TTS Operating Instructions [PDF]

Zitiervorschau

TTS Marine Cargo Cranes OPERATION INSTRUCTION AND SPARE PARTS LIST

SINGLE DECK CRANE KL 30T – 28M

TTS YARD-NO.

: 2-571-7/3165 – 7/3168

YEAR OF CONSTRUCTION : 2008 CLASSIFICATION SOCIETY : LR DATE

: January 2008

JES SHIPYARD HULL NO.: JES 06C-001 TTS-LMG Marine Cranes GmbH Marine Crane Division Einsiedelstrasse 6 D-23554 Lübeck Germany Telephone: +49 451 4501 714 Telefax: +49 451 4501 392 E-mail: [email protected] Internet: www.tts-marine.com © Copyright by TTS-LMG Printed in Germany

TTS-LMG Marine Cranes GmbH 7/3165-7/3168 PREFACE

1. PREFACE 2.

CRANE DESCRIPTION

3.

OPERATION

3.1 SAFETY REGULATIONS 3.2 CRANE OPERATION

4.

MAINTENANCE

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

5.

SPECIFICATION OF THE ELECTRICAL EQUIPMENT FOR A SINGLE DECK CRANE

6.

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

7.

REFACE 3165-3168

ASSEMBLY INSTRUCTION

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1.

PREFACE INDEX 1.

PREFACE

2

1.1

PREFACE

3

1.2

SAFETY REGULATIONS – GENERAL REMARKS

4

1.3 1.3.1 1.3.2 1.3.3 1.3.4

EXPLANATION OF SAFETY SIGNS PROHIBITION SIGNS WARNING SIGNS MANDATORY SIGNS RESCUE SIGNS

5 5 5 6 7

1.4 1.4.1 1.4.2 1.4.3 1.4.4

SAFETY DEVICES – GENERAL REMARKS BRAKES LIGHTING LIMIT SWITCHES SAFETY DEVICES

8 8 8 8 8

1.5 1.5.1 1.5.2

SAFETY REGULATIONS FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS OPERATING INSTRUCTION FOR EMERGENCY EXIT WITH ESCAPE DEVICE

9 9

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11

TTS-LMG Marine Cranes GmbH 7/3165-7/3168 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:

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: [email protected] Internet: www.tts-marine.com Please state the crane no. and type (see data plate) with all enquiries. REFACE 3165-3168

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1.2

SAFETY REGULATIONS – GENERAL REMARKS

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

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1.3

EXPLANATION OF SAFETY SIGNS

1.3.1

PROHIBITION SIGNS

Fire, exposed flame and smoking prohibited

Do not operate switch

No entrance for unauthorized personal

Prohibited for persons with pacemaker

1.3.2

WARNING SIGNS

Warning of hanging load

Warning of electro – magnetic field

Warning of high voltage

Danger of falling

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Warning of danger through batteries

1.3.3

Danger of slipping

Danger through hot surface

Wear eye protection

Wear safety gloves

Wear safety protection

Wear safety helmet

Wear safety boots

Wear ear protection

MANDATORY SIGNS

Follow information on the Component, in the instructions for use and instructions for operating the vehicle REFACE 3165-3168

Switch off power supply

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Use safety devices

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1.3.4

RESCUE SIGNS

First aid

Fire extinguisher

Doctor

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1.4

SAFETY DEVICES – GENERAL REMARKS

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

1.4.1

BRAKES

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

1.4.2

LIGHTING

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

1.4.3

LIMIT SWITCHES

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

1.4.4

SAFETY DEVICES

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

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1.5

SAFETY REGULATIONS

1.5.1

FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS

In the event of fire, immediately set off the fire alarm and switch off the whole electrical system. A portable fire extinguisher is provided in the driver's cabin (5 kg ABC powder) extinguisher. ATTENTION Observe the official fire prevention regulations. Have portable fire extinguishers checked and serviced at regular intervals to ensure that they are always ready for instant use! Portable fire extinguishers :

dry powder extinguishers

Extinguishing agent :

5 kg carbon dioxide

Duration :

9 seconds, so keep calm and use the

extinguisher with

forethought.

The extinguishing effect is achieved by dilution, thinning, isolation or reduction of the oxygen concentration. The jet of dry powder can dislodge light substances such as hot or glowing ash, and may therefore cause the fire to spread. SUITABLE FOR FIRE CLASSES A, B AND C Solids: e.g. wood, paper, coal Liquids:e.g. petrol, benzene, oils, greases, paints, tar Gases: e.g. methane, acetylene PROCEDURE IN CASES OF FIRE: Report fire

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

Move to safety

Warn endangered persons. Remove the injured and helpless. Close doors.

Fight the fire

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

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FIRE EXTINGUISHING SYSTEM/FIRE EXTINGUISHERS RULE NO. 1 IN FIREFIGHTING IS: SAVING HUMAN LIFE IS MORE IMPORTANT THAN FIGHTING THE FIRE. HOWEVER VALUABLE THEY ARE, OBJECTS CAN BE REPLACED. CORRECT USE OF FIRE EXTINGUISHERS:

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1.5.2

OPERATING INSTRUCTION FOR EMERGENCY EXIT WITH ESCAPE DEVICE

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

REMOVE LEVER BRAKE OUT OF THE BAG Fix carabine hook at lever brake onto the lug of the secured belt. Remove lever brake from of the bag and fix carabine hook at lever brake onto the lug of the secured belt.

GRATING TO BE HINGED UP FORWARD AND BOTTOM WINDOW TO BE OPENED. The free end is to be thrown out of the bag via the opening. When actuating the hand, the rope-down procedure via the bottom Window will be started. The device remains in suspended condition when loaded by a person. Only by pressing the hand lever into direction of the device, the rope-down procedure will be started. The rope-down speed will be regulated via the hand lever. When releasing the hand lever, the rope-down procedure is interrupted directly. When pressing hand lever fully down, the rope-down procedure can also be interrupted (decelerated) until standstill. Replace rope after 4-5 years

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TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 DESCRIPTION

2.

DESCRIPTION INDEX 2.

DESCRIPTION

1

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8

GENERAL CRANE TOWER CRANE CABIN JIB SLEW ASSEMBLY HYDRAULIC SYSTEM HOISTING AND LUFFING GEARS SLEWING GEAR ELECTRICAL EQUIPMENT

2 2 2 2 2 2 2 2 2

2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12 2.2.13

TECHNICAL DATA OPERATING CONDITIONS FOR DECK CRANES CRANE LAYOUT – MAIN DIMENSIONS LOAD LIMITATION DEPENDING ON OUTREACH PRINCIPAL DATA GENERAL ARRANGEMENT DRAWING POWER SUPPLY ELECTRIC MOTORS SPLITTER GEARBOX SLEWING RING SLEWING GEAR REDUCER WINCHES ROPES WEIGHTS

DESCRIPTION 3165 - 3168

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3 3 4 5 6 6 7 7 7 7 7 8 8 10

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TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 DESCRIPTION

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 ropedown 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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DESCRIPTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 DESCRIPTION

2.2

TECHNICAL DATA

2.2.1

OPERATING CONDITIONS FOR DECK CRANES Crane Type:

Deck crane for general cargo and container operation at SWL 30T

Rating according to FEM CLASSIFICATION AND LOADING ON STRUCTURES AND MECHANISMS KL 30t - 25m , TTS YARD-NO.: 7/3129 – 7/3148 Calculation of carrying steel structure in accordance with FEM and Classification Society hook operation 30t

grab operation 25t

The Crane as a whole Appliance group Load spectrum class Utilisation class Number of loading cycles during lifetime

A4 Q2 U4 max.250.000

A4 Q2 U4 max.250.000

Calculation of drive in accordance with FEM HOISTING GEAR Mechanism group Class of load spectrum Class of utilization

M5 L2 T5

M5 L2 T5

M5 L2 T5

M5 L2 T5

M5 L2 T5

M5 L2 T5

LUFFING GEAR

Mechanism group Class of load spectrum Class of utilization SLEWING GEAR Mechanism group Class of load spectrum Class of utilization

Standard operation Cranes which hoist the safe working load farly frequently and, normally, loads Between 1/3 and 2/3 of the safe working load Corresponds to an average running time of 2 to 3 hours per day related to one year

DESCRIPTION 3165 - 3168

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2.2.2

2-4

CRANE LAYOUT – MAIN DIMENSIONS

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DESCRIPTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 DESCRIPTION

2.2.3

LOAD LIMITATION DEPENDING ON OUTREACH

The crane has different load ranges (SWL). The maximum outreach is 28 m, it is limited by the luffing gear limit switch. At an outreach of 3,8 – 28 m, loads of up to 30 t by Hook operation can be lifted. If loads are heavier than that, the hoisting gear only will be blocked in the direction "lifting". At an outreach of 3,8 – 28 m, loads of up to 25 t by Grab operation can be lifted. If loads are heavier than that, the hoisting gear only will be blocked in the direction "lifting". If heavier loads are taken up in these limited ranges, the hoisting gear is blocked in the direction "lifting", and the luffing gear in the directions "luffing in" and "luffing out". The load can only be lowered.

DESCRIPTION 3165 - 3168

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2.2.4

PRINCIPAL DATA

Crane type

KL 30t-28m

Type of drive Ambient temperature Lifting capacity

electro – hydraulic -20ºC to +45ºC 30 t – 28 m Hook opeartion 25 t – 28 m Grab operation 3,8 m 34,0 m 1,27 rpm full load 22,0 m/min Load 6t 44,0 m/min no load 45,0 m/min 57,3 sec 5º 2º

Min. outreach Max. lifting height Slewing speed * Hoisting speed * Luffing time * from max. in min. outreach Heeling angle Trim * all movements simultaneously

2.2.5

2-6

GENERAL ARRANGEMENT DRAWING

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DESCRIPTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 DESCRIPTION

2.2.6

POWER SUPPLY

Ship's mains voltage Lighting and heating Nominal rating of motor Short-time load 10* duty cycle Momentary peak 2 - 3 sec. Reverse curr. full load lowering and luffing

2.2.7

440 V/ 60 Hz 220 V/ 60Hz 160 kW 380 kVA 430 kVA 100 kW

ELECTRIC MOTORS

SPLITTER GEARBOX 3-phase A.C. squirrel cage motor Rated voltage Rated output Speed Enclosure Structural shape

440 V,60 Hz 160 kW, S1 1785 min-1 IP 55 V3(IEC34-7)

3-PTC-resistors for switching-off Anti-condensation heating

230 V

2.2.8

SPLITTER GEARBOX

Power of el. motor Drive speed Max. output Output speed Transmission

2.2.9

SLEWING RING

Slew bearing Number of teeth Module

2.2.10

160 kW 1785min-1 1x174kW (hoisting) 1x187 kW (luffing) 1x172 kW (slewing) 2746 min-1 i = 0,65

171 16

SLEWING GEAR REDUCER

Mounting position pinion Output speed Transmission Lantern shaft length P.T.O pinion module P.T.O. pinion no. of teeth P.T.O. pinion width Hydraulic motor type

DESCRIPTION 3165 - 3168

bottom 22,0 rpm 125 short 16 10 136 mm A2FM 56/61 W - PAB02

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2.2.11

WINCHES

HOISTING GEAR Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically, slack rope limit switch Transmission i = 83,4 Drum dia. to centre of rope 630 mm Length of drum 892 mm Rope dia. 30 mm Rope lay 34 mm Direction of rope lay r.h. DIN15061 Rope speed 44 / 88 m/min Hydraulic motor A6VM200EP2D/63 VAB 02 B LUFFING GEAR Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically Transmission i = 108,1 Drum dia. to centre of rope 630 mm Length of drum 892 mm Rope dia. 30 mm Rope lay 34 mm Direction of rope lay r.h. DIN15061 Rope speed 52 m/min Hydraulic motor A2FM125 W6.1A2

2.2.12

ROPES

HOISTING ROPE Rope diameter (mm) Rope length (m) Wire breaking strength (N/mm²) Operation force (kN) Min. breaking strength (kN) Rope design Thimble

30 262 1960 169,2 778,3 Olivera NR15K PPI Left hand regular lay DIN 3091-36GTW

LUFFING ROPE Rope diameter (mm) Rope length (m) Wire breaking strength (N/mm²) Operation force (kN) Min. breaking strength (kN) Rope design Thimble

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30 209 1770 148,3 682,2 Olivera SC8 PPI Left hand regular lay DIN 3091-36GTW

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DESCRIPTION 3165 - 3168

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DESCRIPTION 3165 - 3168

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2.2.13

WEIGHTS

Slewing tower compl Jib compl. Hoisting rope Luffing rope Tackle block Crane compl. approx.

2-10

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23 100 11 810 1 190 843 1 000 37 943

kg kg kg kg kg kg

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DESCRIPTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 OPERATION INSTRUCTION

3.

OPERATION INSTRUCTION INDEX 3.

OPERATION INSTRUCTION

1

3.1 3.1.1 3.1.2 3.1.3

PREPARATORY WORKS OPERATIONAL INSTRUCTIONS AND SAFETY REGULATIONS SETTING OF GRAB/HOOK OPERATION MONITORING DEVICES

2 2 3 4

3.2 3.2.1 3.2.2 3.2.3

GENERAL OPERATION MANUAL CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS CONTROL LEVER (JOY STICKS) INTERACTIVE DIALOGUE SYSTEM ( DISPLAY )

5 5 9 12

3.3 3.3.1 3.3.2 3.3.3 3.3.3.1 3.3.4

CRANE OPERATION SAFETY REGULATIONS SETTING OF GRAB/HOOK OPERATION PUTTING INTO OPERATION TANDEM OPERATION MODE OF DECK CRANES CLOSING DOWN

14 14 15 16 22 23

OPERATION INSTRUTION 3165 - 3168

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3.1

PREPARATORY WORKS

3.1.1

OPERATIONAL INSTRUCTIONS AND SAFETY REGULATIONS

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

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

♦

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

♦

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

♦

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

♦

none of the safety devices are in override status.

♦

All drives must be switched off before the crane driver leaves the cabin (turn switch 26 into “OFF” - position) !

The crane driver must not leave the crane during operation without first handing over control to a suitable authorized relief driver. This must be done while there is no load suspended from the hook. The relief of a crane driver is to be entered in the crane record book as a special incident. lf a driver is on the crane, other persons may enter and leave the crane only with the agreement of the crane driver and while the crane is stationary. The specified safe working load of the crane shall on no account be exceeded. Safety devices must not be rendered inoperable or tampered with. The crane must be put out of operation immediately if brakes or limit switches fail. ATTENTION The instruction contained in the descriptions of the electrical and hydraulic plants are an integral part of the operation manual and must be strictly observed. A warning signal must be given with the horn in the driver´s cabin before the crane is to start so that danger zone ( e.g. area of work / slewing range ) can leave the area in good time.

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OPERATION INSTRUCTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 OPERATION INSTRUCTION

3.1.2

SETTING OF GRAB/HOOK OPERATION

For a change from grab to hook operation please see sketches below: Sketch 1 : Hook Block for Hook operation Sketch 2 : Hook Block with wire ring and chain lug of the grab Sketch 1

Sketch 2

Grab operation will be selected by KEY-SWITCH 31. During grab operation the maximum load is limited from 30 tons down to 25 tons.

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3.1.3

MONITORING DEVICES

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

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

The monitoring devices must be checked regularly to ensure that they work properly and are in perfect con-dition. Defective parts must be replaced immediately by spare parts from the original manufacturer. Monitoring devices may be removed, replaced or overridden only by authorised persons under appropriate supervision when the crane is not in operation and after all necessary safety precautions have been taken. The satisfactory operation of the monitoring devices concerned must be checked after the original state has been restored. All monitoring devices such as limit switches, overload trips, pressure switches, etc., must be checked at regular intervals to ensure that they are in good working order. When checking equipment, make sure that all monitoring devices, especially safety switches and their actuators, are firmly seated. All monitoring devices must be rechecked after repairs or prolonged periods of idleness. All monitoring devices should be checked after the crane or part of it has been cleaned. This should be done regardless of the interval that has elapsed since the last check. The checks must consist of an inspection and a function check.

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3.2

GENERAL OPERATION MANUAL

3.2.1

CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS

CONTROL DESK LEFT

CONTROL DESK RIGHT

CONTROL DESK LEFT HAND

CONTROL DESK RIGHT HAND

1 Control lever

Slewing gear / Luffing gear

10 Selector switch

Windscreen wiper

11 Selector switch

Cabin heater

20 Emerg.-off button

Emergency off

12 Selector switch

Decks light

26 illuminated switch

Start / Stop

13 Selector switch

Warning light red

14 Selector switch

Working light

28 Indication lamp ( red ) Fault

15 Selector switch

Cabin light

30 Key operated button

Jib resting

31 Key operated switch

Grab operation

Bp Blind cap for additional Installation

2 Control lever

Hoisting gear Grab open / close

Ready for operation

Bp Blind cap for additional Installation

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AIR SUPPLY Make sure that air is supplied through crane column. The bottom access door or the hatch must be opened to allow air to get in. THE AIR OUTLET OF THE OIL COOLER FAN IS COVERED´ BY A FLAP. THIS FLAP MUST BE OPENED BEFORE THE CRANE WILL BE STARTED.

Cabin door and hatch to winch platform must be closed during peration.

CRANE - WORKING LIGHT Switch on crane light.

CONTROL LEVERS Before starting the drivers the control levers must be in upright position (zero position). The control lever in the left-hand desk controls luffing of the jib and slewing of the crane. The control lever in the right-hand desk controls the hoisting gear.

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OPERATION INSTRUCTION 3165 - 3168

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STARTING Turn switch 26 into „ON“ – position, the electric drive motors will start up. After abt. 15 secs, crane is ready for operation. Readiness for operation is indicated by signal lamp inside the switch 26 and also on the display

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

STOP Switch off drive motors by turning switch 26 into „OFF“ - position If the temperature sensor has switched on the cooling plant, booster pump, hydraulic oil cooler and engine room ventilator keep on running until the oil temperature has dropped down to below 50*C.The drives are shut off after 10 mins at the latest.

EMERGENCY-OFF push-button ^

The crane must be switched off with the EMERGENCY-OFF button 20 in case of an emergency or a dangerous situation, e.g. if the crane drives do not follow the commands of the crane's control levers. The EMERGENCY-OFF button must never be used for switching the crane off when it is operating normally.

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FAULT – Indication signal lamp Signal lamp 28 is a collective alarm which lights up if one part of the system is defective, or if a function is disturbed. The reason of this fault is indicated on the DISPLAY.

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3.2.2

CONTROL LEVER (JOY STICKS) LUFFING IN AND OUT OF THE JIB Push control lever in l.h. control desk either forward or backward. The speed is infinitely variable. The drive speed is adapted using a ramp time function. SLEWING TO LEFT AND RIGHT Push control lever in l.h. control desk toward l.h. or r.h. side. The speed is infinitely variable. The drive speed is adapted using a ramp time function. LIFTING AND LOWERING OF LOAD Push control lever in r.h. control desk either forward or backward. The speed is infinitely variable. The drive speed is adapted using a ramp time function. If loads are small or if there is no load on the hook at all and the Control lever is pushed right backward or forward, the hoisting speed is automatically accelerated to maximum. In order to stop acceleration or deceleration of the hoisting speed, the excursion of the control lever must be reduced.

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

CONTROL LEVER IN THE LEFT-HAND DESK: Excursion angle to the left = slewing to the left Excursion angle to the right = slewing to the right Wide excursion angle = quick movement Narrow excursion angle = slow movement

OPERATION INSTRUTION 3165 - 3168

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LUFFING IN AND OUT LUFFING IN AND OUT OF THE JIB Push control lever in l.h. control desk either forward or backward. The speed is infinitely variable. The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK: Excursion angle forward = jib lowering Excursion angle to the back = jib lifting Wide excursion angle = quick movement Narrow excursion angle = slow movement

JIB STOPPED AUTOMATICALLY

LIFTING OR LOWERING STOPPED AUTOMATICALLY. The end positions have been reached and cannot be overrun. The limit position will be indicated on the DISPLAY.

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

CONTROL LEVER IN THE RIGHT-HAND DESK: Excursion angle forward = crane hook down Excursion angle to the back = crane hook up Wide excursion angle = quick movement Narrow excursion angle = slow movement

CRANE HOOK STOPPED AUTOMATICALLY

CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY. The end positions have been reached and cannot be overrun. The limit position will be indicated on the display.

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3.2.3

INTERACTIVE DIALOGUE SYSTEM ( DISPLAY )

A display is installed in the r.h. control desk, it is an interactive system divided in 2 menue areas. Menue area 1 is for crane informations only, the information area will be automatically displayed

• • • • •

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

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

OPERATION SELECTED MENUE • • •

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Actual Load Additional safety working load Additional outreach

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

CONDITION • •

CONDITION code and text announcement Detailled informations are given in the 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 • • •

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parameter setting activation of special conditions emergency opreation system

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3.3

CRANE OPERATION

3.3.1

SAFETY REGULATIONS

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

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

♦

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

♦

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

♦

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

♦

none of the safety devices are in override status.

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

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3.3.2

SETTING OF GRAB/HOOK OPERATION

For a change from grab to hook operation please see sketches below: Sketch 1 : Hook Block for Hook operation Sketch 2 : Hook Block with wire ring and chain lug of the grab Sketch 1

Sketch 2

Grab operation will be selected by KEY-SWITCH 31. During grab operation the maximum load is limited from 30 tons down to 25 tons.

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3.3.3

PUTTING INTO OPERATION

SWITCH ON SUPPLY FROM SHIP’S MAINS. Switch on crane control (power supply) with the main switch on the electrical control cabinet. AIR SUPPLY Make sure that air is supplied through crane column. The bottom access door or the hatch must be opened to allow air to get in. THE AIR OUTLET OF THE OIL COOLER FAN IS COVERED´ BY A FLAP. THIS FLAP MUST BE OPENED BEFORE THE CRANE WILL BE STARTED.

Cabin door and hatch to winch platform must be closed during operation.

CRANE - WORKING LIGHT Switch on crane light.

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

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OPERATION INSTRUCTION 3165 - 3168

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STARTING Turn switch 26 into „ON“ – position, the electric drive motors will start up. After abt. 15 secs, crane is ready for operation. Readiness for operation is indicated by signal lamp inside the switch 26 and also on the display Do not move the control lever out of zero position before < READY FOR OPERATION > is displayed. If the crane drives have been stopped by an emergency condition, the start switch must be turned into OFF first before the drives can be started.

EMERGENCY-OFF push-button ^

The crane must be switched off with the EMERGENCY-OFF button 20 in case of an emergency or a dangerous situation, e.g. if the crane drives do not follow the commands of the crane's control levers. The EMERGENCY-OFF button must never be used for switching the crane off when it is operating normally.

OPERATION INSTRUTION 3165 - 3168

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

CONTROL LEVER IN THE LEFT-HAND DESK: Excursion angle to the left = slewing to the left Excursion angle to the right = slewing to the right Wide excursion angle = quick movement Narrow excursion angle = slow movement

LUFFING IN AND OUT LUFFING IN AND OUT OF THE JIB Push control lever in l.h. control desk either forward or backward. The speed is infinitely variable. The drive speed is adapted using a ramp time function.

CONTROL LEVER IN THE LEFT-HAND DESK: Excursion angle forward = jib lowering Excursion angle to the back = jib lifting Wide excursion angle = quick movement Narrow excursion angle = slow movement

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JIB STOPPED AUTOMATICALLY

LIFTING OR LOWERING STOPPED AUTOMATICALLY. The end positions have been reached and cannot be overrun. The limit position will be indicated on the DISPLAY.

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

CONTROL LEVER IN THE RIGHT-HAND DESK: Excursion angle forward = crane hook down Excursion angle to the back = crane hook up Wide excursion angle = quick movement Narrow excursion angle = slow movement

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CRANE HOOK STOPPED AUTOMATICALLY CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY. The end positions have been reached and cannot be overrun. ATTENTION If outreaches are small, care must be taken to work with utmost caution in order to avoid damage to the cra-ne tower and in particular to the cabin. The working movements of the lifting and luffing gears are limited by Limit switches. Before reaching a limit position, all speeds are reduced automatically. The limit position will be indicated on the DISPLAY NOTE WORKING MOVEMENT LIMIT SWITCHES ARE SAFETY DEVICES AND SHOULD NOT BE ACTUATED IN NORMAL OPERATION. ATTENTION THE INSTRUCTIONS CONTAINED IN THE DESCRIPTIONS OF THE ELECTRICAL AND HYDRAULIC PLANTS ARE AN INTEGRAL PART OF THE OPERATION MANUAL AND MUST BE STRICTLY OBSERVED. GRAB OPERATION With the key-operated switch in the r.h. control desk the crane operation can be selected between hook operation and grab operation. In grab operation the maximum load capacity will be limited up to 25 tons. The grab can be closed / opened by means of the hoisting gear control lever: ♦ Push the control lever into direction left for grab closing. ♦ Push the control lever into direction right and additionally press the button on the control lever handle for grab opening. OVERLOAD INDICATION If the maximum lifting capacity ( SWL ) of the crane is exceeded, the lifting and luffing-out procedure is blocked, this will be indicated on the DISPLAY.

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OPERATION INSTRUCTION 3165 - 3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 OPERATION INSTRUCTION

FAULT - INDICATION SIGNAL LAMP (SIGNAL LAMP 28)

Signal lamp 28 is a collective alarm which lights up if one part of the system is defective, or if a function is disturbed. Please refer to the numbers on the inside of the control cabinet door to find out the cause for the alarm, then refer to description of electrical equipment and list given there for details. The reason of this fault is indicated on the DISPLAY. ATTENTION The instructions contained in the descriptions of the electrical and hydraulic plants are an integral part of the operation manual and must be strictly observed.

STOP Switch off drive motors by turning switch 26 into „OFF“ - position If the temperature sensor has switched on the cooling plant, booster pump, hydraulic oil cooler and engine room ventilator keep on running until the oil temperature has dropped down to below 50*C.The drives are shut off after 10 mins at the latest.

♦ ♦ ♦ ♦

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

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

OPERATION INSTRUTION 3165 - 3168

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3.3.3.1

TANDEM OPERATION MODE OF DECK CRANES

Prior to lifting a load with two (or more) cranes, the signal person and the crane drivers have to agree upon signals and all operational steps. It is the signal person´s task to survey all operation. During operation, the crane drivers strictly have to adher to the instructions of the signal person who has to observe the load permanently.

The heavy-load-cross beam (item 1) is designed according to its specific operational conditions (such as load capacity, arrangement of hooks, length of cross beam) and minimizes the total lifting capacity of the cranes for tandem operation by its own weight. The heavy-load-cross beam must always be kept in horizontal position ! In any case, the hoisting wire ropes must be operated vertically only (no slanting pull !)

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3.3.4

CLOSING DOWN

(SEE “CRANE OPERATION“ FOR SAFETY REGULATIONS) ALL FUNTIONS AND SWITCHES ARE DESCRIBED IN CHAPTER “PUTTING INTO OPERATION“..

STARTING Turn switch 26 into „ON“ – position, the electric drive motors will start up. After abt. 15 secs, crane is ready for operation. Readiness for operation is indicated by signal lamp inside the switch 26 and also on the display

♦

Bring crane into sea voyage position - luff-down jib ( bridge limit switch with key-operated button 30 )

♦

Crane hook must be empty.

ATTENTION : BRIDGING-OVER WITH KEY-OPERATED SWITCH 30 PUTS LIMIT SWITCHES FOR LIMITATION OF HOISTING AND LUFFING MOVEMENTS OUT-OF-ACTION. THE CRANE MUST BE OPERATED WITH THE UTMOST CARE. THE JIB MUST NEVER BE LUFFED DOWN FURTHER THAN SPECIFIED IN THE TECHNICAL DATA (GENERAL ARRANGEMENT DRAWING), AS THIS MAY DAMAGE THE JIB OR REEL THE LUFFING ROPE COMPLETELY OFF THE DRUM. ♦

Lash crane hook.

♦

Pull ropes to tighten them slightly.

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STOP Switch off drive motors by turning switch 26 into „OFF“ - position If the temperature sensor has switched on the cooling plant, booster pump, hydraulic oil cooler and engine room ventilator keep on running until the oil temperature has dropped down to below 50*C.The drives are shut off after 10 mins at the latest.

♦

Close cabin window.

♦

Switch off cabine fan, working light and cabin light.

♦

Switch off crane control ( voltage supply ) with main switch in control cabinet.

♦

When leaving crane, lock doors and hatches properly.

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

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TTS-LMG Marine Cranes GmbH 7/3165-7/3168 MAINTENANCE

4.

MAINTENANCE INDEX 4.

MAINTENANCE

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12 4.1.13 4.1.14 4.1.15 4.1.16 4.1.17 4.1.17.1 4.1.17.1.1 4.1.17.1.2 4.1.17.1.3 4.1.17.2 4.1.17.2.1 4.1.17.2.2 4.1.17.2.3 4.1.17.3 4.1.17.4 4.1.17.4.1 4.1.17.4.2 4.1.17.4.3 4.1.17.4.4 4.1.17.4.5 4.1.17.5 4.1.17.5.1 4.1.17.5.2 4.1.17.5.3 4.1.17.6 4.1.17.7 4.1.18 4.1.18.1 4.1.18.1.1 4.1.18.1.2 4.1.18.2 4.1.18.2.1 4.1.18.3 4.1.18.3.1 4.1.18.3.2 4.1.18.3.3 4.1.18.3.4 4.1.18.4 4.1.18.4.1 4.1.18.4.2

GENERAL REMARKS CHECKING OIL LEVELS, OIL CHANGES VISIBLE OIL LOSSES OILS, GREASES AND HYDRAULIC OILS FILTERS SEALS AND GASKETS SEALING SURFACES THREADED PIPE CONNECTORS; HOSES GREASE LUBRICATION GREASING MARKING OF PARTS REPLACEMENT UNITS AFTER MAINTENANCE WORK INSPECTION OF THE HOOK ROPE - HOISTING AND LUFFING ROPES ROPE - INSPECTION MULTI-DISK BRAKES / MOTOR SHAFT DOG SLEWING GEAR GENERAL INFORMATION MANUAL AIM INFORMATION ON SAFETY PRODUCT IDENTIFICATION NOTES DELIVERY CONDITIONS TRANSPORT STORAGE LIFTING AND HANDLING INSTALLATION HYDRAULIC MOTOR INSTALLATION INSTALLATION OF THE SLEW DRIVE ON THE MACHINE CONNECTION OF THE BRAKE CONNECTIN OF THE DRAINING PORT REPLACING OF THE BREATHER VALVE AS LOOSE PART LUBRICATION GEARBOX LUBRICATION OIL FILLING OIL DRAINING AND REPLACEMENT START UP AND RUNNING IN MAINTENANCE HOISTING AND LUFFING GEAR WINCH DRIVE – 7C SERIES MANUAL AIM INFORMATION ON SAFETY PRODUCT IDENTIFICATION PRODUCT DESCRIPTION NOTES DELIVERY CONDITIONS TRANSPORT STORAGE LIFTING AND HANDLING INSTALLATION DIRECTION OF ROTATION CONSTRUKTION OF THE DRUM FRAME

MAINTENANCE 3165-316

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1

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3 4 4 4 4 4 4 4 4 5 5 5 5 5 6 8 9 10 11 11 11 12 13 13 13 14 15 16 16 17 18 19 19 20 20 21 21 22 23 24 25 25 26 27 28 29 29 29 30 30 31 31 32

TTS-LMG Marine Cranes GmbH 7/315-7/3168 MAINTENANCE

4-2

4.1.18.4.3 4.1.18.4.4 4.1.18.4.5 4.1.18.5 4.1.18.5.1 4.1.18.5.2 4.1.18.5.3 4.1.18.6 4.1.18.7 4.1.18.7.1 4.1.19 4.1.20

HYDRAULIC MOTOR INSTALLATION INSTALLATION OF THE GEARBOX ON THE WINCH CONNECTION OF THE BRAKE LUBRICATION GEARBOX LUBRICATION OIL FILLING OIL DRAINING AND REPLACEMENT START UP AND RUNNING IN MAINTENANCE TROUBLE SHOOTINGS GREASING POINTS – CRANE OIL CHANGE

33 36 37 38 38 39 40 41 42 43 46 47

4.2

MAINTENANCE SCHEDULE

48

4.3

LUBRICANTS

50

4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5

ELECTRICAL EQUIPMENT SAFETY DEVICES LIGHTING MOTORS SLIPRING BODIES CIRCUIT BREAKERS

51 51 52 52 52 52

4.5 4.5.1 4.5.1.1 4.5.1.2 4.5.1.3 4.5.1.4 4.5.1.5 4.5.1.6 4.5.1.7 4.5.1.8 4.5.2 4.5.2.1 4.5.2.2 4.5.2.3

54 57 57 59 59 60 63 63 63 64 66 68 69

4.5.2.3.1 4.5.2.3.2 4.5.2.3.3 4.5.2.3.4 4.5.2.4 4.5.2.5

HYDRAULIC EQUIPMENT FUNCTIONAL DESCRIPTION HOISTING GEAR CIRCUIT 1.0 LUFFING GEAR CIRCUIT 2.0 SLEWING GEAR CIRCUIT 3.0 BOOSTING AND CONTROL OIL CIRCUIT 4.0 OIL COOLING 5.0 HYDRAULIC OIL TANK 6.0 FILLING 7.0 EMERGENCY OPERATION 8.0 GENERAL REMARKS PUTTING SYSTEMS INTO OPERATION (BY WORKS PERSONNEL) INSPECTION AND MAINTENANCE OPERATION AND MAINTENANCE OF HYDRAULIC PUMPS AND MOTORS GENERAL REMARKS INSTALLATION FIRST START ROUTINE MAINTENANCE TROUBLESHOOTING TROUBLESHOOTING

4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5

ASSEMBLY AND DISMANTLING GENERAL REMARKS ROPE REPLACEMENT HAND SIGNALS FOR CRANES TIGHTENING TORQUES FOR HEXAGON BOLTS AND SPANNER BOLTS INSTALLATION OF HOSES

79 79 82 85 86 87

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72 72 72 72 73 73 74

MAINTENANCE 3165-3168

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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 operation 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 lubricated 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 prevent 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. Locate 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 replacements 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 permitted. All filters are carefully matched to the equipment they serve. Only the use of original parts from TTSLMG 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 damage 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 oilcontaminated 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 inspected 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. The hook of a crane or the prong of a fork-lift truck might damage the rope.

Ropes should be stored in a clean, cool and dry place. They must be kept clear of the floor. Ropes stored outside must be protected against rain.

UNCOILING

UNREELING

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

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Unreel wire rope by using an unreeling stand.

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AVOIDING KINKS

Never unwind wire ropes without rotating the coil or reel, otherwise the rope will tend to form loops during installation or in service. When pulled taut, the loops form kinks.

COILING

The rope should travel from the top of the reel to the top of the drum or from the bottom of the reel to the bottom of the drum. A reverse bend will create problems.

INSTALLATION

Ropes should be installed under tension.

BREAKING IN

The first operations with a new rope should be carried out with low loads.

INSPECTION IN SERVICE

Inspect steel wire ropes regularly. Keep record of the rope diameter, the lay length, broken wires or other defects. Discard the rope in time (while it is still safe).

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LUBRICATION

Lubrication helps prevent corrosion and reduces friction. Steel wire ropes 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 abrasive wear

Wire rope with contraction

Wire rope with knot

Wire rope with kink

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4.1.16

MULTI-DISK BRAKES / MOTOR SHAFT DOG 1 Brake piston 2 Brake cylinder 3 Disk carrier 4 Internal disks 5 External disks 6 Sealing ring 7 Sealing ring The brakes on the hoisting, luffing and slewing gears are multi-disk brakes which are lifted hydraulically and applied by spring tension. The hydraulic systems of these brakes ensure that they are not applied until the drive speed has dropped to zero. The brakes are not intended to dissipate energy , but only to apply a holding torque. The disks are not subject to wear under these conditions.However, they are applied instantly in the event of power failures or if an emergency OFF button is pressed, without having to ramp the drive speed down to zero beforehand. Under these circumstances they dissipate energy and are subject to considerable wear. The brakes must be checked after only a few such braking operations. The brakes are designed to run "dry". Nevertheless, small amounts of oil seep past the sealing ring (6) and enter the disk space. In the case of slewing gears, the see page oil must be drained off every three months.

The following procedure should be used to check the holding torque of the brakes: ♦

Luff the jib to its minimum outreach.

♦

Take any load off the hook - hook must be empty.

♦

Check the slewing gear at a heel of 5° with the jib parallel to the ship´s centreline.

♦

Pull the plug of the brake valve out to prevent the brake from lifting.

Activate the drives for about 5 sec. The maximum pressure corresponding to the maximum torque must be built up within this time. The winches (or the slewing gear of the crane) must not move ! The holding torque should be checked every three month. Operation must be stopped after power failures and emergency OFF actuation until brake torque has been checked. After repair, fill the spring pressure actuated multi-disc brake of the slewing,hoisting and Luffing gear with oil (AUTOMATIC TRANSMISSION FLUID) (cf. chapter 4.1.17 and 4.1.18). The brakes must be overhauled annually. The disk packs must be replaced if wear is excessive. Sealing rings 6 and 7 should be replaced if leaks become apparent (e.g. excessive seepage oil is found). When checking the brakes the spline profiles of motor and gear reducer should be checked for wear at the same time. If the dog/motor is replaced or refitted, a suitable grease should be applied to prevent fretting corrosion. We recommend to use Gleitmo 805 or similar.

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4.1.17

SLEWING GEAR

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

THE BRAKE MUST BE FILLED WITH APPROX. 0,2ltrs GEAR OIL ATF A PRIOR TO MOUNTING THE MOTOR

1 2 3 4

Oil filling and breather valve (setting 0,35bar) Oil level plug Oil draining plug Brake port

OIL CHANGE First oil change after 200 crane operating hours. After every 1000 hours, oil should be changed again, but at least once a year. OIL CHANGE : See instruction of manufacturers OIL TYPE Gear oil CLP 220 (see lubrication chart section 4.3) OIL QUANTITY 2 gearboxes with abt. 12 l each – in total 24 l. The hydraulically lifted disc brake has to be filled with 1 ltr. oil when fitting the engine. Suitable are above all hydraulic oil scustomary in commerce relatively to friction, coking of the oil, foam formation, a.s.o. Oil type (multi-disk brake): See instruction of manufacturers

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4.1.17.1 4.1.17.1.1

GENERAL INFORMATION MANUAL AIM

This manual has been devised by the manufacturer to give necessary information to those authorised to work on this product for example the design engineers, installers, repair and maintenance technicians. Besides helping one understand the rules of good manufacturing techniques used, the information given must be read attentively and strictly put into action. Failure to observe this information may lead to health and safety risks to persons as well as economic loss. INFORMATION! A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE. Photographic documentation and drawings are supplied for educational purposes, so as to safely and properly carry out maintenance operations. Minor deviations from pictures of this manual may appear on the actual gearbox. However, these discrepancies are not relevant to the main parameters, or maintenance functions.

4.1.17.1.2

INFORMATION ON SAFETY

Carefully read the instructions given in this instruction manual as well as the ones attached to the product and make sure to follow the information concerning safety. Personnel, which perform any type of work on the product during its life span, must possess precise technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do so may lead to health and safety risks to persons. It is recommended that when handling the product attention is paid to the information given in this manual or simply follow the instructions given on the packaging (if present). Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee given by the manufacturer. Keep the product in perfect working order by following the scheduled maintenance procedure set out by the manufacturer. Good maintenance will ensure the best performances, a longer period of operation and a constant safeguard towards security requirements. To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is important to follow adequate safety conditions for one self and for others in compliance with the rules and regulations that govern safety in the workplace. When replacing worn parts, use original spare parts. Use oils and greases recommended by the manufacturer. Doing this, will ensure that the product works properly and that the safety level is "acceptable".

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4.1.17.1.3

PRODUCT IDENTIFICATION

The identification data of the unit are shown on a name plates put on it. INFORMATION! FOR ALL ENQUIRIES REGARDING GENERAL INFORMATION ON THE PRODUCT, SPARE PARTS, ASSITANCE, ALWAYS GIVE THE IDENTIFICATION DATA STAMPED ON THE ID PLATE. THE PLATE MUST BE REMOVED OR DAMAGED DURING THE LIFE OF THE PRODUCT. The following illustration shows how the data is set out

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

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4.1.17.2 4.1.17.2.1

NOTES DELIVERY CONDITIONS

Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions: Ready for installation in the mounting position specified when ordering. Factory filled with lubricanting oil at level: oil type SHELL SPIRAX A 80W-90 All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants. External surfaces are protected with an antioxidant water resistant grey color and painted with a blue synthetic finish coat (painting data are shown on the installation drawing). Machined surfaces are not painted. Tested toin-house specifications. Appropriately packaged to facilitate handling, transport and storage. INFORMATION! WHEN THE PRODUCT ARRIVES, ENSURE THAT IT MEETS THE INFORMATION CONTAINED IN THE PURCHASE AGREEMENT AND THAT THERE ARE NO DAMAGES OR IRREGULARITIES. IF THERE ARE ANY PROBLEMS CONTACT THE MANUFACTURERS' SALES NETWORK DIRECTLY.

4.1.17.2.2

TRANSPORT

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

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4.1.17.2.3

STORAGE

OBSERVE THE FOLLOWING INSTRUCTIONS TO ENSURE CORRECT STORAGE OF DELIVERED PRODUCTS: 1. 2. 3.

Do not store outdoors, in areas exposed to weather or with excessive humidity. Always place boards of wood or other material between floor and products, to avoid direct contact with the floor. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and couplingsmust be protected with a suitable anti-oxidation product (SHELL ENSIS FLUID SDC or equivalent product).

THE FOLLOWING MEASURES MUST BE TAKEN FOR PRODUCTS WHICH EXPECTED STORAGE PERIOD EXCEEDS 6 MONTHS: 4. 5.

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

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

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4.1.17.3

LIFTING AND HANDLING

If the handling occurs when the product is still packaged, simply follow the instructions given on the packaging and/or use normal hoisting means. WARNING! CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING, IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT. TO LIFT AND HANDLE THE PRODUCT, AFTER HAVING OPENED THE PACKAGING, FOLLOW THE INFORMATION GIVEN BELOW: 1. 2. 3.

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

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4.1.17.4 4.1.17.4.1

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. 2.

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. Assemble the hydraulic motor to the gearbox frame by using the screws shown in the following table

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

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4.1.17.4.2 1. 2. 3. 4.

INSTALLATION OF THE SLEW DRIVE ON THE MACHINE

Move the slew drive in the mounting area applying lifting methods shown in section 3.4. 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). 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). Fix the slew drive to the machine frame by using the screws shown in the following table

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4.1.17.4.3

CONNECTION OF THE BRAKE

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

1.

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

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4.1.17.4.4

CONNECTIN OF THE DRAINING PORT

INFORMATION! IF THE FRAME OF THE MACHINE DOES NOT ALLOW THE ACCESS TO THE PLUG, IT IS NECESSARY, DURING THE SLEW DRIVE INSTALLATION, TO FIT AN EXTENTION WHICH TAKES THE OIL AWAY FROM THE MACHINE. 1.

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

4.1.17.4.5

REPLACING OF THE BREATHER VALVE AS LOOSE PART

At the slew drive installation on the machine frame replace the plug with breather valve supplied as loose part. 1.

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

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4.1.17.5 4.1.17.5.1

LUBRICATION GEARBOX LUBRICATION

The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing. The gearbox is factory filled with lubricanting oil at level. Oil type: SHELL SPIRAX A 80W-90 (specified when ordering). Otherwise, the recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP characteristics according to: MIL-L-2105 C & API GL5. In the following table the most common brands of lubricant and the types recommended are shown. INFORMATION! DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

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4.1.17.5.2 1. 2. 3. 4.

OIL FILLING

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

APROXIMATE OIL CAPACITY LITERS ARE: 12 L ±10%

4.1.17.5.3 1. 2. 3.

OIL DRAINING AND REPLACEMENT

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. Wait a few minutes until all the oil is drained and then proceed to screw on DRAINING PLUG. Proceed with the oil fill-up following the procedures given (see Section 5.2).

WARNING! NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA. WARNING! DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

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4.1.17.6

START UP AND RUNNING IN

In this first stage it is advised to follow the measures given below: 1. 2.

Check the correctly lubrication of the unit. 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. 5. 6.

Check the correct revolution and direction of rotation. Make sure that the functioning is regular and with-out any excessive noises and vibrations. 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. 8.

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

It could happen that due to the presence of air, during the first start up, the opening action of the brake could be slowed down. It is advised to repeat the opening and closing function of the brake. Check that there are no other problems in general

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4.1.17.7

MAINTENANCE

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

INFORMATION! IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE SUGGESTIONS OF THIS MANUAL. DO NOT HESITATE TO CONTATCT THE GEARBOX DISTRIBUTOR OR MANUFACTURER IF FURTHER INSTRUCTIONS ARE NECESSARY OR IN CASE OF PARTICULAR PROBLEMS.

This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL resres 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 2 3 4

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Oil filling and breather valve (setting 0,4bar) Oil level plug Oil draining plug Brake port

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4.1.18.1

WINCH DRIVE – 7C SERIES

Installation and service manual GENERAL information

4.1.18.1.1

MANUAL AIM

This manual has been devised by the manufacturer to give necessary information to those authorised to work on this product for example the design engineers, installers, repair and maintenance technicians. Besides helping one understand the rules of good manufacturing techniques used, the information given must be read attentively and strictly put into action. Failure to observe this information may lead to health and safety risks to persons as well as economic loss.

INFORMATION! A STRICT AND CONSISTENT COMPLIANCE WITH THE SPECIFICATIONS OF THIS TECHNICAL MANUAL ENSURE THE MINIMUM OPERATING COSTS AND A LONGER UNIT LIFE. Photographic documentation and drawings are supplied for educational purposes, so as to safely and properly carry out maintenance operations. Minor deviations from pictures of this manual may appear on the actual gearbox. However, these discrepancies are not relevant to the main parameters, or maintenance functions.

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4.1.18.1.2

INFORMATION ON SAFETY

Carefully read the instructions given in this instruction manual as well as the ones attached to the product and make sure to follow the information concerning safety. Personnel, which perform any type of work on the product during its life span, must possess precise technical qualifications as well as recognised skills and experience gained in the specific sector. Failure to do so may lead to health and safety risks to persons. It is recommended that when handling the product attention is paid to the information given in this manual or simply follow the instructions given on the packaging (if present). Utilise the product only for the use specified by the manufacturer. Improper use of the product could lead to health and safety risks to persons as well as economic loss and furthermore will invalidate the guarantee given by the manufacturer. Keep the product in perfect working order by following the scheduled maintenance procedure set out by the manufacturer. Good maintenance will ensure the best performances, a longer period of operation and a constant safeguard towards security requirements. To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is important to follow adequate safety conditions for one self and for others in compliance with the rules and regulations that govern safety in the workplace. When replacing worn parts, use original spare parts. Use oils and greases recommended by the manufacturer. Doing this, will ensure that the product works properly and that the safety level is "acceptable".

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4.1.18.2

PRODUCT IDENTIFICATION

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

INFORMATION! For all enquiries regarding general information on the product, spare parts, assitance, always give the identification data stamped on the ID plate. The plate must be removed or damaged during the life of the product. The following illustration shows how the data is set out

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

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4.1.18.2.1

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PRODUCT DESCRIPTION

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4.1.18.3

NOTES

4.1.18.3.1

DELIVERY CONDITIONS

Gearboxes are supplied by BONFIGLIOLI TRASMITAL at the following standard conditions: · Ready for installation in the mounting position specified when ordering. · To guarantee their reliability, the internal parts are properly lubricated with a layer of oil, the same as the one used in the final test of the gearbox and compatible with the recommended oils (section 5.1). Lubricating oil has not been added (as shown on the card). · All unmachined parts and surfaces to be coupled are appropiately trated by antioxidants. · External surfaces are protected with an antioxidant water resistant grey color suitable for finish painting. Machined surfaces are not painted. Finish coat to be applied by the customer. · Tested to in-house specifications. · Appropriately packaged to facilitate handling, transport and storage.

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

4.1.18.3.2

TRANSPORT

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

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4.1.18.3.3

STORAGE

Observe the following instructions to ensure correct storage of delivered products: 1. Do not store outdoors, in areas exposed to weather or with excessive humidity. 2. Always place boards of wood or other material between floor and products, to avoid direct contact with the floor. 3. For storage periods of over 60 days, all machined surfaces such as flanges, shafts and couplings must be protected with a suitable anti-oxidation product (SHELL ENSIS FLUID SDC OR EQUIVALENT PRODUCT). The following measures must be taken for products which expected storage period exceeds 6 months: 4. Cover outer machined parts and mating parts with grease to avoid oxidation. 5. Fill completely the gearboxes with lubticant oil. INFORMATION! BEFORE USE, THE GEARBOXES SHOULD BE FILLED WITH THE PROPER AMOUNT OF LUBRICANT OF THE RECOMMENDED TYPE.

4.1.18.3.4

LIFTING AND HANDLING

If the handling occurs when the product is still packaged, simply follow the instructions given on the packaging and/or use normal hoisting means. WARNING! CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING, IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT. Handling should be undertakenwith maximum caution avoiding impacts.

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

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4.1.18.4 4.1.18.4.1

INSTALLATION DIRECTION OF ROTATION

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

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4.1.18.4.2

CONSTRUKTION OF THE DRUM FRAME

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

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4.1.18.4.3

HYDRAULIC MOTOR INSTALLATION

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

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

1. ASSEMBLE THE HYDRAULIC MOTOR WITH ITS O-RING SEAL TO THE GEARBOX. 2. TIGHTEN THE MOTOR SCREWS AT A TORQUE SHOWN ON THE FOLLOWING TABLE:

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4.1.18.4.4

INSTALLATION OF THE GEARBOX ON THE WINCH

1. MOVE THE WINCH DRIVE IN THE MOUNTING AREA APPLYING LIFTING METHODS SHOWN IN SECTION 3.4. 2. CLEAN THE MATING SURFACES FROM OILS OR PAINT AND FIT THE GEARBOX ON THE MACHINE (FOR THE CORRECT ORIENTATION REFE TO THE INSTALLATION DRAWING). 3. FIX THE GEARBOX TO THE WINCH FRAME BY USING THE SCREWS (A) TIGHTENED AT A TORQUE SHOWN ON THE FOLLOWING TABLE: 4. FIX THE GEARBOX TO THE DRUM BY USING THE SCREWS (B) TIGHTENED AT A TORQUE SHOWN ON THE FOLLOWING TABLE:

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4.1.18.4.5

CONNECTION OF THE BRAKE

THE GEARBOX DRIVE CAN BE SUPPLIED WITH A SAFETY NEGATIVE MULTIDISC BRAKE HYDRAULICALLY DRIVEN (PARKING BRAKE). FOR INFORMATION REGARDING THE CHARACTERISTICS OF THE BRAKE, PORT TYPES AND DIMENSIONS, REFER TO THE INSTALLATION DRAWING. 1. TO OPERATE THE BRAKE, CONNECT THE BRAKE PILOT PIPE TO THE BRAKE PORT.

AS THE GEARBOX INSTALLATION HAS BEEN COMPLETED, A STATIC SEALING TEST HAS TO BE CARRIED OUT ACCORDING TO THE WORKING CONDITIONS: 1. a load equal or higher than the max operating one has to be applied per 5 min. at least and check that no drum rotation happened.

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4.1.18.5 4.1.18.5.1

LUBRICATION GEARBOX LUBRICATION

The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing. The recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP characteristics according to MIL-L-2105 C & API GL5. In the following table the most common brands of lubricant and the types recommended are shown. INFORMATION! DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.

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4.1.18.5.2

OIL FILLING

WARNING! The gearbox is supplied without oil; anyway it has filling, draining and oil level plugs. Before putting the gearbox 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 (Indicative values). Belove are reported the standard gearbox oil filling-draining sketche.

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4.1.18.5.3

OIL DRAINING AND REPLACEMENT

Unscrew the plugs and let the oil flow in a large enough container; in order to facilitate the draining must be oil still warm. 3. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs. 4. Proceed with the oil fill-up following the procedures given (see Section 5.2). WARNING! NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA. WARNING! DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY. INFORMATION! IN CASE THE GEARBOX IS FACTORY FILLED WITH LUBRICANT OIL AT LEVEL, FOLLOW THE PROCEDURES GIVEN IN DETAIL AT SECTIONS 5.2-5.3 ONLY FOR THE OIL REPLACEMENTS FOLLOWING THE START UP AND RUNNING IN.

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4.1.18.6

START UP AND RUNNING IN

In this first stage it is advised to follow the measures given below: 1. Bleed air from every part of the hyraulic and add oil in the tank if necessary. INFORMATION! THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES. 2. Start the gearmotor at a low speed and gradually increase it after having verified that it is functioning correctly without any noises or vibrations. INFORMATION! DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT. DURING THE RUNNING-IN STAGE FOLLOW THE STEPS GIVEN BELOW. 3. Check the correct revolution and direction of rotation. 4. Make sure that the functioning is regular and with-out any excessive noises and vibrations. 5. Make sure that the oil temperature does not exceed 90°. After having terminated this first running-in follow the steps given below. 6. Check that there are no oil leakages. If present, proceed to remove them. 7. Check the level of lubricating oil in the gearmotor. 8. It could happen that due to the presence of air, during the first start up, the opening action of the brake could be slowed down. It is advised to repeat the opening and closing function of the brake. 9. Check that there are no other problems in general.

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4.1.18.7

MAINTENANCE

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

INFORMATION! IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE SPARE PART LISTS EXPLODED IEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE SUGGESTIONS OF THIS MANUAL. Do not hesitate to contatct the gearbox distributor or manufacturer if further instructions are necessary or in case of particular problems.

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4.1.18.7.1

TROUBLE SHOOTINGS

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

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This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL reserves 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

ITEM

GREASING POINTS – CRANE

INTERVALS

1 2 3 4 5 6 7 8

monthly

9

quarterly

10 11 12

see instruction of manufacturers

MAINTENANCE POINT

Hoisting gear - second journal bearing Luffing gear - second journal bearing Slewing ring Gearing-slewing-ring Jib bearing

NUMBER OF LUBRICATION POINTS 1 nipple 1 nipple 20 nipples 1 ring 2 × 1 nipple

TYPE OF LUBRICANT * multi-purpose grease multi-purpose grease multi-purpose grease Lub. oil or gear grease multi-purpose grease

Hook

1 nipple

multi-purpose grease

Ropes

Hoisting and luffing ropes

rope grease

Electr. motor

13 * Grease see 4.3 lubricants

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4.1.20

OIL CHANGE

CHECK OIL LEVEL CURRENTLY RESP. DAILY Item 1

Intervals every 1500 h or

Maintenance point Slewing gear

No. 2 gears

Type of lubricant*) gear oil

2

every 1500 h or

Hoisting gear

1 gear

gear oil

Lubricant tool and quantity Oil can abt. 12 l (3 x 24 l) Oil can abt. 6,0 l

3 6 7

every 1500 h or 2000 - 3000 hrs. 2000 - 3000 hrs.

Luffing gear Hydraulic tank Hydraulic sytem

1 gear

gear oil Hydr. oil VG 46 Hydr. oil VG 46

Oil can abt. 6,0 l total capacity 500 l total capacity 570 l

Tank, 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 LubPoints Intervalls 1 2 3 4 5 6 7 8 9 10 11 12 13 14

currently resp. daily

15 16 17 18

20 21 22 23 24 25

Slewing bearing Gearing of slewing bearing Jib bearing Hook tackle block Oil condition / oil samples Ropes (hoisting and luffing ropes)

19

quarterly

26

Refilling and Quantity

Section

Oil level Oil temperature Check of filters without clogging indicators Outer leaks Damages Pressure valves / Current valves

Condensed moisture to be dropped 14 days resp. Change of filters after 250 hrs. without clogging indicators Hoisting gear 1 nipple counter bearing Luffing gear – 1nipple counter bearing monthly

Lubricants Oil type ¹)

Cleaning of Breathers Hoisting gear rope Luffing gear rope Slipring assembly Multi-disk brake Check of the connections for fastening Check for wear of brushes

Multi-purpose grease

4.1.19

Multi-purpose grease

4.1.19

20 nipples Gearing

Multi-purpose grease Open-gear grease

4.1.19 4.1.19

2 × 1 nipple 1 nipple

Multi-purpose grease Multi-purpose grease

4.1.19 4.1.19

Hoisting and luffing gear rope

Rope grease

4.1.14

4.1.15 4.1.15 4.1.16

Electr. equipment

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

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Item Maintenance Intervals 27

after 1000 hrs.

Maintenance Points

Nos. of LubPoints

Lubricants Oil Type ¹)

Refilling and Quantity

Sectiont

Oil can abt. 12 l (2×24 l) Oil can abt. 6,0 l

4.1.17 4.1.22 4.1.18 4.1.22

Oil can abt. 6,0 l

4.1.18 4.1.22

Cleaning of breathers

28

Slewing gear

2 gearboxes

Gear oil

29

Hoisting gear

1 gearbox

Gear oil

30

Luffing gear

1 gearbox

Gear oil

31 32 33 34

yearly resp after 1500 hrs.

Load hooks Power circuit breaker

contacts

35

Monitoring units

Electr. equipment

36

Terminals

connection

37

Fuses

38

Hydraulic system

39

Hydraulic tank

40

2000-3000 hrs.

40

Hydraulic system

4.5.2.2 4.5.2.3 Tank, hoses, etc.

Hydr. oil VG 46

500 l

Hydr. oil VG 46

Filling pump ca. 570 l

Oil change

41

yearly

Measuring Instruments (Pressure gauges)

42

see instruction of manufacturers

Electr. motor

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

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4.3

LUBRICANTS

Lubricants

Types of Lubr. perm.

Maker

mainly tropical areas

Aral

Equivalent types of other makes can also be used

Hydraulic oil Quality 1) HV 46

46

Gear Oil C-LP220

mainly moderate areas Gear Oil C-LP150

Epona Z 220

Epona Z 150

Visga 46

BP

Vitam BG 220 Enersyn HTX 220

Vitam BG 150 Epona Z 150

Chevron

Energol GR-XP 220 Non-Leaded Gear

Castrol

1) HLP

Multi-PurposeGrease K-L2K

Lubricant for gear rim

Lubricant for ropes

Vitam GF 4

Epexa 2

Cardrexa DC 1

Cardrexa DC 1

Vitam HF 46 Bartran

6 Energol HLP46

Aralub HLP 2 Energrease MP

Aralub LFZ 1 Energrease MP

Aralub LFZ 1 Energrease MP

Vitam BD 150 Non-Leaded Gear

HV 46 Mechanism

Energol HLP46 Mechanism

MG 2 Dura-Lith

MG 2 Pinion Grease

MG 2 Pinion Grease

Compound 220 Alphasyn HG 220

Compound 150 Alphasyn HG 220

LPS 46 Hyspin

LPS 46 Hyspin

Grease EP2 Spheerol

250 CB Spheerol

250 CB Spheerol

Esso

Alpha SP 220 Spartan EP 220

Alpha SP 150 Spartan EP 150

AWH 46 UNIVIS N 46

AWS 46 NUTO H 46

SX 2 Beacon 2

SX 2 Surett Fluid 4K

Mobil

Mobilgear 630

Mobilgear 629

DTE 15

Unirex N2 Mobilux 2

Shell

Shell Omala 220

Shell Omala 150

Tellus Oel

DTE 25 Hydr. Oel HLPD 46 Tellus Oe

SX 2 Surett Fluid 4K Cazar K2 Beacon EP 2 Mobiltac D

Alvania Fett R2

Cardium Fluid C

Cardium Fluid C

DEA/Texaco

Meropa 220

Meropa 150

T46 Rando oil

46 Rando oil

Multifak EP 2

Texclad 2

Texclad 2

HDZ 46

HD 46

Mobilarma 798 Mobiltac D

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

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

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4.4

ELECTRICAL EQUIPMENT

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

4.4.1

SAFETY DEVICES

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

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4.4.2

LIGHTING

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

4.4.3

MOTORS

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

4.4.4

SLIPRING BODIES

CAUTION ! THE CRANE IS SUPPLIED FROM SEVERAL POINTS IN THE SHIP'S MAINS . BEFORE WORKING ON SLIP-RING BODIES, MAKE SURE THAT THE POWER SUPPLY FROM THE SHIP'S POWER SUPPLY SYSTEM IS SWITCHED OFF ! Work to be performed every three months ♦ Check the brushes for wear. ♦ Coat the slip rings with a thin film of contact grease to reduce wear. ♦ Grease the bearings. ♦ Check that all connections are firmly seated, mainly the terminals of the main switch and the power contactors must be proper tighten.

4.4.5

CIRCUIT BREAKERS

The intervals at which all contacts should be checked for wear will depend on service conditions, but should not exceed one year. ANNUAL CHECKS OF THE WHOLE ELECTRICAL SYSTEM The following checks and work must be performed : ♦

Check that the specified enclosure conditions are met.

♦

Check the fastenings of all units (especially safety devices, limit switches etc.).

♦

Check all terminals for firm connection.

♦

Check all protective earth connections.

♦

Replace damaged or worn units and parts (contacts).

♦

Check that all fuses are firmly seated.

♦

Clean all parts of the plants.

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4.5

HYDRAULIC EQUIPMENT

HYDRAULIC SYSTEM A powerful electric motor drives the hydraulic pumps via a distribution gearbox with constant speed and always with the same direction of rotation: The individual crane gears (hoisting-, luffing and slewing gear) will be driven electro-hydraulically. A threephase 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 electric 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“ 4-54

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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 displacement 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 displacement 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Hoisting gear circuit 1.0 Luffing gear circuit 2.0 Slewing gear circuit 3.0 Boosting and control oil circuit 4.0 Cooling system 5.0 Oil tank 6.0 Manuel filling pump 7.0 Manual pump for emergency operation 8.0

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° 0°

inclination corresponds to maximum discharge 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 displacement 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. MAINTENANCE 3165-316

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REMARK: If the variable displacement motor swashes back, i.e. the piston stroke decreases and the rotation speed increase (hoisting speed increases), the pressure will increase while the load remains the same. The max. swash angle is 25°. To keep the max. rpm within certain limits, the minimum swash angle is limited to abt. 10°. Displacement control is described in detail in Section "Control Oil Circuit" - Adjustment of Hoisting Motors". With this system, variable displacement pump + variable displacement motor, high operating speeds can be attained in operation with partial loads or no load, while components are kept small. Hose lines are also small. LEAFLETS OF PUMPS AND MOTORS Displacement of pump and motor are adjusted according to the diagram below:

A=

pump adjusts from o-stroke to max. displacement. Motor starts with max. piston stroke and stays there.

B=

pump at max. piston stroke and stays there. Motor swashes from max. stroke back to smaller stroke (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.

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4.5.1.2

LUFFING GEAR CIRCUIT 2.0

The luffing gear pump ( 2.1 and 2.2 ) delivers to the luffing gear motor (2.5). From the motor, the oil flow returns to the pumps. This closed circuit as well is shown in the diagram by heavy lines. The luffing gear pump is also a variable displacement pump type A4VG125 EP The luffing gear motor is a fixed displacement motor with fixed piston stroke. Its displacement in cm³/revolution is constant. The motor speed is solely dependent upon the variable pump discharge. Section "control oil circuit - pump control" applies to the control of the pump, same as for the hoisting and luffing gear.

4.5.1.3

SLEWING GEAR CIRCUIT 3.0

The slewing gear pump ( 3.1 ) delivers to the slewing gear motors (3.4). From the motors, the oil flow is returned to the pump. Here, too, this "closed circuit" is marked by heavy lines in the diagram. The slewing pump also is a variable displacement pump type A4VG125 EP. The slewing gear motors are fixed displacement motors, i.e. the piston stroke remains unchanged. The consumption of cm³/revolution is constant. The rotating speed is solely determined by the variable pump discharge volume. For control of the pump of the slewing gear, please refer to section "Boosting and Control Oil Circuit - Pump Control". In the case of the slewing gear the high and the low pressure sides change, depending on the direction in which the crane is required to slew against the heeling angle of the vessel. This is the information concerning the "closed circuits" of the hoisting gear, the slewing gear and the luffing gear. So far the drives are still incomplete. The leakage oil emerging from the pumps and motors (broken lines in the diagram) flows to the tank and has to be replaced in the circuits being cooled and filtered at the same time (boosting circuit). Auxiliary equipment, such the brakes, have to be operated.

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4.5.1.4

BOOSTING AND CONTROL OIL CIRCUIT 4.0

The 3 "pump units" for the hoisting, slewing and luffing gear not only consist of the pumps themselves but also include all valves required to feed into the circuits and to control the pressure. In addition, the respective control devices to adjust the discharge rate and reverse the direction of discharge are flanged on The first step of the twin pump (5.1) is a fly pump (PVH 98). It supplies the boosting and control oil circuit. The fly pump draws the required oil from the tank and delivers it through the filter (4.9) to the three pump connections Fa of pumps 1.1, 2.1, 3.1. Oil is delivered to the respective low pressure side via non- return valves. The discharge rate controller (4.1.1) keeps the feed oil pressure at a constant 28 bar. THE CONTROL OIL CIRCUIT . The control oil circuit maintains the control pressure needed for : 1. Pump displacement control (volume and direction of discharge) 2. Operation of holding brakes. This control oil circuit is supplied by the same pump (5.1) as the boosting oil circuit, i.e. after filter (4.9), the control oil is branched off from the boosting oil circuit, i.e. it is taken to the pump control units (1.1, 2.1, 3.1) after entering into the pump units (Fa). The 28 bar pressure relief valve for the boosting circuit also ensures pressure relief for the control circuit. The control oil circuit has the following functions: PUMP CONTROL (adjustment of discharge volume and change of the direction of flow) The hydraulic control is designed to convert the electric signal quickly and precisely, i.e. current which can very between abt. 200 to 600 mA coming from the master controller in the operator's cabin, into the corresponding pump position within the swashing range of the pump. The control device consists of the respective actuation devices 1.1.2, 2.1.2, 3.1.2 with the flange-connected magnets a + b and the respective control cylinders. The actuation devices convert the incoming electric signal into the corresponding control pressure. Depending on the direction of delivery, this control pressure exists either in line X1 or X2. In control line (X1) nozzle (V1) is fitted which throttles the incoming oil and thus determines the speed of the control cylinder. The movement of the control cylinder is transferred to the actuating devices 1.1.2 or 2.1.2 or 3.1.2 via the return lever. The return lever acts upon springs and the adjustment comes to a standstill when the magnetic force exerted by the control magnet (a) is compensated by the force of the spring. In this way, the volume of pump discharge adjusts itself in proportion to the magnetic force. The direction of pump discharge is reversed when the other control magnet (b) is actuated. Analogous to the procedure just described, pressure is admitted to the control piston, so that the swash plate slews into the other direction through the 0-position.

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ACTUATION OF THE HYDRAULIC HOLDING BRAKES The holding brakes for main hoisting, luffing, auxiliary hoisting and slewing gears which are hydraulically lifted and engaged by spring force are supply with pressurefrom the control oil circuit. Actuation of the slewing gear brakes in the simplest one. When operating the slewing gear in the cabin, magnet 3.17 (on the valve panel) is excited. The valve isolates the brake line from the tank line and connects with the control oil circuit. The brakes open. AFTER SWITCHING OFF THE SLEWING MOVEMENT, THE BRAKES ENGAGE WITH TIME LAG. (THE MOVEMENT HAS TO COME TO A COMPLETE STAND-STILL FIRST). After switching off the slewing movement, the brakes engage with time lag. (The movement has to come to a complete stand-still first). This procedure also applies to the main hoisting gear via magnet 1.24, luffing gear via magnet 2.22, but opening of the brakes is delayed until the level of pressure has been reached in the respective high pressure lines after a pause with the brakes still engaged which had been there prior to engagement of the brakes. This is effected by pressure value sensor 1.23 for the hoisting gear and 2.20 for the luffing gear.

SPECIAL EQUIPMENT EQUIPMENT FOR JERKFREE STARTING If a load is stopped, i.e. the brake engages in the hoisting gear, the high pressure line becomes pressureless owing to leakage oil losses. If the brake would be released now, the load would drop into an oil column without pressure and there would be hard knocks and corresponding pressure peaks. The electric pressure sensor 1.23 prevents starting of the load with a jerk. The brake is only lifted when the high pressure line has reached the respective load pressure stored in the memory. The control stores the load pressure when the brake engages. When switching to "lowering", the hoisting gear pump is switched to deliver in the opposite direction at the beginning, until the equivalent pressure is built up. When the pressure sensor 1.23 gives the signal to open brakes, the pump is also switched to deliver in lowering direction. The whole process of jerkfree starting is automatic. PIPE BURST SAFETY DEVICES Readiness for operation of the crane is monitored by several pressure switches, i.e. item nos. 1.27, 2.14, 3.12, 3.13. Therefore, the pressure controls in the boosting circuit also act as pipe burst safety devices for the main pipes, i.e. in case of a hose burst or a noticeable leakage, the boosting pressure in the low pressure line collapses. Due to this, the pressure control automatically switches the crane off and the holding brakes engage.

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FILTER CLOGGING INDICATOR The filter is equipped with a protective valve. If the filter is very dirty, the protective valve for the filter at the bypass opens at a certain pressure differential (abt. 1 bar) and thus prevents destruction of the filter insert owing to further rise in pressure. To prevent such an occurrence which would allow unfiltered oil to get into the circuit, the high pressure filter (4.9) in the boosting circuit is equipped with an electric clogging indicator (differential pressure measuring device). When clogging is indicated, the filter cartridge 4.9.2 needs replacing. If this is not done, the electric contact in the clogging indicator switches and the crane becomes non-operational because the control voltage for the electrical equipment is switched off. HYDRAULIC PRESSURE RELIEF In the main lines of all three drives, pressure relief valves are installed which protect the drive as well as the pipe and hose lines from overloads. Whereas the slewing gear has two high pressure valves (3.1.5 and 3.1.6) as the high pressure side changes, the hoisting and luffing gear are provided with only one high pressure valve (1.1.6, and 2.1.6) and a low pressure valve (1.1.5, and 2.1.5). ELECTRONIC AND HYDRAULIC CONSTANT PRESSURE CONTROL (Power control) The constant pressure control in the hoisting gear is a special type of power control acting only upon the variable displacement motor. Actuation of the variable displacement motor (1.5) reduces the specific volume of piston stroke. Owing to this, the power take-off speed or working speed as well as the working pressure increase. The output limit of the drive is reached at max. discharge volume of the pump and max. pressure set at the pressure relief valves (1.1.3). The constant pressure control has the effect that the variable displacement motors adjust to low working volume only until the maximum pressure is almost reached. In this position which depends on the load, the motor remains. This process is electronically controlled in the hoisting gear. The pressure sensor (1.23) serve as pick-ups for the maximum pressure for the lowering and hoisting functions respectively. The pressure sensor (1.23) gives also a signal when the working pressure is about to exceed the max. permissible pressure. At that point, the working volume of the variable displacement motor (1.5) is increased again. The hydraulic pressure control at the hoisting gear motor (1.5) is installed for safety reasons. The hydraulic control has the same effect as the electronic control of the pressure sensor. The hydraulic control is superimposed on the electronic control and operates only if the electronic control is not functioning. By doubling the system in the hoisting gear, it is ensured that the motor (1.5) never adjust to a working volume smaller than permissible and therefore will not open the pressure relief valve (1.1.6). LEAKAGE OIL The excess oil quantity of the pressure relief valves (items 1.1.4, 2.1.4, 3.1.4) as well as the quantity of leakage oil from the pumps flow through connection T1 or T2 (main hoisting gear, luffing gear, and slewing gear pumps) to the collecting block and then to the tank. In addition, the leakage oil from the motors and brakes is returned to the tank.

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4.5.1.5

OIL COOLING 5.0

Circuit 5.0 cools the hydraulic oil. The second step of the twin pump (5.1) draws the oil from the tank, delivers it through filter (5.3.1) and the cooling set to the pump housings (1.1, 2.1, 3.1, 10.1) and from there back to the tank. To avoid high pressures when starting with cold oil, a bypass valve (5.3.3) with a spring pretension of 3 bar is fitted in the line. The cooling set consists of an electric motor (5.8.2) with screwed-on fan and with a honeycomb radiator (5.8.3). After passing through the honeycomb radiator, the air is discharged into the open through the exhaust flap. The hydr. oil quickly warms up to suitable operating temperature, as the ventilator is only switched on by the temperature sensor (5.5.1) when the oil temperature in the tank reaches abt. 50° C.

4.5.1.6

HYDRAULIC OIL TANK 6.0

The hydraulic oil tank has a maximum oil volume of ab. 500l. The oil level can visuelly be checked by two sight glasses (6.1 - 1xmax; 1xmin) - the oil level should always be between the two sight glasses. A double pump, complete with connecting piece on the suction side and hoses for the boosting and control oil circuit (5.1) and for oil cooling (5.2) is installed the tank. Besides this a breather filter (6.2) is provided that makes an air exchange possible when the oil level varies. At the bottom of the tank a drain cock (6.3) is installed that is used to empty the tank partly or completely.

4.5.1.7

FILLING 7.0

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

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4.5.1.8

EMERGENCY OPERATION 8.0

In case it should become necessary to carry out a crane movements without drive, each ship’s set of the cranes is equipped with a hand pump for emergency operation in order to release the relevant brakes. LOWERING OF A LOAD IN THE HOISTING GEARS RESP. OF THE JIB IN THE LUFFING GEAR. ATTENTION: The emergency lowering by means of a hand pump is only allowed during emergency, i. e. failure of the hydraulic system. The brake is released by means of the hand pump. The load in the hook or the jib-weight is supported 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 Commissioning of a new system or recommissioning of an existing system Installation, filling with fluid, bleeding, basic adjustment, running-in

INSPECTION Condition and operation

Observation, measurements, test run

MAINTENANCE SERVICING Continued operation Changing of spare parts Cleaning and replacement of components (fluid change, filter inserts, seals)

TROUBLESHOOTING Pinpointing and rectification of malfunctions and damage Fault-finding requires close and logical attention to detail Repair of damage by replacement of components 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. 4-68

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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 inspection. FLUID CONDITION Ageing of the fluid depends on a number of factors such as temperature, dirty environment, operating pressure, humidity, etc. APPEARANCE Dark in colour

CONTAMINANTS Products of oxidation

POSSIBLE CAUSES Overheating,fluid not changed in time (possible contamination by other oils) Ingress of water or air Ingress of water,

Milkiness Water segregation

Water or foam Water

Air bubbles

Air

Floating contaminants or sediment

Solids

Ingress of air, e.g. due to low fluid level or leaky suction Wear, dirt, ageing products

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 Fault Consequence A

Excessive noise

1 Mechn driving section 1. Coupling incorrectly aligned 2. Coupling loose 3. Coupling faulty 4. Pumpor motor mouting loose 5. Other transmission component (V-belt, gear wheel) faulty 6. Pump or motor faulty 7. Direction of rotation incorrect

2 Intakte conditions

3 Pump

Resistance in Suction ine too Great because:

1. Pump speed too high

1. Cock insuction line not open or only partly open 2. Suction filter clogged or too small 3. Suction line clogged or leaking

2. Maximum pump pressure exceeded 3. Charge pump faulty 4. Shaft seal or packing on the suction side faulty

4 Pressure line 1. Pipe fixing missing or loose 2. Not laid properly 3. Crosssections too small

5 Return line As 4 A 1. Return line ends above fluid level 2. Return line filter clogged

4. As 4 C

6. Pressure and return lines reversed

5. Fluid level too low

7. Regulating system ascillating

1. Valve chatters, worn awing to fouled valve seat 2. Insufficient clamping (type not suitable) 3. Noise of flow during statup 4. Unfavourable characteristic

5. Pump faulty

4. Suction line too small or oo many bends in line

6 Pressure control valves

5. Incorrect design

8. As 1 A B

8. Confiuration not optimal for noise reduction (elastic metals) B

Insufficient force and torque at drives

1. Fault in Power transmission

(insufficient pressure)

2. V-belt or Sprocke belt slipping

2. Type unsuitable

3. Incorrect Direction of rotation

4. Governor pressure set to low or control device faulty

As 2 A

3. Pump faulty

4. Motor faulty 5. Key on pump or motor seared off.

C

Cylinder or motor Movements jerky (fluctuations in pressure and flow)

As 1 A 1 - 7

1. Internal leakage owing to wear

1. Leaks 2. Excessive line resistance 3. Pressure filter clogged

1. Excessive line resistance

1. Woking pressure set too low

2. Filter clogged

2. Internal leakage owing to wear 3. Valve seat fouled or damaged 4. Spring broken 5. Type unsuitable (setting range too low)

As 2 A

1. Variable capacity pumps: Regulator fauty 2. Pump faulty 3. Feedback on pumps from the system Regulators (DMV; SRV)

1. Installation not completely bled

As 5 B

As 6 A 1...2 1. Excessively long undamped telecontrol line 2. Unsuitable tele-control valve

4. Pilot valves unsuitable

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM Source of the Fault Consequence D

E

1 Mechn driving section

Drive fails to turn or turns to slowly (no delivery or insuiffcient delivery)

As 1 A 1 - 7

Operating temperature too high

.

2 Intakte conditions As 2 A

3 Pump 1. Internal leakage owing to wear

As 4 B

1. Utilization coefficient losses owign to wear

Pressure fluid foaming

1. Leak in suction line 2. Fluid level too low 3. Tank design incorrect

Sequence control: 1. Sequence valve set too high or faulty 1. Line crosssecton too smal Consequently frictional resistance

As 4 E

1. Excessive continuaus delivery 2. Unsuitable valve type (crosssections too small)

2. Pressure filters clogged

3. Pressure setting too high 4. Resonse time too long

1. Shaft seal or packking on intake side faulty

1. Return line ends above liquid level 2. Vortex effect caused by poor routing

2. Leakage line ot below oil level

Cylinder logs

6 Pressure control valves As 6 B

3. Supply and return lines reversed

3. Speed or delivery too high

G

As 4 B

5 Return line

2. Pump faulty

2. Variable capacity pumps Regulator faulty

F

4 Pressure line

1. Hoses too elastic 2. Lines not bled

H

Lines hit during Switchng

As 4 A 1. Excessive accumulator capacity of the pipe sysem

I

On/off switching frequency of the pump to high

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1. Pump faulty 2. Accumulators system: Pump too smal

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Lines loose

1. Switches too fault 2. Throttles or baffles damages

Sequence or cut off valve incorrectly set or faulty

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM Source of the fault Consequence A

Excessive noise

7 Flow control valves 1. Valve oscillates and induces oscillation in other regulators 2. Noise of flow 3. As 3 A 7

8 Control valves

9 Pressure fluid

1. Valve chatters, 1. Problems with as solenoid fault intake, as or voltage too a) Fluid level to low low b) Viscosity too 2. Valve fauy high owing to wear (temperature or dirt to low) 3. Excessive 2. Fluid contamidelivery nated causing 4. Valves with damage and adjustable clogging of dedamping advices justment not 3. Fluid foaming carried out

10 Drive (Motor, cyl.)

11 Other

1. Wear of bearing surface 2. As 3 A 7

5. Check electrical control system B

Insufficient force and torque at drives (insufficient pressure)

1. Excessive pressure losses 2. Seltting incorrect 3. As 3 A 7

1. Incorrect switching position (e. g. pressureless circulation fails to switch off)

2. Viscosity too high resistance to flow too great

2. Solenoid faulty

3. Fluid foams

1. Viscosity too low thus leakage too great

3. Internal leakage owing to wear

1. Internal leakage (e. g. cylinder boolts worn) 2. See 10 A

1. Fault in control or regulating cicuit of pressure (regulating control system)

2. Indicating in3. Excessive strument faulty internal friction (poor effciently)

4. Excessive resistance to flow 5. Spool sticks C

D

Jerky cylinder or motor movements (fluctuations in pressure and delivery)

1. Valve fouled

Output fals to turn or turns too slowly (no delivery or delivery too low)

1. Delivery set too low

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1. Pressure fluid fouled 2. Pressure fluid foamed

2. Unsuitable type (setting range too low) 3. Valve clogged (fouled)

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As 8 A

2. As 7 A 1

As 8 B

As 9 B

1. Spool sticking 2. Manually operated valves (cocks) not in thriugh.Flow position

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1. Stick slip effect, as friction of the cyinder boots too high. Speed of hydraulic motor below minimum

1. Insfficient load bracing on the rear of the output (e. g. lowering throttle, pressure drop valve)

As 10 B

Conditions for starting not met (regulator faulty). Electrical control line (plug-in connection) broken. Signal elements (e. g. pressure switch set incorrectly or faulty limit switch not actuated)

1. Output blocked (e. g. pistion seizure)

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM Source of the fault Effect E

Operating temperature too high

7 Flow control valves

8 Control valves

1. Set to excessively low delivery (Pump delivers too much through pressure reliefvalve)

1. Leakage losses too high

2. Valve faulty

9 Pressure fluid As 9 B

2. Pressureless circulation fails to switch on 3. Spool sticking

10 Drive (Motor, cyl.)

11 Other

1. Loss of effi1. Cooling capacciency owing to ity of the unit wear (of the installation) too low n 2. Excessive relation to the internal friction power rating or (poor effiency) the duty time 3. Internal 2. No pressureless leakeage ciculation during losses 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 temperature too high 8. Ambiente temperature too high 9. Deposits in cooler 10. Insufficient heat emission owing to encapsulation

F

Foaming of pressure fluid

G

Cylinder lags

1. Unsuitable type 1. Switching time setting too slow

1. Internal leakage

2. Solenoid faulty leakage

2. Inadequate bleeding

3. Valve fouled

1. Piloted check valve dos not close immediately,as a) slit fouled or faulty b) Circuit fault 2. Limit switch is overrun

H

Shocks during switching

1. Switching time setting too fast

1. Pressure fluid foamed

2. Type unsuitable (chane in orifice cross-section too rapid)

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1. Masses and forces too high 2. No damping

1. No throttles upstream of selector valves in accumulator systems

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CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEM Source of the fault Effect I

7 Flow control valves

8 Control valves

9 Pressure fluid

On/off switching frequency of the pump to high

10 Drive (Motor, cyl.)

11 Other Installations with pressure accumulators: Pre-set gas pressure too low. Bladder diaphragm faulty: Pressure switch set incorrectly

TYPES OF FLUID The satisfactory operation, long life and efficiency of a hydraulic system depend to a great extent on the selection of a suitable fluid. VISCOSITY Pumps and hydraulic motors require suitable operating viscosity. Too high a viscosity (thick fluid) leads to cavitation problems. Too low a viscosity causes higher leakage losses, higher temperatures with a corresponding further drop in viscosity and ultimatey loss of the lubrication properties of the fluid. For further information, please refer to the TTS-LMG oil table

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4.6

ASSEMBLY AND DISMANTLING

4.6.1

GENERAL REMARKS

This chapter describes procedures for fitting and removing ropes and other components. The descriptions are provided for guidance only and do not preclude the use of other suitable methods. The accident prevention regulations must be observed at all times. SAFETY RULES 1. Observe accident prevention regulations and stipulated working procedures at all times. 2. Act in a responsible manner, and pay just as much attention to the safety of others as to your own safety. 3. Check all tools and safety equipment frequently to make sure they are safe to use. 4. Inform yourself and others about the dangers of the work and workplace, and about safe ways of doing routine jobs. 5. Ask others about ways of doing unusual jobs. Getting on with a job without first considering all steps can lead to expensive accidents. 6. Consider potential causes of accidents and injury before embarking on a project. Take suitable precautions to protect yourself and others. 7. Warn others about potential causes of accidents and injury if they are seen working without taking suitable precautions and thus creating potential hazards. 8. Increased attention is needed if working conditions and procedures change. 9. Inform your superiors immediately of dangerous actions or conditions. Do not leave it to others. 10. Keep your place of work tidy. Clear away all tools and materials, and make sure they are stored properly. Before starting work, read the appropriate parts of the manual and study both the sectional views shown in the spare parts catalogue and the corresponding drawings. Use only new parts when replacing or repairing parts and assemblies. WELDING The earth connection must be located as close as possible to the welding point. Make sure that the welding current is not conducted through rolling bearings, gears or similar assemblies. SPARE PARTS CATALOGUE The assemblies and subassemblies are listed in detail together with the quantities required and the catalogue 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

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10.The agreed crane signals shall be given to the crane driver clearly and in his view so that the load can be moved as required. See the item "Hand signals" at the end of this chapter. 11.Before the signal is given to lift the load, the person who has secured the load must make the following checks: There must be no loose material , tools, dirt, bolts, etc., lying on the load. Unused ends of the sling must be secured by threading them through the main ring or fastening them together with a shackle. Unused ends must not hang loose. All persons must be outside the danger zone before the lifting operation starts. 12.After the sling has been hauled taut, check that the fastening gear is secure and symmetric at all points. Check the fastening gear to ensure that it is still protected against sharp edges and that machined surfaces are protected from the fastening gear. The load brake must be checked when the load has been lifted a few centimetres from the ground and is being carried entirely by the hoisting gear. The fastening gear must also be checked again in all places13.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 surfacesCondition of the shoring: Shoring material must be in good condition and of a uniform size. Do not use damaged shoring, e.g. shoring which has rounded edges, is rotten or broken, or contains large knots. 17. Lower the load slowly until its full weight is supported by the ground or shoring. WARNING Equipment used to protect the fastening gear such as iron edge protectors, leather straps or timbers can fall out as the sling becomes slack. Personnel must therefore keep clear of these areas until the se items have been removed. 18. After the lifting operation has been completed, remove the fastening gear and inspect it for damage. lf it is no longer needed, it must be returned to the storage rack.

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4.6.2

ROPE REPLACEMENT

The rope reevings shown below are schematic representations !

1. Dismantle rope from locating point on crane tower, catch rope and put it down on deck. 2. Cut off wire rope socket.

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

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4. Run the wire rope off the winch drum, and let the old rope run down in front of the crane tower until only four windings of the old rope remain on the drum. 5. Unbolt wire rope clamps on drum.

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

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

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

9. Repeat this until the new rope has been pulled through the rope sheaves on the drum. Run abt. 4 windings of the new ropeon the winch drum, catch the rope and remove the chinese finger between old and new ropes 10. Fasten end of new rope in the rope clamps of the drum. 11. Run off the four rope windings which have been run on the drum at random and start running the rope on the drum normally, starting at the rope clamps. 12. Fasten rope socket to locating point on crane tower.

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4.6.3

HAND SIGNALS FOR CRANES

HOIST With forearm vertical, forefinger pointing uo, move in smal horizontal circle.

LOWER With arm extended downward, forefinger pointing down, mowe hand in small horizontal circles

USE MAIN HOIST Tap fist on head; then use regular singnals.

SWING Arm extended point with finger in direction of swing of boom.

STOP Arm extended, palm down, hold position rigidly.

EMERGENCY STOP Arm extended, palm down move hand rapidly right and left.

USE WHIPLINE (Auxiliary Hoist) Tap elbow with one hand; then use regular signals.

RAISE BOOM Arm extended, finger closed, thumb pointing upward.

LOWER BOOM Arm extended, fingers closed, thumb pointing downward.

TRAVEL Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.

TRAVEL (Both Tracks.) Use both fists in front of body, making a circular motion about each other, indicating direction of travel; forward or backward.

MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as an example.)

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4.6.4

TIGHTENING TORQUES FOR HEXAGON BOLTS AND SPANNER BOLTS

Nominal thread dia.

M5 M6 M8 M 10 M 12 M 16 M 20 M 24 M 30 M 36

6.9 535 5 350 755 7 550 1 390 13 900 2 210 22 100 3 240 32 400 6 150 61 500 9 600 96 000 13 800 138 000 22 100 221 000 32 300 323 000

Pre-load kp Fv in Nm Property Class 8.8 10.9 635 895 6 350 8 950 900 1 260 9 000 12 600 1 650 2 320 16 500 23 200 2 620 3 690 26 200 36 900 3 850 5 400 38 500 54 000 7 300 10 200 73 000 102 000 11 400 16 000 114 000 160 000 16 400 23 000 164 000 230 000 26 200 36 800 262 000 368 000 38 200 53 800 382 000 538 000

12.9 1 070 10 700 1 510 15 100 2 790 27 900 4 430 44 300 6 450 64 500 12 300 123 000 19 200 192 000 27 600 276 000 44 200 442 000 64 500 645 000

6.9 0,50 5,00 0,85 8,50 2,1 21,0 4,1 41,0 7,2 72,0 18,0 180 34,5 345 60 600 120 1 200 214 2 140

Torques kpm Ma in Nm Property Class 8.8 10.9 0,60 0,85 6,00 8,50 1,0 1,4 10,0 14,0 2,5 3,5 25,0 35,0 4,9 6,9 49,0 69,0 8,6 12,0 86,0 120 21,0 29,5 120 295 41 59,7 410 597 71 102 710 1020 145 200 1 450 2 000 253 356 2 530 3 560

12.9 1,0 10,00 1,7 17,0 4,1 41,0 8,3 83,0 14,5 145 35,5 355 69 690 120 1200 240 2 400 428 4 280

The tightening torques habe been calculated with the following frication coefficients: µ tot. = 0.14 for oiled bolts µ tot. = 0.16 for bolts secured with liquid (Loctite, Omnifit) CHECK OF HSFG BOLT CONNECTIONS Check HSFG bolt connections visually by examining state of paint work of components bolted together. If paint appears cracked or flakes off this means that the bolt connection moves, and the bolts must be replaced at once. Use only perfect torque spanners for tightening the bolts. Check to be carried out monthly.

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4.6.5

INSTALLATION OF HOSES

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5.

SPECIFICATION OF THE ELECTRICAL EQUIPMENT SINGLE DECK CRANE

TABLE OF CONTENTS 5.

SPECIFICATION OF THE ELECTRICAL EQUIPMENT

5.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.3.3 5.3.3.1 5.3.3.2 5.3.3.3 5.3.3.4 5.3.4 5.3.4.1 5.3.4.2 5.3.4.3 5.3.4.4 5.3.4.5 5.4 5.4.1 5.4.2 5.4.3 5.4.3.1 5.4.3.2 5.5 5.5.1 5.5.2 5.5.3 5.5.3.1 5.5.3.2 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 5.5.9 5.5.10 5.6 5.6.1 5.6.2 5.6.3

TECHNICAL DATA GENERAL DESCRIPTION SUPPLY SOURCES GENERAL DRIVE SYSTEM REMARKS CRANE OPERATION (NORMAL MODE) DESCRIPTION OF ELECTRICAL COMPONENTS SWITCH GEAR SENSORS LIMIT SWITCHES GEARED LIMIT SWITCHES - SERIES 51 ASSEMBLY OF THE GEARED LIMIT SWITCH CONTACT ADJUSTMENT (SEE FIG. 3) BLOCK ADJUSTMENT (SEE FIG. 4) PROGRAMMABLE LOGIC CONTROLLER (PLC) COMPACT MODULE PWM COMPACT MODULE DIGITAL / ANALOGE CABINET-MODULE INCLINOMETER ( SPECIAL EQUIPMENT ) LCD-DISPLAY DISPLAY AND INDICATORS INDICATOR LIGHTS DISPLAY OF CRANE INFORMATIONS DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT PANEL) OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS HOW TO ENTER MAIN MENU COMMISSIONING AND ADJUSTMENTS GENERAL DEFAULT SETTING ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER PUMP) SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT) SETTING LAYER CHANGE POSITION RESETTING OF REFERENCE POSITIONS ADJUSTABLE WORKING RANGE LIMITATION SPECIAL MODUS FOR ROPE CHANGE CALIBRATION OF LOAD INDICATION REPORT OF CHANGE ZERO-SETTING OF POTENTIOMETERS SETTING OF OPERATION HOURS ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT) INTERLOCKING FOR SEA VOYAGE (SPECIAL EQUIPMENT) LOCKING UNLOCKING FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM

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1 3 4 4 5 6 7 7 8 9 9 10 11 12 13 25 37 49 58 65 70 70 70 71 72 72 79 80 81 82 85 86 89 92 93 94 95 95 95 96 96 97 98

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5.6.3.1 5.6.3.2 5.7 5.7.1 5.8 5.8.1 5.8.2 5.8.3 5.9 5.9.1 5.9.1.1 5.9.1.2 5.9.1.3 5.9.2 5.10 5.11 5.11.1 5.11.2 5.11.3 5.11.4

SETTING THE PRESSURE LIMITING VALVE LOCK / UNLOCK IN EMERGENCY OPERATION PMS – POWER MANAGEMENT SYSTEM (SPECIAL EQUIPMENT) FUNCTIONAL DESCRIPTION SPECIAL OPERATION MODES TEST OPERATION POWER / SPEED REDUCTION DISABLE TRIMOT TROUBLE SHOOTING GENERAL REMARKS POWER SUPPLY AND CONTROL VOLTAGE PLC STATUS INDICATORS ADDITIONAL INDICATIONS LIST OF FAULT MESSAGES EMERGENCY OPERATION SYSTEM SERVICE MAINTENANCE INFORMATION FOR HYDRAULICAL MAINTENANCE OF ELECTRICAL EQUIPMENT SPARE PARTS CIRCUIT DIAGRAMS

101 102 103 103 104 104 104 104 105 105 106 106 106 107 160 162 162 163 165 166

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

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5.1

TECHNICAL DATA

The electrical equipment of the crane conforms to the Rules of the classification societies. It is designed for operation at ambient temperatures between -25 and +45 °C. Supply voltages Mains supply: Auxiliary supply: Control voltage:

440 V AC, 60 Hz, 3-phase 220 V AC, 60 Hz, 2-phase 24 V DC

List of motors Pump drive main motor: Boost pump (control oil pump): Hydraulic oil cooler:

160 kW, duty cycle S1, 4 pole 9 kW, duty cycle S1, 4 pole 1,5 kW, duty cycle S1, 4 pole

Lighting and heating Interior lighting: Jib floodlight: Working floodlight below cabin: Warning light red: Machinery space heating: Cabin heating:

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3 x 20 W 1000 W, halogen 2 x 1000 W, halogen 1 x 60 W 2000 W 1400 W

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5.2

GENERAL DESCRIPTION

5.2.1

SUPPLY SOURCES

Before starting work on the electrical system, switch off all supply sources to the crane and check that all equipment is inactive. Power is fed to the crane via a slip ring assembly containing Main supply 4 rings (3 + earth) Auxiliary supply and controls 10 rings

for 500 V, 600 A for 250 V, 60 A

The main supply is taken from the slip ring body to the connection terminals of main switch =M01-S1. To switch on power supply to the crane, shift the switch to the position "1". The switch must be reset to the position "0" before leaving the crane. The switch can be secured in the position "0" by means of a padlock to prevent unauthorised tampering. The auxiliary supply leads from the slip ring body to terminals X3/1 and -2 in the control cabinet. The auxiliary supply can be switched off by means of the master switch (=M01-S2) for repair and maintenance work. From master switch =M01-S2 the feeder branches to the automatic circuit breakers =M03-F31 to -F36 and the various lighting and heating consumer circuits.

The auxiliary supply should be constantly connected so that the anti-condensation heater is operational.

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5.2.2

GENERAL DRIVE SYSTEM REMARKS

All crane motions are powered by electro-hydraulically controlled hydraulic motors. While the crane is in use, the main motor (=M02-M1) runs continuously at constant speed and drives the hydraulic pumps via a multiple distribution gear. The hydraulic pumps supply oil independently to the hoisting, luffing and slewing gear motors. The pumps are electro-hydraulically controlled by means of control units with two proportional solenoid valves each. If they receive no control power, the pumps run with zero stroke and, therefore without oil delivery. The rate and direction of pump delivery is governed by the current flowing through the solenoids of the proportional valves. Variation of the solenoid current thus permits infinitely variable control of the pump delivery and, consequently, of the drive speeds. The solenoid current is about 200 to 600 mA.. This value depends on the deflection of the control lever if no restrictions are given (e.g. speed limitation by rope length measurement), at minimal deflection it is about 200 mA – at full about 600 mA.. The hoisting gear circuit incorporates a variable displacement hydraulic motor (TRIMOT) which permits small loads or the empty hook to be handled at higher speeds. This motor is controlled by a proportional solenoid valve drawing a current of 200 to 500 mA. The actual control current varies according to the load on the hoisting gear, which is measured by pressure sensor. Besides the pump adjustment arrangements, the control system also controls solenoid valves of brakes used enable the various drives. Further particulars are given in the specification of the hydraulic system.

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5.2.3

CRANE OPERATION (NORMAL MODE)

By turning the selector switch =M07-S06 into ON-position, contactor =M02-K11 will be activated and starts the booster (control oil) pump. Additionally the crane system sends a POWER REQUEST SIGNAL to the ship´s control system. When the crane system receives a POWER AVAILABLE SIGNAL from the ship´s control system the time relay = M02-K4 switches on the contactors = M01-K2 and -K3 to start the main motor by means of a stardelta circuit. The star/delta change is switched over after about 4 seconds. If the POWER AVAILABLE SIGNAL is not given within 50 seconds, the starting procedure of the crane will be stopped and must be repeated for a new start. During the starting sequence is shown on the display. After that the system will make an auto-calibration of the drives, displayed with . If all systems are in good order, is shown and the crane can be operated by shifting the joystick (control lever). If the joystick (control lever) is shifted too soon, or the deadman switch (optional equipment) is actuated, the status monitoring system C006 responds and prevents operation of the crane. The crane is controlled by a programmable logic control (PLC). The PLC processes the digital input signals it receives from the switches (contacts of contactors and the joystick (control lever), limit switches, etc.) and the analogue values received from the controls (set-up values) and sensors (pressures, temperatures) in the way defined by the algorithms of the stored programs (software), produces the output control signals needed to switch the indicator lights, contactors or solenoid valves and generates the pulse-width modulated (PWM) control current for the proportional solenoid valves controlling the delivery of the pumps. In normal operation mode the main crane data (load, outreach etc.) are shown on the display. When the crane operation is finished the drives will be stopped by turning the selector switch =M07-S06 into OFF-position and the drives will be shut down by the control system. < SYSTEM SHUT DOWN> is now displayed. Preheating the hydraulic oil At sub-zero temperatures, the hydraulic oil should be preheated before the crane is put into operation. This is done by turning on the crane control system by means of the main switch =M01-S1. The oil temperature is measured by temperature sensor =M07-B01. If the temperature is below 5°C, the feed oil (booster) pump will start and heat up the hydraulic oil until the temperature reaches 8°C. Cooling The hydraulic oil cooler is switched on and off automatically during crane operation when the temperature exceeds 50°C depending on the oil temperature in the hoisting gear circuit (sensor =M07-B01). If the pump drive is switched off while the cooling system is running, the main motor stops, but the booster pump hydraulic oil cooler and (engine room fan) remain in operation to cool the oil down. It keeps running until the oil temperature is below 50°C, but operation in this cooling mode ceases after 10 minutes at the latest.

DO NOT STOP the drives by using the emergency button. The crane drives must be stopped when the driver is leaving the cabin. When the crane has stopped owing to a fault or a loss of power supply the switch must be turned to OFF-position before the crane can be started again.

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5.3

DESCRIPTION OF ELECTRICAL COMPONENTS

5.3.1

SWITCH GEAR

The power switch gear consists of contactors =M02-K2 (star circuit contactor) and =M02-K3 (delta circuit contactor). The control voltage of these contactors is 440/400 V ): Contactors =M02-K2 and -K3 are switched by timing relay =M02-K4. The contactors =M02-K11 + -K12 both have a control voltage of 24 V and, like =M027-K4, are switched directly by a PLC output. The main motor is protected against overload by thermistors and additionally by monitoring the amperage with the current-transformer =M02-T1. The aux. drive motors =M02-M11 + -M12 are protected from overload by MCB´s. The 24 V DC control voltage is produced by the three-phase rectifier bridge =M05-U1.

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5.3.2

SENSORS

The current-transformer =M02-T1 measures the amperage of the main motor. The output signal is 0 – 20 mA DC, corresponding to the primary current 0 – 500 amp. AC. The current-transformer is supplied with 220 V AC (auxiliary supply source / circuit breaker =M03-F34) The pressure of the hoisting and luffing gear circuits is monitored by pressure sensors (=M07-B10 / -B20) which convert the hydraulic pressure 0 – 600 bar into an analogue output signal 4-20 mA. The oil temperature is monitored by a temperature sensors (=M07-B01) which convert the temperature -50 to +150°C bar into an analogue output signal 4-20 mA. The rope length will be measured by incremental encoders (=M06-IE16 / -IE26), they are mounted inside the limit switches. The control lever (joysticks) contain potentiometers, are permanently connected to 24 V supply, and their output voltages vary, depending on joystick deflection, between 12 V in the zero or neutral position and 0 V respectively. 24 V at maximum joystick deflection. A 2-axle-inclinometer (=M07-A8) is installed in the control cabinet for measuring the heeling of the crane (ship). The heeling angle is displayed in the right-hand control desk. (optional equipment)

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5.3.3

LIMIT SWITCHES

The travel route of the hoisting gear and also the luffing gear are limited by rope length measurement and additionally by mechanical limit switches. These limit switches are directly mounted on the winches of the corresponding drives. Main-Hoisting gear - defines the highest and lowest hook positions: Gear-driven cam actuated limit switch series 51, with incremental encoder. Luffing gear - defines the maximum and minimum outreaches : Gear-driven cam-actuated limit switch series 51, with incremental encoder.

5.3.3.1

GEARED LIMIT SWITCHES - SERIES 51

Construction, functioning, constructional male characteristics (see Fig.1) The fitted maintenance-free planetary gears with or without spur gear pre-step down are made of thermoplastic plastics. Because of the applied modular technology the switching steps are equipped with the same parts as the planetary gears. A cam disc and an adjusting worm are added. The planetary and switching steps as well as the spur gear pre-step down (not necessary for certain reductions) are mounted into a glass-fibre reinforced modular housing of synthetic material. The contacts are actuated by the cam discs of the switching steps.

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5.3.3.2

ASSEMBLY OF THE GEARED LIMIT SWITCH

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

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5.3.3.3

CONTACT ADJUSTMENT (SEE FIG. 3)

For contact adjustment, remove the cap of the limit switch. Thereby the live contact connections are laid bare. Danger ! Do not touch live parts! An infinitely adjustable cam disc is provided for each contact. Independent of each other, the cam discs (1) can be set with the adjusting worm (2). lt is not necessary to loosen any parts for the adjustment. The worm is self-locking. The worm can be turned by means of a screwdriver of 1 0 mm or 4 mm or by means of a hexagon socket screw key of 4mm. mm or with a 4 mm hexagonal internal key. When turning the worm through one clockwise revolution (360º), the cam disc is turned clockwise as well through 2,464º (view of the rear part, the B-side of the switch). The standard cam discs are designed to dispose of a max. useful travel and a max. overtravel Cam discs with other useful travels can be fitted as special discs. When exceeding the overtravel, the switch is not damaged. The contact, however, is opened or closed again.

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5.3.3.4

BLOCK ADJUSTMENT (SEE FIG. 4)

Functioning The planetary gear construction allows a block adjustment in addition to the individual contact adjustment from the usable revolution 17.5. The final gear stage is also provided with an adjusting worm, coloured black. All cam discs (1) can be commonly adjusted by means of this adjusting worm (2). The relative adjustments of the individual contacts to each other are not modified. When turning the black worm clockwise through one revolution (360°), the cam discs are also turned clockwise by 0.575° (view of the rear part, the B-side of the switch).

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

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5.3.4

PROGRAMMABLE LOGIC CONTROLLER (PLC)

Hardware description Most of the work involved in crane control is performed by the PLC, which receives all control signals, processes them as foreseen by the stored program and generates appropriate control signals for the final control units. The 24 V supply for the PLC is fed across fuses =M05-F21 and -F22. The control unit consists of a Controller R360 (PLC), three Compact modules, a Cabinet module and a LCD-Display. All components are networked over CAN-BUS interface and located as follow: ITEM Controller R360 Cabinet Module Compact Module PWM Compact Module Analogue Compact Module Digital LCD-Display

located Electrical control cabinet r-h Control desk in crane cabin Nearby the hydraulic pumps Nearby the hydraulic pumps Nearby the hydraulic pumps r-h Control desk in crane cabin

The modules must be plugged in at the specified locations and nowhere else. For more detailed information please refer to the unit specification supplied by ifm electronic. The PLC (Programmable Logic Controller) controls and monitors the electro hydraulic system of the crane. The status of current signals and operating data are continuously fed to the PLC where they are processed in accordance with the control program (software) and stored. If the control system malfunctions, the fault should first be sought outside the PLC as experience has shown that faults are much more common in the PLC periphery than in the PLC itself. In any case, PLC should be replaced only as a last resort to eliminate a fault as it leads to loss of stored information and all setting work has to be repeated. Before replacing these modules, the status of the operating hour counters must also be noted down as they are all reset to "000" during the setting work.

General information about the CAN-BUS ( CAN –open ) All components are networked over CAN-BUS. This is 2-wire-system, called CAN_H and CAN_L.. When the network system is operational on all components the green LED is blinking with 2 Hz. All components are connected in serial, that means whenever the control line is physically interrupted, the complete system will not work. Both ends of the network must be provided with a 120Ω resistor, in the crane network these resistors are located at the compact module =M07-A2 and the terminal strip X72 in the right control desk console. When the bus network is physically OK, you must measure a resistance of 60Ω.

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NOTES

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CONTROLLER R360

Mounting - and installation instructions

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Safety instructions This description is part of the unit. It contains texts and drawings concerning the correct handling of the controller and must be read before installation or use.

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

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

The controllers can be used as CANopen master. The controllers "ClassicController R 360" are not approved for safety-relevant tasks in the field of personal safety.

Programming The application software can be easily created by the user with the Ifm programming system "ecolog 100 plus" according to IEC 61131-3. In addition to the programming system the complete system manual is required to program the controller. If this manual is not available, please contact one of the Ifm branch offices overleaf for your free copy. The system manual (pdf format) can also be downloaded from the web (www.ifm-electronic.com).. System manual R 360; English (order no. EC2041) Data sheet direct CR0505 Additional data

The user is responsible for the safe functioning of the application programs which he creates himself. If necessary, he must additionally obtain approval according to the corresponding national regulations issued by the corresponding testing and supervisory organisations. NGLISH

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

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

Designation supply voltage sensors/module supply voltage outputs supply voltage via relays

Potential

Pin no.

Fuse

VBB S VBB O VBB R

23 05 34

max. 1 A max. 15 A max. 15 A

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

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

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

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CLASSICCONTROLLER NOTES

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5.3.4.1

COMPACT MODULE PWM

Mounting - and installation instructions DEUTSCH E

COMPACTMODUL METAL CR2031

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

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

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

• -

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

•

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

•

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

•

The module expects a synch object. The CAN identifier of the synch object can be configured.

•

• The module supports "node guarding" and "heartbeat". The "guard time", the "life time factor" and the "heartbeat time" can be configured.

•

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

•

• The module stores the last error. The error code of the corresponding emergency object is stored.

•

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

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

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COMPACTMODUL METAL CR2031 CR2031 Wiring

Parameters and EMCY object overview Automatic saving of the communication and unit parameters can be activated or deactivated by means of the "save all parameters" entry (see object directory, index 1010). When the value 0x02 is entered into SIdx 01, all parameters are automatically saved if changes were made. With the value 0x00 there is no automatic saving, i.e. changed parameters will only be valid until the unit is switched off or until the next reset is made. With the function "restore" (see object directory, index 1011) the parameters (except the baud rate and the node ID) can be assigned to the factory default values. With the next power on they become valid.

Control characteristics (index 2004...7) The current control behaviour can be parameterised separately for each channel pair in the P and I values. For each of the 4 output pairs the max. load current [mA] has to be indicated. By means of this value the respective measuring range (1 A or 4 A) is automatically selected.

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

COMPACTMODUL METAL CR2031 Maintenance, repair and disposal As the module does not contain any components which must be maintained by the user, the housing must not be opened. The maintenance of the module may only be carried out by the manufacturer. The disposal must be carried out according to the corresponding national environmental regulations.

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

ENGLISH

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COMPACTMODUL METAL CR2031 NOTES

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5.3.4.2

COMPACT MODULE DIGITAL / ANALOGE

Mounting - and installation instructions

COMPACTMODULE METAL CR2033

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COMPACTMODULE METAL CR2033

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

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COMPACTMODULE METAL CR2033 Function and features The CR2033 I/O module enables decentralised evaluation of sensor signals and decentralised triggering of actuators and proportional valves. • •

The module supports binary/analogue inputs/outputs and is therefore classified in the device profile "I/O module" to CiA DS 401. As regards the input/output functions, the module can be configured and it supports the following functions: - analogue inputs (0...10/32 V, 0...20 mA, ratiometric, binary and binary with diagnosis) - binary inputs - binary outputs - PWM outputs up to 4 A

•

There are 1 server SDO and the 4 default PDOs to CiA DS 401. The PDO mapping cannot be changed (static PDO mapping). The default identifiers are assigned according to the "predefined connection set".

•

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

•

The module expects a synch object. The CAN identifier of the synch object can be configured.

•

The module supports "node guarding" and "heartbeat". The "guard time", the "life time factor" and the "heartbeat time" can be configured.

•

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

•

The module stores the last error. The error code of the corresponding emergency object is stored.

•

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

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

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COMPACTMODULE METAL CR2033 Maintenance, repair and disposal As the module does not contain any components which must be maintained by the user, the housing must not be opened. The maintenance of the module may only be carried out by the manufacturer. The disposal must be carried out according to the corresponding national environmental regulations.

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

ENGLISH

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COMPACTMODUL METAL CR2033 NOTES

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5.3.4.3

CABINET-MODULE

Mounting - and installation instructions DEUTSCH ENGLISH

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INPUT/OUTPUT MODULE CR2012

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

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INPUT/OUTPUT MODULE CR2012

Function and features The CR2012 input/output module is used for connection of controls and indicators in driver's cabs, control panels or control boxes to CAN bus. •

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

•

As regards the input/output functions the module can be configured.

•

The input/output module supports the following I/O configurations: 8 binary inputs + 4 binary/analogue inputs + 4 binary inputs/outputs

•

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

•

The COB IDs of the PDOs as well as the transmission type (synch / asynch) of the individual PDOs can be configured. The transmission type is non-volatile stored. Changed PDOs (PDO linking) are volatile stored.

•

The module expects a synch object. The CAN identifier of the synch object can be configured. After a change the ID is automatically nonvolatile stored.

•

The module supports "node guarding". The "guard time", "life time factor" and the CAN identifier of the guard object can be configured and are non-volatile stored.

•

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

•

The module stores the last 4 errors. The error code of the corresponding emergency object is stored.

•

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

ENGLISH

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INPUT/OUTPUT MODULE CR2012

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

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

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COMPACTMODUL METAL CR2012 NOTES

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5.3.4.4

INCLINOMETER ( SPECIAL EQUIPMENT )

Mounting - and installation instructions

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COMPACTMODUL METAL CR2101

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

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COMPACTMODUL METAL CR2101 Function and features The 2-axis inclination sensor enables zero point levelling and position detection of mobile machines. Typical applications are, for example, the position detection of access platforms, levelling of mobile cranes and mobile machines. Operating principle: Two measuring cells which operate to the conductometric principle evaluate the change in conductivity of a liquid. By applying an alternating voltage between the electrodes, a current flows through the liquid and generates an electric field. When the sensor is inclined the electric field changes and thus the conductivity of the liquid depending on the level. Arranging the electrodes in pairs results in a signed angle of inclination. •

Parameter setting of the sensor resolution and the 2-axis zero point is possible.

•

1 server SDO and 2 Transmit PDOs conforming to CiA DS 401 are available. The PDO mapping cannot be changed (static PDO mapping). Default identifiers have been assigned according to the "predefined connection set".

•

The COB IDs of the PDOs as well as the type of transmission (synch/asynch) of the individual PDOs can be configured. The type of transmission is non volatile stored. Changed PDOs (PDO linking) are volatile stored.

•

The inclination sensor expects a synch object. The CAN identifier of the synch object can be configured. After a change the ID is automatically non volatile stored.

•

The inclination sensor supports "node guarding". The "guard time", the lifetime factor" and the CAN identifier of the guard object can be configured and are stored non volatilely.

•

The inclination sensor generates an emergency object. The COB ID of the EMCY object can be configured.

•

The inclination sensor stores the last 4 errors occurred. The error code of the respective emergency object is stored.

•

The inclination sensor supports a reset function, i.e. upon request the parameters are assigned to the factory default values*.

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INCLINATION SENSOR CR2101

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

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

ENGLISH

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COMPACTMODUL METAL CR2101 NOTES

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5.3.4.5

LCD-DISPLAY

Mounting - and installation instructions

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LCDDisplay CR1031 Contrast and brightness adjustment Independently of the device type, contrast and brightness are adjusted via the ESC key and the cursor keys. This description therefore applies for all LCD device ranges. You have to call up the "LCD service page" at the Dialogue Module menu. How to do, see chapter “ Operation of the Dialogue Module over the function keys”. Then, you can adjust the contrast and brightness at least for this page. Proceed as follows to modify the settings: 1. Press the ESC key and keep it pressed during the following steps. 2. Wait for approx. 2 seconds. 3. Adjust (with the ESC key pressed) brightness and contrast via the cursor keys. The key mapping is as follows: Reduce brightness Increase brightness Reduce contrast Increase contrast

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

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LCDDisplay CR1031 NOTES

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5.4

DISPLAY AND INDICATORS

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

5.4.1

INDICATOR LIGHTS

=M07-H06 "READY FOR OPERATION" is inside the selector switch and lights up when the crane is ; i.e. when the main motor is running in the delta circuit and all systems are in order. During start up procedure this pilot signal blinks until the self adjustment is finished. =M07-H07 "FAULT" is in the right control desk and lights up as a collective signal when the status monitoring system signals a fault. This indicator lights are installed additionally to the crane information system on the display, located on the right hand control desk. Normally all relevant fault indications and operation conditions are shown on the display. Only if the display itself is defective is the main information indicated by these lights.

5.4.2

DISPLAY OF CRANE INFORMATIONS

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

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

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5.4.3

DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT PANEL)

A LCD Display with 8 plunger-operated buttons and status LEDs is installed in the right hand control desk of the crane cabin. The dialogue module communicates via CAN bus with the control system ecomat 100 type R 360 interactively and sends or receives operational status information of the crane. The following information of the dialogue module can be handled at the menu structure − − − −

Fault / Condition messages Operating states messages Additional messages. Service inputs

Operational state messages Under normal conditions, the indications shown by the dialogue module is SWL – LOAD, ACTUAL LOAD, OUTREACH and HOOK HEIGHT to signify normal, trouble-free operation or, if the temperature of the hydraulic oil is below 0 °C, " TEMPERATURE < 5° PREHEATING ACTIVE" to show that the booster pump is working in the oil pre-heating mode. Fault messages are indicated by a separate fault picture with the "FAULT CODE" and the respective cleartext of this fault. Fault messages have the highest priority and therefore overwrite existing operating conditions or special messages. A fault message can be cleared by pressing the RESET button F2. Condition messages are indicated by a separate condition picture with the "CONDITION CODE" and the respective clear text of this condition. e.g. " Condition 2214" with clear text „LUFFNG OUT PRELIMITATION “, is a typical operating condition message, for instance, and indicates that the luffing direction is approaching the maximum of luffing gear out direction. Additional messages do not appear on the display during normal operation. They must be called separately. Additional messages are suppressed when the detailed points are selected over the menu. Button „BACK“ must be pressed to return from the additional message page to the normal mode. Faults and conditions not eliminated during the menu are selected. Service inputs could be entered over a separate secured Password area. In this special area e.g. the system values could be reset to default settings, Emergency Codes could be activated or some values could be displayed.

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5.4.3.1

OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS

Normal operation is basically done using the following 6 function keys: ESC key Cursor keys Enter key

Special keys are: Function key F1

ENTER Main Menu, anytime at call.

Function key F2 single Quit of displayed Fault

5.4.3.2

HOW TO ENTER MAIN MENU

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

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Menu structure Is divided into sections. •

The normal and free available area:

display values and operational state

•

The secured password area:

Service Menu / set values

Enter a menu item The menu structure and meaning of keys are self-explanatory. We will in any case explain the function in detail on the basis of some examples. EXAMPLE:

Display of detail “ACTUAL LOAD” ( capital letters )

After crane is started above picture is normally displayed. to activate the menu. The first item is now reversible. Press keys, you can now change between the available menu items. Select now Using the „ACTUAL LOAD“ and press

The “BACK”

to change the display.

key takes you back to the previous picture.

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EXAMPLE:

Display of crane information: Operating hours

At the given picture press

Then select with

key to enter the main menu.

the “CRANE INFORMATION” item and press

Enter to display.

Now you will have the information displayed. The “BACK”

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key takes you back to the previous picture.

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EXAMPLE:

SERVICE INPUT: RESET TO DEFAULT SETTINGS

At the given picture press

After that select with

key to enter the main menu.

the “SECURED AREA” item and press

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

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Enter to display.

Enter to confirm this message.

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EXAMPLE:

... SERVICE INPUT: RESET TO DEFAULT SETTINGS

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

To insert the Security Code press press

Enter. Now the code column will be displayed in reverse. Now

Enter again. and the first digit of security code blinks. With

you modify the value

you can go to the next digit. When you have inserted everything press and with confirm the insert security code of your entry.

Enter to

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

Enter to confirm your entry. Now the selected crane number is displayed and you number press “NEXT” or “BACK” takes you to previous picture. can go further press

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EXAMPLE:

... SERVICE INPUT: RESET TO DEFAULT SETTINGS

You are now in the Service menu

With

you can go to the next range of service points.

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

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

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Enter to confirm

Enter to confirm this message.

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Now you must press go “BACK”.

EXAMPLE:

Enter to set the system back to default settings. Otherwise press

key to

... SERVICE INPUT: RESET TO DEFAULT SETTINGS

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

press

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

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5.5

COMMISSIONING AND ADJUSTMENTS ( CODE SECURED AREA )

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.

Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship. Procedure: • Set • Select • Select • Select

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

If you want to leave this secured area and especially before you leave the crane:

Switch off the power to de-activate all emergency codes. (Emergency Operation System = EOS-Codes) If the EOS system has been activated an information will be written into the flash memory. The status of the EOS codes can be called up under INDICATIONS EOS STATUS MEMORY

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5.5.1

GENERAL DEFAULT SETTING

During the first start i.e. when activating the control system for the first time and after replacing the main controller R 360 (located in the control cabinet), the internal memory of the PLC must be formated and paramaterized with the default operational values. If this default setting is carried out all previous personnel adjustments of the control system will be overwritten. Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. Procedure: • Set • Select • Select

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MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) SET DEFAULT SETTINGS follow the instruction displayed

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5.5.2

ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER PUMP)

This special mode will have to be activated in order to adjust the control oil pressure without starting the main drive motor – only the motor =M02-M11 for the booster pump (control oil supply pump) will be started / stopped by the switch. During this special mode possible low-pressure-alarm is suppressed, the technician must take care that there is oil in the system and the pump is running with the right sense of rotation. On the display is shown the average pressure measured in the hoisting gear circuit. Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. Procedure: • Set • Select • Select

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

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5.5.3

SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)

Work on the electrical equipment of the crane is to be performed only by well trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship. The luffing- and hoisting gear travel way is limited by mechanical limit switch contacts and additionally by measurement of the rope length. This rope length measurement is carried out by incremental encoders which are mounted inside the limit switches. (see also the technical description of the limit switches under item: „DESCRIPTION OF ELECTRICAL COMPONENTS“) Only on the first start of the crane or after exchange of the limit switch (also when a rope change is not carried out corresponding to the instruction „SPECIAL MODUS FOR ROPE CHANGE“ the mechanical limit switch contact have to be adjusted.. Procedure: • Set MAIN MENU • Select SECURED AREA (KEY-CODE IS ON DEMAND) • Select SET LIMIT SWITCHES • Select LUFFING GEAR or MAIN HOISTING GEAR or AUXILIARY HOISTING GEAR (OPTIONAL) follow the instruction displayed If another fault is indicated during the limit switch adjustment procedure, the reason for this fault must be eliminated prior to any further action.

ATTENTION: all limit switches are by-passed, the drive will not stop in the limit position, only a STOP command is shown on the display when this position is reached. ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be damaged, or the wire could unreel completely from the drum. The following runs have to be done at slow speed. The order of the adjustment steps must be kept strictly and exactly in the described manner. Start with the adjustment of the luffing gear limit switch. STEP 1: Luff the jib in completely in the most upright position (the gap between the jib and rubber buffer should be 5 – 10 cm). Stop the drive. STEP 2: In this jib position the limit switch contact for minimum outreach, contact no.1 (seen from the drive shaft) must be adjusted by turning the adjusting worm in counter-clockwise direction. The contact must switch over from closed position into opened position. If the contact has been opened while driving with the jib into the most upright position (precedent adjustment) the contact must be closed and opened again by means of the adjusting worm. See also the description “GEARED LIMIT SWITCHES - Series 51”.

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STEP 3: Luff out the jib until Step 4 is shown on the display. Step 4 will be displayed when the limit switch contact is closing again. If not Step 4 but Step 1 is displayed again during this procedure, it is the information that the limit switch contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange. Steps 1 and 2 must be repeated. (The contact must open by turning the adjusting worm in counterclockwise 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 counterclockwise direction)

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STEP 4: Lift up the hook until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again. Now the adjustment of the highest position is completed and you can drive with the hook to the deepest hook position. During this procedure the actual hook height (below highest position in meters) is shown on the display. STEP 5: There is no automatic stop during lowering, the hook should be stopped when the position is approx. 1 meter above the ground. In this position press the DONE key on the display. In this position the limit switch contact for the deepest position, contact no.2 (seen from the drive shaft) must be adjusted by turning the adjusting worm in clockwise direction. The contact must switch over from closed position into opened position. If the contact has been opened while driving with the jib into the maximal outreach position (precedent adjustment) the contact must be closed and opened again by means of the adjusting worm. STEP 6: Lift up the hook until the step 7 is displayed. Step 7 will be displayed when the limit switch contact is closing again. If not Step 7 but Step 5 is displayed during this procedure, it is the information that the limit switch contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange. (The contact must open by turning the adjusting worm in clockwise direction). Step 5 must be repeated. STEP 7: Lower again the hook until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again and the adjustment of the hoisting gear limit switch is completed. Leave the adjustment procedure by pressing EXIT on the display.

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5.5.3.1

SETTING LAYER CHANGE POSITION

If the hoisting rope is wheeled up on the winch in 2 layers, the layer change position must be checked or set when this position is not displayed correctly. Procedure: • Set • Select • Select

MAIN MENU INDICATIONS SPEED AND COUNTER VALUES

When the indication of counter values is activated on the dialogue module the actual hoisting position counter value and also the layer (1 or 2) is indicated. This layer indication must change from 1 to 2 before the rope will turn in the 2nd layer. If this layer change indication is not properly adjusted the layer changing position must be set by selection of the setting mode in the secured area. Turn the winch into the right position before the rope begins to shift over. Procedure: • Set • Select • Select

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) SET LAYERCHANGE POSITION LAYER2 must be selected on TRUE and entered

Now the limit switches are adjusted and the settings stored in the PLC memory. Switch off the controls in order to deactivate the limit switch setting system.

Finally check all limit switch cut-out positions.

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5.5.3.2

RESETTING OF REFERENCE POSITIONS

The rope length measuring system is carried out by means of incremental encoders inside the limit switches. The fault indication F1312 or F2312 will be displayed, if a previous failure of the rope length measuring system has stopped the corresponding drive. To reset this alarm and to restore the system, the corresponding drive must be driven into its reference position. • Jib to the maximum outreach (max. working range) • Hook / both hooks (if the crane has this equipment) into highest hook position (approx. 1 m below the jib-head or 0,5 m below the chain limiter) • Jib in max. outreach and hook(s) in highest position is the crane reference/default position – Procedure:

The function and how to operate the function-buttons of the display is described in the specification of the electrical equipment under item: Operation of the dialogue module over the function keys

•

Set

MAIN MENU (by pressing button F1)

•

Select

SECURED AREA and press ENTER • (KEY-CODE IS ON DEMAND that means the code number must be entered into the system) • Read the information about the emergency system in the specification of the electrical equipment under item: COMMISSIONING AND ADJUSTMENTS

•

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Select

Jump over the next pages by pressing NEXT

RESET OF REFERENCE POSITIONS and press ENTER

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YES must be selected and entered and the information must be confirmed by pressing ENTER again (If this mode is activated the contents of the counter values for luffing and hoisting drive are displayed.)

Do not activate the emergency system EOS-codes when the reference positions shall be reset, because these codes will oppress possible system failures. In case EOS-codes had been entered into the PLC before, the power must be switched off to de-activate the emergency codes, and the previous procedure must be repeated. ATTENTION: Now all limit switches are by-passed, the drive will not stop in the limit position, only LIMIT SWITCH CONTACT HAS OPENED will be displayed, when this position is reached. ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be damaged, or the wire could unreel completely from the drum. The following runs have to be done at slow speed. Restorage luffing gear reference position: The jib position must be in the normal working area, not beyond the maximum outreach limitation (bypassed with JIB-RESTING switch. Luff out the jib to the maximum outreach position (maximum working area), the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display when this position is reached, stop the drive. Lift up the jib until LIMIT SWITCH CONTACT HAS OPENED extinguishes, then lower the jib again, until the signal LIMIT SWITCH CONTACT HAS OPENED is shown on the display again. Restorage main hoisting gear reference position: Drive the jib to the maximum outreach position (maximum working area), ), the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display. When this position is reached, stop the drive. (The jib should be driven into this position first, it is easier to find the right reference position for the hook, because this is now close to the jib head – approx. 1 m below.) Lift up the main hook, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display when this position is reached, stop the drive. Lower the hook until LIMIT SWITCH CONTACT HAS OPENED is deleted. Lift up the main hook again, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display when this position is reached, stop the drive and then lower the hook approx. 2 m.

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Restorage auxiliary hoisting gear reference position: (if the crane has an aux. Hoisting gear) The procedure corresponds to the main hoisting gear, using the aux. hook. Restorage slewing gear reference position: The fault indication F3312 will be displayed, if a failure of the slewing ring counting system has stopped the drive. To reset this alarm and to restore the system, the slewing drive must be driven into the reference position. The reference position is the interlocking position of the tower for sea voyage ( jib in direction forward ). When the right position is reached LIMIT SWITCH CONTACT HAS OPENED will be displayed. If during this procedure another fault is indicated, the reason for this fault must be eliminated prior to any further action. When the reference positions have been reset by the described procedure it is

very important to de-activate this reference setting system before the power of the crane is switched off. Otherwise the reference position data will not be stored in the retain memory and this procedure must be repeated when the power is switched on again.

Press EXIT to leave page P184, page P149 now will be displayed

Press BACK several times until one of the following pages will be displayed

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5.5.4

ADJUSTABLE WORKING RANGE LIMITATION ( SPECIAL EQUIPMENT ) slewing gear reference position

restricted area circle chord actual outreach chord distance crane

max. working radius

The crane is equipped with an adjustable working range limitation, whereby the area of working range limitation is forming a segment of the circle. For adjusting you must first define the reference position of the slewing gear. A steel plate which activates the proximity switch =M06-B802 must be screwed to the relevant threaded bolts of the slewing ring. The other two proximity switches =M06-B810/-B811 count the gear teeth of the slewing ring and define the slewing angle.

The WORKING RANGE LIMITATION will be activated / de-activated by means of the dialogue module (display). Press to enter the main menu

Select WORKING RANGE SETTINGS and press ENTER.

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

887564.

Keep the code numbers secret for activating the secured area.

Now you can activate / de-activate the working range limitation

To de-activate the working range limitation press the “OFF” key and leave the working range settings with EXIT. When the working range limitation has been activated the slewing gear must slowly be driven into the reference position (zero position of the slewing angle) and the drive must be stopped when the reference position is reached (the menu will change and REFERENCE POSITION IS SET is blinking).

On this menu the actual distance of the circle chord from the centre of the crane radius is displayed. If the chord distance shall not be changed press the NEXT key. Menu P72 will be called up again, the status of the working range limitation is now “ON” you can now leave the working range settings by pressing EXIT. If the chord distance shall be changed press the ADJUST key and follow the instruction on this menu.

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On this menu the changed chord value is displayed now. If EXIT is pressed menu P72 will be called up again, the status of the working range limitation is now “ON”. You can now leave the working range settings by pressing EXIT.

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5.5.5

SPECIAL MODUS FOR ROPE CHANGE

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. When a rope has to be exchanged a special mode will support this procedure. If this special mode is activated the rope length measuring system and also the limit switches are bypassed. • • • • •

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 • Select • Select • Select • Select

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MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) ROPE CHANGE MODUS L_ROPE_CHANGE or H_ROPE_CHANGE FALSE or TRUE and ENTER

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5.5.6

CALIBRATION OF LOAD INDICATION

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. The crane load will be calculated as a function of the hoisting pressure. The oil pressure in the hoisting circuit consists of the idle running pressure + losses through floating resistances + working pressure. This working pressure always depends on the lifted load. The default load data for the calculation of the load weight are stored in the memory-module. These data can be overwritten if the displayed load weight is not similar to the lifted test weight. Procedure: • Set • Select • Select

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) LOAD ADJUSTMENT

Lift up the test weight with slow speed approx. 1 meter. When the drive has stopped on the display you can see the measured and calculated load, in the 2nd line the actual value for the load calculation in the 3rd line you can select a new calculation value (a higher one would increase the load) by entering this value, the 2nd line actual value for the load calculation and also the displayed load will change. If the load displayed corresponds to the lifted weight, you can leave this program.

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5.5.7

REPORT OF CHANGE

If during the adjustments some PLC-values have been changed, please report the new values to our electrical design department so that we can renew the default data of the PLC program corresponding to these changes. In case of any spare part delivery the new actual values will be delivered and set automatically, otherwise the personally changed values will be overwritten by the default (old) data. e-mail: [email protected]

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5.5.8

ZERO-SETTING OF POTENTIOMETERS

The potentiometers of the control levers set the direction and the speed of the corresponding drive. They are supplied by 24 V DC (not a fixed/regulated voltage) and in neutral position of the control lever the output of this potentiometer shall be ½ of the supply voltage. If this potentiometer is not exactly adjusted or the potentiometer resistance is non-linear, it is possible to set the potentiometer output level to zero. (Offset value) (This is only possible when the potentiometer is more or less correctly adjusted, otherwise a fault indication will result.) Procedure: • Set • Select • Select

5.5.9

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) ZERO-SET OF POTENTIOMETERS PRESS ENTER TO CALIBRATE

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 • Select • Select

5.5.10

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) 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.

ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT)

A feature of the crane control equipment is a heeling monitoring system. The heeling angle is shown on the display. If the angle exceeds 5° a pre-warning signal is given, and if the angle exceeds 8° the hoisting-, luffing out- and slewing operation is blocked. At even keel an angle of 0° should be displayed. If this value does not corresponds the output of the inclinometer can be set to zero. Procedure: • Set • Select • Select

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) ZERO-SETTING OF INCLINOMETER Select YES and ENTER

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5.6

INTERLOCKING FOR SEA VOYAGE (SPECIAL EQUIPMENT)

5.6.1

LOCKING

The operating system must be in order before the system for locking is switched on. During normal operation when the crane is not near the locking area the status of all signals from the monitoring proximity switches must be "TRUE": =M06-B804 - =M06-B809 cylinder position control =M06-B802 - =M06-B803 slewing gear position control The locking mode is selected by the key-operated switch on the right control desk. One of the two proximity switches monitoring the slewing gear position must be depressed? when this is done (signal-status = FALSE), i.e. the crane must have been slewed into the approximate locking position. The display shows the information that the locking system is been activated. The crane can now be slewed into the exact locking position only; motion in the opposite direction is blocked. Once the locking position has been reached (both slewing gear proximity switches must be depressed) the slewing gear is switched off automatically and the locking cylinders extended. If, due to the heel of the ship, the crane drifts out of the exact locking position, i.e. if either of the slewing gear proximity switches is no longer depressed, the slewing gear will be automatically returned to the correct position. To extend the locking cylinders, the luffing gear pump powers and the locking gear directional control valve is set to the position for locking. The display shows the progress of the locking procedure. When all locking cylinders are completely extended the corresponding signal-status of the proximity switches must be FALSE. The luffing gear pump and directional control valve are switched off, and the display shows the information that the crane tower is locked.. While locking , the pressure is limited to about 150 bar by sensor =M07-B20. A semi-automatic luffing gear positioning system is activated in the locking mode and automatically stops the jib from being lowered further when the locking position is reached. If the locking position lies outside the working range, the luffing gear stops at maximum outreach. In this case, actuate the key-operated switch JIB RESTING to continue luffing out until the jib stops automatically at the locking point. Caution: When using the JIB RESTING switch to leave the working range the hook block may be drawn against the jib head. If the jib is to be moved again by renewed movement of the control lever (joystick) after the luffing gear has been switched off automatically, the luffing gear positioning system must be reactivated by briefly switching the key-operated switch for the sea locking system OFF and ON. The semi-automatic luffing gear positioning system works only in the direction for luffing out. Once the slewing gear is locked and the jib is in the locking position, the lashing rope can be attached. The hook is now hoisted and slowly (carefully) roved into the hook block carrier. The hoisting gear is further run slowly in the hoisting direction until the lashing rope is taut, the jib being lifted slightly by the hook block at the same time. When the tension in the lashing rope is sufficient, the hoisting gear is automatically stopped and the luffing gear automatically activated to take up the slack in the luffing gear rope.

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5.6.2

UNLOCKING

The operating system must be in order before the system for locking for sea is switched on. During normal operation when the crane is locked, the status of all signals from the monitoring proximity switches must be "FALSE": =M06-B804 - =M06-B809 cylinder position control =M06-B802 - =M06-B803 slewing gear position control To unlock the crane, the hook must first be lowered and the lashing rope disconnected, and then the keyactuated switch of the sea locking system must be turned to the zero position. To retract the locking cylinders, the luffing gear pump powers and the locking gear, the directional control valve is set to the position for unlocking. The display shows the progress of the locking procedure. When all locking cylinders are completely retracted the corresponding signal-status of the proximity switches must be TRUE. The luffing gear pump and directional control valve are switched off, and the display shows the information that the crane tower is unlocked.. While unlocking , the pressure is limited to about 210 bar by sensor =M07-B20. As a rule, unlocking takes about 10 ... 15 seconds. If it has not been completed by this time, the slewing gear is activated briefly in both directions to ease the jammed locking pin free. The slewing gear pressure is limited to 80 bar by pressure switch =M07-S82 during this. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal

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5.6.3

FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM

The following fault messages are generated by the interlocking system: F F F F F

4301 4302 4303 4304 4305

CYLINDER NOT IN UNLOCK POSITION STATUS FAILURE OF PROXIMITY SWITCHES CRANE REMOVED FROM LOCKING POSITION LOCKING TIME LIMITATION EXCEEDED UNLOCKING TIME LIMITATION EXCEEDED

F

4301

CYLINDER NOT IN UNLOCK POSITION

Proximity switches =M06-B804 to B809 monitor the upper positions of the locking cylinders during normal crane operation. The status signals from the monitoring proximity switches must be "TRUE": =M06-B804 - =M06-B809 cylinder position control The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action

− − − − −

Check the positions of the locking cylinders. Check proximity switches =M06-B804 to B809. Check the power supply and leads to the proximity switches. Check the wiring. Replace PLC.

Attention by activation of emergency code EOS4301: Should the cylinder monitoring system be by-passed by emergency code, it must first be checked that all cylinders are completely retracted. If any cylinder extends, a damage of the slewing gear (slewing ring) is possible.

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F

4302

STATUS FAILURE OF PROXIMITY SWITCHES

The position of the locking cylinders is monitored by proximity switches. This fault will be announced if the signalled condition is not logical. The actual input status can be displayed: • • • •

Set Select Select Select

MAIN MENU INDICATIONS INPUT / OUTPUT VALUES DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal

Remedial action

− Check the conditions signalled by the proximity switches. When the locking cylinders are completely retracted proximity switches =M06-B804 to B809 must be TRUE, when these cylinders are fully extended, the same signals must be FALSE. − Check the proximity switches and their fastenings − Check the leads − Check the wiring. − Replace PLC.

Attention by activation of emergency code EOS4302: If the cylinder monitoring system is by-passed by emergency code, at first it must be checked that all cylinders are completely retracted. If any cylinder extends, a damage of the slewing gear (slewing ring) is possible.

F

4303

CRANE REMOVED FROM LOCKING POSITION

When locking, the slewing gear is stopped in the locking position and, if it leaves that position owing to heel, etc., is automatically returned to the locking position. This fault message is generated if this does not work and the crane has not returned to the locking position within 8 seconds. The position is monitored by proximity switches = M06-B802 - B803. When the crane is in "at-interlocking" position, the proximity switches must signal "FALSE". The actual input status can be displayed: • • • •

Set Select Select Select

MAIN MENU INDICATIONS INPUT / OUTPUT VALUES DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal

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

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F F

4304 4305

LOCKING TIME LIMITATION EXCEEDED UNLOCKING TIME LIMITATION EXCEEDED

Locking or unlocking procedures should take no longer than approx.15 sec. The above fault announcement will appear if locking or unlocking procedures are not finished within 30 sec. Remedial action - Check the electrical and hydraulic locking controls. - The additional pump (luffing gear pump) must have power for locking and unlocking. - The directional valve for locking or unlocking and the release valve must be actuated. - The cylinders should be unlocked with approx. 210 bar pressure, they should be locked with approx. 150 bar pressure. The pressure (luffing gear pressure) can be read on the display or measured with a pressure gauge. The actual sensor output value can be displayed: • • • •

Set Select Select Select

MAIN MENU INDICATIONS INPUT / OUTPUT VALUES 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 • Select • Select

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MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) EOS INTERLOCKING SYSTEM

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5.6.3.1

SETTING THE PRESSURE LIMITING VALVE

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship. The pressure is limited to 150/210 bar by sensor =M07-B20 during locking and unlocking. For higher safety level it is advisable to set the pressure limiting valve in the switching block of the sea locking system to 240 bar. This setting should be undertaken only at nominal voltage (e.g. 440 V, 60 Hz, i.e. at the shipyard using the ship's mains fed by the ship's generators) with hydraulic oil that is operationally warm (>40 °C). When the operating system is activated for the setting operation, the locked or unlocked status is not switched off if the cylinders are in their end positions and the electronic pressure limitation is not in effect. Procedure: Turn the crane into the sea locking position and, using the normal operating system, lock it and unlock it again to check that the locking system is in order. Select EOS INTERLOCKING SYSTEM Set PRESSURE ADJUSTMENTS on TRUE: The pressure will be shown automatically on the display. Lock / Unlock the crane by SET OPERATION. The pump delivery increases slightly when the cylinders are fully extended. The hydraulic pressure setting can be adjusted at this point. By activating the emergency operating system the locking cylinders can be extended and retracted even when the proximity switches and pressure sensors are out of order. In such cases care must be taken that the slewing gear is exactly in the locking position because all monitoring facilities are overridden. Explanation in the case of locking: The locking pressure then appears automatically on the display; if the sensor is defective the pressure must be checked by pressure gauge. When the LOCK soft-key is pressed (it must be held down throughout the locking process), the directional control valve is switched to the locking position and the luffing gear pump is started at low (minimum) current. The current, and therefore the delivery of the pump, is increased by ramp function and must be observed to prevent the pressure from becoming too high (release the soft-key briefly). Once the slewing gear is locked (cylinder completely extended) the procedure is ended by releasing the softkey.

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5.6.3.2

LOCK / UNLOCK IN EMERGENCY OPERATION

Work on the electrical equipment of the crane is to be performed only by well trained personnel. All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code. Keep the code numbers secret for activating the secured area. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account. This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship. If the interlocking system is not working properly an emergency system can be activated for overriding and direct control of the interlocking cylinder. Procedure: • Set • Select • Select

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) 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 softkey. 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 softkey. Take care that all locking cylinders are completely retracted and than set the status of the interlocking system on UNLOCKED by selection of CRANE IS UNLOCKED and entering TRUE.

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5.7

PMS – POWER MANAGEMENT SYSTEM (SPECIAL EQUIPMENT)

5.7.1

FUNCTIONAL DESCRIPTION

The crane drives will be started by activating the START - switch. At first, the feed oil pump motor (9 kW) starts while simultaneously the POWER-REQUEST signal (potential-free N.O. contact) will be given to the ship control system of the ECR (engine control room) via the slip ring body. In case of sufficient power supply of the generator, the crane control system will get a POWER-AVAILABLE signal (potential-free N.O.contact) from the ECR. The main motor (160-kW-motor) will start only if the POWER-AVAILABLE signal is available. If the POWER-AVAILABLE signal will not be received within 30 sec after START (= POWER-REQUEST), the feed oil pump motor will be stopped and the starting procedure must be repeated. Display: FAULT OF PMS-SYSTEM If the POWER-AVAILABLE signal drops out (e.g. in case of power outage / generator failure) during crane operation, the crane drives will run down and the motors will be switched-off. Display: FAULT OF PMS-SYSTEM Within 10 min after normal termination of the crane operation, the POWER-REQUEST signal will be cut off. The following status signals can be seen on the display: :

FAULT OF PMS-SYSTEM POWER-REQUEST POWER-AVAILABLE

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5.8

SPECIAL OPERATION MODES

5.8.1

TEST OPERATION

This special mode allows to check all solenoid valve circuits without running pump motors. Therefore the crane control will be set into operable and all relevant limitations will be by-passed. When the test operation mode is activated it is not possible to start the pump drive motors. Procedure: • Set • Select • Select

5.8.2

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) SET / RESET TEST OPERATION TEST OPERATION can now be activated = TRUE / deactivated = FALSE by selection and entering

POWER / SPEED REDUCTION

This special mode will limit the speed of all drives at about 50 percent of it’s maximal speed. This mode can be used to reduce the power consumption of the crane in case of problems with the supply source (shore connection / generator failure), or when the drive speeds shall be reduced to prevent collision conflicts etc. Procedure: • Set • Select • Select

5.8.3

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) SET SPEED REDUCTION SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE by selection and entering

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 • Select • Select

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MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) DISABLE TRIMOT T_DISABLE: can now be activated = TRUE / deactivated = FALSE by selection and entering

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5.9

TROUBLE SHOOTING

5.9.1

GENERAL REMARKS

The electronic assemblies include ICs in C-MOS Technology, the assemblies should never be extracted or plugged in while the power is connected. While designing the electrical equipment, great value was attached to providing a status monitoring system that would monitor as many operating criteria as possible and would generate an appropriate message in the event of malfunctions on the display. If a malfunction occurs, the red collective fault indicator light in the control console lights up. After the part of the system concerned has been checked and, if necessary, repaired, the crane can be put into operation again by pressing the button < F2 >. The following text describes the messages given by the status monitoring system in more detail. The status monitoring system consists of several subsystems handling various criteria. The first distinction has to be made between fault messages and condition status messages. "FAULT" signalises malfunctions or faults which interrupt crane operation or certain functions and must be RESET after repair. "CONDITIONS", in contrast, are intentional interruptions or limits set on the basis of monitoring criteria (e.g. hoisting gear limit switches or excessive hook loads). "CONDITION" displays that a limiting device has responded, but not that there is a fault in the system.

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5.9.1.1

POWER SUPPLY AND CONTROL VOLTAGE

The power supply is feed from the ship's mains to the crane main switch across slip ring body. If the main switch cannot be turned on, check the following points : 1. Is the power feeder from the ship's supply switched on? 2. Is an EMERGENCY OFF button being pressed? 3. Is the breaker =M01-Q1 in the OFF position. The 24 V DC control voltage is produced by the three-phase rectifier bridge =M01-U1. The 24 V control voltage is distributed into different circuits which are protected by fuses =M01-F11 to – F18. If one of these fuses is out of order (for instance, blown owing to a short circuit), the fault is indicated by the LED in the fuse terminal.

5.9.1.2

PLC STATUS INDICATORS

The main status of the PLC-system is indicated by LED’s on the main controller and on the input and output Compact Modules. When the system is running in good order the green LED is blinking with a 2 Hz signal. Detailed information about the status indication is given in the hardware description of the PLC components. The signal status of each input and output on the Compact Modules is also indicated by a LED.

5.9.1.3

ADDITIONAL INDICATIONS

Detailed information about the input- output-status or value will be displayed, if the corresponding indication sheet is selected, e.g.: DRIVE VALUES potentiometer value, setup value, nominal / actual speed value SENSOR VALUES digital inputs and outputs (TRUE / FALSE) analogue inputs (current or voltage) current outputs (PWM value in mA) COUNTER VALUES position of the drive and drive speed By calls of this information you are able to check a lot of relevant system data, e.g. it is possible to check the status of an input or a sensor value (output current) will be read into the PLC. Procedure: • Set • Select

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MAIN MENU INDICATIONS Choose the required information

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5.9.2

LIST OF FAULT MESSAGES and fault identification instructions

F

0010

STATUS FAILURE DELTA CONTACTOR

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the corresponding PLC input itself is defective. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F F F F

0011 0012 0013 0014

− 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.

STATUS FAILURE LIMIT SWITCH LUFFING IN STATUS FAILURE LIMIT SWITCH LUFFING OUT STATUS FAILURE LIMIT SWITCH HOISTING STATUS FAILURE LIMIT SWITCH LOWERING

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the corresponding PLC input itself is defective. Additional the status the limit switch contacts will be monitored: Each contact block contains a NC and NO contact that means the voltage on the corresponding PLC inputs must alternate. If both inputs have an identical signal level at the same time the corresponding fault will be set. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− Check the contact of the displayed circuit line, e.g. F0015 indicates voltage at input IX4.01, although the contact of the pressure switch =M07-S10 must be open. − Eliminate the extraneous voltage, if present. − Exchange the PLC or the corresponding Compact Module.

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F F F F

0015 0016 0017 0018

STATUS FAILURE PRESS. SWITCH HOISTING STATUS FAILURE PRESS. SWITCH LUFFING STATUS FAILURE PRESS. SWITCH SLEWING STATUS FAILURE PRESS. SWITCH SLEWING

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the corresponding PLC input itself is defective. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

003

− 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.

MAIN SWITCH CONTROL

Appears if main switch is switched off while pump drive motors are still running. Press button to eliminate. The crane shall not be stopped by pressing the emergency stop button. Remedial action:

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− Check the auxiliary contact of the main switch, this contact must be opened when the main switch is ON.

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F

004

FAULT OF PMS-SYSTEM

For further information see functional description of the PMS-System. This message appears if the power available signal is not given within 30 sec. after starting of the electrical drives of the crane or when the signal drops out (e.g. in case of power outage / generator failure) during crane operation). The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

C

0041

− Check the relay =M06-KRQ, this relay must be switched on during run time of the crane. − Check the relay =M06-KEN, this relay will be activated by the power available signal from ECR. − Check the wiring and the connections via slipring assembly − Check the control system of the ship controls in the engine control room (ECR) PMS POWER REQUEST

This signal will be displayed if the starting procedure of the main motor is delayed because there is no start enable by the power available signal. C

0042

PMS POWER AVAILABLE

The PMS-System has received the start enable signal and will start the main motor.

F

005

DRIVE CONTACTOR NOT IN DELTA

The motor of the main pump is switched from the star to the delta circuit by means of timing relay =M02K4. This is intended to happen after about four seconds. This message appears if the switch-over has not taken place after 10 seconds. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− − − − −

Set the switching time on the star/delta timing relay to 4 seconds. Replace the timing relay if defective. Repair the contactor for the delta circuit if necessary. Check the wiring. Replace the PLC.

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006

CONTROL LEVER NOT IN NEUTRAL POSITION

The control levers are not to be operated until 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 is displayed. This message appears also if the dead man switch is actuated before is displayed. (optional equipment) The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

007

− 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.

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 Select Select

5-110

MAIN MENU SECURED AREA (KEY-CODE IS ON DEMAND) SET OPERATING HOURS SET NEW OPERATION HOURS M01:by corresponding data input

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F

0110

CONTROL OIL PRESSURE /= 4 mA is now displayed, then the temperature sensor itself or the connector cable is defective. − Exchange the PLC or the corresponding Compact Module.

FILTER OVERPRESSURE

This fault message appears if the pressure switch (=M07-S08) of the filter clogging indicator has tripped. The switch trips when the pressure dropped across the filter exceeds 5 bar (cf. specification of the hydraulic system). The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− Replace the filter cartridge. − Check the pressure switch characteristics (the contact must be closed). − Check the wiring. − Exchange the PLC or the corresponding Compact Module.

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F

0220

OVERLOAD FEED OIL PUMP

This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q11 for the control oil / booster pump has tripped. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs are displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

0230

− Reset the MCB. − Check the power supply for phase failure. − Compare the current set on the MCB with the specified nominal motor current. − Measure the motor amperage. If it is too high, the cause must be sought in the booster pump or hydraulic system. − Check the wiring. − Replace the PLC.

OVERLOAD OIL COOLER

This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q12 for the hydraulic oil cooler has tripped. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− Reset the MCB. − Check the power supply for phase failure. − Compare the current set on the MCB with the specified nominal motor current. − Measure the motor amperage. If it is too high, the cause must be sought in the booster pump or hydraulic system. − Check the wiring. − Replace the PLC.

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F

0240

OVERLOAD MAIN MOTOR (THERMISTOR)

This fault message appears when the overload protection circuit for the main motor (=M02-M1) trips. The protection circuit consists of a thermistor controlled relay (=M02-F4). The thermistor controlled relay will trip if the pump drive is overloaded or the motor is not being adequately cooled. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

− Check the air circulation in the machinery space (air supply via the crane column, exhaust via the hydraulic oil cooler). − Check the thermistors in the motor. − The thermistor resistance is normally 250 to 700 ohms, but exceeds 3.5 kilo ohm if the temperature is too high. BE CAREFUL WHEN CHECKING THERMISTORS! They are extremely sensitive and will be destroyed if a voltage exceeding 2 V is applied. − Check that the thermistor-controlled relay is working properly. − Check the wiring. − Replace the PLC.

F

0251

OVERCURRENT MAIN MOTOR

The current drawn by the main motor is monitored in addition to the winding temperature. This is done by current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current. Fault message appears if the drawn current exceeds 2.3 times the nominal current. The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and the calculated motor amperage A. (A=I(v1-v2) * 1,73 Remedial action:

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− Check the voltage and the current drawn by the motor. − Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn). − Replace the PLC.

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F

0252

NO AMPERAGE MAIN MOTOR

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current. Fault message appears if the current drawn is lower than that normally drawn under no-load conditions (protection against phase failure). The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and the calculated motor amperage A. (A=I(v1-v2) * 1,73 Remedial action:

F

0253

− The sensor works with 220 V, i.e. the supply for lighting and heating must be switched on via fuse =M03-F34. − Check the voltage and the current drawn by the motor. − Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn). − Replace the PLC.

IDLE RUNNING AMPERAGE MAIN MOTOR

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current. Fault message appears if the current drawn is higher than that normally drawn under no-load conditions (protection against phase failure). The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and the calculated motor amperage A. (A=I(v1-v2) * 1,73 Remedial action:

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− Check the voltage and the current drawn by the motor. − Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn). − Replace the PLC.

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C

0711

POWER REDUCTION (MAIN MOTOR AMPERAGE)

The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current. This message appears if the hoisting speed is reduced because current drawn by the main motor is too high. This can happen if all three crane motions are activated at full speed simultaneously under full load. If the message appears while working at part load, the power supply to the motor should be checked. The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and the calculated motor amperage A. (A=I(v1-v2) * 1,73 Remedial action:

C

0713

− Check the voltage and the current drawn by the motor. − Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn). − Replace the PLC.

SPEED REDUCTION (SPEC. OPERATION MODE)

This message indicates that the speed reduction mode has been activated. Remedial action:

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− De-activate this mode. • Set MAIN MENU • Select SECURED AREA (KEY-CODE IS ON DEMAND) • Select SET SPEED REDUCTION SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE by selection and entering

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F

1010

HOISTING PRESSURE 40 bar

If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil pressure). This message appears if the pressure remains at a level >40 bar.

The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and bar. Remedial action:

F

1060

− Compare the pressure displayed with a measurement carried out by a pressure gauge. − Check the control unit of the hydraulic pump, maybe the pump control unit is not shifting back into neutral position − (see description of the hydraulic plant). − Check pressure sensor =M07-B10. − e.g. interchange the hoisting pressure sensor against the luffing pressure sensor, if the failure is now displayed in the luffing circuit, then the hoisting pressure sensor itself or the connector cable is defective. − Exchange the PLC or the corresponding Compact Module.

HOISTING CONTROL LEVER (OFFSET)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection. The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value. Fault message is generated if the output voltage deviates more than 10% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes). The actual control lever conditions can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS • Select NEXT / POTENTIOMETER CHECK The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the contact condition is displayed false/true. The potentiometer value must be below 100 when the contact condition is false. To check these values move the lever very slowly out of neutral position. Remedial action:

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− Measure the output voltage of the potentiometer (control lever in neutral position). − Check the contacts of the control lever. − Re-adjust the potentiometer. − Check the wiring. − Replace the PLC or the Cabinet Module. − Additional information regarding EOS 1060: For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. 2-571-7/365-7/3168

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If one of the contacts is defective, the drive can be controlled by the potentiometer only, this will be activated by the EOS-code. Now the drive will be started and stopped by the potentiometer in the control lever without safety control-check. This is a dangerous condition: if now the potentiometer or the analogue input becomes defective the drive will start without driver command and can be stopped by emergency stop only.

F

1070

HOISTING CONTROL LEVER (SUPPLY)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection. The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value. Fault message is generated if the output voltage deviates more than 90% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes). The actual control lever conditions can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS • Select NEXT / POTENTIOMETER CHECK The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the contact condition is displayed false/true. The potentiometer value must be below 100 when the contact condition is false. To check these values move the lever very slowly out of neutral position. Remedial action:

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− Check the wiring and the supply connections of the potentiometer. − Measure the output voltage of the potentiometer (control lever in neutral position). − Most of time it is a supply failure or the potentiometer itself is defective. − Check the contacts of the control lever. − Replace the PLC or the Cabinet Module. − Additional information regarding EOS 1070. For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If the potentiometer is defective, the drive can be controlled by the control lever contacts only, this will be activated by the EOScode. In normal conditions the contacts of the control lever are connected in parallel, it does not matter in which direction the control lever is actuated. For control with the EOS 1070-code it is necessary to remove the bridge which is connecting the contacts (the bridge on the supply side must remain), and now the contact which will close in lowering direction must be connected to the terminal for the EOS-input (IX5.01). Now the drive will be started and stopped by the contacts in the control lever without potentiometer speed control. For safety reasons the drive speed is limited to half of its maximum.

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F F

1080 1081

HOISTING PWM-OUTPUT FAILURE =M07-A3 HOISTING PWM-OUTPUT FAILURE =M07-A7

The control current for the proportional solenoid vales of the pump is generated in the Compact Module by Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is taken although the corresponding PWM output is activated by the nominal value . The drive condition can be displayed: • Set MAIN MENU • Select INDICATIONS • Select DRIVE VALUES Remedial action:

F

1090

− Check the wiring to the solenoid valve. − Check the resistance of the solenoid coil. (approx. 24-30Ω) − Replace the PLC or the Cabinet Module.

HOISTING WINCH OVERTEMPERATURE

The maximum temperature of the winch gear box is controlled by a temperature switch, the contact will open when the temperature is exceeding the maximum value. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

1091

− − − −

Check the winch temperature. Check the temperature switch Check the wiring between switch and PLC Replace the PLC.

SECURITY CHECK WINCH OVERTEMPERATURE

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the PLC input itself is defective. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− Eliminate the extraneous voltage, if present. − Exchange the PLC. 2-571-7/365-7/3168

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C

1210

LIFTING LIMIT (SAFETY LIMIT-SWITCH)

Additional to the electronic limit protection, there are 2 mechanical limit switches installed for collision protection between hook and jib (anti-two-block). One of these limit switches is actuated. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− − − − − −

Lower the hook or luff in the jib. Check the limit switches, mounted at the jib head. Check the wiring to the limit switches. Check the relays =M06-K1S, -K2S. It is not possible to override this fault by the emergency system.

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C

1211

LIFTING LIMIT (MECHANICAL SWITCH)

The lifting distance of the crane is limited by the hoisting gear limit switch =M06-S16. If this message appears although the hoisting gear is in the "free" range, the following checks should be carried out: The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action: − Check the mechanism of the limit switch (connection to the hoisting gear drum, limit switch coupling, limit switch gear, cam shaft) − Check the switching contacts. − Check the wiring. − Replace the PLC.

C

1212

LIFTING LIMIT (ROPE LENGHT)

The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16. If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

C

1214

LIFTING PRE-LIMITATION

The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16. Before the final limit position is reached the drive speed will be ramped down by the rope length measurement. If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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1216

LOWERING LIMIT (MECHANICAL SWITCH)

The lowering distance of the crane is limited by the hoisting gear limit switch =M06-S16. If this message appears although the hoisting gear is in the "free" range, the following checks should be carried out: The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action: − Check the mechanism of the limit switch (connection to the hoisting gear drum, limit switch coupling, limit switch gear, cam shaft) − Check the switching contacts. − Check the wiring. − Replace the PLC. C

1217

LOWERING PRE-LIMITATION

The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16. Before the final limit position is reached the drive speed will be ramped down by the rope length measurement. If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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1220

SLACK ROPE

The slack rope monitoring system of the hoisting gear has responded and blocked the motion. Haul the rope taut by cautious operation in the opposite direction. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action

C

1221

− Check the contact rail; the contact rail is connected to a 24 V output channel of the PLC. If the lifting gear rope is slack, it will touch the rail, thereby earthing it so that the output voltage will drop down. In other words, the lifting gear rope must not touch the contact rail, and the contact rail must also be free from any dirt that might cause an earth fault. − Check the wiring. − Replace the PLC.

LOWERING LIMIT (ROPE LENGTH)

The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16. If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

C

1222

DEADMAN SWITCH NOT ACTUATED

The control leaver is equipped with a deadman switch. This switch must be actuated before the leaver is moved from neutral position. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action

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− Check the mechanism of the control leaver (automatic return into zero position; in zero position the directional contacts must be open) − Check the deadman switching contact. − Check the wiring. − Replace the cabinet module. 2-571-7/365-7/3168

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F

1301

HOISTING COUNTER EQUALITY FAILURE

This fault is an internal fault in the PLC. The output pulses from the incremental encoder are counted to ascertain the position of the drive. For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are compared. It is also necessary to make sure that the correct position information is stored if an emergency cut-out is tripped. This fault message is generated if the counter contents are not identical. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“ − The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.

F

1302

HOISTING COUNTER OUT OF RANGE

The output pulses from the incremental encoder are counted to ascertain the position of the drive. This position counter value is limited by a minimum and maximum size. This fault message is generated if the counter contents is not inside its limits. This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“ − The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.

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F

1303

HOISTING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the drive has passed the limit position without opening of the contact). When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

F

1304

− −

Check the limit switch contacts (function and adjustment) Check the counter value of the position counter

−

follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

HOISTING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the contact has opened before the drive has reached the electronic measured limit position). When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

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− − −

Check the limit switch contacts (function and adjustment) Check the counter value of the position counter Replace the PLC.

−

follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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F

1305

HOISTING GEAR IS BLOCKED

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails. • The winch does not move although the drive command is given (- the brake is not released; - or the gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective). Remedial action:

F

1306

− Check the electrical power of the brake valve (the LED on the valve connector plug should light up). − Check the hydraulic control pressure for the brake at the respective pressure measuring point. − Press the emergency button on the solenoid valve of the brake, the pressure must increase up to 25-28 bar − Press the emergency button on the solenoid valve of the pump control unit, the pressure must increase up to 300 bar − Replace the PLC, or digital input/output module

HOISTING ENCODER OUTPUTS EXCHANGED

The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses generated by the encoder are phase-shifted with respect to each other (see illustration below) .

If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed around. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− interchange the outputs of the encoder − Replace the encoder − Replace the PLC. − follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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F

1307

HOISTING NO COUNTING PULSES

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails. • The electrical encoder system fails When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− Check the hydraulic working pressure of the pump, if the drive is set for lifting run the pressure on the high pressure side of the pump must increase from 40 bar up to 300 bar − Press the emergency button on the solenoid valve of the pump control unit, the pump must increase up to 300 bar − Check the encoder power supply. − Check the encoder installation (coupling) inside the limit switch − Check the wiring − Replace the encoder − Replace the PLC, or the PWM module − follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

F

1308

HOISTING WRONG ROTARY MOTION

The winch monitoring system has indicated that the winch is turning in the paying out direction although the control command calls for the opposite sense of rotation. If this fault message appears after replacing the encoder, the encoder outputs must changed around. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

ELECTRICAL EQUIPMENT 7/3165-3168

− Check the complete drive system to ascertain that the winch moves in accordance with the joystick deflection (direction and speed). − interchange the outputs of the encoder − Replace the encoder − Replace the PLC

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F

1309

HOISTING STANDSTILL DRUM MONITORING

If the drive is not activated (brake applied), the winch monitoring system must not signal any motion. The actual output status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

1310

− Check the brake concerned. − Check the electrical controls of the brake valves; if necessary, replace the Compact Module.

HOISTING OVERSPEED (FULL LOAD)

The speed of the winch is monitored by an incremental encoder. This maximum drum speed has been exceeded. The drive speed can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

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− Check the hydraulic system : pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system). − Check the electrical power of the TRIMOT control. There must be no output signal when a full load is to be lifted / lowered.

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F

1311

HOISTING OVERSPEED (EMPTY HOOK)

The speed of the winch is monitored by an incremental encoder. This maximum drum speed has been exceeded. The drive speed can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

F

1312

− Check the hydraulic system : pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system). − Check the minimum displacement angle of the TRIMOT. (see specification of the hydraulic system).

HOISTING MUST RUN INTO REF. POSITION

This fault indication appears as a result of a previous failure. The previous failure which has caused this indication is also displayed as ORIGIN FAULT. This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according to the corresponding fault description. It is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

ELECTRICAL EQUIPMENT 7/3165-3168

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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F F

1330 1331

TRIMOT OVERPRESSURE HOISTING TRIMOT OVERPRESSURE LOWERING

This fault message appears when the safety cut-out of the variable displacement hydraulic motor (TRIMOT) for the hoisting gear trips. This fault could be caused by a driver mistake, when he starts lifting a load with full speed, although the load is not lifted up from the ground (slack rope). The current output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES Select CURRENT OUTPUTS The actual amperage is displayed The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and bar. The following action should be taken if this fault occurs frequently : − Check pressure hoisting pressure on the display and with a gauge. − Check the current drawn by the solenoid valve. (Set the controls to the test mode, shift the hoisting gear control lever to maximum deflection. In this state, the current drawn by the solenoid valve should rise from about 200 to about 500 mA within about 4 seconds.) − If the measured currents are within limits, check the hydraulic controls. − If the current is outside of the limits, replace the PLC. − Check the wiring.

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F

2010

LUFFING PRESSURE 40 bar

If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil pressure). This message appears if the pressure remains at a level >40 bar.

The actual sensor output value can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS The value of the sensor is displayed in µA and bar. Remedial action:

ELECTRICAL EQUIPMENT 7/3165-3168

− Compare the pressure displayed with a measurement carried out by a pressure gauge. − Check the control unit of the hydraulic pump, maybe the pump control unit is not shifting back into neutral position − (see description of the hydraulic plant). − Check pressure sensor =M07-B20. − e.g. interchange the luffing pressure sensor against the hoisting pressure sensor, if the failure is now displayed in the hoisting circuit, then the pressure sensor itself or the connector cable is defective. − Exchange the PLC or the corresponding Compact Module.

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F

2060

LUFFING CONTROL LEVER (OFFSET)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection. The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value. Fault message is generated if the output voltage deviates more than 10% from the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes). The actual control lever conditions can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS • Select NEXT / POTENTIOMETER CHECK The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and the contact condition is displayed false/true. The potentiometer value must be below 100 when the contact condition is false. To check these values move the lever very slowly out of neutral position. Remedial action:

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− Measure the output voltage of the potentiometer (control lever in neutral position). − Check the contacts of the control lever. − Re-adjust the potentiometer. − Check the wiring. − Replace the PLC or the Cabinet Module. − Additional information regarding EOS 2060: For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If one of the contacts is defective, the drive can be controlled by the potentiometer only, this will be activated by the EOS-code. Now the drive will be started and stopped by the potentiometer in the control lever without safety control-check. This is a dangerous condition: if the potentiometer or the analogue input now becomes defective the drive will start without driver command and can be stopped by emergency stop only.

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F

2070

LUFFING CONTROL LEVER (SUPPLY)

The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection. The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value. Fault message is generated if the output voltage deviates more than 90% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes). The actual control lever conditions can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select ANALOGUE INPUTS • Select NEXT / POTENTIOMETER CHECK The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and the contact condition is displayed false/true. The potentiometer value must be below 100 when the contact condition is false. To check these values move the lever very slowly out of neutral position. Remedial action:

ELECTRICAL EQUIPMENT 7/3165-3168

− Check the wiring and the supply connections of the potentiometer. − Measure the output voltage of the potentiometer (control lever in neutral position). − Most of time it is a supply failure or the potentiometer itself is defective. − Check the contacts of the control lever. − Replace the PLC or the Cabinet Module. − Additional information regarding EOS 2070. For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If the potentiometer is defective, the drive can be controlled by the control lever contacts only, this will be activated by the EOScode. In normal conditions the contacts of the control lever are connected in parallel, it does not matter in which direction the control lever is to be actuated. For control with the EOS 2070 code it is necessary to remove the bridge which is connecting the contacts (the bridge on the supply side must remain), and now the contact which will close in luffing out direction must be connected to the terminal for the EOS-input (IX5.01). Now the drive will be started and stopped by the contacts in the control lever without potentiometer speed control. For safety reasons the drive speed is limited to half of its maximum.

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F F

2080 2081

LUFFING PWM-OUTPUT FAILURE =M07-A3 LUFFING PWM-OUTPUT FAILURE =M07-A7

The control current for the proportional solenoid values of the pump is generated in the Compact Module by Pulse Width Modulation. A fault message appears when no control current measurement (actual value) is taken although the corresponding PWM output is activated by the nominal value . The drive condition can be displayed: • Set MAIN MENU • Select INDICATIONS • Select DRIVE VALUES Remedial action:

F

2090

− Check the wiring to the solenoid valve. − Check the resistance of the solenoid coil. (approx. 24-30Ω) − Replace the PLC or the Cabinet Module.

LUFFING WINCH OVERTEMPERATURE

The maximum temperature of the winch gear box is controlled by a temperature switch, the contact will open when the temperature is exceeding the maximum value. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

2091

− − − −

Check the winch temperature. Check the temperature switch Check the wiring between switch and PLC Replace the PLC.

SECURITY CHECK WINCH OVERTEMPERATURE

The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the PLC input itself is defective. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− Eliminate the extraneous voltage, if present. − Exchange the PLC. 2-571-7/3165-7/3168

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C

2210

LUFF. OUT LIMIT (SAFETY LIMIT-SWITCH)

Additional to the electronic limit protection there are 2 mechanical limit switches installed for collision protection between hook and jib (anti-two-block). One of these limit switches is actuated. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

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− − − − − −

Lower the hook or luff in the jib. Check the limit switches, mounted at the jib head. Check the wiring to the limit switches. Check the relays =M06-K1S, -K2S. It is not possible to override this fault by the emergency system.

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C

2211

LUFF. OUT LIMIT (MECHANICAL SWITCH)

The maximum outreach of the crane is limited by the luffing gear limit switch =M06-S26. If this message appears although the luffing gear is in the "free" range, the following checks should be carried out: The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action: − Check the mechanism of the limit switch (connection to the luffing gear drum, limit switch coupling, limit switch gear, cam shaft) − Check the switching contacts. − Check the wiring. − Replace the PLC.

C

2212

LUFF. OUT LIMIT (ROPE LENGHT)

The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26. If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

C

2214

LUFF. OUT PRE-LIMITATION

The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26. Before the final limit position is reached the drive speed will be ramped down by the rope length measurement. If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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2216

LUFF. IN LIMIT (MECHANICAL SWITCH)

The minimum outreach of the crane is limited by the luffing gear limit switch =M06-S26. If this message appears although the luffing gear is in the "free" range, the following checks should be carried out: The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action: − Check the mechanism of the limit switch (connection to the luffing gear drum, limit switch coupling, limit switch gear, cam shaft) − Check the switching contacts. − Check the wiring. − Replace the PLC.

C

2217

LUFF. IN PRE-LIMITATION

The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26. Before the final limit position is reached the drive speed will be ramped down by the rope length measurement. If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

C

2218

LUFF. IN (ROPE LENGTH)

The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26. Before the final limit position is reached the drive speed will be ramped down by the rope length measurement. If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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2219

LUFF. OUT FINAL SAFETY POSITION

The final (maximum) outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26. ATTENTION: If this limitation is to be by-passed RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be damaged, or the wire could unreel completely from the drum.

C

2222

DEADMAN SWITCH NOT ACTUATED

The control leaver is equipped with a deadman switch. This switch must be actuated before the leaver is moved from neutral position. The actual input status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action

F

2301

− Check the mechanism of the control leaver (automatic return into zero position; in zero position the directional contacts must be open) − Check the deadman switching contact. − Check the wiring. − Replace the cabinet module.

LUFFING COUNTER EQUALITY FAILURE

This fault is an internal fault in the PLC. The output pulses from the incremental encoder are counted to ascertain the position of the drive. For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are compared. It is also necessary to make sure that the correct position information is stored if an emergency cut-out is tripped. This fault message is generated if the counter contents are not identical. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“ − The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.

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2302

LUFFING COUNTER OUT OF RANGE

The output pulses from the incremental encoder are counted to ascertain the position of the drive. This position counter value is limited by a minimum and maximum size. This fault message is generated if the counter content is not within its limits. This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“ − The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.

F

2303

LUFFING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the drive has passed the limit position without opening of the contact). When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

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− −

Check the limit switch contacts (function and adjustment) Check the counter value of the position counter

−

follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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F

2304

LUFFING COUNTER MONITORING

The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the contact has opened before the drive has reached the electronic measured limit position). When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. The counter values can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

F

2305

− − −

Check the limit switch contacts (function and adjustment) Check the counter value of the position counter Replace the PLC.

−

follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

LUFFING GEAR HAS BLOCKED

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails. • The winch does not move although the drive command is given (- the brake is not released; - or the gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective). Remedial action:

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− Check the electrical power of the brake valve (the LED on the valve connector plug should light up). − Check the hydraulic control pressure for the brake at the respective pressure measuring point. − Press the emergency button on the solenoid valve of the brake, the pressure must increase up to 25-28 bar − Press the emergency button on the solenoid valve of the pump control unit, the pressure must increase up to 300 bar − Replace the PLC, or digital input/output module

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TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 ELECTRICAL EQUIPMENT

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2306

LUFFFING ENCODER OUTPUTS EXCHANGED

The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses generated by the encoder are phase-shifted with respect to each other (see illustration below) .

If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed around. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− interchange the outputs of the encoder − Replace the encoder − Replace the PLC. − follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

F

2307

LUFFING NO COUNTING PULSES

The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails. • The electrical encoder system fails When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

− Check the hydraulic working pressure of the pump, if the drive is set for luffing in run the pressure on the high pressure side of the pump must increase from 40 bar up to 300 bar − Press the emergency button on the solenoid valve of the pump control unit, the pump must increase up to 300 bar − Check the encoder power supply. − Check the encoder installation (coupling) inside the limit switch − Check the wiring − Replace the encoder − Replace the PLC, or the PWM module − follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

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2308

LUFFING WRONG ROTARY MOTION

The winch monitoring system has indicated that the winch is turning in the paying out direction although the control command calls for the opposite sense of rotation. If this fault message appears after replacing the encoder, the encoder outputs must changed around. When this fault has been reset, will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

F

2309

− Check the complete drive system to ascertain that the winch moves in accordance with the joystick deflection (direction and speed). − interchange the outputs of the encoder − Replace the encoder − Replace the PLC

LUFFING STANDSTILL DRUM MONITORING

If the drive is not activated (brake applied), the winch monitoring system must not signal any motion. The actual output status can be displayed: • Set MAIN MENU • Select INDICATIONS • Select INPUT / OUTPUT VALUES • Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram) The status of the inputs is displayed with or . TRUE = DC 24V, FALSE = no voltage signal Remedial action:

F

2310

− Check the brake concerned. − Check the electrical controls of the brake valves; if necessary, replace the Compact Module.

LUFFING OVERSPEED

The speed of the winch is monitored by an incremental encoder. This maximum drum speed has been exceeded. The drive speed can be displayed: • Set MAIN MENU • Select INDICATIONS • Select SPEED AND COUNTER VALUES displays the programmed value for the limitation of the drive displays the actual counter value of the drive displays the quantity of layers wheeled up on the drum displays the speed (rotations per minute) of the drum Remedial action:

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− Check the hydraulic system : pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system).

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2312

LUFFING MUST RUN INTO REF. POSITION

This fault indication appears as a result of a previous failure. The previous failure which has caused this indication is also displayed as ORIGIN FAULT. This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according to the corresponding fault description. It is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:

F

3010

− follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

SLEWING PRESSURE 5° HEELING ANGLE >8°

The heeling angle of the crane is monitored by an inclinometer inside the control cabinet. The actual heeling value is displayed on the operation menu and when heeling exceeds 5° an additional warning signal is given. When heeling exceeds 8° the slewing gear, luffing out and lifting, is blocked. Remedial action:

F

5124

− − − − −

Reduce the load or outreach. Replace the inclinometer (=M07-A8). Check the wiring. Replace the PLC. Re-adjust the heeling level, see description under item

GRAB OPERATION MUST BE ACTIVATED

The analysis from the working process results that the hoisting gear is equipped with a grab. Therefore the GRAB OPERATION must be activated with the key-switch in the right hand control desk. If the analysis result is wrong this fault must be bypassed with the emergency operation system.

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5125

LOWERING BLOCKAGE BY LOW PRESSURE

When the GRAB OPERATION is activated the hoisting gear pressure will be monitored and the lowering of the grab is switched off by dropping down of the pressure when the grab is put on the ground. After the control leaver has been set back to neutral it is possible to lower the grab again. If this message appears when the grab is hanging free (not put on the ground) this feature can be bypassed with the emergency operation system, or easier by pressing the key when C5125 is shown on the display.

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5310

WORKING RANGE-LIMITATION

The working area of the crane is limited to prevent a collision. This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit position is reached the drive speed will be ramped down (pre-limitation). If this message appears although the luffing gear is in the "free" range, the rope length measurement system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

C

5311

WORKING RANGE-PRE-LIMITATION

The working area of the crane is limited to prevent a collision. This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit position is reached the drive speed will be ramped down. If this message appears although the luffing gear is in the "free" range, the rope length measurement system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted. Remedial action: follow up the procedure, described under item „RESET OF REFERENCE POSITIONS“

5-158

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ELECTRICAL EQUIPMENT 3165-3168

TTS-LMG Marine Cranes GmbH 7/3165 - 7/3168 ELECTRICAL EQUIPMENT

F

810

Compact Module DIGITAL not initiated

The compact module =M07-A2 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

820

Compact Module PWM not initiated

The compact module =M07-A3 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

830

Compact Module ANALOG not initiated

The compact module =M07-A4 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

840

Cabinet Module not initiated

The cabinet module =M07-A5 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

0850

Compact Module PWM_2 not initiated

The compact module =M07-A3 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

0880

Inclinometer not initiated

The compact module =M07-A8 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller. F

0886

Large LED display not initiated

The compact module =M07-A11 is defective and must be renewed. If this message appears at first check the CAN-BUS system, described under item Programmable logic controller.

F

0888

FAILURE OF CRANE IDENTIFICATION

If a new PLC is installed or the system is generally reset to DEFAULT data the corresponding crane number must be entered into the system. Procedure: • Set • Select • Select • Select

MAIN MENU SECURED AREA (accepted must be entered) SECURITY CODE must be set and entered SET CRANE NUMBER (corresponding crane number must be entered)

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5.10

EMERGENCY OPERATION SYSTEM

Work on the electrical equipment of the crane is to be performed only by fully-trained personnel. Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override messages in the emergency operating mode and must take the instructions given here into account. This member of the crew is responsible for explaining the changed situation to the crane operator. The identification and elimination of malfunctions are greatly simplified by the circuit diagrams, units specifications and manufacturer's documentation, the list of fault status messages and the explanation of the reason for the failures with recommended trouble shooting hints are described under item TROUBLE SHOOTING. If a fault can not be remedied immediately, for instance because the appropriate spare part is not available, it should be remembered that the causes of many faults can be remedied temporarily by means of an emergency operating system. ATTENTION! Before overriding a fault message by means of the emergency operating system, always check that the corresponding monitored criterion, which is intended to protect the machinery against overload and damage, is faulty and that the plant itself has not failed. The emergency control system only overrides the fault message. It does not eliminate the cause! The cause of the fault must be identified and eliminated as quickly as possible in order to avoid danger. The crane is never to be operated by the emergency operating system for normal crane operations. To de-activate the emergency operation system and set back the control into normal condition the control power must be switched off completely (main switch). Example 1 : Status message C 2211 LUFF. OUT LIMIT (MECHANICAL SWITCH) blocks the luffing gear in the direction for luffing out. The message is caused by a faulty switch contact in the luffing gear limit switch. The maximum outreach is limited by the mechanical switch and additionally by the rope length measurement system. No replacement contact is available, and the status message is therefore overridden by means of the emergency operating system until a replacement has been obtained. Under these conditions, the luffing range is now restricted to the maximum permissible outreach by the rope length measurement system only so that there is a higher risk of exceeding the maximum outreach and overload. Example 2 : Fault message F 1031 HOISTING SENSOR OUTPUT