFFING WINCH
-X5 =M06-S26.1 7+S 2 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
-X5 -XS26 7+S 3 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
-X5 =M06-S26.2 7+S 2 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
W-S30 -XA4 =M07-S30 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR =M07/2.6
W-S31 -XA4 =M07-S31 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR =M07/2.8
W-S31/X3 -X3 -X60 (L)M2XH-Jú 7/PE 7/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V =M03/2.1
W-S34/X3 -X3 -X60 (L)M2XH-J 3/PE 3/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V =M03/3.1
W-S4 -X4 -X75 (L)M2XH-J 3/PE 3/PE 1.5 6 EMERGENCY STOP IN CONTROL DESK =M01/1.7
1 1.2

Ch.
1.1
Com-No ass.-gr.
7/3945 97.25 50 1.2

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
W-SUPPLY220VL4/L5 -X3 -XSR (L)M2XH 2 2 6 10 AUX. POWER SUPPLY L4/L5 =M01/1.2
W-SUPPLYL1 -XSR =M01-S1 (L)M2XH 2x1 1 70 10 MAIN POWER SUPPLY L1 =M01/1.0
W-SUPPLYPE -XSR =M01-PE (L)M2XH-PE 1/PE 1/PE 70 6 MAIN POWER SUPPLY PE =M01/1.2
W-SWIPER -X62 -XM50 Quattro 5/PE 4 1 5.5 WINDSCREEN WIPER =M05/1.2
W-X12/X12.1 -X12 -X12.1 (L)M2XH-Jú 5/PE 5/PE 1.5 5.5 CONNECTION AT JIB MIDDLE =M03/2.4
W-X12.1/X13 -X13 -X12.1 H07RN 5/PE 5/PE 1.5 32 CONNECTION ON JIB =M03/2.4
W-X3/X12 -X3 -X12 (L)M2XH-Jú 5/PE 5/PE 1.5 5.5 CONNECTION TO JIB =M03/2.4
W-X4/X11 -X4 -X11 (L)M2XH_J_1 4/PE 4/PE 2.5 10.5 HYDRAULIC OIL COOLER =M02/2.4
W-X60/E8 -X60 =M03-E8 H07RN 3/PE 3/PE 1 1 HEATING FAN CABIN =M03/3.0
W-X62_24V -X5 -X62 Quattro 3/PE 2 1 6 CONN. CONTROL DESK LEFT 24V =M05/1.6
W-X72A5 -X72 -X3A5 LYCY 12+S 2+S 0.5 1.5 CAN BUS CABLE X72/CR2012 =M07/4.1
W-X72A6 -X72 -XA6 LYCY 4+S 3 0.5 1.5 CAN BUS CONNECTION X72/CR1031 =M07/4.1
W-Y1 -XA2 -XY1 IFM M12/DINA 3 2 0.5 1 HOISTING GEAR BRAKE =M07/3.4
W-Y11 -XA2 -XY11 IFM M12/DINA 3 2 0.5 1 PRE HEATING =M07/3.8
W-Y1A -XA3 -XY1A IFM M12/DINA 2 2 0.75 2 SN 4243444 =M07/1.4
W-Y1B -XA3 -XY1B IFM M12/DINA 2 2 0.75 2 SN 4243444 =M07/1.4
W-Y1T -X5 -XY1T Quattro 3/PE 2 1 11.5 TRIMOT =M06/7.1
W-Y2 -XA2 -XY2 IFM M12/DINA 3 2 0.5 1 LUFFING GEAR BRAKE =M07/3.5
W-Y3 -XA2 -XY3 IFM M12/DINA 3 2 0.5 1 SLEWING GEAR BRAKE =M07/3.6
1.1

Ch.
1.2
Com-No ass.-gr.
7/3945 97.25 50 1.2

7/3945 – 7/3948 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 18.00.00 DRIVING HOUSE COMPL.
ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.
ASSEMBLY GROUP 25.00.00 ELECTRICAL EQUIPMENT COMPL.
ASSEMBLY GROUP 66.00.00 HYDRAULIC SYSTEM COMPL.
ASSEMBLY GROUP 97.00.00 TECHNICAL DOKUMENTS

SPARE PARTS LIST

ORDER NO. 5 003 945-00
DESCRIPTION: DECK CRANE KL 30T – 25M
CRANE COMPL. ONLY CRANE NO. 1 : LMG YARD NO.: 2-571-73945 ORDER NO.: 5 003 945
ASSEMBLY MATERIAL DRAWING

GROUP QTY QC DESCRIPTION NO. NO.
00.00.00.00.00 1 PC DECK CRANE COMPL. 5003945 5003945
01.00.00.00.00 1 PC CRANE TOWER COMPL. 5006935 5006935

02.00.00.00.00 1 PC JIB COMPL. 5007050 5007050
05.00.00.00.00 1 PC ROPE PLAN 5007145 5007145
07.00.00.00.00 1 PC CARGO GEAR COMPL. 5007496
12.00.00.00.00 1 PC PANEL LIST 5004095 5004095
14.00.00.00.00 1 PC PARTS WITHOUT ATTECH IN WORK 5006953
18.00.00.00.00 1 PC DRIVERS CABIN COMPL. 5005840 2389487
19.00.00.00.00 1 PC WINCH MODULE 5006242 5006242
25.00.00.00.00 1 PC ELECTRICAL EQUIPMENT COMPL. 5002991
66.00.00.00.00 1 PC HYDRAULIC SYSTEM COMPL. 5007688
97.00.00.00.00 1 PC TECHNICAL DOKUMENTS 5007569
ASSEMBLY GROUP 00.00.00.00.00

SPARE PARTS LIST

ORDER NO. 5 003 946-00


02.00.00.00.00 1 PC JIB COMPL. 5007053 5007050
05.00.00.00.00 1 PC ROPE PLAN 5007145 5007145
12.00.00.00.00 1 PC PANEL LIST 5004095 5004095
19.00.00.00.00 1 PC WINCH MODULE 5006242 5006242

SPARE PARTS LIST

ORDER NO. 5 003 947-00


02.00.00.00.00 1 PC JIB COMPL. 5007055 5007050
05.00.00.00.00 1 PC ROPE PLAN 5007145 5007145
12.00.00.00.00 1 PC PANEL LIST 5004095 5004095
19.00.00.00.00 1 PC WINCH MODULE 5006242 5006242

SPARE PARTS LIST

ORDER NO. 5 003 948-00


02.00.00.00.00 1 PC JIB COMPL. 5007057 5007050
05.00.00.00.00 1 PC ROPE PLAN 5007145 5007145
12.00.00.00.00 1 PC PANEL LIST 5004095 5004095
19.00.00.00.00 1 PC WINCH MODULE 5006242 5006242

SPARE PARTS LIST 06.2009
SPARE PARTS LIST

ORDER NO. 5 006 935-00
DESCRIPTION: SLEWING TOWER COMPL.

01.00.00.00.00 1 PC SLEWING TOWER COMPL. 5006935 5006935
01.10.00.00.00 1 PC PROTECTION FOR CABIN 2067984 2067984

01.12.00.00.00 1 PC ROPE PULLEYS RIGHT HAND COMPL. 5005096 5005096
01.15.00.00.00 1 PC ROPE PULLEYS COMPL. 5005091 5005091
01.16.00.00.00 2 PC JIB BEARING DIA 160 5005087 5005087
01.17.00.00.00 1 PC SLEWING GEAR COMPL. 5006428 5006428
01.18.00.00.00 1 PC BALL BEARING COMPL. 5006449 5006449
01.23.00.00.00 1 PC FLAP COOLER CAP COMPL. 5005207 5005207
01.31.00.00.00 1 PC ROPE PULLEYS LEFT HAND COMPL. 5005094 5005094

SPARE PARTS LIST

ORDER NO. 5 005 096-00
DESCRIPTION: ROPE PULLEYS DIA 630 COMPL.

01.12.00.00.00 1 PC ROPE PULLEYS DIA 630 COMPL. 5005096 5005096
01.12.01.00.00 2 PC ROPE PULLRY DIA 630 3327643 3327643

01.12.02.00.00 2 PC ROLLER BEARIN 1350987
01.12.03.00.00 4 PC SPR-SPACER 1656791
01.12.04.00.00 1 PC AXLE 5005092 5005092
01.12.05.00.00 1 PC WASHER 0173102 0173102
01.12.06.00.00 3 PC RIPPSCREW 2361684

SPARE PARTS LIST

ORDER NO. 5 005 091-01

01.15.00.00.00 1 ST ROPE 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 BEARING 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

SPARE PARTS LIST

ORDER NO. 5 005 087-00
DESCRIPTION: JIB BEARING DIA 160

SPARE PARTS LIST

ORDER NO. 5 005 087-00
DESCRIPTION: JIB BEARING DIA 160

01.16.00.00.00 2 PC JIB BEARING DIA 160 5005087 5005087
01.16.01.00.00 1 PC BAERING HOUSING 2389246 2389246

01.16.02.00.00 1 PC AXLE 5005088 5005088
01.16.03.00.00 1 PC PRESSURE DISC 5001771 5001771
01.16.04.00.00 2 PC BEARING COVER 2389367 2389367
01.16.05.00.00 1 PC DIPCANCE BUSH 5005089 5005089
01.16.06.00.00 1 PC JOURNAL 2389251 2389251
01.16.07.00.00 1 PC JOINT BEARING 1657952
01.16.08.00.00 2 PC SHAFT SEAL 0422109
01.16.09.00.00 3 PC HEXAGON SCREW 0057076
01.16.10.00.00 16 PC HEXAGON SCREW 0035035
01.16.13.00.00 4 PC HEXAGON SCREW 0152618
01.16.14.00.00 4 PC WASHER 2479256
01.16.19.00.00 1 PC FLAT GREASE NIPPLE 0155286
01.16.20.00.00 16 PC WASHER 8408962
01.16.21.00.00 8 PC PROTECTIVE PLUG 1609235

SPARE PARTS LIST

ORDER NO. 5 006 428-00
DESCRIPTION: SLEWING GAER COMPL.
The brake must be filled with GEAR OIL prior to mounting the motor

01.17.00.00.00 1 PC SLEWING GEAR COMPL. 5006428 5006428
01.17.02.00.00 2 PC SLEWING GEAR 5005146 5005146

SUBSUPPLIER SEE
ASSEMBLY GROUP 01.17.02.00
01.17.05.00.00 48 PC HEXAGON SCREW 1637385
01.17.06.00.00 52 PC WASHER 3343769
01.17.07.00.00 2 PC WASHER 5005143 5005143

SPARE PARTS LIST
SLEWING GEAR
i= 125
PART-NO.: 5 005 146


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
INSTALLATION INSTRUCTION
WEIGHT: 300,0 KG OIL QUANTITY:: 12,0 LTR.
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 146-00
DESCRIPTION: SLEWING GEAR
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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 PC L
1 6630070500* PIMION SHAFT 1 PC
2 6662005120* SPACER 1 PC
3 0712710128A* NILOS RING 1 PC
4 0712758094* BEARING 1 PC
5 6650009960* GEARBOX HOUSING 1 PC
6 710301024A* SEAL RING 1 PC
8 0712758046* BEARING 1 PC
9 6662003530* SPACER 1 PC
10 6660000270* NUT 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2T261708290*

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
1 0715303258* O-RING 2 PC
2 6641020300* TOOTHER RING 1 PC
3 2T235346100* REDUCTION ASSEMBLY 1 PC L
4 6643021150* SUN GERA 1 PC
5 6653501530* COVER 1 PC
6 0720967023* SCREW 24 PC
7 0715303410* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2T261708290*

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
2 0715303410* O-RING 2 PC
3 6641010030* TOOTHED RING 1 PC
4 6643010070* SUN GEAR 1 PC
6 6653500920* COVER 1 PC
7 0720955031* SCREW 12 PC
8 0720955030* SCREW 4 PC
9 715303268A* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2T261708290*

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
1 715303268A* O-RING 2 PC
3 6641000360* TOOTHED RING 1 PC
4 6643000190* SUN GEAR 1 PC
5 2T235332030* REDUCTION STAGE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2T261708290*

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
1 0718299106* CIRCLIP 2 PC
2 6660300500* SPRING RETAINER 1 PC
3 6633030481* BRAKE SHAFT 1 PC
4 6680700040* STEEL RING 5 PC
5 6680900040* SINTERED DISC 6 PC
6 6652500452* BREAKE HOUSING 1 PC
7 0718416007* PLUG 1 PC
8 6682500271* OIL LEVEL PLUG 1 PC
9 0722369001* BACKUP RING 2 PC
10 0715307255* O-RING 2 PC
11 6662050090* SPACER 1 PC
12 0722369002* BACKUP RING 1 PC
13 0715307250* O-RING 1 PC
14 6635050140* PISTON 1 PC
15 6680300070* SPRING 10 PC
16 6660300240* SPRING RETAINER 1 PC
17 715303245A* O-RING 1 PC
18 0720954115* SCREW 12 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2T261708290*

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
1 6654503850* FLANGE 1 PC
2 0715303287* O-RING 1 PC
3 0718298752* CIRCLIP 2 PC
4 712753055A* EARING 1 PC
5 6646001580* COUPLING 1 PC
6 718299076A* CIRCLIP 1 PC
7 720955005A* SCREW 4 PC
8 0720971006* SCREW 8 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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.
INFORMATION!
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
manufacturer. Doing this, will ensure that the product works properly and that the safety level is "acceptable".

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 hole s of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.

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.

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

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.

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).

LUBRICATION
GEARBOX LUBRICATION
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.
INFORMATION!

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.
WARNING!
WARNING!

START UP AND RUNNING IN

1. Check the correctly lubrication of the unit.

INFORMATION!
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!
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
During the running-in stage follow the steps given below.

6. Make sure that the oil temperature does not exceed 85-90°C intermittent.
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

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!

SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
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.

SPARE PARTS LIST

ORDER NO. 5 006 449-01
DESCRIPTION: BALL BEARING SLEWING RING COMPL.

01.18.00.00.00 1 PC BALL BEARING SLEWING RING 5006449 5006449

COMPL.
01.18.01.00.00 1 PC BALL BEARING SLEWING RING 5006448 5006448

01.18.02.00.00 119 PC WASHER 5005115 5005115
01.18.03.00.00 239 PC HEXAGON NUT 2028445 2028445
01.18.04.00.00 239 PC STUD BOLT 2370718 2370718
01.18.05.00.00 120 PC WASHER 1601526 1601226
01.18.07.00.00 12 PC GREASE NIPPLE 0010530

SPARE PARTS LIST

ORDER NO. 5 005 207-00
DESCRIPTION: FLAP COOLER CAP COMPL.

SPARE PARTS LIST

ORDER NO. 5 005 207-00
DESCRIPTION: FLAP COOLER CAP COMPL.

01.23.00.00.00 1 PC FLAP COOLER CAP COMPL. 5005207 5005207
01.23.01.00.00 1 PC FLAP COOLER CAP 5005208 5005208
01.23.01.06.00 1 PC FLAT
01.23.01.07.00 1 PC FLAT
01.23.01.09.00 1 PC ROUND
01.23.01.10.00 1 PC ROUND
01.23.01.14.00 2 PC RING
01.23.02.00.00 4 PC PART OF JOINT 5004079

01.23.03.00.00 6 PC PIN 0583196
01.23.04.00.00 6 PC SPLIT-PIN 0119814
01.23.05.00.00 6 PC HEXAGON NUT 0057127
01.23.06.00.00 3 M SEALING PROFILE 5005147
01.23.07.00.00 2 PC HEXAGON SCREW 2533314
01.23.08.00.00 2 PC CLEVIS HEAD 5004451
01.23.09.00.00 1 PC SPRING PIN 0013825
01.23.11.00.00 3 PC HEXAGON NUT 0057130
01.23.14.00.00 2 PC SET-SCREW 0576549
01.23.15.00.00 2 PC PART OF JOINT 5005145
01.23.16.00.00 4 PC HEXAGON NUT 0057133
01.23.22.00.00 1 PC HOLE COVER 0490348


SPARE PARTS LIST

ORDER NO. 5 005 094-00

01.31.00.00.00 1 PC ROPE PULLEYS DIA 630 COMPL. 5005094 5005094
01.31.01.00.00 1 PC ROPE PULLRY DIA 630 3327643 3327643

01.31.02.00.00 1 PC ROLLER BEARIN 1350987
01.31.03.00.00 2 PC SPR-SPACER 1656791
01.31.04.00.00 1 PC AXLE 5005095 5005095
01.31.05.00.00 1 PC WASHER 0173102 0173102
01.31.06.00.00 3 PC RIPPSCREW 2361684

SPARE PARTS LIST

ORDER NO. 5 007 050-00
DESCRIPTION: JIB COMPL.
JIB COMPL. ONLY CRANE NO. 1 : LMG YARD NO.: 2-571-73945 ORDER NO.: 5 007 050

02.00.00.00.00 1 PC JIB COMPL. 5007050 5007050
02.01.00.00.00 1 PC JIB STEEL STRUCTURE COMPL. 5007051 5007050

02.04.00.00.00 1 PC ROPE PULLEYS COMPL: 5005108 5005108
02.09.00.00.00 1 PC LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 PC BUFFER STOP 2389406
ELECTRICAL EQUIPMENT SEE
02.25.00.00.00 ASSEMBLY GROUP 25.02.00


SPARE PARTS LIST

ORDER NO. 5 007 053-00

02.00.00.00.00 1 PC JIB COMPL. 5007053 5007050

02.20.00.00.00 1 PC BUFFER STOP 2389406
02.25.00.00.00 ASSEMBLY GROUP 25.02.00


SPARE PARTS LIST

ORDER NO. 5 007 055-00

02.00.00.00.00 1 PC JIB COMPL. 5007055 5007050

02.20.00.00.00 1 PC BUFFER STOP 2389406
02.25.00.00.00 ASSEMBLY GROUP 25.02.00


SPARE PARTS LIST

ORDER NO. 5 007 057-00

02.00.00.00.00 1 PC JIB COMPL. 5007057 5007050

02.20.00.00.00 1 PC BUFFER STOP 2389406
02.25.00.00.00 ASSEMBLY GROUP 25.02.00

SPARE PARTS LIST

ORDER NO. 5 005 108-00
DESCRIPTION: ROPE PULLEYS JIB HEAD COMPL.

02.04.00.00.00 1 PC ROPE PULLEYS JIB HEAD COMPL. 5005108 5108
02.04.01.00.00 6 PC ROPE PULLRY DIA 630 COMPL. 3327643 3327643

02.04.02.00.00 6 PC ROLLER BEARING 1350987
02.04.03.00.00 12 PC SPR-SPACER 1656791
02.04.04.00.00 2 PC AXLE 5005109 5005109
02.04.05.00.00 4 PC WASHER 0173102 0173102
02.04.06.00.00 12 PC RIPPSCREW 2361684

SPARE PARTS LIST

ORDER NO. 2 067 941-03
DESCRIPTION: LAMP BRACKET L.H

02.09.00.00.00 1 PC LAMP BRACKET L.H 2067941 2067941
02.09.06.00.00 1 PC WASHER 0841470 0841470

02.09.07.00.00 2 PC HEXAGON. NUT 0057130
02.09.08.00.00 1 PC HEXAGON. NUT 0057125
02.09.09.00.00 1 PC SLIT WASHER 0511788
02.09.10.00.00 1 PC WASHER 0053741
02.09.11.00.00 6 PC HEXAGON SCREW 0056659
02.09.12.00.00 6 PC SPRING LOCK WASHER 0249845
02.09.13.00.00 1 PC RUBBER-MET.COBBECTION 2063050
02.09.14.00.00 1 PC BUSH 2067164 2067164

SPARE PARTS LIST

ORDER NO. 2 389 406-01
DESCRIPTION: BUFFER STOP

02.20.00.00.00 1 PC BUFFER STOP 2389406 2389406
02.20.01.00.00 1 PC STOP-RAIL 1636914

02.20.02.00.00 4 PC HEXAGON NUT 0057130
02.20.03.00.00 4 PC CURVED SPRING LOCK WASHER 0249845

SPARE PARTS LIST

ORDER NO. 5 007 145-00
DESCRIPTION: ROPE PLAN 30T – 25M

05.00.00.00.00 1 PC ROPE PLAN KL 30T – 25M 5007145 50071457
05.01.00.00.00 1 PC ROPE 30 199M ( HOISTING ROPE ) 5007146 5007146

05.02.00.00.00 1 PC ROPE 30 192M ( LUFFING ROPE ) 5005216 5005216
05.03.00.00.00 2 PC BUSH 2094863
05.04.00.00.00 2 PC ADJUSTING-RING 0033190
05.05.00.00.00 2 PC HEXAGON SCREW 7120053
05.06.00.00.00 2 PC EXAGON-NUT 0146559


SPARE PARTS LIST

ORDER NO. 5 007 145-00
DESCRIPTION: ROPE PLAN 30T – 25M

SPARE PARTS LIST

ORDER NO. 5 007 496-00
DESCRIPTION: CARGO GEAR COMPL.

07.01.00.00.00 1 PC CARGO BLOCK 5006469 5006469

07.02.00.00.00 1 PC GRAB SUPPORT 5005267 5005267

7/3945 - /3948PARE PARTS LIST

SPARE PARTS LIST

ORDER NO. 5 006 469-00
DESCRIPTION: CARGO BLOCK SWL 35T COMPL.

SPARE PARTS LIST

ORDER NO. 5 006 469-00

SPARE PARTS LIST

ORDER NO. 5 006 469-00

07.01.00.00.00 1 PC CARGO BLOCK SWL 35T COMPL. 5006469 5006469
07.01.01.00.00 1 PC BEARING PLATE F. CARGO BLOCK 5007095 5007095

07.01.02.00.00 1 PC SWIVEL EYE 5005152 5005152
07.01.03.00.00 1 PC PIN 5005136 5005136
07.01.04.00.00 1 PC THRUST WASHER 5005137 5005137
07.01.05.00.00 1 PC PIN 5005139 5005139
07.01.06.00.00 1 PC THRUST WASHER 5005148 5005148
07.01.07.00.00 2 PC WASHER 5001927 5001927
07.01.08.00.00 1 PC ROPE PULLEY 5005138 5005138
07.01.09.00.00 1 PC CYLINDER ROLLER BEARING 1382156
07.01.10.00.00 2 PC RETAINING RING 0650844
07.01.11.00.00 1 PC RAMSHORN SHANK HOOK 5005162 5005162
07.01.12.00.00 1 PC LIFTING HOOK NUT 5005153 5005153
07.01.13.00.00 1 PC SAFETY LUG 5005169 5005169
07.01.14.00.00 1 PC BUSHING 2094863
07.01.15.00.00 1 PC SUSPENSION 5005171 5005171
07.01.16.00.00 6 PC DISTANCE TUBE 5005161 5005161
07.01.17.00.00 6 PC SELF-LOCKING-NUT 0589418
07.01.18.00.00 6 PC HEXAGON SCREW 0013217
07.01.19.00.00 3 PC HEXAGON SCREW 0013046
07.01.20.00.00 3 PC RIPP-SCREW 0012913
07.01.21.00.00 2 PC HEXAGON SCREW 0054405
07.01.22.00.00 2 PC HEXAGON SCREW 0056668
07.01.23.00.00 2 PC WASHER 0952012
07.01.24.00.00 1 PC AXIAL-CYLINDER ROLLER BEARING 5001630
07.01.25.00.00 1 PC GREASE NIPPLR 0010528
07.01.26.00.00 1 PC V-RING 0750868
07.01.27.00.00 2 PC HEXAGON SCREW 0840133
07.01.28.00.00 1 PC BUSH 5005263 5005263
07.01.31.00.00 2 PC SLIDING PLATE 5007111 5007111
07.01.32.00.00 8 PC CAP-SCREW 1608749
07.01.33.00.00 8 PC WASHER 0056992


SPARE PARTS LIST

ORDER NO. 5 005 267-00
DESCRIPTION: GRAB MOUNTING

07.02.00.00.00 1 PC GRAB MOUNTING 5005267 5005267
07.02.01.00.00 1 PC WEAR RING 5001277 5001277

SPARE PARTS LIST

ORDER NO. 5 004 095-00
DESCRIPTION: PANEL LIST SLEWING TOWER

SPARE PARTS LIST

ORDER NO. 5 004 095-00

SPARE PARTS LIST

ORDER NO. 5 004 095-00

12.00.00.00.00 1 PC PANEL LIST SLEWING TOWER 5004095 5004095
12.02.00.00.00 1 PC TYPE PLATE 5001168 5001168

12.04.00.00.00 1 PC PLATE "DANGER" 3337851 3337851
12.05.00.00.00 1 PC PLATE "MOUNTING HATCH" 3337852 3337852
12.06.00.00.00 1 PC PLATE "OPERATING" 3337853 3337853
12.08.00.00.00 1 PC BLADE EMERGENCY EXIT 2008698 2008698
12.09.00.00.00 1 PC EMERGENCY EXIT 2389652 2389652
12.10.00.00.00 1 PC LABEL 1604793 1604793
12.11.00.00.00 1 PC PLATE "SEAT BELT" 3337855 3337855
12.12.00.00.00 1 PC PLATE "DANGER" 3337856 3337856
12.13.00.00.00 1 PC PLATE 3337857 3337857
12.14.00.00.00 1 PC PALTE “OPERATING INSTRUCTION” 5001164 5001164
12.15.00.00.00 6 PC ST-SCREW 1520120
12.16.00.00.00 6 PC WASHER 2372234
12.17.00.00.00 1 PC BLADE VENTILATION 2509888 2509888
12.18.00.00.00 1 PC PLATE "DOOR OPEN" 3396157 3396157
12.19.00.00.00 2 PC NAME PLATE TTS 5001397
12.20.00.00.00 4 PC ROUND HEAD GROVED PIN 0040708
12.21.00.00.00 1 PC PLATE VENTILATOR COVER CLOSE 5004094
12.22.00.00.00 1 PC PLATE VENTILATOR COVER OPEN 5004093

SPARE PARTS LIST

ORDER NO. 5 006 953-00
DESCRIPTION: PARTS WITHOUT ATTACH IN WORK

14.00.00.00.00 1 PC PARTS WITHOUT ATTACH IN WORK 5006953
14.02.00.00.00 1 PC EXTINGUISHER 3330836
14.03.00.00.00 1 PC ROPE DOWN DEVICE 2544045 2544045
14.25.00.00.00 1 PC E - PARTS FOR ASSEMBLY 14.00 5002648

7/3945– 7/3948 SPARE PARTS LIST
SPARE PARTS LIST

ORDER NO. 5 002 648-00
DESCRIPTION: E - PARTS FOR ASSEMBLY GROUP 14

14.25.00.00.00 1 PC E - PARTS FOR ASSEMBLY GROUP 14 5002648
14.25.20.00.00 1 PC SLIP RING BODY 2078876

SEE SUBSUPPLIER
ASSEMBLY GROUP 14.25.20
14.25.21.00.00 1 PC ACCESSORIES FOR SLIP RING 5002489
14.25.30.00.00 1 PC FLOODLIGHT 1x1000W HAL. 2350939
14.25.31.00.00 2 PC DECKS LIGHTING 5002302

SPARE PARTS LIST
SLIPRING BODY
PART-NO.: 2 078 876

SPARE PARTS LIST

ORDER NO. 2 078 876
DESCRIPTION: SLIPRING BODY
L = ASSEMBLY GROUP
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2 078 876

2 078 876 SLIPRING BODY 1 PC L
1 A 100.9306-4* FLANGE 1 PC
2 100:9382-4* SPACER RING 1 PC
3 N 100.47-2* BEARING SUPPORT 1 PC
5 SLIPRING; Ø200x24 3 PC
6 THREADED ROD 3 PC
7 100.07-4 REDUCTION RING 1 PC
8 PIPE 4 PC
9 PIPE 1 PC
10 A 100.422-4* INTERMEDIATE WASHER 1 PC
11 HGW 2375.12* GFK-PIPE 12.6x16 2 PC
12 THREADED ROD 4 PC
13 100.11-2* BEARING FLANGE 1 PC
14 100.47-2* MOUNTING PLATE 1 PC
16 1206E* SELF-ALIGNING BALL BEARING 1 PC
17 CAP SCREW 1 PC
18 HEXAGON NUT 10 PC
19 100.21-4* BEARING RING 30/100 1 PC
20 100.998-4* CAP 1 PC
21 300.02-3* INSULATING RING 7 PC
22 A 300.03-4* SLIPRING Ø125x3 6 PC
24 400.4.0.09.1-4* SPACER SLEEVE 3 PC
25 HGW2375.21x30-4* GFK-PIPE 21.2x30 3 PC
26 3 343 623 GFK-PIPE 21.2x30 9 PC
27 HGW2375.14x20-4* GFK-PIPE 14.2x20 2 PC
28 120.31-3* EARTHING RING Ø200X24 1 PC
29 A 490.01-4* EARTHING SLEEVE 20x3 2 PC
30 A 100.38-4* BEARING RING 1 PC
31 CAP SCREW 6 PC
32 HEXAGON SCREW 31 PC
33 100.9467-4* FOLLOWER 1 PC
34 HEXAGON NUT 9 PC
36 E 100.6150-1* HOOD 1 PC
37 SEEGER RING 1 PC
38 HGW2375.8x18-4* GFK-PIPE 8.2x18 1 PC
39 HGW2375.25x14-4* GFK-PIPE 25x14 2 PC
40 A 100.927-3* BEARING RING 1 PC
41 100.960-3* BRUSH HOLDER 60A 6 PC
42 142.02-3* BRUSH HOLDER 60A 8 PC
44 HGW2375.14x20-4* GFK-PIPE 8.2x18 3 PC
45 LOCK WASHER 2 PC
L = ASSEMBLY GROUP
• *= FOREIGN NUMBER
•
SPARE PARTS LIST

ORDER NO. 2 078 876
L = ASSEMBLY GROUP
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 2 078 876

46 LOCK WASHER 11 PC
47 LOCK WASHER 12 PC
48 LOCK WASHER 5 PC
49 HEXAGON NUT 14 PC
50 HEXAGON SCREW 12 PC
51 WASHER 12 PC
52 HP2061.25x12-4* HP-WASHER 16 PC
53 E 100.12.2-4* FELT WASHER 1 PC
54 E 100.12.1-4* WASHER 1 PC
55 WASHER 1 PC
56 LOCK WASHER 1 PC
57 LOCK WASHER 1 PC
58 LOCK WASHER 3 PC
59 COUNTER-SUNK SCREW 2 PC
60 HGW2375.8x10-4* GFK-PIPE 82.x10 3 PC
61 HEXAGON NUT 2 PC
62 WASER 2 PC
63 B 100.75-3* CURRENT COLLECTOR. 600A 4 PC
64 K 100.9391-4* PLATE 2 PC
66 CAP SCREW 2 PC
67 LOCK WASHER 2 PC
69 RK 6-10 PA* INE-UP TERMINAL 6 PC
70 EW 35* SIDE ANGLE 2 PC
71 TW 2.5-10 PA* SEPARATING WALL 1 PC
L = ASSEMBLY GROUP
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 489-01
DESCRIPTION: ACCESSORIES FOR SLIP-RING

14.25.21.00.00 1 PC ACCESSORIES FOR SLIP-RING 5002489
14.25.21.01.00 4 PC PIPE 5006554 5006554

14.25.21.02.00 4 PC HEXAGON SCREW 0955986
14.25.21.03.00 4 PC HEXAGON NUT 2507318
14.25.21.09.00 20 PC CABLE TIE 1624720
14.25.21.11.00 8 PC CABLE THIMBLE 5002355
SPARE PARTS LIST

ORDER NO. 2 350 939-02
DESCRIPTION: LIGHTING FOR JIB

14.25.30.00.00 1 PC LIGHTING FOR JIB 2350939
14.25.30.01.00 1 PC FLOOD LIGHT 1627792

14.25.30.02.00 1 PC SCREW BUSH 1624414
14.25.30.03.00 1 PC HALOGEN-LAMP 0625145
14.25.30.04.00 2 PC HEXAGON SCREW 1683991
14.25.30.05.00 2 PC HEXAGON NUT 1683743
14.25.30.06.00 2 PC CONTACT WASHER 2079812
14.25.30.07.00 10 PC CABLE STRAP 1660206
14.25.30.08.00 1 PC INNERPARTS FOR CABLE INLET 1627507
14.25.30.09.00 1 PC SIKAFLEX 3398165

SPARE PARTS LIST

ORDER NO. 5 002 302-00
DESCRIPTION: DECK LIGHTING

14.25.31.00.00 1 PC DECK LIGHTING 5002302
14.25.31.02.00 1 PC LAMP 1637159

14.25.80.03.00 1 PC HALOGEN-STICK 1673957
14.25.80.05.00 2 PC SCREW BUSH 1624414
14.25.80.06.00 2 PC GASKET FOR CABLE GLAND 5002076
14.25.80.08.00 2 PC HEX.-SCREW 1683948
14.25.80.09.00 2 PC HEX.NUT 1683742

SPARE PARTS LIST

ORDER NO. 5 005 840-00
DESCRIPTION: DRIVING HOUS COMPL.

18.00.00.00.00 1 PC DRIVING HOUS COMPL. 5005840 2389487
18.01.00.00.00 1 PC CABIN STEEL NO.3 2509643

18.02.00.00.00 1 PC CABIN COMPONENTS 2544087


SPARE PARTS LIST

ORDER NO. 2 544 087-03
DESCRIPTION: CABIN COMPONENTS

SPARE PARTS LIST

ORDER NO. 2 544 087-03

SPARE PARTS LIST

ORDER NO. 2 544 087-03

18.02.00.00.00 1 PC CABIN COMPONENTS 2544087
18.02.03.00.00 1 PC MOTOR VEHICLE WANDHOLDER 3330837

18.02.04.00.00 3 PC SHOCK ABSORBING ELEM. 1355813
18.02.05.00.00 1 PC DOUBLE TAPE OF RUBBER 1627721
18.02.07.00.00 7,5 M OWA-TAPE 1636997
18.02.08.00.00 2 PC CAP-SCREW 0490263
18.02.09.00.00 1 PC CAP-SCREW 1636423
18.02.10.00.00. 3 PC DISK 1885320
18.02.11.00.00 4 PC CAP-SCREW 0153331
18.02.12.00.00 1 PC DOOR LATCH 1608569
18.02.13.00.00 3 PC CONTERS: SCREW 0599714
18.02.14.00.00 3 PC HEXAGON NUT 0421223
18.02.15.00.00 9 PC WASHER 0063713
18.02.17.00.00 12 PC WASHER 2381601
18.02.18.00.00 12 PC HEX-SCREW 0063317
18.02.19.00.00. 12 PC HEX. NUT 0057130
18.02.21.00.00 1 PC WIPER BLADE 5004897
18.02.22.00.00 1 PC GUIDE ARM 4510072
18.02.23.00.00 1 PC WIPER ARM 4510071
18.02.24.00.00 1 PC BRACKET 0750219
18.02.25.00.00 1 PC HEXAGON SCREW 0784494
18.02.26.00.00 1 PC OPERATOR'S SEAT 5001336
18.02.27.00.00 1 PC GLAS PANE 3330512
18.02.28.00.00 1 PC GLAS PANE 3330513
18.02.29.00.00 1 PC GLAS PANE 3330514
18.02.30.00.00 2 PC GLAS PANE 3330515
18.02.31.00.00 1 PC GLAS PANE 2549770
18.02.32.00.00 1 PC HANDLE SUITE DS COMPL. 2 549771 2392097
18.02.33.00.00 1 PC PROFILE CYLINDER 2549772 2392097
18.02.34.00.00 3 PC 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 PC HINGE 2549776
18.02.38.00.00 38 PC SELF CUTTING SCREW 3330510
18.02.39.00.00 1 PC NEOPRENE 3330511
18.02.40.00.00 1 PC DOOR RUBBER SEALING 2549779
18.02.41.00.00 1 PC GISTA PROFILE 2549780
18.02.42.00.00 1 PC LEVER PLUG 2549781
18.02.44.00.00 1 PC WINDOW PLUG 2549783
18.02.45.00.00 1 PC WINDOW PLUG 2549784
18.02.46.00.00 1 PC TELESCOPE COVER 2549785
18.02.47.00.00 3 PC HEXAGON SCREW 0054379
18.02.48.00.00 3 PC WASHER 1684578
18.02.51.00.00 4 PC HEXGON SCREW 1683942
18.02.52.00.00 4 PC HEXAGON NUT 2095060
18.02.53.00.00 4 PC WASHER 0063704

SPARE PARTS LIST

ORDER NO. 5 006 242-00
DESCRIPTION: WINCH MODULE COMPL.

SPARE PARTS LIST

ORDER NO. 5 006 242-00

SPARE PARTS LIST

ORDER NO. 5 006 242-00

19.00.00.00.00 1 PC WINCH MODULE COMPL. 5006242 5006242
19.01.00.00.00 1 PC WINCH MODULE 5005274 5005274

19.32.00.00.00 1 PC LIMIT SWITCH SLACK ROPE 5001059 5001059
19.100.00.00.00 1 PC PIN 5001075 5001075
19.101.00.00.00 1 PC THRUST PLATE 5001074 5001074
19.102.00.00.00 1 PC DISTANCE BUSHING 5001080 5001080
19.103.00.00.00 4 PC WASHER 2067451 2067451
19.104.00.00.00 4 PC WASHER 2067452 2067452
19.105.00.00.00 3 PC RIPPSCREW 2361684
19.107.00.00.00 2 PC PROTECTIVE PLUG 1609236
19.108.00.00.00 1 PC PIN 5001079 5001079
19.109.00.00.00 1 PC WASHER 2049788
19.110.00.00.00 1 PC SPLIT PIN 2049787
19.112.00.00.00 2 PC HEXAGON SCREW 0650775
19.114.00.00.00 2 PC HEXAGON NUT 0053502
19.115.00.00.00 3 PC WASHER 2392782 2392782
19.116.00.00.00 6 PC WASHER 0152895
19.117.00.00.00 6 PC HEXAGON SCREW 0054379


SPARE PARTS LIST

ORDER NO. 5 005 274-01
DESCRIPTION: WINCH MODULE

19.01.00.00.00 1 PC WINCH MODULE 5005274 5005274
19.01.01.00.00 1 PC LUFFING GEAR WINCH COMPL. 5005289 5005289

19.01.02.00.00 1 PC HOISTING GEAR WINCH COMPL. 5005290 5005290
19.01.08.00.00 1 PC PRESSURE ROLLER 5005292 5005292
19.01.17.00.00 1 PC WINCH UNIT STEEL COMPL. 5005228 5005228

SPARE PARTS LIST

ORDER NO. 5 005 289-00
DESCRIPTION: LUFFING GEAR WINCH COMPL.

SARE PARTS LIST

ORDER NO. 5 005 289-00
DESCRIPTION: LUFFING GEAR WINCH COMPL.

19.01.01.00.00 1 PC LUFFING GEAR WINCH COMPL. 5005289 5005289
19.01.01.01.00 1 PC WINCHGEAR 5005199 5005199

SEE SUBSUPPLIER
ASSEMBLY 19.01.01.01.00
19.01.01.02.00 1 PC ROPE DRUM DIA 600 5005280 5005280
19.01.01.03.00 1 PC BEARING COVER 5005217 5005217
19.01.01.04.00 1 PC SPACER DISK 5005219 5005219
19.01.01.05.00 1 PC BEARING FLANGE 5005206 5005206
19.01.01.06.00 1 PC CANSHAFT 5005218 5005218
19.01.01.07.00 1 PC ROPE WEDGE 5005303 5005303
19.01.01.08.00 1 PC SPACER RING 5005278 5005278
19.01.01.10.00 1 PC ROLLER – BEARING 0011418
19.01.01.11.00 3 PC DOWEL PIN 0013807
19.01.01.12.00 1 PC SPRING PIN 0054147
19.01.01.13.00 1 PC FELTRING 5005291
19.01.01.15.00 1 PC CYLINDRICAL SCREW 1758053
19.01.01.16.00 3 PC HEXAGON SCREW 0054379
19.01.01.17.00 6 PC HEXAGON SCREW 0518173
19.01.01.18.00 1 PC GREASE NIPPLE 0010528
19.01.01.19.00 1 PC SET-SCREW 0219019
19.01.01.22.00 24 PC HEXAGON SCREW 1637385
19.01.01.23.00 24 PC WASHER 2115513


SPARE PARTS LIST
WINCH GEAR
i= 108,1
PART-NO.: 5 005 199


SPARE PARTS LIST

ORDER NO. 5 005 199-00
DESCRIPTION: WNCH GEAR
5005199 WINCH GEAR 715 i= 108,1
56481360* INSTALLATION DRAWING
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER


SPARE PARTS LIST

ORDER NO. 5 005 199-00
DESCRIPTION: WINCH GEAR 715 i=108,1
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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

SPARE PARTS LIST

ORDER NO. 2T264801082*
DESCRIPTION: WINCH GEAR 7 15 C 3 B 15 A0 108 I7 6WHY U26 CC

2T264801082* WINCH GEAR 7 15 C 3 B 15 A0 108 I7 6WHY U26 CC 1 PC L
1 0720968010* SCREW 16 PC
2 6682500640* OIL BREATHER PLUG 2 PC
3 0718006008* WASHER 2 PC
4 0715303276* O-RING 1 PC
5 6663350310* PAD 1 PC
6 2T237179022* COVER ASSEMBLY 1 PC
7 6643010430* SUN GEAR 1 PC
8 2T235379050* 1. REDUCTION ASSEMLY 1 PC
9 6643020590* SUN GEAR 1 PC
11 6643040150* SUN GEAR 1 PC
12 0720965816* SCREW 4 PC
13 2T2352379013* REDUCTION ASSEMBLY 1 PC
14 6661000441* BUSH 4 PC
15 2T237470830* HOUSING AND BEARING 1 PC
16 0710317016* LIFTIME SEAL 1 PC
17 6660300411* DISCS RETAINER 1 PC
18 6632592820* HUB 1 PC
19 6633032670* BRAKE SHAFT 1 PC
21 6680700060* STEEL DISC 6 PC
22 0722369044* BACKUP RING 1 PC
23 0715307367* O-RING 1 PC
24 0715307371* O-RING 1 PC
25 0722369045* SPIRAL RING 1 PC
26 6635060153* BRAKE PISTON 1 PC
27 6680000100* SPRING 21 PC
28 6660300420* SPRING RETAINER PLAT 1 PC
29 0718299136* CIRCLIP 1 PC
30 0715303257* O-RING 1 PC
31 6654509210* MOTOR ADAPTOR 1 PC
32 720956001A* SCREW 8 PC
33 715303253A* O-RING 1 PC
35 0718006008* WASHER 5 PC
36 6668200590* EXTENSION 3 PC
37 0718401048* BREATHER PLUG 1 PC
38 6668200121* ELBOW 1 PC
39 0722366103* PLUG 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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.
INFORMATION!

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.

INFORMATION ON SAFETY
manufacturer. Doing this, will ensure that the product works properly and that the safety level is
"acceptable".

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

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

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:



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:

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.

LUBRICATION
GEARBOX LUBRICATION
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.
INFORMATION!

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.

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.
WARNING!
WARNING!
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.

START UP AND RUNNING IN

INFORMATION!
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!
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT. DURING THE RUNNING-IN STAGE
FOLLOW THE STEPS GIVEN BELOW.
5. Make sure that the oil temperature does not exceed 90°.
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.

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!

SPARE PART LISTS EXPLODED IEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
Do not hesitate to contatct the gearbox distributor or manufacturer if further instructions are necessary or in
case of particular problems.

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



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.

SPARE PARTS LIST

ORDER NO. 5 005 290-00
DESCRIPTION: HOISTING GEAR WINCH COMPL.

SARE PARTS LIST

ORDER NO. 5 005 290-00
DESCRIPTION: HOISTING GEAR WINCH COMPL.

19.01.02.00.00 1 PC HOISTING GEAR WINCH COMPL. 5005290 5005290
19.01.02.01.00 1 PC WINCHGEAR 5005198 5005198

SEE SUBSUPPLIER
ASSEMBLY 19.01.02.01.00
19.01.02.02.00 1 PC ROPE DRUM DIA 600 5005195 5005195
19.01.02.03.00 1 PC BEARING COVER 5005217 5005217
19.01.02.04.00 1 PC SPACER DISK 5005219 5005219
19.01.02.05.00 1 PC BEARING FLANGE 5005206 5005206
19.01.02.06.00 1 PC CANSHAFT 5005218 5005218
19.01.02.07.00 1 PC ROPE WEDGE 5005303 5005303
19.01.02.11.00 3 PC DOWEL PIN 0013807
19.01.02.12.00 1 PC SPRING PIN 0054147
19.01.02.13.00 1 PC FELTRING 5005291
19.01.02.16.00 3 PC HEXAGON SCREW 0054379
19.01.02.17.00 6 PC HEXAGON SCREW 0518173
19.01.02.18.00 1 PC GREASE NIPPLE 0010528
19.01.02.19.00 1 PC SET-SCREW 0219019
19.01.02.22.00 24 PC HEXAGON SCREW 0072005
19.01.02.23.00 24 PC WASHER 0784905


SPARE PARTS LIST
WINCH GEAR
i= 83,3
PART-NO.: 5 005 198


SPARE PARTS LIST

ORDER NO. 5 005 198-00
DESCRIPTION: WNCH GEAR
5005198 WINCH GEAR 716 i= 83,3
I7160C002400* INSTALLATION DRAWING
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER


SPARE PARTS LIST

ORDER NO. 5 005 198-00
DESCRIPTION: WINCH GEAR 716 i=83,3
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

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

SPARE PARTS LIST

ORDER NO. 2T716C3083001*
DESCRIPTION: WINCH GEAR 7 C 16 3 B 10 A0 83 J9 6W1A145 U26

2T716C3083001* WINCH GEAR 7 C 16 3 B 10 A0 83 J9 6W1A145 U26 1 PC L
1 720968004A* SCREW 17 PC
2 2T237179250* COVER ASSEMBLY 1 PC
3 0718006008* WASHER 2 PC
4 6682500640* OIL BREATHER PLUG 2 PC
5 6663350310* O-RING 1 PC
6 6663350310* PAD 1 PC
7 6643011200* SUN GEAR 1 PC
9 6643021110* SUN GEAR 1 PC
10 2T235369310* REDUCTION ASSEMLY 1 PC
11 6643040330* SUN GEAR 1 PC
12 0718298055* CIRCLIP 5 PC
13 2T235569300* PLANETARY ASSEMBLY 5 PC
14 6662005710* SPACER 5 PC
15 6660000700* NUT 1 PC
16 2T237470890* GEARBOX HOUSING 1 PC
17 0710317016* LIFTIME SEAL 1 PC
18 0718299199* CIRCLIP 1 PC
19 6660300411* DISCS RETAINER 1 PC
20 6632592310* HUB 1 PC
21 0715303026* O-RING 1 PC
22 6633031730* BRAKE SHAFT 1 PC
23 6680700060* STEEL DISC 6 PC
25 0722369044* BACKUP RING 1 PC
26 0715307367* O-RING 1 PC
27 0715307371* O-RING 1 PC
28 0722369045* SPIRAL RING 1 PC
29 6635060153* BRAKE PISTON 1 PC
30 6680000100* SPRING 30 PC
31 6660301020* SPRING RETAINER PLAT 1 PC
32 0718299136* CIRCLIP 1 PC
33 0715303257* O-RING 1 PC
34 6654507511* MOTOR ADAPTOR 1 PC
35 0715303300* O-RING 1 PC
36 0711397006* SCREW 4 PC
37 0720956102* SCREW 8 PC
38 0718401048* BREATHER PLUG 1 PC
39 6668200121* ELBOW 1 PC
40 6668200620* ETENSION 3 PC
41 0722366103* PLUG 3 PC
42 0718006008* WASHER 6 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

INSTALLATION INSTRUCTION FOR WINCH GERA ASSEMBLY GROUP

01.19.01.02.01 SEE UNDER ASSEMBLY GROUP 01.19.01.01.01
SPARE PARTS LIST

ORDER NO. 5 005 292-01
DESCRIPTION: PRESSURE ROLLER

19.01.03.00.00 1 PC PRESSURE ROLLER 5005292 5005292
19.01.03.01.00 2 PC CLAMPING PIECE 5005293 5005293

19.01.03.02.00 1 PC AXLE 5005294 5005294
19.01.03.03.00 2 PC BEARING RING 5005295 5005295
19.01.03.04.00 1 PC PIPE 5005296 5005296
19.01.03.05.00 1 PC ROLLER 5005297 5005297
19.01.03.06.00 4 PC SPACER 5005298 5005298
19.01.03.07.00 1 PC WASHER 5005506 5005506
19.01.03.12.00 1 PC CIRCLIP 0012506
19.01.03.13.00 1 PC HEXAGON SCREW 0054399
19.01.03.14.00 2 PC HEXAGON SCREW 0056677
19.01.03.15.00 2 PC WASHER 0056992
19.01.03.16.00 2 PC SPRING PIN 0218766

SPARE PARTS LIST

ORDER NO. 5 005 228-00
DESCRIPTION: WINCH UNIT STEEL COMPL,

19.01.17.00.00 1 PC WINCH UNIT STEEL COMPL. 5005228 5005228
19.01.17.01.00 1 PC WINCH UNIT STEEL 5005230 5005230

19.01.17.02.00 1 PC SAFETY DUARD 5005211 5005211
19.01.17.03.00 1 PC GUARD PLATE 5005210 5005210
19.01.17.04.00 8 PC HEXAGON SCREW 0057013
19.01.17.05.00 8 PC SL-WASHER 0118704
19.01.17.06.00 8 PC HEXAGON SCREW 0118372
19.01.17.07.00 16 PC WASHER 0012796
19.01.17.08.00 8 PC HEXAGON NUT 0057127

SPARE PARTS LIST

ORDER NO. 5 001 059-02
DESCRIPTION: LIMIT SWITCH SLACK ROPE

19.32.00.00.00 1 PC LIMIT SWITCH SLACK ROPE 5001059 5001059
19.32.01.00.00 1,18 M PIPE 2535203

19.32.02.00.00 2 PC CLAMP 1444367
19.32.03.00.00 4 PC CARRIER RAIL NUT 3398455
19.32.04.00.00 1 PC CAP-SCREW 0038015
19.32.05.00.00 2 PC HEX.NUT 8476065

SPARE PARTS LIST

ORDER NO. 5 002 991-00
DESCRIPTION: ELECTRICAL EQUIPMENT COMPL .

25.00.00.00.00 1 PC ELECTRICAL EQUIPMENT COMPL: 5002991
25.01.00.00.00 1 PC ELECTRO-EQUIPMENT SLEWING TOWER 5002891

25.02.00.00.00 1 PC E-SYSTEM JIB 2350938
25.15.00.00.00 1 PC ELECTRICAL EQUIPMENT POWER PACK 5002996
25.18.00.00.00 1 PC ELECTRICAL EQUIPMENT FOR CABIN 5002894
ASEMBLY GROUP 25.00.00.00.00

SPARE PARTS LIST

ORDER NO. 5 002 891-00
DESCRIPTION: E-PART SLEWING TOWER

25.01.00.00.00 1 PC E-PART SLEWING TOWER 5002891
25.01.03.00.00 1 PC LIGHTING AND HEATING 5002074

25.01.60.00.00 1 PC WORKSHOP INSTALLATION 5002892
SPARE PARTS LIST

ORDER NO. 5 002 074-01
DESCRIPTION: LIGHTING AND HEATING

25.01.03.00.00 1 PC LIGHTING AND HEATING 5002074
25.01.03.01.00 1 PC LAMP 5002079

25.01.03.03.00 2 PC FLUORESCENT LAMP 0058132
25.01.03.05.00 1 PC SCREW BUSH 1624414
25.01.03.07.00 1 PC ROOM HEATER 2535250
25.01.03.11.00 2 PC HEXAGON NUT 0650234
25.01.03.12.00 2 PC CNTACT WASHER 2079808
25.01.03.13.00 2 PC HEXAGON SCREW 1683943
25.01.03.14.00 4 PC HEXAGON SCREW 1683937
25.01.03.15.00 4 PC SLIT WASHER 0511788
25.01.03.16.00 4 PC WASHER 1684578
25.01.03.17.00 1 PC SCREW PLUG 1627280

SPARE PARTS LIST

ORDER NO. 5 002 892-01
DESCRIPTION: MOUNTING IN WORKSHOP

25.01.60.00.00 1 PC MOUNTING IN WORKSHOP 5002892
25.01.60.01.00 1 PC PROTECTION EARTHING OF JIB 5002785
25.01.60.03.00 8 M CABLE TRAY 1627349

25.01.60.04.00 40 PC CABLE TRAY NUT 2012404 2012404
25.01.60.05.00 6 PC BOLTED CONNECTION FOR CABLE GUIDE 1624652
25.01.60.06.00 2 PC DISTRIBUTION BOX 1627768
25.01.60.07.00 7 PC SCREW BUSH 1624414
25.01.60.08.00 3 PC INSIDE FOR CABLE GUIDE 1627506
25.01.60.09.00 2 PC SCREW PLUG 1627280
25.01.60.10.00 4 PC HEXAGON SCREW 0842417
25.01.60.11.00 4 PC SPRING RING 3398003
25.01.60.12.00 4 PC WASHER 3330214
25.01.60.20.00 2 PC CONDUIT BUSHING 1360534
25.01.60.21.00 2 M EDGE PROTECTION 0597527
25.01.60.22.00 2 M EDGE PROTECTION 0153957 0153957
25.01.60.23.00 3 PC GASKET FOR CABLE GLAD 5002076
25.01.60.24.00 50 PC CABLE TIE 1624720
25.01.60.25.00 50 M CABLE STRAP 1660206
25.01.60.26.00 12 PC STEEL CABLE JOINT 5002310
SPARE PARTS LIST

ORDER NO. 5 002 785-01
DESCRIPTION: SUPPLY FOR PROTECTIVE EARTH

25.01.60.01.00 1 PC SUPPLY FOR PROTECTIVE EARTH 5002785
25.01.60.01.01 1,5 M CABLE 1637432

25.01.60.01.02 2 PC CABLE SHOE 0216411
25.01.60.01.03 4 PC HEXAGON NUT 1683742
25.01.60.01.10 6 M CABLE IEC 60092 5002063
25.01.60.01.11 2 PC CABLE SHOE 10-70 0216411
25.01.60.01.12 1 PC HEXAGON NUT 1683742

SPARE PARTS LIST

ORDER NO. 2 350 938-06
DESCRIPTION: E-SYSTEM JIB

25.02.00.00.00 1 PC E-SYSTEM JIB 2350938
25.02.01.00.00 1 PC HNA-STANDARD FITTING 1624721

25.02.02.00.00 1 PC TWO-BASE BULB 1624722
25.02.03.00.00 1 PC INCANDESCENT LAMP 1660212
25.02.05.00.00 1 PC HNA-JUNCTION BOX 1624723
25.02.06.00.00 4 PC SCREW BUSH 1624414
25.02.07.00.00 4 PC HEXAGON SCREW 0842417
25.02.08.00.00 4 PC SPRING RING 3398003
25.02.10.00.00 37 M CABLE 0505898
25.02.11.00.00 5 M CABLE 0505897
25.02.13.00.00 3 PC INNERPARTS FOR CABLE INLET 1627507
25.02.14.00.00 1 PC SIKAFLEX 221 BLACK 4228427
25.02.15.00.00 1 PC HEAT SHRINK TUBE 5002985

SPARE PARTS LIST

ORDER NO. 5 002 996-00
DESCRIPTION: ELECTRICAL EQUIPMENT POWER PACK

25.15.00.00.00 1 PC ELECTRICAL EQUIPMENT POWER PACK 5002996
25.15.03.00.00 1 PC LIGHTING 220V/60HZ 5002109

25.15.10.00.00 1 PC PUMP DRIVE UNIT 5002908
25.15.15.00.00 1 PC LIMIT SWITCH FOR WINCHES 5002495
25.15.50.00.00 1 PC CONTROL CABINET 5002992
SPARE PARTS LIST

ORDER NO. 5 002 109-01
DESCRIPTION: LIGHTING

25.15.03.00.00 1 PC LIGHTING 220V / 60Hz 5002109
25.15.03.01.00 1 PC LAMP 2010837

25.15.03.03.00 1 PC FLUORESCENT LAMP 0058132
25.15.03.04.00 1 PC CONTACT BREAKER 1608349
25.15.03.05.00 2 PC SCREW BUSH 1624414
25.15.03.16.00 2 PC HEX.NUT 0650234
25.15.03.18.00 2 PC HEX-SCREW 1683943
25.15.03.19.00 1 PC PLUG 1627280

SPARE PARTS LIST

ORDER NO. 5 002 908-00
DESCRIPTION: PUMP DRIVE UNIT

25.15.10.00.00 1 PC PUMP DRIVE UNIT 5002908
25.15.10.01.00 1 PC DS-MOTOR 160KW 5002027

SEE SUBSUPPLIER
25.15.10.60.00 1 PC INSTALLATION POWER PACK 5002909

SPARE PARTS LIST
E-MOTOR
PART-NO.: 5 002 027

SPARE PARTS LIST

ORDER NO. 5 002 027
DESCRIPTION: E-MOTOR
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 002 909-00
DESCRIPTION: INSTALLATION POWER PACK

25.15.10.60.00 1 PC INSTALLATION POWER PACK 5002909
25.15.10.60.01 1 PC DIGITAL MODULE CR203 – ID01 5002203

25.15.10.60.02 1 PC ANALOG MODULE CR2033 – ID03 5002204
25.15.10.60.03 1 PC COMPACT MODULE PWM – ID02 5002256
25.15.10.60.04 2 PC CABLE CAN-BUS M12/M12-0,3m 4243111
25.15.10.60.05 1 PC PLUG-RESISTOR M12-120R 4243112
25.15.10.60.06 4 PC CABLE 5002038
25.15.10.60.07 6 PC CABLE M12/DIN A - CURRENT 4243444
25.15.10.60.08 5 PC CABLE PLUG M12-2m 4243115
25.15.10.60.09 1 PC CONNECT PLUG 5002853
25.15.10.60.10 2 PC PRESSURE TRANSMITTER TYP HT-PD 5002899 5002899
25.15.10.60.11 1 PC TEMPERATURE SENSOR 5002900 5002900
25.15.10.60.12 3 PC CONNECTING CABLE FOR SENSORS 5002905 5002905
25.15.10.60.14 10 PC RECEPTACLE 6,3-1 NR 2079546
25.15.10.60.15 40 PC CABLE STRAP 1660206
25.15.10.60.21 12 PC NUT 1676821
25.15.10.60.22 12 PC SL-WASHER 0725726

SPARE PARTS LIST

ORDER NO. 5 002 203-00
DESCRIPTION: DIGITAL MODULE

25.15.10.60.01.00 1 PC DIGITAL MODULE 5002203
25.15.10.60.01.02 1 PC COMPACT MODULE I/O 4243106

25.15.10.60.01.03 1 PC PLATE COMPACT MODULE DIGITAL 5002201 5002201
ASSEMBLY GROUP 25.15.10.60.01.00
SPARE PARTS LIST

ORDER NO. 5 002 204-00
DESCRIPTION: ANALOG MODULE

25.15.10.60.02.00 1 PC ANALOG MODULE 5002204
25.15.10.60.02.02 1 PC COMPACT MODULE I/O 4243106

25.15.10.60.02.03 1 PC PLATE COMPACT MODULE ANALOG 5002202 5002202
SPARE PARTS LIST

ORDER NO. 5 002 256-01
DESCRIPTION: COMPACT MODULE

25.15.10.60.03.00. 1 PC COMPACT MODULE 5002256
25.15.10.60.03.02 1 PC COMPACT MODULE 4243105

25.15.10.60.03.03 1 PC PLATE MODULE 5002257 5002257

SPARE PARTS LIST

ORDER NO. 5 002 495-00
DESCRIPTION: LIMIT SWITCH FOR WINCHES

25.15.15.00.00 1 PC LIMIT SWITCH FOR WINCHES 5002495
25.15.15.01.00 2 PC LIMIT SWITCH 5002244 5002244

25.15.15.10.00 14 M LTG.-OELFLEX 140 CY D=16,1 5002412
25.15.15.11.00 6 PC HEXAGON-SCREW 0840883
25.15.15.12.00 6 PC SPRING RING 3398003
25.15.15.13.00 2 PC BLIND GASKET 4236998
SPARE PARTS LIST

ORDER NO. 5 002 992-00
DESCRIPTION: CONTROLL CABINET

25.15.50.00.00 1 PC CABINET 5002992
25.15.50.01.00 1 PC CABINET 5002993

25.15.50.02.00 1 PC EQUIPMENT PART = M01 5002667
25.15.50.03.00 1 PC EQUIPMENT PART = MO2 5002668
25.15.50.06.00 1 PC STANDARD INSTALLATION 5002790

SPARE PARTS LIST

ORDER NO. 5 002 993-00
DESCRIPTION: CABINET

25.15.50.01.00 1 PC CABINET 1800x600x300 5002993
25.15.50.01.01 1 PC CABINET SERIE 18500 5002941

25.15.50.01.02 1 PC LOCK LINK 5002054
25.15.50.01.03 1 PC DOOR CATCH 5002055

SPARE PARTS LIST

ORDER NO. 5 002 667-02
DESCRIPTION: EQUIPMENT PART =M01

25.15.50.02.00 1 PC EQUIPMENT PART =M01 5002667
25.15.50.02.01 1 PC LOAD BREAKER 5002251 5002251

25.15.50.02.02 1 PC LOAD BREAK SWITCH T3-1 2381873
25.15.50.02.03 1 PC CAP 2381874
25.15.50.02.06 1 PC PILOT LAMP “POWER SUPPLY“ 5002044
25.15.50.02.07 1 PC PILOT LAMP “AUX. SUPPLY“ 5002045
25.15.50.02.13 1 PC MOTOR OVERLOAD PROTECTOR 2544253
25.15.50.02.14 1 PC MOTOR CIRCUIT BREAKER 2544252
25.15.50.02.30 1 PC POWER SUPPLY 5002582
25.15.50.02.81 1 PC SI-CIRCUIT REAKER GSTA 00 NO.09318 2335438
25.15.50.02.101 1 PC TRIPPLE POLE FUSE ISOLATOR 1608376
25.15.50.02.102 3 PC FUSE LINK D02 440/35 1608405
25.15.50.02.103 3 PC FITTING SLEEVE D02/35 1608403
25.15.50.02.105 2 PC FUSE CARTRIDGE C3 2533904
25.15.50.02.106 5 PC FUSE CARTRIDGE C 7,5 4510378
25.15.50.02.108 2 PC TERMINAL GR. 282-601 1791281
25.15.50.02.109 1 PC TERMINAL PROTECTIVE 1791283
25.15.50.02.110 7 PC FUSE TERMINAL W.LED 282-698 2535436
25.15.50.02.111 1 PC PLATE 282334 2535437
25.15.50.02.112 6 PC TERMINAL CLIP 282-402 1791285
25.15.50.02.118 4 PC SIDE ANGLE 1791302
25.15.50.02.119 1 PC TITLE CARD 209-700/209-124 1667814
25.15.50.02.121 6 M ISO. WIRE NSGAFOEU-1,7 1608435
25.15.50.02.122 3 M CABLE NSGAFOEU-1,7 5002431
25.15.50.02.123 2 M CABLE NSGAFOEU-1,7 1637432
25.15.50.02.125 3 M CABLE THIMBLE 1637540
25.15.50.02.182 3 PC LOW VOCT: POWER FUSE 0058095

SPARE PARTS LIST

ORDER NO. 5 002 044-00
DESCRIPTION: PILOT LAMP POWER SUPPLY COMPL.

25.15.50.02.06 1 PC PILOT LAMP POWER SUPPLY COMPL. 5002044
25.15.50.02.06.01 1 PC PILOT LAMP 5002048

25.15.50.02.06.02 1 PC LED-LINK M22 5002046
25.15.50.02.06.03 2 PC R-LINK M22 5002047
25.15.50.02.06.04 1 PC FASTENER M22 4228113
25.15.50.02.06.05 1 PC PLATE HOLDER M22 4228103
25.15.50.02.06.06 1 PC PLATE M22 POWER SUPPLY 5002049
SPARE PARTS LIST

ORDER NO. 5 002 045-00
DESCRIPTION: PILOT LAMP AUX. SUPPLY COMPL.

25.15.50.02.06 1 PC PILOT LAMP AUX. SUPPLY COMPL. 5002044
25.15.50.02.06.01 1 PC PILOT LAMP 5002048

25.15.50.02.06.02 1 PC LED-LINK M22 5002046
25.15.50.02.06.04 1 PC FASTENER M22 4228113
25.15.50.02.06.05 1 PC PLATE HOLDER M22 4228103
25.15.50.02.06.06 1 PC PLATE M22 POWER SUPPLY 5002050

SPARE PARTS LIST

ORDER NO. 5 002 668-01

25.15.50.03.01 1 PC CONTACTOR 4226209

25.15.50.03.03 2 PC CLEMPINGBLOCK 4236664
25.15.50.03.05 1 PC CONTACTOR 5002377
25.15.50.03.07 1 PC STARPOINT BAR 5002378
25.15.50.03.08 1 PC CURRENT-CONVERTER 2368074
25.15.50.03.10 1 PC CONTACTOR DIL9-10 5002084
25.15.50.03.11 1 PC CONTACTOR DIL25-10 5002085
25.15.50.03.19 1 PC SUPPLY TERMINAL 5002517
25.15.50.03.20 1 PC PROTECTION SWITCH 2546539
25.15.50.03.21 1 PC PROTECTION SWITCH 2546542
25.15.50.03.22 1 PC 3-PHASE BAND 2544249
25.15.50.03.23 2 PC AUXILIARY SWITCH NH/11-PKZM0 2544250
25.15.50.03.24 1 PC TIME RELAY-DELTA STAR TE 2088712
25.15.50.03.25 1 PC THERMAL RELAY MS 220 2094520
25.15.50.03.101 6 PC TERMINAL GR. 282-601 1791281
25.15.50.03.102 2 PC TERMINAL PROTECTIVE COND. 1791283
25.15.50.03.103 1 PC SIDE PLATE 1791284
25.15.50.03.110 2 PC SIDE ANGL 1791302
25.15.50.03.111 1 PC PLATE HOLDER 1667815
25.15.50.03.120 2 M CABLE NSGAFOEU-1,7/3KV 1637432

SPARE PARTS LIST

ORDER NO. 5 002 994-00
DESCRIPTION: EQUIPMEMT PART =M03

25.15.50.04.11 1 PC FILTERFAN 5002904

25.15.50.04.13 1 PC THERMOSTAT 5002903
25.15.50.04.14 1 PC HEATING FLH 2094564
25.15.50.04.82 1 PC CONTRACTOR DILM12-10 5002735
25.15.50.04.101 2 PC TERMINAL 1666904
25.15.50.04.102 1 PC FINAL PLATE 1666905
25.15.50.04.105 5 PC TERMINAL 1791281
25.15.50.04.106 2 PC PE-TERMINAL 1791283
25.15.50.04.107 1 PC ENDPLATE 1791284
25.15.50.04.108 1 PC TERMINAL BRIDGE 1791285
25.15.50.04.110 25 PC TERMINAL 1666916
25.15.50.04.111 1 PC FINAL PLATE 1666917
25.15.50.04.112 20 PC TERMINAL BRIDGE 1791265
25.15.50.04.113 4 PC WIRE CLIP 1676951
25.15.50.04.118 2 PC SIDE ANGLE 1791302
25.15.50.04.119 1 PC PLATE HOLDER 1667815
25.15.50.04.120 2 M CABLE 1654809
25.15.50.04.121 3 M ISO WIRE 2010796
25.15.50.04.122 25 M CABLE 1656359
25.15.50.04.125 20 PC CABLE TIMBLE 1637542
25.15.50.04.130 5 PC CIRCUIT BREAKER 5002000
25.15.50.04.131 1 PC BUS BAR 5002008
25.15.50.04.132 2 PC END CAP 5002010
25.15.50.04.181 1 PC CIRCUIT BREAKER 5002000

SPARE PARTS LIST

ORDER NO. 5 002 789-01

25.15.50.05.01 1 PC CONTROLLER R360 5002196

25.15.50.05.02 1 PC CABLE CONNECTOR 4243437
25.15.50.05.101 75 PC TERMINAL GR. 3 LADDER 280-641 1791266
25.15.50.05.102 1 PC SIDE PLATE GR. 280-312 1791269
25.15.50.05.103 30 PC TERMINAL CLIP 1791265
25.15.50.05.104 2 PC SIDE ANGLE 209-101 1791302
25.15.50.05.105 1 PC PLATE HOLDER 209-112 1667815
25.15.50.05.106 1 PC BAR FOR SCREEN CLAMP 790-115 5002088
25.15.50.05.107 2 PC SCREEN-CLAMP 790-108 5002089
25.15.50.05.108 4 PC SCREEN-CLAMP 790-116 5002090
25.15.50.05.110 1 PC SUB-D 289-575 4228649
25.15.50.05.120 1 PC COUPLING RELAY 4236676
25.15.50.05.121 1 PC FIELD RELAY 230V 5002352
SPARE PARTS LIST

ORDER NO. 5 002 196-00
DESCRIPTION: PLC R360

25.15.50.05.01.00 1 PC PLC R360 5002196
25.15.50.05.01.01 1 PC PLC R360 4243104

25.15.50.05.01.02 1 PC PLATE CONTROLLER 5002156 5002156

SPARE PARTS LIST

ORDER NO. 5 002 790-00
DESCRIPTION: STANDARD INSTALLATIONS
25.15.50.06.00. 1 PC STANDARD INSTALLATIONS 5002790
25.15.50.06.01 4 PC HEXAGON-SCREW 7121363

25.15.50.06.04 4 PC CYLINDRICAL-SCREW 1683926
25.15.50.06.05 4 PC HEXAGON-SCREW 1683940
25.15.50.06.06 4 PC HEXAGON-SCREW 7121112
25.15.50.06.07 10 PC HEXAGON-SCREW 1683937
25.15.50.06.08 40 PC COUNTER SUNK SCREW 6705038
25.15.50.06.10 8 PC HEXAGON-NUT 1683741
25.15.50.06.11 12 PC WASHER 1684578
25.15.50.06.15 30 PC HEXAGON-SCREW 1652159
25.15.50.06.17 6 PC HEXAGON-SCREW 0063275
25.15.50.06.19 6 PC NUT 1652515
25.15.50.06.24 8 PC HEXAGON-NUT 1683740
25.15.50.06.25 12 PC SL-WASHER 0725726
25.15.50.06.26 12 PC WASHER 1684548
25.15.50.06.30 20 PC SCREW 2088718
25.15.50.06.21 1 M CABLE HOSE 2031738
25.15.50.06.22 1 M HOLDER CABLE HOSE 2031739
25.15.50.06.33 1 M CABLE HOSE 1676983
25.15.50.06.34 1 PC HOLDER CABLE HOSE 1676984
25.15.50.06.36 1 PC PLATE –CONTROL 2078572 2078572
25.15.50.06.37 1 PC PLATE WARNING 1686093 1686093
25.15.50.06.40 2 M PROFILRAIL 1652510
25.15.50.06.41 4 M CARRIER RAIL 1080033
25.15.50.06.42 2 M CABLE DUCT 1657371
25.15.50.06.43 1 M CABLE DUCT 1657370
25.15.50.06.44 2 M CABLE DUCT 1657369
25.15.50.06.45 1 M CABLE DUCT 2079527
25.15.50.06.50 1 PC EARTHING STRIP 1652483
25.15.50.06.51 5 M LINE H07V-K4-GNGE 0337832
25.15.50.06.52 10 M LINE 1654809
25.15.50.06.53 10 M ISO. WIRE 2010796
25.15.50.06.54 20 M LINE UL 1656359
25.15.50.06.55 5 M LINE UL 1654810
25.15.50.06.57 3 M LINE UL 1657410
25.15.50.06.58 50 M LINE UL 1656357
25.15.50.06.60 2 PC TITLE CARD 1666929
25.15.50.06.61 1 PC TITLE CARD 1666930

SPARE PARTS LIST 06.2009
SPARE PARTS LIST

ORDER NO. 5 002 995-00
DESCRIPTION: WORKSHOP INSTALLATION

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
15.25.60.08.00 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=11,5
15.25.60.12.00 40 M CABLE 3XG1,0 1655148
15.25.60.13.00 3 M CABLE H07RN-F4G1,5 0725174
15.25.60.19.00 1 PC REDUCTION 5012064
15.25.60.20.00 1 M SHRINK TUBE 5002128
15.25.60.22.00 0,25 PC SHRINK HOSE BLACK -HSB 1000-0 1655414
15.25.60.23.00 1 PC CABLE UNIT 4236259
15.25.60.24.00 1 PC CABLE UNIT 4236745
15.25.60.26.00 3 M EDGE PROTECTION 4610027 0597527
15.25.60.27.00 1 PC PL 3-RUPPER EITH WARP 3 0153691
15.25.60.30.00 7 PC CABLE THIMBLE 0215244
15.25.60.31.00 10 PC CABLE SHOE 10-70 0216411
15.25.60.32.00 2 PC CABLE THIMBLE 10-16 0511001
15.25.60.35.00 8 PC CABLE SHOE 6-2,5 0038663
15.25.60.36.00 5 PC 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 PC CABLE TRAM NUT M10 NR. 110199 2012404 2012404
15.25.60.52.00 1 PC HEXAGON SCREW 0067975
15.25.60.53.00 5 PC HEXAGON - NUT 1683742
15.25.60.62.00 50 PC CABLE TIE 1624720
15.25.60.63.00 50 PC CABLE STRAP 1660206

SPARE PARTS LIST

ORDER NO. 5 002 894-00
DESCRIPTION: ELECTRICAL EQUIPMENT CABIN

25.18.00.00.00 1 PC ELECTRICAL EQUIPMENT CABIN 5002894
25.18.02.00.00 1 PC CABINE BUILT-IN 5002102

25.18.10.00.00 1 PC CONTROL DESK LEFT CPL. 5002906
25.18.20.00.00 1 PC CONTROL DESK RIGHT CPL. 5002895
SPARE PARTS LIST

ORDER NO. 5 002 102-00
DESCRIPTION: CABIN BUILT IN

18.25.02.00.00 1 PC CABINE BUILT-IN 5002102
18.25.02.01.00 1 PC LAMP 2532329

18.25.02.02.00 1 PC BULB 0146181
18.25.02.11.00 1 PC VENTILATOR 2532317
18.25.02.20.00 1 PC SOUNDGENERATOR 1096359

SPARE PARTS LIST

ORDER NO. 5 002 906-00
DESCRIPTION: CONTROL DESK LEFT COMPL.

25.18.10.00.00 1 PC CONTROL DESK LEFT CPL. 5002906
25.18.10.01.00 1 PC HOUSINGS 5002096

25.18.10.02.00 1 PC HEATER 4228061
25.18.10.03.00 1 PC CONTROL EQUIPMENT 5002907
SPARE PARTS LIST

ORDER NO. 5 002 096-01
DESCRIPTION: HOUSING

25.18.10.01.00 1 PC HOUSING 5002096
25.18.10.01.01 1 PC DESK LEFT 5002031 5002031

25.18.10.01.02 1 PC SWITCH CABINET 2350251 2350251
25.18.10.01.101 4 PC HEX.SCREW 1683942
25.18.10.01.102 4 PC HEX.NUT 0650234
25.18.10.01.104 3 PC CYL-SCREW 1683913
25.18.10.01.105 3 PC HEX-NUT 1683740
25.18.10.01.107 1 PC CABLE GLAND 5002062
25.18.10.01.108 1 PC NUT 4236264

SPARE PARTS LIST

ORDER NO. 5 002 907-00
DESCRIPTION: LH. CONTROL DESK COMPONENTS

25.18.10.03.00 1 PC LH: CONTROL COMPONENTS 5002907
25.18.10.03.01 1 PC CONTROL LEVER SLEW./LUFF. 2078899

25.18.10.03.02 1 PC SELECTOR SWITCH WORKING LIGHT 2502556
25.18.10.03.03 1 PC SELECTOR SWITCH CABIN LIGHT 2502557
25.18.10.03.04 1 PC SELECTOR SWITCH RED WARNING 2502555
LIGHT
25.18.10.03.05 1 PC SELECTOR SWITCH CABIN HEATER 2502627
25.18.10.03.06 1 PC SELCTOR SWITCH SREEN WIPER 2502558
25.18.10.03.19 1 PC DUMMY COVER 1652429
25.18.10.03.20 1 PC HEATER FLH 010-CABLE 5002902
25.18.10.03.111 1 M CARRIER RAIL 1080033
25.18.10.03.112 1 M CABLE DUCT 1657369
25.18.10.03.115 6 PC HEX.-SCREW 1652159
25.18.10.03.116 6 PC HEX-SCREW 1683937
25.18.10.03.120 30 PC TERMINAL 1791266
25.18.10.03.121 6 PC PROTECTIVE COND.CLAMP 1791268
25.18.10.03.122 3 PC SIDE PLATE 1791269
25.18.10.03.123 3 PC SIDE ANGLE 1791302
25.18.10.03.124 2 PC PLATE HOLDER 1667815
25.18.10.03.125 1 PC TITLE CARD 1666929
25.18.10.03.130 2 M LTG.-OELFLEX 1657707
25.18.10.03.131 10 M LINE 1656357
25.18.10.03.132 12 M LINE 1656359
25.18.10.03.133 10 PC CABLE STRAP 0840069
25.18.10.03.134 1 PC EARTHING STRIP 1660053
25.18.10.03.135 1 PC PLATE 1653236
25.18.10.03.136 1 PC PLATE 1608442

SPARE PARTS LIST

ORDER NO. 2 502 556-00
DESCRIPTION: SELECTOR SWITCH WORKING LIGHT

25.18.10.03.02.00 1 PC SEL. SWITCH WORKING LIGHT 2502556
25.18.10.03.02.01 1 PC SELECTOR SWITCH 4228100

25.18.10.03.02.02 1 PC CONTACT HOLDER 4228101
25.18.10.03.02.03 1 PC CONTACT SEGMENT 4228102
25.18.10.03.02.04 1 PC PLATE HOLDER 4228103
25.18.10.03.02.05 1 PC PLATEWORKING LIGHT 4228105
SPARE PARTS LIST

ORDER NO. 2 502 557-00
DESCRIPTION: SELECTOR SWITCH CABIN LIGHT

25.18.10.03.03.00 1 PC SELECTOR SWITCH CABIN LIGHT 2502557

25.18.10.03.03.02 1 PC SWITCH CONTACT 4228101
25.18.10.03.03.04 1 PC PLATE HOLDER 4228103
25.18.10.03.03.05 1 PC PLATE 4228106

SPARE PARTS LIST

ORDER NO. 2 502 555-00
DESCRIPTION: SELECTOR SWITCH RED WARNING LIGHT

25.18.10.03.04.00 1 PC SELECTOR SWITCH RED WARNING 2502555

LIGHT

25.18.10.03.04.04 1 PC PLATE HOLDER 4228103
25.18.10.03.04.05 1 PC PLATE 4228104
SPARE PARTS LIST

ORDER NO. 2 502 627-00
DESCRIPTION: SELECTOR SWITCH CABIN HEATING

25.18.10.03.05.00 1 PC SELECTOR SWITCH CABIN HEATING 2502627

25.18.10.03.05.04 1 PC PLATE HOLDER 4228103
25.18.10.03.05.05 1 PC PLATE 4228650

SPARE PARTS LIST

ORDER NO. 2 502 558-00
DESCRIPTION: SELECTOR SWITCH SCREEN WIPER

25.18.10.03.06.00 1 PC SELCTOR SWITCH SREEN WIPER 2502558

25.18.10.03.06.04 1 PC PLATE HOLDER 4228103
25.18.10.03.06.05 1 PC PLATE 4228108
SPARE PARTS LIST

ORDER NO. 5 002 895-01
DESCRIPTION: CONTROL DESK RIGHT COMPLETE

25.18.20.00.00 1 PC CONTROL DESK RIGHT COMPLETE 5002895
25.18.20.01.00 1 PC HOUSING 5002097

25.18.20.02.00 1 PC CONTROL EQUIPMENT 5002896
25.18.20.80.00 1 PC EXPANSION SMAG-GRAB CONTROL 5012130

SPARE PARTS LIST

ORDER NO. 5 002 097-01
DESCRIPTION: HOUSING

25.18.20.01.00 1 PC HOUSING 5002097
25.18.20.01.01 1 PC CONTROL DESK RIGHT 5002032 5002032

25.18.20.01.02 1 PC SWITCH CABINET 2350252 2350252
25.18.20.01.101 4 PC HEX.SCREW 1683942
25.18.20.01.102 4 PC HEX.NUT 0650234

SPARE PARTS LIST

ORDER NO. 5 002 896-00
DESCRIPTION: CONTROL EQUIPMENT

25.18.20.02.00.00 1 PC CONTROL EQUIPMENT 5002896
25.18.20.02.01.00 1 PC CONTROL LEVER HOISTING GEAR 2078900

25.18.20.02.02.00 1 PC LCD-DISPLAY 5002205
25.18.20.02.04.00 1 PC CABINET MODULE 5002207
25.18.20.02.05.00 1 PC CONNECTOR SET FOR CM 4243439
25.18.20.02.10.00 1 PC EMERG-STOP BUTTON 2502563
25.18.20.02.11.00 1 PC KEY-OPERATED BUTTON JIB RESTING 2502566
25.18.20.02.12.00 1 PC PILOT LIGHT FAULT 2502565
25.18.20.02.13.00 1 PC SELECTOR SWITCH OFF/ON 2502564
25.18.20.02.14.00 1 PC GRAB OPERATION 2502766
25.18.20.02.16.00 1 PC AUDIO ALARM M22-AMC 5002661
25.18.20.02.17.00 1 PC SOUNDER M22-XAM 5002662
25.18.20.02.19.00 5 PC DUMMY COVER M22B 1652429
25.18.20.02.20.00 1 PC HEATER 1636863
25.18.20.02.121.0 1 M CARRIER RAIL 1080033
25.18.20.02.122.0 1 M CABLE DUCT 1657369
25.18.20.02.123.0 6 PC COUNTER SUNK SCREW 6705038
25.18.20.02.124.0 6 PC HEX.-SCREW 1652159
25.18.20.02.125.0 6 PC HEX-SCREW 1683937
25.18.20.02.126.0 6 PC CONTACT WASHER 2079806
25.18.20.02.127.0 2 PC CAP SCREW 1683914
25.18.20.02.128.0 2 PC SL-WASHER 0725726
25.18.20.02.129.0 2 PC WASHER 1684548
25.18.20.02.140.0 25 PC TERMINAL GR. 3 LADDER 1791266
25.18.20.02.141.0 2 PC PROTECTIVE COND.CLAMP 1791268
25.18.20.02.142.0 3 PC SIDE PLATE 1791269
25.18.20.02.143.0 4 PC SIDE ANGLE 1791302
25.18.20.02.144.0 3 PC PLATE HOLDER 1667815
25.18.20.02.145.0 1 PC TITLE CARD 1666929
25.18.20.02.150.0 2 M LTG.-OELFLEX 1657707
25.18.20.02.151.0 20 M LINE 1656357
25.18.20.02.152.0 3 M LINE 1656358
25.18.20.02.153.0 10 PC CABLE STRAP 0840069
25.18.20.02.154.0 1 PC EARTHING STRIP 1660053
25.18.20.02.156.0 1 PC RESISTOR 5002107
25.18.20.02.157.0 1 PC PLATE NO. 155-25MM 1653236
25.18.20.02.158.0 1 PC PLATE 82 K 1608442

SPARE PARTS LIST

ORDER NO. 5 002 205-00
DESCRIPTION: LCD DISPLAY

25.18.20.02.02.00 1 PC LCD DISPLAY 5002205
25.18.20.02.02.02 1 PC DISPLAY AT6 5002266

25.18.20.02.02.03 1 PC PLATE LCD-DISPLAY 5002157 5002157
SPARE PARTS LIST

ORDER NO. 5 002 207-00
DESCRIPTION: CABINET MODULE


25.18.20.02.04.03 1 PC PLATE CABINET MODULE 5002159 5002159
SPARE PARTS LIST

ORDER NO. 2 502 563-00
DESCRIPTION: EMERGENCY STOP BUTTON

25.18.20.02.10.00 1 PC EMERGENCY-STOP BUTTON 2502563
25.18.20.02.10.01 1 PC EMERG-PUSH BUTTON 4228110

25.18.20.02.10.03 1 PC PROTECTION SHIELD 4228111

SPARE PARTS LIST

ORDER NO. 2 502 566-00
DESCRIPTION: KEY-OPERATED BUTTON JIB RESTING

25.18.20.02.11.00 1 PC KEY-OPERATED BUTTON JIB RESTING 2502566
25.18.20.02.11.01 1 PC KEY-OPERATED BUTTON 4228116

25.18.20.02.11.03 1 PC PLATE HOLDER 4228103
25.18.20.02.11.04 1 PC PLATE 4228117
SPARE PARTS LIST

ORDER NO. 2 502 565-00
DESCRIPTION: PILOT LIGHT FAULT

25.18.20.02.12.00 1 PC PILOT LIGHT FAULT 2502565
25.18.20.02.12.01 1 PC PILOT LIGHT 4228112

25.18.20.02.12.02 1 PC FASTENER 4228113
25.18.20.02.12.03 1 PC LED-INSERT 4228114
25.18.20.02.12.04 1 PC PLATE FAULT 4228115
SPARE PARTS LIST

ORDER NO. 2 502 564-00
DESCRIPTION: SELECTOR SWITCH OFF/ON

25.18.20.02.13.00 1 PC SELECTOR SWITCH OFF/ON 2502564
25.18.20.02.13.01 1 PC ILLUMINATED SELECTOR SWITCH 4228118

25.18.20.02.13.03 1 PC LED-INSERT 4228114
25.18.20.02.13.04 1 PC PLATE 4228119

SPARE PARTS LIST

ORDER NO. 2 502 766-00
DESCRIPTION: SELECTOR SWITCH GRAB OPERATION

25.18.20.03.14.00 1 PC SELECTOR SWITCH GRAB OPERATION 2502766

25.18.20.03.14.02 1 PC SWITCH CONTAC 4228101
25.18.20.03.14.04 1 PC PLATE HOLDER 4228103
25.18.20.03.14.05 1 PC SCHILD 4236701
SPARE PARTS LIST

ORDER NO. 5 002 178-01
DESCRIPTION: WORKSHOP INSTALLATION

25.18.60.01.00 4 M CABLE 5002066

25.18.60.02.00 5 M CABLE 1608342
25.18.60.03.00 3 M CABLE 0337832
25.18.60.04.00 8,5 M CABLE 1655148
25.18.60.05.00 4 M LTG.-OELFLEX 1657707
25.18.60.10.00 1 PC SOCKET CASING 4228204
25.18.60.11.00 5 PC RECEPTACLES 5002255
25.18.60.12.00 4 PC CABLE THIMBLE 0145829
25.18.60.13.00 1 PC INTERIOR PART 1654680
25.18.60.20.00 4 PC CYL-SCREW 1683913
25.18.60.22.00 2 PC ZYL.SCREW 1683919
25.18.60.25.00 4 PC HOLDER 2062983 2062983
25.18.60.26.00 8 PC HEX.SCREW 1683992
25.18.60.27.00 8 PC WASHER 1684581
25.18.60.28.00 8 PC CURVED SPRING LOCK WASHER 0249845

SPARE PARTS LIST

ORDER NO. 5 007 688-00
DESCRIPTION: HYDRAULIC SYSTEM COMPL

66.01.00.00.00 1 PC HYDRAULIC SYSTEM SLEWING TOWER 5007689

66.15.00.00.00 1 PC HYDRAULIC SYSTEM AGGREGATE MODULE 5006984
66.19.00.00.00 1 PC HYDR.SYSTEM WINCH MODULE 5005672


SPARE PARTS LIST

ORDER NO. 5 007 689-00
DESCRIPTION: HYDRAULIC SYSTEM SLEWING TOWER

66.01.00.00.00 1 PC HYDRAULIC SYSTEM SLEWING TOWER 5007689
66.01.02.00.00 1 PC COMPONENTS HYDRAULIC SYSTEM 5005251 5005251

66.01.13.00.00 1 PC HYDR.MOTOR SLEWING GEAR COMPL. 5006693

SPARE PARTS LIST

ORDER NO. 5 005 251-01
DESCRIPTION: COMPONENTS HYDRAULIC SYSTEM

SPARE PARTS LIST

ORDER NO. 5 005 251-01
DESCRIPTION: COMPONENTS HYDRAULIC SYSTEM

66.01.02.00.00 1 PC COMPONENTS HYDRAULIC SYSTEM 5005251 5005251
66.01.02.01.00 1 PC COOL SYSTEM OIL-AIR 5005192 5005192

SEE SUBSUPPLIER
66.01.02.02.00 2 PC UNION 1331028

66.01.02.03.00 2 PC UNION 1636008
66.01.02.04.00 8 PC SELF-LOCKING 0146559
66.01.02.05.00 8 PC WASHER 0063677
66.01.02.06.00 8 PC THRUST WASHER 0153211
66.01.02.10.00 3,2 M SEALING - ADHESIVE TAPE 2548028
66.01.02.12.00 1 PC BRAKE FILTER 1637770
66.01.02.13.00 6 PC SEALING RING 1725417
66.01.02.14.00 12 PC SEALING RING 1725419
66.01.02.18.00 2 PC UNION 1665749
66.01.02.19.00 2 PC UNION 1636027
66.01.02.20.00 1 PC UNION 1636004
66.01.02.21.00 1 PC UNION 1665705
66.01.02.22.00 1 PC TRANSIT.MUFF CONNECT.PIECE 0665861
66.01.02.23.00 1 PC UNION 1665742
66.01.02.24.00 1 PC UNION 1397173
66.01.02.25.00 1 PC UNION 1307809

SPARE PARTS LIST

ORDER NO. 5 006 693-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR COMPL.

66.01.13.00.00 1 PC HYDR.MOTOR SLEWING GEAR COMPL. 5006693

66.01.13.01.00 1 PC HYDR. MOTOR SLEWING GEAR COMPL 5006694 5006694
66.01.13.03.00 1 PC HYDR. MOTOR SLEWING GEAR COMPL. 5006696 5006696

SPARE PARTS LIST

ORDER NO. 5 006 694-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR COMPL.

66.01.13.01.00 1 PC HYDR.MOTOR SLEWING GEAR COMPL 5006694 5006694
66.01.13.01.01 1 PC HYDR. MOTOR 5005874

SEE SUBSUPPLIER
ASSEMBYL 66.01.13.01.01
66.01.13.01.02 1 PC SOCKET PIECE 0625708

66.01.13.01.04 4 PC SAE-FLANGE 0727077
66.01.13.01.05 1 PC SCREWING 0070277
66.01.13.01.06 8 PC SAE-FLANGE HALF 0625571
66.01.13.01.07 2 PC SEAL RING 1725417
66.01.13.01.08 8 PC CAP-SCREW 0939137
66.01.13.01.09 8 PC CYL.SCREW 1758053
66.01.13.01.12 16 PC CAP-SCREW 0861764
66.01.13.01.13 4 PC CYL.SCREW 0119724
66.01.13.01.14 2 PC T-PIECE 2072544 2072544
66.01.13.01.15 2 PC ADAPTER 1397738 1397738
66.01.13.01.16 2 PC SEALING RING 1725419
66.01.13.01.17 4 PC THRUST WASHER 1005866
66.01.13.01.18 1 PC UNION 1665715
66.01.13.01.19 1 PC PIPE FILTER 0986373
66.01.13.01.20 1 PC CLOSING COUPLING 1335578
66.01.13.01.21 1 PC SEAL.RING 0029263
66.01.13.01.22 1 PC ADAPTER SOCKET 5006697


SPARE PARTS LIST
HYDRAULIC MOTOR
SCM 056
PART-NO.: 5 005 874

SPARE PARTS LIST

ORDER NO. 5 005 874
DESCRIPTION: HYDRAULIC MOTOR SCM 056 M2
FIGURE 1

0005006880 HYDRAULIC MOTOR SCM 056 M2 1 PC L
1,2,3 FIGURE 2 SHAFT SEAL KIT M-012/-64 ISO 1 PC
4,5 FIGURE 3 REPAIR KIT M-047/-64 M2 FRONT 1 PC
6 FIGURE 4 ANGULAR HOUSING M-047/-64 M2 1 PC
7 FIGURE 4 PLUG G ½” PLASTIC 1 PC
8 FIGURE 4 SPRING PIN M-025/-108 1 PC
9 FIGURE 4 O-RING 1 PC
10 FIGURE 4 PLUG G ½” 1 PC
11 FIGURE 4 PISTON SC/-M 056 7 PC
12 FIGURE 4 CYLINDRICAL SCREW 4 PC
13 FIGURE 5 REPAIR KIT M-047/-64 M2 1 PC
14, 15, 16 FIGURE 6 SEAL CIT M-047/-64 M2 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 874
FIGURE 2

1 0000050542* SHAFTSEAL KIT M-012/-64 ISO N 1 PC
2 0000050543* SHAFTSEAL KIT M-012/-64 ISO H 1 PC
3 0000050544* SHAFTSEAL KIT M-012/-64 ISO V 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 874
FIGURE 3

4 0000050618* REPAIR KIT M-047/-64 M2 A F 1 PC
5 0000050619* REPAIR KIT M-047/-64 M2 E F 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 874
FIGURE 4

6 0000030275 ANGULAR HOUSING M-047/-64 M2 1 PC
7 0000050337 PLUG G ½” PLASTIC 1 PC
8 0000020326 SPRING PIN M-025/-108 1 PC
9 0000090074 O-RING 1 PC
10 0000091372 PLUG G ½” 1 PC
11 0000050289 PISTON SC/-M 056 7 PC
12 0000091617 CYLINDRICAL SCREW 4 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 874
FIGURE 5

13 0000050612 REPAIR KIT M-047/-64 M2 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 874
FIGURE 6

15 0000050621* REPAIR KIT M-047/-64 N M2 1 PC L
16 0000050622* REPAIR KIT M-047/-64 H M2 1 PC L
17 0000050623* REPAIR KIT M-047/-64 V M2 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 0 625 708-00
DESCRIPTION: SOCKET PIECE

66.01.13.01.02.00 1 PC SOCKET PIECE. 00625708
66.01.13.01.02.01 1 PC SOCKET PIECE ZV206/22/183 5006853

66.01.13.01.02.02 1 PC CONN.-NUT A2L 22 0010699
66.01.13.01.02.03 1 PC TAPER-BUSH L22-ST 0010695

SPARE PARTS LIST

ORDER NO. 5 006 696-00
DESCRIPTION: HYDR. MOTOR SLEWING GEAR COMPL.

66.01.13.03.00 1 PC HYDR. MOTOR SLEWING GEAR COMPL. 5006696 5006696
66.01.13.03.01 1 PC HYDR. MOTOR 5005874

SUBSUPPLIER SEE
66.01.13.03.02 1 PC SOCKET PIECE 0625708
66.01.13.03.04 4 PC SAE-FLANGE 0727077
66.01.13.03.05 1 PC SCREWING 0070277
66.01.13.03.08 8 PC CAP-SCREW 0939137
66.01.13.03.11 4 PC THRUST WASHER 1005866
66.01.13.03.13 4 PC CAP SCREW 0119724
66.01.13.03.22 1 PC ADAPTER SOCKET 5006697

SPARE PARTS LIST

ORDER NO. 5 006 984-00
DESCRIPTION: HYDRAULIC SYSTEM AGGREGATE MODULE

66.15.00.00.00 1 PC HYDRAULIC SYSTEM AGGREGATE MODULE 5006984
66.15.01.00.00 1 PC HYDRAULIC POWER UNIT COMPL. 5005266

66.15.20.00.00 1 PC HYDRAULICTANK EQUIPMENTS 5005657 5005657
66.15.21.00.00 1 PC PUMP UNIT, COMPL 5001106 5001106

SPARE PARTS LIST

ORDER NO. 5 005 266-00
DESCRIPTION: HYDRAULIC AGGREGATE COMPL
DRAWIN
ASSEMBLY MATERIAL G
66.15.01.00.00 1 ST HYDRAULIC AGGREGATE COMPL. 5005266
66.15.01.01.00 1 ST DISTRIBUTION GEAR I = 0,65 5005264 5005264

66.15.01.02.00 1 ST FASTENING PARTS F. DISTRIBUTION GEAR 2093380 2093380
66.15.01.03.00 3 ST DAMPER 2067961 2067961
66.15.01.04.00 1 ST HYDRAULIC POWER UNIT 5004001 5004001

SPARE PARTS LIST

ORDER NO. 5 005 264-03
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

SARE PARTS LIST

ORDER NO. 5 005 264-03
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

66.15.01.01.00 1 PC DISTRIBUTION GEAR I=0,65(440V-60HZ) 5005264 5005264
66.15.01.01.01 1 PC GEAR BOX 4221626 4221626

66.15.01.01.02 1 PC COVER 5006406 5006406
66.15.01.01.03 1 PC SPUR WHEEL Z-66 MN-3,5 Z-66 Mn-3,5 4221591 4221591
66.15.01.01.04 3 PC SPUR WHEEL Z-43 MN-3,5 Z-43 Mn-3,5 4221593 4221593
66.15.01.01.05 3 PC HOLLOW SHAFT 4221598 4221598
66.15.01.01.06 3 PC WAVE DISK 4221595 4221595
66.15.01.01.07 1 PC WAVE DISK 4221594 4221594
66.15.01.01.08 3 PC CENTER BUSHING 4221596 4221596
66.15.01.01.09 1 PC SPACER 4221597 4221597
66.15.01.01.10 1 PC O-RING 4228224
66.15.01.01.11 3 PC O-RING 4228223
66.15.01.01.12 1 PC O-RING 4228240
66.15.01.01.13 1 PC O-RING 0460685
66.15.01.01.14 3 PC O-RING 0830401
66.15.01.01.15 1 PC V-RING 0750367
66.15.01.01.16 1 PC OIL SIGHT GLAS 1655840
66.15.01.01.17 9 PC STUD BOLT 5006664
66.15.01.01.18 12 PC STUD BOLT 5006665
66.15.01.01.19 1 PC HEXAGON SCREW 5006666
66.15.01.01.20 3 PC HEXAGON SCREW 0056638
66.15.01.01.21 21 PC HEXAGON NUT 0057136
66.15.01.01.22 21 PC WASHER 0056993
66.15.01.01.23 1 PC LOCKING BOLT DISK 4228235
66.15.01.01.24 3 PC LOCKING BOLT DISK 2535252
66.15.01.01.25 4 PC SPRING-PIN 0054166

SPARE PARTS LIST

ORDER NO. 2 093 380-01
DESCRIPTION: FASTENING PARTS F. DISTRIBUTION GEAR

66.15.01.02.00 1 PC FASTENING PARTS F. DISTRIBUTION GEAR 2093380 2093380
66.15.01.02.01 1 PC AIR FILTER 0029493

66.15.01.02.02 1 PC UNION 0982729
66.15.01.02.03 1 PC SCREWING 0033589
66.15.01.02.04 1 M PIPE 0065184
66.15.01.02.06 8 PC WASHER 0056993
66.15.01.02.07 8 PC HEXAGON SCREW 0056683

SPARE PARTS LIST

ORDER NO. 2 067 961-01
DESCRIPTION: DAMPER

66.15.01.03.00 3 PC DAMPER 2067961 2067961
66.15.01.03.02 2 PC BUFFER 65SHORE 2067983 2067983

66.15.01.03.09 1 PC HEXAGON SCREW 7120794
66.15.01.03.10 1 PC HEXAGON NUT 0032975
66.15.01.03.11 1 PC HEXAGON NUT 1673943
66.15.01.03.12 2 PC WASHER 0152174
66.15.01.03.14 1 PC WASHER 0034624

SPARE PARTS LIST

ORDER NO. 5 004 001-00
DESCRIPTION: HYDRAULIC-AGGREGATE

SPARE PARTS LIST

ORDER NO. 5 004 001-00
DESCRIPTION: HYDRAULIC-AGGREGATE
ASSEMBLY QTY QC DESCRIPTION MATERIAL DRAWING

GROUP NO. NO.
66.15.01.04.00 1 PC HYDRAULIC AGGREGATE 5004001 5004001
66.15.01.04.01 2 PC VARIABLE DISPLACEMENT PUMP 2376155

A4V G125
SEE SUBSUPPLIER
ASSEMBLY 66.15.01.04.01
66.15.01.04.03 1 PC VARIABLE DISPLACEMENT PUMP 2376174
A4V G125
SEE SUBSUPPLIER
ASSEMBLY 01.66.04.04.03
66.15.01.04.04 4 PC PRESSURE SWITCH 1652151
66.15.01.04.16 9 PC SHEET STEEL SIGN 0303742
66.15.01.04.19 3 PC MEASURING CONNECTION 1709799
66.15.01.04.30 6 PC TRANSITION PIECE 1665757
66.15.01.04.31 6 PC UNION 1636006
66.15.01.04.34 6 PC UNION 8411057
66.15.01.04.35 1 PC UNION 1665749
66.15.01.04.36 1 PC UNION 0304986
66.15.01.04.38 2 PC UNION 1637351
66.15.01.04.41 3 PC UNION 1331029
66.15.01.04.42 9 PC CABLE CLAMP 0661868
66.15.01.04.53 4 PC RUBBER CAP 0625431
66.15.01.04.63 6 PC SEALING RING 1725419
66.15.01.04.64 6 PC MEASURING SOCKE 0310324 310324
66.15.01.04.65 1 PC UNION 1331028
66.15.01.04.81 48 PC CAP – SCREW 0861764
66.15.01.04.82 2 PC UNION 0153812
66.15.01.04.85 10 PC LOCK SCREW 1406392
66.15.01.04.87 6 PC SAE-ELBOW 2072550 2072550


SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG 125
PART-NO.: 2 376 155

SPARE PARTS LIST

ORDER NO.: 2 376 155
DESCRIPTION: VAR. DISPL. PUMP A4VG125
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 2 376 155
2 376 155 VAR. DIPL. PUMP A4VG125 ( 02061001* ) 1 PC L
1 09607937* ROTARY GROUP 1 PC L

2 02012015* CONTROL HYDR. 1 PC L
3 09609518* PORT PLATE WITH VALVES 1 PC L
4 02006333* PUMP CARRIER 1 PC L
5 02052862* CONTROL MODULE 1 PC L
10 02015532* HOUSING 1 PC
13 09435016* JOINT PIN 2 PC
14 09405732* DOWEL ÜIN 1 PC
20 01408251 LOCKING SCREW 140NM 1 PC D
24 09083229* LOCKING SCREW 1 PC D
25 08476823 O-RING 1 PC D
28 09426700* ORIFICE 12NM 2 PC D
31 09154427* CLAMPING PIN 2 PC
37 09156570* LOCKING SCREW 26NM 1 PC
39 09153459* LOCKING SCREW 300NM 1 PC D
46 09154982* THREADED PIN 1 PC D
47 09087405* SEAL-LOCK-NUT 1 PC D
49 09426707* ORIFICE 12NM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09607937*
DESCRIPTION: ROTARY GROUP
09607927* ROTARY GROUP 1 PC L
1 02040556* CYLINDER WITH CONTROL PLATE 1 PC

2 09428131* PISTON-SLIPPER PAD 9 PC
11 09921720* CUP-SPRING STACK 1 PC
12 09445122* CRADLE 1 PC
13 09449034* SLIDE RING 1 PC
14 09921000* DRIVE SHAFT 1 PC
17 09421418* WIRE 2 PC
20 09432505* SHIM 1 PC
20 09432506* SHIM 1 PC
20 09432507* SHIM 1 PC
20 09432508* SHIM 1 PC
24 09921719* RETAINING RING 1 PC
25 09432264* RETAINING BALL 1 PC
26 02066594* BEARING LINER ( PAIR ) 1 PC
27 09921717* WASHER 2 PC
29 09435465* PRESSURE SPRING 1 PC
31 09156269* PLAIN ROLLER BEARING 1 PC
32 09830578* CRADLE BEARING ASSEMBLY ( SET ) 1 PC
36 00012491 RETAINING RING 1 PC
38 01476328 SHAFT SEAL RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02012015*
DESCRIPTION: CONTROL HYDRAULIC
02012015* CONTROL HYDRAULIC 1 PC L
1 02025586* POSITIONING PISTON 1 PC L

3 02010745* COVER 1 PC
4 02010746* COVER 1 PC
16 09157477* HEXAGON NUT 1 PC
17 00515285 SOCKET HEAD SCREW 25NM 8 PC
20 09085360* O-RING 2 PC D
21 09432790* THREADED PIN 2 PC
22 01401644 SEAL-LOCK-NUT 69NM 2 PC D
30 02600839* GUIDE RING 2 PC
31 02600272* TURCON-GLYD-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02025586*
1 02010570* POSITIONING PISTON 1 PC

2 09449241* ROD 1 PC
5 02020493* RING 2 PC
5 02020494* RING 2 PC
5 02020495* RING 2 PC
5 02020496* RING 2 PC
5 02020497* RING 2 PC
5 02020498* RING 2 PC
5 02029756* RING 2 PC
5 02029757* RING 2 PC
5 02043149* RING 2 PC
6 02600767* ASSEMBLY RING 2 PC
7 09652048* SPRING COLLAR 2 PC
19 01402905 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09609518*
DESCRIPTION: PORT PLATE WITH VALVES
09609518* PORT PLATE WITH VALVES 1 PC L
1 02601879* MHDBN32K2 1 PC L
2 09434856* PRESSURE RELIEF VALVE 1 PC L
3 09433834* PRESSURE OVERRIDE VALVE 1 PC L
4 02019663* PRESSURE RELIEF VALVE 1 PC L
5 09651090* PORT PLATE 1 PC
9 09830217* O-RING 1 PC D
11 09831320* DOUBLE BREAK-OFF PIN 1 PC D
26 01402905 O-RING 2 PC D
43 09432774* BUSH 1 PC
44 09432773* BEARING BUSH 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02601879*
DESCRIPTION: MHDBN32K2
02601879* MHDBN32K2 1 PC L
1 02600124* SEAL KIT 1 PC D

2 09157895* CAP 1 PC D
SPARE PARTS LIST

ORDER NO.: 09434856*
DESCRIPTION: PRESSURE RELIEF VALVE
09434856* PRESSURE RELIEF VALVE 1 PC L
1 09436167* LOCKING SCREW 1 PC

2 09449622* ADJUSTING SCREW 1 PC
3 09435899* VALVE PISTON 1 PC
8 00971901 O-RING 1 PC D
9 01412648 SEAL-LOCK-NUT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09433834*
DESCRIPTION: PRESSURE OVERRIDE VALVE
09433834* PRESSURE OVERRIDE VALVE 1 PC L

2 09426552* VALVE BUSHING 1 PC
3 09432301* CONTROL PISTON 1 PC
4 09432163* PISTON 1 PC
6 09432775* POPPET SEAT 1 PC
10 00200485 O-RING 1 PC D
15 00146186 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02019663*
DESCRIPTION: PRESSURE RELÖIEFVALVE
02019663* PRESSURE RELÖIEFVALVE 1 PC L

2 09409929* PISTON 1 PC
4 09409819* GUIDE BUSHING 1 PC
5 09002455* PLUG 1 PC
8 09409822* LOCKING BOLT 1 PC
9 09409930* LOCKING SREW 1 PC
11 09150369* SHIM 1 PC
11 09153402* SHIM 1 PC
17 00950467 O-RING 1 PC D
18 00950467 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09606333*
DESCRIPTION: PUMP COVER
09606333* PUMP COVER 1 PC L
1 09434017* PUMP COVER 1 PC L

2 09650693* WEAR PLATE 1 PC L
SPARE PARTS LIST

ORDER NO.: 09434017*
09434017* PUMP VOVER 1 PC L
1 09650695* PUMP COVER 1 PC

6 09083206* SOCKET HEAD SREW 4 PC
7 04226837 O-RING 1 PC D
8 01435609 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09650693*
DESCRIPTION: WEAR PLATE
09650693* WEAR PLATE 1 PC L
1 09650692* WEAR PLATE 1 PC

2 04226837 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02052862*
DESCRIPTION: CONTROL MODULE
02052862* CONTROL MODULE 1 PC L

3 09443201* COVER 1 PC
4 02063327* DRAW SPRING 1 PC
5 09651478* GASKET 1 PC D
6 02046037* PICKUP RING 2 PC
8 09083183* SOCKET HAED SCREW 8 PC
9 09085831* SOCKET HEAD SCREW 10,4NM 4 PC
10 02600641* O-RING 1 PC D
12 01437359 O-RING 3 PC D
13 02601860* SOLENOID VALVE 2 PC L
15 01402905 O-RING 2 PC
16 00146186 O-RING 1 PC D
17 09083764* O-RING 2 PC D
18 02601640* SPRING COLLAR 2 PC D
19 00765885 PLUG BOX 1 PC
20 01412646 PLUG BOX 1 PC
30 09087338* CYLINDRICAL PIN 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02048768*
1 02067240* CONTROL HOUSING WITH ACCESSOR. 1 PC L

5 02061843* TUNER 1 PC
6 02067213* WASHER 1 PC
6 02067214* WASHER 1 PC
6 02067215* WASHER 1 PC
6 02067216* WASHER 1 PC
6 02067217* WASHER 1 PC
6 02067218* WASHER 1 PC
6 02067219* WASHER 1 PC
6 02067220* WASHER 1 PC
6 02070232* WASHER 1 PC
22 09087453* NEEDLE ROLLER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02067240*
DESCRIPTION: CONTROL HOUSING WITH ACCESSOR.
02067240* CONTROL HOUSING WITH ACCESSOR. 1 PC L
1 02068232* HOUSING 1 PC
3 02067221* CONTROL PISTON WITH CYLINDRICAL PIN 1 PC
4 02050396* LEVER 2 PC
6 02067212* EXENTRIC PIN 1 PC
8 02044854* WASHER 1 PC
21 00219041 SOCKET HEAD SCREW 10,4NM 2 PC D
24 02601243* SOCKET HEAD SCREW 6,1NM 1 PC D
29 09153668* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER


SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG 125
PART-NO.: 2 376 174

SPARE PARTS LIST

ORDER NO.: 2 376 174
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 2 376 174

2 376 174 VAR. DISPL. PUMP A4VG 125 ( 02059896* ) 1 PC L
2 02012015* CONTROL HYDR.. 1 PC L
3 09609517* PORT PLATE WITH VALVES 1 PC L
4 02006333* PUMP CARRIER 1 PC L
10 02015532* HOUSING 1 PC
13 09435016* JOINT PIN 2 PC
14 09405732* DOWEL PIN 1 PC
25 08476823 O-RING 1 PC D
28 09426700* ORIFICE 12NM 2 PC D
31 09154427* CLAMPING PIN 2 PC
37 09156570* LOCKING SCREW 26NM 1 PC
46 09154982* THREADED PIN 1 PC D
47 09087405* SEAL-LOCK-NUT 1 PC D
49 09426707* ORIFICE 12NM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09607937*
09607937* ROTARY GROUP 1 PC L
1 02040556* CYLINDER WITH CONTROL PLATE 1 PC

2 09428131* PISTON-SLIPPER PAD 9 PC
11 09921720* CUP-SPRING STACK 1 PC
12 09445122* CRADLE 1 PC
13 09449034* SLIDE RING 1 PC
17 09421418* WIRE 2 PC
20 09432505* SHIM 1 PC
20 09432506* SHIM 1 PC
20 09432507* SHIM 1 PC
20 09432508* SHIM 1 PC
25 09432264* RETAINING BALL 1 PC
26 02066594* BEARING LINER (PAIR) 1 PC
27 09921717* WASHER 2 PC
31 09156269* PLAIN ROLLER BEARING 1 PC
32 09830578* CRADLE BEARING ASSEMBLY ( SET ) 1 PC
38 01476328 SHAFT SEAK RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02012015*
1 02025586* POSITIONING PISTON 1 PC L

3 02010745* COVER 1 PC
4 02010746* COVER 1 PC
16 09157477* HEXAGON NUT 1 PC
20 09085360* O-RING 2 PC D
30 02600839* GUIDE RING 2 PC
31 02600272* TURCON-GLYD-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02025586*
DESCRIPTION: PORT PLATE WITH VALVES
02025586* PORT PLATE WITH VALVES 1 PC L

2 09449241* ROD 1 PC
5 02020493* RING 2 PC
5 02020494* RING 2 PC
5 02020495* RING 2 PC
5 02020496* RING 2 PC
5 02020497* RING 2 PC
5 02020498* RING 2 PC
5 02029756* RING 2 PC
5 02029757* RING 2 PC
5 02043149* RING 2 PC
6 02600767* ASSEMBLY RING 2 PC
19 01402905 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09609517*
DESCRIPTION: PORT PLATE WITH VALVE
09609517* PORT PLATE WITH VALVE 1 PC L
1 02601879* MHDBN32K2 200NM 1 PC L

2 09434856* PRESSURE RELIEFVALVE 1 PC L
3 09433834* PRESSURE OVERRIDE VALVE 1 PC L
7 00945233 SOCKETHEAD SCREW 310NM 4 PC
9 09830217* O-RING 1 PC D
26 01402905 O-RING 2 PC D
43 09432774* BUSH 1 PC
44 09432773* BEARING BUSH 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02601879*
DESCRIPTION: MHDBN32K2
02601879* MHDBN32K2 1 PC L
1 02600124* SEAL KIT 1 PC D

2 09157895* CAP 1 PC D
SPARE PARTS LIST

ORDER NO.: 09434856*
DESCRIPTION: PRESSURE RELIEF VALVE
09434856* PRESSURE RELIEF VALVE 1 PC L

8 00971901 O-RING 1 PC D
9 01412648 SEAL-LOCK-NUT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09433834*
DESCRIPTION: PRESSURE OVERRIDE VALVE
09433834* PRESSURE OVERRIDE VALVE 1 PC L

4 09432163* PISTON 1 PC
6 09432775* POPPET SEAT 1 PC
10 00200485 O-RING 1 PC D
15 00146186 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09606333*
09606333* PUMP COVER 1 PC L
1 09434017* PUMP COVER 1 PC L

2 09650693* WEAR PLATE 1 PC L
SPARE PARTS LIST

ORDER NO.: 09434017*
DESCRIPTION: PUMP VOVER
09434017* PUMP VOVER 1 PC L
1 09650695* PUMPENDECKEL 1 PC
6 09083206* SOCKET HEAD SCREW 4 PC
7 04226837 O-RING 1 PC D
8 09086378* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 09650693*
DESCRIPTION: WEAR PLATE
09650693* WEAR PLATE 1 PC L
1 09650692* WEAR PLATE 1 PC

2 04226837 O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02052862*

3 09443201* COVER 1 PC
4 02063327* DRAW SPRING 1 PC
5 09651478* GASKET 1 PC D
6 02046037* PICKUP RING 2 PC
10 02600641* O-RING 1 PC D
12 01437359 O-RING 3 PC D
13 02601860* SOLENOID VALVE 19NM / 5NM 2 PC L
15 01402905 O-RING 2 PC D
16 00146186 O-RING 1 PC D
17 00750466 O-RING 2 PC D
18 02601640* SPRING COLLAR 2 PC D
19 00765885 PLUG BOX 1 PC
20 00141264 PLUG BOX 1 PC
30 09087338 CYLINDRICAL PIN 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO.: 02048768*
1 02067240* CONTROL HOUSING WITH ACCESSOR. 1 PC L

5 02061843* TUNER 1 PC
6 02067213* WASHER 1 PC
6 02067214* WASHER 1 PC
6 02067215* WASHER 1 PC
6 02067216* WASHER 1 PC
6 02067217* WASHER 1 PC
6 02067218* WASHER 1 PC
6 02067219* WASHER 1 PC
6 02067220* WASHER 1 PC
6 02070232* WASHER 1 PC
22 09087453* NEEDLE ROLLER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER


SPARE PARTS LIST

ORDER NO.: 02067240*
DESCRIPTION: CONTROL HOUSING WITH ACCESSOR.
02067240* : CONTROL HOUSING WITH ACCESSOR. 1 PC L
1 02068232* HOUSING 1 PC
3 02067221* CONTROL PISTON WITH CYLINDRICAL PIN 1 PC L
4 02050396* LEVER 2 PC
6 02067212* EXCENTRIC PIN 1 PC
8 02044854* SCHEIBE 1 PC D
21 00219041 SOCKET HEAD SCREW 10,4NM 2 PC D
24 02061243* SOCKET HEAD SCREW 6,1NM 1 PC D
29 09153668* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 657-02
DESCRIPTION: HYDRAULIC TANK COMPONENTS

SPARE PARTS LIST

ORDER NO5 005 657-02

66.15.20.00.00 1 PC HYDRAULIC TANK COMPONENTS 5005657 5005657
66.15.20.01.00 1 PC FILTER A.LEACK OIL BLOCK 5001120

SEE SUBSUPPLIER
ASSEMBLY 16.66.20.01.00
66.15.20.03.00 1 PC CONTROL STATION FILTER 5001119

SEE SUBSUPPLIER
ASSEMBLY 66.15.20.03.00
66.15.20.04.00 1 PC NIVEAU SWITCH 5006331

66.15.20.05.00 1 PC VENTILATION FILTER 0156729
66.15.20.06.00 1 PC BALL VALVE 1367718
66.15.20.07.00 1 PC BALL COCK 0830538
66.15.20.08.00 2 PC OIL SIGHT GLAS 1655840
66.15.20.09.00 1 PC SUCTION FILTER 2547561
66.15.20.10.00 1 PC SCREW PLUG 0835058
66.15.20.13.00 2 PC SEAL RING 1725421
66.15.20.14.00 1 PC SEALING RING 1725418
66.15.20.16.00 2 PC SAE-FLANGE 0440207
66.15.20.18.00 1 PC THREAD FLANGE 1656521
66.15.20.19.00 4 PC HEXAGON SCREW 0056672
66.15.20.20.00 4 PC HEXAGON NUT 0011569

SPARE PARTS LIST

ORDER NO5 005 657-02

SPARE PARTS LIST

ORDER NO. 5 005 657-02


66.15.20.23.00 2 PC CYLINDRICAL -SCREW 2168573
66.15.20.28.00 4 PC HEXAGON SCREW 3398122
66.15.20.29.00 8 PC HEXAGON SCREW 2533314
66.15.20.30.00 8 PC WASHER 0056992
66.15.20.33.00 2 PC HEXAGON NUT 0057127
66.15.20.34.00 8 PC HEXAGON NU 0057133
66.15.20.38.00 8 PC WASHER 0063701
66.15.20.39.00 2 PC RETAINER-WASHER 0552981
66.15.20.42.00 1 PC UNION 8411057
66.15.20.44.00 1 PC UNION 1768309
66.15.20.47.00 1 PC UNION 1636028
66.15.20.51.00 2 PC UNION 1367719
66.15.20.52.00 1 PC UNION 2371476
66.15.20.53.00 1 PC UNION 1307804
66.15.20.56.00 1 PC UNION 1636008
66.15.20.64.00 1 PC UNION 0304990
66.15.20.66.00 1 PC BOLT 0773596
66.15.20.68.00 1 PC PLUG FOR COUPLING 0785169
66.15.20.69.00 1 PC PLUG FOR COUPLING 0785169
66.15.20.70.00 1 PC CONN.-NUT 0010731
66.15.20.80.00 2 PC SHEET STEEL SIGN 0303742
66.15.20.81.00 2 PC CABLE CLAMP 0661868
66.15.20.85.00 1 PC UNION 1360742


SPARE PARTS LIST
FILTER A.LEACK OIL COLLECTING

BLOCK
PART-NO.: 5 001 120

SPARE PARTS LIST

ORDER NO. 5 001 120
DESCRIPTION: FILTER A.LEACK OIL COLLECTING BLOCK
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 001 120
DESCRIPTION: FILTER A.LEACK OIL COLLECTING BLOCK

5 001 120 FILTER A.LEACK OIL COLLECTING BLOCK 1 PC L
LT 35D38.0
1 1245655* BLOCK LT 35D38.0 1 PC
2 1231384* HIGH PRESSURE HYDRAULIC-FILTER GR. 2 1 PC
3 1233627* CHECK VALVE 1 PC
6 1239322* FIXING BUSH 3 PC
7 1241442* THERMOMETER 1 PC
8 1240026* FLANGE HALF 2 PC
9 1241447* FLANGE HALF 2 PC
10 1135719* FITTING 5 PC
11 1239370* FITTING 4 PC
12 1135715* FITTING 1 PC
13 1241173* CYLINDER HEAD SCREW 4 PC
16 1238560* O-RING 1 PC
18 1421589* REDUCTION ADAPTER 1 PC
19 1241604* MEASURING PORT 2 PC
20 1421592* SEALING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER


SPARE PARTS LIST
FILTER AND CONTROL STATION
SACH-NR.: 5 001 119

SPARE PARTS LIST

ORDER NO. 5 001 119
DESCRIPTION: FILTER AND CONTROL STATION
L = ASSEMBLY GROUP
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 001 119
DESCRIPTION: FILTER AND CONTROL STATION

5 001 119 CONTROL BLOCK COMPL. ( LT-10-88.0-K ) 1 PC L
1 1421627* CONTROL BLOCK 1 PC
2 1421628* 2/2 WAY SOLENOID VALVE 4 PC
3 1250067* SOLENOID COIL 4 PC
4 1421629* HAND BUTTON 4 PC
5 1420427* NOZZLE 1 PC
6 1280559* THROTTLE CHECK VALVE 1 PC
7 1231466* HIGH PRESSURE HYDRAULIC-FILTER GR. 3 1 PC
8 1238578* O-RING 1 PC
10 1240762* RESOPAL SIGN-BOARD SET 5 PC
11 1240763* RESOPAL SIGN-BOARD SET 6 PC
12 1241604* MEASURING CONNECTOR 5 PC
13 1239370* UNION 4 PC
14 1239371* UNION 4 PC
15 1240956* SCREW PLUG 1 PC
16 1240987* SIDEX-EXPANDER 9 PC
L = ASSEMBLY GROUP
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 001 106-00
DESCRIPTION: PUMP AGGREGAT COMPL.

66.15.21.00.00 1 PC PUMP AGGREGAT COMPL. 5001106 5001106
66.15.21.01.00 1 PC TANK COVER 5001105 5001105

66.15.21.02.00 1 PC PUMP UNIT 5001110 5001110
SEE SUBSUPPLIER
66.15.21.03.00 1 PC SEAL 5001115 5001115
66.15.21.04.00 1 PC SEAL 5001114 5001104
66.15.21.05.00 4 PC STUD BOD 0301702
66.15.21.06.00 10 PC HEXAGON NUT 0057130
66.15.21.07.00 10 PC WASHER 0063701
66.15.21.08.00 18 PC HEXAGON SCREW 0057127
66.15.21.09.00 18 PC WASHER 0056988
66.15.21.10.00 1 PC O-RING 0936425
66.15.21.11.00 6 PC STUD BOLD 0303774
66.15.21.12.00 6 PC HEXAGON SCREW 0056672

SPARE PARTS LIST

ORDER NO. 5 001 105-01
DESCRIPTION: TANK COVER

66.15.21.01.00 1 PC TANK COVER WITH PUMP CARRIER 5001105 5001105
66.15.21.01.01 1 PC PLATE 0050966

66.15.21.01.02 1 PC PLATE 2053639
66.15.21.01.03 1 PC UNION 0215051
66.15.21.01.04 1 PC UNION 0304890
66.15.21.01.05 1 PC UNION 0924291


SPARE PARTS LIST
FUEL FEED AND CONTROL PUMP
PART-NO.: 5 001 110

SPARE PARTS LIST

ORDER NO. 5 001 110-00
DESCRIPTION: FUEL FFED AND CONTROL PUMP
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 001 110-00
DESCRIPTION: FUEL FFED AND CONTROL PUMP

5 001 110 FUEL FEED AND CONTROL PUMP 1 PC L
1 1238311* THREE PHASE MOTOR 1 PC
2 1421506* AXIAL PISTON PUMP K3VL80 1 PC
3 1421507* GEAR PUMPALP3A 1 PC
4 1421508* PUMP CARRIER 1 PC
5 1421509* COUPLING 1 PC
6 1421510* COUPLING 1 PC
7 1421511 COUPLING RING 1 PC
8 1241164* CYLINDRICAL SCREW 6 PC
11 1240026* HALF-FLANGE 4 PC
12 1421632* HYDR. HOSE 1 PC
SEE LIST OF LMG HYDRAULIC HOSES
14 1421562* UNION 1 PC
15 1054529* HYDR. PIPE 1M
16 1239873* UNION 1 PC
17 1421634* HYDR. HOSE 1 PC
18 1421563* TANK UNION 1 PC
19 1421565* TANK UNION 1 PC
22 1421633* HYDR. HOSE 1 PC
23 1421132* SEALING 1 PC
24 1240785* USITRING 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 5 005 672-00
DESCRIPTION: HYDR.SYSTEM WINCH MODULE

66.19.00.00.00 1 PC HYDR.SYSTEM WINCH MODULE 5005672
66.19.02.00.00 1 PC COMPONENTS HYDR. WINCH MODULE 5005165 2389310

66.19.10.00.00 1 PC HYDR. MOTOR HOISTING GEAR COMPL. 2389311 2389311
66.19.11.00.00 1 PC HYDR.MOTOR LUFFING GEAR COMPL. 4243255 4243255

SPARE PARTS LIST

ORDER NO. 5 005 165-00
DESCRIPTION: COMPONENTS HYDR.SYSTEM WINCH MODULE

66.19.02.00.00 1 PC COMPONENTS HYDR. WINCH MODULE 5005165 2389310
66.19.02.01.00 2 PC UNION 1665705

66.19.02.02.00 2 PC UNION 1636004
66.19.02.03.00 2 PC UNION 1665749
66.19.02.04.00 2 PC TRANSIT.MUFF CONNECT.PIECE 0665861
66.19.02.05.00 2 PC UNION 1665742
66.19.02.06.00 2 PC BRAKE FILTER 1637770

SPARE PARTS LIST

ORDER NO. 2 389 311-03
DESCRIPTION: HYDRAULIC MOTOR HOISTING GEAR COMPL.

HYDRAULIC MOTOR HOISTING GEAR

66.19.10.00.00 1 PC COMPL. 2389311 2389311
66.19.10.01.00 1 PC ADJUSTABLE MOTOR 2532117

SEE SUBSUPPLIER
66.19.10.02.00 1 PC SOCKET 1665744
66.19.10.03.00 1 PC UNION 1636031
66.19.10.05.00 16 PC CAP-SCREW 0861764
66.19.10.06.00 4 PC CAP-SCREW 1570492
66.19.10.07.00 4 PC RETAINER-WASHER 0153213
66.19.10.08.00 1 PC ADAPTER 90GR 1397693
66.19.10.09.00 2 PC SEALING RING 1725419
66.19.10.12.00 1 PC SAE-ELBOW 2072550 2072550
66.19.10.13.00 1 PC LOCK SCREW 1406392
66.19.10.14.00 1 PC THREAD JOINT VSTI 0986982
66.19.10.15.00 1 PC UNION VSTI 1637351
66.19.10.16.00 1 PC CHAK VALVE 1636493
66.19.10.17.00 1 PC UNION 0034531
66.19.10.18.00 1 PC UNION 1609955

SPARE PARTS LIST
ADJUSTABLE OIL MOTOR

A6VM 200
PART-NO: 2 532 117

SPARE PARTS LIST

ORDER NO. 2 532 117
DESCRIPTION: ADJUSTABLE OIL MOTOR A6VM 200/63

1 4 532 117 ADJUSTABLE OIL MOTOR A6VM 200/63 ( 09604650* ) 1 PC L
2 09604644* CONTROL 1 PC L
5 09921682* HOUSING 1 PC
8 01466223 LOCKING SCREW 1 PC D
10 09831663* SHAFT SEAL RING 1 PC D
11 09832084* BACK-UP PLATE 1 PC
12 09157314* O-RING 1 PC D
18 01401644 SEAL-LOCK-NUT 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09603916*

1 09603992* ROTARY GROUP, HYDR. SECTION 1 PC L
3 09651659* SHIM 1 PC
10 09157196* TAPERED-ROLLER BEARING 1 PC
11 09157197* TAPERED-ROLLER BEARING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09603992*
DESCRIPTION: ROTARY GROUP, HYDR. SECTION

1 09430072* CYLINDER 1 PC
2 09921791* CONTROL LENS 1 PC
3 09921781* CENTER PIN 1 PC
4 02021906* PISTON WITH PISTON RINGS 7 PC L
6 09921775* ADJUSTMENT SHIM 1 PC
7 09921782* PRESSURESPRING 1 PC
11 02033027* RETAINING PLATE 1 PC
12 09831108* PAN HEAD SCREW WITH TROX 15,8NM 14 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 02021906*
DESCRIPTION: PISTON WITH PISTON RINGS

1 09430104* PISTON 1 PC
2 09831898* STEEL SEALING RING 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09604644*
DESCRIPTION: CONTROL

1 09604634* CONTROL PART 1 PC L
2 09603769* COVER 1 PC L
5 09424057* POSITIONING TRUNNION 1 PC
7 09652204* PISTON 1 PC
10 09422894* VALVE GUIDE 2 PC
11 09426662* BOLT 2 PC
13 09412756* BUSH 2 PC
15 09083131* SOCKET-HEAD SCREW 215NM 8 PC
19 09830726* O-RING 2 PC D
20 09085577* O-RING 6 PC D
21 09086487* O-RING 2 PC D
23 09831057* SOCKET-HEAD SCREW E 150NM 1 PC
24 09832146* SQUARE RING 3 PC D
26 00218305 CYLINDER PIN 2 PC
28 09831318* DOUBLE BREAK-OFF PIN 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09604634*
DESCRIPTION: CONTROL PART

1 02000313* CONTROL HOUSING 1 PC
2 09412246* CONTROL BUSH 1 PC
3 09921942* CONTROL PISTONV 1 PC
4 09651119* ADJUSTING BUSHING 1 PC
14 09085560* O-RING 1 PC D
15 00013445 SOCKET-HEAD SCREW 25NM 4 PC
20 00591375 CYLINDER PIN 1 PC
22 09831317 DOUBLE BREAK-OFF PIN 5 PC
25 02600646* O-RING 1 PC D
27 09441694* PROPORTIONAL SOLENOID 1 PC L
28 00765885 PLUG BOX 1 PC
41 02000492* CONTROL BUSH 1 PC
48 09152686* O-RING 1 PC D
49 09157764* SEAL-LOCK-NUT 11NM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09441694*
DESCRIPTION: PROPORTIONAL SOLENOID

1 09830752* SOLENOID 1 PC
2 09086070* SOCKET-HEAD SCREW 3,1NM 4 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09603769*
DESCRIPTION: COVER

1 09445990* COVER 1 PC
2 09400263* THROTTLE SCREW 1 PC
3 09446625* THROTTLE PIN 1 PC L
4 09400264* THROTTLE SCREW 1 PC
10 09831592* SOCKET-HEAD SCREW 4 PC
11 09154053* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 09446625*
DESCRIPTION: THROTTLE PIN

3 09400262* THROTTLE PIN 1 PC D
4 09411019* THROTTLE PIN 1 PC
18 09425870* THROTTLE PIN 1 PC D
SPARE PARTS LIST

ORDER NO. 09446862*
DESCRIPTION: THREADED PIN

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. 4 243 255-00
DESCRIPTION: HYDR.MOTOR LUFFING GEAR COMPL.

66.19.11.00.00 1 PC HYDR.MOTOR LUFFING GEAR COMPL. 4243255 4243255
66.19.11.01.00 1 PC AXIAL PISTON UNIT 1601518

SEE SUBSUPPLIER
ASSEMBLY 66.19.11.01
66.19.11.02.00 1 PC SOCKET PIECE 0625708
66.19.11.05.00 1 PC THREAD JOINT VSTI 0986982
66.19.11.06.00 1 PC SCREWING 0070277
66.19.11.07.00 12 PC CAP-SCREW 0861764
66.19.11.08.00 4 PC HEXAGON SCREW 0056679
66.19.11.09.00 4 PC THRUST WASHER 0153212
66.19.11.10.00 2 PC ADAPTER 90GR 1627452 1627452
66.19.11.11.00 3 PC SEALING RING 1725419
66.19.11.12.00 1 PC SAE-ELBOW 2072550 2072550
66.19.11.13.00 1 PC LOCK SCREW 1406392
66.19.11.14.00 1 PC UNION 1312318
66.19.11.15.00 1 PC UNION VSTI 1637351
66.19.11.16.00 1 PC CHAK VALVE 1636493
66.19.11.18.00 8 PC HEXAGON SCREW 0056672
66.19.11.19.00 2 PC SEALING RING 1725418


SPARE PARTS LIST
AXIAL PISTON UNIT
PART-NO.: 1 601 518

SPARE PARTS LIST

ORDER NO. 1 601 518
DESCRIPTION: AXIAL PISTON UNIT

1 601 518 AXIAL PISTON UNIT A2FM107 ( R909409691*) 1 PC L
1 R902030550* ROTARY GROUP 1 PC L
3 R902038551* HOUSING 1 PC
4 R909409692* PORT PLATE 1 PC
5 R909084163* CYLINDER PIN 1 PC
6 R909154986* O-RING 1 PC D
7 R909083087* SOCKET-HEAD SCREW 87NM 2 PC
10 R909083104* SOCKET-HEAD SCREW 87NM 4 PC
19 R909156651* LOCKING SCREW 40NM 1 PC D
98 R902002219* SEALING SET COMPL: 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. R902030550*

1 R902028911* ROTARY GROUP; HYDR. SECTION 1 PC L
2 R902030596* DRIVE SHAFT WITH BEARING ASSY 1 PC L
4 R909409482* COVER 1 PC D
12 R909152143* RETAINING RING 1 PC
14 R909831178* SHAFT SEALING RING 1 PC D
15 R909086636* O-RING 1 PC D
17 R909154359* SHIM 2 PC
18 R909154360* SHIM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. R902028911*
DESCRIPTION: ROTARY GROUP, HYDR . SECTION

1 R909421309* CYLINDER 1 PC
2 R909650835* CONTROL PLATE 1 PC
3 R902027352* CENTER PIN 1 PC
4 R902031678* PISTON WITH PISTON RINGS 7 PC L
5 R909409612* WASHER 1 PC
6 R902027329* ADJUSTMENT SHIM 1 PC
7 R902027353* PRESSURE SPRING 1 PC
11 R909444064* RETAINING PLATE 1 PC
12 R902602395* PAN HEAD SCREW W. TORX 7 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. R902031678*
DESCRIPTION: PISTON WITH PISTON RINGS

1 R902028624* PISTON 1 PC
2 R909831891* STEEL SEALING RING 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. R902030596*
DESCRIPTION: DRIVE SHAFT WITH BEARING ASSY

2 R902028923* DRIVE SHAFT 1 PC
3 R909430091* BEARIMG RING 1 PC
6 R902027403* BACK-UP PLATE 1 PC L
7 R909083365* RETAINING RING 1 PC
10 R909154382* TAPERED-ROLLER BEARING 1 PC
11 R909154293* TAPERED-ROLLER BEARING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

SPARE PARTS LIST

ORDER NO. R902027403*
DESCRIPTION: BACK-UP PLATE

1 R909921494* BACK-UP PLATE 1 PC
SPARE PARTS LIST

ORDER NO. R902027403*
DESCRIPTION: BACK-UP PLATE

1 R909831178* SHAFT SEAL RING 1 PC D
2 R909086636* O-RING 1 PC D
3 R909154986* O-RING 1 PC D
4 R909087891* O-RING 2 PC D
5 R909087938* O-RING 1 PC D
6 R909152688* O-RING 2 PC D
7 R909086765* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

7/3945 - 7/3948 SPARE PARTS LIST
SPARE PARTS LIST

ORDER NO. 5 007 569-00
DESCRIPTION: TECHNICAL DOKUMENTS

97.01.00.00.00 1 PC TECHNICAL DOKUMENTATION 5007570
97.01.01.00.00 1 PC DECK-CRANE 3327812 3327812

97.01.02.00.00 1 PC CRANE ARRANGEMENT 3327813 3327813
97.01.06.00.00 1 PC ASSEMBLY INSTRUCTION 5007573 5007573
97.25.00.00.00 1 PC ELECTRIC DOKUMENTATION 5007571
97.25.01.00.00 1 PC ELECTRIC DIAGRAM 5002997 5002997
97.66.00.00.00 1 PC HYDRAULIC DOKUMENTATION 5007572
97.66.01.00.00 1 PC HYDRAULIC DIAGRAM 5006978 5006978

97.66.02.00.00 1 PC LIST OF PARTS FOR HYDR. DIAGRAM 5006979 5006979
97.66.03.00.00 1 PC LIST OF HOSES 5006980 5006980

HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 006 979 Index 00
AUFLISTUNG
LIST OF PARTS
zum
for
HYDRAULIKSCHEMA
HYDRAULIC DIAGRAM
SACH - NR. : / PART - NO. : 5 006 979
KRAN - TYP : / CRANE TYPE : KL 30T – 25M

BAU - NR. : / COMM. NO. : 7/3945 – 7/3948
Auflistung z. Hydraulikschema Ident No. : 5 006 978

Bau 7/3945 – 7/3948 14.01.2009 1/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Pos. im Hydro-Schema Menge Benennung TTS-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

Bau 7/3945 – 7/3948 14.01.2009 2/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
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 5 002 899 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

Bau 7/3945 – 7/3948 14.01.2009 3/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
2.0 1 Wippwerk
Luffing gear
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 5 002 899 HT-PD
Pressure sensor
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

Bau 7/3945 – 7/3948 14.01.2009 4/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
3.0 1 Drehwerk
Slewing gear
3.4 2 Axialkolbeneinheit 5 005 874 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
3/2 Way valve 5 001 119
3.27 2 Druckschalter 1 652 151 0163-407-01-1-025 (7 bar)
Pressure switch
3.28 2 Schutzkappe 625 431 1166621010
Rubber cap

Bau 7/3945 – 7/3948 14.01.2009 5/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
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 11 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 Item in NV08-20A-O-N
Throttle valve 5 001 119
4.24 1 3/2 Wegeventil Item in
3/2 Way valve (Item in 5 001 119) 5 001 119

Bau 7/3945 – 7/3948 14.01.2009 6/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
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 Item in 274A – 2N35 – TL110/123
Filter 5 001 120
5.3.1.1 1 Filtereinsatz 2 546 583 270 – L –123A
Filter cartridge
5.3.2 1 Rückschlagventil Item in Hy5300034 1 bar
Check valve 5 001 120
5.5 1 Temperatursensor 5 002 900
Temperature sensor
5.8 1 Ölkühler kompl. 5 005 192
Oil cooler compl.
5.8.2 1 E-Motor Item in IMB14C140-90L
Elect.-motor 5 005 192
Bau 7/3945 – 7/3948 14.01.2009 7/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
5.8.3 1 Ölkühler Item in
oil cooler 5 005 192

Bau 7/3945 – 7/3948 14.01.2009 8/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
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
6.9 1 Niveauschalter 5 006 331 RFS *KOBO
Niveau switch

Bau 7/3945 – 7/3948 14.01.2009 9/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
7.0 1 Füllhandpumpe 0 478 065
Manual filling pump

Bau 7/3945 – 7/3948 14.01.2009 10/11
HYDRAULISCHE ANLAGE
______________________________________________________________________________________________________________
Type
8.0 1 Handpumpe für Notbetrieb 5 001 738
Manual pump
(Lagerung im Store)
(To be kept in store)

Bau 7/3945 – 7/3948 14.01.2009 11/11
Anschlußform der Schlaucharmatur

nach DIN 20078
Sach.-Nr.:
Part.-No.: 5 006 980 SCHLAUCHLISTE FÜR
HYDRAULIKSCHEMA Blatt:
List of hoses Hydraulic diagram
CH 90 1 von 3
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
1.07 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
1.25 DN08x -N/N -1SN SCAFFOLD
2.01 DN08x4150 -N/N90 -1SN TOWER 2 072 985
2.03 DN12x1700 -P/P90 -1SN TOWER 2 072 988
2.07 DN20x1700 -N/N90 -1SN TOWER 4 221 028
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
Sach.-Nr.:
CH 90 2 von 3

3.02 DN06x1300 -N/N90 -1SN TOWER 2 072 984
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
3.15 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
4.12 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
Sach.-Nr.:
CH 90 3 von 3

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.:
CH 90 4 von 3
7/3945 - 7/3948 ASSEMBLY INSTRUCTION
7. ASSEMBLY INSTRUCTION
Crane type: KL 30 T – 25 M
Crane No.: 7/3945 - 7/3948
Date: 02.2009

Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
Please state the crane no. and type (see data plate) with all enquiries. PART – NO.: 5 007 573
ASSEMBLY INSTRUCTION 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 7-1

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
7-2 Ind. 00 / 008-2009 2-571-7/3945-7/3948 ASSEMBLY INSTRUCTION 3945-3948

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.

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.:

Einsiedelstrasse 6
D-23554 Lübeck
Germany
Telephone: +49 451 4501 714
Telefax: +49 451 4501 392
Please state the crane no. and type (see data plate) with all enquiries.

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. 5002997 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.

Fig. 3
Fig. 4
Fig. 5

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
Fig. 6

7.4.2 PUTTING THE CRANE UPRIGHT
Fig. 7
Fig. 8

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 600 Litres
remaining hydr. equipment 1x 50 Litres
Fig. 9

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.
Fig. 10 Fig. 11

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.
5002997 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
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

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. 5002997 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 ∅30x192m long
Hoisting rope ∅30x199m long
ATTENTION!
Pull ropes off the reel, otherwise they might twist.
Fig. 16

7.10.1 ROPE LAYOUT FOR LUFFING GEAR:
Fig. 17
7.10.2 ROPE LAYOUT FOR MAIN HOISTING GEAR:
Fig. 18

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

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.

7.13 LUBRICANTS RECOMMENDATION
Fig. 23

7.14 TERMINAL CONNECTING PLAN








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TTS Marine Cargo Cranes

SINGLE DECK CRANE KL 30T – 25M

TTS YARD-NO. : 2-571-7/3945 – 7/3948

TTS-LMG Marine Cranes GmbH

© Copyright by TTS-LMG Printed in Germany

5. SPECIFICATION OF THE ELECTRICAL

6. SPARE PARTS LIST

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-1

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-2

TTS-LMG Marine Cranes GmbH

1.2 SAFETY REGULATIONS – GENERAL REMARKS

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-4

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

1.3.3 MANDATORY SIGNS

Wear eye protection Wear safety gloves Wear safety protection

Wear safety helmet Wear safety boots Wear ear protection

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-6

1.3.4 RESCUE SIGNS

First aid Fire extinguisher

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-7

1.4 SAFETY DEVICES – GENERAL REMARKS

1.4.3 LIMIT SWITCHES

1.4.4 SAFETY DEVICES

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-8

1.5 SAFETY REGULATIONS

1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS

Portable fire extinguishers : dry powder extinguishers

Extinguishing agent : 5 kg carbon dioxide

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:

Move to safety Warn endangered persons. Remove the injured and

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-9

FIRE EXTINGUISHING SYSTEM/FIRE EXTINGUISHERS

RULE NO. 1 IN FIREFIGHTING IS:

SAVING HUMAN LIFE IS MORE IMPORTANT THAN FIGHTING THE FIRE.

CORRECT USE OF FIRE EXTINGUISHERS:

REFACE 3945-3948 2-571-7/3945-7/3948 Ind. 00 / 08-2009 1-10

1.5.2 OPERATING INSTRUCTION FOR EMERGENCY

REMOVE ESCAPE DEVICE OUT OF BAG AT THE CABIN WALL.

REMOVE LEVER BRAKE OUT OF THE BAG

GRATING TO BE HINGED UP FORWARD AND BOTTOM WINDOW

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

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

Replace rope after 4-5 years

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7/3945 - 7/3948 DESCRIPTION

DESCRIPTION 3945 - 3948 2-571-7/3945 - 7/3948 Ind. 00 / 08-2009 2-1

7/3945 - 7/3948 DESCRIPTION

2.1.1 CRANE TOWER

2.1.2 CRANE CABIN