TTS 83158 englisch Operating Instruction+Spare Parts List - копия PDF

TTS NMF GmbH
OPERATION INSTRUCTION
AND
SPARE PARTS LIST
SINGLE DECK CRANE KL 45T – 29M
TTS YARD-NO. : 83158

YEAR OF CONSTRUCTION : 2013
CLASSIFICATION SOCIETY : ABS
DATE : OCTOBER 2013
STAR REEFERS SHIPOWNING INC.: M/S “Costa Rica Star” IMO-No.: 9150822
TTS NMF GmbH
Neuenfelder Fährdeich
D-21129 Hamburg
Germany
Telephone: +49 40 554 361 808
Fax: +49 40 554 361 9808
Email: info@ nmf-crane.de
Internet: www.ttsgroup.com
© Copyright by TTS-LMG Printed in Germany

TTS NMF GmbH
83158 - PREFACE
1. PREFACE
2. CRANE DESCRIPTION
3. OPERATION
3.1 SAFETY REGULATIONS
3.2 CRANE OPERATION
4. MAINTENANCE
4.1 GENERAL REMARKS
4.2 MAINTENANCE SCHEDULE
4.3 LUBRICANTS
4.4 ELECTRICAL EQUIPMENT
4.5 HYDRAULIC EQUIPMENT
4.6 ASSEMBLY AND DISMANTLING
5. SPECIFICATION OF THE ELECTRICAL

EQUIPMENT FOR A SINGLE DECK CRANE
6. SPARE PARTS LIST

ASSEMBLY GROUP 00.00.00 DECK CRANE COMPL.
ASSEMBLY GROUP 01.00.00 SLEWING TOWER
ASSEMBLY GROUP 02.00.00 JIB COMPL.
ASSEMBLY GROUP 05.00.00 ROPE PLAN
ASSEMBLY GROUP 07.00.00 CARGO BLOCK
ASSEMBLY GROUP 12.00.00 PANEL LIST
ASSEMBLY GROUP 14.00.00 PART WITHOUT ATTACH IN WORKS
ASSEMBLY GROUP 18.00.00 DRIVING HOUSE COMPL.
ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.
ASSEMBLY GROUP 25.00.00 ELECTRICAL EQUIPMENT COMPL.
ASSEMBLY GROUP 66.00.00 HYDRAULIC SYSTEM COMPL.
ASSEMBLY GROUP 80.00.00 ADDITIONAL EQUIPMENT
ASSEMBLY GROUP 97.00.00 TECHNICAL DOCUMENTS
7. ASSEMBLY INSTRUCTION
PREFACE 83158 83158 Ind. 00 / 10-2013 1-1

TTS NMF GmbH
83158 - PREFACE
1-2 Ind. 00 / 10-2013 83158 PREFACE 83158

TTS NMF GmbH
83158 - PREFACE
1. PREFACE
CONTENTS
1. PREFACE 3
1.1 PREFACE 4
1.2 SAFETY REGULATIONS – GENERAL REMARKS 5
1.3 EXPLANATION OF SAFETY SIGNS 6
1.3.1 PROHIBITION SIGNS 6
1.3.2 WARNING SIGNS 6
1.3.3 MANDATORY SIGNS 7
1.3.4 RESCUE SIGNS 8
1.4 SAFETY DEVICES – GENERAL REMARKS 9
1.4.1 BRAKES 9
1.4.2 LIGHTING 9
1.4.3 LIMIT SWITCHES 9
1.4.4 SAFETY DEVICES 9
1.5 SAFETY REGULATIONS 10
1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS 10
1.5.2 OPERATING INSTRUCTION FOR EMERGENCY EXIT WITH SAFETY HARNESS
12
PREFACE 83158 83158 Ind. 00 / 10-2013 1-3

TTS NMF GmbH
83158 - PREFACE
1.1 PREFACE
The documentation supplied with the deck crane includes the operating manual and the spare parts cata-
logue.
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 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 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 table of contents. 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 operation.
Correct OPERATION and careful MAINTENANCE have a major impact on the performance and availability
of your TTS 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 SPARE PARTS when replacing components. TTS NMF GmbH accepts 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 an extension of terms of sale and delivery of TTS NMF GmbH.
Please direct all enquiries to the following address:
TTS NMF GmbH
Neuenfelder Fährdeich
D-21129 Hamburg
Germany
Telephone: +49 40 554 361 808
Fax: +49 40 554 361 9808
Email: info@ nmf-crane.de
Please state the crane no. and type (see data plate) with all enquiries.
1-4 Ind. 00 / 10-2013 83158 PREFACE 83158

TTS NMF GmbH
83158 - PREFACE
1.2 SAFETY REGULATIONS – GENERAL REMARKS

The purpose of this operating manual is to prevent malfunctions and damage by presenting appropriate op-
erating 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 strictly follow
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 damages 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 malfunc-
tions, 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 su-
pervisor 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 plat-
form)!
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 opera-
tion or safety of the crane or the safety of operatives.
PREFACE 83158 83158 Ind. 00 / 10-2013 1-5

TTS NMF GmbH
83158 - PREFACE
1.3 EXPLANATION OF SAFETY SIGNS
1.3.1 PROHIBITION SIGNS
Fire, exposed flame and smoking prohibited Do not operate switch
No unauthorised access Prohibited for persons with pacemaker
1.3.2 WARNING SIGNS
Warning of hanging load Warning of electro – magnetic field
Warning of high voltage Danger of falling

1-6 Ind. 00 / 10-2013 83158 PREFACE 83158
TTS NMF GmbH
83158 - PREFACE
Warning of danger through batteries Danger of slipping Danger through hot surface
1.3.3 MANDATORY SIGNS
Wear eye protection Wear safety gloves Wear safety protection
Wear safety helmet Wear safety boots Wear ear protection
Follow information on the Switch off power supply Use safety devices
component and in the
operating manual of the
vehicle
PREFACE 83158 83158 Ind. 00 / 10-2013 1-7

TTS NMF GmbH
83158 - PREFACE
1.3.4 RESCUE SIGNS
First aid Fire extinguisher
Doctor
1-8 Ind. 00 / 10-2013 83158 PREFACE 83158

TTS NMF GmbH
83158 - PREFACE
1.4 SAFETY DEVICES – GENERAL REMARKS

The purpose of safety devices is to prevent damage and ensure trouble-free operation. Therefore, their satis-
factory 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 appropri-
ate measures.
1.4.1 BRAKES
After stopping the drives, the brakes remain closed to prevent unintended movement of the driven compo-
nents. Therefore, they are important safety devices and require particularly careful inspection and mainte-
nance 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.
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.
PREFACE 83158 83158 Ind. 00 / 10-2013 1-9

TTS NMF GmbH
83158 - PREFACE
1.5 SAFETY REGULATIONS
1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS

In the event of fire, immediately set off the fire alarm and switch off the whole electrical system. A portable
fire extinguisher is provided in the driver's cabin (5 kg ABC powder).
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 ABC powder
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 CASE OF FIRE:
Report fire Raise the alarm; give information on the source of the fire.
Move to a Warn endangered persons. Remove the injured and

safe place helpless. Close doors and windows.
Fight the fire Take the fire extinguisher. Do not set it off until you
reach the source of the fire.
1-10 Ind. 00 / 10-2013 83158 PREFACE 83158

TTS NMF GmbH
83158 - PREFACE
FIRE EXTINGUISHING SYSTEM/FIRE EXTINGUISHERS
RULE NO. 1 IN FIREFIGHTING IS:
SAVING HUMAN LIFE IS MORE IMPORTANT THAN FIGHTING THE FIRE.

HOWEVER VALUABLE THEY ARE, OBJECTS CAN BE REPLACED.
CORRECT USE OF FIRE EXTINGUISHERS:
PREFACE 83158 83158 Ind. 00 / 10-2013 1-11

TTS NMF GmbH
83158 - PREFACE
1.5.2 OPERATING INSTRUCTION FOR EMERGENCY EXIT WITH

SAFETY HARNESS
TAKE SAFETY HARNESS OUT OF BAG AT THE CABIN WALL.
Take the safety harness below the sliding piece, so that the back belt
and the large opening are facing to the front. Step into the safety har-
ness with the legs - see fig. left. Chest belt and catch loop must be in
front of the body. Push the sliding piece downwards.
TAKE LEVER BRAKE OUT OF THE BAG
Fix snap hook of lever brake onto the lug of the safety harness. Hook
snap hook of the free short rope end into the lug at the cabin roof.
HINGE THE GRATING UP FORWARD AND OPEN BOTTOM

WINDOW.
Take the free rope end out of the bag and throw it out of the cabin
via the opening. When actuating the hand lever, the rope-down pro-
cedure via the bottom window is 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 can be regu-
lated 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 be interrupted (decelerated) until standstill as well.
Replace rope after 4-5 years
1-12 Ind. 00 / 10-2013 83158 PREFACE 83158

TTS- NMF GmbH
83158 - DESCRIPTION
2. DESCRIPTION
INDEX
2. DESCRIPTION 1
2.1 GENERAL 2
2.1.1 CRANE TOWER 2
2.1.2 CRANE CABIN 2
2.1.3 JIB 2
2.1.4 SLEW ASSEMBLY 2
2.1.5 HYDRAULIC SYSTEM 2
2.1.6 HOISTING AND LUFFING GEARS 2
2.1.7 SLEWING GEAR 2
2.1.8 ELECTRICAL EQUIPMENT 2
2.2 TECHNICAL DATA 3
2.2.1 OPERATING CONDITIONS FOR DECK CRANES 3
2.2.2 CRANE LAYOUT – MAIN DIMENSIONS 4
2.2.3 LOAD LIMITATION DEPENDING ON OUTREACH 5
2.2.4 PRINCIPAL DATA 6
2.2.5 GENERAL ARRANGEMENT DRAWING 6
2.2.6 POWER SUPPLY 7
2.2.7 ELECTRIC MOTORS 7
2.2.8 SPLITTER GEARBOX 7
2.2.9 SLEWING RING 7
2.2.10 SLEWING GEAR REDUCER 7
2.2.11 WINCHES 8
2.2.12 ROPES 8
2.2.13 WEIGHTS 8
DESCRIPTION 83158 83158 Ind. 00 / 10-2013 2-1

TTS-NMF GmbH
83158 - 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 rope-
down device. The cabin is suspended elastically in the tower.
2.1.3 JIB
The jib is built as a welded two-beam box-type construction, the connection jib – crane tower is made by
maintenance free uniball bearings.
2.1.4 SLEW ASSEMBLY

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

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

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

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

The electrical equipment of the crane conforms to the rules of the classification society. It is designed for
operation at ambient temperatures between -20 to +45°C. The electrical equipment includes the drive of the
hydraulic pumps and the control of the entire crane.
2-2 Ind. 00 / 10-2013 83158 DESCRIPTION 83158

TTS- NMF GmbH
83158 - 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 45T
Rating according to FEM
CLASSIFICATION AND LOADING ON STRUCTURES AND MECHANISMS
KL 45t-29m , TTS YARD-NO.: 7/3097 + 7/3098
Calculation of carrying steel structure in accordance with FEM
and Classification Society
hook operation 45t
The Crane as a whole
Appliance group A4
Load spectrum class Q2
Utilisation class U4
Number of loading cycles during lifetime max.250.000
Steel structure B4/P2/E3
Calculation of drive in accordance with FEM
HOISTING GEAR
Mechanism group M5
Class of load spectrum L2
Class of utilization T5
LUFFING GEAR
Mechanism group M5
SLEWING GEAR
Mechanism group M5
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 83158 83158 Ind. 00 / 10-2013 2-3

TTS-NMF GmbH
83158 - DESCRIPTION
2.2.2 CRANE LAYOUT – MAIN DIMENSIONS
2-4 Ind. 00 / 10-2013 83158 DESCRIPTION 83158

TTS- NMF GmbH
83158 - DESCRIPTION
2.2.3 LOAD LIMITATION DEPENDING ON OUTREACH
The maximum outreach is 29 m, it is limited by the luffing gear limit switch.
At an outreach of 3,8 – 29 m, loads of up to 45 t by Hook 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 83158 83158 Ind. 00 / 10-2013 2-5

TTS-NMF GmbH
83158 - DESCRIPTION
2.2.4 PRINCIPAL DATA

Crane type KL 45 t – 29m
Type of drive electro – hydraulic
Ambient temperature -20ºC to +45ºC
Lifting capacity 45 t – 29 m
Min. outreach 3,8 m
Max. lifting height 35,0 m
Slewing speed * 0,9 rpm
Hoisting speed * full load 16,0 m/min
no load 40,0 m/min
Luffing time * from max. in min. outreach 60 - 70 sec
Heeling angle 5º
Trim 2º
* all movements simultaneously
2.2.5 GENERAL ARRANGEMENT DRAWING
2-6 Ind. 00 / 10-2013 83158 DESCRIPTION 83158

TTS- NMF GmbH
83158 - DESCRIPTION
2.2.6 POWER SUPPLY

Ship's mains voltage 440 V/ 60 Hz
Lighting and heating 220 V/ 60Hz
Nominal rating of motor 160 kW
Short-time load 10* duty cycle 420 kVA
Momentary peak 2 - 3 sec. 470 kVA
Reverse curr. full load lowering and luffing 100 kW
2.2.7 ELECTRIC MOTORS

SPLITTER GEARBOX
3-phase A.C. squirrel cage motor

Rated voltage 440 V,60 Hz
Rated output 160 kW, S1 100% / duty cycle
245 KW S6 40% / duty cycle
Speed 1480 min-1
Enclosure IP 55
Structural shape V3(IEC34-7)
3-PTC-resistors for switching-off

Anti-condensation heating 230 V
2.2.8 SPLITTER GEARBOX

Power of el. motor 160 kW
Drive speed 1785min-1
Max. output 1x203 kW (hoisting)
1x173 kW (luffing)
1x189 kW (slewing)
Output speed 2746 min-1
Transmission i = 0,65
2.2.9 SLEWING RING

Slew bearing
Number of teeth 175
Module 16
2.2.10 SLEWING GEAR REDUCER

Mounting position pinion bottom
Output speed 12,0 rpm
Transmission 125
Lantern shaft length short
P.T.O pinion module 16
P.T.O. pinion no. of teeth 10
P.T.O. pinion width 170 mm
Hydraulic motor type F12-060-MF
DESCRIPTION 83158 83158 Ind. 00 / 10-2013 2-7

TTS-NMF GmbH
83158 - DESCRIPTION
2.2.11 WINCHES
HOISTING GEAR
Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically, slack rope limit switch
Drum dia. to centre of rope 718 mm
Length of drum 878 mm
Rope dia. 34 mm
Rope lay 38 mm
Direction of rope lay r.h. DIN15061
Rope speed 32 / 86 m/min
Hydraulic motor A6VM200EP2D/63 VAB 02 B
LUFFING GEAR
Rope grooves for two-layer winding, multi-disk brake - lifted hydraulically
Drum dia. to centre of rope 718 mm
Length of drum 878 mm
Rope dia. 34 mm
Rope lay 38 mm
Direction of rope lay r.h. DIN15061
Rope speed 46 m/min
Hydraulic motor A2FM125 W6.1A2
2.2.12 ROPES
HOISTING ROPE
Rope diameter (mm) 34

Rope length (m) 207
Wire breaking strength (N/mm²) 1960
Operation force (kN) 249,15
Min. breaking strength (kN) 1079,0
Rope design Casar Powerplast
left hand lay
Thimble DIN 3091-40GTW
LUFFING ROPE
Rope diameter (mm) 34

Rope length (m) 185
Wire breaking strength (N/mm²) 1960
Operation force (kN) 227,1
Min. breaking strength (kN) 983,3
Rope design Casar Turboplast
left hand lay
Thimble DIN 3091-36GTW
2.2.13 WEIGHTS
Slewing tower compl 32 817 kg
Jib compl. 15 290 kg
Hoisting rope 1 183 kg
Luffing rope 944 kg
Tackle block 1 500 kg
Load turning device 600 kg
Crane compl. approx. 52 334 kg
2-8 Ind. 00 / 10-2013 83158 DESCRIPTION 83158

TTS-NMFGmbH
83158 - OPERATION INSTRUCTION
3. OPERATION INSTRUCTION
INDEX
3. OPERATION INSTRUCTION 1
3.1 PREPARATORY WORKS 2
3.1.1 OPERATIONAL INSTRUCTIONS AND SAFETY REGULATIONS 2
3.1.2 SETTING OF LOAD TURNING DEVICE/HOOK OPERATION 3
3.1.3 MONITORING DEVICES 4
3.2 GENERAL OPERATION MANUAL 5
3.2.1 CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS 5
3.2.2 CONTROL LEVER (JOY STICKS) 9
3.2.3 INTERACTIVE DIALOGUE SYSTEM ( DISPLAY ) 12
3.3 CRANE OPERATION 14
3.3.1 SAFETY REGULATIONS 14
3.3.2 SETTING OF LOAD TURNING DEVICE/HOOK OPERATION 15
3.3.3 PUTTING INTO OPERATION 16
3.3.4 CRANE OPERATION 17
3.3.5 CLOSING DOWN 22
OPERATION INSTRUCTION 83158 83158 Ind. 00 / 10-2013 3-1

TTS-NMF GmbH
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.
3-2 Ind. 00 / 10-2013 83158 OPERATION INSTRUCTION 83158

TTS-NMFGmbH
3.1.2 SETTING OF LOAD TURNING DEVICE/HOOK OPERATION
For a change from load turning device to hook operation please see sketches below:
Sketch 1 : Hook block for hook operation

Sketch 2 : Hook block with load turning device
Sketch 1
Sketch 2
Load turning device operation can be selected by

KEY-SWITCH 34 “GRAB OPERATION” in position “0”.
During load turning device operation the maximum load is limited from 45 tons down to 44,4 tons.

TTS-NMF GmbH
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.
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.

TTS-NMFGmbH
3.2 GENERAL OPERATION MANUAL
3.2.1 CONTROL EQUIPMENT FOR DECK CRANE - CONTROL DESKS
CONTROL DESK LEFT CONTROL DESK RIGHT
CONTROL DESK LEFT HAND CONTROL DESK RIGHT HAND
1 Control lever Slewing gear / Luffing gear 2 Control lever Hoisting gear
1A Control lever Name plate 2A Control lever Name plate
10 Selector switch Windscreen wiper 20 Emerg.-off button Emergency off
11 Selector switch Cabin heater 26 illuminated switch Start / Stop
13 Selector switch Warning light red Ready for operation
14 Selector switch Working light 27 Indication lamp ( white )TWL lock
15 Selector switch Cabin light 29 Indication lamp (red) Fault
30 Indication lamp (green) TWL unlock
31 Key operated button Jib resting
32 Buzzer Alarm
33 Indication lamp ( white )All Landed
34 Key operated switch Spredder operation
Bp Blind cap for additional Installation Bp Blind cap for additional Installation

TTS-NMF GmbH
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.

TTS-NMFGmbH
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.

TTS-NMF GmbH
EMERGENCY-OFF push-button
The crane must be switched off with the EMERGENCY-OFF

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

the crane off when it is operating normally.
FAULT – Indication signal lamp
Signal lamp 29 is a collective alarm which lights up if one part of the

system is defective, or if a function is disturbed.
The reason of this fault is indicated on the DISPLAY.

TTS-NMFGmbH
3.2.2 CONTROL LEVER (JOY STICKS)
LUFFING IN AND OUT OF THE JIB
Push control lever in l.h. control desk either forward or backward.

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

If loads are small or if there is no load on the hook at all and the
Control lever is pushed right backward or forward, the hoisting speed is
automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever
must be reduced.
SLEWING
CONTROL LEVER IN THE LEFT-HAND DESK:
Excursion angle to the left = slewing to the left

Excursion angle to the right = slewing to the right
Wide excursion angle = quick movement

Narrow excursion angle = slow movement

TTS-NMF GmbH
LUFFING IN AND OUT

Excursion angle forward = jib lowering
Excursion angle to the back = jib lifting
JIB STOPPED AUTOMATICALLY
LIFTING OR LOWERING STOPPED AUTOMATICALLY.
The end positions have been reached and cannot be overrun.
The limit position will be indicated on the DISPLAY.

TTS-NMFGmbH
LIFTING AND LOWERING

If loads are small or if there is no load on the hook at all and the control lever is pushed right backward or
forward, the hoisting speed is automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever must be reduced.
CONTROL LEVER IN THE RIGHT-HAND DESK:
Excursion angle forward = crane hook down
Excursion angle to the back = crane hook up
CRANE HOOK STOPPED AUTOMATICALLY
CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.
The limit position will be indicated on the display.

TTS-NMF GmbH
3.2.3 INTERACTIVE DIALOGUE SYSTEM ( DISPLAY )

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

 main operation data (e.g. load indication,
outreach indication)
 operation conditions (e.g. lifting limitation)
 possible system faults
 additional informations (e.g. oil temperature,
working hours, system pressures / must be
selected)
Menue area 1 with selected ACTUAL LOAD shows the information in detail
OPERATION SELECTED MENUE
 Actual Load
 Additional safety working load
 Additional outreach

TTS-NMFGmbH
Condition information will be automatically displayed - .the message shows the reason for a possible crane
operation restriction.
CONDITION
 CONDITION code and text announcement

 Detailled informations are given in the elec-
trical manual
Menue area 2 is a code secured service menue, it must be activated - the functions are described in the
electrical maual ( part 5 ).
SERVIVE MENUE
 parameter setting
 activation of special conditions
 emergency opreation system

TTS-NMF GmbH
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.

TTS-NMFGmbH
3.3.2 SETTING OF LOAD TURNING DEVICE/HOOK OPERATION
For a change from load turning device to hook operation please see sketches below:
Sketch 1 : Hook block for hook operation

Sketch 2 : Hook block with load turning device
Sketch 1
Sketch 2
Load turning device operation can be selected by

KEY-SWITCH 34 “GRAB OPERATION” in position “0”.
During load turning device operation the maximum load is limited from 45 tons down to 44,4 tons.

TTS-NMF GmbH
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.

TTS-NMFGmbH
3.3.4 CRANE OPERATION
STARTING

will start up.
Do not move the control lever out of zero position before

< READY FOR OPERATION > is displayed.
If the crane drives have been stopped by an emergency condition, the

start switch must be turned into OFF first before the drives can be
started.
EMERGENCY-OFF push-button
The crane must be switched off with the EMERGENCY-OFF

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

the crane off when it is operating normally.

TTS-NMF GmbH
SLEWING
Excursion angle to the left = slewing to the left

Excursion angle to the right = slewing to the right

LUFFING IN AND OUT

Excursion angle forward = jib lowering
Excursion angle to the back = jib lifting

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

If loads are small or if there is no load on the hook at all and the control lever is pushed right backward or
forward, the hoisting speed is automatically accelerated to maximum. In order to stop acceleration or
deceleration of the hoisting speed, the excursion of the control lever must be reduced.
CONTROL LEVER IN THE RIGHT-HAND DESK:
Excursion angle forward = crane hook down

Excursion angle to the back = crane hook up


TTS-NMF GmbH
CRANE HOOK STOPPED AUTOMATICALLY
CRANE HOOK UP OR DOWN STOPPED AUTOMATICALLY.
ATTENTION
If outreaches are small, care must be taken to work with utmost caution
in order to avoid damage to the cra-ne tower and in particular to the cabin.
The working movements of the lifting and luffing gears are limited by
Limit switches.
Before reaching a limit position, all speeds are reduced automatically.
The limit position will be indicated on the DISPLAY
NOTE
WORKING MOVEMENT LIMIT SWITCHES ARE SAFETY DEVICES

AND SHOULD NOT BE ACTUATED IN NORMAL OPERATION.
ATTENTION
THE INSTRUCTIONS CONTAINED IN THE DESCRIPTIONS OF THE

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

TTS-NMFGmbH
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

 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.

TTS-NMF GmbH
3.3.5 CLOSING DOWN
(SEE “CRANE OPERATION“ FOR SAFETY REGULATIONS)

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

will start up.
 Bring crane into sea voyage position - luff-down jib ( bridge limit switch with key-operated button 30 )
 Crane hook must be empty.
ATTENTION :
BRIDGING-OVER WITH KEY-OPERATED SWITCH 31 PUTS LIMIT SWITCHES FOR LIMITATION

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

 Pull ropes to tighten them slightly.

TTS-NMFGmbH
STOP

 Close cabin window.

 Switch off cabine fan, working light and cabin light.
 Switch off crane control ( voltage supply ) with main switch in control cabinet.
 When leaving crane, lock doors and hatches properly, close the outer flaps of the oil cooler.
NOTE :
SUPPLY VOLTAGE FOR LIGHTING AND HEATING MUST REMAIN SWITCHED-ON DURING STANDSTILL
OF THE CRANE.

TTS-NMF GmbH

TTS - NMF GmbH
83158 - MAINTENANCE
4. MAINTENANCE
INDEX
4. MAINTENANCE 1
4.1 GENERAL REMARKS 4
4.1.1 CHECKING OIL LEVELS, OIL CHANGES 5
4.1.2 VISIBLE OIL LOSSES 5
4.1.3 OILS, GREASES AND HYDRAULIC OILS 5
4.1.4 FILTERS 5
4.1.5 SEALS AND GASKETS 5
4.1.6 SEALING SURFACES 5
4.1.7 THREADED PIPE CONNECTORS; HOSES 5
4.1.8 GREASE LUBRICATION 5
4.1.9 GREASING 6
4.1.10 MARKING OF PARTS 6
4.1.11 REPLACEMENT UNITS 6
4.1.12 AFTER MAINTENANCE WORK 6
4.1.13 INSPECTION OF THE HOOK 6
4.1.14 ROPE - HOISTING AND LUFFING ROPES 7
4.1.15 ROPE - INSPECTION 9
4.1.16 MULTI-DISK BRAKES / MOTOR SHAFT DOG 10
4.1.17 SLEWING GEAR 11
4.1.17.1 GENERAL INFORMATION 12
4.1.17.1.1 MANUAL AIM 12
4.1.17.1.2 INFORMATION ON SAFETY 12
4.1.17.2 LIFTING AND HANDLING 13
4.1.17.3 INSTALLATION 14
4.1.17.3.1 HYDRAULIC MOTOR INSTALLATION 14
4.1.17.3.2 INSTALLATION OF THE SLEW DRIVE ON THE MACHINE 15
4.1.17.3.3 CONNECTION OF THE BRAKE 16
4.1.17.3.4 CONNECTIN OF THE DRAINING PORT 17
4.1.17.3.5 REPLACING OF THE BREATHER VALVE AS LOOSE PART 17
4.1.17.4 LUBRICATION 18
4.1.17.4.1 GEARBOX LUBRICATION 18
4.1.17.4.2 OIL FILLING 19
4.1.17.4.3 OIL DRAINING AND REPLACEMENT 19
4.1.17.5 START UP AND RUNNING IN 20
4.1.17.6 MAINTENANCE 21
4.1.18 HOISTING AND LUFFING GEAR 22
4.1.18.1 INSTALLATION INSTRUCTION 23
4.1.18.2 MAINTENANCE INSTRUCTION 24
4.1.18.3 RECCOMENDATION FOR LUBRICANTS 25
4.1.18.4 GEARBOX INSPECTION 26
4.1.18.5 TAKING OF AN OIL SAMPLE 27
4.1.18.6 TIGHTENING TORQUES 28
4.1.19 LOADSTABILIZING WINCH 29
4.1.19.1 INSTALLATION INSTRUCTION 30
4.1.19.2 MAINTENANCE INSTRUCTION 31
4.1.19.3 RECCOMENDATION FOR LUBRICANTS 32
4.1.19.4 GEARBOX INSPECTION 33
4.1.19.5 TAKING OF AN OIL SAMPLE 34
4.1.19.6 TIGHTENING TORQUES 35
4.1.20 CABLE REAL 36
4.1.20.1 ASSEMBLY OF THE CABLE REELING DRUM 36
4.1.20.2 MOUNTING OF THE CABLE REELING DRUM 36
4.1.20.3 CONNECTING THE PAYOUT CABLE 37
4.1.20.4 CONNECTING OF THE MAIN POWER CABLE 37
4.1.20.5 CHECK BEFORE COMMISSIONING 37
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-1
TTS - NMF GmbH
83158.- MAINTENANCE
4.1.20.6 MAINTENANCE OF THE CABLE REELING DRUM 38

4.1.20.7 LIABILITY FOR FAULTS 39
4.1.20.8 ENCLOSURE 39
4.1.21 LOAD TURNING DEVICE SWL 44,4T 40
4.1.21.1 GENERAL INFORMATION 40
4.1.21.2 EXPLANATION OF SYMBOLS 41
4.1.21.3 EXPLANATION OF DECALS 41
4.1.21.4 SAFETY REGULATIONS 42
4.1.21.5 PRODUCT INFORMATION 42
4.1.21.6 PUTTING INTO OPERATION 42
4.1.21.7 MOUNTING 43
4.1.21.8 DISMOUNTING 43
4.1.21.9 SPARE PARTS 43
4.1.21.10 CARE AND MAINTENANCE 43
4.1.21.11 HYDRAULIC AGGREGATE 44
4.1.21.12 ANNUAL MAINTENANCE 45
4.1.21.13 CONDITIONS OF GUARANTEE: 45
4.1.21.14 TECHNICAL SPECIFICATIONS 45
4.1.22 LUBRICATION AND MAINTENANCE 46
4.1.23 GREASING POINTS – CRANE 47
4.1.24 OIL CHANGE 48
4.2 MAINTENANCE SCHEDULE 49
4.3 LUBRICANTS 51
4.4 ELECTRICAL EQUIPMENT 52
4.4.1 SAFETY DEVICES 52
4.4.2 LIGHTING 53
4.4.3 MOTORS 53
4.4.4 SLIPRING BODIES 53
4.4.5 CIRCUIT BREAKERS 53
4.5 HYDRAULIC EQUIPMENT 54
4.5.1 FUNCTIONAL DESCRIPTION 56
4.5.1.1 HOISTING GEAR CIRCUIT 1.0 56
4.5.1.2 LUFFING GEAR CIRCUIT 2.0 58
4.5.1.3 SLEWING GEAR CIRCUIT 3.0 58
4.5.1.4 FEED AND CONTROL OIL CIRCUIT 4.0 59
4.5.1.5 OIL COOLING 5.0 62
4.5.1.6 HYDRAULIC OIL TANK 6.0 62
4.5.1.7 FILLING 7.0 62
4.5.1.8 EMERGENCY OPERATION 8.0 63
4.5.1.9 TENSION WINCH DRIVE 9.0 64
4.5.1.10 CABLE REEL 10.0 64
4.5.2 GENERAL REMARKS 65
4.5.2.1 PUTTING SYSTEM INTO OPERATION (BY WORKS PERSONNEL) 67
4.5.2.2 INSPECTION AND MAINTENANCE 68
4.5.2.3 OPERATION AND MAINTENANCE OF HYDRAULIC PUMPS AND
MOTORS 71
4.5.2.3.1 GENERAL REMARKS 71
4.5.2.3.2 INSTALLATION 71
4.5.2.3.3 FIRST START 71
4.5.2.3.4 ROUTINE MAINTENANCE 73
4.5.2.4 TROUBLESHOOTING 73
4.5.2.5 TROUBLESHOOTING 74
4.6 ASSEMBLY AND DISMANTLING 78
4.6.2 ROPE REPLACEMENT 82
4.6.3 HAND SIGNALS FOR CRANES 85
4.6.4 TIGHTENING TORQUES FOR HEXAGON BOLTS AND SPANNER BOLTS 86
4-2 Ind. 00 / 10-2013 83158 MAINTENANCE 83158
TTS - NMF GmbH
83158 - MAINTENANCE
4.6.5 INSTALLATION OF HOSES 87
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-3

TTS - NMF GmbH
83158.- MAINTENANCE
4.1 GENERAL REMARKS

The relevant official regulations, particularly those relating to accident prevention, must be observed during
repairs and maintenance work.
ATTENTION!
THE INSTRUCTIONS SAFETY REGULATIONS MUST ALSO BE OBSERVED DURING MAINTENANCE
WORK!
Crane maintenance work must be assigned only to suitable, reliable personnel who are familiar with the op-
eration of the crane and its mechanical and electrical assemblies.
The same personnel must also monitor the condition of the whole plant, ensure that it is adequately lubri-
cated and, in particular, regularly check the condition of the brakes and safety devices. In particular, these
persons must report all plant malfunctions to the supervisor concerned. They must immediately stop the
operation of the crane if brakes or safety devices fail.
Safe operation and the service life of the equipment depend greatly on standards of maintenance.
BEFORE STARTING MAINTENANCE WORK

Scrupulous cleanliness and reasonable planning are prerequisites for all successful maintenance work.
All units in the vicinity of the work area must be cleaned before work starts. The cleansing agent must be
chosen to suit the material of which the units are made.
Example: Solvents or a steam lance must not be used to clean

rubber or electrical components.
When dismantling equipment, blank off all open holes, connections, casings, etc., in a way suitable to pre-
vent dirt from entering them. All parts that have been removed must be protected from rust, dirt and damage
if work is interrupted for a considerable period. Use only lint-free cleaning rags, especially when working on
hydraulic systems.
Secure drives to prevent unauthorized or unintended starting.
ATTENTION
DO NOT ALTER THE NOMINAL PRESSURES OF PRESSURE LIMITING VALVES WITHOUT THE
EXPRESS AGREEMENT OF TTS - NMF.
DO NOT REMOVE SEALS FROM PRESSURE LIMITING VALVES.
4-4 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.1 CHECKING OIL LEVELS, OIL CHANGES

Change oil while the equipment is still warm from operation because warm oil can be drained off more easily.
The suspended solids contained in warm oil, such as oil coke, wear particles, etc., settle to the bottom of the
sump if the equipment is not used for some time and do not flow out if the oil is cold. Use only lint-free rags
to wipe the dip-stick.
DANGER
Hot lubricating or hydraulic oil flowing out without control can cause serious scalds.
4.1.2 VISIBLE OIL LOSSES

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

lf oil or grease grades are changed for technical or other reasons, the qualities and viscosities of the re-
placements must be identical to those recommended.
4.1.4 FILTERS
All filters and filter cartridges must be changed at the specified intervals unless cleaning is expressly permitted.
All filters are carefully matched to the equipment they serve. Only the use of original parts from TTS-LMG
will ensure trouble-free operation and a long service life.
4.1.5 SEALS AND GASKETS

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

Clean sealing surfaces before assembling the parts.
Check that joints do not leak after assembly.
4.1.7 THREADED PIPE CONNECTORS; HOSES

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

Clean grease fittings before greasing according to schedule.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-5

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.9 GREASING
Grease all exposed metallic surfaces of machine components at regular intervals to prevent by rust.
4.1.10 MARKING OF PARTS

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

These must be serviced at the same intervals as the units they replace.
4.1.12 AFTER MAINTENANCE WORK

ATTENTION
REPLACE ALL GUARDS AFTER THE WORK IS FINISHED.
Check that the units function correctly.

Observe environmental protection regulations when disposing of oil, grease, cleaning fluids or oil-
contaminated components such as filter cartridges.
4.1.13 INSPECTION OF THE HOOK
The cargo hook must be checked by an appropriately trained and authorised engineer once a year. The
measured values are to be entered in the crane record book.
1. Check the root of the thread, the shaft and the hook surface for cracks.
2. Welding work on cargo hooks, for instance to build up worn surfaces, is forbidden!
4-6 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.14 ROPE - HOISTING AND LUFFING ROPES

The exterior of the wire rope must be cleaned and regreased every three months. The ropes must be in-
spected before this is done.
Always wear leather gloves when handling wire ropes.
To grease a whole rope, the whole length of the rope must be removed and laid out. However, it must not be
dragged along the ground because otherwise dirt and foreign bodies will adhere to it. This will increase the
rate of wear.
lf the whole length of the rope is not removed and laid out, the grease should be applied by brush where the
rope runs round the drum or a pulley and the strands are forced slightly apart. This will allow the grease to
penetrate into the rope more easily.
Care must be taken to handle the rope properly when removing a rope and when installing a new one.
UNLOADING STORING
Use web slings to unload steel wire Ropes should be stored in a clean,
ropes. The hook of a crane or the cool and dry place. They must be kept
prong of a fork-lift truck might damage clear of the floor. Ropes stored out-
the rope. side must be protected against rain.
UNCOILING UNREELING
Uncoil wire rope by using an uncoiling Unreel wire rope by using an un-
stand or by rolling the coil along the reeling stand.
ground. Make sure the ground is clean.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-7

TTS - NMF GmbH
83158.- MAINTENANCE
AVOIDING KINKS COILING
Never unwind wire ropes without rotating The rope should travel from the
the coil or reel, otherwise the rope will top of the reel to the top of the
tend to form loops during installation or in drum or from the bottom of the
service. When pulled taut, the loops form reel to the bottom of the drum. A
kinks. reverse bend will create problems.
INSTALLATION BREAKING IN
Ropes should be installed under tension. The first operations with a new
rope should be carried out with
low loads.
INSPECTION LUBRICATION
IN SERVICE
Inspect steel wire ropes regularly. Keep record of Lubrication helps prevent
the rope diameter, the lay length, broken wires or corrosion and reduces
other defects. Discard the rope in time (while it is friction. Steel wire ropes
still safe). should be lubricated at
regular intervals.
4-8 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.15 ROPE - INSPECTION

The ropes must be inspected every three months.
Rope inspection books must be kept for all ropes. The results of each inspection must be recorded in these
books, which must also contain the works certificates supplied by the rope manufacturer.
The supervisor entrusted with the inspection must ascertain the general condition of the rope by
inspecting its whole length.
THE FOLLOWING FINDINGS MUST BE RECORDED:

 wear of external wires
 rust
 loosening of the structure
 changes in shape
 crushed wires and strands
 damage to seizings.
The rope must be freed from grease and dirt in several places for the inspection.
During intermediate inspections, attention must be given especially to parts of the rope that run over
pulleys or are close to rope suspension or rope attachment points.
It broken wires are found, the rope must be compared with the values given in the tables "Readiness for
discarding of wire ropes on the basis of wire breaks" in DIN 15020, part 2, and scrapped if necessary.
ROPES MUST BE REJECTED IF THE FOLLOWING FORMS OF DAMAGE ARE FOUND :
Wire rope with corkscrew shaped deformation Wire rope with basket formation
Wire rope with loop formation of wires Wire rope with nodes
Wire rope with slackened wires due to corrosion and Wire rope with contraction
abrasive wear
Wire rope with knot Wire rope with kink
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-9

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.16 MULTI-DISK BRAKES / MOTOR SHAFT DOG
1 Brake piston 2 Brake cylinder

3 Disk carrier 4 Internal disks
5 External disks 6 Sealing ring
7 Sealing ring
The brakes on the hoisting, luffing and slewing gears

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

only to apply a holding torque. The disks are not sub-
ject to wear under these conditions.However, they are
applied instantly in the event of power failures or if an
emergency OFF button is pressed, without having to
ramp the drive speed down to zero beforehand. Under
these circumstances they dissipate energy and are
subject to considerable wear. The brakes must be
checked after only a few such braking operations.
The brakes are designed to run "dry". Nevertheless,
small amounts of oil seep past the sealing ring (6) and
enter the disk space. In the case of slewing gears, the
see page oil must be drained off every three months.
The following procedure should be used to check the holding torque of the brakes:
 Luff the jib to its minimum outreach.
 Take any load off the hook - hook must be empty.
 Check the slewing gear at a heel of 5° with the jib parallel to the ship´s centreline.
 Pull the plug of the brake valve out to prevent the brake from lifting.
Activate the drives for about 5 sec. The maximum pressure corresponding to the maximum torque must be
built up within this time. The winches (or the slewing gear of the crane) must not move !
The holding torque should be checked every three month. Operation must be stopped after power failures
and emergency OFF actuation until brake torque has been checked.
After repair, fill the spring pressure actuated multi-disc brake of the slewing,hoisting and Luffing gear with
oil (AUTOMATIC TRANSMISSION FLUID) (cf. chapter 4.1.17 and 4.1.18).
The brakes must be overhauled annually.
The disk packs must be replaced if wear is excessive. Sealing rings 6 and 7 should be replaced if leaks
become apparent (e.g. excessive seepage oil is found).
When checking the brakes the spline profiles of motor and gear reducer should be checked for wear at the
same time. If the dog/motor is replaced or refitted, a suitable grease should be applied to prevent fretting
corrosion. We recommend to use Gleitmo 805 or similar.
4-10 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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 OI L ATF A PRIOR TO MOUNTING
THE MOTOR
1 Oil filling and breather valve (setting 0,35bar)

2 Oil level plug
3 Oil draining plug
4 Brake port
OIL CHANGE
First oil change after 200 crane operating hours. After every 1000 hours, oil should be changed again, but at
least once a year.
OIL CHANGE :
See instruction of manufacturers
OIL TYPE
Gear oil CLP 220 (see lubrication chart section 4.3)
OIL QUANTITY
3 gearboxes with abt. 12 l each – in total 36 l.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-11

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.17.1 GENERAL INFORMATION

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

Carefully read the instructions given in this instruction manual as well as the ones attached to the product
and make sure to follow the information concerning safety.
Personnel, which perform any type of work on the product during its life span, must possess precise techni-
cal 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 con-
stant safeguard towards security requirements.
To undertake maintenance procedures in areas which are hard to reach or otherwise dangerous it is impor-
tant to follow adequate safety conditions for one self and for others in compliance with the rules and regula-
tions that govern safety in the workplace.
When replacing worn parts, use original spare parts. Use oils and greases recommended by the manufac-
turer. Doing this will ensure that the product works properly and that the safety level is "acceptable".
4-12 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.17.2 LIFTING AND HANDLING

If the handling occurs when the product is still packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.
WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.
TO LIFT AND HANDLE THE PRODUCT, AFTER HAVING OPENED THE PACKAGING, FOLLOW THE
INFORMATION GIVEN BELOW:
1. Unscrew the nos.4 screws M12x20-8.8 and remove the closing plate from the motor adapror flange.
2. Tighten nos.2 eyebolts M12 UNI ISO 3266 at 180° on the thread holes of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-13

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.17.3 INSTALLATION
4.1.17.3.1 HYDRAULIC MOTOR INSTALLATION
The mating areas and the pilot diameter of the gearbox where the motor is to be mounted must be clean and
without burrs.
1. Fit the O-ring seal, supplied with the gearbox, in its seat in the hydraulic motor, and assemble it to
the gearbox being careful not to damage the seal already fitted.
2. Assemble the hydraulic motor to the gearbox tightening the nos.4 screws M12x35, grade 8.8
(supplied as a loose part), by a torque wrench at 86 Nm torque
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.
4-14 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.17.3.2 INSTALLATION OF THE SLEW DRIVE ON THE MACHINE

1. Move the slew drive in the mounting area applying lifting methods shown in section 3.4.
2. Clean the mating surfaces from oils or paint and fit the slew drive on the machine frame
(for the correct orientation refe to the installation drawing).
3. In case the pinion shaft-slew ring backlash has to be increased or decreased, turn the eccentric
gearbox housing on the machine frame (see installation drawing).
4. Fix the slew drive to the machine frame by using nos.24 screws M16 minimum grade 10.9,
tightened by a torque wrench at 295 Nm torque
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-15

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.17.3.3 CONNECTION OF THE BRAKE

The gearbox drive is supplied with a safety negative multidisc brake hydraulically driven
(parking brake). For information regarding the characteristics of the brake, port types and
dimensions, refer to the installation drawing.
1. To operate the brake, connect the brake pilot pipe to the brake port.
4-16 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.17.3.4 CONNECTIN OF THE DRAINING PORT

INFORMATION!
IF THE FRAME OF THE MACHINE DOES NOT ALLOW THE ACCESS TO THE PLUG, IT IS
NECESSARY, DURING THE SLEW DRIVE INSTALLATION, TO FIT AN EXTENTION WHICH TAKES THE
OIL AWAY FROM THE MACHINE.
1. Remove the drain plug and screw on a pipe to the drain port(for hose size and dimension refer to
the installation drawing).
4.1.17.3.5 REPLACING OF THE BREATHER VALVE AS LOOSE PART

At the slew drive installation on the machine frame replace the plug with breather valve supplied
as loose part.
1. Tigthen the brather valve supplied as loose part(for size and dimension refer to the installation
drawing).
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-17

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.17.4 LUBRICATION
4.1.17.4.1 GEARBOX LUBRICATION

The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing.
The gearbox is factory filled with lubricanting oil at level.
Oil type: SHELL SPIRAX A 80W-90 (specified when ordering).
Otherwise, the recommended oil type has to be SAE 80W/90 OR SAE 85W/140 norms with EP
characteristics according to: MIL-L-2105 C & API GL5.
In the following table the most common brands of lubricant and the types recommended are shown.
INFORMATION!
DURING THE OPERATION THE OIL TEMPERATURE MUST NOT EXCEED 85-90°C INTERMITTENT.
4-18 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.17.4.2 OIL FILLING

1. Unscrew the FILLING LEVEL OIL PLUG (2) and add the lubricating oil which has the
characteristics given in section 5.1.
2. By using the dipstick, check that the oil level is somewhere between the
MIN and MAX notch and then screw the plug back on.
3. Operate the slew drive, after a few minutes, stop and check the oil level.
4. If necessary, refill with lubricant oil. Size and dimension of plugs are shown on the
installation drawing.
APROXIMATE OIL CAPACITY LITERS ARE: 12 L ±10%
4.1.17.4.3 OIL DRAINING AND REPLACEMENT

1. Unscrew the DRAINING PLUG and let the oil flow in a large enough container; in order to facilitate
the draining it is better to operate with the oil still warm.
2. Wait a few minutes until all the oil is drained and then proceed to screw on DRAINING PLUG.
3. Proceed with the oil fill-up following the procedures given (see Section 5.2).
WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.
WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-19

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.17.5 START UP AND RUNNING IN

In this first stage it is advised to follow the measures given below:
1. Check the correctly lubrication of the unit.

2. Bleed air from every part of the hyraulic and add oil in the tank if necessary.
INFORMATION!
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.
3. Start the gearmotor at a low speed and gradually increase it after having verified that
it is functioning correctly without any noises or vibrations.
INFORMATION!
DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
During the running-in stage, follow the steps given below.
4. Check the correct revolution and direction of rotation.

5. Make sure that the functioning is regular and with-out any excessive noises and vibrations.
6. Make sure that the oil temperature does not exceed 85-90°C intermittent.
After having terminated this first running-in follow the steps given below.
7. Check that there are no oil leakages. If present, proceed to remove them.
8. Check the level of lubricating oil in the gearmotor.
It could happen that due to the presence of air, during the first start up, the opening action of the
brake could be slowed down. It is advised to repeat the opening and closing function of the brake.
Check that there are no other problems in general.
4-20 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.17.6 MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and oil
changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation. For a proper maintenance of the gearbox, the following checks and
operations have to be done.
INFORMATION!
IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE

SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.
DO NOT HESITATE TO CONTATCT THE GEARBOX DISTRIBUTOR OR MANUFACTURER IF FURTHER

INSTRUCTIONS ARE NECESSARY OR IN CASE OF PARTICULAR PROBLEMS.
This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL res-
res the right to implement modifications without notice. This manual cannot be reproduced, even partially,
without prior written consent.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-21

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.18 HOISTING AND LUFFING GEAR
ATTENTION !
Oil level can only be inspected with non-running gear
1
CHECK OIL LEVEL (LUFFING AND HOISTING GEAR)
If oil is below the oil level mark, oil must be added
...3
2 OIL CHANGES (LUFFING AND HOISTING GEAR
First oil change after 150 crane operating hours.

After 1500 crane operating hours but at least once a
...3 year further oil change.
Crane must be shut down
Oil must be warm as in operation
1 Oil drainage - loosen drain screw 2, drain oil into a
receptacle which is kept in readiness are visable.
Clean gear - Flush the gears with some of the new oil
2 (temperature abt. 80ºC), so that most of the dirt drains
off.
Fill in oil - tighten drain screw 2 (with new sealing ring)
Unscrew ventscrew 1, fill oil into opening 1. Check oil
level - when the correct oil level is reached, close
opening 1.
Oil change :
See instruction of manufacturers
Oil type :
OIL QUANTITY :
Luffing gear abt. 16,0 l , hoisting gear abt. 16,0 l
ITEM 3
THE BRAKES MUST BE FILLED WITH APPROX. 0,4LTRS GEAR OI L CLP 220 FOR WET RUNNIG
MOTOR SHAF
4-22 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.18.1 INSTALLATION INSTRUCTION

GENERAL
Please also note the indication in our drawings:
Installation drawing-winch unit- and installation drawing –rope winch-
The winch unit with support is supplied completely assembled
The drive units are already assembled to drive-working-position (see installation drawing-rope winch-)
Before assembling the winch unit, verify your steel construction according to our installation drawing.
Please note installation position of winch according to our installation drawing – winch unit-!
Strenght classes and torque moments for screw see installation drawing.
ASSEMBLY
Put winch unit with winch support into steel frame.
Fix winch support
Carry out following assembly steps for each winch:
Remove transport cover off the flange.
Connect brake line ( see installation drawing –rope winch- ).
Release hydraulically holding brake.
The drive sleeve in the drive unit must turn easy.
Remove plug off the drive sleeve of the drive unit.
For protection against corrosion the drive sleeve is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before montage of the motor.
Attention: Motor shaft grease free!
Centre motor in the motor flange.
Seal connecting surface.
Fix motor with screws.
Before test-running, fill motor flange completely with gear oil.
Check oil level with oil dipstick.
Refill oil if necessary.
If the rope winch is supplied without oil, this is indicated on a corresponding label.
Oil type see name plate resp. maintenance instruction.
Oil quantity see name plate resp. spare parts list.
Check rope winch with running motor as to function.
Check above all the control and function of the holding brake and the drive motor.
After test-running check oil level once more with oil dipstick.
During the test-running, the oil level in the gear and motor flange is adjusting itself and so fills the
Space to the motor shaft slowly with gear oil. Therefore the oil level may be reduced.
If necessary, refill oil.
Insert rope and fix it.
Secure screws accordingly.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-23

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.18.2 MAINTENANCE INSTRUCTION

LUBRICATION
The planetary gear of rope winch has splashed lubrication.
Oil filling ex works : AVIA gear oil RSX 220
Choice according to DIN : DIN 51502
Description according to DIN : Oil, DIN 51517-CLP 220
The oil quantity is marked on the name plate. If the gear is delivered without oil, we point out to that with a
sticker.
The bearing of the second journal bearing is filled with grease.

Grease filling ex factory :AVIA AVIALITH 2 EP
Choice according to DIN :DIN 51502
Description according to DIN :Grease, DIN 51825-KP2K
Before taking into operation grease again second journal bearing till grease emerges at the sealing profile.
Further oil and grease types see recommendations for lubricants.
RECOMMENDATION FOR MAINTENANCE INTERVALS

Oil control: Weekly.
Control oil level only with non-running gear.
First oil change after 200, then after each 3000 service hours, but at least every 3 years.
The intervals refer to the service temperatures indicated in the installation drawing.
Oil change only with service temperature condition.
We recommend to clean with a pre-heated part of new oil when ambient temperature is low, so that abrasion
and contaminations can flow away.
Greasing intervals: Once a week or before taking rope winch into operation.
4-24 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.18.3 RECCOMENDATION FOR LUBRICANTS
CHOICE LIST
CHOOSEN ACCORDING CHOOSEN ACCORDING CHOOSEN ACCORDING

TO API GL 5 TO DIN 51502 TO DIN 51502
GREASE, DIN 51825 –

OIL, SAE 90 OIL, DIN 51517 – CLP 220
KP2K
ARAL ARAL GEAR OIL HYP 90 BG 220 ARAL GREASE HLP 2
AVIA GEAR OIL

AVIA RSX 220 AVIA AVIALITH 2 EP
HYPOID 90 EP
BP BP HYPOGEAR EP 90 GR-XP 220 BP ENERGR. LS EP 2
CASTROL SPHEEROL
CASTROL CASTROL EPX 90 ALPHA SP 220
EPL 2 GREASE
ELF TRANSELF TYP B SAE 90 REDUCTELF SP 220 ELF EPEXA 2
ESSO GEAR OIL

ESSO SPARTAN EP 220 ESSO BEACON 2 EP
GX-D90
FUCHS GEAR OIL

FUCHS COMPOUND 106 VG 220 FUCHS RENOLIT FEP 2
RENOGEAR HYPOID 90
GULF MULTI-PURPOSE GULF CROWN GREASE

GULF EP LUBRICANT HD 220
GEAR LUBRICANT SAE 90 NO.2
MOBIL MOBILUBE HD-A 90 MOBILGEAR 630 MOBILUX 2 EP
SHELL SHELL SPIRAX MB 90 OMALA 220 SHELL ALVANIA EP 2
TEXACO GEARTEX EP-B 85W-90 MEROPA 220 MULTIFAK EP 2
Oil change and greasing intervals see maintenance instruction.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-25

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.18.4 GEARBOX INSPECTION

GEAR OIL ANALYSES _ PREVENTIVE MAINTENANCE
Surveying mechanisms for machines and gearboxes get more and more important, because the require-
ments and service conditions are often differing from the ones that are foreseen from the designers.
Systematic oil tests during regular intervals give a trendy reliable diagnostic regarding the wear development
and beginning damage. The point at issue will be which oil, permitted according the lubrication recommenda-
tion, has really been used.
Why oil analyses ?
Advanced diagnosis of damages:
Wear-particles “float” in the oil. These can be stated by oil analysis and give notes as to the wear of the con-
struction part from which they have been abrased.
Maintenance depending on status:
A damage that was stated early enough through an oil analysis obviously means less repair and still-stand
charges.
Damage analysis to small expenses:
An estimated reason for the damage can be given by such an oil inspection to small expenses. Spurs of dirt
by dust and water, mixture with other oils, parts of worn metals as well as changements of the oil level give a
detailed early recognition of damages.
SIMPLE SURVEILLANCE:
In order to get a detailed information on the status of the gearbox, regular oil analyses prevent partial or
complete disassemblies.
Influencing interference factors of the lubrication oil:
Worn metals, dirt, changements of oil level and additives may influence very negatively the effectiveness of
the used lubricating oil. Oil analyses, effected by an authorised laboratory, give information regarding worn
metals, dirt etc.
The analysis is commented according to the disposed dates and information.
The more exact the indications regarding the used oil, service time and operation conditions are, the more
detailed and effective can be instructed preventive measurements.
There are no reliable comparing and limit values as to wear metal and contaminations. An important factor is
always the oil quantity from which the oil sample was taken.
A reliable possibility to diagnose is not possible than by a competent laboratory. Extremely high values re-
sulting in the evaluation must not absolutely show a beginning damage.
Based on their experience all values noted are considered in the correct coordination by the laboratory ana-
lysing the oil. Oil analyses made in regular intervals show a sure value as to wear resp. as to a beginning
damage of a certain construction unit.
Each gear shows its own wear according to the corresponding conditions of operation.
Magnetizing particles larger than 5 µm noted in the analysis, are probably showing a beginning pitting of a
construction part.
Particles of a size of 40 µm in clear oil are visible with the eye. If so there is certainly already a progressed
damage of the gear.
4-26 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.18.5 TAKING OF AN OIL SAMPLE

A certain evidencing diagnostics of an oil sample depends decisively of the kind of taking the sample.
The taking of the sample has to e made always in the same manner. In principle the oil should be at least
hand warm when taking it. If possible the oil to be analysed has to be taken in about the middle of the oil
level.
At winch gear where it is not possible to have access to the oil level, the oil to be analysed has to be taken
off the oil drain line. About 1-2 l oil have to be drained into a container and an oil sample has to be taken
from the draining oil.
The access to a good oil level at the slewing gears is also difficult. Here too we recommend to have a part of
oil drained by removing the accessible oil draining screw and to take an oil sample off the draining oil.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-27

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.18.6 TIGHTENING TORQUES

TIGHTENING TORQUES FOR FIXING SCREWS M 4 TO M 36 AND FOR STRENGTH CLASSES 8.8,
10.9 AND 12.9 AT A COEFFICIENT OF FRICTION 0,125.
8.8 10.9 12.9

M4 = 2,7 Nm 3,8 Nm 4,6 Nm
M5 = 5,5 Nm 8,0 Nm 9,5 Nm
M6 = 9,5 Nm 13,0 Nm 16,0 Nm
M8 = 23,0 Nm 32,0 Nm 39,0 Nm
M 10 = 46,0 Nm 64,0 Nm 77,0 Nm
M 12 = 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
M 36 = 2350,0 Nm 3300,0 Nm
 THE INDICATED TIGHTENING TORQUES ARE MAXIMUM VALUES.

 SCREWS SECURED BY LOCTITE TYPE 242.
 FITTING SURFACES SEALED BY LOCTITE TYPE 640.
 SURFACING ON BRAKE SEALED BY LOCTITE TYPE 573.
 SCREWING OF THE TUBING AND THE CONNECTION SURFACES OF THE DRIVE MOTOR TO
 THE GEAR ARE SEALED
 WITH LOCTITE TYPE 572.
 Note application instructions of Loctite
4-28 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.19 LOADSTABILIZING WINCH
ATTENTION !
Oil level can only be inspected with non-running gear
CHECK OIL LEVEL LOADSTABILIZING GEAR)

If oil is below the oil level mark, oil must be added
OIL CHANGES (LOADSTABILIZING GEAR 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 2, 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 1 (with new sealing ring)
Check oil level - when the correct oil level is reached, close opening 1.
Oil change :
See instruction of manufacturers under Hoisting and Luffing gear
Oil type :
OIL QUANTITY :
Loadstabilizing gear abt. 0,5 l
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-29

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.19.1 INSTALLATION INSTRUCTION

GENERAL
Please also note the indication in our drawings:
The drive units are already assembled to drive-working-position (see installation drawing-rope winch-)
Strenght classes and torque moments for screw see installation drawing.
ASSEMBLY
Fix winch support
Put rope winch unit with winch support into steel frame.
Fix winch support with screws.
Connect brake line( see installation drawing )
Release hydraulically multiple disc brake.
Remove transport cover of the motor flange.
Before montage of the motor we recommend to treat the surface of the output shaft of the motor and
the profile of the drive sleeve in the drive unit with “Optimoly Paste White T” against fretting corrosion.
Check rope winch with running motor as to unction.
Check above all the control and unction o the holding brake and the drive motor.
Introduce the rope and draw in the rope key.
The rope must be wound up with at least 10% o the nominal rope pull.
4-30 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.19.2 MAINTENANCE INSTRUCTION

LUBRICATION
Oil filling ex factory : AVIA gear oil Hypoid 90 EP
Choice according to DIN : DIN 51502 resp. API GL5
sticker.

RECOMMENDATION FOR MAINTENANCE INTERVALS

First oil change after 200, then after each 3000 service hours, but at least every 3 years.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-31

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.19.3 RECCOMENDATION FOR LUBRICANTS
CHOICE LIST
CHOOSEN ACCORDING CHOOSEN ACCORDING CHOOSEN ACCORDING

TO API GL 5 TO DIN 51502 TO DIN 51502
GREASE, DIN 51825 –

OIL, SAE 90 OIL, DIN 51517 – CLP 220
KP2K
AVIA GEAR OIL

HYPOID 90 EP
CASTROL SPHEEROL
EPL 2 GREASE
ESSO GEAR OIL

GX-D90
FUCHS GEAR OIL

RENOGEAR HYPOID 90

4-32 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.19.4 GEARBOX INSPECTION

GEAR OIL ANALYSES _ PREVENTIVE MAINTENANCE
Why oil analyses ?
charges.
SIMPLE SURVEILLANCE:
metals, dirt etc.
construction part.
damage of the gear.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-33

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.19.5 TAKING OF AN OIL SAMPLE

level.
4-34 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.19.6 TIGHTENING TORQUES

TIGHTENING TORQUES FOR FIXING SCREWS M 4 TO M 36 AND FOR STRENGTH CLASSES 8.8,
10.9 AND 12.9 AT A COEFFICIENT OF FRICTION 0,125.
8.8 10.9 12.9

M4 = 2,7 Nm 3,8 Nm 4,6 Nm
M5 = 5,5 Nm 8,0 Nm 9,5 Nm
M6 = 9,5 Nm 13,0 Nm 16,0 Nm
M8 = 23,0 Nm 32,0 Nm 39,0 Nm
M 10 = 46,0 Nm 64,0 Nm 77,0 Nm
M 12 = 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
M 36 = 2350,0 Nm 3300,0 Nm
 THE INDICATED TIGHTENING TORQUES ARE MAXIMUM VALUES.

 SCREWS SECURED BY LOCTITE TYPE 242.
 FITTING SURFACES SEALED BY LOCTITE TYPE 640.
 SURFACING ON BRAKE SEALED BY LOCTITE TYPE 573.
 SCREWING OF THE TUBING AND THE CONNECTION SURFACES OF THE DRIVE MOTOR TO
 THE GEAR ARE SEALED
 WITH LOCTITE TYPE 572.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-35

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.20 CABLE REAL
4.1.20.1 ASSEMBLY OF THE CABLE REELING DRUM

The cable reeling drum is constructed for heavy duty. The construction consists of the following main parts
which are apparent of the spare parts drawing 2122-1002_ETZ. The drum body (3) is install to the drum
flange (2) onto the hollow shaft of the gearbox (1). On the opposite side of the drum body (3) the slip ring
body with its slip rings and brush holder unit is installed. The driving of the drum body (3) are given through a
electric break motor with an intermediate coupling, an magnetic coupling and a gearbox (1) on the drum
body (3) (the drive unit is supplied by the costumer). The heating (13) prevent the accumulation of the con-
densation water inside the slip ring housing (heating must run in continuous operation).
4.1.20.2 MOUNTING OF THE CABLE REELING DRUM

The gear box of the cable reeling drum is provided with 6 pieces of borings, bore-size approx. ø= 17mm. The
cable reeling drum will be installed firmly at these borings with the appropriate screws at the intended loca-
tion.
NOTE: When assembling of the cable reeling drum it is to be made certain that the mounting console is
even.
NOTE: Please consider the torque of the screws (see B+E 00 069).
NOTE! PLEASE CONSIDERED THE OPERATING MANUAL AND HANDLING INSTRUCTIONS

OF THE CABLE MANUFACTURER!!!
4-36 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.20.3 CONNECTING THE PAYOUT CABLE

Remove the cover (9) from the drum body (3) and the slip ring cover (14). The reeling cable goes through the
gland (7) at the drum body (3) and connected to each terminal strip (8).
Afterwards tighten the compression gland (7), thereby ensuring stain-relief and a good seal onto the cable
and replace the slip ring cover (9), too. Start now to coil on the cable including 2 safety windings for strain
relief onto the drum body (3).
Coiling on the cable onto the drum:
Lay the cable non-twisted onto the ground. Coil on the cable layer by layer by turning the drum body (3).
4.1.20.4 CONNECTING OF THE MAIN POWER CABLE

Remove the slip ring cover (14). The main power cable, coming from the distribution box through the gland
(12) at the slip ring housing (11) and is fixed to the brushes.
NOTE: The 1st, slip ring (17) nearest the axle is always earth ╧.
Replace the slip ring cover (14) and tighten the compression gland (12), thereby ensuring stain-relieved and
a good seal onto the cable.
4.1.20.5 CHECK BEFORE COMMISSIONING

Before the drum is put into operation, we recommend the following check:
a.) NOTE: Protective motor switch is always necessary.
b.) Check terminal block for proper sealing.
c.) Check slip ring unit for dampness, no moisture must be present.
d.) Check brush holders for proper contacts to slip rings.
e.) Rotation must be smooth.
f.) Grease slip rings slightly with contact grease.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-37

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.20.6 MAINTENANCE OF THE CABLE REELING DRUM

A.) WEAR PARTS
The brush holders/collector and slip rings/plane slip rings are subject to a natural wear and are depending
upon need to be replaced. The brush bearing surfaces are to be cleaned and the mobility of the pendulum
brush holders are to examine (with wire brush holding the pressure * is to the slip rings to examine), if nec-
essarily should take place a cleaning or an exchange (during 2/3 wear of the brush coals). After cleaning of
the slip rings these should be injected with contact spray. You receive the for this necessary special spray
over our spare part sales. It is to be made certain that the slip rings are always clean and no brush coal dust
at the slip rings set (flash over). After running in (after commissioning for the first time after 3 months) of the
brush coals the brush coal dust in the slip ring area is to be removed. You have to made weekly mainte-
nance in the running-in period (approx. 4-8 weeks) after commissioning. That’s important to ensure correct
function further on. Afterwardsin regular intervals (every 6 months and/or depending upon turnings of the slip
rings) repeat this procedure. If you fall into no pattern, please you request a maintenance plan from us (with
description of your data e.g. turnings, layer duration, travel speed). The inserted grooved ball bearings are by
the factory plentifully provided with camp fat, so that a greasing is necessary only in larger time intervals. It is
to be made certain by the customer that the steel flange is closely screwed on and the cable entry is well
after IP54 (IP65) sealed.
Pressure* = when easy one-sided taking from 3-4 mm off should set itself the hook again well on the slip ring
course. If this effected can take place re-bent and/or must an exchange.
The electrical connection must be done according to VDE 0100 - 0113 resp. IEC-Nr.: 204-1:1992 or
CENELEC.
D.) GEARBOX
Lubrication of the gearbox:

Gearboxes are delivered with the suitable lubrication according to the mentioned operation condition.
OIL FILLING
In gearbox, the oil has to be replaced according to the working hours after about 10.000 working hours. It is
recommended, that the oil should be drained shortly after having stopped the gear. If possible, refill the gear
with the same type of oil.
Type of oil: Shell-Tivella

Temperature range: -40°C to +170°C
Oil quantity: 2.8 liter
IT IS IMPORTANT TO CARRY OUT THE CHANGING OF THE OIL UNDER CLEAN CONDITIONS.
Maintenance of the gearbox:

All roller bearings are well dimensioned and lubricated with high quality lubrication. Therefore a long service
life is expected. The gearbox housing is dust-tight and Hose proofed and can be installed in any position.
SEAL RINGS, BEARINGS AND OIL ARE SUBJECT TO NORMAL WEAR.
We recommend the following maintenance:

At normal load and temperature conditions the lubrication should be renewed after 10.000 working hours.
But because the lubrication gets old while the drum is switched off, the lubrication should be changed after 3
years, not depending on the working hours.
4-38 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.20.7 LIABILITY FOR FAULTS

If any alterations or repairs to the cable reeling drum are done by anyone else within the time of warranty, we
do not take any further liability for faults.
NOTICE
According the EC recommendation 89/392/EEC, we point out that rotating parts have to be secured against
danger of accident.
4.1.20.8 ENCLOSURE
General security for motor reeling drums B+E 00 049
Screws / tightening torque B+E 00 069
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-39

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.21 LOAD TURNING DEVICE SWL 44,4T
4.1.21.1 GENERAL INFORMATION

There are two types of machine regulations, within the domain of the National Board of Occupational Safety
and Health; directives for the product and directives for the working environment. The intentions of the in-
structions are to make uniform the product requirements in each country in order to eliminate the so-called
trade barriers. This agreement to conformity makes the technical requirements of the products the same in
all member countries. The intention of regulating the working environment is that no country will gain unfair
business advantages by maintaining a poor working environment (making their products cheaper than prod-
ucts of other countries by risking the health and safety of their employees). In the machine regulations there
are three different parties; the manufacturer, the company and the operator. The manufacturer or his agent is
responsible for the machine meeting the minimum requirements, the implication of this is that the machine is
to accompanied by instructions for use. The company/ the user is required to train the driver/operator so he
can use the machine properly. The driver/ operator is to follow the rules and instructions necessary for him to
protect himself and others from accidents and to run the machine properly.
4-40 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.21.2 EXPLANATION OF SYMBOLS

The instructions contain important information, which is to be understood by all users, prior to putting the
machine in use. Therefore we have placed symbols in the instructions where we particularly want to focus
your attention.
CAUTION ADVICE
Vital information warning for Vital information on how to Advice on operation, care and
incident which can result in prevent personal and maintenance of the machine.
personal injury if instructions equipment damage.
are not followed.
4.1.21.3 EXPLANATION OF DECALS

Decals conveying vital information are placed in strategic areas on the machine. The users of the machine
must understand what the decals mean before they operate the machine.
Wear protective,
Warning! Danger of helmet, ear protectors,
getting crushed. protective goggles and
visor.
Prior to using, study the

safety regulations in the Wear durable,.
manual. non-slip gloves.
Wear reinforced
boots with nonslip
soles
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-41

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.21.4 SAFETY REGULATIONS

The following list of safety regulations is an excerpt from the general safety precautions which we want to
emphasize. Our intention is to make the personnel aware of the risks and dangers when the cargo-turner is
in operation.
1. Study and learn the meaning of all the warning symbols, safety precautions and instructions
in the manual. Study and learn the meaning of all the decals on the machine. See that you
fully understand the instructions before you start operating the cargo-turner.
2. Report all incidents and accidents to the responsible foreman.
3. If possible, use protective gloves, reinforced boots and protective goggles to protect your
hands, feet and eyes from getting cut or crushed; and to protect them from solvents, grease and oil.
4. Permit no unauthorized or under-aged persons in the working area.
5. Warning, prohibiting and informative decals must not be concealed, changed or damaged.
6. Do not climb onto the instrument or allow anyone else to.
7. Check the instrument for damage before each use. Repair damage before using the instrument.
8. Do not allow untrained personnel to start or use any of the equipment without the guidance
of a trained operator.
4.1.21.5 PRODUCT INFORMATION

Cargo-turner is used to efficiently hoist cargo and place it exactly where the crane operator wants its. It can
be used for all types of lifting equipment; on cranes, in docks or on ships. Use of the cargo-turner increases
efficiency by reducing the amount of time required for loading and unloading which also reduces operating
costs and risk of accidents.
4.1.21.6 PUTTING INTO OPERATION

It is important that everyone who is to use the cargo-turner is given the opportunity to read through the
instructions with an instructor or another trained person.
FOR THE INTRODUCTION WE RECOMMEND THAT YOU:

ADVICE
1. Go through the instructions carefully to determine possible difficulties.
2. Check that all safety devices are in place.
3. Make sure that the lighting is satisfactory.
UNAUTHORIZED PERSONNEL MUST NOT BE WITHIN THE WORKING AREA

WHEN THE CARGO-TURNER IS IN OPERATION
4-42 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.21.7 MOUNTING
The crane on which the cargo-turner is to be mounted must be approved (been granted a test hoisting
certificate) and must meet the prevalent rules and regulations.
1. Check that the lighting is satisfactory and that the cargo-turner is standing steadily.
2. Fit the lockings and connect the supply current. Prior to the test run check the lockings.
3. During the test run and operation of the cargo-turner nobody is permitted in the working area.
4. Never hoist a load above or near people and make sure that the operator has a good view of the
working area.
4.1.21.8 DISMOUNTING
1. Make sure that lighting is satisfactory.
2. While dismounting the cargo-turner is to be placed in it’s transport frame.
3. Remove the lockings and disconnect the supply current.
PRIOR TO REMOVING THE INSPECTION

COVER, THE OPERATOR MUST BE
CERTAIN THAT THE POWER SUPPLY
IS DISCONNECTED.
BE CAREFUL! DANGER OF GETTING
CRUSHED. (SEE PICTURE 1)
Picture 1
4.1.21.9 SPARE PARTS
When replacing damaged parts make sure that they are approved by the manufacturer.
4.1.21.10 CARE AND MAINTENANCE

1. The purpose of all service and repair should be to maintain or
restore the cargo-turner to original function. If the function
of the machine is altered, the party responsible for the
alteration will be held liable according to the Machine Directive.
2. The person who repairs and services the machine must be
knowledgeable about the machine.
3. The person responsible for operating the machine must know
when and how the machine is to be serviced.
4. The machine is to be serviced only when lighting is satisfactory
lighting.
This high quality cargo-turner has a long life of high function despite strenuous tasks and a difficult
environment to function in.
To get the most out of the cargo-turner functionally and economically it must be maintained and serviced
properly.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-43

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.21.11 HYDRAULIC AGGREGATE

AFTER 8 HOUR OF USE...
* Check oil level (level should be between the marks on the oil gauge).
* Check for leaks.
AFTER 50 HOURS OF USE...
* Check that the hydraulic couplings and anchor bolts for the hydraulic aggregate,
hydraulic oil tank and hydraulic motor are tightened.
* Check hydraulic hoses.
* Make sure electric cables and plugs are not broken and are clean.
* Grease slewing ring gear and pinion
Check hydraulic pressure.

To check maximum working pressure, the
rotating part must go to stop. At this time
the pressure should be 80 bar.
(see picture 2 Pressure measurement).
Picture 2
* Change the hydraulic oil

DISMOUNTING OF HYDRAULIC UNIT
1. Check that lighting is satisfactory. Prior to open the inspection cover the operator must be certain that
the supply current is disconnected.
2. Open the inspection covers on both sides of the Cargo-Tuner
3. Disconnect the electric cable from the electric motor.
4. Disconnect all hydraulic hoses.
5. Screw off the bolts on the fastening plate of the hydraulic unit. Remove the fastening plate with the
hydraulic unit from the Cargo-Tuner.
CHANGE OF HYDRAULIC OIL
1. Check that lighting is satisfactory. Prior to opening the inspection cover the operator must be certain
that supply current is disconnected.
2. Dismount the hydraulic unit.
3. . Screw off the fastening of the hydraulic plate.
4. Drain oil tank through filling hole to collecting pail for waste oil.
5. Unscrew the oil tank from the hydraulic block.
6. Clean inside of oil tank, check the sealing between oil tank and block before mounting it back.
7. Fill new hydraulic oil through filling hole to correct level.
8. Check for leakage between block / oil tank before the hydraulic unit is fitted to the Cargo-Tuner.
4-44 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
Clean all equipment after each commission. Inspect equipment for damage
ADVICE and repair any possible damage so that it is operable for the next
commission.
Make sure that electric plug is not broken and is clean.
CAUTION When handling grease and oil great caution should be exercised.
Avoid skin contact.
The oil tank holds approximately 5,0 L.
Type of hydraulic oil: Shell Tellus T 32 S

BP Bartran HV 32
ESSO Univis N 32
Mobil Flowrex SHS 32
4.1.21.12 ANNUAL MAINTENANCE

1. Clean equipment thoroughly.
2. Inspect for wear and tear.
3. Exchange damaged parts, touch- up damaged areas and give anti-corrosive treatment.
4. Lubricate all bearings.
5. Renew test hoisting certificate according to regulations.
4.1.21.13 CONDITIONS OF GUARANTEE:

The guarantee does not cover damage that has occurred due to misuse or because repairs have been
carried out incorrectly. The guarantee is also invalid if other than original parts have been used to repair the
machine. The guarantee is also invalid if the instructions in the instruction manual have not been adhered to.
4.1.21.14 TECHNICAL SPECIFICATIONS

Type CS10040
Serial No. 40093, 40094
Build year. 02-2008
Lifting capacity 44,4 ton SWL
Weight 600 kg
Electric motor 440 V 60 Hz 1,8 kW IP55
Working pressure 80 Bar
Rotation torque. 2600 Nm
Rotation speed 2.4 - 3.0 rev/min
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-45

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.22 LUBRICATION AND MAINTENANCE
For Example only
The first relubrication of the raceway and lubrication of the gear must be carried out immediately after instal-
lation. For this and each subsequent lubrication, the lubricants named in Table 4.3 are to be used. These
raceway greases are solely K-L2K greases, i.e. lithium-saponified mineral oils of NLGI Grade 2 with EP addi-
tives. The raceway lubricants listed in Table 4.3 can be mixed together. The lubricants are listed in random
order and not according to quality. The grease filling is there to reduce friction, seal the bearing and provide
protection against corrosion. Therefore, the bearing must always be greased liberally so that a collar of
fresh grease forms around the whole circumference of the bearing gaps and seals. The bearing
should be rotated during relubrication.
Lubricants
Queries concerning lubricants should be answered by the appropriate manufacturer. The greases listed in
Table 4.3 are approved for our large diameter antifriction bearings and tested for compatibility with the mate-
rials stipulated by us for spacers and seals. We can examine other lubricants only for the purpose of assess-
ing the aggressivity of a particular grease on the parts we use (spacers and seals), which are made of plastic
or other synthetic materials. When employing other lubricants, the user must therefore obtain confirmation
from the lubricant manufactuere or supplier that the grease he has chosen is suitable for the intended appli-
cation and that its properties are at least equivalent to those of the greases oisted in our table. It must be
guaranteed that the lubricant will not undergo any change it its composition and this also applies to future
deliveries. If no automatic lubrication devices are installed, a sufficient grease pump is neccssary in order to
provide a proper amount of grease as required. With low temperatures special lubricants are necessary. It is
the responsibility of the maintenance personnel to ensure individual consumption rates by accurate checking
of the lubricated condition of both the raceway and gear.
Lubrication period for the running system
Select according to operating conditions. With special required parameters, consultation with TTS should be
held. Generally about every 100 operating hours. Roller bearings about every 50 operating hours. Shorter
lubrication periods: In the tropics, by high amounts of moisture, after dust or dirt effects, strong temperature
changes, as well as continuous rotation motions. For bogie bearings, from rail vehicles and tram vehicles as
well as bearings for wind energy, special regulations apply. If there are standstill times between bearing in-
stallation and equipment start-up, respective maintenance procedures will be required, e.g. relubrication
under rotation no later than after 3 months and every 3 months thereafter. Before and after prolonged stop-
page of the equipment, relubrication is absolutely necessary. This is especially important after a winter shut-
down. When cleaning the equipment, care must be taken to prevent cleaning agents from damaging the
seals or penetrating into the raceways. The seals must be checked every 6 months.
Lubrication intervals for the gear
We recommend automatic gear lubrication. In case of hand lubrication, pinion and gear are to be greased
sufficiently with grease recommended in Table 4.3. A weekly gear lubrication is recommended. The gear
should always have sufficient grease.
4-46 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.1.23 GREASING POINTS – CRANE
ITEM INTERVALS MAINTENANCE POINT NUMBER OF TYPE OF

LUBRICATION LUBRICANT *
POINTS
1 Hoisting gear - second journal bearing 1 nipple multi-purpose grease
2 Luffing gear - second journal bearing 1 nipple multi-purpose grease
3 Slewing ring 24 nipples multi-purpose grease
4 Gearing-slewing-ring 1 ring Lub. oil or gear grease
monthly
5 Jib bearing 2 × 1 nipple multi-purpose grease
6
7 Hook 2 nipple multi-purpose grease
8 Load Turning Device 1 nipple multi-purpose grease
9 quarterly Ropes Hoisting and luffing rope grease
ropes
10
11
12 see instruction Electr. motor
of manufactur-
ers
13 weekly
* Grease see 4.3 lubricants
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-47

TTS - NMF GmbH
83158.- MAINTENANCE
4.1.24 OIL CHANGE
CHECK OIL LEVEL CURRENTLY RESP. DAILY
Item Intervals Maintenance point No. Type of lubricant*) Lubricant tool and quantity
1 Slewing gear 3 gears gear oil Oil can abt. 12 l
(1 x 36 l)
2 every 1500 h Hoisting gear 1 gear gear oil Oil can abt. 16,0 l
or
3 yearly Luffing gear 1 gear gear oil Oil can abt. 11,0 l
4 Loadstabilizing gear 1 gear gear oil Oil can abt. 0,5 l
5 Cable drum 1 gear Shell-Tivella Oil can abt. 2,8 l
6 Hydraulic tank Hydr. oil VG 46 total capacity 600 l
Tank,
7 2000 - 3000 hrs. Hydraulic sytem hoses etc.
Hydr. oil VG 46 total capacity 650 l
Tank,
8 Load Turning Device hoses etc.
*) Type of lubricants see section 4.3 and Manufacturer of gears
4-48 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.2 MAINTENANCE SCHEDULE

Pos. Maintenance Maintenance points Nos. Of Lub- Lubricants Refilling and Sec-
Points Quantity tion
Intervalls Oil type ¹)
1 Oil level
2 Oil temperature
3 Check of filters with-
currently out clogging indica-
resp. tors
4 daily Outer leaks
5 Damages
6 Pressure valves /
Current valves
7
8 Condensed moisture
to be dropped
14 days resp.
9 after 250 hrs. Change of filters
without clogging
indicators
10 Hoisting gear - coun- 1 nipple Multi-purpose grease 4.1.22
ter bearing
11 Luffing gear – 1nipple Multi-purpose grease 4.1.22
counter bearing
12 Slewing gear 3 x 1 nipple Multi-purpose grease 4.1.22
13 monthly Slewing bearing 20 nipples Multi-purpose grease 4.1.22
14 Gearing of slewing Gearing Open-gear grease 4.1.22
bearing
15 Jib bearing 2 × 1 nipple Multi-purpose grease 4.1.22
16 Hook tackle block 3 nipple Multi-purpose grease 4.1.22
17 Load turning device 1nipple Multi-purpose grease 4.1.22
18 Oil condition / oil
samples
19 Ropes (hoisting and Hoisting and Rope grease 4.1.14
luffing ropes) luffing gear
rope
20 Cleaning of Breath-
ers
21 Hoisting gear rope 4.1.15
quarterly
22 Luffing gear rope 4.1.15
23 Loadstabilizing rope 4.1.15
24 Slipring assembly
25 Multi-disk brake 4.1.16
26 Check of the connec-
tions for fastening
27 Check for wear of Electr.
brushes equipment
¹) Type of lubricants see section 4.3and manufacturers of gears
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-49

TTS - NMF GmbH
83158.- MAINTENANCE
Item Maintenance Maintenance Nos. of Lub- Lubricants Refilling and Sectiont

Intervals Points Points Quantity
Oil Type ¹)
28 after 1000 Cleaning of
hrs. breathers
29 Slewing gear 3 gearboxes Gear oil Oil can abt. 4.1.17
(3x12 l) 4.1.23
36 l
30 Oil can 4.1.18
Hoisting gear 1 gearbox Gear oil
abt. 16,0 l 4.1.23
31 Oil can 4.1.18
Luffing gear 1 gearbox Gear oil
abt. 16,0 l 4.1.23
32 Loadstabilizing 1 gearbox Gear oil Oil can 4.1.19
yearly gear abt. 0,5 l 4.1.23
33 resp Cable drum 1 gearbox Shell-Tivella Oil can 4.1.20
after 1500 abt. 2,8 l 4.1.23
hrs.
34 Load hooks
35 Power circuit contacts
breaker
36 Monitoring units Electr.
equipment
37 Terminals connection
38 Fuses
39 Hydraulic system 4.5.2.2
4.5.2.3
40 Hydraulic tank Hydr. oil VG 46 600 l 4.1.23
41 2000-3000 Hydraulic system Tank, hoses, Hydr. oil VG 46 Filling pump 4.1.23
hrs. etc. ca. 650 l
42 Load Turning De- Tank, hoses 4.1.21
vice etc. 4.1.23
43 yearly Measuring Instru-
ments (Pressure
gauges)
44 see instruc- Electr. motor
tion of manu-
facturers
¹) Type of lubricants see section 3.3 and manufacturers of gears
4-50 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.3 LUBRICANTS
Lubricants Types of Lubr. perm. Equivalent types of other makes can also be used
Maker mainly tropical areas mainly moderate Hydraulic oil 46 Multi-Purpose- Lubricant for Lubricant for
areas Quality Grease gear rim ropes
1) HV 46 1) HLP
Gear Oil C-LP220 Gear Oil C-LP150 K-L2K
Aral Epona Z 220 Epona Z 150 Visga 46 Vitam GF 4 Epexa 2 Cardrexa DC 1 Cardrexa DC 1
Vitam BG 220 Vitam BG 150 Vitam HF 46 6 Aralub HLP 2 Aralub LFZ 1 Aralub LFZ 1
BP Enersyn HTX 220 Epona Z 150 Bartran Energol HLP46 Energrease MP Energrease MP Energrease MP
Energol GR-XP 220 Vitam BD 150 HV 46 Energol HLP46 MG 2 MG 2 MG 2

Chevron Non-Leaded Gear Non-Leaded Gear Mechanism Mechanism Dura-Lith Pinion Grease Pinion Grease
Compound 220 Compound 150 LPS 46 LPS 46 Grease EP2 250 CB 250 CB
Castrol Alphasyn HG 220 Alphasyn HG 220 Hyspin Hyspin Spheerol Spheerol Spheerol
Alpha SP 220 Alpha SP 150 AWH 46 AWS 46 SX 2 SX 2 SX 2

Esso Spartan EP 220 Spartan EP 150 UNIVIS N 46 NUTO H 46 Beacon 2 Surett Fluid 4K Surett Fluid 4K
Cazar K2
Unirex N2 Beacon EP 2
Mobil Mobilgear 630 Mobilgear 629 DTE 15 DTE 25 Mobilux 2 Mobiltac D Mobilarma 798
Hydr. Oel Mobiltac D
HLPD 46
Shell Shell Omala 220 Shell Omala 150 Tellus Oel Tellus Oe Alvania Fett R2 Cardium Fluid C Cardium Fluid
C
T46 46
DEA/Texaco Meropa 220 Meropa 150 Rando oil Rando oil Multifak EP 2 Texclad 2 Texclad 2
HDZ 46 HD 46
1) With considerably varying ambient temperatures we recommend the use of oil quality HV for the hydraulic system
Note: The oil types listed in the „List of Hydraulic Oils“ are interchangeable and can be mixed with each oth-
er. It is not necessary to drain off the oil or flush the hydraulic pipes prior to refill with a different type
of oil.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-51

TTS - NMF GmbH
83158.- MAINTENANCE
4.4 ELECTRICAL EQUIPMENT

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

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

PERMITTED ONLY AFTER CONSULTATION WITH AND APPROVAL BY
TTS-LMG MARINE CRANES GMBH.
Electrical safety devices may be removed, replaced or bridged only by authorised persons under
appropriate supervision when the crane is not in operation, and after all necessary safety precautions
have been taken. The satisfactory operation of the safety devices concerned must be checked after the
original state has been restored.
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.
4-52 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-53

TTS - NMF GmbH
83158.- MAINTENANCE
4.5 HYDRAULIC EQUIPMENT

HYDRAULIC SYSTEM
A powerful electric motor drives the hydraulic pumps via a distribution gearbox with constant speed and al-
ways with the same direction of rotation:
The individual crane gears (hoisting, luffing and slewing gear) are driven electro-hydraulically. A three-phase
electric motor with constant speed and invariable direction of rotation drives three independent hydraulic
circuits via a splitter gearbox.
ALL THREE CRANE 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 corresponds to zero stroke - the pumps do not deliver oil to the
motors.
DEFINITIONS
CLOSED CIRCUIT
“Closed circuit“ of a hydraulic system means that the oil returned from the load will be delivered directly to
the hydraulic pump.
The HIGH-PRESSURE SIDE is the side on which the oil is delivered from the pump to the motor.
The LOW-PRESSURE SIDE is the side on which the oil is returned from motor to pump.
The pump is driven in an invariable direction of rotation.
Speed control and reversal of the hydraulic motor are possible 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 secure 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 the ship’s mains.
This applies mainly for drives of winches, travel and slewing gears.
TYPICAL FEATURES OF CLOSED CIRCUITS 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 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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, depending on the type of motor.
OPEN CIRCUIT
„Open circuit“ means that - in general - the suction line of a pump is led below an 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 load (motor, cylinder). The oil is returned from the load to the reservoir.
The pump conveys only in one direction of flow. Modification of the direction of the load can be achieved by
installation of a directional valve between pump and load.
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:
A multiple of max. pump flow in litres
 Pump arrangement:
Next to or under the tank
 Drive speeds:
Limited by amount of suction
 Unloading in the return line via valves
SWIVEL ANGLE (A2F-MOTOR)
The swivel angle of the fixed displacement unit is set by the housing and hence it is fixed. In a variable dis-
placement unit this angle may be smoothly adjusted between certain limits.
By changing the swivel angle a different piston stroke is obtained and hence an adjustable displacement
volume may be produced.
SLEWING ANGLE (A4VG-PUMP)
The swivel angle of the swash plate in the housing in the fixed displacement unit is fixed. In a variable dis-
placement unit the angle of the swash plate may be smoothly adjusted between specific limits. By changing
the angle of the swash plate it is possible to change the piston stroke and hence the displacement volume.
VOLUME FLOW
Volume flow is the volume of fluid which passes through a given surface per unit time. The air flow is always
indicated in an intake condition - referring to normal conditions. In hydraulics, the volume flow is normally
indicated in L/min; in pneumatics in m³/min.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-55

TTS - NMF GmbH
83158.- MAINTENANCE
4.5.1 FUNCTIONAL DESCRIPTION

Basis of this description is the enclosed hydraulic diagram. The items included in the diagram are divided
into 8 groups:
1. Hoisting gear circuit 1.0

2. Luffing gear circuit 2.0
3. Slewing gear circuit 3.0
4. Oil feed and control circuit 4.0
5. Cooling system 5.0
6. Oil tank 6.0
7. Manual filling pump 7.0
8. Manual pump for emergency operation 8.0
9. Tension winch drive 10.0
10. Cable drum drive 11.0
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 oil 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 thick 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 dis-
charge.
25° inclination corresponds to maximum discharge

0° inclination: no discharge.
When the swash plate passes the 0-position and inclines to the other side, the direction of delivery changes
while the direction of rotation of the pump remains the same.
Displacement control of the pumps is described in detail in section “Control Oil Circuit - Pump Control“.
The hoisting gear is equipped with a variable displacement motor (1.5) in addition to the variable displace-
ment pump (1.1). The type of the hoisting motor is A6VM 200 EP (TRIMOT is the brand name of this motor).
For 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.
4-56 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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°. In order to keep the max. rpm within certain limits, the minimum swash angle
is limited to about 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 0-stroke to B= pump at max. piston stroke and

max. displacement. stays there. Motor swashes from
Motor starts with max. piston max. stroke back to smaller stroke
stroke and stays there. (not to 0) while the working pressure
increases with constant load.
The sequence (first displacement of pump and then 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 PLEASE NOTE:

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 fed 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 the
control cylinder is charged with pressure from the high pressure circuit via non-return valves. The control
cylinder has a solenoid valve. The displacement angle of the variable displacement motor is proportional to
the magnetic force.
HYDRAULIC DIAGRAM SEE CHAPTER 6.0 ASSEMBLY GROUP 97.66.00
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-57

TTS - NMF GmbH
83158.- MAINTENANCE
4.5.1.2 LUFFING GEAR CIRCUIT 2.0

The luffing gear pump (2.1) delivers to the luffing gear motor (2.5). From the motor, the oil flow returns to the
pumps. This closed circuit is shown in the diagram by thick lines as well. 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 only depends on the variable pump discharge.
Section "control oil circuit - pump control" applies to the control of the pump, as well 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 re-
turned to the pump.
Here too, this "closed circuit" is marked by thick lines in the diagram. The slewing pump is a variable dis-
placement pump type A4VG125 EP.
The slewing gear motors are fixed displacement motors, i.e. the piston stroke remains unchanged. The con-
sumption in cm³/revolution is constant.
The rotating speed is only determined by the variable pump discharge volume.
For control of the pump of the slewing gear, please refer to section "Feed and Control Oil Circuit - Pump
Control".
For 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 (feed circuit).
Auxiliary equipment, such as the brakes, has to be operated.
4-58 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.5.1.4 FEED 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 for adjusting the discharge rate and reversing the direction of discharge are flanged on.
The first stage of the double pump (4.1) is an axial piston pump (K3VL 80). It supplies the feed and control oil
circuit.
The axial piston 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 and 3.1. Oil is delivered to the respective low pressure side via non-
return valves.
The discharge rate controller (4.1.1) keeps the feed oil pressure at a constant 28 bar.
THE CONTROL OIL CIRCUIT
The control oil circuit maintains the control pressure needed for:
1. Pump displacement control (volume and direction of discharge)
2. Operation of holding brakes.
This control oil circuit is supplied by the same pump (4.1) as the feed oil circuit, i.e. after filter (4.9), the con-
trol oil is branched off from the feed 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 feed 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 quickly and precisely convert the electric signal, i.e. current which can vary
between abt. 200 and 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 and 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 ei-
ther in line X1 or X2.
Nozzle (V1) is fitted in control line (X1) and throttles the incoming oil and thus determines the speed of the con-
trol 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 delivered to the control piston, so that the swash plate slews into the other
direction through the 0-position.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-59

TTS - NMF GmbH
83158.- MAINTENANCE
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 supplied with pressure from 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 it 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)
This procedure also applies to the main hoisting gear via magnet 1.24 and to the luffing gear via magnet 2.22,
but here opening of the brakes is delayed until the pressure present before engagement of the brakes has been
reached again in the respective high pressure lines after a pause with the brakes still engaged. Pressure sen-
sors 1.23 for the hoisting gear and 2.23 for the luffing gear are used for this purpose.
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 with-
out pressure and there would be hard knocks and corresponding pressure peaks. The electric pressure sen-
sor 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 pressure sensor 1.23 gives the signal to open the brakes, the pump is also switched to deliver in low-
ering direction.
The whole process of jerkfree starting takes place automatically.
PIPE BURST SAFETY DEVICES
Readiness for operation of the crane is monitored by several pressure switches, i.e. item nos. 1.27, 2.27,
3.12 and 3.27.
Therefore, the pressure controls in the feed 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 feed pressure in the low pressure line collapses. Due
to this, the pressure control automatically switches off the crane and the holding brakes engage.
4-60 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
FILTER CLOGGING INDICATOR
The filter is equipped with a protective valve. If the filter is very dirty, the protective valve for the filter opens
at the bypass at a certain pressure difference (abt. 1 bar) and thus prevents destruction of the filter insert
owing to further rise in pressure. In order to prevent such an occurrence which would allow unfiltered oil to
get into the circuit, the high pressure filter (4.9) in the feed circuit is equipped with an electric clogging indica-
tor (differential pressure measuring device). When clogging is indicated, the filter cartridge 4.9.2 needs re-
placing.
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
Pressure relief valves which protect the drive as well as the pipe and hose lines from overloads are installed
in the main lines of all three drives. While 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 one low pressure valve each (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. The motor remains in this position which de-
pends on the load. This process is electronically controlled in the hoisting gear. The pressure sensor (1.23)
serves as pick-up for the maximum pressure for the lowering and hoisting functions respectively.
The pressure sensor (1.23) also gives a signal when the working pressure is about to exceed the max. per-
missible pressure.
At that point, the working volume of the variable displacement motor (1.5) is increased again. The hydraulic pres-
sure 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 adjusts 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 and 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.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-61

TTS - NMF GmbH
83158.- MAINTENANCE
4.5.1.5 OIL COOLING 5.0

Circuit 5.0 cools the hydraulic oil. The second stage of the double 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.
In order 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 honeycomb radiator (5.8.3).
After passing through the honeycomb radiator, the air is discharged to atmosphere through the exhaust flap. The
hydraulic oil quickly warms up to suitable operating temperature, as the ventilator is only switched on by the tem-
perature sensor (5.5) when the oil temperature in the tank reaches abt. 50 °C.
4.5.1.6 HYDRAULIC OIL TANK 6.0

The hydraulic oil tank has a maximum oil volume of about 500l. The oil level can be checked visually with the
help of 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 feed 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. It can be 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 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.
4-62 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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 A LOAD IN THE HOISTING GEARS / LOWERING THE JIB IN THE LUFFING GEAR
ATTENTION:
Emergency lowering by means of a hand pump is only allowed in case of emergency, i.e. failure of
the hydraulic system.
The brake is released by means of the hand pump. The load in the hook or the jib-weight is sup-
ported on the pump via the oil column in the hose line.
Lowering to be done via the existing leak oil in the pumps or motors.
PROCEDURE:
1.Screw off hose line item 1.01 or 2.01 at the screw joint of the brake filter.
2.Close hose line with plug and connect hose of the emergency hand pump to screw joint of the
brake filter.
3.Close relief valve in the main hand pump by turning the hand wheel.
4.Built up pressure by means of the lever of hand pump. The brake starts to release at about 10 bar
(if necessary: vent air in the hose line by unscrewing the cap-nut).
NOTE:
Pay attention to the movement of the rope drum. If rope drum starts to turn quicker, open the relief
valve with the hand wheel.
The brake will become pressureless and engages.
5.Lower the load and fit hose item 1.01 or 2.01 again.
hand pump
hand lever
hand wheel relief valve
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-63

TTS - NMF GmbH
83158.- MAINTENANCE
TURNING OF CRANE TOWER
In case of emergency it might become necessary to turn the crane tower without a drive.
In principle the procedure is the same as lowering under emergency. However, it is necessary to turn the
crane tower by means of external actuation.
The easiest way is to use a deck winch. A turn of a mooring rope is put around the crane tower and the free
end is fastened at a fixed point. 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.
4.5.1.9 TENSION WINCH DRIVE 9.0

The motor (10.3) of the load stabilising winch is driven by a variable displacement pump type A10V28
(10.1). This pump with stepless adjustment of discharge rate is flanged on to the slewing gear pump
The drive is started automatically together with the start of the hydraulic pump set and prevents the load
from oscillating heavily during crane operation, i.e. oscillating load is braked by a steadying rope.
The steadying force is obtained by pressure relief valve .
4.5.1.10 CABLE REEL 10.0

The motor (11.3) of the cable reel is also driven by the variable displacement pump mentioned in
Sect. 4.5.1.9 This drive effects a constant pull of the power supply cable of load turning device and
spreader, preventing the cable from coming off the reel.
To prevent excessive tensile loads acting on the cable driving the lowering process, the pressure relief
valve is activated through the 4/2-way valve .
The pressure switch prevents hoisting if the set pressure is reached. This arrangement prevents
cable loops which will cause cable damage during the hoisting process.
4-64 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.5.2 GENERAL REMARKS

Strict adherence to the operating and maintenance manual published by the manufacturer is necessary for
trouble-free operation. The work required to put hydraulic systems into operation and keep them in good
working order is outlined in the following:
COMMISSIONING MAINTENANCE
INSPECTION SERVICING TROUBLESHOOTING
Commissioning of a Checking condition and Preserving perform- Pinpointing and rectifi-
new system or recom- functioning ance cation of malfunctions
missioning of an exist- Changing spare parts and damage
ing system
Fault-finding requires
Installation, filling with Observations, meas- Cleaning and replacing close and logical atten-
fluid, bleeding, basic urements, test run components (fluid tion to detail
adjustment, running-in change, filter inserts,
seals) Repair of damage by
replacement of compo-
nents
Repair of components
by manufacturer
A hydraulic circuit diagram is indispensible when handling problems in hydraulic systems. Defective hydraulic
systems respond in different ways. Always find out when, under which conditions and how often a problem
occurs, e.g.
* after a relatively short period of operation,

* at regular intervals, or
* after long periods of trouble-free operation.
In case of a malfunction, first check whether the pressure is being build up.
GENERAL REMARKS
General instructions for work on hydraulic systems:

To avoid accidents, never slacken pipe couplings, hose connections or mechanisms as long as the system is
under pressure. Loads must be lowered to the ground and secured, and all pumps must be switched off be-
forehand.
DO NOT WORK WITH OILY HANDS!
Keep everything absolutely clean during all stages of the work because dirt is the greatest enemy of hydrau-
lic 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 nitro-
cellulose.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-65

TTS - NMF GmbH
83158.- MAINTENANCE
INSTALLING HOSES
When selecting hoses and couplings/flanges, make sure you choose the right pattern (wall thickness, mate-
rial) for the pressure concerned.
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 edg-
es 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 such 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 be installed without stress to prevent jamming of the control pis-
tons. Mounting faces must be absolutely flat, and fixing bolts must be tightened uniformly with the specified
torque.
4-66 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.5.2.1 PUTTING SYSTEM 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 loads according to 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 reser-
voir for dirt and clean it if necessary. Check the hydraulic fluid for water. The contamination of the hydrau-
lic 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 (approx. 1 - 3 seconds).
 Slowly start the drive motor.
Run the electric motor in inching mode.
 Let the pumps run in idling mode.
 Check for leakage.
 Bleed the system in the load lines, preferably at their highest points. Operate directional control valves
and extend and retract loads several times. Slowly increase the load. Increase the settings of pressure
valves and regulators. The system has been bled properly when foam is no longer present in the reser-
voir, 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 whether cooler switches on correctly.
 Set the pressures for the different circuits and seal the pressure relief valves.
 Carry out a 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). Re-
move all external oil and grease from the hydraulic system by washing it with detergent and inspect for leak-
age for about an hour.
Check once again and retighten all connections after operation at full load.
Replace all oil filters and clean all magnetic bars after the trial run.
ATTENTION:
It is very important that the feed pressure for the closed circuit (DMP 7) is maintained during the pressure
check and the operation of the main pumps.
If the feed pressure drops to below 20 bar, the drive motor is switched off immediately because of the danger
of cavitation involved.
During operation, the feed oil pressure is monitored by pressure sensors.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-67

TTS - NMF GmbH
83158.- MAINTENANCE
4.5.2.2 INSPECTION AND MAINTENANCE
TTS hydraulic components have been designed for long and trouble-free operation. They require very little
maintenance. However, the little attention they need is absolutely necessary for trouble-free operation, as
practical experience has shown that up to 80% of 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 summarised 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 40 ºC and 90 ºC.
The oil temperature in the reservoir must be monitored continuously. Gradually increasing temperatures may
indicate contamination, clogging, or worn metal components or seals and should be seen as a reason to
examine the corresponding components.
Sudden rises in temperature are an alarm signal, and the system should be shut down immediately for in-
spection.
FLUID CONDITION
Aging of the fluid depends on a number of factors such as temperature, dirty environment, operating pres-
sure, humidity, etc.
APPEARANCE CONTAMINANTS POSSIBLE CAUSES

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

Water segregation Water Ingress of water
Air bubbles Air Ingress of air, e.g. due to low fluid

level or leaky suction
Floating contaminants or Solids Wear, dirt, aging products

sediment
Smell of burnt oil Aging 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.
4-68 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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 lev-
el.
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 dam-
age to the hydraulic system.
NOTE!
Paper filter cartridges must not be washed or blown clean with compressed air.
ONLY USE 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 for leaks regularly. Leaks can be located only if the external surfaces of the hy-
draulic system are kept clean. Leaky hoses must be replaced immediately. Replace the O-rings if leaks are
found at flanged or compression couplings using O-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.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-69

TTS - NMF GmbH
83158.- MAINTENANCE
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 moni-
tored 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 for both
the running in and the subsequent operation stage.
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 to 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 off the oil into a receptacle positioned at a lower point.
4-70 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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. Afterwards 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 to fill the pump completely for the first time.
 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 unnecessarily high pressure.
 Secure the final setting to prevent inadvertent maladjustment.
TEMPERATURE
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-71
TTS - NMF GmbH
83158.- MAINTENANCE
 Check the fluid temperature under normal service conditions.
4-72 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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 bench-
es), 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 rec-
tified 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 equip-
ment 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 hy-
draulic systems naturally makes fault-finding more difficult and requires good cooperation between electrical
and hydraulic 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.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-73

TTS - NMF GmbH
83158.- MAINTENANCE
4.5.2.5 TROUBLESHOOTING
CAUSES OF FAULTS AND THEIR CONSEQUENCES IN OIL-HYDRAULIC SYSTEMS

Source of fault 1 2 3 4 5 6
Mech. driving Intake Pump Pressure line Return line Pressure
Consequence section conditions control valves
A Excessive 1. Coupling Resistance in 1. Pump speed 1. Pipe fixing As 4 A 1. Valve chat-
noise incorrectly suction line too too high missing or ters, worn
aligned high because: 2. Maximum loose 1. Return line owing to
2. Coupling pump pres- 2. Not laid ends above fouled valve
loose 1. Cock in sure ex- properly fluid level seat
suction line ceeded 2. Return line 2. Insufficient
3. Coupling not open or 3. Cross-
faulty 3. Feed pump sections too filter clogged clamping
only partly (type not
4. Pump or open faulty small
suitable)
motor 2. Suction filter 4. Shaft seal or 4. As 4 C
mounting packing on 3. Noise of flow
clogged or during
loose too small the suction
side faulty startup
5. Other trans- 3. Suction line
mission 5. Pump faulty 4. Unfavour-
clogged or able charac-
component leaking 6. Pressure
(V-belt, gear teristics
4. Suction line and return
wheel) faulty lines re- 5. Incorrect
too small or design
6. Pump or too many versed
motor faulty bends in line 7. Regulating
7. Direction of 5. Fluid level system oscil-
rotation in- too low lating
correct 8. As 1 A B
8. Configuration
not optimal
for noise re-
duction (elas-
tic metals)
B Insufficient 1. Fault in As 2 A 1. Internal 1. Leaks 1. Excessive 1. Working

force and power leakage ow- 2. Excessive line resis- pressure set
torque at drives transmission ing to wear line resistance too low
(insufficient 2. V-belt or 2. Type unsuit- tance 2. Filter 2. Internal
pressure) sprocket belt able 3. Pressure clogged leakage ow-
slipping 3. Pump faulty filter clogged ing to wear
3. Incorrect 4. Governor 3. Valve seat
Direction of pressure set fouled or
rotation to low or damaged
4. Motor faulty control de- 4. Spring
5. Key on pump vice faulty broken
or motor 5. Type unsuit-
seared off. able (setting
range too
low)
C Cylinder or As 1 A 1 - 7 As 2 A 1. Variable 1. Installation As 5 B As 6 A 1...2

motor move- capacity not com-
ments jerky pumps: pletely bled
(fluctuations in Regulator 1. Excessively
pressure and faulty long un-
flow) damped tel-
2. Pump faulty econtrol line
3. Feedback on 2. Unsuitable
pumps from telecontrol
the system valve
regulators
(DMV; SRV)
4. Pilot valves
unsuitable
4-74 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE

Source of fault 1 2 3 4 5 6
Mech. driving Intake Pump Pressure line Return line Pressure
Consequence section conditions control valves
D Drive fails to As 1 A 1 - 7 As 2 A 1. Internal As 4 B As 4 B As 6 B
turn or turns too leakage ow-
slowly ing to wear
(no delivery or Sequence
2. Pump faulty control:
insufficient
delivery) 3. Supply and 1. Sequence
return lines valve set too
reversed high or faulty
E Operating . 1. Utilisation 1. Line cross- As 4 E 1. Excessive

temperature too coefficient section too continuous
high losses owing small, con- delivery
to wear sequently 2. Unsuitable
2. Variable frictional re- valve type
capacity sistance (cross-
pumps regu- 2. Pressure sections too
lator faulty filters small)
3. Speed or clogged 3. Pressure
delivery too setting too
high high
4. Response
time too long
F Pressure fluid 1. Leak in 1. Shaft seal or 1. Return line

foaming suction line packing on ends above
2. Fluid level intake side liquid level
too low faulty 2. Vortex effect
3. Tank design 2. Leakage line caused by
incorrect not below oil poor routing
level
G Cylinder logs 1. Hoses too

elastic
2. Lines not
bled
H Lines hit during As 4 A Lines loose 1. Switches too

switching fast
1. Excessive 2. Throttles or
accumulator baffles dam-
capacity of aged
the pipe sys-
tem
I On/off switching 1. Pump faulty Sequence or

frequency of the 2. Accumulators cut off valve
pump too high system: incorrectly set
Pump too or faulty
small
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-75

TTS - NMF GmbH
83158.- MAINTENANCE

Source of fault 7 8 9 10 11
Flow control Control valves Pressure fluid Drive Other
Consequence valves (motor, cyl.)
A Excessive noise 1. Valve oscillates 1. Valve chatters, 1. Problems with 1. Wear of bear-
and induces os- as solenoid intake, as ing surface
cillation in other faulty or voltage a) Fluid level to 2. As 3 A 7
regulators too low low
2. Valve faulty b) Viscosity too
2. Noise of flow high
owing to wear
3. As 3 A 7 or dirt (temperature
too low)
3. Excessive
delivery 2. Fluid contami-
nated causing
4. Valves with damage and
adjustable clogging of de-
damping: ad- vices
justment not
carried out 3. Fluid foaming
5. Check electrical
control system
B Insufficient force 1. Excessive 1. Incorrect 1. Viscosity too low 1. Internal leak- 1. Fault in control
and torque at pressure losses switching posi- thus leakage too age (e. g. cyl- circuit of pres-
drives (insufficient tion (e. g. pres- great inder bolts sure control
pressure) 2. Setting incorrect sureless circula- 2. Viscosity too worn) system
3. As 3 A 7 tion fails to high resistance 2. See 10 A 2. Indicating in-
switch off) to flow too great strument faulty
3. Excessive
2. Solenoid faulty 3. Fluid foams internal friction
(poor effi-
3. Internal leakage ciency)
owing to wear
4. Excessive
resistance to
flow
5. Spool sticks
C Jerky cylinder or 1. Valve fouled As 8 A 1. Pressure fluid 1. Stick slip ef- 1. Insufficient load
motor movements 2. As 7 A 1 fouled fect, as friction bracing on the
(fluctuations in 2. Pressure fluid of the cylinder rear of the out-
pressure and foamed boots too high. put (e. g. lower-
delivery) Speed of hy- ing throttle,
draulic motor pressure drop
below mini- valve)
mum
D Output fails to turn 1. Delivery set too As 8 B As 9 B As 10 B Conditions for

or turns too slowly low 1. Output blocked starting not met
(no delivery or 1. Spool sticking (controller faulty).
2. Unsuitable type (e. g. piston
delivery too low) 2. Manually oper- seizure) Electrical control
(setting range line (plug-in con-
too low) ated valves
(cocks) not in nection) broken.
3. Valve clogged flow position Signal elements (e.
(fouled) g. pressure switch
set incorrectly or
faulty limit switch
not actuated)
4-76 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE

Source of fault 7 8 9 10 11
Flow control Control valves Pressure fluid Drive Other
Consequence valves (motor, cyl.)
E Operating tem- 1. Set to exces- 1. Leakage losses As 9 B 1. Loss of effi- 1. Cooling capac-
perature too high sively low deliv- too high ciency owing to ity of the unit
ery (pump de- 2. Pressureless wear (of the installa-
livers too much circulation fails 2. Excessive tion) too low in
through pres- to switch on internal friction relation to the
sure relief (poor effi- power rating or
valve) 3. Spool sticking the duty time
ciency)
2. Valve faulty 3. Internal leak- 2. No pressureless
age losses circulation dur-
ing long breaks
in operation
(with pump run-
ning)
3. Insufficient
pressure fluid in
the installation
4. Coolant valve
fails to switch
5. Thermostat set
too high
6. No coolant or
fan failure
7. Coolant tem-
perature too
high
8. Ambient tem-
perature too
high
9. Deposits in
cooler
10. Insufficient heat
emission ow-
ing to encapsu-
lation
F Foaming of pres- 1. Unsuitable type

sure fluid
G Cylinder lags 1. Switching time 1. Internal leak- 1. Piloted check
setting too slow age valve does not
2. Solenoid faulty 2. Inadequate close immedi-
leakage bleeding ately, as
a) Slit fouled or
3. Valve fouled faulty
b) Circuit fault
2. Limit switch is
overrun
H Shocks during 1. Switching time 1. Pressure fluid 1. Masses and 1. No throttles

switching setting too fast foamed forces too high upstream of se-
2. Type unsuitable 2. No damping lector valves in
(change in ori- accumulator
fice cross- systems
section too rap-
id)
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-77

TTS - NMF GmbH
83158.- MAINTENANCE

Source of the 7 8 9 10 11
fault Flow control Control valves Pressure fluid Drive Other
Effect valves (Motor, cyl.)
I On/off switching Installations with
frequency of the pressure accumu-
pump to high lators: Pre-set gas
pressure too low.
Bladder diaphragm
faulty:
Pressure switch
set incorrectly
TYPES OF FLUID
The satisfactory operation, long life and efficiency of a hydraulic system depend to a great extent on the se-
lection 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 resulting in a
further drop of viscosity and ultimately loss of the lubrication properties of the fluid.
For further information, please refer to the TTS oil table.
4.6 ASSEMBLY AND DISMANTLING

This chapter describes procedures for fitting and removing ropes and other components. The descriptions
are provided for guidance only and do not preclude the use of other suitable methods.
The accident prevention regulations must be observed at all times.
SAFETY RULES
1. Observe accident prevention regulations and stipulated working procedures at all times.
2. Act in a responsible manner, and pay just as much attention to the safety of others as to your own safety.
4-78 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
3. Check all tools and safety equipment frequently to make sure they are safe to use.
4. Inform yourself and others about the dangers of the work and workplace, and about safe ways of
doing routine jobs.
5. Ask others about ways of doing unusual jobs. Getting on with a job without first considering all steps
can lead to expensive accidents.
6. Consider potential causes of accidents and injury before embarking on a project. Take suitable
precautions to protect yourself and others.
7. Warn others about potential causes of accidents and injury if they are seen working without taking
suitable precautions and thus creating potential hazards.
8. Increased attention is needed if working conditions and procedures change.
9. Inform your superiors immediately of dangerous actions or conditions. Do not leave it to others.
10. Keep your place of work tidy. Clear away all tools and materials, and make sure they are stored properly.
Before starting work, read the appropriate parts of the manual and study both the sectional views shown
in the spare parts catalogue and the corresponding drawings.
Use only new parts when replacing or repairing parts and assemblies.
WELDING
The earth connection must be located as close as possible to the welding point. Make sure that the welding
current is not conducted through rolling bearings, gears or similar assemblies.
SPARE PARTS CATALOGUE
The assemblies and subassemblies are listed in detail together with the quantities required and the cata-
logue number (order no.) of each part in the spare parts catalogue.
FITTING AND REMOVING PARTS
Recommendations for handling parts.

The following general precautions should be taken when handling parts:
 When lifting or removing parts, make sure that the hoists are adequate for the job.
 The weights of assemblies and parts are stated in the spare parts catalogue to help you choose the
right cranes, chain tackles, etc.
 Clean and lubricate all parts thoroughly, and check them carefully for damage and defects.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-79

TTS - NMF GmbH
83158.- MAINTENANCE
MACHINED AND LOAD-CARRYING SURFACES
 Take special care to prevent damage to machined or load-carrying surfaces. Machined.

 and load-carrying surfaces must be protected by a coat of oil or rust inhibitor if they will be exposed to
the open air for a considerable period of time
 Machined surfaces must be placed on timbers or special supports NEVER place them on the bare
ground.
REMOVAL FROM STORAGE
Before reassembling parts, the Tust inhibitor must be removed from all surfaces by means of a suitable
solvent. Oil poured into spaces to prevent rust must be drained off completely. Complete flushing should
be unnecessary. Inspect all parts for signs of corrosion or damage that might impair the operation of
mechanical assemblies. All problems must be dealt with before the parts are installed or assembled.
SAFE FASTENING OF LOADS
1. The physical characteristics of a load (weight, size and shape) must be checked before it is lifted or
handled.
2. The weights of the main assemblies and the components are generally stated in the maintenance
manual. lf the weight of a part can not be found, the supervisor must be asked before attempting to
lift it.
3. The size and shape of a load govern the method used to secure it - i.e. slings, basket or sling with a
special cradle. The size and shape also determine the gear used to fasten it (wire rope, alloy steel
chain, hook eyes, shackle, etc.).
4. The correct size of the fastening gear can be selected after the weight of the load, the angle at which
it acts and the gear for fastening it have been ascertained.
5. lf the load to be lifted exceeds the permissible safe working load of a given sling size or the
corresponding fastening gear, the next larger size capable of carrying the load must be used. The
permissible safe working load of the fastening gear must not be exceeded.
6. lf there is any doubt regarding the best way to secure a load or conceming the type and size of gear
needed to secure it, the supervisor must be consulted.
7. The fastening gear must be carefully inspected when it is taken from the rack in the store. Damaged
gear must be excluded from use and must be reported to the supervisor.
8. Do not overload fastening gear. This will prolong its service life and enhance safety when using it.
lt must also be protected by sacking, iron edge protectors or timbers, etc., against sharp edges of the
load. Machined surfaces of the load must be protected against damage by the fastening gear.
Material used for protection should be secured to the load or sling to prevent it from falling when the
sling is slackened.
9. The sling can be hauled taut after the fastening gear has been correctly positioned. Pay attention to
the positions of fingers to prevent them from being squashed. See Fig. a and b
Fig. a: Position of hand when Fig. b: Position of hand when

hauling sling tight. guiding hook.
4-80 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
10.The agreed crane signals shall be given to the crane driver clearly and in his view so that the load can
be moved as required. See the item
"Hand signals" at the end of this chapter.
11.Before the signal is given to lift the load, the person who has secured the load must make the following
checks:
There must be no loose material , tools, dirt, bolts, etc., lying on the load.
Unused ends of the sling must be secured by threading them through the main ring or fastening them
together with a shackle. Unused ends must not hang loose.
All persons must be outside the danger zone before the lifting operation starts.
12.After the sling has been hauled taut, check that the fastening gear is secure and symmetric at all points.
Check the fastening gear to ensure that it is still protected against sharp edges and that machined
surfaces are protected from the fastening gear. The load brake must be checked when the load has been
lifted a few centimetres from the ground and is being carried entirely by the hoisting gear. The fastening
gear must also be checked again in all places-
13.Do not move the load over the heads of people. lf this is unavoidable, adequate waming must be given
(signal horn).
14.Set the load down in a selected place. Sufficient shoring material must already be available there.
15.Stop the load just before setting it down on the ground so that the shoring can be readjusted to suit the
position of the load.
DANGER!
Keep hands and feet clear of squeezing points between the shoring and the load.
16. Correctly positioned shoring ensures that the load will lie in the desired stable position after it has been
set down on the ground. Take the following into account when arranging the piling:
Weight of the load: The piling must form a stable surface capable of supporting the whole weight of the
load.
Machined surfaces of the load: machined surfaces must be protected by wadding the supports and
fastening gear with sacking, firm cardboard, leather straps, etc.
Load size and shape: Shafts, forgings and rings must be wedged and supported Shorings of identical
dimensions ensure that the load will lie flat and evenly. Loads which can easily become unbalanced must
be adequately shored.
Working surfaces: The shoring must be arranged or adjusted to compensate for irregular surfaces-
Condition of the shoring: Shoring material must be in good condition and of a uniform size. Do not use
damaged shoring, e.g. shoring which has rounded edges, is rotten or broken, or contains large knots.
17. Lower the load slowly until its full weight is supported by the ground or shoring.
WARNING
Equipment used to protect the fastening gear such as iron edge protectors, leather straps or timbers
can fall out as the sling becomes slack. Personnel must therefore keep clear of these areas until the
se items have been removed.
18. After the lifting operation has been completed, remove the fastening gear and inspect it for damage. lf
it is no longer needed, it must be returned to the storage rack.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-81

TTS - NMF GmbH
83158.- MAINTENANCE
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.
4-82 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
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.
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-83

TTS - NMF GmbH
83158.- MAINTENANCE
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.
4-84 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.6.3 HAND SIGNALS FOR CRANES
HOIST LOWER USE MAIN HOIST

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

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

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

Arm extended forward, hand (Both Tracks.) Use one hand to give any motion
open and slightly raised, make Use both fists in front of body, signal and place other hand mo-
pushing motion in direction of making a circular motion about tionless in front of hand giving the
travel. each other, indicating direction of motion signal. (Hoist slowly
travel; forward or backward. shown as an example.)
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-85

TTS - NMF GmbH
83158.- MAINTENANCE
4.6.4 TIGHTENING TORQUES FOR HEXAGON BOLTS AND

SPANNER BOLTS
Nominal Pre-load Torques

thread kp kpm
dia. Fv in Ma in
Nm Nm
Property Class Property Class
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M5 535 635 895 1 070 0,50 0,60 0,85 1,0
5 350 6 350 8 950 10 700 5,00 6,00 8,50 10,00
M6 755 900 1 260 1 510 0,85 1,0 1,4 1,7
7 550 9 000 12 600 15 100 8,50 10,0 14,0 17,0
M8 1 390 1 650 2 320 2 790 2,1 2,5 3,5 4,1
13 900 16 500 23 200 27 900 21,0 25,0 35,0 41,0
M 10 2 210 2 620 3 690 4 430 4,1 4,9 6,9 8,3
22 100 26 200 36 900 44 300 41,0 49,0 69,0 83,0
M 12 3 240 3 850 5 400 6 450 7,2 8,6 12,0 14,5
32 400 38 500 54 000 64 500 72,0 86,0 120 145
M 16 6 150 7 300 10 200 12 300 18,0 21,0 29,5 35,5
61 500 73 000 102 000 123 000 180 120 295 355
M 20 9 600 11 400 16 000 19 200 34,5 41 59,7 69
96 000 114 000 160 000 192 000 345 410 597 690
M 24 13 800 16 400 23 000 27 600 60 71 102 120
138 000 164 000 230 000 276 000 600 710 1020 1200
M 30 22 100 26 200 36 800 44 200 120 145 200 240
221 000 262 000 368 000 442 000 1 200 1 450 2 000 2 400
M 36 32 300 38 200 53 800 64 500 214 253 356 428
323 000 382 000 538 000 645 000 2 140 2 530 3 560 4 280
The tightening torques habe been calculated with the following frication coefficients:
µ tot. = 0.14 for oiled bolts

µ tot. = 0.16 for bolts secured with liquid (Loctite, Omnifit)
CHECK OF HSFG BOLT CONNECTIONS
Check HSFG bolt connections visually by examining state of paint work of components bolted together.
If paint appears cracked or flakes off this means that the bolt connection moves, and the bolts must be
replaced at once.
Use only perfect torque spanners for tightening the bolts.
Check to be carried out monthly.
4-86 Ind. 00 / 10-2013 83158 MAINTENANCE 83158

TTS - NMF GmbH
83158 - MAINTENANCE
4.6.5 INSTALLATION OF HOSES
MAINTENANCE 83158 83158 Ind. 00 / 10-2013 4-87

TTS NMF GmbH
83156 - 83159 ELECTRICAL EQUIPMENT
5. SPECIFICATION OF THE ELECTRICAL

EQUIPMENT
SINGLE DECK CRANE
TABLE OF CONTENTS
5. SPECIFICATION OF THE ELECTRICAL EQUIPMENT 1

5.1 TECHNICAL DATA 3
5.2 GENERAL DESCRIPTION 4
5.2.1 SUPPLY SOURCES 4
5.2.2 GENERAL DRIVE SYSTEM REMARKS 5
5.2.3 MAIN SWITCH 5
5.2.4 CRANE OPERATION (NORMAL MODE) 6
5.2.5 SWITCH GEAR 7
5.2.6 SENSORS 8
5.2.7 LIMIT SWITCHES 9
5.2.8 PROGRAMMABLE LOGIC CONTROLLER (PLC) 10
5.3 DISPLAY AND INDICATORS 11
5.3.1 INDICATOR LIGHTS 11
5.3.2 DISPLAY OF CRANE INFORMATIONS 11
5.3.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT PANEL) 12
5.3.3.1 OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS 14
5.3.3.2 HOW TO ENTER MAIN MENU 14
5.4 COMMISSIONING AND ADJUSTMENTS 21
5.4.1 GENERAL DEFAULT SETTING 22
5.4.2 PLC CHANGE 23
5.4.3 SETTING THE MINIMUM CURRENT FOR SLEWING GEAR 24
5.4.4 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER PUMP) 25
5.4.5 CRANE LIMIT SWITCHES AND POSITIONING SYSTEM 26
5.4.5.1 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT) 27
5.4.5.2 SETTING LAYER CHANGE POSITION 30
5.4.5.3 SETTING OF REFERENCE POSITIONS 31
5.4.5.4 FORCING OF REFERENCE POSITIONS 35
5.4.6 ADJUSTABLE WORKING RANGE LIMITATION 36
5.4.7 SPECIAL MODUS FOR ROPE CHANGE 39
5.4.8 CALIBRATION OF LOAD INDICATION 40
5.4.9 REPORT OF CHANGE 43
5.4.10 ZERO-SETTING OF POTENTIOMETERS 44
5.4.11 SETTING OF OPERATION HOURS 44
5.4.11.1 MAIN MOTOR OPERATION HOURS 44
5.4.11.2 OPERATION HOURS OF HYDRAULIC GEAR DRIVES 44
5.4.12 ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT) 45
5.5 CRANE OPERATION MODES 46
5.5.1 SPREADER OPERATION 46
5.5.1.1 CONTROL LEVER FOR SPREADER CONTROL 46
5.5.1.2 OPERATE THE SPREADER 47
5.5.1.3 LOAD TURNING DEVICE 47
5.6 INTERLOCKING FOR SEA VOYAGE (SPECIAL EQUIPMENT) 48
5.6.1 LOCKING 48
ELECTRICAL EQUIPMENT 83156 - 83159 Ind. 00 /08-2013 5-1
TTS NMF GmbH
5.6.2 UNLOCKING 49

5.6.3 FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM 50
5.6.3.1 SETTING THE PRESSURE LIMITING VALVE 53
5.6.3.2 LOCK / UNLOCK IN EMERGENCY OPERATION 54
5.7 PMS – POWER MANAGEMENT SYSTEM (SPECIAL EQUIPMENT) 55
5.7.1 FUNCTIONAL DESCRIPTION 55
5.8 SPECIAL OPERATION MODES 56
5.8.1 TEST OPERATION 56
5.8.2 POWER / SPEED REDUCTION 56
5.8.3 DISABLE TRIMOT 56
5.9 TROUBLE SHOOTING 57
5.9.1.1 FAULT INDICATIONS 57
5.9.1.2 CONDITION INDICATIONS 57
5.9.1.3 PLC STATUS INDICATORS 58
5.9.1.4 ADDITIONAL INDICATIONS 58
5.9.2 LIST OF FAULT MESSAGES 59
5.10 EMERGENCY OPERATION SYSTEM 132
5.11 SERVICE 134
5.11.1 MAINTENANCE INFORMATION FOR HYDRAULICAL 134
5.11.2 MAINTENANCE OF ELECTRICAL EQUIPMENT 135
5.11.3 SPARE PARTS 137
5.12 APPENDIX 138
5.12.1 DESCRIPTION OF THE ELECTRICAL COMPONENTS 138
5.12.1.1 MAIN SWITCH (LOAD BREAKER) 138
5.12.1.2 GEARED LIMIT SWITCHES - SERIES 51 145
5.12.1.3 PROGRAMMABLE LOGIC CONTROLLER (PLC) 149
5.12.1.4 COMPACT MODULE PWM 158
5.12.1.5 COMPACT MODULE DIGITAL / ANALOGE 166
5.12.1.6 CABINET-MODULE 174
5.12.1.7 INCLINOMETER ( SPECIAL EQUIPMENT ) 181
5.12.1.8 LCD-DISPLAY 186
5.12.2 CIRCUIT DIAGRAMS 190
We reserve the right to make technical alterations without prior notice. Technische Änderungen behalten wir uns ohne
vorherige Ankündigung vor. • • Nous nous réservons le droit de modifier les données techniques sans préavis.
5-2 Ind. 00 /08-2013 ELECTRICAL EQUIPMENT 83156 - 83159

TTS NMF GmbH
5.1 TECHNICAL DATA
The electrical equipment of the crane conforms to the Rules of the classification societies.
It is designed for operation at ambient temperatures between -25 and +45 C.
Supply voltages
Mains supply: 440 V AC, 60 Hz, 3-phase
Auxiliary supply: 220 V AC, 60 Hz, 2-phase
Control voltage: 24 V DC
List of motors
Pump drive main motor: 160 kW, duty cycle S1, 4 pole
Boost pump (control oil pump): 11.0 kW, duty cycle S1, 4 pole
Hydraulic oil cooler: 1.5 kW, duty cycle S1, 4 pole
Lighting and heating

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

TTS NMF GmbH
5.2 GENERAL DESCRIPTION
5.2.1 SUPPLY SOURCES

Before starting work on the electrical system, switch off all supply sources to the crane and check that all
equipment is inactive.
Power is fed to the crane via a slip ring assembly containing

Main supply 4 rings (3 + earth) for 500 V, 600 A
Auxiliary supply 2 rings for 250 V, 60 A
Auxiliary supply and controls up to 13 rings for 250 V, 16 A
The main supply is taken from the slip ring assembly to the connection terminals of main switch =M01-S1.
To switch on power supply to the crane, shift the switch to the position "1". The switch must be reset to the
position "0" before leaving the crane.
The switch can be secured in the position "0" by means of a padlock to prevent unauthorised tampering.
The auxiliary supply leads from the slip ring assembly to terminals X3-1 and -2 in the control cabinet.
The auxiliary supply can be switched off by means of the main switch (=M01-S2) for repair and maintenance
work.
From main switch =M01-S2 the feeder branches to the automatic circuit breakers =M03-F31 to -F36 and the
various lighting and heating consumer circuits.
The auxiliary supply should be constantly connected so that

The anti condensation heating is operational.

TTS NMF GmbH
5.2.2 GENERAL DRIVE SYSTEM REMARKS

All crane motions are powered by electro-hydraulically controlled hydraulic motors.
While the crane is in use, the main motor (=M02-M1) runs continuously at constant speed and drives the
hydraulic pumps via a multiple distribution gear. The hydraulic pumps supply oil independently to the
hoisting, luffing and slewing gear motors.
The pumps are electro-hydraulically controlled by means of control units with two proportional solenoid
valves each.
If they receive no control power, the pumps run with zero stroke and, therefore without oil delivery. The rate
and direction of pump delivery is governed by the current flowing through the solenoids of the proportional
valves.
Variation of the electrical solenoid current thus permits infinitely variable control of the pump delivery and,
consequently, of the drive speeds. The solenoid current is about 200 to 600 mA. This value depends on the
deflection of the control lever if no restrictions are given (e.g. speed limitation by rope length
measurement), at minimal deflection it is about 200 mA – at full about 600 mA.
The hoisting gear circuit incorporates a variable displacement hydraulic motor (TRIMOT) which permits
small loads or the empty hook to be handled at higher speeds. This motor is controlled by a proportional
solenoid valve drawing a current of 200 to 450 mA. The actual control current varies according to the load
on the hoisting gear, which is measured by a pressure sensor.
Besides the pump adjustment arrangements, the control system also controls solenoid valves of brakes
used enable the various drives.
Further particulars are given in the specification of the hydraulic system.
5.2.3 MAIN SWITCH

The main switch =M01-S1is a load breaker acc. IEC/EN 60204 with an emergency shut-off release.
The crane will be switched on and off with the main switch.
For switching on the handle of the main switch first must be turned in clockwise direction into the position
“O→”; in this position the interlocking mechanism will be locked. Then the handle must be turned in counter
clockwise direction into position “I” to switch on.
The emergency shut-off function of the main switch will be actuated by an under voltage release; this will
unlock the interlocking mechanism of the main switch. An emergency stop button in the right hand control
desk and on the deck area (optional equipment) is connected to this under voltage release.
The main switch can be switched on only when there is power on this under voltage release.
If the main switch can not be switched on please check that the emergency stop buttons are not actuated
(pushed down); the emergency stop buttons have an automatic lock in this position and must be turned to
unlock the button.
Check the voltage of the main power supply (the control light “POWER SUPPLY” in the cabinet door must
be on), and check that the circuit breaker =M01-Q1 is on.
Remark: If the under voltage release unit of the main switch itself is defective the main switch can be
switched on when this under voltage release unit will be removed from the main switch.
This should be done only in case of emergency when no spare is available. Without under voltage
release unit no emergency stop (cut off) is given. This is a very dangerous situation – no normal
crane operation is allowed without emergency stop function of the main switch.
See also DESCRIPTION OF ELECTRICAL COMPONENTS (APPENDIX)

TTS NMF GmbH
5.2.4 CRANE OPERATION (NORMAL MODE)

By turning the selector switch =M07-S06 <START> into ON-position, contactor =M02-K11 will be activated
and starts the booster (control oil) pump.
Additionally the crane system sends a POWER REQUEST SIGNAL to the ship control system.
When the crane system receives a POWER AVAILABLE SIGNAL from the ship control system the time
relay = M02-K4 switches on the contactors = M01-K2 and -K3 to start the main motor by means of a star-
delta procedure. The star/delta change is switched over after about 4 seconds.
If the POWER AVAILABLE SIGNAL is not given within 50 seconds, the starting procedure of the crane will
be stopped and must be repeated for a new start. <FAULT OF PMS-SYSTEM>
The PMS POWER MANAGEMENT SYSREM is an optional equipment without this the main motor will start
with a delay of 8 seconds after starting the booster pump.
During the starting sequence <START UP OF DRIVES > is shown on the display.
After that the system will make an auto-calibration of the drives, displayed with <SELF ADJUSTMENT>.
If all systems are in good order, <READY FOR OPERATION> is shown and the crane can be operated by
shifting the joystick (control lever).
If the joystick (control lever) is shifted too soon, or the dead man switch (optional equipment) is actuated,
the status monitoring system C006 responds and prevents operation of the crane.
The crane is controlled by a programmable logic control (PLC). The PLC processes the digital input signals
it receives from the switches (contacts of contactors and the joystick (control lever), limit switches, etc.) and
the analogue values received from the controls (set-up values) and sensors (pressures, temperatures) in
the way defined by the algorithms of the stored programs (software), produces the output control signals
needed to switch the indicator lights, contactors or solenoid valves and generates the pulse-width
modulated (PWM) control current for the proportional solenoid valves controlling the delivery of the pumps.
In normal operation mode the main crane data (load, outreach etc.) are shown on the display.
When the crane operation is finished the drives will be stopped by turning the selector switch =M07-S06
into OFF-position and the drives will be shut down by the control system. < SYSTEM SHUT DOWN> is
now displayed.
Preheating the hydraulic oil

At sub-zero temperatures, the hydraulic oil should be preheated before the crane is put into operation. This
is done by turning on the crane control system by means of the main switch =M01-S1.
The oil temperature is measured by temperature sensor =M07-B01. If the temperature is below 5C, the
feed oil (booster) pump will start and heat up the hydraulic oil until the temperature reaches 15°C.
Cooling
The hydraulic oil cooler is switched on and off automatically during crane operation when the temperature
exceeds 50C depending on the oil temperature measured with the sensor =M07-B01.
If the pump drive is switched off while the cooling system is running, the main motor stops, but the booster
pump hydraulic oil cooler and (engine room fan) remain in operation to cool the oil down. It keeps running
until the oil temperature is below 50C, but operation in this cooling mode ceases after 10 minutes at the
latest.
DO NOT STOP the drives by using the emergency button.
The crane drives and pumps must be stopped when the driver is leaving the cabin.
When the crane has stopped owing to a fault or a loss of power supply the
<START> switch must be turned into OFF-position before the crane can be started
again.

TTS NMF GmbH
5.2.5 SWITCH GEAR

The crane control will be switched on and off with the main switch =M01-S1.
This main switch has an under voltage release connected to the emergency stop button in the r.h. control
desk and on deck area (special equipment).
The power switch gear consists of contactors =M02-K2 (star circuit contactor) and =M02-K3 (delta circuit
contactor).
The control voltage of these contactors is 440/400 V):
Contactors =M02-K2 and -K3 are switched by timing relay =M02-K4.
The contactors =M02-K11 + -K12 both have a control voltage of 24 V and, like =M02-K4, are switched
directly by a PLC output.
The main motor is protected against overload by thermistor and additionally by monitoring the amperage
with the current-transformer =M02-T1.
The aux. drive motors =M02-M11 + -M12 are protected against overload by motor circuit breakers.
The 24 V DC control voltage is produced by the three-phase power unit =M01-U1.

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

TTS NMF GmbH
5.2.7 LIMIT SWITCHES

The travel route of the hoisting gear(s) and also the luffing gear are limited by rope length measurement
and additionally by mechanical limit switches.
These limit switches are directly mounted on the winches of the corresponding drives.
Main-Hoisting gear - defines the highest and lowest hook positions:

Gear-driven cam actuated limit switch series 51, with incremental encoder.
Luffing gear - defines the maximum and minimum outreaches:

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

TTS NMF GmbH
5.2.8 PROGRAMMABLE LOGIC CONTROLLER (PLC)
Hardware description
Most of the work involved in crane control is performed by the PLC, which receives all control signals,
processes them as foreseen by the stored program and generates appropriate control signals for the final
control units.
The 24 V supply for the PLC is fed across fuses =M01-F21 / -F22.
The control unit consists of a Controller R360 (PLC), three Compact Modules, a Cabinet Module and a
LCD-Display.
All components are networked over CAN-BUS interface and located as follow:
ITEM located
Controller R360 Electrical control cabinet
Cabinet Module r-h Control desk in crane cabin
Compact Module PWM Nearby the hydraulic pumps
Compact Module Analogue Nearby the hydraulic pumps
Compact Module Digital Nearby the hydraulic pumps
LCD-Display r-h Control desk in crane cabin
The modules must be plugged in at the specified locations and nowhere else.
For more detailed information please refer to the unit specification supplied by ifm electronic in appendix
DESCRIPTION OF ELECTRICAL COMPONENTS.
The PLC (Programmable Logic Controller) controls and monitors the electro hydraulic system of the crane.
The status of current signals and operating data are continuously fed to the PLC where they are processed in
accordance with the control program (software) and stored. If the control system malfunctions, the fault should
first be sought outside the PLC as experience has shown that faults are much more common in the PLC
periphery than in the PLC itself.
In any case, PLC should be replaced only as a last resort to eliminate a fault as it leads to loss of stored
information and all setting work has to be repeated.
Before replacing these modules, the status of the operating hour counters must also be noted down as they
are all reset to "000" during the setting work.
General information about the CAN-BUS (CAN –open)

All components are networked over CAN-BUS. This is 2-wire-system, called CAN_H and CAN_L.
When the network system is operational on all components the green LED is blinking with 2 Hz.
All components are connected in serial that means whenever the control line is physically interrupted, the
complete system will not work.
Both ends of the network must be provided with a 120 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 60.

TTS NMF GmbH
5.3 DISPLAY AND INDICATORS

A horn (=M05-H50) is attached to the cabin for giving danger signals and can be activated by pressing the
button in the left joystick.
The horn operates with a voltage of 24 V.
In the r-h control desk a small buzzer is installed which sounds short signals in case of condition and fault
status.
5.3.1 INDICATOR LIGHTS

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

Normally on the display the operation manual shows the indications of
SWL – LOAD
ACTUAL LOAD
OUTREACH
HOOK HEIGHT
By pressing the soft-key button MENUE an additional menu page is called up and
CRANE INFORMATION can be selected the following information is displayed now:
CRANE NUMBER (software identification number)
TEMPERATURE (actual oil temperature)
OPERATION HOURS M01 (elapsed working time of the main motor)
SELECTED CRANE No.: Crane 1 is front (bow) crane the highest number is the rearmost crane.
For safety reasons the operational hours should be written down every 2-3
months.
If the PLC system (main processor) becomes defective and must be renewed, the
stored operational hour value is lost and must be manually entered into the new
PLC.

TTS NMF GmbH
5.3.3 DIALOGUE MODULE ( OPERATING -, OBSERVE - AND INPUT

PANEL)
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
A LCD Display with 8 plunger-operated buttons and status LED´s is installed in the right hand control
desk of the crane cabin.
The dialogue module communicates via CAN bus with the control system ecomat 100 type R 360
interactively and sends or receives operational status information of the crane. The following
information of the dialogue module can be handled at the menu structure
 Fault / Condition messages
 Operating states messages
 Additional messages.
 Service inputs

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

TTS NMF GmbH
5.3.3.1 OPERATION OF THE DIALOGUE MODULE BY FUNCTION KEYS
Normal operation is basically done using the following 6 function keys:
ESC key
Cursor keys
Enter key
Special keys are:
Function key F1 ENTER Main Menu, anytime at call.
Function key F2 single Quit of displayed Fault
5.3.3.2 HOW TO ENTER MAIN MENU
After crane is started above picture is normally displayed.

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

TTS NMF GmbH
Menu structure
Is divided into sections:
 The normal and free available area: display values and operational state
 The secured password area: Service Menu / set values
Enter a menu item
The menu structure and meaning of keys are self-explanatory.

We will in any case explain the function in detail on the basis of some examples.
EXAMPLE: Display of detail “ACTUAL LOAD” ( capital letters )
After crane is started above picture is normally displayed.

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

TTS NMF GmbH
EXAMPLE: Display of crane information: Operating hours
At the given picture press key to enter the main menu.
Then select with the “CRANE INFORMATION” item and press Enter to display.
Now you will have the information displayed.

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

TTS NMF GmbH
EXAMPLE: SERVICE INPUT: RESET TO DEFAULT SETTINGS
At the given picture press key to enter the main menu.
After that select with the “SECURED AREA” item and press Enter to display.
Now you must press Enter to select “YES” and press again Enter to confirm this message.
Otherwise press key to go “BACK”.

TTS NMF GmbH
EXAMPLE: ... SERVICE INPUT: RESET TO DEFAULT SETTINGS
After conformity you have the following picture (KEY-CODE IS ON DEMAND). The security code is
written in capture (capitals?) GENERAL DEFAULT SETTING
To insert the Security Code press Enter. Now the code column will be displayed in reverse. Now
press Enter again and the first digit of security code blinks. With you modify the value and
with you can go to the next digit. When you have inserted everything press Enter to
confirm the insert security code of your entry.
If the code is invalid a message will inform you “NOT ACCEPTED TRY AGAIN”. Please do so as
described above.
If the code is valid go to next picture
To insert the crane number, press Enter. Now the value will be displayed in reverse. Now press
Enter again and the digit blinks. With you modify the value. If you have selected the right
number press Enter to confirm your entry. Now the selected crane number is displayed and you
can go further press “NEXT” or “BACK” takes you to previous picture.

TTS NMF GmbH
You are now in the Service menu
With you can go to the next range of service points.
With you can select the menu item “SET DEFAULT SETTINGS”. Press Enter to confirm
your entry
Now you must press Enter to select “YES” and press again Enter to confirm this message.
Otherwise press key to go “BACK”.

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

TTS NMF GmbH
5.4 COMMISSIONING AND ADJUSTMENTS

(CODE SECURED AREA)
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is
only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship
should be allowed to override values or messages in the crane computer system and must take the
instructions given here into account.
This member of the crew is responsible for explaining the changed situation to the crane operator
and must report it to the management of the ship.
Procedure:
 Set MAIN MENU
 Select SECURED AREA (accepted must be entered)
 Select SECURITY CODE must be set and entered ( CODE NUMBER = 257377 )
 Select SET CRANE NUMBER (corresponding crane number must be entered)
Now the menu for the secured area modes is opened and the intended mode must be
selected
If you want to leave this secured area and especially before you leave the crane:
Switch off the power to de-activate all emergency codes.
(Emergency Operation System = EOS-Codes)
If the EOS system has been activated an information will be written into the flash memory.
The status of the EOS codes can be called up under
INDICATIONS
EOS STATUS MEMORY

TTS NMF GmbH
5.4.1 GENERAL DEFAULT SETTING

During the first start i.e. when activating the control system for the first time and after replacing the
main controller R 360 (located in the control cabinet) the internal memory of the PLC must be
formatted and parameterised with the default operational values.
If this default setting is carried out all previous personnel adjustments of the control system will be
overwritten.
Procedure:
 Set MAIN MENU
 Select SECURED AREA (KEY-CODE IS ON DEMAND)
 Select SET DEFAULT SETTINGS
Follow the instruction displayed

TTS NMF GmbH
5.4.2 PLC CHANGE

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

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

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

TTS NMF GmbH
5.4.3 SETTING THE MINIMUM CURRENT FOR SLEWING GEAR

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

TTS NMF GmbH
5.4.4 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER

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

To set = TRUE or reset = FALSE this special mode
Additionally the PRE-HEATING of the hydraulic oil can be switched on or off to calibrate
the throttle valve for the hydraulic pressure control and the amperage measurement of the
drive motor =M02-M11for the control oil pressure pump.
Before you leave this menu by pressing the BACK button; the pressure adjustment mode must be
deactivated by setting PRESSURE ADJUST on FALSE.

TTS NMF GmbH
5.4.5 CRANE LIMIT SWITCHES AND POSITIONING SYSTEM

Work on the electrical equipment of the crane is to be performed only by well trained personnel.
GENERAL
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.
A proximity switch will be actuated by the wire rope clamp at each revolution of the winch drum.
The rising trigger signal (synchronize pulse) of this proximity switch will be used to check the right function
of the incremental encoder.
(See also the technical description of the limit switches under item: „DESCRIPTION OF ELECTRICAL
COMPONENTS“)
The following description is subdivided into the parts (see the corresponding section):
SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)
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
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.
SETTING OF REFERENCE POSITIONS
Caused by some faults of the positioning system the reference position of the corresponding drive will
be reset. Then it is necessary to set this reference position back again.
Normally after a system fault a semiautomatic program will be started (F1312 or F2312 “DRIVE MUST
RUN INTO REFERENCE POSITION”). Now it is necessary to drive into the reference position for
reset and confirmation of the counter system. Until the system has not been reset the drive speed is
restricted and the crane load is limited to the SWL value which the crane can lift at maximal outreach
range.
Additionally the setting of reference position can be activated in the secured area of the PLC control
system. This procedure only can be carried out if no limit switch contact and no proximity switch (for
synchronize pulse) has been exchanged or re-adjusted.
To reset this alarm and to restore the system, the corresponding drive must be driven into its reference
position.
FORCING OF REFERENCE POSITIONS
Therefore it is possible to reset all reference positions together; this is called FORCING OF
REFERENCE POSITIONS.

TTS NMF GmbH
5.4.5.1 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)

GENERAL
The rising trigger signal of this proximity switch will be used to check the right function of the incremental
encoder.
COMPONENTS“)
Only on the first start of the crane or after exchange of the limit switch (also when a rope change is
not carried out corresponding to the instruction „SPECIAL MODUS FOR ROPE CHANGE“ the
mechanical limit switch contact have to be adjusted
Procedure:
 Set MAIN MENU
 Select SET LIMIT SWITCHES
 Select LUFFING GEAR or MAIN HOISTING GEAR or AUXILIARY HOISTING GEAR
Follow the instruction displayed
If another fault is indicated during the limit switch adjustment procedure, the reason for this fault
must be eliminated prior to any further action.
ATTENTION: all limit switches are by-passed the drive will not stop in the limit position,
only a STOP command is shown on the display when this position is reached.
ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib
could be damaged, or the wire could unreel completely from the drum.
The following runs have to be done at slow speed.
Before the adjustment of the limit switches will be carried out the function of the rope length measuring
system should be checked.
Actuate the luffing drive and watch the counter value and the synchronize pulse on the display.
When jib will be luffed in than the counter value must decrease; in the opposite drive direction the value
must increase. When the winch is turning at each revolution the proximity switch must be actuated; this will
be shown at SYNC - the announcement will change from FALSE to TRUE.

TTS NMF GmbH
The order of the adjustment steps must be kept strictly and exactly in the described manner.
Start with the adjustment of the luffing gear limit switch.
STEP 1:
Luff in the jib completely in the most upright position (the gap between the jib and rubber buffer should be 5
– 10 cm). Stop the drive.
STEP 2:
In this jib position the limit switch contact for minimum outreach, contact no.1 (seen from the drive shaft)
must be adjusted by turning the adjusting worm in counter-clockwise direction. The contact must switch
over from closed position into opened position. If the contact has been opened while driving with the jib into
the most upright position (precedent adjustment) the contact must be closed and opened again by means
of the adjusting worm. See also the description “GEARED LIMIT SWITCHES - Series 51”
STEP 3:
Follow the instruction on the display and luff out the jib. When the limit switch is closed again then the
display will show “Luff in again until STOP”.
If not this text but step 1 is displayed again during this procedure, it is the information that the limit switch
contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange.
Steps 1 and 2 must be repeated. (The contact must open by turning the adjusting worm in counter-
clockwise direction)
STEP 4:
Luff in the jib until the STOP command is displayed. The STOP 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:
Follow the instruction on the display and luff in the jib. When the limit switch is closed again then the
display will show “Luff out again until STOP”.
If not this text 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 contacts is completed and STEP 6 and STEP 7 must be
repeated.
During this procedure this distance between the actuation of the limit switch contact and the actuation of
the proximity switch will be determined because the synchronize pulse of the proximity will be used to
check the right function of the rope length measuring system (encoder signals).
Now the adjustment of the luffing gear limit switch and the rope length measuring system is completed.
Leave the adjustment procedure by pressing EXIT on the display.

TTS NMF GmbH
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), and also before the
adjustment of the limit switches will be carried out the function of the rope length measuring system should
be checked.
Actuate the hoisting drive and watch the counter value and the synchronize pulse on the display.
When hook will be lifted than the counter value must decrease; in the opposite drive direction the value
must increase. When the winch is turning at each revolution the proximity switch must be actuated; this will
be shown at SYNC - the announcement will change from FALSE to TRUE.
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:
Follow the instruction on the display and lower the hook. When the limit switch is closed again then the
display will show “lift up again until STOP”.
If not this text but Step 1 is displayed again during this procedure, it is the information that the limit switch
contact is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange.
Steps 1 and 2 must be repeated. (The contact must open by turning the adjusting worm in counter-
clockwise direction)
STEP 4:
Lift up the hook until the STOP command is displayed. This command is given in the moment when the
limit switch contact is opening again.
Now the adjustment of the limit switch contact for the highest position is completed and STEP 3 and STEP
4 must be repeated.
During this procedure this distance between the actuation of the limit switch contact and the actuation of
the proximity switch will be determined because the synchronize pulse of the proximity will be used to
check the right function of the rope length measuring system (encoder signals).
Now the adjustment of the highest position and the rope length measuring system 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:
Follow the instruction on the display and lift up the hook. When the limit switch is closed again then the
display will show “lower again until STOP”.
If not this text but Step 5 is displayed during this procedure, it is the information that the limit switch contact
is not adjusted correctly – the contact is adjusted on the wrong side of the cam / run out flange. (The
contact must open by turning the adjusting worm in clockwise direction). Step 5 must be repeated.
STEP 7:
Lower again the hook until the STOP command is displayed. This command is given in the moment when
the limit switch contact is opening again and the adjustment of the hoisting gear limit switch is completed.
Leave the adjustment procedure by pressing EXIT on the display.
After the basic adjustment of the limit switches the LAYER CHANGE POSITION (next chapter) has to be
checked; respectively must be set.

TTS NMF GmbH
5.4.5.2 SETTING LAYER CHANGE POSITION

If the hoisting rope is wheeled up on the winch in 2 layers, the layer change position must be checked or
set when this position is not displayed correctly.
Procedure:
 Set MAIN MENU
 Select INDICATIONS
 Select SPEED AND COUNTER VALUES
When the indication of counter values is activated on the dialogue module the actual hoisting position
counter value and also the layer (1 or 2) is indicated. This layer indication must change from 1 to 2 before
the rope will turn in the 2nd layer.
If this layer change indication is not properly adjusted the layer changing position must be set by selection
of the setting mode in the secured area.
Turn the winch into the right position before the rope begins to shift over.
Procedure:
 Set MAIN MENU
 Select SET LAYERCHANGE POSITION
On this menu page the “ENTER” button must be pressed.

The LAYER2 indication will change from FALSE into TRUE (as long as the button is
pressed) and the position data in the PLC-program will be reset.
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 and the layer change position.

TTS NMF GmbH
5.4.5.3 SETTING OF REFERENCE POSITIONS

GENERAL
The rising trigger signal of this proximity switch (synchronize pulse) will be used to check the right function
COMPONENTS“)
This procedure only can be carried out if no limit switch contact and no proximity switch (for
synchronize pulse) has been exchanged or re-adjusted.
To reset this alarm and to restore the system, the corresponding drive must be driven into its
reference position.
 Jib to the maximum outreach (max. working range)
 Hook / both hooks (if the crane has this equipment) into highest hook position (approx. 1 m below the
jib-head or 0,5 m below the chain limiter)
 Jib in max. outreach and hook(s) in highest position is the crane reference/default position –
Procedure: The function and how to operate the function-buttons of the display is described in the
specification of the electrical equipment under chapter:
Operation of the dialogue module over the function keys
 Set MAIN MENU (by pressing button F1)
 Select SECURED AREA and press ENTER

 (KEY-CODE IS ON DEMAND that means the code number must be entered into the
system)
 Read the information about the emergency system in the specification of the electrical
equipment under item:
COMMISSIONING AND ADJUSTMENTS
 Jump over the next pages by pressing NEXT

TTS NMF GmbH
 Select RESET OF REFERENCE POSITIONS and press ENTER
YES must be selected and entered and the information must be confirmed
by pressing ENTER again
(If this mode is activated the contents of the counter values for luffing hoisting and slewing
drive are displayed.)
Do not activate the emergency system EOS-codes when the reference positions shall be reset,
because these codes will oppress possible system failures. In case EOS-codes had been entered
into the PLC before, the power must be switched off to de-activate the emergency codes, and the
previous procedure must be repeated.
If during this procedure another fault is indicated, the reason for this fault must be eliminated prior
to any further action.
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.
Before the setting of the reference position will be carried out the function of the rope length measuring
system should be checked.
Actuate the corresponding drive and watch the counter value and the synchronize pulse on the display.
When jib will be luffed in, or the hook will be lifted than the counter value must decrease; in the opposite
drive direction the value must increase. When the winch is turning at each revolution the proximity switch
must be actuated; this will be shown at SYNC - the announcement will change from FALSE to TRUE.
Normally all the indications for the reference values must be TRUE. If any value is on FALSE the
corresponding drive fault has been reset the reference value.
For example a failure in the positioning system of the hoisting drive will reset the reference value for
highest hook position (indication HIGH changes to FALSE).
The reference value for deepest hook position (indication DEEP) will be reset only when the complete PLC
program is set on DEFAULT, or the positioning system is reset by procedure POSITIONING SYSTEM TO
DEFAULT SETTING, or the positioning system is reset by procedure SET LIMIT SWITCHES.

TTS NMF GmbH
Restoring luffing gear reference position:

The jib position must be in the normal working area, not beyond the maximum outreach limitation (by-
passed with JIB-RESTING switch.
Luff out the jib to the maximum outreach position (maximum working area), the signal
LIMIT SWITCH CONTACT HAS OPENED will be shown on the display when this position is reached, stop
the drive.
Lift up the jib until LIMIT SWITCH CONTACT HAS OPENED extinguishes, then lower the jib again, until
the signal LIMIT SWITCH CONTACT HAS OPENED is shown on the display again.
If the reference value for IN is FALSE the minimum outreach reference value must also be set accordingly
to the procedure for the maximum.
The reference value for the maximum outreach must be set absolutely first.
Restoring main hoisting gear reference position:

Drive the jib to the maximum outreach position (maximum working area) the signal
LIMIT SWITCH CONTACT HAS OPENED will be shown on the display. When this position is reached, stop
the drive. (The jib should be driven into this position first; it is easier to find the right reference position for
the hook, because this is now close to the jib head – approx. 1 m below.)
Lift up the main hook, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the display
when this position is reached, stop the drive. Lower the hook until
LIMIT SWITCH CONTACT HAS OPENED is deleted.
Lift up the main hook again, the signal LIMIT SWITCH CONTACT HAS OPENED will be shown on the
display when this position is reached, stop the drive and then lower the hook approx. 2 m.
If the reference value for DEEP is FALSE the deepest position reference value must also be set
accordingly to the procedure for the highest.
The reference value for the highest hook position must be set absolutely first.
Restoring auxiliary hoisting gear reference position: (if the crane has an aux. Hoisting gear)
The procedure corresponds to the main hoisting gear, using the aux. hook.
Restoring slewing gear reference position:

The fault indication F3312 will be displayed, if a failure of the slewing ring counting system has stopped the
drive.
To reset this alarm and to restore the system, the slewing drive must be driven into the reference position.
The reference position is the parking/interlocking position of the tower for sea voyage (jib in direction
forward). When the right position is reached LIMIT SWITCH CONTACT HAS OPENED will be displayed.
Normally the reference positions of the crane will be reset by driving with the corresponding drive into these
positions:
For the hoisting drive(s) = highest hook position
For the luffing drive = maximum outreach.
It could happen that the crane control also has lost the data for the deepest hook position and minimum
outreach. This will happen if the codes <SET DEFAULT SETTINGS> or <POSITIONING SYSTEM TO
DEFAULT SETTINGS> or <SET LIMIT SWITCHES> has been activated before.
Now it is necessary to drive into all the reference positions:
Therefore it is possible to reset all reference positions together; this is called FORCING OF REFERENCE
POSITIONS.
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.

TTS NMF GmbH
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

TTS NMF GmbH
5.4.5.4 FORCING OF REFERENCE POSITIONS

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

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

TTS NMF GmbH
5.4.6 ADJUSTABLE WORKING RANGE LIMITATION

(SPECIAL EQUIPMENT)
slewing gear reference position

(zero-position of restricted area)
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 (zero-position of restricted area) of the slewing
gear.
A steel plate which activates the proximity switch =M06-B802 must be screwed to the relevant threaded
bolts of the slewing ring.
The other two proximity switches =M06-B810/-B811 count the gear teeth of the slewing ring and define the
slewing angle.
The WORKING RANGE LIMITATION will be activated / de-activated by means of the dialogue module
(display).
Press <F1> to enter the main menu
Select WORKING RANGE SETTINGS and press ENTER.

TTS NMF GmbH
In the following menu the security code for the activation must be entered
by using the keys  the security code is 887564.
Now you can activate / de-activate the working range limitation
To de-activate the working range limitation, press the “OFF” key and leave the working range settings with
EXIT.
When the working range limitation has been activated the slewing gear must slowly be driven into the
reference position (zero position of the slewing angle) and the drive must be stopped when the reference
position is reached (the menu will change and REFERENCE POSITION IS SET is blinking).
On this menu the actual distance of the circle chord from the centre of the crane radius is displayed.
If the chord distance shall not be changed press the NEXT key.
Menu P72 will be called up again, the status of the working range limitation is now “ON” you can now leave
the working range settings by pressing EXIT.
If the chord distance shall be changed press the ADJUST key and follow the instruction on this menu.

TTS NMF GmbH
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.

TTS NMF GmbH
5.4.7 SPECIAL MODUS FOR ROPE CHANGE

When a rope has to be exchanged a special mode will support this procedure.
If this special mode is activated the rope length measuring system and also the limit switches are by-
passed.
 Drive with the corresponding drive into a definite position (e.g. the jib into the jib resting position or the
hook is touching the deck).
 In this position activate the rope change mode and then remove the limit switch from the winch. (Take
care that the shaft of the limit switch will not be turned.)
 Now the rope can be paid out completely from the winch and the new rope can be installed. (Drive
carefully – no limitation is active.)
 When the new rope is installed and the hook/jib is in the same position where limit switch has been
removed, at this position the limit switch must be fixed to the winch again.
 De-activate the rope change mode.
Procedure:
 Set MAIN MENU
 Select ROPE CHANGE MODUS
 Select L_ROPE_CHANGE or H_ROPE_CHANGE
 Select FALSE or TRUE and ENTER

TTS NMF GmbH
5.4.8 CALIBRATION OF LOAD INDICATION

The crane load will be calculated as a function of the hoisting pressure. The oil pressure in the hoisting
circuit consists of the idle running pressure + losses through floating resistances + working pressure. This
working pressure always depends on the lifted load.
The default load data for the calculation of the load weight are stored in the memory-module.
These data can be overwritten if the displayed load weight is not similar to the lifted test weight.
Procedure:
 In Main Page select MENUE
 In MAIN MENU select SECURED AREA (KEY-CODE IS ON DEMAND)
 In SECURED AREA press NEXT until Page 152 appears

TTS NMF GmbH
 NEXT
 In Page 152 select LOAD ADJUSTMENT

TTS NMF GmbH
On Page 205 LOAD ADJUSTMENT the actual load is shown. Lift up the test weight with slow speed
approx. 1 meter. The test weight should have a weight near by the SWL-Load of the crane. When the drive
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). To overwrite the calculated value chooses the Item OVERWRITE CALC_VALUE and press
ENTER. Page 207 will appear. To store the new value press ENTER and go back to the load adjustment
settings page with the BACK button. If the load displayed corresponds now to the lifted weight, you can
leave the load adjustment settings with the BACK button until the MAIN MENUE page will appear.
 Page 207 to store the new value in the PLC

TTS NMF GmbH
5.4.9 REPORT OF CHANGE

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

TTS NMF GmbH
5.4.10 ZERO-SETTING OF POTENTIOMETERS

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

The crane operating time is counted by means driving the main motor. Additional the running time of the
hydraulic gear drives will be recorded.
5.4.11.1 MAIN MOTOR OPERATION HOURS

When the PLC has been changed and the system has been set back to default data the contents of the
operation hours counter is set to zero.
It is possible to override the zero-value with the actual counter value (should be written down every 2-3
months).
Procedure:
 Set MAIN MENU
 Select SET OPERATION HOURS
 Select MAIN MOTOR M01
Press ACCEPT to select by the keys  and put in the required value
and then press ACCEPT again to store this value as actual operation counter value.
5.4.11.2 OPERATION HOURS OF HYDRAULIC GEAR DRIVES

When the PLC has been changed and the system has been set back to default data the content of the
operation hour 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).
After a hydraulic drive has been changed the corresponding operation hour counter should be set to zero.
Procedure:
 Set MAIN MENU
 Select SECURED AREA (KEY- CODE IS ON DEMAND)
 Select SET OPERATION HOURS
 Select HOISTING GEAR DRIVE or LUFFING GEAR DRIVE or SLEWING GEAR DRIVE
Press ENTER and select the space after NEW OPERATION HOURS and put in required
value by using  keys. Press ENTER again. To store this value select CONFIRM
NEW VALUE and press ENTER one time more.

TTS NMF GmbH
5.4.12 ZERO-SETTING OF INCLINOMETER (SPECIAL EQUIPMENT)

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

TTS NMF GmbH
5.5 CRANE OPERATION MODES

The normal operation mode is the hook operation.
The crane is equipped with an optional container spreader operation mode. The crane control
system must be set into this operation mode if a container spreader is connected to the crane.
5.5.1 SPREADER OPERATION

If a container spreader is connected to the crane the key operated switch <SPREADER OPERATION> in
the r.h. control desk must be activated to start the spreader operation mode.
The connected spreader in activated spreader operation mode is monitored by a pilot signal which must be
always “high” (24VDC) while the spreader is ready for operation. If this pilot signal drops the hoisting gear
blocks and a fault indication is shown on the display:
“F5012 FAULT IN SPREADER CONTROL”
5.5.1.1 CONTROL LEVER FOR SPREADER CONTROL

The control levers are equipped with coloured push-buttons to control the spreader. Each push-button is
processed in the PLC system and converted to a specific signal type for the transmission to the spreader
control system.
5.5.1.1.1 LEFT HAND CONTROL LEVER
1: Blue: n.c.
2: Green: Expand telescope
3: Red: Retract telescope
4: Yellow: n.c.
5: Black Move G.P. to black
6: White Move G.P. to white
Handling:
-Telescope to the next position:

Expand or Retract telescope push-button must be pressed less
than 1 second, spreader telescopes to the next position in the
corresponding direction.
- Telescope to the final position:
Expand or Retract telescope push-button must be pressed longer
than 1 second, spreader will telescope to final position in the
corresponding direction.
- Move G.P. to white or black:

Move G.P. with push-button <Move G.P.to black> or move <G.P.
to to white> in the corresponding direction (pulse type signal 0,5 sec).
-Move G.P to centre position:
Press both push-buttons <Move G.P to white> and Move <G.P. to
black> simultaneously to move G.P. in centre position.
Note: G.P. will move automatically to centre position while the
empty spreader (TWL unlocked) is lifted for 3 sec. minimum.

TTS NMF GmbH
5.5.1.1.2 RIGHT HAND CONTROL LEVER
1: Blue n.c.
2: Green Green flippers down (both flippers together)
3: White White flipper down
4: Red Red flippers down (both flippers together)
5: Black Black flipper down
6: Yellow All flippers up
All signals are pulse signal type 0,5 sec.
7: Red TWL lock

8: Green TWL unlock
All signals are pulse type signals 0,5 sec.
5.5.1.2 OPERATE THE SPREADER

When the spreader is lowered and borne on the container completely the pilot lamp =M07-H11 “ALL
LANDED” in the r.h. control desk is on and no further movement in lowering direction is possible.
To drive the hoisting gear in lifting direction it is absolutely necessary that the TWISTLOCKS are locked or
unlocked which is indicated with pilot lamps in the r.h. control desk (=M07-H09 and –H10) otherwise the
hoisting gear in lifting direction is blocked and a condition message is shown on the display:
“C5013 TWL NOT LOCKED/ UNLOCKED”
5.5.1.3 LOAD TURNING DEVICE

The load turning device is operated with the right hand control lever. A lever deflection to the left direction
effects that the load turns to the left (counter-clockwise). If the lever is deflected to the right direction the
load will turn to the right (clockwise).
When the load turning device is connected to the crane the hydraulic oil control pressure to the equipment
is monitored by means of the pressure switch =M07-S82G. If the pressure drops below 20 bar the hoisting
gear is blocked and a fault indication is shown on the display:
F5010 PRESSURE FAULT CARGO GEAR
Additionally the electrical supplies to the load turning device are monitored. In case of a circuit breaker trips
a fault indication is shown on the display:
F5011 FAULT OF CARGO GEAR CONTROL

TTS NMF GmbH
5.6 INTERLOCKING FOR SEA VOYAGE

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

TTS NMF GmbH
5.6.2 UNLOCKING
The operating system must be in order before the system for locking for sea is switched on.
During normal operation when the crane is locked, the status of all signals from the monitoring proximity
switches must be "FALSE":
=M06-B802 - =M06-B803 slewing gear position control
To unlock the crane, the hook must first be lowered and the lashing rope disconnected, and then the key-
actuated switch of the sea locking system must be turned to the zero position.
To retract the locking cylinders, the luffing gear pump powers and the locking gear, the directional control valve
is set to the position for unlocking. The display shows the progress of the locking procedure.
When all locking cylinders are completely retracted the corresponding signal-status of the proximity switches
must be TRUE. The luffing gear pump and directional control valve are switched off, and the display shows the
information that the crane tower is unlocked.
While unlocking the pressure is limited to about 210 bar by sensor =M07-B20.
As a rule, unlocking takes about 10 ... 15 seconds. If it has not been completed by this time, the slewing gear is
activated briefly in both directions to ease the jammed locking pin free. The slewing gear pressure is limited to
80 bar by pressure switch =M07-S82 during this.
The actual input status can be displayed:

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

TTS NMF GmbH
5.6.3 FAULT MESSAGES AND EMERGENCY OPERATION SYSTEM

The following fault messages are generated by the interlocking system:
F 4301 CYLINDER NOT IN UNLOCK POSITION
F 4302 STATUS FAILURE OF PROXIMITY SWITCHES
F 4303 CRANE REMOVED FROM LOCKING POSITION
F 4304 LOCKING TIME LIMITATION EXCEEDED
F 4305 UNLOCKING TIME LIMITATION EXCEEDED
Proximity switches =M06-B804 to B809 monitor the upper positions of the locking cylinders during normal
crane operation. The status signals from the monitoring proximity switches must be "TRUE":

 Set MAIN MENU
Remedial action
 Check the positions of the locking cylinders.
 Check proximity switches =M06-B804 to B809.
 Check the power supply and leads to the proximity switches.
 Check the wiring.
 Replace PLC.
Attention by activation of emergency code EOS4301:

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

TTS NMF GmbH

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

Remedial action
 Check the conditions signalled by the proximity switches. When
the locking cylinders are completely retracted proximity switches
=M06-B804 to B809 must be TRUE, when these cylinders are fully
extended, the same signals must be FALSE.
 Check the proximity switches and their fastenings
 Check the leads
 Replace PLC.
Attention by activation of emergency code EOS4302:

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

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

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

TTS NMF GmbH

Locking or unlocking procedures should take no longer than approx.15 sec.

The above fault announcement will appear if locking or unlocking procedures are not finished within 30 sec.
Remedial action
- Check the electrical and hydraulic locking controls.
- The additional pump (luffing gear pump) must have power for locking and unlocking.
- The directional valve for locking or unlocking and the release valve must be actuated.
- The cylinders should be unlocked with approx. 210 bar pressure; they should be locked with approx.
150 bar pressure. The pressure (luffing gear pressure) can be read on the display or measured with a
pressure gauge.
The actual sensor output value can be displayed:
 Set MAIN MENU

 Select ANALOGUE INPUTS
The value of the sensor is displayed in A and bar.
If the interlocking system is not working properly an emergency system can be activated for overriding and
direct control of the interlocking cylinder.
Procedure:
 Set MAIN MENU
 Select EOS INTERLOCKING SYSTEM

TTS NMF GmbH
5.6.3.1 SETTING THE PRESSURE LIMITING VALVE

The pressure is limited to 150/210 bar by sensor =M07-B20 during locking and unlocking.
For higher safety level it is advisable to set the pressure limiting valve in the switching block of the sea locking
system to 240 bar.
This setting should be undertaken only at nominal voltage (e.g. 440 V, 60 Hz, i.e. at the shipyard using the
ship's mains fed by the ship's generators) with hydraulic oil that is operationally warm (>40 °C).
When the operating system is activated for the setting operation, the locked or unlocked status is not switched
off if the cylinders are in their end positions and the electronic pressure limitation is not in effect.
Procedure:
Turn the crane into the sea locking position and, using the normal operating system, lock it and unlock it again
to check that the locking system is in order.
Select EOS INTERLOCKING SYSTEM

Set PRESSURE ADJUSTMENTS on TRUE: The pressure will be shown automatically on the display.
Lock / Unlock the crane by SET OPERATION. The pump delivery increases slightly when the cylinders are
fully extended. The hydraulic pressure setting can be adjusted at this point.
By activating the emergency operating system the locking cylinders can be extended and retracted even when
the proximity switches and pressure sensors are out of order.
In such cases care must be taken that the slewing gear is exactly in the locking position because all monitoring
facilities are overridden.
Explanation in the case of locking:

The locking pressure then appears automatically on the display; if the sensor is defective the pressure must be
checked by pressure gauge.
When the LOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the locking position and the luffing gear pump is started at low (minimum) current.
The current, and therefore the delivery of the pump, is increased by ramp function and must be observed to
prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is locked (cylinder completely extended) the procedure is ended by releasing the soft-
key.

TTS NMF GmbH
5.6.3.2 LOCK / UNLOCK IN EMERGENCY OPERATION

If the interlocking system is not working properly an emergency system can be activated for overriding and
direct control of the interlocking cylinder.
Procedure:
 Set MAIN MENU
 Select EOS INTERLOCKING SYSTEM
Procedure:
By activating the emergency operating system, the locking cylinders can be extended and retracted even when
the proximity switches and pressure sensors are out of order.
Turn the crane into the sea locking position. Care must be taken that the slewing gear is exactly in the locking
position because all monitoring facilities are overridden
Lock / Unlock procedure will be carried out by SET OPERATION.

The locking pressure then appears automatically on the display. If the sensor is defective the pressure must be
checked by pressure gauge.
Locking procedure:
When the LOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the locking position and the luffing gear pump is started at low (minimum) current.
The current, and therefore the delivery of the pump, is increased by ramp function and must be observed to
prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is locked (cylinder completely extended) the procedure is ended by releasing the soft-
key.
Take care that all locking cylinders are completely extended and than set the status of the interlocking system
on LOCKED by selection of CRANE IS LOCKED and entering TRUE.
Unlocking procedure:
When the UNLOCK soft-key is pressed (it must be held down throughout the locking process), the directional
control valve is switched to the unlocking position and the luffing gear pump is started at low (minimum)
current. The current, and therefore the delivery of the pump, is increased by ramp function and must be
observed to prevent the pressure from becoming too high (release the soft-key briefly).
Once the slewing gear is unlocked (cylinder completely retracted) the procedure is ended by releasing the soft-
key.
Take care that all locking cylinders are completely retracted and than set the status of the interlocking system
on UNLOCKED by selection of CRANE IS UNLOCKED and entering TRUE.

TTS NMF GmbH
5.7 PMS – POWER MANAGEMENT SYSTEM (SPECIAL

EQUIPMENT)
5.7.1 FUNCTIONAL DESCRIPTION
The crane drives will be started by activating the START - switch. At first the feed oil pump motor starts
while simultaneously the POWER-REQUEST signal (potential-free N.O. contact) will be given to the ship
control system of the ECR (engine control room) via the slip ring assembly.
In case of sufficient power supply of the generator, the crane control system will get a POWER-AVAILABLE
signal (potential-free N.O. contact) from the ECR. The main motor (160-kW-motor) will start only if the
POWER-AVAILABLE signal is available.
If the POWER-AVAILABLE signal will not be received within 50/90 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

TTS NMF GmbH
5.8 SPECIAL OPERATION MODES

5.8.1 TEST OPERATION
This special mode allows checking all solenoid valve circuits without running pump motors.
Therefore the crane control will be set into operable and all relevant limitations will be by-passed.
When the test operation mode is activated it is not possible to start the pump drive motors.
Procedure:
 Set MAIN MENU
 Select SET / RESET TEST OPERATION
TEST OPERATION can now be activated = TRUE / deactivated = FALSE
by selection and entering
5.8.2 POWER / SPEED REDUCTION

This special mode will limit the speed of all drives at about 50 percent of its maximal speed.
This mode can be used to reduce the power consumption of the crane in case of problems with the supply
source (shore connection / generator failure), or when the drive speeds shall be reduced to prevent
collision conflicts etc.
Procedure:
 Set MAIN MENU
 Select SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE
5.8.3 DISABLE TRIMOT

This special mode will limit the speed of the hoisting drive by switching off the control of the variable
displacement motor (TRIMOT).
Procedure:
 Set MAIN MENU
 Select DISABLE TRIMOT
T_DISABLE: can now be activated = TRUE / deactivated = FALSE

TTS NMF GmbH
5.9 TROUBLE SHOOTING

The electronic assemblies include ICs in C-MOS Technology; the assemblies should never be extracted or
plugged in while the power is connected.
While designing the electrical equipment, great value was attached to providing a status monitoring system
that would monitor as many operating criteria as possible and would generate an appropriate message in
the event of malfunctions on the display.
If a malfunction occurs, the red collective fault indicator light in the control console lights up.
After the part of the system concerned has been checked and, if necessary, repaired, the crane can be put
into operation again by pressing the button < F2 >.
The following text describes the messages given by the status monitoring system in more detail.
The status monitoring system consists of several subsystems handling various criteria.
The first distinction has to be made between fault messages and condition status messages.
5.9.1.1 FAULT INDICATIONS

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

"CONDITIONS" are intentional interruptions or limits set on the basis of monitoring criteria (e.g. hoisting
gear limit switches or excessive hook loads).
"CONDITION" displays that a limiting device has responded, but not that there is a fault in the system.
CONDITIONS will be reset automatically when the drive is actuated in the opposite direction.

TTS NMF GmbH
POWER SUPPLY AND CONTROL VOLTAGE
The power supply is feed from the ship's mains to the crane main switch via slip rings.
If the main switch cannot be turned on, check the following points:
1. Is the power feeder from the ship's supply switched on?
2. Is an EMERGENCY OFF button being pressed?
3. Is the breaker =M01-Q1 in the OFF position.
The 24 V DC control voltage is produced by the three phase-primary switcher unit =M01-U1.
The 24 V control voltage is distributed into different circuits which are protected by fuses =M01-F11 to –
F18. If one of these fuses is out of order (for instance, blown owing to a short circuit), the fault is indicated
by the LED in the fuse terminal.
5.9.1.3 PLC STATUS INDICATORS

The main status of the PLC-system is indicated by LED’s on the main controller and on the input and
output Compact Modules.
When the system is running in good order the green LED is blinking with a 2 Hz signal.
Detailed information about the status indication is given in the hardware description of the PLC
components.
The signal status of each input and output on the Compact Modules is also indicated by a LED.
5.9.1.4 ADDITIONAL INDICATIONS
Detailed information about the input- output-status or value will be displayed, if the corresponding indication
sheet is selected, e.g.:
DRIVE VALUES potentiometer value, setup value, nominal / actual speed value
SENSOR VALUES digital inputs and outputs (TRUE / FALSE)
Analogue inputs (current or voltage)
Current outputs (PWM value in mA)
COUNTER VALUES position of the drive and drive speed
By calls of this information you are able to check a lot of relevant system data, e.g. it is possible to check
the status of an input or a sensor value (output current) will be read into the PLC.
Procedure:
 Set MAIN MENU
Choose the required information

TTS NMF GmbH
5.9.2 LIST OF FAULT MESSAGES

and fault identification instructions
The list shows all the possible messages.

Some of the messages are not activated by the current program.
F 0003 MAIN SWITCH CONTROL
Appears if main switch trips while pump drive motors are running
Press <F2> button to eliminate.
The crane shall not be stopped by pressing the emergency stop button.
Remedial action:
 Check the auxiliary contact of the main switch, this contact must
be opened when the main switch is ON.
F 0004 FAULT OF PMS-SYSTEM
For further information see functional description of the PMS-System.

This message appears if the power available signal is not given within 50/90 sec. after starting of the
electrical drives of the crane or when the signal drops out (e.g. in case of power outage / generator failure)
during crane operation).

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

TTS NMF GmbH
F 0005 DRIVE CONTACTOR NOT IN DELTA
The motor of the main pump is switched from the star to the delta circuit by means of timing relay =M02-
K4. This is intended to happen after about four seconds.
This message appears if the switch-over has not taken place after 10 seconds.

 Set MAIN MENU
Remedial action:
 Set the switching time on the star/delta timing relay to 4 seconds.
 Replace the timing relay if defective.
 Repair the contactor for the delta circuit if necessary.
 Replace the PLC.
C 0006 CONTROL LEVER NOT IN NEUTRAL POSITION
The control levers are not to be operated until <READY FOR OPERATION> is displayed.
This is checked by means of the contacts in the control levers.
This message appears if one or more contacts are closed before <READY FOR OPERATION> is
displayed.
This message appears also if the dead man switch is actuated before <READY FOR OPERATION> is
displayed. (Optional equipment)

 Set MAIN MENU
Remedial action:
 Set the control levers to the neutral (zero) position (check the
return springs and replace if necessary).
 Check the control lever contacts and replace them if necessary.
 Replace the Cabinet Module in the right control desk.

TTS NMF GmbH
F 0007 OPERATION HOURS COUNTER
Memory contents of the operation hours counter is not correct. This occurs only if the processor module is
defective or if the PLC main controller has been changed.
Remedial action:
 Set the operation hours counter back to zero or to the relevant

counter value.

 Set MAIN MENU
 Select SET OPERATING HOURS
SET NEW OPERATION HOURS M01: by corresponding data input
F 0010 STATUS FAILURE DELTA CONTACTOR
The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the
crane control system is switched on. If this message occurs, it means that an extraneous voltage is
reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture)
or that the corresponding PLC input itself is defective.

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

TTS NMF GmbH
F 0011 STATUS FAILURE LIMIT SWITCH LUFFING IN

F 0012 STATUS FAILURE LIMIT SWITCH LUFFING OUT
F 0013 STATUS FAILURE LIMIT SWITCH HOISTING
F 0014 STATUS FAILURE LIMIT SWITCH LOWERING
Additional the status the limit switch contacts will be monitored:
Each contact block contains a NC and NO contact that means the voltage on the corresponding PLC inputs
must alternate. If both inputs have an identical signal level at the same time the corresponding fault will be
set.

 Set MAIN MENU
Remedial action:

TTS NMF GmbH
F 0015 STATUS FAILURE PRESS. SWITCH HOISTING

F 0016 STATUS FAILURE PRESS. SWITCH LUFFING
F 0017 STATUS FAILURE PRESS. SWITCH SLEWING
F 0018 STATUS FAILURE PRESS. SWITCH SLEWING

 Set MAIN MENU
Remedial action:
For example:
On the crane the fault F0017 is displayed that means there is an input signal on channel 5 or
channel 7 of the analogue input module =M07-A4.
Please check which LED indication for channel 5 or channel 7 is lighting (normally the LED´s must
be off).
Then check the corresponding pressure switch M07-S30 or -S31. Maybe the connecting pins are
bended so that the plugs will contact or the pressure switch itself is defective (the contact must be
open).
C 0041 PMS POWER REQUEST
This signal will be displayed if the starting procedure of the main motor is delayed because there is no
start enable by the power available signal.
C 0042 PMS POWER AVAILABLE
The PMS-System has received the start enable signal and will start the main motor.

TTS NMF GmbH
F 0110 CONTROL OIL PRESSURE <15bar
The minimum permissible control pressure for the hydraulic system is 15 bar (normal operating pressure:
26 bar). Fault message F011 appears on the display if the pressure measured by the two pressure sensors
(=M07-B10 and -B20) is lower than this value.
The actual sensor output values can be displayed:

 Set MAIN MENU
The values of the sensors are displayed in A and bar.
Remedial action:
 Check the hydraulic oil circuit.
(cf. specification of the hydraulic system.)
 Measure the pressure with a pressure gauge and compare this
value with the displayed one.
 Check the power supply DC 24V of the Compact Module.
F 0140 OIL LEVEL MINIMUM
The level in the hydraulic oil tank will be controlled by an oil level switch.
Fault message F0140 appears on the display if oil level is below the minimum permissible stand.

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

TTS NMF GmbH
F 0160 OIL OVERTEMPERATURE

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

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

 Set MAIN MENU
The value of the sensor is displayed in A and °C.
Remedial action:
 Check the hydraulic oil cooling circuit.
(cf. specification of the hydraulic system.)
 Check temperature sensor =M07-B01.
F 0161 TEMPERATURE SENSOR OUTPUT <4mA

F 0162 TEMPERATURE SENSOR OUTPUT >18mA
This fault message appears if the temperature signal from the temperature sensor =M07-B01. The output
current from the temperature measurement must be between 4 and 18 mA (cf. specification of the
temperature sensor). Messages are generated if the measured value is outside.

 Set MAIN MENU
The value of the sensor is displayed in A and °C.
Remedial action:
 Check temperature sensor =M07-B01.
 E.g. connect a pressure sensor to the input of the temperature
sensor, if a value of >/= 4 mA is now displayed, then the
temperature sensor itself or the connector cable is defective.

TTS NMF GmbH
F 0210 FILTER OVERPRESSURE
This fault message appears if the pressure switch (=M07-S08) of the filter clogging indicator has tripped.
The switch trips when the pressure dropped across the filter exceeds 5 bar (cf. specification of the
hydraulic system).

 Set MAIN MENU
Remedial action:
 Replace the filter cartridge.
 Check the pressure switch characteristics (the contact must be
closed).
F 0220 OVERLOAD FEED OIL PUMP
This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q11 for the control oil /
booster pump has tripped.

 Set MAIN MENU
Remedial action:
 Reset the MCB.
 Check the power supply for phase failure.
 Compare the current set on the MCB with the specified nominal
motor current.
 Measure the motor amperage. If it is too high, the cause must be
sought in the booster pump or hydraulic system.

TTS NMF GmbH
F 0230 OVERLOAD OIL COOLER
This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q12 for the hydraulic oil
cooler has tripped.

 Set MAIN MENU
Remedial action:
 Reset the MCB.
 Check the power supply for phase failure.
 Compare the current set on the MCB with the specified nominal
motor current.
 Measure the motor amperage. If it is too high, the cause must be
sought in the booster pump or hydraulic system.
F 0240 OVERLOAD MAIN MOTOR (THERMISTOR)
This fault message appears when the overload protection circuit for the main motor (=M02-M1) trips. The
protection circuit consists of a thermistor controlled relay (=M02-F4). The thermistor controlled relay will trip
if the pump drive is overloaded or the motor is not being adequately cooled.

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

TTS NMF GmbH
F 0251 OVERCURRENT MAIN MOTOR
The current drawn by the main motor is monitored in addition to the winding temperature. This is done by
current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is
proportional to the current.
Fault message appears if the drawn current exceeds 2.3 times the nominal current.

 Set MAIN MENU
The value of the sensor is displayed in A and the calculated motor amperage A.
(A=I(v1-v2) * 1,73
Remedial action:
 Check the voltage and the current drawn by the motor.
 Check the power supply and output signal of the sensor (about 4
mA output current per 100 A drawn).
F 0252 NO AMPERAGE MAIN MOTOR
The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line.
The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
Fault message appears if the current drawn is lower than that normally drawn under no-load conditions
(protection against phase failure).

 Set MAIN MENU
(A=I(v1-v2) * 1,73
Remedial action:
 The sensor works with 220 V, i.e. the supply for lighting and
heating must be switched on via fuse =M03-F34.

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

 Set MAIN MENU
(A=I(v1-v2) * 1,73
Remedial action:
C 0711 POWER REDUCTION (MAIN MOTOR AMPERAGE)
This message appears if the hoisting speed is reduced because current drawn by the main motor is too
high.
This can happen if all three crane motions are activated at full speed simultaneously under full load.
If the message appears while working at part load, the power supply to the motor should be checked.

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

TTS NMF GmbH
C 0713 SPEED REDUCTION (SPEC. OPERATION MODE)
This message indicates that the speed reduction mode has been activated.
Remedial action:
 De-activate this mode.
 Set MAIN MENU
 Select SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be
activated = TRUE / deactivated = FALSE
F 1010 HOISTING PRESSURE <7bar
The pressure in the hoisting gear hydraulic circuit is monitored by switch =M07-S10. Fault signal appears
on the display if the pressure drops below 7 bars.

 Set MAIN MENU
Remedial action:
 Check the hydraulic pressure by measuring it with a pressure
gauge. (cf. specification of the hydraulic system.)
 Measure the characteristics of the switch and replace if
necessary.
 (Status must be <TRUE> when the pump drive is running.)

TTS NMF GmbH
F 1020 HOISTING PRESSURE <>15bar
This fault message appears if pressure sensor =M07-B10 (hoisting gear) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is activated, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf.
specification of the pressure sensor.

 Set MAIN MENU
Remedial action:
 Check pressure sensor =M07-B10.
 E.g. interchange the hoisting pressure sensor against the luffing
pressure sensor, if the failure is now displayed in the luffing
circuit, then the pressure sensor itself or the connector cable is
defective.
F 1031 HOISTING SENSOR OUTPUT <4mA

F 1032 HOISTING SENSOR OUTPUT >18mA
This fault message appears if pressure sensor =M07-B10 (hoisting gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the
pressure sensor.

 Set MAIN MENUE
Remedial action:
defective.
F 1033 AUX. HOISTING SENSOR OUTPUT <4mA

F 1034 AUX. HOISTING SENSOR OUTPUT >18mA
The reason for this message corresponds to F 1031 / F.1032; it is created by malfunction of the auxiliary
pressure sensor =M07-B11.

TTS NMF GmbH
F 1040 HOISTING PRESSURE TEST FAILURE
The hydraulic pump is tested after starting the pumps and every time before a new lifting/lowering cycle is
started with a gradually increasing electrical control current for the high-side pressure proportional solenoid
valve „B“ until the pressure reaches 50 bars (or the memorised pressure value from the previous hoisting
cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.

 Set MAIN MENU
Remedial action:
 Compare the pressure displayed with a measurement carried out
by a pressure gauge.
 If no pressure build-up can be noticed, press the emergency
button of the solenoid valve directly for functional test of the
pump.
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.

TTS NMF GmbH
F 1050 HOISTING PRESSURE >40 bar
If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil
pressure). This message appears if the pressure remains at a level >40 bars.

 Set MAIN MENU
Remedial action:
 Compare the pressure displayed with a measurement carried out
 Check the control unit of the hydraulic pump, maybe the pump
control unit is not shifting back into neutral position
 (See description of the hydraulic plant).
circuit, then the hoisting pressure sensor itself or the connector
cable is defective.

TTS NMF GmbH
F 1060 HOISTING CONTROL LEVER (OFFSET)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output
voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control
lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position
both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 10% of the rated value when the
control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:

 Set MAIN MENU
 Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the
contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is FALSE.
To check these values move the lever very slowly out of neutral position.
Remedial action:
 Measure the output voltage of the potentiometer (control lever in
neutral position).
 Check the contacts of the control lever.
 Re-adjust the potentiometer.
 Replace the PLC or the Cabinet Module.
 Additional information regarding EOS 1060:
For safety reasons the potentiometer output and also the
switching contacts of the control lever are monitored by the PLC.
If one of the contacts is defective, the drive can be controlled by
the potentiometer only, this will be activated by the EOS-code.
Now the drive will be started and stopped by the potentiometer in
the control lever without safety control-check.
This is a dangerous condition: if now the potentiometer or
the analogue input becomes defective the drive will start
without driver command and can be stopped by emergency
stop only.

TTS NMF GmbH
F 1070 HOISTING CONTROL LEVER (SUPPLY)
lever deflection.

 Set MAIN MENU
The potentiometer value must be below 100 when the contact condition is false.
Remedial action:
 Check the wiring and the supply connections of the
potentiometer.
 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.
 Additional information regarding EOS 1070.
If the potentiometer is defective, the drive can be controlled by
the control lever contacts only, this will be activated by the EOS-
code.
In normal conditions the contacts of the control lever are
connected in parallel, it does not matter in which direction the
control lever is actuated. For control with the EOS 1070-code it is
necessary to remove the bridge which is connecting the contacts
(the bridge on the supply side must remain), and now the contact
which will close in lowering direction must be connected to the
terminal for the EOS-input (IX5.01).
Now the drive will be started and stopped by the contacts in the
control lever without potentiometer speed control. For safety
reasons the drive speed is limited to half of its maximum.

TTS NMF GmbH
F 1080 HOISTING PWM-OUTPUT FAILURE =M07-A3

F 1081 HOISTING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid vales of the pump is generated in the Compact Module by
Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is
taken although the corresponding PWM output is activated by the nominal value.
The drive condition can be displayed:

 Set MAIN MENU
 Select DRIVE VALUES
Remedial action:
 Check the wiring to the solenoid valve.
 Check the resistance of the solenoid coil. (approx. 24-30)
F 1090 HOISTING WINCH OVERTEMPERATURE
The maximum temperature of the winch gear box is controlled by a temperature switch; the contact will
open when the temperature is exceeding the maximum value.

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

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

 Set MAIN MENU
Remedial action:
 Exchange the PLC.
C 1210 LIFTING LIMIT (SAFETY LIMIT-SWITCH)
Additional to the electronic limit protection, there are 2 mechanical limit switches installed for collision
protection between hook and jib (anti-two-block).
One of these limit switches is actuated.

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

TTS NMF GmbH
C 1211 LIFTING LIMIT (MECHANICAL SWITCH)
The lifting height of the crane is limited by the hoisting gear limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the following checks should be
carried out:

 Set MAIN MENU
Remedial action:
 Check the mechanism of the limit switch (connection to the
hoisting gear drum, limit switch coupling, limit switch gear, cam
shaft)
 Check the switching contacts.
REMARK: Only when the jib is in the maximal outreach position (maximal working range) and the
hook is in the highest position there is a distance of approx. 1 meter between jib head and hook
block.
When the jib is luffed in (lifted up) the distance between jib head and hook block will increase
because the hook is moving in a horizontal way.
C 1212 LIFTING LIMIT (ROPE LENGHT)
The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out
by means of incremental encoders, mounted inside of the limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement
system must be re-adjusted.
Remedial action:
Follow up the procedure, described under item
„RESET OF REFERENCE POSITIONS“
block.

TTS NMF GmbH
C 1214 LIFTING PRE-LIMITATION
The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out
by means of incremental encoders, mounted inside of the limit switch =M06-S16.
Before the final limit position is reached the drive speed will be ramped down by the rope length
measurement.
Remedial action:
block.
C 1216 LOWERING LIMIT (MECHANICAL SWITCH)
The lowering distance of the crane is limited by the hoisting gear limit switch =M06-S16.
If this message appears although the hoisting gear is in the "free" range, the following checks should be
carried out:

 Set MAIN MENU
Remedial action:
 Check the mechanism of the limit switch (connection to the
hoisting gear drum, limit switch coupling, limit switch gear, cam
shaft)
 Check the switching contacts.
C 1217 LOWERING PRE-LIMITATION
The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried
out by means of incremental encoders, mounted inside of the limit switch =M06-S16.
measurement.
Remedial action:

TTS NMF GmbH
C 1220 SLACK ROPE
The slack rope monitoring system of the hoisting gear has responded and blocked the motion. Haul the rope
taut by cautious operation in the opposite direction.

 Set MAIN MENU
 Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
Remedial action
 Check the contact rail; the contact rail is connected to a 24 V output
channel of the PLC. If the lifting gear rope is slack, it will touch the
rail, thereby earthen it so that the output voltage will drop down.
In other words, the lifting gear rope must not touch the contact rail,
and the contact rail must also be free from any dirt that might cause
an earth fault.
C 1221 LOWERING LIMIT (ROPE LENGTH)
The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried
Remedial action:
C 1222 DEAD MAN SWITCH NOT ACTUATED
The control leaver is equipped with a dead man switch. This switch must be actuated before the leaver is
moved from neutral position.

 Set MAIN MENU
Remedial action
 Check the mechanism of the control leaver (automatic return into
zero position; in zero position the directional contacts must be
open)
 Check the dead man switching contact.
 Replace the cabinet module.

TTS NMF GmbH
F 1301 HOISTING COUNTER EQUALITY FAILURE
This fault is an internal fault in the PLC.

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.
The output pulses from the incremental encoder are counted to ascertain the position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are
compared. It is also necessary to make sure that the correct position information is stored if an emergency
cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed
automatically, it is necessary to drive into the reference position for reset and confirmation of the counter
system. During this time the hoisting gear speed is reduced.
Remedial action:
Please follow the instructions displayed:

1. The reference position for the hoisting gear is the highest hook position and the hook must be lifted
up to reach this position. In this position the limit switch contact will open and the drive will stop. If
the hook is already in the highest position then the hook must be lowered first.
2. The hook must be lowered a little bit (until the limit switch contact is closing again).
3. The hook must be lifted again until STOP signal is shown.
4. The hook must be lowered again (the wire rope clamp must pass the proximity switch).
5. The hook must be lifted again until STOP signal is shown; now the procedure is finished and the
crane will run in normal operation.

TTS NMF GmbH
F 1302 HOISTING COUNTER OUT OF RANGE
GENERAL
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter contents are not inside its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed.
The counter values can be displayed:

 Set MAIN MENU

<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive (during lowering operation the
value must increase; during lifting increase)
<SYNC> the indication changes from FALSE to TRUE every time when the wire rope
clamp is passing the proximity switch
<LAYER> displays the quantity of layers wheeled up on the drum
<SPEED> displays the speed (rotations per minute) of the drum

TTS NMF GmbH
Remedial action:


TTS NMF GmbH
F 1303 HOISTING COUNTER MONITORING
GENERAL
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).

 Set MAIN MENU


TTS NMF GmbH
Remedial action:


TTS NMF GmbH
F 1306 HOISTING ENCODER DEFECTIVE

F 1316 SYNCHRO PULSE OUT OF MONITORING RANGE
GENERAL
This fault message is generated when the synchronize pulse of the proximity switch is not right to the
counter value of the encoder.
At first the counter value and the status of the proximity switch should be checked:
 Set MAIN MENU

Remedial action:
If the counter value is not changing during winch turn then
 Check the encoder fastening inside the limit switch
 Check the limit switch drive
 Check the wiring (connection to the PLC inputs and check the
supply voltage of the encoder)
 Exchange the encoder
 Exchange the PLC
Remark: When this menu page is selected it will remain for only 20
seconds on the display then it´s changing back to the fault announcement.
Maybe the procedure must be repeated once again.

TTS NMF GmbH


TTS NMF GmbH
F 1307 PROXIMITY SWITCH =M06-B16 DEFECTIVE
GENERAL
This fault message is generated when the synchronize pulse of the proximity switch is not activated at each
revolution of the winch.
 Set MAIN MENU

Remedial action:
 Check the proximity switch fastening and the distance (gab)
between proximity switch and wire rope clamp =3-4 mm
supply voltage of the proximity switch)
 Exchange the proximity switch
 Exchange the PLCX

TTS NMF GmbH


TTS NMF GmbH
F 1308 HOISTING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the unwind direction although the
control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around.
Remedial action:
* Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
* interchange the outputs of the encoder
* Replace the encoder
* Replace the PLC
F 1309 HOISTING STANDSTILL DRUM MONITORING
If the drive is not activated (brake applied), the winch monitoring system must not signal any motion.
The actual output status can be displayed:

 Set MAIN MENU
 Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
Remedial action:
* Check the brake concerned.
* Check the electrical controls of the brake valves; if necessary,
replace the Compact Module.
F 1310 HOISTING OVERSPEED (FULL LOAD)
The speed of the winch is monitored by an incremental encoder.

This maximum drum speed has been exceeded.
The drive speed can be displayed:

 Set MAIN MENU
<COUNTER> displays the actual counter value of the drive
Remedial action:
* Check the hydraulic system:
pump delivery limitation system, oil leakage from pump or motor
(see specification of the hydraulic system).
* Check the electrical power of the TRIMOT control. There must be
no output signal when a full load is to be lifted / lowered.

TTS NMF GmbH
F 1311 HOISTING OVERSPEED (EMPTY HOOK)


 Set MAIN MENU
Remedial action:
* Check the minimum displacement angle of the TRIMOT.
(See specification of the hydraulic system).

TTS NMF GmbH
F 1312 HOISTING MUST RUN INTO REF. POSITION
GENERAL
encoder.
COMPONENTS“)
This fault indication appears as a result of a previous failure.

The previous failure which has caused this indication is also displayed as ORIGIN FAULT.
This ORIGIN FAULT has stopped the crane drive and the reason for this failure must be checked according
to the corresponding fault description.
It is necessary to drive into the reference position for reset and confirmation of the counter system.
Until the system has not been reset the drive speed is restricted and the crane load is limited to the SWL
value which the crane can lift at maximal outreach range.

the hook is already in the highest position then the hook must be lowered first. If it is not possible to
reset the positioning system because the required spare part is not available and the hook must be
lifted to secure the load then fault 1312 and sometimes the origin fault has to be bypassed by the
emergency operation system.

TTS NMF GmbH

TTS NMF GmbH
F 1330 TRIMOT OVERPRESSURE HOISTING

F 1331 TRIMOT OVERPRESSURE LOWERING
This fault message appears when the safety cut-out of the variable displacement hydraulic motor
(TRIMOT) for the hoisting gear trips.
This fault could be caused by a driver mistake, when he starts lifting a load with full speed, although the
load is not lifted up from the ground (slack rope).
The current output value can be displayed:

 Set MAIN MENU
Select CURRENT OUTPUTS
The actual amperage is displayed

 Set MAIN MENU
The following action should be taken if this fault occurs frequently:

* Check pressure hoisting pressure on the display and with a gauge.
* Check the current drawn by the solenoid valve.
(Set the controls to the test mode; shift the hoisting gear control
lever to maximum deflection. In this state, the current drawn by
the solenoid valve should rise from about 200 to about 500 mA
within about 4 seconds.)
* If the measured currents are within limits, check the hydraulic
controls.
* If the current is outside of the limits, replace the PLC.
* Check the wiring.

TTS NMF GmbH
F 2010 LUFFING PRESSURE <7bar
The pressure in the luffing gear hydraulic circuit is monitored by switch =M07-S20. Fault signal appears on
the display if the pressure drops below 7 bar.

 Set MAIN MENU
Remedial action:
* Check the hydraulic pressure by measuring it with a pressure
gauge. (Cf. specification of the hydraulic system.)
* Measure the characteristics of the switch and replace if necessary.
* Check the wiring.
* Exchange the PLC or the corresponding Compact Module.
* (Status must be <TRUE> while the pump drive is running.)
F 2020 LUFFING PRESSURE <>15bar
This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is activated, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf.
specification of the pressure sensor.

 Set MAIN MENU
Remedial action:
* Check pressure sensor =M07-B20.
* e.g. interchange the luffing pressure sensor against the hoisting
pressure sensor, if the failure is now displayed in the hoisting
defective.

TTS NMF GmbH
F 2031 LUFFING SENSOR OUTPUT <4mA

F 2032 LUFFING SENSOR OUTPUT >18mA
This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the
pressure sensor.

 Set MAIN MENU
Remedial action:
* E.g. interchange the luffing pressure sensor against the hoisting
defective.

TTS NMF GmbH
F 2040 LUFFING PRESSURE TEST FAILURE
The hydraulic pump is tested after starting the pumps and every time before a new luffing cycle is to be
started with a gradually increasing electrical control current for the high-side pressure proportional solenoid
valve „B“ until the pressure reaches 50 bar (or the memorised pressure value from the previous luffing
cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.

 Set MAIN MENU
Remedial action:
* Compare the pressure displayed with a measurement carried out
* If no pressure build-up can be noticed, press the emergency button
of the solenoid valve directly for functional test of the pump.
defective.
F 2050 LUFFING PRESSURE >40 bar
If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil
pressure). This message appears if the pressure remains at a level >40 bar.

 Set MAIN MENU
Remedial action:
* Compare the pressure displayed with a measurement carried out
* 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).
defective.

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

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

TTS NMF GmbH
F 2070 LUFFING CONTROL LEVER (SUPPLY)
lever deflection.

 Set MAIN MENU
Remedial action:
* Check the wiring and the supply connections of the potentiometer.
neutral position).
* Most of time it is a supply failure or the potentiometer itself is
defective.
* Additional information regarding EOS 2070.
the control lever contacts only, this will be activated by the EOS-
code.
In normal conditions the contacts of the control lever are
control lever is to be actuated. For control with the EOS 2070 -
code it is necessary to remove the bridge which is connecting the
contacts (the bridge on the supply side must remain), and now
the contact which will close in luffing out direction must be
connected to the terminal for the EOS-input (IX5.01).

TTS NMF GmbH
F 2080 LUFFING PWM-OUTPUT FAILURE =M07-A3

F 2081 LUFFING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid values of the pump is generated in the Compact Module by
Pulse Width Modulation. A fault message appears when no control current measurement (actual value) is

 Set MAIN MENU
Remedial action:
* Check the wiring to the solenoid valve.
* Check the resistance of the solenoid coil. (approx. 24-30)
F 2090 LUFFING WINCH OVERTEMPERATURE
The maximum temperature of the winch gear box is controlled by a temperature switch; the contact will
open when the temperature is exceeding the maximum value.

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

 Set MAIN MENU
Remedial action:
* Eliminate the extraneous voltage, if present.
* Exchange the PLC.

TTS NMF GmbH
C 2210 LUFF. OUT LIMIT (SAFETY LIMIT-SWITCH)
Additional to the electronic limit protection there are 2 mechanical limit switches installed for collision
protection between hook and jib (anti-two-block).
One of these limit switches is actuated.

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

TTS NMF GmbH
C 2211 LUFF. OUT LIMIT (MECHANICAL SWITCH)
The maximum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be
carried out:

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

TTS NMF GmbH
C 2216 LUFF. IN LIMIT (MECHANICAL SWITCH)
The minimum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be
carried out:

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

TTS NMF GmbH
F 2219 LUFF. OUT FINAL SAFETY POSITION
The final (maximum) outreach of the crane is limited by the luffing gear rope length measurement system,
carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
ATTENTION: If this limitation is to be by-passed

RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°), the jib could be damaged, or
the wire could unreel completely from the drum.

 Set MAIN MENU
Remedial action
* Check the mechanism of the control leaver (automatic return into
open)
* Check the dead man switching contact.
* Check the wiring.
* Replace the cabinet module.

TTS NMF GmbH
F 2301 LUFFING COUNTER EQUALITY FAILURE

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

1. The reference position for the luffing gear is the maximum outreach position in the normal working
area and the jib must be luffed out to reach this position. In this position the limit switch contact will
open and the drive will stop. If the jib is already in the maximum outreach position or beyond the
maximum outreach limitation (by-passed with JIB-RESTING switch) then the jib must be luffed in
first. If it is not possible to reset the positioning system because the required spare part is not
available and the jib must be stored in the resting position then fault 2312 and also the origin fault
has to be bypassed by the emergency operation system.
2. The jib must be luffed in a little bit (until the limit switch contact is closing again).
3. The jib must be luffed out again until STOP signal is shown.
4. The jib must be luffed in again (the wire rope clamp must pass the proximity switch).
5. The jib must be luffed out again until STOP signal is shown; now the procedure is finished and the

TTS NMF GmbH
F 2302 LUFFING COUNTER OUT OF RANGE
GENERAL
This fault message is generated if the counter contents are not inside its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed.

 Set MAIN MENU


TTS NMF GmbH
Remedial action:


TTS NMF GmbH
F 2303 LUFFING COUNTER MONITORING
GENERAL
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).

 Set MAIN MENU


TTS NMF GmbH
Remedial action:


TTS NMF GmbH
F 2306 LUFFING ENCODER DEFECTIVE

F 2316 SYNCHRO PULSE OUT OF MONITORING RANGE
GENERAL
This fault message is generated when the synchronize pulse of the proximity switch is not right to the
counter value of the encoder.
 Set MAIN MENU

Remedial action:
 Check the encoder fastening inside the limit switch
 Check the limit switch drive
supply voltage of the encoder)
 Exchange the encoder
 Exchange the PLC

TTS NMF GmbH


TTS NMF GmbH
F 2307 PROXIMITY SWITCH =M06-B26 DEFECTIVE
GENERAL
This fault message is generated when the synchronize pulse of the proximity switch is not activated at each
revolution of the winch.
When this fault has been reset, <LUFING MUST RUN INTO REF. POSITION> will be displayed
 Set MAIN MENU

Remedial action:
 Check the proximity switch fastening and the distance (gab)
between proximity switch and wire rope clamp = 3-4 mm
supply voltage of the proximity switch)
 Exchange the proximity switch
 Exchange the PLCX

TTS NMF GmbH


TTS NMF GmbH
F 2308 LUFFING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the unwind direction although the
control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around.
system.
Remedial action:
* Check the complete drive system to ascertain that the winch moves
in accordance with the joystick deflection (direction and speed).
* interchange the outputs of the encoder
* Replace the encoder
* Replace the PLC
F 2309 LUFFING STANDSTILL DRUM MONITORING
If the drive is not activated (brake applied), the winch monitoring system will not signal any motion.
The actual output status can be displayed:

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


 Set MAIN MENU
Remedial action:

TTS NMF GmbH
F 2312 LUFFING MUST RUN INTO REF. POSITION
GENERAL
encoder.
COMPONENTS“)

Until the system has not been reset the drive speed is restricted and the crane load is limited to the SWL
value which the crane can lift at maximal outreach range.
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.

available and the jib must be stored in the resting position then fault 2312 and sometimes the origin
fault has to be bypassed by the emergency operation system.

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

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

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

 Set MAIN MENU
Remedial action:
neutral position).
* Re-adjust the potentiometer.
* Check the wiring.
* Additional information regarding EOS 3060:
This is a dangerous condition: if the potentiometer or the
analogue input now becomes defective the drive will start
stop only.

TTS NMF GmbH
F 3070 SLEWING CONTROL LEVER (SUPPLY)
lever deflection.

 Set MAIN MENU
Remedial action:
* Check the wiring and the supply connections of the potentiometer.
neutral position).
* Most of time it is a supply failure or the potentiometer itself is
defective.
* Additional information regarding EOS 3070.
the control lever contacts only. This will be activated by the EOS-
code.
In normal condition the contacts of the control lever are
control lever will be actuated. For control with the EOS 3070 -
code it is necessary to remove the bridge which is connecting the
contacts (the bridge on the supply side must remain), and now
the contact which will close in slewing left direction must be
connected to the terminal for the EOS-input (IX5.01).

TTS NMF GmbH
F 3080 SLEWING PWM-OUTPUT FAILURE =M07-A3

F 3081 SLEWING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid values of the pump is generated in the Compact Module by
Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is

 Set MAIN MENU
Remedial action:
* Check the wiring to the solenoid valve.
* Check the resistance of the solenoid coil. (approx. 24-30)
C 3211 RIGHT LIMIT (WORKING RANGE)
The maximum slewing range of the crane is limited by the slewing angle measurement system, carried out
by means of 2 proximity switches, mounted at the slewing rim; these proximity switches are counting the
teeth.
If this message appears although the slewing and luffing gear are in the "free" range, the measurement
Remedial action:
C 3214 RIGHT PRE-LIMITATION
Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
teeth.
Remedial action:

TTS NMF GmbH
C 3216 LEFT LIMIT (WORKING RANGE)
teeth.
Remedial action:
C 3217 LEFT PRE-LIMITATION
Before the final limit position is reached the drive speed will be ramped down by the slewing angle
measurement.
teeth.
Remedial action:
C 3218 SLEW. LIMIT (JIB RESTING MODE)
When the jib resting mode has been activated it is not possible to turn the crane tower in any direction
without actuation of the key-operated switch <JIB RESTING>.

 Set MAIN MENU
Remedial action
* Check the mechanism of the control leaver (automatic return into
open)
* Check the dead man switching contact.
* Check the wiring.
* Replace the cabinet module.

TTS NMF GmbH
F 3301 SLEWING COUNTER EQUALITY FAILURE

The teeth of the slewing rim are counted by 2 proximity switches (=M06-B810/B811) to ascertain the
position of the drive.
cut-out is tripped.
When this fault has been reset, <SLEWING MUST RUN INTO REF.-POSITION> will be displayed
system.
Remedial action:
* follow up the procedure, described under item
* The fault should have vanished when the plant is switched on again.
If it has not, or if the fault occurs often, the PLC must be replaced.
F 3302 SLEWING COUNTER OUT OF RANGE
The teeth of the slewing rim are counted by 2 proximity switches (=M06-B810/B811) to ascertain the
position of the drive.
Every time when the slewing drive is passing the reference/zero position (interlocking position for sea
voyage) the slewing position counter will be reset.
This fault message is generated if the counter content is not inside its limits.
When this fault has been reset, <SLEWING MUST RUN INTO REF. POSITION> will be displayed
system.

 Set MAIN MENUE
Remedial action:
* Check the proximity switches (=M06-B802/B803) of the interlocking
system, the output signal of both switches must be <FALSE>)
when the crane is in the interlocking position.
* 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.

TTS NMF GmbH
F 3306 PROXIMITY SWITCHES EXCHANGED
The sense of rotation and speed of the tower is monitored by proximity switches (pulsors). The pulses
generated are phase-shifted with respect to each other (see illustration below).
If this fault message appears (for instance after replacing the pulsors), the pulsors must be changed
around.
system.
Remedial action:
* interchange the proximity switches (pulsors)
* Replace the proximity switches (pulsors)
* Replace the PLC.

F 3307 SLEWING NO COUNTING PULSES
The outputs of the proximity switches (pulsors) are monitored while the tower is turning, the signal status at
the outputs must constantly change. This fault message is generated if the pulse train fails.
There are two possibilities for activation of this fault:
 The tower does not move although the drive command is given (- the brake is not released; - or the
gear of the slewing is broken and blocks the drive, - or the hydraulic pump is defective).
 The electrical proximity switches (pulsors) system fails
system.
Remedial action:
* Check the electrical power of the brake valve (the LED on the
valve connector plug should light up).
* Check the hydraulic control pressure for the brake at the respective
pressure measuring point.
* Check the hydraulic working pressure of the pump, if the drive is
set the pressure of the pump must increase up to 300 bar
* Press the emergency button on the solenoid valve of the pump
control unit, the pump must increase up to 300 bar
* Check the proximity switches (pulsors) power supply.
* Check the proximity switches (pulsors) installation at the slewing
ring
* Check the wiring
* Replace the proximity switches (pulsors)
* Replace the PLC


TTS NMF GmbH
F 3312 SLEWING MUST RUN INTO REF. POSITION

Remedial action:
C 4101 OVERLOAD
The crane is protected against overload by a load measuring system.

The lifted load is calculated as a function of the hydraulic pressure.
If this message appears, check whether the load being lifted exceeds the maximum allowed load (SWL) for
the outreach range currently in use.
The overload will be reset by the system when the load is lowered.

 Set MAIN MENU
Remedial action:
* Reduce the load or outreach.
* Check the hydraulic oil pressure in the hoisting gear circuits.
(Compare the value measured with a pressure gauge with the
displayed value given.)
* Replace the hoisting gear pressure sensor (=M07-B10).
* Check the wiring.
* Replace the PLC or the corresponding Compact Module.

TTS NMF GmbH
C 4102 OVERLOAD 110%
The crane is protected against overload by a load measuring system.

The lifted load is calculated as a function of the hydraulic pressure.
If this message appears, check whether the load being lifted exceeds the maximum allowed load (SWL) for
more than 10% depending on the outreach range currently in use.
The overload could also be displayed when the driver will lift up the load with too high speed (rough
operation by driver). The overload will be reset by the system when the load is lowered.

 Set MAIN MENU
Remedial action:
* Check the wiring.
C 4103 OVERLOAD HOOK LASHING
The pull of the hook is reduced to a level for lashing the hook if the maximum outreach is exceeded by the
jib resting mode.
This message indicates that this pull has been reached or exceeded. After the crane controls have been
switched on (main switch ON), the hook must first be lowered a little in order to reset the pull limiting
system.
Remedial action :
* Briefly operate the hoisting gear in the direction "lowering".
* Check the wiring.

TTS NMF GmbH
C 4203 OVERLOAD JIB RESTING
When the maximum outreach shall be exceeded by activation of the jib resting mode, the crane must not
have any load in the hook.
This message appears when the monitoring system has detected a load in the hook.

These failures are generated by the interlocking system (special equipment).

For explanation and trouble shooting see item: Interlocking for sea voyage.
C 4310 COLLISION ALARM - JIB IN REST POSITION
When the jib of the other crane is parked in the rest position and this jib shall be lowered below the
maximal outreach position (jib resting mode) than this alarm will occur to warn the crane driver that he must
drive carefully and pay attention for the parked jib of the other crane.
If this alarm occur although the jib of the other crane is not parked in the rest position than the control
device must be checked.

 Set MAIN MENU
Remedial action:
* Check the proximity switch on the rest position (supply voltage and
output signal
* Check the cable connection (especially the slip ring connection
* Check the PLC input status (must be TRUE)
* Exchange the PLC
C 4311 JIB IS MOVED FROM REST POSITION
The parked jib of the other crane is moving out of the rest position.
This alarm will occur to warn the crane driver that he must drive carefully and pay attention for the jib of the
other crane.

TTS NMF GmbH
F 5010 PRESSURE FAULT CARGO GEAR
The pressure of the cargo gear is monitored by switch =M07-S82G. A fault signal appears on the display if
the pressure drops below 20 bars.

 Set MAIN MENU
Remedial action:
* Measure the characteristics of the switch and replace as
necessary.
* Check the wiring.
* (Status must be <TRUE> when the main pump drive is running.)
F 5011 FAULT IN CARGO GEAR CONTROL
The cargo gear equipment (Load turning device/ container spreader) is protected against overload by
motor protection relay =M80-Q85 and circuit breakers =M80-F82..-F84.
This message appears when one of these devices has been tipped.

 Set MAIN MENU
Remedial action:
 Check the overload relay =M80-Q85 and circuit breaker
=M80-F82..-F84 (Status must be <TRUE>)
 Measure the motor amperage of the load turner motor.
 Measure the supply amperage to the spreader
 Exchange the PLC.

TTS NMF GmbH
F 5012 FAULT IN SPREADER CONTROL
The cargo gear equipment (Load turning device/ container spreader) is protected against overload by
motor protection relay =M80-Q85 and circuit breakers =M80-F82..-F84. Additionally the container spreader
provides a pilot signal which must be always “high” (24VDC) if the container spreader is connected to the
crane and the spreader operation mode is activated. This signal will be cut from the spreader control in
case of internal spreader faults.
This massage appears if the pilot signal from the spreader control dropped or one of the overload devices
has been tripped.
Remedial action:
 Check the overload relay =M80-Q85 and circuit breaker =M80-
F82..-F84 (Status must be <TRUE>)
 Measure the motor amperage of the load turner motor.
 Measure the supply amperage to the spreader
 Check pilot signal from spreader control =M80-K90 (Status must
be <TRUE>.
C 5013 TWL NOT LOCKED/ UNLOCKED
The spreader control provides the information for the TWISTLOCKS are locked (=M07-H09) or unlocked
(=M07-H10). If both signals are not given the hoisting gear blocks in lifting direction.
C 5020 HEELING ANGLE >5°

C 5021 HEELING ANGLE >8°
The heeling angle of the crane is monitored by an inclinometer inside the control cabinet.
The actual heeling value is displayed on the operation menu and when heeling exceeds 5° an additional
warning signal is given.
When heeling exceeds 8° the slewing gear, luffing out and lifting, is blocked.
Remedial action:
* Replace the inclinometer (=M07-A8).
* Check the wiring.
* Replace the PLC.
* Re-adjust the heeling level, see description under item
<ZERO-SET OF INCLINOMETER>

TTS NMF GmbH
C 5030 SPEED REDUCTION BY REVERSE POWER CTRL
The power management system of the crane is signalling a too high reverse power of the crane. Therefore
the speed for lowering the hook and luffing out the jib will be reduced to minimize the reverse power.
The reverse power signal will be set by the ship control system (ECR) and the power available signal relay
=M06-KEN (PMS START ENABLE) will trip.

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

TTS NMF GmbH
F 5124 GRAB OPERATION MUST BE ACTIVATED
The analysis from the working process results that the hoisting gear is equipped with a grab.
Therefore the GRAB OPERATION must be activated with the key-switch in the right hand control desk.
If the analysis result is wrong this fault can be eliminated by entering <NO GRAB> into the PLC.
Explanation sees under Item GRAB OPERATION.
C 5121 SPEED LIMITATION BY GRAB CONTROL

C 5122 SPEED LIMITATION BY GRAB CONTROL
The hoisting speed is reduced by the crane control to prevent hard shocks from the crane equipment
during pick up the grab from the ground or closing procedure of the grab.
C 5125 GRAB ON GROUND
When the GRAB OPERATION is activated the hoisting gear pressure will be monitored and the lowering of
the grab is switched off by dropping down of the pressure when the grab is put on the ground.
After the control leaver has been set back to neutral it is possible to lower the grab again.
If this message appears when the grab is hanging free (not put on the ground) this feature can be
bypassed with the emergency operation system or easier by pressing the <F2> key when C5125 is shown
on the display.
C 5310 WORKING RANGE-LIMITATION
The working area of the crane is limited to prevent a collision.

This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit
position is reached the drive speed will be ramped down (pre-limitation).
system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted.
Remedial action:
C 5311 WORKING RANGE-PRE-LIMITATION
The working area of the crane is limited to prevent a collision.

This is carried out by monitoring the outreach and the slewing angle of the crane. Before the final limit
position is reached the drive speed will be ramped down.
system of the luffing gear and / or the slewing gear angle measurement must be re-adjusted.
Remedial action:

TTS NMF GmbH
F 810 Compact Module DIGITAL not initiated
The compact module =M07-A2 is defective and must be renewed.

If this message appears at first check the CAN-BUS system, described under item
Programmable Logic Controller.
F 820 Compact Module PWM not initiated

F 830 Compact Module ANALOG not initiated

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

F 0850 Compact Module PWM_2 not initiated

F 0880 Inclinometer not initiated

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


TTS NMF GmbH
F 0887 SHIPS SERIAL NUMBER NOT VALID
If a new PLC is installed or the system is generally reset to DEFAULT data the corresponding ship number
must be entered into the system. This message appears when no ship number of a wrong ship number has
been entered into the system
Procedure:
 Set MAIN MENU
 Select SECURITY CODE must be set and entered
 Select SET SHIP NUMBER (corresponding crane number must be entered)
F 0888 FAILURE OF CRANE IDENTIFICATION
If a new PLC is installed or the system is generally reset to DEFAULT data the corresponding crane
number must be entered into the system.
Procedure:
 Set MAIN MENU
 Select SECURITY CODE must be set and entered
 Select SET CRANE NUMBER (corresponding crane number must be entered)

TTS NMF GmbH
5.10 EMERGENCY OPERATION SYSTEM

should be allowed to override messages in the emergency operating mode and must take the
This member of the crew is responsible for explaining the changed situation to the crane operator.
The identification and elimination of malfunctions are greatly simplified by the circuit diagrams, unit’s
specifications and manufacturer's documentation, the list of fault status messages and the explanation of
the reason for the failures with recommended trouble shooting hints are described under item TROUBLE
SHOOTING.
If a fault can not be remedied immediately, for instance because the appropriate spare part is not available,
it should be remembered that the causes of many faults can be remedied temporarily by means of an
emergency operating system.
ATTENTION!
Before overriding a fault message by means of the emergency operating system, always check that the
corresponding monitored criterion, which is intended to protect the machinery against overload and
damage, is faulty and that the plant itself has not failed.
The emergency control system only overrides the fault message. It does not eliminate the cause!
The cause of the fault must be identified and eliminated as quickly as possible in order to avoid danger.
The crane is never to be operated by the emergency operating system for normal crane operations.
Drive slowly and very carefully with the crane.
Notice that depending on the activated emergency code parts of the control system are by-passed;
this could cause damages on the crane or accidents.
To de-activate the emergency operation system and set back the control into normal condition the
control power must be switched off completely (main switch).
Example 1:
Status message
C 2211 LUFF. OUT LIMIT (MECHANICAL SWITCH)
blocks the luffing gear in the direction for luffing out. The message is caused by a faulty switch contact in
the luffing gear limit switch.
The maximum outreach is limited by the mechanical switch and additionally by the rope length
measurement system.
No replacement contact is available, and the status message is therefore overridden by means of the
emergency operating system until a replacement has been obtained.
Under these conditions, the luffing range is now restricted to the maximum permissible outreach by the
rope length measurement system only so that there is a higher risk of exceeding the maximum outreach
and overload.
Example 2:
Fault message
F 1031 HOISTING SENSOR OUTPUT <4mA
blocks the hoisting gear. The message is caused by a fault in the pressure sensor and is overridden by the
emergency operating system until a replacement sensor is available.
This means that the hoisting gear is being used without the hydraulic pressure being checked
automatically. In other words, the hydraulic oil is under no pressure when a lifting operation is initiated.
Overload protection and tension limiters will not work and must be by-passed, if necessary. The use of the
TRIMOT is blocked. Prolonged operation without pressure checking will lead to damage in the drive
systems.

TTS NMF GmbH
Example 3:
Fault message
F 2010 LUFFING PRESSURE <7bar
blocks the complete crane operation. The message is caused by a faulty pressure switch contact in the
luffing gear hydraulic circuit.
No replacement pressure switch is available, and the fault message is therefore overridden by means of
the emergency operating system until a replacement has been obtained.
Normally if a hose bursts, the pressure will drop down and the corresponding pressure switch will shut
down immediately all drives and the brakes will engage.
Under emergency operation condition, the luffing circuit is no longer controlled against hose bursting.
The jib could fall down with the risk of damage and loss of life of personnel.
How to activate the Emergency Operation System (key code) see the description under
Overriding fault messages by means of the emergency operating system:
 Set MAIN MENU

 Select SET EMERGENCY OPERATION SYSTEM
Now the Emergency Operation System CODE can be selected and entered, the EOS
CODE corresponds always to the fault or condition message number,
E.g.: F2010 LUFFING PRESSURE <7bar will be overridden by the EOS CODE 2010.
E.g.: F1301 HOISTING SENSOR OUTPUT <4mA will be overridden by the EOS CODE
1301.
How to activate the Emergency Operation System (key code) see the description under

TTS NMF GmbH
5.11 SERVICE
5.11.1 MAINTENANCE INFORMATION FOR HYDRAULICAL
The PLC monitors the crane equipment and will report a recommended maintenance instruction on the
display. If maintenance works are necessary this information is displayed after switching on the crane
control and can be reset by pressing the QUIT – button (F2).
If the maintenance work has been carried out, the maintenance instruction can be reset durable:
 Set MAIN MENU
 Select MAINTENANCE
 Select ACKNOWLEDGE
M 901 MAINTENANCE CHECK HYDRAULIC OIL
Every 500 operational hours the hydraulic oil should be checked by taking of an oil sample.
A certain evidencing diagnostics of an oil sample depends decisively on the method of sample taking.
The taking of the sample always has to be made in the same manner. In principle, the oil should be at least
hand warm when taking it. If possible the oil to be analysed has to be taken from about the middle of the oil
level.
from the oil drain line. About 1-2L oil has to be drained into a container and an oil sample has to be taken
The access to a good oil level at the slewing gears is also difficult. Here too we recommend having a part
of the oil drained by removing the accessible oil draining screw and taking an oil sample from the draining
oil.
M 911 MAINTENANCE CHECK MAIN HOISTING GEAR

M 912 MAINTENANCE CHECK AUX. HOISTING GEAR
M 921 MAINTENANCE CHECK LUFFING GEAR
M 931 MAINTENANCE CHECK SLEWING GEAR
The control system checks that the corresponding drive speed is below 80% of the nominal rated speed.
This points to a higher oil leakage in the drive circuit, caused by wear of the pump and/or motor.
For further information, see the hydraulic manuals.

TTS NMF GmbH
5.11.2 MAINTENANCE OF ELECTRICAL EQUIPMENT

Safety regulations
All maintenance and repair work is to be carried out exclusively by trained electricians and only
after the whole plant is dead. Care must be taken that current labour safety regulations are
observed. In addition, all rules and regulations issued by local authorities concerning cranes and
accident prevention and works' regulations are to be followed.
Special care must be taken to ensure that the feeders for auxiliary equipment and deck illumination
are switched off (separate feeders).
If the crane has not been used for a considerable time, depending on conditions at the place of use, the
wiring, motors and switch gear for the low voltage installations are to be checked for satisfactory insulation,
cleaned and, if necessary, dried (condensation).
The whole equipment is always to be kept clean.
The electrical equipment belonging to the plant should be inspected at regular intervals. Defects such as
loose terminals or singed cables should be rectified immediately.
Use only fuses from the same manufacturer as the original fuses, and make sure that their ratings are as
specified. Switch the plant off immediately if faults develop in the power supply system.
After completion of maintenance work, all covers that have been removed must be replaced and the
electrical units closed as specified in the corresponding regulations. The feeders, especially those serving
the heating circuits, must be switched on again to prevent condensation when maintenance work has been
completed.
Tightness of all terminals

4 weeks after commissioning of the crane the terminals of the power circuits, especially main switch, main
contactors, main motor and slip ring assembly must be checked for tight seating and fastened if necessary.
Motors
All motors are fitted with anti-friction bearings. These must be re-greased as specified by the corresponding
manufacturers.
The lubricating properties of grease and oil deteriorate during long periods of inactivity. This can lead to
rusting in the bearings. The motor should therefore be started for a short period every one or two months.
Slip ring assembly

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

TTS NMF GmbH
Safety devices
All monitoring equipment such as limit switches, overload protection devices, pressure switches, etc.,
should be checked regularly to ensure that they are in perfect working order.
All monitoring equipment, and especially safety switches and their actuating mechanisms, must be checked
for tight seating whenever they are inspected.
The modification of safety equipment and the installation of other units is permissible only after consultation
and after approval has been given by TTS-LMG.
All safety equipment must be tested once again after repairs and after the crane has not been used for a
considerable time.
For safety reasons the operational hours should be noted every 2-3 month.
If the PLC system becomes defective and must be renewed the stored operation hours value is lost
and must be manually entered into the new PLC.
Annual checks of the entire electrical equipment

Attention is to be paid to the following items:
* Fastening of the units, especially of monitoring equipment, limit
switches, etc.
* Conformity to the specified enclosure requirements
* Tightness of all terminals
* Integrity of protective conductor connections
* Replacement of all damaged or worn units and parts (e.g.
contacts)
* Firm seating of fuses
* Cleaning of all parts of the plant

TTS NMF GmbH
5.11.3 SPARE PARTS

The spare parts documentation of the electrical equipment is located in a separate folder.
This folder is categorised corresponding to the assembly groups.
Additionally in the electrical circuit diagram you can find the part number of the device directly below
the electrical identification (mark of the unit).
Example:
The part number of the main switch -S1 is 2502406

The 3-pole fuse –F1 is divided into 2 part numbers: 1608376 for fuse switch-breaker
1608405 for fuse cartridge

TTS NMF GmbH
5.12 APPENDIX
5.12.1 DESCRIPTION OF THE ELECTRICAL COMPONENTS

5.12.1.1 MAIN SWITCH (LOAD BREAKER)

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.2 GEARED LIMIT SWITCHES - SERIES 51

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

TTS NMF GmbH
5.12.1.2.1 ASSEMBLY OF THE GEARED LIMIT SWITCH

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

TTS NMF GmbH
5.12.1.2.2 CONTACT ADJUSTMENT (SEE FIG. 3)

For contact adjustment, remove the cap of the limit switch.
Thereby the live contact connections are laid bare.
Danger!
Do not touch live parts!
An infinitely adjustable cam disc is provided for each contact. Independent of each other, the cam discs (1)
can be set with the adjusting worm (2). It 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.

TTS NMF GmbH
5.12.1.2.3 BLOCK ADJUSTMENT (SEE FIG. 4)
Functioning
The planetary gear construction allows a block adjustment in addition to the individual contact adjustment
from the usable revolution 17.5. The final gear stage is also provided with an adjusting worm, coloured
black. All cam discs (1) can be commonly adjusted by means of this adjusting worm (2). The relative
adjustments of the individual contacts to each other are not modified.
When turning the black worm clockwise through one revolution (360°), the cam discs are also turned
clockwise by 0.575° (view of the rear part, the B-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.

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

TTS NMF GmbH
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.

TTS NMF GmbH
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 and 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

TTS NMF GmbH
CLASSICCONTROLLER
Mounting
In order to expose the controller to the minimum mechanical stress it should preferably be mounted
horizontally or vertically on the mounting panel. The module must be fixed with four screws to DIN 7500 or
DIN 7984 (M5 x L).
If possible, the controller should be mounted in such a way that the cable entry of the plug points
downwards.
As the self-heating of the electronics of the unit is dissipated via the housing, sufficient cooling must be
ensured in case of "sandwich-mounting" of controllers.
Electrical connection
To guarantee the electrical interference protection of the controller, the housing must be
connected to GND (e.g. to the ground of the vehicle). To protect the whole system (wiring and
controller) the individual electric circuits must be protected.
Designation Potential Pin no. Fuse

supply voltage sensors/module VBB S 23 max. 1 A
supply voltage outputs VBB O 05 max. 15 A
supply voltage via relays VBB R 34 max. 15 A
Interaction between the inputs and outputs within one group of connections
In the application, the following must be observed as regards the use of the terminals as input and output:
Within one output group inputs and outputs should not be mixed. One output group is marked by a
common VBBX potential.
The background is a possible internal cross-connection of the outputs from the externally supplied inputs.
This may occur unexpectedly if the supply to the outputs is switched off externally.
Should a mixture still be carried out for reasons of optimising the terminals, please read in detail about the
situation described in the system manual and the restrictions resulting from this. Follow these instructions
for your application and keep records of this.
Maintenance, repair and disposal

As the Controller does not contain any components which must be maintained by the user, the housing
must not be opened. The repair of the controller may only be carried out by the manufacturer. The disposal
must be carried out according to the corresponding national environmental regulations.
Declaration of conformity
The CE-marking is applied on the basis of the EMC guideline EMC 89/336/EEC implemented in the
standards EN 61000-6-4 (2001) and EN 61000-6-2 (2001) as well as the low voltage guideline
NS73/23/EEC implemented in the standard EN 61010-1 (2001). ENGLISH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.4 COMPACT MODULE PWM

DEUTSCH E
COMPACTMODUL METAL CR2031

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

TTS NMF GmbH
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.

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.5 COMPACT MODULE DIGITAL / ANALOGE
COMPACTMODULE METAL CR2033

TTS NMF GmbH
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.

TTS NMF GmbH
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, ratio metric, binary and binary with diagnosis)
- Binary inputs
- Binary outputs
- PWM outputs up to 4 A
can be configured.
The CAN identifier of the synch object can be configured.
 The module supports "node guarding" and "heartbeat".
The "guard time", the "life time factor" and the "heartbeat time" can be configured.
 The module generates an emergency object. The COB ID of the EMCY object
can be configured.
 The module stores the last error.
 The module supports a reset function, i.e. assignment of the parameters to the factory default values*
upon request.
The CR2033 I/O module is not approved for safety-relevant tasks in the field
of personal safety.

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.6 CABINET-MODULE

DEUTSCH ENGLISH

TTS NMF GmbH
INPUT/OUTPUT MODULE CR2012
Safety instructions

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

people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
In the case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the device can lead to considerable risks for the safety of
people and plant. It is not permitted and leads to an exclusion of any liability
and warranty claims.

TTS NMF GmbH
INPUT/OUTPUT MODULE CR2012
The CR2012 input/output module is used for connection of controls and indicators in driver's cabs, control
panels or control boxes to CAN bus.
 The module supports binary/analogue inputs and binary outputs and is therefore classified in the
device profile "I/O module" to CiA DS 401.
 As regards the input/output functions the module can be configured.
 The input/output module supports the following I/O configurations:
8 binary inputs
+ 4 binary/analogue inputs
+ 4 binary inputs/outputs
can be configured. The transmission type is non-volatile stored. Changed PDOs (PDO linking) are
volatile stored.
The CAN identifier of the synch object can be configured. After a change the ID is automatically non-
volatile stored.
 The module supports "node guarding".
The "guard time", "life time factor" and the CAN identifier of the guard object can be configured and are
non-volatile stored.
 The module generates an emergency object.
The COB ID of the EMCY object can be configured.
 The module stores the last 4 errors.
 The module supports a reset function, i.e. assignment of the parameters to the factory default values*
upon request.
ENGLISH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.7 INCLINOMETER ( SPECIAL EQUIPMENT )

TTS NMF GmbH
Safety instructions

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

people and plant.
The device may only be installed, connected and commissioned by qualified
personnel.
In the case of malfunctions or uncertainties please contact the manufacturer.
Tampering with the device can lead to considerable risks for the safety of
people and plant. It is not permitted and leads to an exclusion of any liability
and warranty claims.

TTS NMF GmbH
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 conduct metric 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 volatility.
 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*.

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
5.12.1.8 LCD-DISPLAY

TTS NMF GmbH

TTS NMF GmbH

TTS NMF GmbH
LCD Display 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.

TTS NMF GmbH
5.12.2 CIRCUIT DIAGRAMS

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

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

CLASSIFICATION SOCIETY : GL
KL 45t - 29m YEAR OF CONSTRUCTION : 2013
PLC SYSTEM : ifm R 360
MAIN POWER SUPPLY : 440V

CRANE-No.:83156-59
Schutzvermerk nach DIN 34 beachten
AUX. POWER SUPPLY : 220V AC
FREQUENCY : 60Hz
MANUFACTURER
____________ :
RATED CURRENTS : 285A, 30A
TTS NMF GmbH
CONTROL VOLTAGES : 440V , 24V DC
Neuenfelder F„hrdeich 120
D- 21229 Hamburg
PROJECT ENGINEER : Mr. Grimm

DEPARTMENT : ELEC.-DESIGN
REV. 01 / 02.10.2013 / ASC
TELEPHONE : 040 / 554361-854 REV. 02 / 08.11.2013 / ASC

TELEFAX :
=GEN/1
Bau-Nr./ Baugr./ Datum/date Name/name Bl.

Com-No ass.-gr.
Ch.
SINGLE DECK CRANE Sach-Nr. 5022372 Sh.
1
geprft/checked 08.Nov.2013
COVER PAGE Typ Bl.
83156 25.97 50 letzte nd./last mod. 08.Nov.2013 TGR
TTS Marine GmbH 1 Sh.
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = COV

0 1 2 3 4 5 6 7 8 9
Seite / Seitenbenennung / letzte Bearbeitung/ Bemerkungen /

PAGE PAGE NAME LAST CHANGE REMARKS
Datum / Name
DATE / NAME
=COV/1 COVER PAGE 08.Nov.2013 TGR
=GEN/1 TABLE OF CONTENTS 08.Nov.2013 TGR
=GEN/5 GENERAL MARKINGS 22.Apr.2013 Alpers

=GEN/6 MARKS OF THE TERMINAL BLOCKS 08.Nov.2013 Alpers
=GEN/7 CONTROL CABINET 1800x600x300 DESIGN VIEW 17.Apr.2013 TGR
=GEN/8 CONTROL CABINET 1800x600x300 DESIGN VIEW 09.Apr.2013 ALP
=GEN/9 CONTROL DESK LEFT VIEW 25.Apr.2013 Alpers
=GEN/10 CONTROL DESK RIGHT VIEW 29.Mai.2013 Alpers
=GEN/11 CABINET CARGO GEAR VIEW 21.Mai.2013 TGR
=GEN/12 OVERVIEW PLC INPUTS/OUTPUTS 02.Okt.2013 ASC
=GEN/14 OVERVIEW PLC INPUTS/OUTPUTS 24.Apr.2013 ASC

=GEN/15 OVERVIEW PLC INPUTS/OUTPUTS 24.Apr.2013 ASC
=SRK/1 SLIP RING CONNECTION 08.Nov.2013 TGR
=SL/1 SINGLE LINE DIAGRAM MAIN POWER SUPPLY 21.Mai.2013 TGR
=SL/2 SINGLE LINE DIAGRAM LIGHT AND HEATER 22.Apr.2013 TGR
=SL/3 PLC OVERVIEW 27.M„r.2013 TGR
=SL/4 PLC OVERVIEW 22.M„r.2013 TGR
=SL/5 PLC OVERVIEW 09.Apr.2013 TGR
=M01/1 POWER SUPPLY CIRCUIT DIAGRAM 08.Nov.2013 TGR

=COV/1 2

Com-No ass.-gr.
Ch.
1
TABLE OF CONTENTS Typ Bl.
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = GEN

0 1 2 3 4 5 6 7 8 9

Datum / Name
DATE / NAME
=M01/2 CONTROL VOLTAGE SUPPLY CIRCUIT DIAGRAM 28.Mai.2013 TGR
=M01/3 24 V DC CONTROL VOLTAGE SUPPLY 28.Mai.2013 TGR
=M02/1 MAIN MOTOR CIRCUIT DIAGRAM 28.Mai.2013 TGR
=M02/2 AUXILIARY DRIVES CIRCUIT DIAGRAM 28.Mai.2013 TGR
=M02/3 STAR/DELTA CONTROL MAINMOTOR CIRCIUT DIAGRAM 28.Mai.2013 TGR
=M03/1 LIGHT CIRCUIT DIAGRAM 08.Nov.2013 TGR

=M03/2 LIGHT CIRCUIT DIAGRAM 08.Nov.2013 TGR
=M03/3 HEATERS CIRCUIT DIAGRAM 08.Nov.2013 TGR
=M03/4 HEATERS CIRCUIT DIAGRAM 08.Nov.2013 TGR
=M05/1 AUXILIARY 24V-DC CONSUMERS CIRCUIT DIAGRAM 08.Mai.2013 TGR
=M06/1 PLC SUPPLY 24V DC CIRCUIT DIAGRAM 02.Okt.2013 Alpers
=M06/2 PLC INPUTS CIRCUIT DIAGRAM 02.Okt.2013 Alpers
=M06/5 PLC INPUTS CIRCUIT DIAGRAM 02.Okt.2013 ALP

=M06/6 PLC OUTPUTS CIRCUIT DIAGRAM 02.Okt.2013 TGR
=M07/1 COMPACT MODULE PWM-OUTPUTS CIRCUIT DIAGRAM 10.Apr.2013 ALP
=M07/2 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 04.Apr.2013 ALP
=M07/3 COMPACT MODULE IN-/OUTPUTS CIRCUIT DIAGRAM 02.Okt.2013 TGR
=M07/4 CABIN MODULE INPUTS CIRCUIT DIAGRAM 02.Okt.2013 Alpers
=M07/5 CABIN MODULE INPUTS CIRCUIT DIAGRAM 02.Okt.2013 Alpers
=M07/6 CABIN MODULE INPUTS / OUTPUTS CIRCUIT DIAGRAM 02.Okt.2013 TGR
=M07/7 DISPLAY CONNECTION DIAGRAM 28.Mai.2013 TGR
=M07/8 CABIN MODULE INPUTS CIRCUIT DIAGRAM 02.Okt.2013 TGR
=M07/9 CABIN MODULE INPUTS CIRCUIT DIAGRAM 02.Okt.2013 TGR

1 3

Com-No ass.-gr.
Ch.
2

0 1 2 3 4 5 6 7 8 9

Datum / Name
DATE / NAME
=M07/10 CABIN MODULE OUTPUTS CIRCUIT DIAGRAM 02.Okt.2013 Alpers
=M80/1 ADD. EQUIPMENT CIRCUIT DIAGRAM 21.Mai.2013 TGR
=M80/5 ADD. EQUIPMENT CIRCUIT DIAGRAM 02.Okt.2013 TGR

=M80/8 ADD. EQUIPMENT CIRCUIT DIAGRAM 02.Okt.2013 TGR
=PE/1 PE CIRCUIT DIAGRAM 21.Mai.2013 TGR
=TERMINALS/1 -XSR SLIP RING ASSEMBLY 21.Mai.2013 TGR
=TERMINALS/2 TERMINAL BLOCK -X3 220V CONTROL CABINET 08.Nov.2013 ALP
=TERMINALS/2.1 TERMINAL BLOCK -X3 220V CONTROL CABINET 08.Nov.2013 ALP
=TERMINALS/2.2 TERMINAL BLOCK -X3 220V CONTROL CABINET 08.Nov.2013 ALP
=TERMINALS/3 TERMINAL BLOCK -X4 380/440V CONTROL CABINET 21.Mai.2013 TGR

=TERMINALS/4 TERMINAL BLOCK -X5 24V CONTROL CABINET 28.Mai.2013 TGR
=TERMINALS/4.1 TERMINAL BLOCK -X5 24V CONTROL CABINET 28.Mai.2013 TGR
=TERMINALS/5 TERMINAL BLOCK -X11 TERMINAL BOX OIL COOLER 21.Mai.2013 TGR
=TERMINALS/6 TERMINAL BLOCK -X12 TERMINAL BOX JIB-BEARING 21.Mai.2013 TGR
=TERMINALS/7 TERMINAL BLOCK -X13 TERMINAL BOX JIB TOP 21.Mai.2013 TGR
=TERMINALS/8 TERMINAL BOX -X51 24V SYNC. PULSE PROXIS 21.Mai.2013 TGR
=TERMINALS/9 TERMINAL BLOCK -X60 CONTROL DESK LEFT CABIN 21.Mai.2013 TGR
=TERMINALS/10 TERMINAL BLOCK -X62 CONTROL DESK LEFT CABIN 02.Okt.2013 ALP
=TERMINALS/10.1 TERMINAL BLOCK -X62 CONTROL DESK LEFT CABIN 02.Okt.2013 ALP
=TERMINALS/11 TERMINAL BLOCK -X70 CONTROL DESK RIGHT CABIN 21.Mai.2013 TGR
2 4

Com-No ass.-gr.
Ch.
3

0 1 2 3 4 5 6 7 8 9

Datum / Name
DATE / NAME
=TERMINALS/12 TERMINAL BLOCK -X72 CONTROL DESK RIGHT CABIN 02.Okt.2013 ALP
=TERMINALS/12.1 TERMINAL BLOCK -X72 CONTROL DESK RIGHT CABIN 02.Okt.2013 ALP
=TERMINALS/13 PLUG CONNECTOR -X75 380/440V CONTROL DESK RIGHT 21.Mai.2013 TGR
=TERMINALS/14 TERMINAL BLOCK -X82 440/220V SUPPLY CARGO GEAR 21.Mai.2013 TGR
=TERMINALS/15 TERMINAL BLOCK -X81 SLEWING GEAR 21.Mai.2013 TGR
=TERMINALS/16 TERMINAL BLOCK -X100 CARGO GEAR/ CABLE REEL 21.Mai.2013 TGR
=TERMINALS/16.1 TERMINAL BLOCK -X100 CARGO GEAR/ CABLE REEL 21.Mai.2013 TGR
=TERMINALS/17 PLUG CONNECTOR -XM50 WINDSCREEN WIPER 21.Mai.2013 TGR
=TERMINALS/18 -XA1 24V PLC CABINET 21.Mai.2013 TGR
=TERMINALS/18.1 -XA1 24V PLC CABINET 21.Mai.2013 TGR
=TERMINALS/19 -X1A5 24V CAN NODE CABIN 21.Mai.2013 TGR

=TERMINALS/25 -XSRK1 SCABLE REEL 21.Mai.2013 TGR
=TERMINALS/25.1 -XSRK1 SCABLE REEL 21.Mai.2013 TGR
=TERMINALS/26 PLUG CONNECTOR -XS82 TURNING DEVICE SPREADER 21.Mai.2013 TGR
=TERMINALS/26.1 PLUG CONNECTOR -XS82 TURNING DEVICE SPREADER 21.Mai.2013 TGR
=TERMINALS/27 TERMINAL STRIP -XS12 CONTROL LEVER HG 02.Okt.2013 ALP
=TERMINALS/28 TERMINAL STRIP -XS22 CONTROL LEVER LG/SG 02.Okt.2013 ALP
=CABLES/1 CABLE OVERVIEW 08.Nov.2013 ALP
=CABLES/1.1 CABLE OVERVIEW 08.Nov.2013 ALP
3 5

Com-No ass.-gr.
Ch.
4

0 1 2 3 4 5 6 7 8 9
MARKS OF THE LOCATION MARKS OF THE UNIT MARKS OF THE EQUIPMENT PART
+A1 OUTSIDE EQUIPMENT GENERAL -A SYSTEM GROUPS 01 POWER SUPPLY
+A1.J JIB -B TRANSFORMERS ELECTRIC <-> NOT-ELECTRIC 02 3~AC MOTOR DRIVES
+A1.S COLUMN (SLIP RING ASSEMBLY) -C CAPACITORS 03 LIGHT AND HEATER
+A1.W WINCH PLATFORM -D STORAGE DEVICES
-E LIGHT/HEATERS 05 24V-AUXILIARY CONSUMERS
+F1 CABIN -F PROTECTION DEVICES 06 PLC - IN-/OUTPUTS
+F1.PR CONTROL DESK RIGHT CABIN -G GENERATORS, POWER SUPPLIES 07 PLC - CAN-KNOTS
+F1.PL CONTROL DESK LEFT CABIN -H SIGNALING DEVICES 08 PE

-K RELAYS/CONTACTORS
+P1 POWER MODULE
-L INDUCTORS
+P1.P PUMP UNIT
-M MOTORS
+P1.V VALVE BOARD
-N AMPLIFIERS/REGULATORS
+P1.H CONTROL CABINET
-P MEASURING/TESTING EQUIPMENT
+P1.M CONTROL CABINET MC
-Q MECHANICAL SWITCHING DEVICES FOR POWER CIRCUITS
+P1.C CONTROL CABINET PLC
-R RESISTORS
-S SWITCHES/SELECTORS
+T1.O CRANE TOWER TOP

-T TRANSFORMERS
+T1.U CRANE TOWER BELOW
-U MODULATORS/TRANSFORMERS
+T1.W WINCH MODULE
-V TUBES/SEMICONDUCTORS
+T0.H CABINET (CARGO GEAR)
-W TRANSMISSION PATHS/WAVEGUIDES/AERIALS
-X TERMINALS/PLUGS/SOCKETS
-Y ELECTRIC OPERATED MECHANICAL DEVICES
ADDITIONAL TO THE MARKS OF UNIT
IS A NUMBERCODING AS CROSS REFERENCE
TO IDENTIFICATION THE UNIT IN THE SPARE PART LIST
4 6

Com-No ass.-gr.
Ch.
5
GENERAL MARKINGS Typ Bl.
83156 25.97 50 letzte nd./last mod. 22.Apr.2013 Alpers

0 1 2 3 4 5 6 7 8 9
PLUG CONNECTORS TERMINAL BLOCKS CONDUCTOR COLOURS /

CROSS-SECTIONAL AREAS
-X65 220V HEATING CONTROL DESK LEFT -X1 TERMINAL BOX COLUMN (OPTIONAL)
-X66 220V LIGHTING CONTROL DESK LEFT -X2 SUPPLY TERMINALS CONTROL CABINET
BASED ON SHIPOWNERS SPECIFICATIONS
-X67 24V CONTROL DESK LEFT -X3 220V CONTROL CABINET
THE FOLLOWING COLOURS AND
-X3.1 TERMINAL BOX DECK LIGHTS
CROSS-SECTIONS ARE VALID,
-X75 380/440V CONTROL DESK RIGHT -X4 380/440V CONTROL CABINET
IF NO FURTHER INSTRUCTIONS ARE MADE:
-X5 24V CONTROL CABINET
-X76 220V HEATING CONTROL DESK RIGHT
-X51 24V SYNC. PULSE PROXIS
-X77 220V LIGHTING CONTROL DESK RIGHT
-X60 220V CONTROL DESK LEFT CABIN MAIN CIRCUITS AWG-16 BK
-X78 24V CONTROL DESK RIGHT

-X61 220V CONTROL DESK LEFT CABIN - AC CONTROL CIRCUITS AWG-16 RD
-XS82 LOAD TURNING DEVICE -X62 24V CONTROL DESK LEFT CABIN - DC CONTROL CIRCUITS AWG-20 BU
SPREADER (OPTIONAL)
-X70 220V CONTROL DESK RIGHT CABIN - PLC CIRCUITS 24VDC AWG-20 WH
-XM11 440V FEED OIL PUMP
-X72 24V CONTROL DESK RIGHT CABIN
-XM50 24V WINDSCREEN WIPER
-X75 380/440V CONTROL DESK RIGHT # = SHORT CIRCLE PROOF
-X11 TERMINAL BOX OIL COOLER
-X12 TERMINAL BOX JIB-BEARING - NOTE TO THE CONDUCTOR COLOURS:

-X12.1 TERMINAL BOX JIB-MIDDLE SHORTENING DELAYED TO DIN IEC 60757
-X13 TERMINAL BOX JIB TOP
-XA1 24V PLC-CABINET BK = BLACK

-X39 TERMINAL BOX DECK LIGHTING BU = BLUE
-XA2 24V CAN NODE I/O -X41 TERMINAL BOX DECK LIGHTING BN = BROWN
-XA2C CAN BUS OR = ORANGE
-X80 440/220V SUPPLY CARGO GEAR RD = RED
-XA3 24V CAN NODE PWM WH = WHITE
-XA3C CAN BUS -X81 -X81 TERMINAL BOX PROX. SWITCHES GN = GREEN
SLEWING GEAR YE = YELLOW
-XA4 24V CAN NODE IDA
-XA4C CAN BUS -X82 24V CONTROL CARGO GEAR
-X83 CABLE REEL (OPTIONAL) PE = GNYE (PROTECTIVE EARTH)
-X1A5 24V CAN NODE CABIN -X100 CARGO GEAR
-X2A5 24V CAN NODE CABIN -XS16 TERMINAL BLOCK LIMIT SH / SC = SHIELD / SCREEN
-X3A5 24V CAN NODE CABIN SWITCH HOISTING GEAR
-XA6 24V CAN DISPLAY -XS26 TERMINAL BLOCK LIMIT

SWITCH LUFFING GEAR
-XA8 24V CAN INCLINOMETER
-XSR SLIP RING ASSEMBLY
-X1A9 24V CAN NODE CABIN -XSRK1 SLIP RING ASSEMBLY CABLE REEL
-X2A9 24V CAN NODE CABIN -XM1 MOTOR TERMINALS
-X3A9 24V CAN NODE CABIN
-XA2T 24V CAN NODE I/O
5 -XA3T 24V CAN NODE PWM 7

Com-No ass.-gr.
Ch.
6
MARKS OF THE TERMINAL BLOCKS Typ Bl.
83156 25.97 50 letzte nd./last mod. 08.Nov.2013 Alpers

0 1 2 3 4 5 6 7 8 9
-T1
=M02
-S35
=M03
POWER UNIT
=M02-K3
CONTACTOR
DELTA
=MO1-U1
-F30-F34
=M03
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75
CABLE TUNNEL 35x75

CABLE TUNNEL 50x75
-Q1
=M01 =M01 =M02 =M02
=M01-S1
MAIN SWITCH
-F1
=M01
X5
-Q2
=M02-F4
=M02-K2
CONTACTOR
STAR
-Q11 -Q12
=M02-K4
1-2
-K11 -K12
=M02 =M02
CABLE TUNNEL 50x75
CLAMPS
SHIELD
-XSAPI
-F2
=M01
X4
X3
=M01
-F11-F17
CABLE TUNNEL 75x75

2- =M06-KEN (OPTIONAL)
1- =M06-KRQ (OTIONAL)
NEAR THE FUSE E. G. ON CABLE TUNNEL.

AND SIZE OF THE FUSE MUST BE LOCATED
-F11 -- -F17 WITH FUSE NO., TYPE
NOTE: ADDITIONAL LABEL FOR FUSES
DATA FOR TYPE LABEL
1: KL 45t-29m
2: 2013
3: 440VAC
4: 220VAC
5: 24VDC
6: 83156 ... 83159
7: GL
8: 60Hz
9: 210KVA
10: 285A
11: 5022372
6 8

Com-No ass.-gr.
Ch.
7
CONTROL CABINET 1800x600x300 Typ Bl.
83156 25.97 50 letzte nd./last mod. 17.Apr.2013 TGR
DESIGN VIEW
0 1 2 3 4 5 6 7 8 9
CONTROL CABINET CONTROL CABINET

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

MAIN SUPPLY ON
AUX. SUPPLY ON
PLC - R360
MAIN SWITCH 68x68mm
LIGHTING +
HEATING
MAIN SWITCH
POWER SUPPLY
CABINET HEATER
7 9

Com-No ass.-gr.
Ch.
8
CONTROL CABINET 1800x600x300 Typ Bl.
83156 25.97 50 letzte nd./last mod. 09.Apr.2013 ALP
DESIGN VIEW
0 1 2 3 4 5 6 7 8 9
1
1A 1 = CONTROL LEVER =M06-S22 SLEWING / LUFFING GEAR

=M05-S22H HORN
H =M05-S22.1.. SPREADER CONTROL
-S22.6
1A = CONTROL LEVER NAME PLATE
10 = SELECTOR SWITCH =M05-S1 WINDSCREEN WIPER

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

BP
13 14 15
BP = BLIND CAP FOR ADDITIONAL INSTALLATION
8 10

Com-No ass.-gr.
Ch.
9
CONTROL Typ Bl.
83156 25.97 50 letzte nd./last mod. 25.Apr.2013 Alpers
DESK LEFT VIEW
0 1 2 3 4 5 6 7 8 9
DISPLAY
2 = CONTROL LEVER =M07-S12 HOISTING GEAR/

LOAD TURNER
2A
=M07-S12.1.. SPREADER CONTROL
-S12.8
2
2A = CONTROL LEVER NAME PLATE
20 = EMERG. - OFF BUTTON =M01-S4 EMERG. - OFF

20
26 = ILL. SWITCH =M07-S06/H06 START/STOP

READY FOR OPERATION
27 = INDICATION LAMP WHITE =M07-H9 TWL LOCK

32 33 34
29 = INDICATION LAMP RED =M07-H07 FAULT
30 = INDICATION LAMP GREEN =M07-H010 TWL UNLOCK

29 30 31 31 = KEY OPERATED BUTTON =M07-S07 JIB RESTING
32 = BUZZER =M07-H08 ALARM
26 27 BP 33 = INDICATION LAMP WHITE =M07-H11 ALL LANDED
34 = KEY OPERATED SWITCH =M07-S85 SPREADER OPERATION

BP = BLIND CAP FOR ADDITIONAL INSTALLATION
9 11

Com-No ass.-gr.
Ch.
10
CONTROL Typ Bl.
83156 25.97 50 letzte nd./last mod. 29.Mai.2013 Alpers
DESK RIGHT VIEW
0 1 2 3 4 5 6 7 8 9
CABLE CONNECTION TO CABLE REEL
CABLE GLANTS EN 50262

1X M50
600 1X M20
670
CABLE TUNNEL 75x50
-Q85
-F82 -F83 -F84 -T80
1: =M80-K80
2: =M80-K86
3: =M80-K84
CABLE TUNNEL 75x50
CABLE TUNNEL 75x75

4: =M80-K85
5: =M80-K90
6: =M80-K91
-K81
-K82
-K99
-K98
7: =M80-K92
8: =M80-K93
600
9: =M80-K100
4X M8 10: =M80-K101
CABLE TUNNEL 75x50 11: =M80-K102
755
12: =M80-K103
13: =M80-K104
CABLE TUNNEL 75x50

14: =M80-K105
-X100 3-19
12 15: =M80-K106
16: =M80-K107
17: =M80-K108
CABLE TUNNEL 75x50 CABLE TUNNEL 75x50 18: =M80-K109
19: =M80-K110
-X80 -X81
CABLE TUNNEL 75x50
CABLE GLANTS EN 50262

1X M40
2X M25
CABLE CONNECTION FROM CONTROL CABINET 1X M20
10 12

Com-No ass.-gr.
Ch.
11
CABINET Typ Bl.
83156 25.97 50 letzte nd./last mod. 21.Mai.2013 TGR
CARGO GEAR VIEW
0 1 2 3 4 5 6 7 8 9
=M06
-A1
=M06/1.1
CR 0505/0020
PLC MAIN BOARD
-XA1
INPUTS CAN BUS
AND SERIAL 55-PIN PLUG CONNECTOR
-XA1
CONNECTIONS
MAIN MOTOR AMPERAGE =M06/2.1
08
IW03 CAN 1H
14
=M06/1.5 CAN 1H
PLC
27 32
FAULT IN CARGO GEAR =M06/5.2 IX0.01 CAN 1L =M06/1.5 CAN 1L
09 33
SYNCHRON PULSE LG =M06/3.7 IX0.02 CAN GND =M06/1.4 CAN GND
28 06
MAIN SWITCH =M06/2.4 IX0.03 RXD =M06/1.4 RXD
10 07
FEED OIL PUMP =M06/2.5 IX0.04 TXD =M06/1.4 TXD
29 24
HYDRAULIC OIL COOLER =M06/2.6 IX0.05 TEST =M06/1.3 TEST
11
DELTA CONTACTOR =M06/2.7 IX0.06 OUTPUTS
30
MAIN MOTOR THERMISTOR RELAY =M06/2.8 IX0.07 I/O's depending on
hardware configuration
-XA1
44 44
IX0.08 QX0.00 =M06/6.1 TRIMOT (PWM-OUTPUT)
45 45
IX0.09 QX0.01 =M06/6.7 SOLENOID VALVE CABLE REEL
46 46
LIMIT LUFFING IN =M06/3.1 IX0.10 QX0.02
47 47
LIMIT LUFFING OUT =M06/3.3 IX0.11 QX0.03
20
LG INCREMENTAL ENCODER "B" =M06/3.4 IX0.12
02
LG INCREMENTAL ENCODER "A" =M06/3.5 IX0.13
21
HG INCREMENTAL ENCODER "B" =M06/4.4 IX0.14
38
HG INCREMENTAL ENCODER "A" =M06/4.5 IX0.15 I/O's depending on
36 36
IX0.16 QX0.04 =M06/6.3 MAIN MOTOR TIME RELAY
54 54
IX0.17 QX0.05 =M06/6.4 FEED OIL PUMP
17 17
IX0.18 QX0.06 =M06/6.5 HYDRAULIC OIL COOLER
53 53
IX0.19 QX0.07 =M06/6.8 SUPPLY SAFETY CIRCUITS
19
LIMIT HOISTING =M06/4.1 IX0.20
55
LIMIT LOWERING =M06/4.3 IX0.21
18
SLACK ROPE SW. HOISTING GEAR =M06/2.2 IX0.22
37
SYNCHRON PULSE HG =M06/4.7 IX0.23 I/O's below the line

only available on CR 0020
and depending on
39 39
IX0.24 QX0.08 =M06/7.4 GREEN FLIPPERS DOWN
03 03
IX0.25 QX0.09 =M06/7.5 WHITE FLIPPER DOWN
40 40
IX0.26 QX0.10 =M06/7.6 RED FLIPPERS DOWN
22 22
IX0.27 QX0.11 =M06/7.7 BLACK FLIPPERS DOWN
41 41
IX0.28 QX0.12 =M06/8.1 ALL FLIPPERS UP
42 42
TWL LOCKED =M06/5.3 IX0.29 QX0.13
43 43
TWL UNLOCKED =M06/5.4 IX0.30 QX0.14
04 04
ALL LANDED =M06/5.5 IX0.31 QX0.15
48 48
IX0.32 QX0.16 =M06/8.2 TWL LOCK
49 49
IX0.33 QX0.17 =M06/8.3 TWL UNLOCK
31 31
IX0.34 QX0.18 =M06/8.4 EXPAND TELESCOPE
50 50
IX0.35 QX0.19 =M06/8.5 RETRACT TELESCOPE
51 51
IX0.36 QX0.20 =M06/8.6 MOVE G.P. TO WHITE
52 52
IX0.37 QX0.21 =M06/8.7 MOVE G.P. TO BLACK
16 16
IX0.38 QX0.22 =M06/7.2 LOAD TURNER LEFT
35 35
IX0.39 QX0.23 =M06/7.3 LOAD TURNER RIGHT LOAD TURNER LEFT
11 13

Com-No ass.-gr.
Ch.
12
OVERVIEW Typ Bl.
83156 25.97 50 letzte nd./last mod. 02.Okt.2013 ASC
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A2
=M07/3.1
CR 2033
MODULE DIGITAL
-XA2T
03
MODULE SUPPLY GND =M07/3.1 GND
05
24VDC SUPPLY
MODULE SUPPLY +24VDC =M07/3.2 +VBB
INPUTS OUTPUTS
-XA2 -XA2
1.4 2.4
FILTER OVERPRESSURE =M07/3.4 IX2.01 QX2.02 =M07/3.4 HOISTING GEAR BRAKE
CHANNEL 1 CHANNEL 2
1.1 2.3
FILTER OVERPRESSURE =M07/3.4 +24V_CH1 GND_CH2 =M07/3.4 HOISTING GEAR BRAKE
3.4 4.4
OIL LEVEL =M07/3.5 IX2.03 QX2.04 =M07/3.5 LUFFING GEAR BRAKE
CHANNEL 3 CHANNEL 4
3.1 4.3
OIL LEVEL =M07/3.6 +24V_CH3 GND_CH4 =M07/3.6 LUFFING GEAR BRAKE
5.4 6.4
SLEWING GEAR BRAKE =M07/3.7 IX2.05 QX2.06 =M07/3.7 SLEWING GEAR BRAKE
CHANNEL 5 CHANNEL 6
5.1 6.3
=M07/3.7 +24V_CH5 GND_CH6 =M07/3.7 SLEWING GEAR BRAKE
7.4 8.4
PRE HEATING =M07/3.8 IX2.07 QX2.08 =M07/3.8 PRE HEATING
CHANNEL 7 CHANNEL 8
7.1 8.3
=M07/3.9 +24V_CH7 GND_CH8 =M07/3.9 PRE HEATING
CAN IN CAN OUT

-XA2C -XA2C
1.4 2.4
CAN_H IN =M07/3.3 CAN_H CAN_H =M07/3.3 CAN_H OUT
1.5 2.5
CAN_L IN =M07/3.3 CAN_L CAN_L =M07/3.3 CAN_L OUT
12 14

Com-No ass.-gr.
Ch.
13
OVERVIEW Typ Bl.
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A3
=M07/1.0
CR 2031
MODULE PWM I
-XA3T
03
MODULE SUPPLY GND =M07/1.1 GND
05
24VDC SUPPLY
MODULE SUPPLY +24VDC =M07/1.1 +VBB
OUTPUTS OUTPUTS
-XA3 -XA3
1.4 2.4
HOISTING GEAR HOISTING =M07/1.4 +24V_CH1 +24V_CH2 =M07/1.4 HOISTING GEAR LOWERING
CHANNEL 1 CHANNEL 2
1.2 2.2
HOISTING GEAR HOISTING =M07/1.5 CURRENT 1 CURRENT 2 =M07/1.5 HOISTING GEAR LOWERING
3.4 4.4
LUFFING GEAR LUFF. IN MAIN =M07/1.5 +24V_CH3 +24V_CH4 =M07/1.5 LUFFING GEAR LUFF. OUT MAIN
CHANNEL 3 CHANNEL 4
3.2 4.2
LUFFING GEAR LUFF. IN MAIN =M07/1.6 CURRENT 3 CURRENT 4 =M07/1.6 LUFFING GEAR LUFF. OUT MAIN
5.4 6.4
SLEWING GEAR CLKW (RIGHT) =M07/1.7 +24V_CH5 +24V_CH6 =M07/1.7 SLEWING GEAR C-CLKW (LEFT)
CHANNEL 5 CHANNEL 6
5.2 6.2
SLEWING GEAR CLKW (RIGHT) =M07/1.8 CURRENT 5 CURRENT 6 =M07/1.8 SLEWING GEAR C-CLKW (LEFT)
7.4 8.4
LUFFING GEAR LUFFING OUT AUX. =M07/1.9 +24V_CH7 +24V_CH8 =M07/1.9 LUFFING GEAR LUFFING IN AUX.
CHANNEL 7 CHANNEL 8
7.2 8.2
=M07/1.9 CURRENT 7 CURRENT 8 =M07/1.9
CAN IN CAN OUT

-XA3T -XA3C
01 2.4
02 2.5
13 15

Com-No ass.-gr.
Ch.
14
OVERVIEW Typ Bl.
83156 25.97 50 letzte nd./last mod. 24.Apr.2013 ASC
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A4
=M07/2.0
CR 2033
MODULE ANALOG
DIG. INPUTS ANA. INPUTS
-XA4 -XA4
1.4 2.1
HOIST. GEAR PRESSURE (7 bar) =M07/2.4 IX4.01 +24V_CH2 =M07/2.3 HOIST. GEAR PRESSURE (0-600 bar)
CHANNEL 1 CHANNEL 2
1.1 2.2
HOIST. GEAR PRESSURE (7 bar) =M07/2.4 +24V_CH1 IW4.02 =M07/2.4 HOIST. GEAR PRESSURE (0-600 bar)
2.5
GND_CH2
3.4 4.1
LUFFING GEAR PRESSURE (7 bar) =M07/2.5 IX4.03 +24V_CH4 =M07/2.5 LUFFING GEAR PRESSURE (0-600 bar)
CHANNEL 3 CHANNEL 4
3.1 4.2
LUFFING GEAR PRESSURE (7 bar) =M07/2.6 +24V_CH3 IW4.04 =M07/2.6 LUFFING GEAR PRESSURE (0-600 bar)
4.5
GND_CH4 =M07/2.6
5.4 6.1
SLEWING GEAR PRESSURE (7 bar) =M07/2.7 IX4.05 +24V_CH6 =M07/2.7 SLEWING GEAR
CHANNEL 5 CHANNEL 6
5.1 6.2
SLEWING GEAR PRESSURE (7 bar) =M07/2.7 +24V_CH5 IW4.06 =M07/2.7
6.5
GND_CH6 =M07/2.8
7.4 8.1
SLEWING GEAR PRESSURE (7 bar) =M07/2.8 IX4.07 +24V_CH8 =M07/2.8 OIL TEMPERATURE -50-150 DEGREES)
CHANNEL 7 CHANNEL 8
7.1 8.2
SLEWING GEAR PRESSURE (7 bar) =M07/2.9 +24V_CH7 IW4.08 =M07/2.9 OIL TEMPERATURE -50-150 DEGREES)
8.5
GND_CH8 =M07/2.9
CAN IN CAN OUT

-XA4C -XA4C
1.4 2.4
1.5 2.5
14 16

Com-No ass.-gr.
Ch.
15
OVERVIEW Typ Bl.
83156 25.97 50 letzte nd./last mod. 24.Apr.2013 ASC
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A5
=M07/4.0
CR 2012
CABINET MODULE 1/2
-X1A5
18
MODULE SUPPLY GND =M07/4.2 GND_CH8
2
24VDC SUPPLY
MODULE SUPPLY +24V =M07/4.2 +UB_CH1
DIG. INPUTS ANA. INPUT
-X1A5 -X1A5
1 5
EOS =M07/4.3 IX5.01 +UB_CH5 =M07/4.8
CHANNEL 1 CHANNEL 5
11
IW5.05 =M07/4.8 SET VALUE HOISTING GEAR
13
GND_CH5 =M07/4.8
14
GND_SH5 =M07/4.9
3
SWITCH PUMPS START/STOP =M07/4.4 IX5.02
CHANNEL 2 12
IX5.06 =M07/6.4 LEFT
4
+UB_CH2
CHANNEL 6
DIG. OUTPUT
5 15
KEY BUTTON JIB RESTING =M07/4.5 IX5.03 QX5.07 =M07/6.1 READY FOR OPERATION
CHANNEL 3 CHANNEL 7
6 16
+UB_CH3 GND_CH7 =M07/6.3
7 17
CONTROL LEVER HOISTING =M07/4.6 IX5.04 QX5.08 =M07/6.2 FAULT
CHANNEL 4 CHANNEL 8
8 18
+UB_CH4 GND_CH8
CAN IN
-X3A5
6
CAN_H IN =M07/4.1 CAN_H
5
CAN_L IN =M07/4.1 CAN_L
15 17

Com-No ass.-gr.
Ch.
16
OVERVIEW Typ Bl.
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A5
=M07/4.0
CR 2012
CABINET MODULE 2/2
-X2A5
18
=M07/5.8 GND_CH16
2
24VDC SUPPLY
+UB_CH9
-X2A5 -X2A5
1 11
CONTROL LEVER LUFFING IN =M07/5.1 IX5.09 IW5.13 =M07/5.3 SET VALUE LUFFING GEAR
CHANNEL 9 CHANNEL 13
2 9
+UB_CH9 +UB_CH13
13
GND_CH13 =M07/5.2 SET VALUE LUFFING GEAR
3 12
SLEWING CLKW (RIGHT) =M07/5.5 IX5.10 IW5.14 =M07/5.6 SET VALUE SLEWING GEAR
4 14
+UB_CH10 GND_SH14
DIG. OUTPUTS
5 15
RIGHT =M07/6.5 IX5.11 QX5.15 =M07/6.3 BUZZER ALARM
6 16
+UB_CH11 GND_CH15
DIG. INPUTS
7 17
IX5.12 IX5.16 =M07/6.6 SPREADER OPERATION ON
8 18
+UB_CH12 GND_CH16
16 18

Com-No ass.-gr.
Ch.
17
OVERVIEW Typ Bl.
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A9
=M07/8.0
CR 2012
CABINET MODULE 1/2
-X1A9
18
MODULE SUPPLY GND =M07/8.2 GND_CH8
2
24VDC SUPPLY
MODULE SUPPLY +24V =M07/8.2 +UB_CH1
-X1A9 -X1A9
1 5
SPREADER GREEN FLIPPERS DOWN =M07/9.3 IX9.01 +UB_CH5
CHANNEL 1 CHANNEL 5
11
IX9.05 =M07/9.6 ALL FLIPPERS UP
13
GND_CH5
14
GND_SH5
3
WHITE FLIPPERS DOWN =M07/9.3 IX9.02
CHANNEL 2 12
IX9.06
4
SUPPLY SPREADER CONTROL SWITCHES =M07/9.1 +UB_CH2
CHANNEL 6
DIG. OUTPUT
5 15
RED FLIPPERS DOWN =M07/9.4 IX9.03 QX9.07 =M07/10.1 TWL LOCK
CHANNEL 3 CHANNEL 7
6 16
+UB_CH3 GND_CH7 =M07/10.5
7 17
BLACK FLIPPERS DOWN =M07/9.5 IX9.04 QX9.08 =M07/10.2 TWL UNLOCK
CHANNEL 4 CHANNEL 8
8 18
+UB_CH4 GND_CH8
CAN IN
-X3A9
6
CAN_H IN =M07/8.1 CAN_H
5
CAN_L IN =M07/8.1 CAN_L
17 19

Com-No ass.-gr.
Ch.
18
OVERVIEW Typ Bl.
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
=M07
-A9
=M07/8.0
CR 2012
CABINET MODULE 2/2
-X2A9
18
GND_CH16
2
24VDC SUPPLY
+UB_CH9
-X2A9 -X2A5
1 11
SPREADER EXPAND TELESCOPE =M07/8.5 IX9.09 IX9.13 =M07/9.7 TWL LOCK
2 9
SUPPLY SPREADER CONTROL SWITCHES =M07/8.4 +UB_CH9 +UB_CH13
13
GND_CH13
3 12
RETRACT TELESCOPE =M07/8.6 IX9.10 IX9.14 =M07/9.7 TWL UNLOCK
4 14
+UB_CH10 GND_SH14
DIG. OUTPUTS
5 15
SPREADER MOVE G.P. TO WHITE =M07/8.7 IX9.11 QX9.15 =M07/10.3 ALL LANDED
6 16
MODULE SUPPLY =M07/9.8 +UB_CH11 GND_CH15 =M07/8.9
7 17
MOVE G.P. TO BLACK =M07/8.8 IX9.12 QX9.16 =M07/10.4 SPARE
8 18
+UB_CH12 GND_CH16 =M07/9.8
18 =SRK/1

Com-No ass.-gr.
Ch.
19
OVERVIEW Typ Bl.
PLC INPUTS/OUTPUTS
0 1 2 3 4 5 6 7 8 9
*) MUST BE SUPPLIED FROM
SPARE
3PE
MAIN SUPPLY
SPARE
LIGHT + HEATER
ON SHIP
EMERGENCY SWITCHBOARD OF ECR
~
(1N
~
60Hz 440V
~)
60Hz 220V
ON CRANE
L3
L2
L1
L9
(L)M2XH - 70mmý
L8
L7
L6
L5
L4
L3
L2
L1
PE
L1
L2 TO CONTROL CABINET +P1.H (L)M2XH - 3x2x70mmý
L3
1 2 3 4 5 6
L4-L5 TO CONTROL CABINET +P1.H (L)M2XH - 2x6mmý
L6-L7 SPARE
SPARE
60A
60A
60A
60A
60A
60A
400A
400A
400A
400A
SLIP RING ASSEMBLY

=GEN/19 =SL/1

Com-No ass.-gr.
Ch.
1
SLIP RING CONNECTION Typ Bl.
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = SRK

0 1 2 3 4 5 6 7 8 9
*) TECHNICAL DATAS
----------------
440V 70mmý # 6mmý DATA FOR SUPPLY CABLE RATING :
3x1 MEAN EFFECTIVE LOAD : 210 kVA

x70mmý
DATA FOR GENERATOR LOADS :
MEAN EFFECTIVE POWER CONSUMPTION : 180 kVA
SHORT TIME LOAD (10% DUTY CYCLE): 420 kVA
-S1 3 -K3 -K2 -F2 -F1 PEAK LOAD (2-3S): 470 kVA
400A 50A 35A
REVERSE POWER WHEN LOWERING FULL LOAD: 100 kW

3x1
x70mmý STARTING CURRENT OF EL. MOTOR : 660 A
25mmý NOTE:
IMPORTANT FOR CIRCUIT BREAKER WITH ELECTRONIC
SHORT CIRCUIT DETECTION !
BY SWITCHING THE MAIN MOTOR FROM STAR TO DELTA

A CURRENT PEAK (RUSH - EFFECT) IS ORIGINATE.
THIS CURRENT OCCURS ONLY A SHORT TIME (<10MS)

AND CAN RISE UP TO 4.500 A.
BUS BAR
PE
BK 3x2
x70mmý 1x70mmý
-Q11 3
-Q12 3
-Q1 3
17-23A 4-6,3A 2,5-4A
-XSR
S S
L1-L3 PE -K11 -K12 -U1
R R 400-500V
--------
24V, 20A
4x2,5mmý 4x1,5mmý
3+PE 3+PE 3+PE

-A1
L1-3 PE L1-L3
-M1 -M11 -M12
160kW 11,5KW 1,8KW CTRL
3
MAIN MAIN POWER SUPPLY FEED OIL HYDRAULIC OIL CONTROL

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

Com-No ass.-gr.
Ch.
1
SINGLE LINE DIAGRAM Typ Bl.
MAIN POWER SUPPLY
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = SL
0 1 2 3 4 5 6 7 8 9
220V AWG 10 BUS BAR
-S2 2 -F30 2 -F31 2 -F32 2 -F33 2 -F34 2
10A 10A 10A 10A 10A

-S03 -S31 -S32 -S33
-XSR
S
R
L4-5
-E2/ -E8/
-E31 -E32 -E36 -E37 -E38 -E6 -E7
-E3 -E9
1x18W 2x18W 40W 1000W 60W 2KW 0,55 kW
BELOW TOP 20W 10W
AUX. POWER SUPPLY 33W
220V AC, 60Hz
LIGHT LIGHT WORKING WARNING DESK HEATER CONTROL HEATER

CRANE CABIN LIGHT LIGHT HEATER, CRANE CABINET ADD.
TOWER BELOW/TOP AT JIB AT JIB CABIN TOWER HEATER, EQUIPMENT
FAN
NOTE: DECKS LIGHT CONTROL
FROM WHEELHOUSE AND CABIN
1 3

Com-No ass.-gr.
Ch.
2
SINGLE LINE DIAGRAM Typ Bl.
LIGHT AND HEATER
0 1 2 3 4 5 6 7 8 9
MAIN CONTROL CABINET
MAIN MOTOR
CURRENT
24V DC
K Kx
Q BX
6 4
VIQ IX QX IW
CR0505 / 0020
IX = 9 (14)
A1 IxC = 4 (6)
IW = 1 (2)
CR 0505 / CR 0020
QX = 4 (5)
QX
PWM IX IX IX (C) IX IX (C) QX IX C1 QX(PWM) = 1 (2)
1(2)
-KX
-YT -SL -S16 -S26 PMS

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

Com-No ass.-gr.
Ch.
3
PLC OVERVIEW Typ Bl.
83156 25.97 50 letzte nd./last mod. 27.M„r.2013 TGR

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

-Y1
5022372
SOL. VALVES
QD2
PRESSURE LUFF. GEAR BRAKE

ID
-Y2
SWITCHES
PS
8
Sach-Nr.
SOL. VALVES
QD1
PRESSURE SLEW. GEAR BRAKE

ID
-Y3
SWITCHES
CR 2033
= SL
Typ
PS
SOL. VALVES
QD1
PRE-HEATING
-Y11
7
VBB
24VDC-V
C1
SINGLE DECK CRANE

A2
6
C2
IA4
PLC OVERVIEW
PRESSURE
D4
SWITCHES
PS
PRESS./TEMP.
IA3
PRESSURE TRANSMITTER
D3
SWITCHES
5
-B01
PS
PRESSURE PRESS./TEMP.
IA2
TTS Marine GmbH

D2
CR 2033
SWITCHES TRANSMITTER
-B20
PS
PRESSURE
D1
PRESS./TEMP.
4
SWITCHES
IA1
TRANSMITTER
PS
-B10
C1
A4
3
C2
Name/name
PROP. VALVES PROP. VALVES
4B
4A
PUMP CONTROL PUMP CONTROL
TGR
TGR
-4B
4A
08.Nov.2013
22.M„r.2013
20.M„r.2013
Datum/date
2
3B
3A
-3B
3A
letzte nd./last mod.
erstellt/designed
CR 2031
geprft/checked
2B
2A
-2B
2A
1
1B
1A
Ch.
50
-1B
1A
ass.-gr.
-K5
Baugr./
25.97
Abt./departm.:
VBB
CR2031 24VDC-P
C1
3.8/
0
Bau-Nr./
A3
Com-No
83156
3
OBSERVE COPYRIGHT AS PER DIN 34 Schutzvermerk nach DIN 34 beachten
0 1 2 3 4 5 6 7 8 9
CONTROL DESK
DRIVERS CABIN
COMMANDS
SPREADER
SPREADER
CONTROL
CONTROL
CONTROL
LEVER
LAMPS
PILOT
LAMPS
PILOT
COM CL H SCOM H TDM MONITOR
4 3 3 4 3 3
ID IA QD ID IA QD
A5 CR 2012 A9 CR 2012 A6 AT62
CAN CAN RS CAN

3.8/ CR2012
4 =M01/1

Com-No ass.-gr.
Ch.
5
PLC OVERVIEW Typ Bl.

0 1 2 3 4 5 6 7 8 9
SLIP RING ASSEMBLY MAIN SWITCH AUXILIARY LOAD SPREADER MAIN SWITCH
POWER SUPPLY DRIVES TURNING SUPPLY POWER SUPPLY
MAIN POWER AUX.
DEVICE
SUPPLY POWER SUPPLY EMERGENCY OFF
SUPPLY
220V AC #6MMý BK
L4.1 /=M03/1.0
L5.1 /=M03/1.0
440V AC #2,5mmý BK
#70mmýBK
L1.2 /=M02/1.1
L2.2 /=M02/1.1
L3.2 /=M02/1.1
2 4
-S2 #25mmýBK
1 3
1 3 5
PN 5022144
3x2x70mmý
1 3 5
-S1
.8
-Q1
400A
0,6-1A
U< 2 4 6
2 4 6
PN 5002251 1 3 5 1 3 5 PN 5022350
-X3 1 2
-F1 -F2 1,5mmý
2 4 6 2 4 6
63A 63A RD
--- ---
35A 50A X1
-H1
PN 5022145 PN 5022145 X2
PE PN 5022213 PN 5022146 440V
WHITE
70mmý BK
PE PE D1 313 PN 5022351
6mmý BK
70mmý -S1.H
314
PE
-S1
.3 D2
-XSR
PN 2078876 -X4 1 5
L1 L2 L3 PE L4 L5
-X75 1
3PE 440V 220V
AC 60Hz AC 60Hz
+A1.S 21
-S4
22
PN 5022257
+F1.PR -X75 2 3PE
-X4 2 3PE 4
PE
L1.1
L2.1
L3.1
M1-U1
M1-V1
M1-W1
L1.11
L2.11
L3.11
L1.CARGO
L2.CARGO
L3.CARGO
PE.CARGO
PE
PE
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
=M02/1.1/
2.1/
2.1/
2.1/
=M80/2.1/
=M80/2.1/
=M80/2.1/
=M80/2.2/
=SL/5 2

Com-No ass.-gr.
Ch.
1
POWER SUPPLY Typ Bl.
CIRCUIT DIAGRAM
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = M01 +P1.H
0 1 2 3 4 5 6 7 8 9
24VDC
POWER SUPPLY
CONTROL CIRCUITS
440V AC
1.5/ L1.11 L1.11 /=M02/2.1
1.5/ L2.11 L2.11 /=M02/2.1
1.5/ L3.11 L3.11 /=M02/2.1
1 3 5
-Q2
2,5-4A
(3A)
2 4 6
PN 5022161
CV.L2 /=M02/3.1
CV.L3 /=M02/3.1
Power Unit
DIP-SWITCH
L1 L2 L3
settings
-U1 ON A = OFF
400-500VAC
50/60Hz
24VDC - +
OFF B = ON
20A
A B
PN 5002582
2,5mmý BU
2,5mmý BU
PE
PE
PE
24VN 24VP
3.1 3.1
1 3

Com-No ass.-gr.
Ch.
2
CONTROL VOLTAGE SUPPLY Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
24 V DC FUSE SEPARATION
PLC PLC PLC INTERNAL EXTERNAL EXTERNAL AUXILIARY
MODULE SUPPLY SUPPLY CONSUMERS CONSUMERS CONSUMERS CONSUMERS
SUPPLY OUTPUTS OUTPUTS
2,5mmý BU
2.2/ 24VP
-F11 -F12 -F13 -F14 -F15 -F16 -F17

4A 8A 8A 4A 8A 8A 8A
PN 5022147
PN 5022148
PN 5022149
2,5mmý BU 24N_INT /=M02/3.1

2.2/ 24VN 24N_EXT /=M05/1.1
-X5 10 11 12 13
-X5 1 2 5 6 7
24V_X51
24V_CARGO
24V-PLC-VBB
24V-PLC-OUT05
24V-PLC-OUT34
24V_INT
24V-P1.P
24V-P1.V
24V-CAB
GND-P1.P
GND-P1.V
GND-CAB
24V-AUX
=M06/3.1/
=M02/3.1/
=M07/4.1/
=M07/4.1/
=M05/1.1/
=M06/5.1/
=M07/1.1/
=M07/3.1/
=M07/1.1/
=M07/3.1/
=M06/1.1/
=M06/1.1/
=M06/1.1/
2 =M02/1

Com-No ass.-gr.
Ch.
3
24 V DC Typ Bl.
CONTROL VOLTAGE SUPPLY
0 1 2 3 4 5 6 7 8 9
MAIN DELTA STAR STANDSTILL THERMISTOR

CONTACTOR CONTACTOR CONTACTOR HEATER
400V AC
=M01/1.3/ L1.1
=M01/1.3/ L2.1
=M01/1.4/ L3.1
=M01/1.9/ L1.2
=M01/1.9/ L2.2
=M01/1.9/ L3.2
=M01/1.4/ M1-U1
=M01/1.4/ M1-V1
=M01/1.4/ M1-W1 1 3 5 2 4 6
-K3 -K2
3.3 2 4 6 3.2 1 3 5
PN 5022167
500/5A
-T1
PN 5022168
1200/5A
PN 5022359
-T1
CURRENT CONVERTER
5/0,02A
I1+ M1+ I-MAIN /=M06/2.1

S1
M1- 24N_INT /=M06/6.8
L UH /=M03/4.5
S2
N VH /=M03/4.6
3x1x70mmý
3x1x70mmý
I1-
M1-L /=M03/4.6
M1-N /=M03/4.6
AWG 16 WH
M1/1 /3.1
M1/2 /3.1
-X5 65 66
PE PE
PE
PE
-M1
160KW
PN 5012572
-XM1 U1 V1 W1 W2 U2 V2 L N T1 T2
U1 V1 W1
W2 U2 V2
+P1.P
=M01/3 2

Com-No ass.-gr.
Ch.
1
MAIN MOTOR Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
FEED OIL PUMP HYDRAULIC OIL COOLER

MOTOR MOTOR
BUS BAR
=M01/2.8/ L1.11
=M01/2.8/ L2.11
=M01/2.8/ L3.11
1 3 5 1 3 5
13 13
-Q11 14
-Q12 14
=M06/2.5
=M06/2.6
17-23A 4-6,3A
(In=18,0A) (In=4,7A)
2 4 6 2 4 6
BK AWG 14
PN 5022158 PN 5022160
PN 5022162 PN 5022162
1 3 5 1 3 5
-K11 -K12
=M06/6.4 2 4 6 =M06/6.5 2 4 6
PE PE PE
PE
-X4 6 7 8 9PE 10 11 12 13PE
-X11 1 2 3 4PE
PN 1627768
W1 V1 U1 W1 V1 U1
-M11 -M12
10,5 kW 1,8kW
(In=18,0A) (In=4,7A)
PE
+P1 +T1.O
1 3

Com-No ass.-gr.
Ch.
2
AUXILIARY DRIVES Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
MAIN MOTOR CONTROL

STAR DELTA THERMISTOR RELAY
24V DC
=M01/3.4/ 24V_INT 24V_INT /=M06/2.1
=M01/3.8/ 24N_INT 24N_INT /=M06/1.1
1.8/ M1/1
1.8/ M1/2
=M01/2.8/ CV.L2 A1 T1 T2 11 A2
-F4
PN 5022169
12 14
F4/14 /=M06/2.8
17
-K4
=M06/6.3 18 28
21 21
-K3 -K2
.3 22 .2 22
A1 A1
-K2 -K3
A2 A2
PN 5022158 PN 5022354
PN 5022126 PN 5022126
=M01/2.8/ CV.L3
1 2 1.5 1 2 1.5
3 4 1.6 3 4 1.5
5 6 1.6 5 6 1.5
21 22 .3 21 22 .2
31 32 =M03/4.6 31 32 =M03/4.6
43 44 =M06/2.7
2 =M03/1

Com-No ass.-gr.
Ch.
3
STAR/DELTA CONTROL Typ Bl.
MAINMOTOR
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR CIRCIUT DIAGRAM = M02 +P1.H
0 1 2 3 4 5 6 7 8 9
LIGHTING LIGHT CRANE LIGHT

SWITCH TOWER BELOW POWER
MODULE
EMERGENCY LIGHT
220V AC BUS BAR

=M01/1.9/ L4.1 L4.1 /2.0
=M01/1.9/ L5.1 L5.1 /2.0
1 3
-F30
B10A
2 4
PN 5022178
PE PE PE PE PE1 PE
PE
-X3 6 7 8PE 9 10 11PE 12 13 14PE 3 4 5PE 15 16 17PE
L N PE L1 N1
-E31
2x18W L N PE
PN 5012497
1 3 PE PN 0058132 -E32
2x20W
-S03
2 4
PN 1608349 PN 5002080
PN 0058132
+A1.S +P1
+T1
=M02/3 2

Com-No ass.-gr.
Ch.
1
LIGHT Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
POWER SUPPLY 220V AC SPARE WORKING WARNING LIGHT

CONTROL DESK LEFT, LIGHT RED
CABIN LIGHT
220V AC BUS BAR

1.8/ L4.1 L4.1 /3.0
1.8/ L5.1 PE L5.1 /3.0
1 3
-F31
B 10A
PN 5022178 2 4
AWG 14
-X3 21 22 23PE
-X60 1 2 3PE
13 33 13 33 13 33
-S31 -S32 -S33

14 34 14 34 14 34
PN 5022236 PN 5022237 PN 5022235
PE1 PE2
PE2
PE
+F1.PL -X60 7 8 9PE 10 11 12 13
-X3 24 25 26PE
PE PE PE
PE
-X3 27 28 29PE 30 31 32PE

PE
+A1 -X12 1 2 3 4 5PE
-X13 1 2 5PE 3 4 6PE

L N PE
-E36
40W L N PE L N PE
PN 5022251 -E37 -E38

PN 0146181 1000W 60W
PN 5022285 PN 1624721
PN 5022389 PN 1624722
PN 1660212
+F1
+A1.J
1 3

Com-No ass.-gr.
Ch.
2
LIGHT Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
HEATING FAN DESK HEATER DESK HEATER

CABIN CONTROL DESK CONTROL DESK
RIGHT LEFT
220V AC BUS BAR

2.9/ L4.1 L4.1 /4.0
2.9/ L5.1 PE PE L5.1 /4.0
1 3
PE
-F32
B 10A
2 4
PN 5022178
-X3 33 34 35PE
-X60 4 5 6PE
L N
13 33
-S34 -E3
14 34 10W
PN 5022381
PN 5022242
PE5 PE5
PE2
+F1.PL -X60 14 15 16PE -X60 17 18 19PE

-X70 1 2 3PE
L N PE L N PE
-E8 -E2
1,4kW 10W
PN 4228061 PN 5022242
+F1 +F1-PR
2 4

Com-No ass.-gr.
Ch.
3
HEATERS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
HEATER HEATER FAN SUPPLY FOR STANDSTILL- HEATER SUPPLY AUX.

CRANE TOWER CONTROL CABINET CONTROL AMPERAGE HEATER CARGO GEAR SUPPLY
CABINET MONITOR MAIN MOTOR ON
220V AC BUS BAR

3.9/ L4.1
3.9/ L5.1
1 3 1 3
-F33 -F34
B 10A B 10A
2 4 2 4
PN 5022178 PN 5022178
AWG 14
3 31 X1
=M02
-S35 -H2
1 2 -K2 32 X2
40øC 230VAC
=M02/3.2 white
PN 5022175 PN 5022136
31
=M02
-K3 32
=M02/3.3
PE PE PE PE PE PE PE PE
-X3 36 37 38PE 39 40 41PE 42 43 44PE 45 46 47PE 48 49 50PE 63 64 65PE 66 67 68PE
PE
UH
VH
M1-L
M1-N
L6.1_CARGO
L7.1_CARGO
PE_CARGO
L N PE L N PE L N PE
=M02/1.3/
=M02/1.3/
-E6 -E5 -M31
2kW 400W 35W
=M02/1.8/
=M02/1.8/
PN 2535250 PN 5022176 PN 5022174
=M80/1.2/
=M80/1.2/
=M80/1.2/
+T1.U
3 =M05/1

Com-No ass.-gr.
Ch.
4
HEATERS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
WINDSCREEN WIPER FAN HORN
=M01/3.8/ 24N_EXT 24N_EXT /=M06/3.1

=M01/3.8/ 24V-AUX
-X5 9 14
-X62 11 12
OFF
ON
21 33
-S8
22 34
PN 5022238
=M07-S22H PE
PE PE
4 PE Schiene
PN 2078899
-X62 13 14 15 17 16 18 19 20 21PE
+F1.PL
1 2 PE
-XM50 2 3 5 1 -H50
BK/WH
53 31b 53a PN 1096359
-M50 -M51 +
PN 2532317
31 -
BK
+F1
31 53 31b 53a
PLUG CONNECTOR
1 5 FOR WIPER
=M03/4 =M06/1

Com-No ass.-gr.
Ch.
1
AUXILIARY 24V-DC CONSUMERS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
PLC MAIN BOARD

=M01/3.3/ 24V-PLC-OUT34
=M01/3.2/ 24V-PLC-OUT05
A1 -XA1 05 34
=GEN/12.4
PN 5002194
+24V +24V
CR 0505/0020
GND GND GND +24V CAN 1L
TEST TXD RXD CAN GND CAN 1H
-XA1 12 15 01 23 24 07 06 33 14 32
2,5mmý GN/YE
SCREEN CLAMP
-X5 22 23 24 8 30 31 32 35 36 37 40 41 42
PE
-XSAPI
1 2 3 4 5 6 7 8 9
SUB-D
API
CAN-L1 /=M07/1.1
APPLICATION PROGRAMMING INTERFACE
CAN-H1 /=M07/1.1
PE PN 4228649
CAN-L4 /=M07/4.1
PE
CAN-H4 /=M07/4.1
PE
=M01/3.1/ 24V-PLC-VBB
=M02/3.8/ 24N_INT 24N_INT /6.1
=M05/1 2

Com-No ass.-gr.
Ch.
1
PLC SUPPLY 24V DC Typ Bl.
83156 25.97 50 letzte nd./last mod. 02.Okt.2013 Alpers
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
AUXILIARY CONTACTS
MAIN MOTOR SLACK ROPE SW. MAIN FEED OIL HYDRAULIC DELTA MAIN MOTOR
AMPERAGE HOISTING GEAR SWITCH PUMP OIL CONTACTOR THERMISTOR
COOLER RELAY
24V DC
SECQ
6.8/ SECQ /3.1
=M02/3.8/ 24V_INT
1.X1 13 13 43
=M01 =M02 =M02 =M02
-S1 1.X2 -Q11 14 -Q12 14 -K3 44
=M01/1.3 =M02/2.3 =M02/2.6 =M02/3.3

-S19
SLACK ROPE SWITCH 13 13
=M02-K11 =M02-K12
6.4 14 6.5 14
HG-ROPE
METAL-BAR
+P1 INSULATING MATERIAL
=M02/3.8
F4/14
=M02/1.3/ I-MAIN
-X5 50
A1 -XA1 08 18 28 10 29 11 30
1.1
PN 5002194 IW03 IX0.22 IX0.03 IX0.04 IX0.05 IX0.06 IX0.07
CR 0505/0020 // PLC MAINBOARD INPUTS
1 3

Com-No ass.-gr.
Ch.
2
PLC INPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
LIMIT SWITCH LUFFING GEAR

LIMIT LIMIT LIMIT SWITCH INCREMENTAL SYNCHRON
LUFFING IN LUFFING OUT CHECK CONTACT ENCODER PULSE LG
24V DC
SECQ
2.9/ SECQ /4.1
=M01/3.5/ 24V_X51
=M05/1.8/ 24N_EXT 24N_EXT /4.1
SCREEN CLAMP
-X5 45 15 -X5 16
PE
48BM-299G+IMP1000
24N_X51 /4.6
24V_X51 /4.6
-S26 -XS26 2 1 -X51 1 3

48BM
PN 5002244
-XB26 1 3
L+ L- 1 3
-IE26
1000ppr -B26
11
-S26.2 21 PN 2507753
-S26.1
12 14 22 24
-XB26 4
B A
-X51 5
-XS26 4 3
+T1.W
-X5 51 52 53 54 55
A1 -XA1 46 47 20 02 09
1.1
PN 5002194 IX0.10 IX0.11 IX0.12 IX0.13 IX0.02
2 4

Com-No ass.-gr.
Ch.
3
PLC INPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
LIMIT SWITCH HOISTING GEAR

LIMIT LIMIT LIMIT SWITCH INCREMENTAL SYNCHRON
HOISTING LOWERING CHECK CONTACT ENCODER PULSE HG
24V DC
SECQ
3.8/
3.8/ 24N_EXT 24N_EXT /6.1
SCREEN CLAMP
-X5 46 17 18
PE
48BM-299G+IMP1000
3.8/ 24N_X51
3.8/ 24V_X51
-S16 -XS16 2 1 -X51 2 4

48BM
PN 5002244
-XB16 1 3
L+ L- 1 3
-IE16
1000ppr -B16
11
-S16.2 21 PN 2507753
-S16.1
12 14 22 24
-XB16 4
B A
-X51 6
-XS16 4 3
+T1.W
-X5 56 57 58 59 60
A1 -XA1 19 55 21 38 37
1.1
PN 5002194 IX0.20 IX0.21 IX0.14 IX0.15 IX0.23
3 5

Com-No ass.-gr.
Ch.
4
PLC INPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
FAULT IN TWL TWL ALL SPREADER

CARGO GEAR LOCKED UNLOCKED LANDED OPERATION
=M01/3.5/ 24V_CARGO
-X5 3 4
-X81 1
11
=M80-K80
=M80/4.2 14
-X72 47
21 11 11 11 -S85
=M80-K95 =M80-K90 =M80-K91 =M80-K92 =M80-K93 PN 5022434
7.1 22 =M80/5.2 =M80/5.3 14 =M80/5.4 14 =M80/5.5 14
S85 /=M07/6.6
-X72 48
+T0.H -X81 2 3 4 5 +F1.PR

SPR_OP /7.0
PE
SCREENCLAMP
-X5 61 62 63 64
PE
A1 -XA1 27 42 43 04
1.1
PN 5002194 IX0.01 IX0.29 IX0.30 IX0.31
CR 0020 // PLC MAINBOARD INPUTS
4 6

Com-No ass.-gr.
Ch.
5
PLC INPUTS Typ Bl.
83156 25.97 50 letzte nd./last mod. 02.Okt.2013 ALP
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
TRIMOT MAIN MOTOR FEED OIL PUMP HYDRAULIC SOLENOID VALVE SUPPLY SAFETY
(PWM-OUTPUT) TIME RELAY OIL COOLER CABLE REEL CIRCUITS
24V DC
A1
1.1
PN 5002194
CR 0505/0020 // PLC MAINBOARD OUTPUTS
QX0.00 QX0.04 QX0.05 QX0.06 QX0.01 QX0.07
-XA1 44 36 54 17 45 53
-X5 67 68
SECQ
2.1
-XY1T 1 -XY84 1
1 1
-Y1T -Y84
2 2
B 24ê B 24ê
-XY1T 2 -XY84 2
+T1.W +P1.P
A1 A1 A1
=M02-K4 =M02-K11 =M02-K12

A2 A2 A2
PN 5022358 PN 5022156 PN 5022155
PN 5022272 PN 5022272
-X5 19 20
1.8/ 24N_INT 24N_INT /=M02/1.3

4.8/ 24N_EXT 24N_EXT /8.0
18 =M02/3.2 1 2 =M02/2.2 1 2 =M02/2.5

28 =M02/3.3 3 4 =M02/2.2 3 4 =M02/2.5
5 6 =M02/2.2 5 6 =M02/2.5
13 14 2.5 13 14 2.6
5 7

Com-No ass.-gr.
Ch.
6
PLC OUTPUTS Typ Bl.
83156 25.97 50 letzte nd./last mod. 02.Okt.2013 TGR
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
SPREADER LOAD TURNER LOAD TURNER GREEN WHITE RED BLACK

OPERATION LEFT RIGHT FLIPPERS FLIPPER FLIPPERS FLIPPERS
DOWN DOWN DOWN DOWN
24V DC
A1
PN 5002194
1.1
QX0.22 QX0.23 QX0.08 QX0.09 QX0.10 QX0.11
16 35 39 03 40 22
SCREEN CLAMP PE
5.8/ SPR_OP
-X5 69 70 71 72 73 74 75
PE
-X81 19 6 7 8 9 10 11
A1 A1 A1 A1 A1 A1 A1
=M80 =M80 =M80 =M80 =M80 =M80 =M80

-K95 A2 -K84 A2 -K85 A2 -K100 A2 -K101 A2 -K102 A2 -K103 A2
PN 5022132 PN 5022367 PN 5022367 PN 5022367 PN 5022367 PN 5022367 PN 5022367

PN 5022363
24N_SPR /8.1
+T0.H
11 14 =M80/4.3 11 14 =M80/4.4 11 14 =M80/4.5 11 14 =M80/7.1 11 14 =M80/7.2 11 14 =M80/7.2 11 14 =M80/7.3

21 22 5.1
6 8

Com-No ass.-gr.
Ch.
7
PLC OUTPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
ALL TWL TWL EXPAND RETRACT MOVE G.P. MOVE G.P.

FLIPPERS LOCK UNLOCK TELESCOPE TELESCOPE TO WHITE TO BLACK
UP
24V DC
A1
PN 5002194
1.1
QX0.12 QX0.16 QX0.17 QX0.18 QX0.19 QX0.20 QX0.21
-XA1 41 48 49 31 50 51 -XA1 52
SCREEN CLAMP PE
-X5 76 77 78 79 80 81 82
PE
-X81 12 13 14 15 16 17 18
A1 A1 A1 A1 A1 A1 A1
=M80 =M80 =M80 =M80 =M80 =M80 =M80

-K104 A2 -K105 A2 -K106 A2 -K107 A2 -K108 A2 -K109 A2 -K110 A2
PN 5022367 PN 5022367 PN 5022367 PN 5022367 PN 5022367 PN 5022367 PN 5022367
7.8/ 24N_SPR
-X81 20
+T0.H
-X5 21
6.8/ 24N_EXT
11 14 =M80/7.4 11 14 =M80/7.5 11 14 =M80/7.5 11 14 =M80/7.6 11 14 =M80/7.7 11 14 =M80/7.7 11 14 =M80/7.8
7 =M07/1

Com-No ass.-gr.
Ch.
8
PLC OUTPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
SOLENOID VALVES
=M06/1.8/ CAN-L1 HOISTING GEAR LUFFING GEAR SLEWING GEAR LUFFING GEAR
=M06/1.8/ CAN-H1
HOISTING LUFFING IN CLKW (RIGHT) LUFFING IN AUX.
=M01/3.5/ 24V-P1.P
=M01/3.7/ GND-P1.P
-XY1B 2 -XY2B 2 -XY31A 2 -XY3B 2 -XY21A 2
2 2 2 2 2
-Y1B -Y2B -Y31A -Y3B -Y21A

1 1 1 1 1
24ê 24ê 24ê 24ê 24ê
-XY1B 1 -XY2B 1 -XY31A 1 -XY3B 1 -XY21A 1

-A3 -XA3T 03 04 05 06 07 01 02 -XA3 1.4 1.2 3.4 3.2 5.4 5.2 7.4 7.2
=GEN/14.4
PN 5002197 GND +VBB CAN_H CAN_L +24V_CH1 CURRENT 1 +24V_CH3 CURRENT 3 +24V_CH5 CURRENT 5 +24V_CH7 CURRENT 7
CAN IN CHANNEL 1 CHANNEL 3 CHANNEL 5 CHANNEL 7
COMPACT MODULE CR2031 PWM
CAN OUT CHANNEL 2 CHANNEL 4 CHANNEL 6 CHANNEL 8
CAN_H CAN_L +24V_CH2 CURRENT 2 +24V_CH4 CURRENT 4 +24V_CH6 CURRENT 6 +24V_CH8 CURRENT 8
-XA3C 2.4 2.5 -XA3 2.4 2.2 4.4 4.2 6.4 6.2 8.4 8.2
-XY1A 1 -XY2A 1 -XY31B 1 -XY3A 1 -XY21B 1
1 1 2 1 1
-Y1A -Y2A -Y31B -Y3A -Y21B

2 2 1 2 2
24ê 24ê 24ê 24ê 24ê
-XY1A 2 -XY2A 2 -XY31B 2 -XY3A 2 -XY21B 2
2.1/ CAN-H2
2.1/ CAN-L2
HOISTING GEAR LUFFING GEAR SLEWING GEAR LUFFING GEAR
LOWERING LUFFING OUT C-CLKW (LEFT) LUFFING OUT AUX.
=M06/8 2

Com-No ass.-gr.
Ch.
1
COMPACT MODULE Typ Bl.
PWM-OUTPUTS
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR CIRCUIT DIAGRAM = M07 +P1.P
0 1 2 3 4 5 6 7 8 9
PRESSURE SWITCHES
1.1/ CAN-L2 HOISTING LUFFING SLEWING SLEWING
1.1/ CAN-H2
GEAR GEAR GEAR GEAR
1 1 1 1
-S10 -S20 -S30 -S31

3 3 3 3
7 bar 7 bar 7 bar 7 bar
BK BN BK BN BK BN BK BN
-A4 -XA4C 1.4 1.5 -XA4 1.4 1.1 3.4 3.1 5.4 5.1 7.4 7.1
=GEN/15.4
PN 5002204 CAN_H CAN_L IX4.01 +24V_CH1 IX4.03 +24V_CH3 IX4.05 +24V_CH5 IX4.07 +24V_CH7
COMPACT MODULE CR2033 ANALOG
CAN_H CAN_L +24V_CH2 IW4.02 GND_CH2 +24V_CH4 IW4.04 GND_CH4 +24V_CH6 IW4.06 GND_CH6 +24V_CH8 IW4.08 GND_CH8
-XA4C 2.4 2.5 -XA4 2.1 2.2 2.5 4.1 4.2 4.5 6.1 6.2 6.5 8.1 8.2 8.5
3.1/ CAN-L3
3.1/ CAN-H3
XB10 3 1 XB20 3 1 XB01 3 1
-B10 +Ub OUT -B20 +Ub OUT -B01 +Ub OUT
PN 5002899 PN 5002899 PN 5002900

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

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

PRESSURE PRESSURE TEMPERATURE
ANALOG SENSORS
1 3

Com-No ass.-gr.
Ch.
2
IN-/OUTPUTS
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR CIRCUIT DIAGRAM = M07 +P1.P
0 1 2 3 4 5 6 7 8 9
FILTER OIL LEVEL SPARE PRESSURE SWITCH

CAN-L3
2.1/
OVERPRESSURE CARGO GEAR
2.1/ CAN-H3
=M01/3.6/ 24V-P1.V
terminal 5+6 to be removed

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

1 21 1
-S08 -S09 -S82G

2 22 2
5 bar 20 bar
+P1.P
-A2 XA2T 03 04 05 06 07 -XA2C 1.4 1.5 -XA2 1.4 1.1 3.4 3.1 5.4 5.1 7.4 7.1
=GEN/13.4
PN 5002203 GND +VBB CAN_H CAN_L IX2.01 +24V_CH1 IX2.03 +24V_CH3 IX2.05 +24V_CH5 IX2.07 +24V_CH7
COMPACT MODULE CR2033 DIGITAL
CAN_H CAN_L QX2.02 GND_CH2 QX2.04 GND_CH4 QX2.06 GND_CH6 QX2.08 GND_CH8
-XA2C 2.4 2.5 -XA2 2.4 2.3 4.4 4.3 6.4 6.3 8.4 8.3
120R
PN 4243112 -XY1 1 -XY2 1 -XY3 1 -XY11 1
1 1 1 1
-Y1 -Y2 -Y3 -Y11

2 2 2 2
24ê 24ê 24ê 24ê
-XY1 2 -XY2 2 -XY3 2 -XY11 2
HOISTING GEAR LUFFING GEAR SLEWING GEAR PRE HEATING

BRAKE BRAKE BRAKE
SOLENOID VALVES
2 4

Com-No ass.-gr.
Ch.
3
IN-/OUTPUTS
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR CIRCUIT DIAGRAM = M07 +P1.V
0 1 2 3 4 5 6 7 8 9
CAN-BUS MODULE EOS SWITCH KEY BUTTON CONTROL LEVER SET VALUE
SUPPLY SUPPLY PUMPS JIB HOISTING LOWERING HOISTING GEAR
START/STOP RESTING
=M01/3.6/ 24V-CAB 24V-CAB /5.0
=M01/3.8/ GND-CAB GND-CAB /5.0
=M06/1.8/ CAN-H4 CAN-H4 /8.1

=M06/1.8/ CAN-L4 CAN-L4 /8.1
24V_S12LTD /6.1
-X72 1 4 7 10 15 20
13 13 -S12 3 5
-S06 -S07
14 14 03 05
PN 5022384 PN 5022259 PN 5022436
A S
TERMINATING
RESISTOR
-A5 -X3A5 6 5 -X1A5 2 18 1 4 3 5 7 8 11 13 14

=GEN/16.4
PN 5002207 CAN_H CAN_L +UB_CH1 IX5.01 IX5.02 IX5.04 IW5.05 GND_SH5
+UB_CH2 IX5.03
GND_CH8 +UB_CH5 GND_CH5
+24V +24V
CR2012
3 5

Com-No ass.-gr.
Ch.
4
CABIN MODULE INPUTS Typ Bl.
CIRCUIT DIAGRAM
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = M07 +F1.PR
0 1 2 3 4 5 6 7 8 9
CONTROL LEVER SET VALUE CONTROL LEVER

LUFFING LUFFING LUFFING GEAR SLEWING SLEWING SET VALUE SPARE
IN OUT C-CLKW CLKW SLEWING GEAR
(LEFT) (RIGHT)
4.8/ 24V-CAB 24V-CAB /7.1
4.8/ GND-CAB GND-CAB /7.1
A6CAN-GND /7.1
E E
-S22 3 5 -S32 3 5
03 05 03 05
PN 5022435 PN 5022435
A S A S
-X62 1 2 3 4 5 6 7 9
+F1.PL
-X72 21 22 23 24 25 26 27 28 11 16
-A5 -X2A5 1 13 11 3 14 12 4 16 6 18
4.0
PN 5002207 IX5.09 IW5.13 GND_CH14 +UB_CH10 GND_CH15 GND_CH16
GND_CH13 IX5.10 IW5.14 +UB_CH11
+24V +24V
CR2012
4 6

Com-No ass.-gr.
Ch.
5
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
INDIC. LIGHTS
READY FOR FAULT BUZZER LOAD TURNING SPREADER
OPERATION ALARM DEVICE OPERATION
ON
LEFT RIGHT
4.8/ 24V_S12LTD
3 5
-S12LTD
PN: 5022436 03 05
X2 X2 X2
S85 /=M06/5.8
-H06 -H07 -H08
X1 X1 X1
PN 5022384 PN 5022260 PN 5022263
-A5 -X1A5 15 17 -X2A5 15 -X1A5 16 12 -X2A5 5 17

4.0
PN 5002207 QX5.07 QX5.08 QX5.15 GND_CH7 IX5.06 IX5.11 IX5.16
CR2012 CABINET MODULE
5 7

Com-No ass.-gr.
Ch.
6
CABIN MODULE INPUTS / OUTPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
CAN-BUS MONITOR DISPLAY

SUPPLY
5.9/ 24V-CAB
5.9/ GND-CAB
5.9/ A6CAN-GND
8.8/ CAN-H6
8.8/ CAN-L6
-X72 14 19
-A6 -XA6 3 5 1 6 2
PN 5002205
CAN_H
CAN_GND CAN_L +24V GND
LCD DISPLAY AT6200C

2,5mmý GN/YE
PE
PE
PE
6 8

Com-No ass.-gr.
Ch.
7
DISPLAY Typ Bl.
CONNECTION DIAGRAM
0 1 2 3 4 5 6 7 8 9
CAN-BUS MODULE SUPPLY SPARE SPREADER SPARE SPREADER

SUPPLY SUPPLY SPREADER EXPAND RETRACT MOVE G.P. MOVE G.P.
CONTROL TELESCOPE TELESCOPE TO WHITE TO BLACK
SWITCHES
8.8/ 24V-CAB 24V-CAB /8.1
4.8/ CAN-H4 CAN-H6 /7.1

4.8/ CAN-L4 CAN-L6 /7.1
-S22
-X72 2 5 8 3 6 12 17 PN: 5022435
1 1 1 1 1 1
-S22.1 -S22.2 -S22.3 -S22.4 -S22.5 -S22.6

2 2 2 2 2 2
BU GN RD YE WH BK
-XS22 1 2 3 4 5 6 7
-X62 22 23 24 25 26 27 28
-R1
120ê
+F1.PL
TERMINATING
RESISTOR
-X72 30 31 32 33 34 35 36 37
-A9 -X3A9 6 5 -X1A9 2 18 -X2A9 2 1 3 5 7 16

=GEN/18.4
PN 5002828 CAN_H CAN_L +UB_CH1 IX9.09 IX9.10 IX9.12 GND_CH15
+UB_CH9 IX9.11
GND_CH8
+24V
CR2012
7 9

Com-No ass.-gr.
Ch.
8
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
SUPPLY SPARE SPREADER MODULE

SPREADER GREEN WHITE RED BLACK ALL TWL TWL SUPPLY
CONTROL FLIPPERS FLIPPERS FLIPPERS FLIPPERS FLIPPERS LOCK UNLOCK
SWITCHES DOWN DOWN DOWN DOWN UP
9.9/ 24V-CAB 24V-CAB /9.0

-S12
PN 5022436
1 1 1 1 1 1 1 1
-S12.1 -S12.2 -S12.3 -S12.4 -S12.5 -S12.6 -S12.7 -S12.8

2 2 2 2 2 2 2 2
BU GN WH RD BK YE RD GN
-XS12 1 2 3 4 5 6 7 8 9
-X72 38 39 40 41 42 43 44 45 46 13 18
-A9 -X1A9 4 1 3 5 7 11 -X2A9 11 12 6 18

8.0
PN 5002828 IX9.01 IX9.02 IX9.04 IX9.05 IX9.13 IX9.14 +UB_CH11 GND_CH16
+UB_CH2 IX9.03
+24V
CR2012
8 10

Com-No ass.-gr.
Ch.
9
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
SPREADER
TWL TWL ALL SPARE

LOCK UNLOCK LANDED
X2 X2 X2
-H09 -H10 -H11

X1 X1 X1
PN 5022431 PN 5022432 PN 5022433
-A9 -X1A9 15 17 -X2A9 15 17 -X1A9 16

8.0
PN 5002828 QX9.07 QX9.08 QX9.15 QX9.16 GND_CH7
CR2012 CABINET MODULE
9 =M80/1

Com-No ass.-gr.
Ch.
10
CABIN MODULE OUTPUTS Typ Bl.
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
220V 60Hz HEATER HEATER

HEATER SUPPLY CONTROL CABINET CABLE REEL
220V AC 1,5mmý BK
PE PE PE PE PE
-X80 5 6 7PE 8 9 10PE 11 12 13PE

35mmý
PE
PE
PE
CRANE
TOWER
PE
L6.1_CARGO
L7.1_CARGO
PE_CARGO
L N L N PE
+T1.O -E8 -E9

10W 33W
PN 5022242
PE
=M03/4.7/
=M03/4.7/
=M03/4.7/
+A1
=M07/10 2

Com-No ass.-gr.
Ch.
1
ADD. EQUIPMENT Typ Bl.
CIRCUIT DIAGRAM
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = M80 +TO.H
0 1 2 3 4 5 6 7 8 9
POWER SUPPLY CONTROL VOLTAGE

440V, 60Hz 220V, 60Hz
440V AC # 25mmý BK BUS BAR

CARGO/L1 /3.1
CARGO/L2 /3.1
CARGO/L3 /3.1
L.LTD /4.0
N.LTD /4.0
1 3 5
13
-F82 14
25mmý BK
4.2
4A
PN 5022425
2 4 6
PN 5022439
1,5mmý BK
PE PE
PE
-X80 1 2 3 4PE
1.2 1.3
-T80
prim.: 440V, 60Hz
sek.: 220V, 630VA
L1.CARGO
L2.CARGO
L3.CARGO
PE.CARGO
PN 5002690 2.2 2.1
1,5mmý RD
=M01/1.6/
=M01/1.6/
=M01/1.6/
=M01/1.7/
PE
PE
PE
1 3

Com-No ass.-gr.
Ch.
2
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
440V SPREADER 440V SPREADER LOAD TURNING DEVICE

SUPPLY 1 SUPPLY 2 MOTOR
RIGHT LEFT
BUS BAR # 2,5mmý

2.8/ CARGO/L1
2.8/ CARGO/L2
2.8/ CARGO/L3
1 3 5 1 3 5 1 3 5
13 13 13
-F83 14
-F84 14
-Q85 14
4.2
4.2
4.2
C16A C16A 2,5-4A
PN 5022427 PN 5022427 PN 5022161
2 4 6 2 4 6 2 4 6
PN 5022439 PN 5022439 PN 5022162
PN 5022447
1 3 5 1 3 5 1 3 5 1 3 5
-K98 -K99 -K81 -K82
4.3 2 4 6 4.3 2 4 6 4.4 2 4 6 4.5 2 4 6
2,5mmý BK
2,5mmý BK
1,5mmý BK
SPR/L1.1
SPR/L2.1
SPR/L3.1
SPR/L1.2
SPR/L2.2
SPR/L3.2
LTD/L1
LTD/L2
LTD/L3
6.1/
6.1/
6.1/
6.1/
6.1/
6.1/
6.1/
6.1/
6.1/
2 4

Com-No ass.-gr.
Ch.
3
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
INQUIRY FUSES SPREADER LOAD LOAD TURNING DEVICE

AND MOTOR OPERATION TURNING DEVICE FREE WHEELING VALVE
PROTECTION
RIGHT LEFT
220V AC SWITCHES
2.8/ L.LTD SPR/L /7.0
13 11 11 13 13
-F82 -K84 -K85 -K81 -K82
2.7 14 =M06/7.2 14 =M06/7.3 14 .4 14 .5 14
13
-Q85
61 61
3.6 14 -K82 -K81
.5 62 .4 62
13
-F83
3.2 14
LTD/VL /6.1
13
-F84 LTD/VN /6.1
3.4 14
11
-K95
=M06/7.1 14
A1 A1 A1 A1 A1
-K80 -K98 -K99 -K81 -K82

A2 A2 A2 A2 A2
PN 5022363 PN 5022450 PN 5022450 PN 5022426 PN 5022426
PN 5022362
2.8/ N.LTD SPR/N /5.1
11 14 =M06/5.2 1 2 3.1 1 2 3.3 1 2 3.6 1 2 3.6

3 4 3.2 3 4 3.4 3 4 3.6 3 4 3.7
5 6 3.2 5 6 3.4 5 6 3.6 5 6 3.7
13 14 .6 61 62 .4
61 62 .5 13 14 .7
3 5

Com-No ass.-gr.
Ch.
4
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
FAULT IN TWL TWL ALL

SPREADER LOCKED UNLOCKED LANDED
CONTROL
220VAC
LANDED /8.1
UNLOCKED /8.1
LOCKED /8.1
SPR_FAULT /8.1
A1 A1 A1 A1
-K90 -K91 -K92 -K93

A2 A2 A2 A2
PN 5022365 PN 5022365 PN 5022365 PN 5022365
4.8/ SPR/N SPR/N /6.1
=M06/5.2 11 14 =M06/5.3 11 14 =M06/5.4 11 14 =M06/5.5
4 6

Com-No ass.-gr.
Ch.
5
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
LOAD TURNING DEVICE SPREADER CARGO GEAR

PE
FREE SUPPLY 1
MOTOR CONTROL SUPPLY 2
WHEELING
SUPPLY VOLTAGE
VALVE 440V
220V 440V
440V AC
3.1/ SPR/L1.1
3.2/ SPR/L2.1
3.2/ SPR/L3.1
220V AC
7.8/ SPR/L
5.8/ SPR/N
440V AC
3.3/ SPR/L1.2
3.4/ SPR/L2.2
3.4/ SPR/L3.2
440V AC
3.6/ LTD/L1
3.6/ LTD/L2
3.6/ LTD/L3
220V AC
4.8/ LTD/VL
4.8/ LTD/VN
PE PE PE
-X100 24 25 26 27 28 1 2 3 4PE 5 6 7 8 9 30PE

CABLE BETWEEN
SWITCH-BOARD AND CABLE DRUM
PE
-XSRK1
CABLE
REEL
-XSRK1 24 25 26 27 28 1 2 3 4 5 6 7 8 9 30
DRUM CABLE
-XS82
PLUG
CONNECTOR PE
PE
-XS82 24 25 26 27 28 1 2 3 4 5 6 7 8 9 -XS82 30
PE
+A1
5 7

Com-No ass.-gr.
Ch.
6
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
GREEN WHITE RED BLACK ALL TWL TWL EXPAND RETRACT MOVE MOVE
FLIPPERS FLIPPER FLIPPERS FLIPPER FLIPPERS LOCK UNLOCK TELESCOPE TELESCOPE G.P. TO G.P. TO
DOWN DOWN DOWN DOWN UP WHITE BLACK
220VAC
4.8/ SPR/L SPR/L /6.1
11 11 11 11 11 11 11 11 11 11 11
-K100 -K101 -K102 -K103 -K104 -K105 -K106 -K107 -K108 -K109 -K110
=M06/7.4 14 =M06/7.5 14 =M06/7.6 14 =M06/7.7 14 =M06/8.1 14 =M06/8.2 14 =M06/8.3 14 =M06/8.4 14 =M06/8.5 14 =M06/8.6 14 =M06/8.7 14
-X100 10 11 12 13 14 15 16 17 18 19 20
CABLE BETWEEN
-XSRK1
CABLE
REEL
-XSRK1 10 11 12 13 14 15 16 17 18 19 20
DRUM CABLE
-XS82
PLUG
CONNECTOR
-XS82 10 11 12 13 14 15 16 17 18 19 20
+A1
6 8

Com-No ass.-gr.
Ch.
7
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
TWL TWL ALL FAULT IN

LOCKED UNLOCKED LANDED SPREADER
CONTROL
5.8/ LOCKED
5.8/ UNLOCKED
5.8/ LANDED
5.8/ SPR_FAULT
-X100 21 22 23 29
CABLE BETWEEN
-XSRK1
CABLE
REEL
-XSRK1 21 22 23 29
DRUM CABLE
-XS82
PLUG
CONNECTOR
-XS82 21 22 23 29
+A1
7 =PE/1

Com-No ass.-gr.
Ch.
8
CIRCUIT DIAGRAM
0 1 2 3 4 5 6 7 8 9
POWER
SUPPLY
SLIP RING
ASSEMBLY
-XSRK PE
+A1.S
(L)M2XH
70mmý
PE
CRANE TOWER CRANE TOWER

PE PE
PE PE
+T1.U
(L)M2XH NSGA
70mmý 70mmý
PE
ye/gn
PUMP MODULE 16mmý
PE
PE P1:PE
JIB
PE
F1 PE
(L)M2XH (L)M2XH
70mmý 70mmý
ye/gn ye/gn
4mmý 4mmý
PE
CABINET
-M1 PE PULT_L PE PULT_R PE
CONTROL
=M02-M1
CABINET
+P1.H +M1 +F1-PL +F1-PR
+P1 +F1 +A1.J
=M80/8 =TERMINALS/1

Com-No ass.-gr.
Ch.
1
PE Typ Bl.
CIRCUIT DIAGRAM
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = PE +P1.H
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-ELIGHTSUPPLY
(L)M2XH
W-L4L5
(L)M2XH-PE
W-PE
(L)M2XH
W-L3
(L)M2XH
W-L2
(L)M2XH
W-L1
TERMINAL BLOCK -XSR
3x1.5mmý
2x6mmý
1x70mmý
2x1x70mmý
2x1x70mmý
2x1x70mmý
EXTERNAL TERMINAL INTERNAL
SIDE/
PATHTEXT TARGET CONT. No. BRIDGES TARGET CONT. PATH
POWER SUPPLY L1 BK =M01-S1 1 L1 =M01/1.1
POWER SUPPLY PE BK =M01-PE PE =M01/1.1

AUX. POWER SUPPLY BK -X3 1 L4 =M01/1.2
AUX. POWER SUPPLY BU -X3 2 L5 =M01/1.2
POWER SUPPLY L6 BK -X3 3 L6 =M03/1.1
POWER SUPPLY L7 BU -X3 4 L7 =M03/1.1

=PE/1 2

Com-No ass.-gr.
Ch.
1
-XSR SLIP RING ASSEMBLY Typ Bl.
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = TERMINALS

0 1 2 3 4 5 6 7 8 9
(L)M2XH-Jú
W-S31/X3
(L)M2XH-J
W-E32
(L)M2XH-Jú
W-S03/LIGHTING
(L)M2XH-J
W-E31
(L)M2XH
W-L4L5
(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK -X3
7x1.5mmý
3x1.5mmý
5x1.5mmý
5x1.5mmý
2x6mmý
5x1.5mmý
SIDE/
AUX. POWER SUPPLY BK -XSR L4 1 =M01-S2 1 =M01/1.2
AUX. POWER SUPPLY BU -XSR L5 2 =M01-S2 3 =M01/1.2
LIGHT CRANE TOWER BELOW 1 =M03-E31 L1 3 =M03-F30 2 =M03/1.6
LIGHT CRANE TOWER BELOW 2 =M03-E31 N1 4 =M03-F30 4 =M03/1.6

PE 5PE =M03-PE1 =M03/1.6
1 =M03-S03 1 6 =M03-F30 2 =M03/1.2
2 =M03-S03 3 7 =M03-F30 4 =M03/1.2
PE 8PE =M03-PE =M03/1.2
3 =M03-S03 2 9 =M03/1.3
4 =M03-S03 4 10 =M03/1.3
PE PE =M03-S03 PE 11PE =M03-PE =M03/1.3
LIGHT CRANE TOWER BELOW 3 =M03-E31 L 12 =M03/1.5

LIGHT CRANE TOWER BELOW 4 =M03-E31 N 13 =M03/1.5
PE PE =M03-E31 PE 14PE =M03-PE =M03/1.5
LIGHT POWER MODULE BK =M03-E32 L 15 =M03/1.8
LIGHT POWER MODULE BU =M03-E32 N 16 =M03/1.8
PE PE =M03-E32 PE 17PE =M03-PE =M03/1.8
SUPPLY CONTROL DESK RIGHT 220V 1 -X60 1 21 =M03-F31 2 =M03/2.1
SUPPLY CONTROL DESK RIGHT 220V 2 -X60 2 22 =M03-F31 4 =M03/2.1
SUPPLY CONTROL DESK LEFT PE PE -X60 3PE 23PE =M03-PE =M03/2.2
WORKING LIGHT 3 -X60 10 24 -X12 1 1 =M03/2.5
WORKING LIGHT 4 -X60 11 25 -X12 2 2 =M03/2.5
PE =M03-PE 26PE =M03/2.5
SPARE 27 =M03/2.3
1 SPARE 28 2.1
=M03/2.3

Com-No ass.-gr.
Ch.
2
TERMINAL BLOCK -X3 Typ Bl.
83156 25.97 50 letzte nd./last mod. 08.Nov.2013 ALP
220V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-X3/X80
(L)M2XH-J
W-M1/HEATER
(L)M2XH-J
W-E6
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-X3/X12
(L)M2XH-Jú
W-S31/X3
TERMINAL BLOCK -X3
3x1.5mmý
3x1.5mmý
3x1.5mmý
3x1.5mmý
5x1.5mmý
7x1.5mmý
SIDE/
SPARE PE 29PE =M03-PE =M03/2.4
WARNING LIGHT RED 3 -X12 3 30 -X60 12 5 =M03/2.6
WARNING LIGHT RED 4 -X12 4 31 -X60 13 6 =M03/2.7
PE PE -X12 5PE 32PE =M03-PE =M03/2.7

SUPPLY CONTROL DESK LEFT 220V BK -X60 4 33 =M03-F32 2 =M03/3.1
SUPPLY CONTROL DESK LEFT 220V BU -X60 5 34 =M03-F32 4 =M03/3.1
SUPPLY CONTROL DESK LEFT PE PE -X60 6PE 35PE =M03-PE =M03/3.2
HEATER CRANE TOWER BK =M03-E6 L 36 =M03-F33 2 =M03/4.1
HEATER CRANE TOWER BU =M03-E6 N 37 =M03-F33 4 =M03/4.1
HEATER CRANE TOWER PE PE =M03-E6 PE 38PE =M03-PE =M03/4.2
HEATER CONTROL CABINET =M03-E5 L 39 =M03-S35 1 =M03/4.3
HEATER CONTROL CABINET =M03-E5 N 40 =M03/4.3

HEATER CONTROL CABINET PE =M03-E5 PE 41PE =M03-PE =M03/4.4
FAN CONTROL CABINET =M03-M31 L 42 =M03-S35 2 =M03/4.5
FAN CONTROL CABINET =M03-M31 N 43 =M03/4.5
FAN CONTROL CABINET PE =M03-M31 PE 44PE =M03-PE =M03/4.5
SUPPLY FOR AMPERAGE MONITOR =M02-T1 L 45 =M03-F34 2 =M03/4.5
SUPPLY FOR AMPERAGE MONITOR =M02-T1 N 46 =M03/4.6
SUPPLY FOR AMPERAGE MONITOR PE 47PE =M03-PE =M03/4.6
STANDSTILLHEATER MAIN MOTOR BK -XM1 L 48 =M02-K3 32 =M03/4.6
STANDSTILLHEATER MAIN MOTOR BU -XM1 N 49 =M03/4.6
STANDSTILLHEATER MAIN MOTOR PE PE 85PE 50PE =M03-PE =M03/4.7
HEATER SUPPLY CARGO GEAR BK -X80 5 63 =M02-K2 31 =M03/4.7
HEATER SUPPLY CARGO GEAR BU -X80 6 64 =M03-H2 X2 =M03/4.7
2 HEATER SUPPLY CARGO GEAR PE PE -X80 7PE 65PE =M03-PE 2.2

=M03/4.7

Com-No ass.-gr.
Ch.
2.1
0 1 2 3 4 5 6 7 8 9
TERMINAL BLOCK -X3

SIDE/
SPARE 66 =M03/4.8
SPARE 67 =M03-F34 4 =M03/4.8
SPARE 68PE =M03-PE =M03/4.9

2.1 3

Com-No ass.-gr.
Ch.
2.2
0 1 2 3 4 5 6 7 8 9
(L)M2XH_J_1 4x2.5mmý
W-X4/X11
W-M11
(L)M2XH-J
W-S04
TERMINAL BLOCK -X4
3x1.5mmý
SIDE/
EMERGENCY OFF BK -X75 1 1 =M01-S1 D2 =M01/1.8
EMERGENCY OFF BU -X75 2 2 =M01/1.8
EMERGENCY OFF PE -X75 3PE 3PE =M01-PE =M01/1.8
EMERGENCY OFF 4 =M01/1.9

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

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

Com-No ass.-gr.
Ch.
3
380/440V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
Quattro
W-Y1T
Oelflex 110CY
W-S16
Oelflex 110CY
W-S26
Quattro
W-X62_24V
CAN_4x0,75
W-CAN4
QUATTRO-O
W-P1Q
Quattro
W-S85
Oelflex 110CY
W-X81/X5
3Norm
W-X5/X51
CAN_4x0,75
W-CAN1
TERMINAL BLOCK -X5
3x1mmý
7x0.5mmý
7x0.5mmý
3x1mm
4x0.75mmý
2x1.5mmý
3x1mmý
7x1mmý
5x1mmý
4x0.75mmý
SIDE/
EXTERNAL CONSUMERS GN -XA3T 05 1 =M01-F15 =M01/3.5
EXTERNAL CONSUMERS 1 -X51 1 2 =M01/3.5
FAULT IN CARGO GEAR 1 -X81 1 3 =M06/5.2
SPREADER OPERATION 1 -X72 47 4 =M06/5.8

EXTERNAL CONSUMERS 1 XA2T 05 5 =M01/3.6
EXTERNAL CONSUMERS GN -X72 10 6 =M01-F16 =M01/3.6
EXTERNAL CONSUMERS 7 =M01/3.6
+24V =M01-F11 8 -XA1 23 =M06/1.3
SUPPLY AUX. CONSUMERS 1 -X62 11 9 =M01-F17 =M05/1.6
24N (GND) YE -XA3T 03 10 =M01-U1 - =M01/3.7
24N (GND) 2 XA2T 03 11 =M01/3.7
24N (GND) YE -X72 15 12 =M01/3.8

24N (GND) 13 =M01/3.8
24N_EXT 2 -X62 12 14 =M05/1.7
24N_EXT 2 -XS26 1 15 =M06/3.5
24N_EXT 2 -X51 3 16 =M06/3.7
24N_EXT 2 -XS16 1 17 =M06/4.5
24N_EXT 18 =M06/4.8
24N_EXT 2 -XY1T 2 19 =M06/6.1
3 4.1

Com-No ass.-gr.
Ch.
4
24V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
3Norm
W-X5/X51
Quattro
W-S19
Oelflex 110CY
W-S16
Oelflex 110CY
W-S26
CAN_4x0,75
W-CAN1
CAN_4x0,75
W-CAN4
Oelflex 110CY
W-X5/X81
Quattro
W-Y84
TERMINAL BLOCK -X5
5x1mmý
3x1mmý
7x0.5mmý
7x0.5mmý
4x0.75mmý
4x0.75mmý
18x1mmý
3x1mmý
SIDE/
24N_EXT 1 -XY84 2 20 =M06/6.7
24N_EXT 1 -X81 20 21 =M06/8.7
24N_INT =M02-F4 A2 22 -XA1 12 =M06/1.1
24N_INT 23 -XA1 15 =M06/1.2

24N_INT =M02-K4 A2 24 -XA1 01 =M06/1.2
24N (GND) 30 -XA1 33 =M06/1.6
24N (GND) 31 =M06/1.6
24N (GND) 32 =M06/1.6
CAN BUS WH -X72 1 35 -XA1 14 =M06/1.7
CAN BUS WH -XA3T 01 36 =M06/1.7
CAN BUS 37 =M06/1.7
CAN BUS BN -X72 4 40 -XA1 32 =M06/1.7

CAN BUS BN -XA3T 02 41 =M06/1.8
CAN BUS 42 =M06/1.8
LIMIT SW. LUFFING GEAR 24V DC 1 =M06-S26.1 11 45 =M02-K3 43 =M06/3.1
LIMIT SW. HOISTING GEAR 24V DC 1 =M06-S16.1 11 46 =M06/4.1
SLACK ROPE SW. HOISTING GEAR 1 =M06-S19 50 -XA1 18 =M06/2.2
LIM. SW. LG LUFFING IN 3 =M06-S26.1 12 51 -XA1 46 =M06/3.1
LIM. SW. LG LUFFING OUT 4 =M06-S26.2 22 52 -XA1 47 =M06/3.3
INCREMENTAL ENCODER 5 -XS26 4 53 -XA1 20 =M06/3.4
INCREMENTAL ENCODER LUFFING 6 -XS26 3 54 -XA1 02 =M06/3.5
GEAR
SYNCHRON PULSE LG 3 -X51 5 55 -XA1 09 =M06/3.7
LIMIT HOISTING 3 =M06-S16.1 12 56 -XA1 19 =M06/4.1
4 LIMIT LOWERING 4 =M06-S16.2 22 57 -XA1 55 4.2

=M06/4.3

Com-No ass.-gr.
Ch.
4.1
24V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
Oelflex 110CY
W-X5/X81
Quattro
W-Y84
Quattro
W-Y1T
Quattro
W-M1/THERM
Oelflex 110CY
W-X81/X5
3Norm
W-X5/X51
Oelflex 110CY
W-S16
Quattro
W-S85
TERMINAL BLOCK -X5
18x1mmý
3x1mmý
3x1mmý
3x1mmý
7x1mmý
5x1mmý
7x0.5mmý
3x1mmý
SIDE/
INCREMENTAL ENCODER 5 -XS16 4 58 -XA1 21 =M06/4.4
INCREMENTAL ENCODER HOIST. 6 -XS16 3 59 -XA1 38 =M06/4.5
GEAR
SYNCHRON PULSE HG 4 -X51 6 60 -XA1 37 =M06/4.7

FAULT IN CARGO GEAR 2 -X81 2 61 -XA1 27 =M06/5.2
TWL LOCKED 3 -X81 3 62 -XA1 42 =M06/5.3
TWL UNLOCKED 4 -X81 4 63 -XA1 43 =M06/5.4
ALL LANDED 5 -X81 5 64 -XA1 04 =M06/5.5
THERMISTOR MAIN MOTOR 1 -XM1 T1 65 =M02-F4 T1 =M02/1.7
THERMISTOR MAIN MOTOR 2 -XM1 T2 66 =M02-F4 T2 =M02/1.8
TRIMOT (PWM-OUTPUT) 1 -XY1T 1 67 -XA1 44 =M06/6.1
SOLENOID VALVE CABLE REEL 2 -XY84 1 68 -XA1 45 =M06/6.7

SPREADER OPERATION 2 =M80-K95 A1 69 -X72 48 2 =M06/7.1
LOAD TURNER LEFT 3 -X81 6 70 A1 16 =M06/7.2
LOAD TURNER RIGHT 4 -X81 7 71 A1 35 =M06/7.3
GREEN FLIPPERS DOWN 5 -X81 8 72 A1 39 =M06/7.4
WHITE FLIPPER DOWN 6 -X81 9 73 A1 03 =M06/7.5
RED FLIPPERS DOWN 7 -X81 10 74 A1 40 =M06/7.6
BLACK FLIPPERS DOWN 8 -X81 11 75 A1 22 =M06/7.7
ALL FLIPPERS UP 9 -X81 12 76 -XA1 41 =M06/8.1
TWL LOCK 10 -X81 13 77 -XA1 48 =M06/8.2
TWL UNLOCK 11 -X81 14 78 -XA1 49 =M06/8.3
EXPAND TELESCOPE 12 -X81 15 79 -XA1 31 =M06/8.4
RETRACT TELESCOPE 13 -X81 16 80 -XA1 50 =M06/8.5
4.1
MOVE G.P. TO WHITE 14 -X81 17 81 -XA1 51 4.3
=M06/8.6

Com-No ass.-gr.
Ch.
4.2
24V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
Oelflex 110CY
W-X5/X81
TERMINAL BLOCK -X5
18x1mmý
SIDE/
MOVE G.P. TO BLACK 15 -X81 18 82 -XA1 52 =M06/8.7

4.2 5

Com-No ass.-gr.
Ch.
4.3
24V CONTROL CABINET
0 1 2 3 4 5 6 7 8 9
H07RN
W-M12
W-X4/X11
TERMINAL BLOCK -X11
4x1.5mmý
SIDE/
HYDRAULIC OIL COOLER MOTOR BK =M02-M12 W1 1 -X4 10 BK =M02/2.5
HYDRAULIC OIL COOLER MOTOR BN =M02-M12 V1 2 -X4 11 BN =M02/2.5
HYDRAULIC OIL COOLER MOTOR GY =M02-M12 U1 3 -X4 12 GY =M02/2.5
HYDRAULIC OIL COOLER MOTOR PE =M02-M12 4PE -X4 13PE GNYE =M02/2.6
4.3 6

Com-No ass.-gr.
Ch.
5
TERMINAL BOX OIL COOLER
0 1 2 3 4 5 6 7 8 9
H07RN
W-X12/X13
(L)M2XH-Jú
W-X3/X12
TERMINAL BLOCK -X12
5x1.5mmý
5x1.5mmý
SIDE/
WORKING LIGHT BK -X13 1 1 -X3 24 1 =M03/2.5
WORKING LIGHT GY -X13 2 2 -X3 25 2 =M03/2.5
WARNING LIGHT RED BN -X13 3 3 -X3 30 3 =M03/2.6
WARNING LIGHT RED BU -X13 4 4 -X3 31 4 =M03/2.7

WARNING LIGHT RED PE -X13 6PE 5PE -X3 32PE PE =M03/2.7

5 7

Com-No ass.-gr.
Ch.
6
TERMINAL BOX JIB-BEARING
0 1 2 3 4 5 6 7 8 9
H07RN
W-E38
H07RN
W-E37
H07RN
W-X12/X13
TERMINAL BLOCK -X13
3x1.5mmý
3x1.5mmý
5x1.5mmý
SIDE/
WORKING LIGHT BN =M03-E37 L 1 -X12 1 BK =M03/2.5
WORKING LIGHT BU =M03-E37 N 2 -X12 2 GY =M03/2.5
WARNING LIGHT RED BN =M03-E38 L 3 -X12 3 BN =M03/2.6
WARNING LIGHT RED BU =M03-E38 N 4 -X12 4 BU =M03/2.7

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

6 8

Com-No ass.-gr.
Ch.
7
TERMINAL BOX JIB TOP
0 1 2 3 4 5 6 7 8 9
EVC003
W-X51/B16
EVC003
W-X51/B26
3Norm
W-X5/X51
TERMINAL BLOCK -X51
4x0.34mmý
4x0.34mmý
5x1mmý
SIDE/
SYNCHRON PULSE LG BN -XB26 1 1 -X5 2 1 =M06/3.7
SYNCHRON PULSE HG BN -XB16 1 2 =M06/4.7
SYNCHRON PULSE LG BU -XB26 3 3 -X5 16 2 =M06/3.7
SYNCHRON PULSE HG BU -XB16 3 4 =M06/4.7

SYNCHRON PULSE LG BK -XB26 4 5 -X5 55 3 =M06/3.7
SYNCHRON PULSE HG BK -XB16 4 6 -X5 60 4 =M06/4.7

7 9

Com-No ass.-gr.
Ch.
8
TERMINAL BOX -X51 Typ Bl.
24V SYNC. PULSE PROXIS
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E2
H07RN
W-X60/E8
(L)M2XH-J
W-E36
(L)M2XH-J
W-S34/X3
(L)M2XH-Jú
W-S31/X3
TERMINAL BLOCK -X60
3x1.5mmý
3x1mmý
3x1.5mmý
3x1.5mmý
7x1.5mmý
SIDE/
DESK HEATER 1 -X3 21 1 =M03-S31 13 =M03/2.1
DESK HEATER 2 -X3 22 2 =M03-S31 33 =M03/2.1
LIGHT CABIN PE PE -X3 23PE 3PE =M03-PE1 PE2 =M03/2.2
HEATING FAN CABIN BK -X3 33 4 =M03-S34 13 =M03/3.1

HEATING FAN CABIN BU -X3 34 5 =M03-S34 33 =M03/3.1
PE PE -X3 35PE 6PE =M03-PE1 PE2 =M03/3.2
LIGHT CABIN BK =M03-E36 L 7 =M03-S31 14 =M03/2.1
LIGHT CABIN BU =M03-E36 N 8 =M03-S31 34 =M03/2.1
LIGHT CABIN PE PE =M03-E36 PE 9PE =M03-PE1 PE2 =M03/2.2
WORKING LIGHT 3 -X3 24 10 =M03-S32 14 =M03/2.5
WORKING LIGHT 4 -X3 25 11 =M03-S32 34 =M03/2.5
WARNING LIGHT RED 5 -X3 30 12 =M03-S33 14 =M03/2.6

WARNING LIGHT RED 6 -X3 31 13 =M03-S33 34 =M03/2.7
HEATING FAN CABIN BN =M03-E8 L 14 =M03-S34 14 =M03/3.1
HEATING FAN CABIN BU =M03-E8 N 15 =M03-S34 34 =M03/3.1
PE PE =M03-E8 PE 16PE =M03-PE1 PE5 =M03/3.1
DESK HEATER CONTROL DESK RIGHT BK -X70 1 17 =M03-S34 13 =M03/3.3
DESK HEATER CONTROL DESK RIGHT BU -X70 2 18 =M03-S34 33 =M03/3.3
PE PE -X70 3PE 19PE =M03-PE1 PE5 =M03/3.3
8 10

Com-No ass.-gr.
Ch.
9
CONTROL DESK LEFT CABIN
0 1 2 3 4 5 6 7 8 9
™lfl140CY
W-X62/X72SPR
Quattro
W-HORN
Quattro
W-FAN
Quattro
W-SWIPER
Quattro
W-X62_24V
™lfl140CY
W-S22V
™lfl140CY
W-S22
TERMINAL BLOCK -X62
12x0.5mmý
3x1mmý
3x1mm
5x1mmý
3x1mm
12x0.5mmý
12x0.5mmý
SIDE/
CONTROL LEVER LUFFING IN 1 -X72 21 1 =M07-S22 03 1 =M07/5.1
SET VALUE LUFFING GEAR 2 -X72 22 2 =M07-S22 A 2 =M07/5.2
SET VALUE LUFFING GEAR 3 -X72 23 3 =M07-S22 S 3 =M07/5.3
SLEWING CLKW (RIGHT) 4 -X72 24 4 =M07-S32 05 4 =M07/5.5

SET VALUE SLEWING GEAR 5 -X72 25 5 =M07-S32 A 5 =M07/5.5
SET VALUE SLEWING GEAR 6 -X72 26 6 =M07-S32 S 6 =M07/5.6
SET VALUE SLEWING GEAR 7 -X72 27 7 =M07-S32 E 7 =M07/5.6
SPARE SH -X72 28 9 W-S22 S SH =M07/5.7
SUPPLY 24V CONTR.DESK RIGHT 1 -X5 9 11 =M07-S22H 3 =M05/1.6
SUPPLY 24V CONTR.DESK RIGHT 2 -X5 14 12 =M05/1.7
WINDSCREEN WIPER 24V DC 2 -XM50 2 13 =M05-S8 21 =M05/1.2
WINDSCREEN WIPER 24V DC 3 -XM50 3 14 =M05-S8 22 =M05/1.3

WINDSCREEN WIPER 24V DC 4 -XM50 5 15 =M05/1.3
FAN 24V DC 1 =M05-M51 + 16 =M05-S8 34 =M05/1.5
WINDSCREEN WIPER 0V DC 1 -XM50 1 17 =M05/1.3
FAN 0V DC 2 =M05-M51 - 18 =M05/1.5
HORN 24V DC 1 =M05-H50 1 19 =M07-S22H 4 =M05/1.6
HORN 0V DC 2 =M05-H50 2 20 =M05/1.7
HORN PE PE =M05-H50 PE 21PE =M05-PE PE =M05/1.7
SUPPLY SPREADER CONTROL 1 -X72 30 22 -XS22 1 =M07/8.4
SWITCHES
SPARE 2 -X72 31 23 -XS22 2 =M07/8.4
SPREADER EXPAND TELESCOPE 3 -X72 32 24 -XS22 3 =M07/8.5
RETRACT TELESCOPE 4 -X72 33 25 -XS22 4 =M07/8.6
9 SPARE 5 -X72 34 26 -XS22 5 10.1

=M07/8.6

Com-No ass.-gr.
Ch.
10
0 1 2 3 4 5 6 7 8 9
™lfl140CY
W-X62/X72SPR
TERMINAL BLOCK -X62
12x0.5mmý
SIDE/
SPREADER MOVE G.P. TO WHITE 6 -X72 35 27 -XS22 6 =M07/8.7
MOVE G.P. TO BLACK 7 -X72 36 28 -XS22 7 =M07/8.8

10 11

Com-No ass.-gr.
Ch.
10.1
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-E2
TERMINAL BLOCK -X70
3x1.5mmý
SIDE/
DESK HEATER CONTROL DESK RIGHT BK -X60 17 1 =M03-E2 L =M03/3.3
DESK HEATER CONTROL DESK RIGHT BU -X60 18 2 =M03-E2 N =M03/3.3
DESK HEATER CONTROL DESK RIGHT PE -X60 19PE 3PE =M03-E2 PE =M03/3.3
10.1 12

Com-No ass.-gr.
Ch.
11
CONTROL DESK RIGHT CABIN
0 1 2 3 4 5 6 7 8 9
™lfl140CY
W-S22V
LYCY
W-X72A5
LYCY
W-X72A6
LYCY
W-X72A9
CAN_4x0,75
W-CAN4
LYCY
W-X72A5
LYCY
W-X72A6
TERMINAL BLOCK -X72
12x0.5mmý
4x0.5mmý
4x0.5mmý
4x0.5mmý
4x0.75mmý
4x0.5mmý
4x0.5mmý
SIDE/
CAN-BUS SUPPLY WH -X5 35 1 -X3A5 6 2 =M07/4.1
CAN-BUS SUPPLY 2 -X3A9 6 2 =M07/8.1
CAN-BUS SUPPLY 2 -XA6 5 3 =M07-R1 =M07/8.2
CAN-BUS SUPPLY BN -X5 40 4 -X3A5 5 1 =M07/4.1

CAN-BUS SUPPLY 1 -X3A9 5 5 =M07/8.1
CAN-BUS SUPPLY 1 -XA6 1 6 =M07-R1 =M07/8.2
CAN-BUS SUPPLY SH W-X72A5 S 7 W-X72A5 S SH =M07/4.1
CAN-BUS SUPPLY SH W-X72A9 S 8 W-X72A6 S SH =M07/8.1
MODULE SUPPLY GN -X5 6 10 -X1A5 2 =M07/4.2
SPARE -X2A5 6 11 =M07/5.8
MODULE SUPPLY -X72 12 12 -X1A9 2 =M07/8.2

CAN-BUS SUPPLY -XA6 6 14 =M07/7.3
MODULE SUPPLY YE -X5 12 15 -X1A5 18 =M07/4.2
SPARE -XA6 3 16 -X2A5 18 =M07/5.8
CAN-BUS SUPPLY -XA6 2 19 =M07/7.3
EOS 20 -X1A5 1 =M07/4.3
CONTROL LEVER LUFFING IN 1 -X62 1 21 -X2A5 1 =M07/5.1
SET VALUE LUFFING GEAR 2 -X62 2 22 -X2A5 13 =M07/5.2
SET VALUE LUFFING GEAR 3 -X62 3 23 -X2A5 11 =M07/5.3
SLEWING CLKW (RIGHT) 4 -X62 4 24 -X2A5 3 =M07/5.5
SET VALUE SLEWING GEAR 5 -X62 5 25 -X2A5 14 =M07/5.5
11SET VALUE SLEWING GEAR 6 -X62 6 26 -X2A5 12 12.1

=M07/5.6

Com-No ass.-gr.
Ch.
12
0 1 2 3 4 5 6 7 8 9
Quattro
W-S85
W-X72/=M06-S85
™lfl140CY
W-X62/X72SPR
™lfl140CY
W-S22V
Quattro
W-S85
TERMINAL BLOCK -X72
3x1mmý
1x
12x0.5mmý
12x0.5mmý
3x1mmý
SIDE/
SET VALUE SLEWING GEAR 7 -X62 7 27 -X2A5 4 =M07/5.6
SPARE SH -X62 9 28 -X2A5 16 =M07/5.7
SUPPLY SPREADER CONTROL 1 -X62 22 30 -X2A9 2 =M07/8.4
SWITCHES
SPARE 2 -X62 23 31 =M07/8.4
SPREADER EXPAND TELESCOPE 3 -X62 24 32 -X2A9 1 =M07/8.5
RETRACT TELESCOPE 4 -X62 25 33 -X2A9 3 =M07/8.6
SPARE 5 -X62 26 34 =M07/8.6
SPREADER MOVE G.P. TO WHITE 6 -X62 27 35 -X2A9 5 =M07/8.7
MOVE G.P. TO BLACK 7 -X62 28 36 -X2A9 7 =M07/8.8
GND SH W-X62/X72SPR
S 37 -X2A9 16 =M07/8.9
SUPPLY SPREADER CONTROL -XS12 1 38 -X1A9 4 =M07/9.1

SWITCHES
SPARE -XS12 2 39 =M07/9.2
SPREADER GREEN FLIPPERS DOWN -XS12 3 40 -X1A9 1 =M07/9.3
WHITE FLIPPERS DOWN -XS12 4 41 -X1A9 3 =M07/9.3
RED FLIPPERS DOWN -XS12 5 42 -X1A9 5 =M07/9.4
BLACK FLIPPERS DOWN -XS12 6 43 -X1A9 7 =M07/9.5
ALL FLIPPERS UP -XS12 7 44 -X1A9 11 =M07/9.6
TWL LOCK -XS12 8 45 -X2A9 11 =M07/9.7
TWL UNLOCK -XS12 9 46 -X2A9 12 =M07/9.7
SPREADER OPERATION 1 =M06-S85 47 -X5 4 1 =M06/5.8
SPREADER OPERATION 2 -X5 69 48 =M06-S85 =M06/5.8
12 13

Com-No ass.-gr.
Ch.
12.1
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
W-S04
TERMINAL BLOCK -X75
3x1.5mmý
SIDE/
MAIN SWITCH POWER SUPPLY BK -X4 1 1 =M01-S4 21 =M01/1.8
MAIN SWITCH POWER SUPPLY BU -X4 2 2 =M01-S4 22 =M01/1.8
MAIN SWITCH POWER SUPPLY PE -X4 3PE 3PE =M01/1.8

12.1 14

Com-No ass.-gr.
Ch.
13
PLUG CONNECTOR -X75 Typ Bl.
380/440V CONTROL DESK RIGHT
0 1 2 3 4 5 6 7 8 9
(L)M2XH-J
WX31-E3
(L)M2XH-J
W-X3/X80
(L)M2XH-J
W-CARGO_SUPPLY
TERMINAL BLOCK -X80
3x1.5mmý
3x1.5mmý
4x25mmý
SIDE/
POWER SUPPLY 440V, 60Hz BK =M01-F2 2 1 =M80-F82 1 =M80/2.1
POWER SUPPLY 440V, 60Hz BU =M01-F2 4 2 =M80-F82 3 =M80/2.1
POWER SUPPLY 440V, 60Hz BN =M01-F2 6 3 =M80-F83 5 =M80/2.1
POWER SUPPLY 440V, 60Hz PE =M01-PE 4PE =M80-PE =M80/2.2

POWER SUPPLY 220V BK -X3 63 5 =M80/1.2
AC/L
POWER SUPPLY 220V BU -X3 64 6 =M80/1.2
AC/N
SUPPLY PE PE -X3 65PE 7PE =M80-PE =M80/1.2
HEATER CONTROL CABINET =M80-E8 L 8 =M80/1.3
HEATER CONTROL CABINET =M80-E8 N 9 =M80/1.3
HEATER CONTROL CABINET 10PE =M80-PE =M80/1.4

HEATER CABLE REEL BK =M80-E9 L 11 =M80/1.5
HEATER CABLE REEL BU =M80-E9 N 12 =M80/1.5
HEATER CABLE REEL PE =M80-E9 PE 13PE =M80-PE =M80/1.5
13 15

Com-No ass.-gr.
Ch.
14
440/220V SUPPLY CARGO GEAR
0 1 2 3 4 5 6 7 8 9
Oelflex 110CY
W-X5/X81
Oelflex 110CY
W-X81/X5
TERMINAL BLOCK -X81
18x1mmý
7x1mmý
SIDE/
FAULT IN CARGO GEAR 1 -X5 7 1 =M80-K80 11 =M06/5.2
FAULT IN CARGO GEAR 2 -X5 61 2 =M80-K90 =M06/5.2
TWL LOCKED 3 -X5 62 3 =M80-K91 14 =M06/5.3
TWL UNLOCKED 4 -X5 63 4 =M80-K92 14 =M06/5.4

ALL LANDED 5 -X5 64 5 =M80-K93 14 =M06/5.5
LOAD TURNER LEFT 2 -X5 68 6 =M80-K84 A1 =M06/7.1
LOAD TURNER RIGHT 3 -X5 69 7 =M80-K85 A1 =M06/7.2
SPREADER OPERATION 4 -X5 70 8 =M80-K95 A1 =M06/7.3
GREEN FLIPPERS DOWN 5 -X5 71 9 =M80-K100 A1 =M06/7.4
WHITE FLIPPER DOWN 6 -X5 72 10 =M80-K101 A1 =M06/7.5
RED FLIPPERS DOWN 7 -X5 73 11 =M80-K102 A1 =M06/7.6
BLACK FLIPPERS DOWN 8 -X5 74 12 =M80-K103 A1 =M06/7.7

ALL FLIPPERS UP 9 -X5 75 13 =M80-K104 A1 =M06/8.1
TWL LOCK 10 -X5 76 14 =M80-K105 A1 =M06/8.2
TWL UNLOCK 11 -X5 77 15 =M80-K106 A1 =M06/8.3
EXPAND TELESCOPE 12 -X5 78 16 =M80-K107 A1 =M06/8.4
RETRACT TELESCOPE 13 -X5 79 17 =M80-K108 A1 =M06/8.5
MOVE G.P. TO WHITE 14 -X5 80 18 =M80-K109 A1 =M06/8.6
MOVE G.P. TO BLACK 15 -X5 81 19 =M80-K110 A1 =M06/8.7
LOAD TURNER GND 1 -X5 21 20 =M80-K110 A2 =M06/8.7
14 16

Com-No ass.-gr.
Ch.
15
SLEWING GEAR
0 1 2 3 4 5 6 7 8 9
Semoflex
WX100-XSRK1
TERMINAL BLOCK -X100
30x2.5mmý
SIDE/
SPREADER SUPPLY 1 440V 1 -XSRK1 1 1 =M80-K99 2 =M80/6.4
CONTROL VOLTAGE 220V 4 -XSRK1 4 4PE =M80-PE =M80/6.5

CONTROL VOLTAGE 220V 5 -XSRK1 5 5 =M80-K110 11 =M80/6.6
CONTROL VOLTAGE 220V 6 -XSRK1 6 6 =M80-K93 A2 =M80/6.6
SUPPLY 2 440V 7 -XSRK1 7 7 =M80-K98 2 =M80/6.7
SUPPLY 2 440V 8 -XSRK1 8 8 =M80-K98 4 =M80/6.7
SUPPLY 2 440V 9 -XSRK1 9 9 =M80-K98 6 =M80/6.7
GREEN FLIPPERS DOWN 10 -XSRK1 10 10 =M80-K100 14 =M80/7.1
WHITE FLIPPER DOWN 11 -XSRK1 11 11 =M80-K101 14 =M80/7.2
RED FLIPPERS DOWN 12 -XSRK1 12 12 =M80-K102 14 =M80/7.2

BLACK FLIPPER DOWN 13 -XSRK1 13 13 =M80-K103 14 =M80/7.3
ALL FLIPPERS UP 14 -XSRK1 14 14 =M80-K104 14 =M80/7.4
TWL LOCK 15 -XSRK1 15 15 =M80-K105 14 =M80/7.5
TWL UNLOCK 16 -XSRK1 16 16 =M80-K106 14 =M80/7.5
EXPAND TELESCOPE 17 -XSRK1 17 17 =M80-K107 14 =M80/7.6
RETRACT TELESCOPE 18 -XSRK1 18 18 =M80-K108 14 =M80/7.7
MOVE G.P. TO WHITE 19 -XSRK1 19 19 =M80-K109 14 =M80/7.7
MOVE G.P. TO BLACK 20 -XSRK1 20 20 =M80-K110 14 =M80/7.8
TWL LOCKED 21 -XSRK1 21 21 =M80-K91 A1 =M80/8.2
TWL UNLOCKED 22 -XSRK1 22 22 =M80-K92 A1 =M80/8.2
ALL LANDED 23 -XSRK1 23 23 =M80-K93 A1 =M80/8.3
LOAD TURNING DEVICE FREE 24 -XSRK1 24 24 =M80-K82 14 =M80/6.2
15WHEELING VALVE 16.1

Com-No ass.-gr.
Ch.
16
CARGO GEAR/ CABLE REEL
0 1 2 3 4 5 6 7 8 9
Semoflex
WX100-XSRK1
TERMINAL BLOCK -X100
30x2.5mmý
SIDE/
LOAD TURNING DEVICE FREE 25 -XSRK1 25 25 =M80-K82 A2 =M80/6.2
WHEELING VALVE
MOTOR SUPPLY 26 -XSRK1 26 26 =M80-K81 2 =M80/6.3

FAULT IN SPREADER CONTROL 29 -XSRK1 29 29 =M80-K90 A1 =M80/8.4
PE PE -XSRK1 30 30PE =M80-PE =M80/6.8

16 17

Com-No ass.-gr.
Ch.
16.1
CARGO GEAR/ CABLE REEL
0 1 2 3 4 5 6 7 8 9
Quattro
W-SWIPER
TERMINAL BLOCK -XM50
5x1mmý
SIDE/
WINDSCREEN WIPER =M05-M50 31 1 -X62 17 1 =M05/1.3
WINDSCREEN WIPER =M05-M50 53 2 -X62 13 2 =M05/1.2
WINDSCREEN WIPER =M05-M50 31b 3 -X62 14 3 =M05/1.3
WINDSCREEN WIPER =M05-M50 53a 5 -X62 15 4 =M05/1.3

16.1 18

Com-No ass.-gr.
Ch.
17
PLUG CONNECTOR -XM50 Typ Bl.
WINDSCREEN WIPER
0 1 2 3 4 5 6 7 8 9
TERMINAL BLOCK -XA1

SIDE/
24N(GND) -X5 24 01 =M06/1.2
INCREMENTAL ENCODER LUFFING -X5 54 02 =M06-A1 IX0.13 =M06/3.5
GEAR
ALL LANDED -X5 64 04 =M06-A1 IX0.31 =M06/5.5

+24V =M01-F12 05 =M06/1.1
RS232 (RXD) =M06-SUB-D 3 06 =M06-A1 RXD =M06/1.4
RS232 (TXD) =M06-SUB-D 2 07 =M06-A1 TXD =M06/1.4
MAIN MOTOR AMPERAGE =M02-T1 M1+ 08 =M06-A1 IW03 =M06/2.1
SYNCHRON PULSE LG -X5 55 09 =M06-A1 IX0.02 =M06/3.7
FEED OIL PUMP =M02-K11 14 10 =M06-A1 IX0.04 =M06/2.5
DELTA CONTACTOR =M02-K3 44 11 =M06-A1 IX0.06 =M06/2.7
24N(GND) -X5 22 12 =M06/1.1

CAN 1H -X5 35 14 =M06-A1 CAN1H =M06/1.5
24N(GND) -X5 23 15 =M06/1.2
HYDRAULIC OIL COOLER =M02-K12 A1 17 =M06-A1 QX0.06 =M06/6.6
SLACK ROPE SW. HOISTING GEAR -X5 50 18 =M06-A1 IX0.22 =M06/2.2
LIMIT HOISTING -X5 56 19 =M06-A1 IX0.20 =M06/4.1
INCREMENTAL ENCODER -X5 53 20 =M06-A1 IX0.12 =M06/3.4
INCREMENTAL ENCODER -X5 58 21 =M06-A1 IX0.14 =M06/4.4
+24V -X5 8 23 =M06/1.3
TEST =M06-SUB-D 1 24 =M06-A1 TEST =M06/1.3
FAULT IN CARGO GEAR -X5 61 27 =M06-A1 IX0.01 =M06/5.2
MAIN SWITCH ON =M01-S1 1.X2 28 =M06-A1 IX0.03 =M06/2.4
HYDRAULIC OIL COOLER =M02-K12 14 29 =M06-A1 IX0.05 =M06/2.6
17MAIN MOTOR THERMISTOR RELAY =M02-F4 14 30 =M06-A1 IX0.07 18.1

=M06/2.8

Com-No ass.-gr.
Ch.
18
-XA1 24V PLC CABINET Typ Bl.

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

SIDE/
EXPAND TELESCOPE -X5 78 31 =M06-A1 QX0.18 =M06/8.4
CAN 1L -X5 40 32 =M06-A1 CAN1L =M06/1.5
CAN GND -X5 30 33 =M06-A1 CANGND =M06/1.4
+24V =M01-F13 34 =M06/1.2

MAIN MOTOR TIME RELAY =M02-K4 A1 36 =M06-A1 QX0.04 =M06/6.3
SYNCHRON PULSE HG -X5 60 37 =M06-A1 IX0.23 =M06/4.7
INCREMENTAL ENCODER HOIST. -X5 59 38 =M06-A1 IX0.15 =M06/4.5
GEAR
ALL FLIPPERS UP -X5 75 41 =M06-A1 QX0.12 =M06/8.1
TWL LOCKED -X5 62 42 =M06-A1 IX0.29 =M06/5.3
TWL UNLOCKED -X5 63 43 =M06-A1 IX0.30 =M06/5.4
TRIMOT (PWM-OUTPUT) -X5 67 44 =M06-A1 QX0.00 =M06/6.1

LIMIT LUFFING IN -X5 51 46 =M06-A1 IX0.10 =M06/3.1
LIMIT LUFFING OUT -X5 52 47 =M06-A1 IX0.11 =M06/3.3
TWL LOCK -X5 76 48 =M06-A1 QX0.16 =M06/8.2
TWL UNLOCK -X5 77 49 =M06-A1 QX0.17 =M06/8.3
RETRACT TELESCOPE -X5 79 50 =M06-A1 QX0.19 =M06/8.5
MOVE G.P. TO WHITE -X5 80 51 =M06-A1 QX0.20 =M06/8.6
MOVE G.P. TO BLACK -X5 81 52 =M06-A1 QX0.21 =M06/8.7
SUPPLY SAFETY CIRCUITS =M02-K3 43 53 =M06-A1 QX0.07 =M06/6.8
FEED OIL PUMP =M02-K11 A1 54 =M06-A1 QX0.05 =M06/6.5
LIMIT LOWERING -X5 57 55 =M06-A1 IX0.21 =M06/4.3
18 19

Com-No ass.-gr.
Ch.
18.1
-XA1 24V PLC CABINET Typ Bl.

0 1 2 3 4 5 6 7 8 9
LYCY
W-S12
TERMINAL BLOCK -X1A5
4x0.5mmý
SIDE/
EOS -X72 20 1 =M07-A5 IX5.01 =M07/4.3
MODULE SUPPLY -X72 10 2 =M07-A5 +UB_CH1 =M07/4.2
SWITCH PUMPS START/STOP =M07-S06 14 3 =M07-A5 IX5.02 =M07/4.4
EOS =M07-S06 13 4 =M07-A5 IXS5.02\+UB_CH2 =M07/4.3

KEY BUTTON JIB RESTING =M07-S07 14 5 =M07-A5 IX5.03 =M07/4.5
CONTROL LEVER HOISTING =M07-S12 03 7 =M07-A5 IX5.04 =M07/4.6
LOWERING 1 =M07-S12 A 8 =M07-A5 IW5.05\+UB_CH5 =M07/4.8
SET VALUE HOISTING GEAR 2 =M07-S12 S 11 =M07-A5 IW5.05 =M07/4.8
LEFT =M07-S12LTD 03 12 =M07-A5 IX5.06 =M07/6.4
SET VALUE HOISTING GEAR 3 =M07-S12 E 13 =M07-A5 IW5.05\GND_CH5 =M07/4.8
SET VALUE HOISTING GEAR S 14 =M07-A5 IW5.05\GND_SH5 =M07/4.9
READY FOR OPERATION =M07-H06 X1 15 =M07-A5 QX5.07 =M07/6.1

BUZZER ALARM =M07-H08 X2 16 =M07-A5 QX5.07\GND_CH7 =M07/6.3
FAULT =M07-H07 X1 17 =M07-A5 QX5.08 =M07/6.2
MODULE SUPPLY -X72 15 18 =M07-A5 GND_CH8 =M07/4.2
18.1 20

Com-No ass.-gr.
Ch.
19
-X1A5 24V CAN NODE CABIN Typ Bl.

0 1 2 3 4 5 6 7 8 9

SIDE/
CONTROL LEVER LUFFING IN -X72 21 1 =M07-A5 IX5.09 =M07/5.1
SLEWING CLKW (RIGHT) -X72 24 3 =M07-A5 IX5.10 =M07/5.5
SET VALUE SLEWING GEAR -X72 27 4 =M07-A5 IW5.14\+UB_CH10 =M07/5.6
RIGHT =M07-S12LTD 05 5 =M07-A5 IX5.11 =M07/6.5

SPARE -X72 11 6 =M07-A5 +UB_CH11 =M07/5.8
SET VALUE LUFFING GEAR -X72 23 11 =M07-A5 IW5.13 =M07/5.3
SET VALUE SLEWING GEAR -X72 26 12 =M07-A5 IW5.14 =M07/5.6
SET VALUE LUFFING GEAR -X72 22 13 =M07-A5 IW5.13\GND_CH13 =M07/5.2
SET VALUE SLEWING GEAR -X72 25 14 =M07-A5 IW5.14\GND_CH14 =M07/5.5
BUZZER ALARM =M07-H08 X1 15 =M07-A5 QX5.15 =M07/6.3
SPARE -X72 28 16 =M07-A5 IW5.14\GND_CH15 =M07/5.7
SPREADER OPERATION =M07-S85 17 =M07-A5 IX5.16 =M07/6.6

SPARE -X72 16 18 =M07-A5 GND_CH16 =M07/5.8
19 21

Com-No ass.-gr.
Ch.
20

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

20 22

Com-No ass.-gr.
Ch.
21

0 1 2 3 4 5 6 7 8 9

SIDE/
SPREADER GREEN FLIPPERS DOWN -X72 40 1 =M07-A9 IX9.01 =M07/9.3
MODULE SUPPLY -X72 12 2 =M07-A9 +UB_CH1 =M07/8.2
WHITE FLIPPERS DOWN -X72 41 3 =M07-A9 IX9.02 =M07/9.3
SUPPLY SPREADER CONTROL -X72 38 4 =M07-A9 IXS5.02\+UB_CH2 =M07/9.1

SWITCHES
RED FLIPPERS DOWN -X72 42 5 =M07-A9 IX9.03 =M07/9.4
BLACK FLIPPERS DOWN -X72 43 7 =M07-A9 IX9.04 =M07/9.5
ALL FLIPPERS UP -X72 44 11 =M07-A9 IX9.05 =M07/9.6
TWL LOCK =M07-H09 X1 15 =M07-A9 QX9.07 =M07/10.1
GND_CH7 =M07-H11 X2 16 =M07-A9 QX5.07\GND_CH7 =M07/10.5
TWL UNLOCK =M07-H10 X1 17 =M07-A9 QX9.08 =M07/10.2
MODULE SUPPLY -X72 17 18 =M07-A9 GND_CH8 =M07/8.2

21 23

Com-No ass.-gr.
Ch.
22

0 1 2 3 4 5 6 7 8 9

SIDE/
SPREADER EXPAND TELESCOPE -X72 32 1 =M07-A9 IX9.09 =M07/8.5
SUPPLY SPREADER CONTROL -X72 30 2 =M07-A9 IXS5.02\+UB_CH9 =M07/8.4
SWITCHES
RETRACT TELESCOPE -X72 33 3 =M07-A9 IX9.10 =M07/8.6

SPREADER MOVE G.P. TO WHITE -X72 35 5 =M07-A9 IX9.11 =M07/8.7
MODULE SUPPLY -X72 13 6 =M07-A9 UB_CH11 =M07/9.8
MOVE G.P. TO BLACK -X72 36 7 =M07-A9 IX9.12 =M07/8.8
TWL LOCK -X72 45 11 =M07-A9 IX9.13 =M07/9.7
TWL UNLOCK -X72 46 12 =M07-A9 IX9.14 =M07/9.7
ALL LANDED =M07-H11 X1 15 =M07-A9 QX9.15 =M07/10.3
GND_CH15 -X72 37 16 =M07-A9 GND_CH15 =M07/8.9
SPARE 17 =M07-A9 QX9.16 =M07/10.4

MODULE SUPPLY -X72 18 18 =M07-A9 IW5.05\GND_CH16 =M07/9.8
22 24

Com-No ass.-gr.
Ch.
23

0 1 2 3 4 5 6 7 8 9
LYCY
W-X72A9
4x0.5mmý
SIDE/
CAN-BUS SUPPLY 1 -X72 5 5 =M07-A9 CAN_L =M07/8.1
CAN-BUS SUPPLY 2 -X72 2 6 =M07-A9 CAN_H =M07/8.1

23 25

Com-No ass.-gr.
Ch.
24

0 1 2 3 4 5 6 7 8 9
Semoflex
WXSRK1-XS13
Semoflex
WX100-XSRK1
TERMINAL BLOCK -XSRK1
30x2.5mmý
30x2.5mmý
SIDE/
SPREADER SUPPLY 1 440V 1 -XS82 1 1 -X100 1 1 =M80/6.4
CONTROL VOLTAGE 220V 4 -XS82 4 4 -X100 4PE 4 =M80/6.5

CONTROL VOLTAGE 220V 5 -XS82 5 5 -X100 5 5 =M80/6.6
CONTROL VOLTAGE 220V 6 -XS82 6 6 -X100 6 6 =M80/6.6
SUPPLY 2 440V 7 -XS82 7 7 -X100 7 7 =M80/6.7
SUPPLY 2 440V 8 -XS82 8 8 -X100 8 8 =M80/6.7
SUPPLY 2 440V 9 -XS82 9 9 -X100 9 9 =M80/6.7
GREEN FLIPPERS DOWN 10 -XS82 10 10 -X100 10 10 =M80/7.1
WHITE FLIPPER DOWN 11 -XS82 11 11 -X100 11 11 =M80/7.2
RED FLIPPERS DOWN 12 -XS82 12 12 -X100 12 12 =M80/7.2

BLACK FLIPPER DOWN 13 -XS82 13 13 -X100 13 13 =M80/7.3
ALL FLIPPERS UP 14 -XS82 14 14 -X100 14 14 =M80/7.4
TWL LOCK 15 -XS82 15 15 -X100 15 15 =M80/7.5
TWL UNLOCK 16 -XS82 16 16 -X100 16 16 =M80/7.5
EXPAND TELESCOPE 17 -XS82 17 17 -X100 17 17 =M80/7.6
RETRACT TELESCOPE 18 -XS82 18 18 -X100 18 18 =M80/7.7
MOVE G.P. TO WHITE 19 -XS82 19 19 -X100 19 19 =M80/7.7
MOVE G.P. TO BLACK 20 -XS82 20 20 -X100 20 20 =M80/7.8
TWL LOCKED 21 -XS82 21 21 -X100 21 21 =M80/8.2
TWL UNLOCKED 22 -XS82 22 22 -X100 22 22 =M80/8.2
ALL LANDED 23 -XS82 23 23 -X100 23 23 =M80/8.3
LOAD TURNING DEVICE FREE 24 -XS82 24 24 -X100 24 24 =M80/6.2
24WHEELING VALVE 25.1

Com-No ass.-gr.
Ch.
25
-XSRK1 SCABLE REEL Typ Bl.

0 1 2 3 4 5 6 7 8 9
Semoflex
WXSRK1-XS13
Semoflex
WX100-XSRK1
TERMINAL BLOCK -XSRK1
30x2.5mmý
30x2.5mmý
SIDE/
LOAD TURNING DEVICE FREE 25 -XS82 25 25 -X100 25 25 =M80/6.2
WHEELING VALVE
MOTOR SUPPLY 26 -XS82 26 26 -X100 26 26 =M80/6.3

FAULT IN SPREADER CONTROL 29 -XS82 29 29 -X100 29 29 =M80/8.4
PE PE -XS82 30 30 -X100 30PE PE =M80/6.8

25 26

Com-No ass.-gr.
Ch.
25.1
-XSRK1 SCABLE REEL Typ Bl.

0 1 2 3 4 5 6 7 8 9
Semoflex
WXSRK1-XS13
TERMINAL BLOCK -XS82
30x2.5mmý
SIDE/
SPREADER SUPPLY 1 440V 1 -XSRK1 1 1 =M80/6.46:57
CONTROL VOLTAGE 220V 4 -XSRK1 4 4 =M80/6.58:57

SUPPLY 2 440V 7 -XSRK1 7 7 =M80/6.70:57
SUPPLY 2 440V 8 -XSRK1 8 8 =M80/6.72:57
SUPPLY 2 440V 9 -XSRK1 9 9 =M80/6.74:57
GREEN FLIPPERS DOWN 10 -XSRK1 10 10 =M80/7.15:57
WHITE FLIPPER DOWN 11 -XSRK1 11 11 =M80/7.22:57
RED FLIPPERS DOWN 12 -XSRK1 12 12 =M80/7.29:57

BLACK FLIPPER DOWN 13 -XSRK1 13 13 =M80/7.36:57
ALL FLIPPERS UP 14 -XSRK1 14 14 =M80/7.43:57
TWL LOCK 15 -XSRK1 15 15 =M80/7.50:57
TWL UNLOCK 16 -XSRK1 16 16 =M80/7.57:57
EXPAND TELESCOPE 17 -XSRK1 17 17 =M80/7.64:57
RETRACT TELESCOPE 18 -XSRK1 18 18 =M80/7.71:57
MOVE G.P. TO WHITE 19 -XSRK1 19 19 =M80/7.78:57
MOVE G.P. TO BLACK 20 -XSRK1 20 20 =M80/7.85:57
TWL LOCKED 21 -XSRK1 21 21 =M80/8.23:57
TWL UNLOCKED 22 -XSRK1 22 22 =M80/8.29:57
ALL LANDED 23 -XSRK1 23 23 =M80/8.35:57
LOAD TURNING DEVICE FREE 24 -XSRK1 24 24 =M80/6.22:57
25.1
WHEELING VALVE 26.1

Com-No ass.-gr.
Ch.
26
PLUG CONNECTOR -XS82 Typ Bl.
TURNING DEVICE SPREADER
0 1 2 3 4 5 6 7 8 9
Semoflex
WXSRK1-XS13
30x2.5mmý
SIDE/
LOAD TURNING DEVICE FREE 25 -XSRK1 25 25 =M80/6.24:57
WHEELING VALVE
MOTOR SUPPLY 26 -XSRK1 26 26 =M80/6.31:57

FAULT IN SPREADER CONTROL 29 -XSRK1 29 29 =M80/8.41:57
PE 30 -XSRK1 30 PE =M80/6.88:57
26 27

Com-No ass.-gr.
Ch.
26.1
PLUG CONNECTOR -XS82 Typ Bl.
TURNING DEVICE SPREADER
0 1 2 3 4 5 6 7 8 9

SIDE/
SUPPLY SPREADER CONTROL -X72 38 1 =M07-S12.1 1 =M07/9.1
SWITCHES
SPARE -X72 39 2 =M07-S12.1 2 =M07/9.2
SPREADER GREEN FLIPPERS DOWN -X72 40 3 =M07-S12.2 2 =M07/9.3

WHITE FLIPPERS DOWN -X72 41 4 =M07-S12.3 2 =M07/9.3
RED FLIPPERS DOWN -X72 42 5 =M07-S12.4 2 =M07/9.4
BLACK FLIPPERS DOWN -X72 43 6 =M07-S12.5 2 =M07/9.5
ALL FLIPPERS UP -X72 44 7 =M07-S12.6 2 =M07/9.6
TWL LOCK -X72 45 8 =M07-S12.7 2 =M07/9.7
TWL UNLOCK -X72 46 9 =M07-S12.8 2 =M07/9.7

26.1 28

Com-No ass.-gr.
Ch.
27
TERMINAL STRIP -XS12 Typ Bl.
CONTROL LEVER HG
0 1 2 3 4 5 6 7 8 9

SIDE/
SUPPLY SPREADER CONTROL -X62 22 1 =M07-S22.1 1 =M07/8.4
SWITCHES
SPARE -X62 23 2 =M07-S22.1 2 =M07/8.4
SPREADER EXPAND TELESCOPE -X62 24 3 =M07-S22.2 2 =M07/8.5

RETRACT TELESCOPE -X62 25 4 =M07-S22.3 2 =M07/8.6
SPARE -X62 26 5 =M07-S22.4 2 =M07/8.6
SPREADER MOVE G.P. TO WHITE -X62 27 6 =M07-S22.5 2 =M07/8.7
MOVE G.P. TO BLACK -X62 28 7 =M07-S22.6 2 =M07/8.8

27 =CABLES/1

Com-No ass.-gr.
Ch.
28
TERMINAL STRIP -XS22 Typ Bl.
CONTROL LEVER LG/SG
0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
SOURCE/ TARGET/ LENGHT
CABLE NAME FROM TO CABLE TYPE CORES USED í IN MMý M REMARKS PAGE
W-B01 Sensor 4+S 2+S 0.3 2 TEMPERATURE SENSOR
XB01 -XA4 4+S 2 0.3 TEMPERATURE SENSOR =M07/2.8
S -XA4 4+S 0+S 0.3 TEMPERATURE SENSOR =M07/2.8
W-B10 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR HOISTING
XB10 -XA4 4+S 2 0.3 PRESSURE SENSOR HOISTING =M07/2.3
S -XA4 4+S 0+S 0.3 PRESSURE SENSOR HOISTING =M07/2.3
W-B20 Sensor 4+S 2+S 0.3 2 PRESSURE SENSOR LUFFING
XB20 -XA4 4+S 2 0.3 PRESSURE SENSOR LUFFING =M07/2.5
S -XA4 4+S 0+S 0.3 PRESSURE SENSOR LUFFING =M07/2.5

W-CAN1 -X5 -XA3T CAN_4x0,75 4+S 4 0.75 7.5 CAN BUS CABLE MODULE CR2031 =M01/3.5
W-CAN2 -XA2C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION =M07/3.2
W-CAN3 -XA3C -XA4C CAN-BUS 5+S 2 - 0.3 CAN-BUS CONNECTION =M07/1.2
W-CAN4 -X5 -X72 CAN_4x0,75 4+S 4 0.75 6 CAN BUS CABLE CONNEC. CTRL DESK =M01/3.6
W-CARGO_PE =M80 =M80-PE (L)M2XH-PE 1/PE 1/PE 35 4 PE CARGO GEAR CONTROL =M80/1.1
W-CARGO_SUPPLY (L)M2XH-J 4/PE 4/PE 25 10 SUPPLY CARGO GEAR 440V L3
-X80 =M01-F2 4/PE 3 25 SUPPLY CARGO GEAR 440V L3 =M01/1.6
-X80 =M01-PE 4/PE 1/PE 25 SUPPLY CARGO GEAR 440V L3 =M01/1.6
W-E2 -X60 -X70 (L)M2XH-J 3/PE 3/PE 1.5 3.5 DESK HEATER LEFT =M03/3.3
W-E31 -X3 =M03-E31 (L)M2XH-J 5/PE 5/PE 1.5 4 LIGHT CRANE TOWER BELOW =M03/1.5
W-E32 -X3 =M03-E32 (L)M2XH-J 3/PE 3/PE 1.5 6 LIGHT POWER MODULE =M03/1.8
W-E36 -X60 =M03-E36 (L)M2XH-J 3/PE 3/PE 1.5 3.5 LIGHT CABIN =M03/2.1
W-E37 -X13 =M03-E37 H07RN 3/PE 3/PE 1.5 2 WORKING LIGHT =M03/2.4
W-E38 -X13 =M03-E38 H07RN 3/PE 3/PE 1.5 1.5 WARNING LIGHT RED =M03/2.6
W-E6 -X3 =M03-E6 (L)M2XH-J 3/PE 3/PE 1.5 6 HEATER CRANE TOWER =M03/4.1
W-FAN -X62 =M05-M51 Quattro 3/PE 2 1 4 WINDSCREEN FAN =M05/1.4
W-HORN -X62 =M05-H50 Quattro 3/PE 3/PE 1 3.5 HORN =M05/1.6
W-L1 -XSR =M01-S1 (L)M2XH 2x1 1 70 10 MAIN POWER SUPPLY L1 =M01/1.0
W-L4L5 -X3 -XSR (L)M2XH 2 2 6 10 AUX. POWER SUPPLY L4-L5 =M01/1.2
W-M1/HEATER (L)M2XH-J 3/PE 3/PE 1.5 4 MOTOR HEATER
-X3 -XM1 3/PE 2 1.5 MOTOR HEATER =M03/4.6
-X3 85PE 3/PE 1/PE 1.5 MOTOR HEATER =M03/4.6
W-M1/PE =M02-M1 =M02-PE (L)M2XH 1 1 70 5 MAIN MOTOR PE =M02/1.2
W-M1/THERM -X5 -XM1 Quattro 3/PE 2 1 8 THERMISTOR =M02/1.7
=TERMINALS/28 1.1

Com-No ass.-gr.
Ch.
1
CABLE OVERVIEW Typ Bl.
TTS Marine GmbH 1.3 Sh.
Abt./departm.: -K5 erstellt/designed 20.M„r.2013 TGR = CABLES

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
W-M1/U1 -XM1 =M01-S1 (L)M2XH 1 1 70 7 MAIN MOTOR U1 =M02/1.1
W-M1/U2-1 -XM1 =M02-K3 (L)M2XH 1 1 70 7 MAIN MOTOR U2-1 =M02/1.5
W-M1/V1 -XM1 =M01-S1 (L)M2XH 1 1 70 7 MAIN MOTOR V1 =M02/1.1
W-M1/V2-1 -XM1 =M02-K3 (L)M2XH 1 1 70 7 MAIN MOTOR V2-1 =M02/1.5
W-M1/W1 -XM1 =M01-S1 (L)M2XH 1 1 70 7 MAIN MOTOR W1 =M02/1.1
W-M1/W2-1 -XM1 =M02-K3 (L)M2XH 1 1 70 7 MAIN MOTOR W2-1 =M02/1.4
W-M11 -X4 =M02-M11 (L)M2XH_J_1 4/PE 4/PE 2.5 6.5 FEED OIL PUMP =M02/2.1
W-M12 -X11 =M02-M12 H07RN 4/PE 4/PE 1.5 3 HYDRAULIC OIL COOLER =M02/2.5
W-P1Q XA2T -X5 QUATTRO-O 2 2 1.5 7.5 SUPPLY COMPACT MODULE =M01/3.6
W-PE -XSR =M01-PE (L)M2XH-PE 1/PE 1/PE 70 6.5 MAIN POWER SUPPLY PE =M01/1.1
W-PE16 F1 =PE-PUMPMODULE-P1H07VK 1/PE 1/PE 16 5 CABIN PE =PE/1.5
W-PE170 =PE-CRANETOWER =PE-PUMPMODULE (L)M2XCH-PEú1/PE+S 1/PE 70 4 MODULE PE =PE/1.3
W-PE270 =PE-CABINET =PE-PUMPMODULE (L)M2XCH-PEú1/PE+S 1/PE 70 1 CABINET PE =PE/1.1
W-PE470 =PE-CRANETOWER =PE-JIB NSGA-PE 1/PE 1/PE 70 1.5 JIB PE =PE/1.8
W-PE4L F1 PULT_L SZ2564 1/PE 1/PE 4 0.5 DESK LEFT PE =PE/1.5
W-PE4R F1 PULT_R SZ2564 1/PE 1/PE 4 0.5 DESK RIGHT PE =PE/1.6
W-S03/LIGHTING -X3 =M03-S03 (L)M2XH-Jú 5/PE 5/PE 1.5 9 LIGHTING SWITCH =M03/1.2
W-S04 -X4 -X75 (L)M2XH-J 3/PE 3/PE 1.5 6 EMERGENCY STOP IN CONTROL DESK =M01/1.7
W-S08 -XA2 =M07-S08 IFM 3 2 0.3 2 PRESSURE SWITCH FILTER =M07/3.4
W-S09 -XA2 =M07-S09 IFM 3 2 0.3 2 OIL LEVEL SWITCH =M07/3.5

W-S10 -XA4 =M07-S10 IFM 3 2 0.3 2 PRESSURE SWITCH HOISTING GEAR =M07/2.4
W-S12 -X1A5 =M07-S12 LYCY 4+S 3 0.5 1.5 CONTROL LEVER HG =M07/4.7
W-S16 Oelflex 110CY 7+S 6 0.5 9 LIMIT SWITCH MAIN HOISTING WINCH
-X5 =M06-S16.1 7+S 2 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
-X5 =M06-S16.2 7+S 1 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
-X5 -XS16 7+S 3 0.5 LIMIT SWITCH MAIN HOISTING WINCH =M06/4.1
W-S19 -X5 =M06-S19 Quattro 3/PE 1 1 6 CONN. SLACK ROPE SWITCH HG =M06/2.1
W-S20 -XA4 =M07-S20 IFM 3 2 0.3 2 PRESSURE SWITCH LUFFING GEAR =M07/2.5
W-S22 ™lfl140CY 12/PE+S 7+S 0.5 1.5 CONTROL LEVER LEFT
-X62 =M07-S22 12/PE+S 3 0.5 CONTROL LEVER LEFT =M07/5.0
-X62 =M07-S32 12/PE+S 4 0.5 CONTROL LEVER LEFT =M07/5.0
-X62 S 12/PE+S 0+S 0.5 CONTROL LEVER LEFT =M07/5.0
W-S22V ™lfl140CY 12/PE+S 7+S 0.5 3.5 CONTROL LEVER LEFT
-X62 -X72 12/PE+S 7+S 0.5 CONTROL LEVER LEFT =M07/5.0
S -X72 12/PE+S 0 0.5 CONTROL LEVER LEFT =M07/5.0
1 1.2

Com-No ass.-gr.
Ch.
1.1

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
W-S26 Oelflex 110CY 7+S 6 0.5 8 LIMIT SWITCH LUFFING WINCH
-X5 =M06-S26.1 7+S 2 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
-X5 -XS26 7+S 3 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
-X5 =M06-S26.2 7+S 1 0.5 LIMIT SWITCH LUFFING WINCH =M06/3.1
W-S30 -XA4 =M07-S30 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR =M07/2.6
W-S31 -XA4 =M07-S31 IFM 3 2 0.3 2 PRESSURE SWITCH SLEWING GEAR =M07/2.8
W-S31/X3 -X3 -X60 (L)M2XH-Jú 7/PE 7/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V =M03/2.1
W-S34/X3 -X3 -X60 (L)M2XH-J 3/PE 3/PE 1.5 6 CONN. CONTROL DESK RIGHT 220V =M03/3.1
W-S82G -XA2 =M07-S82G IFM 3 2 0.3 2 CONNECTION CARGO GEAR PRESSURE SWITCH =M07/3.8
W-S85 -X5 -X72 Quattro 3/PE 2 1 6 KEY SWITCH SPREADER OP =M06/5.7
W-SWIPER -X62 -XM50 Quattro 5/PE 4 1 6.5 WINDSCREEN WIPER =M05/1.2
W-X12/X13 -X12 -X13 H07RN 5/PE 5/PE 1.5 32 CONNECTION ON JIB =M03/2.4
W-X3/X12 -X3 -X12 (L)M2XH-Jú 5/PE 5/PE 1.5 5.5 CONNECTION TO JIB =M03/2.4
W-X3/X80 -X3 -X80 (L)M2XH-J 3/PE 3/PE 1.5 10 HEATER SUPPLY CARGO GEAR =M03/4.7
W-X4/X11 -X4 -X11 (L)M2XH_J_1 4/PE 4/PE 2.5 10.5 HYDRAULIC OIL COOLER =M02/2.4
W-X5/X51 -X5 -X51 3Norm 5/PE 4 1 10.5 SUPPLY SYNC. PULSE PROXI =M01/3.5
W-X5/X81 Oelflex 110CY 18+S 15+S 1 11 CONTACT EXCHANGE SPREADER CONTROL
-X5 -X81 18+S 15 1 CONTACT EXCHANGE SPREADER CONTROL =M06/7.1
=M06-SCREENCLAMPS 18+S 0+S 1 CONTACT EXCHANGE SPREADER CONTROL =M06/7.1
W-X51/B16 -X51 -XB16 EVC003 4+S 3 0.34 5 SYNC. PULSE PROXI LG / PN5008086 =M06/4.6
W-X51/B26 -X51 -XB26 EVC003 4+S 3 0.34 5 SYNC. PULSE PROXI LG / PN5008086 =M06/3.6
W-X60/E8 -X60 =M03-E8 H07RN 3/PE 3/PE 1 1 HEATING FAN CABIN =M03/3.0
W-X62/X72SPR ™lfl140CY 12/PE+S 7+S 0.5 3.5 CABLE SPREADER CONTROL
-X62 -X72 12/PE+S 7 0.5 CABLE SPREADER CONTROL =M07/8.3
S -X72 12/PE+S 0+S 0.5 CABLE SPREADER CONTROL =M07/8.3
W-X62_24V -X5 -X62 Quattro 3/PE 2 1 6 CONN. CONTROL DESK LEFT 24V =M05/1.6
W-X72/=M06-S85 -X72 =M06-S85 1 1 - - =M06/5.8
W-X72A5 -X72 -X3A5 LYCY 4+S 2+S 0.5 1.5 CAN BUS CABLE X72/CR2012 =M07/4.1
W-X72A6 LYCY 4+S 2+S 0.5 1.5 CAN BUS CONNECTION X72/A9
-X72 S 4+S 0+S 0.5 CAN BUS CONNECTION X72/A9 =M07/8.1
-X72 -XA6 4+S 2 0.5 CAN BUS CONNECTION X72/A9 =M07/8.1
W-X72A9 -X72 -X3A9 LYCY 4+S 2+S 0.5 1.5 CAN BUS CONNECTION X72/CR1031 =M07/8.1
W-X81/X5 -X5 -X81 Oelflex 110CY 7+S 5 1 11 24V CONTACT EXCHANGE SPREADER =M06/5.2
W-XS82/=M80-XS82 -XS82 =M80-XS82 1 1 - - =M80/6.8
W-Y1 -XA2 -XY1 IFM M12/DINA 3 2 0.5 1 HOISTING GEAR BRAKE =M07/3.4
1.1 1.3

Com-No ass.-gr.
Ch.
1.2

0 1 2 3 4 5 6 7 8 9
CABLE OVERVIEW
W-Y11 -XA2 -XY11 IFM M12/DINA 3 2 0.5 1 PRE HEATING =M07/3.8
W-Y1A -XA3 -XY1A IFM M12/DINA 2 2 0.75 2 SN 4243444 =M07/1.4
W-Y1B -XA3 -XY1B IFM M12/DINA 2 2 0.75 2 SN 4243444 =M07/1.4
W-Y1T -X5 -XY1T Quattro 3/PE 2 1 11.5 TRIMOT =M06/6.0
W-Y2 -XA2 -XY2 IFM M12/DINA 3 2 0.5 1 LUFFING GEAR BRAKE =M07/3.5

W-Y3 -XA2 -XY3 IFM M12/DINA 3 2 0.5 1 SLEWING GEAR BRAKE =M07/3.6
W-Y31B/Y3A -XY3A -XY31B VENT-VERB 2 2 1 0.6 AUX. PUMP SN 5002254 =M07/1.6
W-Y3B/Y31A -XY3B -XY31A VENT-VERB 2 2 1 0.6 AUX. PUMP SN 5002254 =M07/1.6
W-Y84 -X5 -XY84 Quattro 3/PE 2 1 10 SOLENOID VALVE CABLE REEL =M06/6.6
WX100-XSRK1 -X100 -XSRK1 Semoflex 30/PE 30/PE 2.5 11 =M80/6.1

CONNECTION CONTROL CABINET ADD. EQUIPMENT/CABLE REEL
WX31-E3 -X80 =M80-E9 (L)M2XH-J 3/PE 3/PE 1.5 11 HEATER CABLE REEL =M80/1.5
WXSRK1-XS13 -XS82 -XSRK1 Semoflex 30/PE 30/PE 2.5 92 REELING CABLE CABLE REEL =M80/6.1
1.2

Com-No ass.-gr.
Ch.
1.3

TTS – NMF GmbH
83158 - SPARE PARTS LIST
6 SPARE PARTS LISTS CRANES
ASSEMBLY GROUP 00.00.00 DECK CRANE COMPL.
ASSEMBLY GROUP 01.00.00 SLEWING TOWER
ASSEMBLY GROUP 02.00.00 JIB COMPL.
ASSEMBLY GROUP 05.00.00 ROPE PLAN
ASSEMBLY GROUP 07.00.00 CARGO BLOCKS COMPL.
ASSEMBLY GROUP 12.00.00 PANEL LIST
ASSEMBLY GROUP 14.00.00 PART WITHOUT ATTACH IN WORKS
ASSEMBLY GROUP 18.00.00 DRIVING HOUSE COMPL.
ASSEMBLY GROUP 19.00.00 WINCH MODULE COMPL.
ASSEMBLY GROUP 25.00.00 ELECTRICAL EQUIPMENT COMPL.
ASSEMBLY GROUP 66.00.00 HYDRAULIC SYSTEM COMPL.
ASSEMBLY GROUP 80.00.00 ADDITIONAL EQUIPMENT
ASSEMBLY GROUP 97.00.00 TECHNICAL DOCUMENTS

TTS – NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 183 158-00
DESCRIPTION: DECK CRANE KL 45T – 29M
ASSEMBLY MATERIAL DRAWING

GROUP QTY QC DESCRIPTION NO. NO.
00.00.00.00.00 1 PC DECK CRANE COMPL. 5183158 5183156
01.00.00.00.00 1 PC CRANE TOWER COMPL. 5011133 5011133

02.00.00.00.00 1 PC JIB COMPL. 5011138 5011138
05.00.00.00.00 1 PC ROPE PLAN 5011201 5011201
07.00.00.00.00 1 PC CARGO BLOCKS COMPL. 5005947 5005947
12.00.00.00.00 1 PC PANEL LIST 5011142 5011142
14.00.00.00.00 1 PC PARTS WITHOUT ATTECH IN WORK 5011211
18.00.00.00.00 1 PC DRIVERS CABIN COMPL. 5005840 2389487
19.00.00.00.00 1 PC WINCH MODULE 5005955 5005955
25.00.00.00.00 1 PC ELECTRICAL EQUIPMENT COMPL. 5022373
66.00.00.00.00 1 PC HYDRAULIC SYSTEM COMPL. 5011155
80.00.00.00.00 1 PC AUXILLIARY EQUIPMENT 5011243
97.00.00.00.00 1 PC TECHNICAL DOCUMENTS 5011312
ASSEMBLY GROUP 00.00.00.00.00

TTS-NMF GmbH
83158 SPARE PARTS LIST
SPARE PARTS LIST

ORDER NO. 5 011 133-00
DESCRIPTION: SLEWING TOWER COMPL.

01.00.00.00.00 1 ST SLEWING TOWER COMPL. 5011134 50111134

01.05.00.00.00 1
01.10.00.00.00 1 ST PROTECTION FOR CABIN 2067984 2067984
01.12.00.00.00 1 ST ROPE PULLEYS RIGHT HAND COMPL. 2389269 2389269
01.15.00.00.00 1 ST ROPE PULLEYS COMPL. 2389270 2389270
01.16.00.00.00 2 ST JIB BEARING DIA 160 2389245 2389245
01.17.00.00.00 1 ST SLEWING GEAR COMPL. 5005963 5005963
01.18.00.00.00 1 ST ROLLER BEARING COMPL. 5004031 5004031
01.23.00.00.00 1 ST FLAP COOLER CAP COMPL. 5011135 5011135
01.25.00.00.00 1 ST E-PART SLEWING TOWER SEE
ASSEMBLY GROUP 25.01.00.00
01.31.00.00.00 1 ST ROPE PULLEYS LEFT HAND COMPL, 2389280 2389280
01.66.00.00.00 1 ST HYDRAULIC SYSTEM SLEWING TOWER
SEE ASSEMBLY GROUP 66.01.00.00

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 269-02
DESCRIPTION: ROPE PULLEYS DIA 710 COMPL.

01.12.00.00.00 1 ST ROPR PULLEYS DIA 710 COMPL. 2389269 2389269
01.12.01.00.00 1 ST AXLE 2389252 2389252

01.12.02.00.00 1 ST PRESSURE PLATE 2389253 2389253
01.12.03.00.00 2 ST ROPE PULLRY DIA 710 COMPL. 5001881 5001881
01.12.06.00.00 3 ST WASHER 0153212
01.12.07.00.00 3 ST HEXAGON SCREW 0057076

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 881-00
DESCRIPTION: ROPE PULLEY DIA 710 COMPL.

01.12.03.00.00 1 ST ROPR PULLEY DIA 710 COMPL. 5001881 5001881
01.12.03.01.00 1 ST ROPE PULLEY DIA 710 2389166 2389166

01.12.03.02.00 1 ST CYL. ROLLER BEARING 1382156
01.12.03.03.00 2 ST RETAINING RING 0650844

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 270-02

01.15.01.00.00 2 ST WASHER 2389352 2389352

01.15.06.00.00 6 ST WASHER 0153212
01.15.07.00.00 6 ST HEXAGON SCREW 0057076

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 881-00



TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 245-04
DESCRIPTION: JIB BEARING DIA 160

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 245-04
DESCRIPTION: JIB BEARING DIA 160

01.16.00.00.00 2 ST JIB BEARING DIA 160 2389245 2389245
01.16.01.00.00 1 ST BEARING HOUSING 2389246 2389246

01.16.02.00.00 1 ST AXLE 2389247 2389247
01.16.04.00.00 2 ST BEARING COVER 2389367 2389367
01.16.05.00.00 1 ST BUSH 2389250 2389250
01.16.06.00.00 1 ST PIVOT 2389251 2389251
01.16.07.00.00 1 ST JOINT BEARING 1657952
01.16.08.00.00 2 ST SHAFT SEALING RING 0422109
01.16.09.00.00 3 ST HEXAGON SCREW 0057076
01.16.10.00.00 16 ST HEX-SCREW 0035035
01.16.11.00.00 1 ST AXLE HOLDER 2389611 2389611
01.16.12.00.00 3 ST THRUST WASHER 0153212
01.16.13.00.00 4 ST HEX-SCREW 0152618
01.16.14.00.00 10 ST WASHER 0726134
01.16.15.00.00 1 ST UNION 0304986
01.16.16.00.00 1 ST HOSE LINE DN 6 2389354 2389354
01.16.18.00.00 1 ST SOCKET 2533234
01.16.19.00.00 1 ST FLAT GREASE NIPPLE 0155286
01.16.20.00.00 16 ST WASHER 0887813
01.16.21.00.00 8 ST PROTECTIVE PLUG 1609235
01.16.23.00.00 2 ST HEXAGON SCREW 0056685
01.16.24.00.00 2 ST SAFETY DISK 0153214
01.16.25.00.00 2 ST HEXAGON SCREW 0119713
01.16.26.00.00 2 ST RETAINER-WASHER 0153213

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 963-00
DESCRIPTION: SLEWING GAER COMPL.
The brake must be filled with approx. 0,2 ltrs. GEAR OIL ATF A prior to mounting the motor

01.17.00.00.00 1 ST SLEWING GEAR COMPL. 5005963 5005963
01.17.02.00.00 2 ST SLEWING GEAR 5005146 5005146

SUBSUPPLIER SEE
01.17.05.00.00 72 ST HEXAGON SCREW 0074188
01.17.06.00.00 72 ST WASHER 3343769

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

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 146-00
DESCRIPTION: SLEWING GEAR
TYPE AGGREGAT-NO. DESCRIPTION SERIAL-NO
5005146 SLEWING GEAR i= 125
ORDER-NO.: DESCRIPTION
56170890* INSTALLATION DRAWING
INSTALLATION INSTRUCTION
WEIGHT: 300,0 KG OIL QUANTITY:: 12,0 LTR.
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*
DESCRIPTION: 7 09 T 3 F*PA* S020 A 125 5B-S02 H0BC T LA VAH U11E TS CC
POS. ORDER-NO. DESCRIPTION QUANTITY

2T261708290* 7 09 T 3 F*PA* S020 A 125 5B-S02
H0BC T LA VAH U11E TS CC 1 PC L
1 6630070500* PIMION SHAFT 1 PC
2 6662005120* SPACER 1 PC
3 0712710128A* NILOS RING 1 PC
4 0712758094* BEARING 1 PC
5 6650009960* GEARBOX HOUSING 1 PC
6 710301024A* SEAL RING 1 PC
8 0712758046* BEARING 1 PC
9 6662003530* SPACER 1 PC
10 6660000270* NUT 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2T261708290*

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

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

TTS-NMF GmbH
LIFTING AND HANDLING

If the handling occurs when the product is still packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.
WARNING!
CONSIDERING THAT THE SIZE AND FORM OF THE PRODUCT DO NOT ALLOW MANUAL SHIFTING,
IN PARTICULAR HANDLINGS, (E.G. INSTALLATION) IT IS NECESSARY TO USE ACCESSORIES
THAT GUARANTEE HUMAN SAFETY AND WHICH ALSO AVOID DAMAGES TO THE PRODUCT.
TO LIFT AND HANDLE THE PRODUCT, AFTER HAVING OPENED THE PACKAGING, FOLLOW THE
INFORMATION GIVEN BELOW:
1. Unscrew the nos.4 screws and remove the closing plate from the motor adapror flange.
2. Tighten nos.2 eyebolts at 180° on the thread holes of the motor adaptor flange.
3. By using a tackle lift and handle with care avoiding impacts.

TTS-NMF GmbH
INSTALLATION
HYDRAULIC MOTOR INSTALLATION
The mating areas and the pilot diameter of the gearbox where the motor is to be mounted must be clean and
without burrs.
1. Fit the O-ring seal, supplied with the gearbox, in its seat in the hydraulic motor, and assemble it to
the gearbox being careful not to damage the seal already fitted.
2. Assemble the hydraulic motor to the gearbox frame by using the screws shown in the following table
INFORMATION!
UNDER NO CIRCUMSTANCE REMOVE THE PLASTIC LID FROM THE POWER SUPPLY PORTS OF
THE HYDRAULIC MOTOR; THIS WILL HELP AVOID THE ACCIDENTAL INTRODUCTION OF FOREIGN
BODIES INTO THE MOTOR, UNTIL THE HOSES ARE ASSEMBLED.

TTS-NMF GmbH
INSTALLATION OF THE SLEW DRIVE ON THE MACHINE

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

TTS-NMF GmbH
CONNECTION OF THE BRAKE

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

TTS-NMF GmbH
CONNECTIN OF THE DRAINING PORT

INFORMATION!
IF THE FRAME OF THE MACHINE DOES NOT ALLOW THE ACCESS TO THE PLUG, IT IS
NECESSARY, DURING THE SLEW DRIVE INSTALLATION, TO FIT AN EXTENTION WHICH TAKES THE
OIL AWAY FROM THE MACHINE.
1. Remove the drain plug and screw on a pipe to the drain port(for hose size and dimension refer to
the installation drawing).
REPLACING OF THE BREATHER VALVE AS LOOSE PART

At the slew drive installation on the machine frame replace the plug with breather valve supplied
as loose part.
1. Tigthen the brather valve supplied as loose part(for size and dimension refer to the installation
drawing).

TTS-NMF GmbH
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.

TTS-NMF GmbH
OIL FILLING
1. Unscrew the FILLING LEVEL OIL PLUG (2) and add the lubricating oil which has the
characteristics given in section 5.1.
2. By using the dipstick, check that the oil level is somewhere between the
MIN and MAX notch and then screw the plug back on.
3. Operate the slew drive, after a few minutes, stop and check the oil level.
4. If necessary, refill with lubricant oil. Size and dimension of plugs are shown on the
installation drawing.
APROXIMATE OIL CAPACITY LITERS ARE: 12 L ±10%
OIL DRAINING AND REPLACEMENT

1. Unscrew the DRAINING PLUG and let the oil flow in a large enough container; in order to facilitate
the draining it is better to operate with the oil still warm.
2. Wait a few minutes until all the oil is drained and then proceed to screw on DRAINING PLUG.
3. Proceed with the oil fill-up following the procedures given (see Section 5.2).
WARNING!
NEVER MIX MINERAL OILS WITH SYNTHETIC OILS AND VICE VERSA.
WARNING!
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT BUT BE CAREFUL TO ELIMINATE
IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

TTS-NMF GmbH
START UP AND RUNNING IN

In this first stage it is advised to follow the measures given below:
1. Check the correctly lubrication of the unit.

2. Bleed air from every part of the hyraulic and add oil in the tank if necessary.
INFORMATION!
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL MANIFEST ITSELF WITH THE
PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A JERKING OF THE MOTOR AS WELL AS
EXCESSIVE NOISE COMING FROM THE MOTOR AND THE VALVES.
3. Start the gearmotor at a low speed and gradually increase it after having verified that
it is functioning correctly without any noises or vibrations.
INFORMATION!
DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN FILTERED TO
ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
During the running-in stage follow the steps given below.
4. Check the correct revolution and direction of rotation.

5. Make sure that the functioning is regular and with-out any excessive noises and vibrations.
6. Make sure that the oil temperature does not exceed 85-90°C intermittent.
After having terminated this first running-in follow the steps given below.
7. Check that there are no oil leakages. If present, proceed to remove them.
8. Check the level of lubricating oil in the gearmotor.
It could happen that due to the presence of air, during the first start up, the opening action of the
brake could be slowed down. It is advised to repeat the opening and closing function of the brake.
Check that there are no other problems in general

TTS-NMF GmbH
MAINTENANCE
Under normal operating circumstances, no routine maintenance is required, except routine oil checks and
oil changes. As recommended in this manual, unusual operating characteristics, such as noise or overheat,
should indicate further investigation. For a proper maintenance of the gearbox, the following
checks and operations have to be done.
INFORMATION!
IN CASE OF IMPORTANT AND COMPLEX MAINTENANCE OPERATIONS, MAKE REFERENCE TO THE

SPARE PART LISTS EXPLODED VIEW WHICH CAN BE SUPPLIED UNDER REQUEST OR THE
SUGGESTIONS OF THIS MANUAL.
DO NOT HESITATE TO CONTATCT THE GEARBOX DISTRIBUTOR OR MANUFACTURER IF FURTHER

INSTRUCTIONS ARE NECESSARY OR IN
CASE OF PARTICULAR PROBLEMS.
This publication replaces and supersseds any previous issue and revision. BONFIGLIOLI TRASMITAL res-
res the right to implement modifications without notice. This manual cannot be reproduced, even partially,
without prior written consent.

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 004 031-00
DESCRIPTION: ROLLER BEARING SLEWING RING COMPL.

01.18.00.00.00 1 PC ROLLER BEARING SLEWING RING 5004031 5004031

COMPL.
01.18.01.00.00 1 PC ROLLER BEARING SLEWING RING 5004027 5004027

01.18.02.00.00 84 PC WASHER 5004033 5004033
01.18.03.00.00 168 PC HEXAGON NUT 1606485 1606485
01.18.04.00.00 168 PC STUD 2392203 2392203
01.18.05.00.00 84 PC WASHER 3395235 3395235
01.18.07.00.00 24 PC GREASE NIPPLE 0460192 0460192

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 135-01
DESCRIPTION: FLAP COOLER CAP COMPL.

01.23.00.00.00 1 PC FLAP COOLER CAP COMPL. 5011135 5011135
01.23.01.00.00 1 PC FLAP COOLER CAP 5011136 5011136
01.23.02.00.00 4 PC PART OF JOINT 5004079

01.23.03.00.00 4 PC PIN 0583196
01.23.04.00.00 4 PC SPLIT-PIN 0119814
01.23.05.00.00 4 PC HEXAGON NUT 0447323
01.23.06.00.00 3 PC HEXAGON NUT 7121425
01.23.07.00.00 2 PC RUBBER-MET. COBBECTION 2063050
01.23.08.00.00 2 PC HEXAGON NUT 7832404
01.23.09.00.00 1 PC Plug 0490348
01.23.10.00.00 2 PC SPONGE RUBBER PROFILE 5005147

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 280-02

01.31.01.00.00 1 ST WASHER 2389352 2389352

01.31.06.00.00 3 ST WASHER 0153212
01.31.07.00.00 3 ST HEXAGON SCREW 0057076

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 881-00



TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011138
DESCRIPTION: JIB COMPL.

02.00.00.00.00 1 ST JIB COMPL. 5011138 5011138
02.01.00.00.00 1 ST JIB STEEL STRUCTURE COMPL. 5011139 5011139

02.04.00.00.00 1 ST ROPE PULLEYS, JIB HEAD 5001934 5001934
02.09.00.00.00 1 ST LAMP BRACKET L.H. 2067941 2067941
02.20.00.00.00 1 ST BUFFER STOP 2389406
02.25.00.00.00 1 ST E-SYSTEM JIB SEE ASSEMBLY GROUP 2350938
25.02.00

TTS-NMF GmbH

SPARE PARTS LIST
ORDER NO. 5 001 934-01

02.04.00.00.00 1 ST ROPE PULLEYS DIA 710 COMPL. 5001934 5001934

02.04.02.00.00 1 ST BOLT 5001935 5001935
02.04.03.00.00 1 ST PRESSURE WASHER 2389255 2389255
02.04.04.00.00 1 ST PRESSURE WASHER 0173102 0173102
02.04.05.00.00 5 ST WASHER 5001927 5001927
02.04.06.00.00 1 ST BOLT 5001936 5001936
02.04.07.00.00 6 ST RIPPSCREW 2361684
02.04.09.00.00 2 ST HEXAGON. NUT 0308977

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 881-00



TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 067 941-04
DESCRIPTION: LAMP BRACKET L.H

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

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

TTS-NMF GmbH
SPARE PARTS LIST

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

02.20.00.00.00 1 ST BUFFER STO 2389406 2389406
02.20.01.00.00 1 ST STOP-RAIL 1636914

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

TTS-NMFGmbH
SPARE PARTS LIST

ORDER NO. 5 011 201-00
DESCRIPTION: ROPE PLAN 45T – 29M

05.00.00.00.00 1 ST ROPE PLAN KL 45T – 29M 5011201 5011201
05.01.00.00.00 1 ST ROPE 34 207M ( HOISTING ROPE ) 5011221 5011221

05.02.00.00.00 1 ST ROPE 34 185M ( LUFFING ROPE ) 2392298 2392298
05.03.00.00.00 2 ST BUSH 2094863
05.04.00.00.00 2 ST ADJUSTING-RING 0033190
05.05.00.00.00 2 ST HEXAGON SCREW 0725397
05.06.00.00.00 2 ST EXAGON-NUT 0146559

TTS-NMF GmbH

TTS-NMFGmbH
SPARE PARTS LIST

ORDER NO. 5 011201-00
DESCRIPTION: ROPE PLAN 45T – 29M

TTS-NMF GmbH
SPARE PARTS LIST
CARGO BLOCK
SWL 45 T
PART-NO.: 5 005 947

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 005 947-00
DESKRIPTION: CARGO BLOCK SWL 45 T FOR LOAD TURNING DEVICE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 005 947-00
DESKRIPTION: CARGO BLOCK SWL 45 T FOR LOAD TURNING DEVICE

5 005 947 CARGO BLOCK SWL 45 T FOR LOAD 1 ST L
TURNING DEVICE
1 R074381/01* HOOK 1 ST
2 04.710.5022.G* SHEAVE 2 ST
3 R074381/06* BODYPLATE 2 ST
4 R074381/07* WEIGHTPLATE 2 ST
5 R074381/09* POS. RING 2 ST
6 22.90.172.80* BOLT 1 ST
7 22.110.172.80.Z* BOLT 2 ST
8 R074381/24* SPACERTUBE 6 ST
9 51.EV.24.200* HEXAGON SCREW 6 ST
10 54.5022PP* BEARING 2 ST
11 55.EV.24* NYLOC NUT 6 ST
12 64.16.V.E* SAFETY LATCH KIT 2 ST
13 65.EV.8.100* COTTERPIN 3 ST
22 66.10.01* LUBRICATION NIPPLE 3 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011-142-00
DESCRIPTION: SIGN PLATES COMPL.

12.00.00.00.00 1 PC SIGN PLATES COMPL. 5011142
12.01.00.00.00 1 PC SIGN PLATES SLEWING TOWER 5011143 5010365

12.02.00.00.00 1 PC SIGN PLATES JIB 5011144
12.14.00.00.00 1 PC SIGN PLATES COLUMN 5009214 5009214
12.18.00.00.00 1 PC SIGN PLATES CABIN 5009218 5009218

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011-143-00
DESCRIPTION: SIGN PLATES SLEWING TOWER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 143-00
DESCRIPTION: SIGN PLATES SLEWING TOWER

12.01.00.00.00 1 PC SIGN PLATES SLEWING TOWER 5011143 5010365
12.01.02.00.00 1 PC TYPE PLATE 5011145 5001168

12.01.03.00.00 1 PC DESCRIPTION ON CRANE" 3396158
12.01.04.00.00 1 PC LABEL "DANGER" 3337851 3337851
12.01.05.00.00 1 PC LABEL "MOUNTING HATCH" 3337852 3337852
12.01.11.00.00 1 PC LABEL "SEAT BELT" 3337855 3337855
12.01.19.00.00 2 PC COMPANY LABEL TTS 5001397 5001397
12.01.20.00.00 4 PC ROUND HEAD GROVED PIN 0040708
12.01.23.00.00 1 PC POSITION FLAP 5007815 5007815

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 009 214-00
DESCRIPTION: SIGN PLATES COLUMN

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 009 214-00
DESCRIPTION: SIGN PLATES COLUMN

12.14.00.00.00 1 PC SIGN PLATES COLUMN 5009214 5008900
12.14.12.00.00 1 PC LABEL "DANGER" 3337856 3337856

12.14.13.00.00 1 PC LABEL UNAUTHORIZED ACCES 3337857 3337857
12.14.18.00.00 1 PC LABEL "DOOR OPEN" 3396157 3396157

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 009 218-00
DESCRIPTION: SIGN PLATES CABIN

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 009 218-00
DESCRIPTION: SIGN PLATES CABIN

12.18.00.00.00 1 PC SIGN PLATES CABIN 5009218 5008900
12.18.06.00.00 1 PC LABEL "OPERATING" 3337853 3337853

12.18.08.00.00 1 PC LABEL EMERGENCY EXIT 2008698 2008698
12.18.09.00.00 1 PC EMERGENCY EXIT 2389652 2389652
12.18.10.00.00 1 PC LABEL CHAIR 5008847 5008847
12.18.14.00.00 1 PC LABEL “OPERATING INSTRUCTION” 5001164 5001164
12.18.15.00.00 6 PC ST-SCREW 1520120
12.18.16.00.00 6 PC WASHER 1684578
12.18.17.00.00 1 PC LABEL VENTILATION 2509888 2509888
12.18.21.00.00 1 PC LABEL VENTILATOR COVER CLOSE 5004094 5004094
12.18.22.00.00 1 PC LABEL VENTILATOR COVER OPEN 5004093 5004093

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 211-00
DESCRIPTION: PARTS WITHOUT ATTACH IN WORK

14.00.00.00.00 1 ST PARTS WITHOUT ATTACH IN WORK 5011211
14.02.00.00.00 1 ST EXTINGUISHER 3330836
14.03.00.00.00 1 ST ROPE DOWN DEVICE 2544045
14.03.01.00.00 1 ST ROPE DOWN DEVICE 25M 1600698 1600698
14.25.00.00.00 1 ST E - PARTS FOR ASSEMBLY 14.00 5022418

TTS- NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 418-00
DESCRIPTION: E - PARTS WITHOUT ATTACH IN WORK

14.25.00.00.00 1 ST E - PARTS WITHOUT ATTACH IN WORK 5022418
14.25.20.00.00 1 ST SLIP RING BODY 2078876

SEE SUBSUPPLIER
ASSEMBLY GROUP 14.25.20
14.25.21.00.00 1 ST ACCESSORIES FOR SLIP RING 5002489
14.25.30.00.00 1 ST LIGHTING FOR JIB 5022391

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

TTS- NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 078 876

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

TTS- NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 078 876

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

TTS- NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 002 489-00
DESCRIPTION: ACCESSORIES FOR SLIP-RING

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

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

ORDER NO. 5 022 391-00
DESCRIPTION: LIGHTING FOR JIB

14.25.30.00.00 1 PC LIGHTING FOR JIB 5022391
14.25.30.01.00 1 PC HALOGEN LIGHT 5022285

14.25.30.03.00 1 PC HALOGEN-LAMP 5022389
14.25.30.04.00 2 PC HEXAGON SCREW 1683991
14.25.30.05.00 2 PC HEXAGON NUT 0057130
14.25.30.06.00 2 PC CONTACT WASHER 2079812
14.25.30.07.00 10 PC CABLE TIE 1660206

TTS-NMF GmbH
SPARE PARTS LIST

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

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

18.02.00.00.00 1 ST CABIN COMPONENTS 2544087

TTS-NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 544 087-03

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 544 087-03

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

18.02.04.00.00 3 ST SHOCK ABSORBING ELEM. 1355813
18.02.05.00.00 1 ST DOUBLE TAPE OF RUBBER 1627721
18.02.07.00.00 7,5 M OWA-TAPE 1636997
18.02.08.00.00 2 ST CAP-SCREW 0490263
18.02.09.00.00 1 ST CAP-SCREW 1636423
18.02.10.00.00. 3 ST DISK 1885320
18.02.11.00.00 4 ST CAP-SCREW 0153331
18.02.12.00.00 1 ST DOOR LATCH 1608569
18.02.13.00.00 3 ST CONTERS: SCREW 0599714
18.02.14.00.00 3 ST HEXAGON NUT 0421223
18.02.15.00.00 9 ST WASHER 0063713
18.02.17.00.00 12 ST WASHER 2381601
18.02.18.00.00 12 ST HEX-SCREW 0063317
18.02.19.00.00. 12 ST HEX. NUT 0057130
18.02.21.00.00 1 ST WIPER BLADE 5004897
18.02.22.00.00 1 ST GUIDE ARM 4510072
18.02.23.00.00 1 ST WIPER ARM 4510071
18.02.24.00.00 1 ST BRACKET 0750219
18.02.25.00.00 1 ST HEXAGON SCREW 0784494
18.02.26.00.00 1 ST OPERATOR'S SEAT 5001336
18.02.27.00.00 1 ST GLAS PANE 3330512
18.02.28.00.00 1 ST GLAS PANE 3330513
18.02.29.00.00 4 ST GLAS PANE 3330514
18.02.30.00.00 4 ST GLAS PANE 3330515
18.02.31.00.00 4 ST GLAS PANE 2549770
18.02.32.00.00 1 ST HANDLE SUITE DS COMPL. 2 549771 2392097
18.02.33.00.00 1 ST PROFILE CYLINDER 2549772 2392097
18.02.34.00.00 3 ST NIRO-RIBBON 2549773
18.02.35.00.00 2 M WINDOW RIBBON 2549774
18.02.36.00.00 2 M WINDOW RIBBON 2549775
18.02.37.00.00 4 ST HINGE 2549776
18.02.38.00.00 38 ST SELF CUTTING SCREW 3330510
18.02.39.00.00 1 ST NEOPRENE 3330511
18.02.40.00.00 1 ST DOOR RUBBER SEALING 2549779
18.02.41.00.00 1 ST GISTA PROFILE 2549780
18.02.42.00.00 1 ST LEVER PLUG 2549781
18.02.44.00.00 1 ST WINDOW PLUG 2549783
18.02.45.00.00 1 ST WINDOW PLUG 2549784
18.02.46.00.00 1 ST TELESCOPE COVER 2549785
18.02.47.00.00 3 ST HEXAGON SCREW 0054379
18.02.48.00.00 3 ST WASHER 1684578
18.02.51.00.00 4 ST HEXGON SCREW 1683942
18.02.52.00.00 4 ST HEXAGON NUT 2095060
18.02.53.00.00 4 ST WASHER 0063704

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 955-02
DESCRIPTION: WINCH MODULE COMPL.

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 955-02

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 955-02

19.00.00.00.00 1 PC WINCH MODULE COMPL. 5005955 5005955
19.01.00.00.00 1 PC WINCH MODULE 5005890 5005890

19.32.00.00.00 1 PC LIMIT SWITCH SLACK ROPE 5001059 5001059
19.100.00.00.00 1 PC PIN 5001075 5001075
19.101.00.00.00 1 PC THRUST PLATE 5001074 5001074
19.102.00.00.00 1 PC DISTANCE BUSHING 5001080 5001080
19.103.00.00.00 4 PC WASHER 2067451 2067451
19.104.00.00.00 4 PC WASHER 2067452 2067452
19.105.00.00.00 3 PC RIPPSCREW 2361684
19.107.00.00.00 2 PC PROTECTIVE PLUG 1609236
19.108.00.00.00 1 PC PIN 5001079 5001079
19.109.00.00.00 1 PC WASHER 2049788
19.110.00.00.00 1 PC SPLIT PIN 2049787
19.112.00.00.00 2 PC HEXAGON SCREW 0650775
19.113.00.00.00 2 PC HEXAGON SCREW 1307901
19.114.00.00.00 4 PC HEXAGON NUT 0053502
19.115.00.00.00 4 PC WASHER 2392782 2392782
19.116.00.00.00 10 PC WASHER 0152895
19.117.00.00.00 6 PC HEXAGON SCREW 0054379
19.118.00.00.00 1 PC ANGLE 5001082 5001082

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
WINCH MODULE
PART-NO.: 5 005 890

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 890
DESCRIPTION: WINCH MODULE
ZHP 4.29 5005890 ROPE WINCH ZHP 4-29 ( 1064515*) 101 - 103
4.29 10592* INSTALLATION DRAWING

60042900592* ROPE WINCH SERIAL-NO. 163 - 165
00001040035* GEAR
60193005945* ROPE DRUM
00001040038* FLANGE BEARING
60193008729* DRIVE
HYDR. MULTIPLE DISC BRAKE
60193003795* OIL PIPE

00001064514* ROPE WINCH SERIAL-NO. 101 - 103
00001074849* GEAR
60193005945* ROPE DRUM
00001040038* FLANGE BEARING
60193005963* DRIVE
HYDR: MULTIPLE DISC BRAKE
60193003795* OIL PIPE
60193005941* PRESSURE ROLLER
00001060228* WINCH SUPPORT
190000401* INSTALLATION INSTRUCTION

190000204* MAINTENANCE INSTRUCTION
190000315* RECOMMENDATION FOR LUBRICANTS
190000781* GEARBOX INSPECTION
190000159* TIGHTENING TORQUES
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 890
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 890

00005005890 ROPE WINCH ZHP 4-29 ( 1064515*) SERIE 101-103 1 PC L
1 60042900592* ROPE WINCH 0429.10592 SERIAL-NO. 163-165 1 PC L

01 00001040035* GEAR 1 PC L
21 60193005945* ROPE DRUM 1 PC L
22 00001040038* FLANGE BEARING 1 PC L
24 60193008729* DRIVE 1 PC L
60 60193003795* OIL PIPE 1 PC L
2 00001064514* ROPE WINCH 0429. 1064514 SERIAL-NO. 101-103 1 PC L

01 00001074849* GEAR 1 PC L
21 60193005945* ROPE DRUM 1 PC L
24 60193005963* DRIVE 1 PC L
60 60193003795* OIL LINE 1 PC L
36 60193005941* PRESSURE ROLLER 1 PC L
40 00001060228* WINCH SUPPORT 1 PC L
WEIGHT: 3960,0 KG OIL QUANTITY: 0429.10592 : 16,0 LTR.

0429.1064514 : 16,0 LTR.
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60042900592*
DESCRIPTION: ROPE WINCH ZHP 0429. 10592
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60042900592*
DESCRIPTION: ROPE WINCH ZHP 0429.10592

1/ 1 00001040035* GEAR 1 PC L
1/ 21 60193005945* ROPE DRUM 1 PC L
1/ 22 00001040038* FLANGE BEARING 1 PC L
1/ 24 60193008729* DRIVE 1 PC L
1/ 60 60193003795* OIL PIPE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040035*
DESCRIPTION: GEAR
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040035*
DESCRIPTION: GEAR

1/ 1 00001040035* GEAR 1 PC L
1/ 1/ 1 00001040037* OUTPUT DRIVE 1 PC L

1/ 1/ 1/ 1 60242901816* PLANETARY CARRIER 1 PC
1/ 1/ 1/ 3 60242901804* BEARING RING 1 PC
1/ 1/ 1/ 6 60232900716* INTERMEDIATE HOUSING 1 PC
1/ 1/ 1/ 11 60230001258* DISTANCE 4 PC
1/ 1/ 1/ 13 60242901835* DISC 1 PC
1/ 1/ 1/ 21 60411200023* CYLINDRICAL BOLT 18 PC
1/ 1/ 1/ 27 60240700320* DISC 18 PC
1/ 1/ 1/ 31 60441100700* SHAFT SEALING RING 1 PC D
1/ 1/ 1/ 41 60442000001* PROFILED CORD 1,6 M D
1/ 1/ 1/ 42 60542000010* HOLDING STRAP 1,7 M
1/ 1/ 1/ 43 60542100010* BELT LOCK 1 PC
1/ 1/ 1/ 51 60453300171* CYLINDER ROLLER BEARING 1 PC
1/ 1/ 1/ 53 60453000212* GROOVED BALL BEARING 1 PC
1/ 1/ 1/ 60 60403100082* CIR CLIP / LOCKING RING 1 PC
1/ 1/ 1/ 201 60342901315* OUTPUT HOUSING EG 1 PC
1/ 1/ 1/ 203 50404130524* DISC 22 PC
1/ 1/ 1/ 462 60414030111* SCREW PLUG 4 PC
1/ 1/ 1/ 463 60441000223* FLAT SEALING RING 4 PC D
1/ 1/ 1/ 491 60242400492* DISC 1 PC
1/ 1/ 1/ 520 60524100009* OIL VALVE 2 PC
1/ 1/ 11 60100100712* PLANETARY STAGE 1 PC L

1/ 1/ 11/ 1 60233900001* INNER-WHEEL 1 PC
1/ 1/ 11/ 3 60242901904* SUN WHEEL 1 PC
1/ 1/ 21 60100100507* PLANETARY STAGE 1 PC L

1/ 1/ 21/ 1 60233705109* INNER-WHEEL 1 PC
1/ 1/ 21/ 3 60242600736* SUN WHEEL 1 PC
1/ 1/ 24 60100010574* PLANET CARRIER 1 PC L

1/ 1/ 24/ 1 60232600201* PLANET CARRIER 1 PC
1/ 1/ 24/ 4 60403100059* CIR CLIP / SNAP RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040035*
DESCRIPTION: GEAR

1/ 1/ 27 60100020401* INTERMEDIATE HOUSING 1 PC L
1/ 1/ 27/ 2 60411130103* HEXAGON BOLT 24 PC
1/ 1/ 31 60100100291* PLANETARY STAGE. 1 PC L

1/ 1/ 31/ 1 60232200001* INNER-WHEEL 1 PC
1/ 1/ 31/ 3 60242901255* SUN WHEEL 1 PC
1/ 1/ 34 60100010411* PLANET CARRIER 1 PC L

1/ 1/ 39 60100020407* COVER 1 PC L
1/ 1/ 39/ 1 60242400349* COVER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005945*
DESCRIPTION: ROPE DRUM

1/ 21 60193005945* ROPE RUM 1 PC L
1/ 21/ 1 60241901805* ROPE DRUM 1 PC
1/ 21/ 5 60243100481* ROPE PLATE 1 PC
1/ 21/ 20 60411130573* HEXAGON SCREW 24 PC
1/ 21/ 21 60411230100* CYLINDRICAL BOLT 36 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040038*
DESCRIPTION: FLANGE BEARING
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040038*

1/ 22/ 1 60242900831* FLANGE 1 PC
1/ 22/ 2 60242901160* FLANGE PLATE 1 PC
1/ 22/ 3 60234705440* COVER 1 PC
1/ 22/ 4 60403200078* CIR CLIP / LOCKING RING 1 PC
1/ 22/ 5 60688100003* FELT SEALING STRIP 0,4 M D
1/ 22/ 6 60453400072* SELF-ALIGNING ROLLER BEARING 1 PC
1/ 22/ 8 60242900950* COVER 1 PC
1/ 22/ 9 60234605252* DRIVER 1 PC
1/ 22/ 12 60417000094* SLOTTED PIN 1 PC
1/ 22/ 13 60417000094* SLOTTED PIN 1 PC
1/ 22/ 14 60412300409* THREADED PIN 1 PC
1/ 22/ 20 60242200386* INTERMEDIA FLANGE 1 PC
1/ 22/ 25 60541000476* O-RING 1 PC D
1/ 22/ 401 60449900022* INTERMEDIATE FLANGE 1 PC
1/ 22/ 421 60230001181* COVER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 6193008729*
DESCRIPTION: DRIVE
ARRANGEMENT OF DISC ( ITEM 97 + 98 ) SEE PICTURE HYDR. MULTIPLE DISC BRAKE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 6193008729*
DESCRIPTION: DRIVE

1/ 24 6193008729* DRIVE 1 PC L
1/ 24/ 1 60242400491* BRAKE FLANGE 1 PC
1/ 24/ 4 60191000227* DRIVING SLEEVE 1 PC
1/ 24/ 7 60230000776* MOTOR FLANGE 1 PC
1/ 24/ 8 60230000777* MOTOR FLANGE 1 PC
1/ 24/ 18 60242400086* COVER 1 PC
1/ 24/ 25 60411130705* HEXAGON BOLT 4 PC
1/ 24/ 30 60453000039* GROOVED BALL BEARING 1 PC
1/ 24/ 50 60441100573* SHAFT SEALING RING 1 PC D
1/ 24/ 55 60541000017* O-RING 1 PC D
1/ 24/ 58 60541000314* O-RING 1 PC D
1/ 24/ 59 60541000070* O-RING 1 PC D
1/ 24/ 60 60414030001* SCREW PLUG 4 PC
1/ 24/ 61 60441000207* FLAT SEALING RING 4 PC D
1/ 24/ 64 60414030005* SCREW PLUG 1 PC
1/ 24/ 65 60441000213* FLAT SEALING RING 1 PC
1/ 24/ 66 60242400144* COVER 1 PC
1/ 24/ 69 60543400040* AIR FILTER 1 PC
1/ 24/ 70 60404300224* ADJUSTING RING 4 PC
1/ 24/ 75 60402100310* PRESSURE SPRING 20 PC
1/ 24/ 79 60404130015* DISC 4 PC
1/ 24/ 95 00001002700* OIL PRESSURE UNIT 1 PC
1/ 24/ 96 60506700224* DISC HOUSING 1 PC
1/ 24/ 97 60506700162* OUTER DISC 8 PC
1/ 24/ 98 60506700163* INNER DISC 7 PC
1/ 24/ 122 60414030002* SCREW PLUG 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 191000085*
DESCRIPTION: HYDR. MULTIPLE DISC BRAKE
PLEASE TAKE THE NECESSARY QUANTITY OF PRESSURE SPRINGS FROM SPARE PART LIST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193003795*
DESCRIPTION: OIL PIPE

1/ 60 60193003795* OIL PIPE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001044375*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001064514*

01 00001074849* GEAR 1 PC L
21 60193005945* ROPE DRUM 1 PC L
24 60193005963* DRIVE 1 PC L
60 60193003785* OIL PIPE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001074849*
DESCRIPTION: GEAR
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001074849*
DESCRIPTION: GEAR

2/ 1 00001074849* GEAR 1 PC L
2/ 1/ 1 00001040037* OUTPUT DRIVE 1 PC L

2/ 1/ 1/ 3 60242901804* BEARING RING 1 PC
2/ 1/ 1/ 11 60230001258* DISTANCE 4 PC
2/ 1/ 1/ 13 60242901835* DISC 1 PC
2/ 1/ 1/ 27 60240700320* DISC 18 PC
2/ 1/ 1/ 41 60442000001* PROFILED CORD 1,6 M D
2/ 1/ 1/ 42 60542000010* HOLDING STRAP 1,7 M
2/ 1/ 1/ 43 60542100010* BELT LOCK 1 PC
2/ 1/ 1/ 51 60453300171* CYLINDER ROLLER BEARING 1 PC
2/ 1/ 1/ 201 60242901315* OUTPUT HOUSING 1 PC
2/ 1/ 1/ 203 60404130524* DISC 22 PC
2/ 1/ 1/ 462 60414030111* SCREW PLUG 4 PC
2/ 1/ 1/ 491 60242600492* DISC 1 PC
2/ 1/ 1/ 520 60524100009* OIL VALVE 2 PC
2/ 1/ 11 60100100712* BG PLANETARY STAGE 1 PC L

2/ 1/ 11/ 1 60233900001* INNER-WHEEL 1 PC
2/ 1/ 11/ 3 60242901904* SUN WHEEL 1 PC
2/ 1/ 21 60100100507* BG PLANETARY STAGE 1 PC L

2/ 1/ 21/ 1 60233705109* INNER-WHEEL 1 PC
2/ 1/ 21/ 3 60242600736* SUN WHEEL 1 PC
2/ 1/ 24 60100010574* BG PLANETARY CARRIER 1 PC L

2/ 1/ 24/ 4 60503100059* CIR CLIP / SNAP RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001074849*
DESCRIPTION: GEAR

2/ 1/ 27 60100020561* BG INTERMEDIATE HOUSING 1 PC L
2/ 1/ 31 60100100424* BG PLANETARY STAGE. 1 PC L

2/ 1/ 31/ 1 60232400148* INNER-WHEEL 1 PC
2/ 1/ 31/ 3 60242400934* SUN WHEEL 1 PC
2/ 1/ 34 00001040836* BG PLANET CARRIER 1 PC L

2/ 1/ 39 60100020458* BG COVER 1 PC L
2/ 1/ 39/ 1 60243200200* COVER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005945*

2/ 21 60193005945* ROPE DRUM 1 PC L
2/ 21/ 1 60242901805* ROPE DRUM 1 PC
2/ 21/ 5 60243100481* ROPE PLATE 1 PC
2/ 21/ 20 60411130573* HEXAGON BOLT 24 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040038*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001040038*

1/ 22/ 1 60242900831* FLANGE 1 PC
1/ 22/ 2 60242901160* FLANGE PLATE 1 PC
1/ 22/ 3 60234705440* COVER 1 PC
1/ 22/ 5 60688100003* FELT SEALING STRIP 0,4 M D
1/ 22/ 6 60453400072* SELF-ALIGNING ROLLER BEARING 1 PC
1/ 22/ 8 60242900950* COVER 1 PC
1/ 22/ 9 60234605252* DRIVER 1 PC
1/ 22/ 12 60417000094* SLOTTED PIN 1 PC
1/ 22/ 13 60417000094* SLOTTED PIN 1 PC
1/ 22/ 14 60412300409* THREADED PIN 1 PC
1/ 22/ 20 60242200386* INTERMEDIA FLANGE 1 PC
1/ 22/ 25 60541000476* O-RING 1 PC D
1/ 22/ 401 60449900022* INTERMEDIATE FLANGE 1 PC
1/ 22/ 421 60230001181* COVER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005963*
DESCRIPTION: DRIVE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005963*
DESCRIPTION: DRIVE

2/ 24 60193005963* DRIVE 1 PC L
2/ 24/ 1 60242400491* BRAKE FLANGE 1 PC
2/ 24/ 4 60193000633* DRIVE SLEEVE 1 PC
2/ 24/ 7 60230000014* MOTOR FLANGE 1 PC
2/ 24/ 18 60242400085* COVER 1 PC
2/ 24/ 25 60411130519* HEXAGON BOLT 4 PC
2/ 24/ 30 60453000039* GROOVED BALL BEARING 1 PC
2/ 24/ 58 60541000314* O-RING 1 PC D
2/ 24/ 59 60541000447* O-RING 1 PC D
2/ 24/ 60 60414030023* SCREW PLUG 2 PC
2/ 24/ 64 60414030029* SCREW PLUG 1 PC
2/ 24/ 65 60441000213* FLAT SEALING RING 1 PC
2/ 24/ 66 60242400142* COVER 1 PC
2/ 24/ 69 60543400040* AIR FILTER 1 PC
2/ 24/ 70 60404300224* ADJUSTING RING 2 PC
2/ 24/ 79 60404130013* DISC 4 PC
2/ 24/ 95 00001002700* OIL PRESSURE UNIT 1 PC
2/ 24/ 96 60506700224* DISC HOUSING 1 PC
2/ 24/ 97 60506700162* OUTER DISC 8 PC
2/ 24/ 98 60506700163* INNER DISC 7 PC
2/ 24/ 122 60414030002* SCREW PLUG 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 191000095*
DESCRIPTION: HYDR. MULTIPLE DISC BRAKE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193003795*
DESCRIPTION: OIL PIPE

2/ 60 60193003795* OIL PIPE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005941*
DESCRIPTION: PRESSURE ROLLER
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193005941*
DESCRIPTION: PRESSURE ROLLER

36 60193005941* PRESSURE ROLLER 1 PC L
36/ 1 60230000122* FRAME 2 PC
36/ 2 60240000093* SHAFT 2 PC
36/ 3 60230000530* SHAFT 1 PC
36/ 4 60230000520* LEVER 2 PC
39/ 5 60243100654* LEG SPRING 2 PC
36/ 6 60243100655* LEG SPRING 2 PC
36/ 11 60230000683* PIPE 1 PC
36/ 12 60242400636* PIPE 2 PC
36/ 16 60230000537* COVER 2 PC
36/ 18 60230000518* RING 6 PC
36/ 19 60230000519* RING 2 PC
36/ 21 60411230075* CYLINDRICAL BOLT 4 PC
36/ 26 60404130557* DISC 4 PC
36/ 31 60403100030* CIR CLIP / LOCKING RING 2 PC
36/ 36 60417040192* SLOTTED PIN 2 PC
36/ 43 60242701016* DISC 2 PC
36/ 45 60230000800* PIPE 2 PC
36/ 50 60453000231* GROOVED BALL BEARING 6 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001060228*
DESCRIPTION: WINCH SUPPORT
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001060228*

40 00001060228* WINCH SUPPORT 1 PC L
40/ 1 60242901593* CARGO JACK WINCH UNIT 1 PC
40/ 2 60411130676* HEXAGON BOLT 6 PC
40/ 4 60421100575* HEXAGON BOLT 23 PC
40/ 5 60204130524* DISC 23 PC
40/ 6 60411130676* HEXAGON BOLT 6 PC
40/ 8 60421100575* HEXAGON BOLT 23 PC
40/ 9 60404130524* DISC 23 PC
40/ 11 60242200312* DISTANCE 4 PC
40/ 12 60411230043* CYLINDRICAL BOLT 8 PC
40/ 50 60421100575* HEXAGON BOLT 4 PC
40/ 51 60404130524* DISC 4 PC
40/ 120 60242901832* COVER 1 PC
40/ 121 60404130122* DISC 16 PC
40/ 122 60411130455* HEXAGON BOLT 4 PC
40/ 123 60415130009* HEXAGON NUT 4 PC
40/ 125 60230001365* HOLDING BRACKET 2 PC
40/ 127 60411130453* HEXAGON BOLT 8 PC
40/ 130 00001032899* COVER 1 PC
40/ 131 60404130122* DISC 8 PC
40/ 132 60411130452* HEXAGON BOLT 8 PC
40/ 136 60404130149* DISC 8 PC
40/ 137 60411130723* HEXAGON BOLT 8 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
190000401*
GENERAL
Please also note the indications in our installation drawings:
Strength classes and torque moments for screw see installation drawing.
Assembly
Fix winch support
Carry out following assembly Steps for each winch:
Remove transport cover off the motor flange.
Connect brake line ( see installation drawing –rope winch- ).
Release hydraulically holding brake.
Remove plug off the drive sleeve of the drive unit.
For protection against corrosion the drive sleeve is provided with gear oil from the gear. The plug
prevents a filling with oil of the motor flange before montage of the motor.
Attention: Motor shaft grease free!
Seal connecting surface.
Before test-running, fill motor flange completely with gear oil.
Check oil level with oil dipstick.
Refill oil if necessary.
If the rope winch is supplied without oil, this is indicated on a corresponding label.
Oil type see name plate resp. maintenance instruction.
Oil quantity see name plate resp. spare parts list.
Check rope winch with running motor as to function.
Check above all the control and function of the holding brake and the drive motor.
After test-running check oil level once more with oil dipstick.
During the test-running, the oil level in the gear and motor flange is adjusting itself and so fills the
Space to the motor shaft slowly with gear oil. Therefore the oil level may be reduced.
If necessary, refill oil.
Insert rope and fix it.
Secure screws accordingly.
* = FOREIGN NUMBER

TTS-NMF GmbH
190000204
MAINTENANCE INSTRUCTION
Lubrication
The rope winch gear has splashed lubrication.
Oil filling ex works : AVIA gear oil RSX 220
Choice according to DIN : DIN 51502
The quantity of oil filled is indicated on the rating plate. If the gear is delivered without oil, this is indicated by
a sticker.

Recommendation for maintenance intervals

First oil change after 200, then after each 1000 service hours, but at least once a year.
* = FOREIGN NUMBER

TTS-NMF GmbH
19000315*
RECCOMENDATION FOR LUBRICANTS

Choice list
CHOOSEN ACCORDING TO CHOOSEN ACCORDING TO CHOOSEN ACCORDING TO

API GL 5 DIN 51502 DIN 51502
OIL, SAE 90 OIL, DIN 51517 – CLP 220 GREASE, DIN 51825 – KP2K
AVIA GEAR OIL

HYPOID 90 EP
CASTROL SPHEEROL
EPL 2 GREASE
ESSO GEAR OIL

GX-D90
FUCHS GEAR OIL

RENOGEAR HYPOID 90

* = FOREIGN NUMBER

TTS-NMF GmbH
190000781*
GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Why oil analyses ?

charges.
Simple surveillance:
metals, dirt etc.
construction part.
damage of the gear.
+ = FOREIGN NUMBER

TTS-NMF GmbH
190000781
Taking of an oil sample

level.
* = FOREIGN NUMBER

TTS-NMF GmbH
190000159
TIGHTENING TORQUES
Tightening torques for fixing screws M 4 to M 36 and for strength classes 8.8, 10.9
and 12.9 at a coefficient of friction 0,125.
8.8 10.9 12.9
M4 = 2,7 Nm 3,8 Nm 4,6 Nm
M5 = 5,5 Nm 8,0 Nm 9,5 Nm
M6 = 9,5 Nm 13,0 Nm 16,0 Nm
M8 = 23,0 Nm 32,0 Nm 39,0 Nm
M 10 = 46,0 Nm 64,0 Nm 77,0 Nm
M 12 = 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
M 36 = 2350,0 Nm 3300,0 Nm
 The indicated tightening torques are maximum values.

 Screws secured by Loctite Type 242.
 Fitting surfaces sealed by Loctite Type 640.
 Surfacing on brake sealed by Loctite Type 573.
 Screwing of the tubing and the connection surfaces of the drive motor to the gear are sealed
with Loctite Type 572.
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

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

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

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

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 373-00
DESCRIPTION: ELECTRICAL EQUIPMENT COMPL .

25.00.00.00.00 1 PC ELECTRICAL EQUIPMENT COMPL: 5022373
25.01.00.00.00 1 PC ELECTRICAL-EQUIPMENT SLEWING 5022374

TOWER
25.02.00.00.00 1 PC E-SYSTEM JIB 5022375
25.15.00.00.00 1 PC ELECTRICAL EQUIPMENT POWER PACK 5022376
25.18.00.00.00 1 PC ELECTRICAL EQUIPMENT FOR CABIN 5022422
ASEMBLY GROUP 25.00.00.00.00
SPARE PARTS LIST

ORDER NO. 5 022 374-00
DESCRIPTION: E-PART SLEWING TOWER

25.01.00.00.00 1 PC E-PART CRANE TOWER 5022374
25.01.03.00.00 1 PC LIGHTING AND HEATING 5002074

25.01.60.00.00 1 PC WORKSHOP ASSEMBLY 5022408
25.01.80.00.00 1 PC EMERGENCY LIGHTING 5012498

TTS NMF GmbH
SPARE PARTS LIST

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

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

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

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 408-00
DESCRIPTION: WORKSHOP ASSEMBLY
25.01.60.00 1 PC WORKSHOP ASSEMBLY 5022408
25.01.60.01 1 PC SUPPLY FOR PROTECTIVE EARTH 5002785

25.01.60.03 8 M CABLE TRAY 1627349
25.01.60.04 40 PC CABLE TRAY NUT 2012404 2012404
25.01.60.05 6 PC SCREW CONNECTOR 1624652
25.01.60.06 2 PC DISTRIBUTION BOX 1627768
25.01.60.07 7 PC SCREW BUSH 1624414
25.01.60.08 3 PC INSIDE F. CABLE GUIDE 1627506
25.01.60.09 2 PC SCREW PLUG 1627280
25.01.60.10 4 PC HEX. SCREW 0842417
25.01.60.11 4 PC SPRING RING 3398003
25.01.60.12 4 PC WASHER 3330214
25.01.60.13 4 PC CARRIER RAIL NUT 3398455
25.01.60.14 1 PC INTERIOR PART FOR CABLE 5002076
25.01.60.20 2 PC CONDUIT BUSHING 1360534
25.01.60.21 2 M EDGE PROTECTION 0597527
25.01.60.22 2 M EDGE PROTECTION 0153957 0153957
25.01.60.24 100 PC CABLE TIE 1624720
25.01.60.25 50 PC CABLE TIE 1660206
25.01.60.26 15 PC STEEL CABLE JOINT 5002310
SPARE PARTS LIST

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

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

25.01.60.01.02 2 PC CABLE SHOE 0216411
25.01.60.01.03 4 PC HEXAGON NUT 0057127
25.01.60.01.10 6 M CABLE IEC 60092 5002063
25.01.60.01.11 2 PC CABLE SHOE 10-70 0216411
25.01.60.01.12 1 PC HEXAGON NUT 0057127

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 012 498-00
DESCRIPTION: EMERGENCY LIGHTING

25.01.80.00 1 PC EMERGENCY LIGHTING 5012498
25.01.80.01 1 PC BATTERY BACK UP EMERGENCY LIGHT 5012497

25.01.80.02 2 PC FLUORESCENT LAMP 0058132
25.01.80.03 1 PC SCREW BUSH 1624414
25.01.80.04 2 PC HEXAGON NUT 0650234
25.01.80.05 2 PC CONTACT WASHER 2079808
25.01.80.06 2 PC HEXAGON SCREW 1683943
25.01.80.07 1 PC SCREW PLUG 1627280
25.01.80.08 5,0 M CABLE IEC 5002069
25.01.80.09 10 PC CABLE TIE 1660206
25.01.80.11 4 PC TERMINAL 1666916
25.01.80.12 5,0 M CABLE 1656359
SPARE PARTS LIST

ORDER NO. 5 022 375-00
DESCRIPTION: E-SYSTEM JIB

25.02.00.00.00 1 PC E-SYSTEM JIB 5022375
25.02.01.00.00 1 PC HNA-STANDARD FITTING 1624721

25.02.02.00.00 1 PC TWO-BASE BULB 1624722
25.02.03.00.00 1 PC INCANDESCENT LAMP 1660212
25.02.05.00.00 1 PC HNA-JUNCTION BOX 1624723
25.02.06.00.00 4 PC SCREW BUSH 1624414
25.02.07.00.00 4 PC HEXAGON SCREW 0842417
25.02.08.00.00 4 PC SPRING RING 3398003
25.02.09.00.00 4 PC CARRIER RAIL NUT 3398455
25.02.10.00.00 37 M CABLE 0505898
25.02.11.00.00 10 M CABLE 0505897
25.02.12.00.00 14 PC CONDUIT BUSHING 1360534
25.02.13.00.00 3 PC GASKET FOR CABLE GLAND 1627507
25.02.14.00.00 1 PC SIKAFLEX 4228427
25.02.15.00.00 1 PC HEAT SHRINK TUBE 5002985

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 376-00
DESCRIPTION: ELECTRICAL EQUIPMENT POWER PACK

25.15.00.00.00 1 PC ELECTRICAL EQUIPMENT POWER PACK 5022376
25.15.03.00.00 1 PC LIGHTING 220V/60HZ 5002109

25.15.10.00.00 1 PC PUMP DRIVE UNIT 5022406
25.15.15.00.00 1 PC LIMIT SWITCH FOR WINCHES 5022424
25.15.50.00.00 1 PC CONTROL CABINET 5022409
25.15.60.00.00 1 PC WORKSHOP INSTALLATION 5022419
SPARE PARTS LIST

ORDER NO. 5 002 109-02
DESCRIPTION: LIGHTING

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

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

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 406-00
DESCRIPTION: PUMP DRIVE UNIT

25.15.10.00.00 1 PC PUMP DRIVE UNIT 5022406
25.15.10.01.00 1 PC 3PH-MOTOR 160KW 5002027

SEE SUBSUPPLIER
25.15.10.60.00 1 PC INSTALLATION OF PUMP DRIVE UNIT 5022407

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

TTS NMF GmbH
SPARE PARTS LIST

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

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 027
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO 5 022 0272
L= ASSEMBLY GROUP
D= SEALING ELEMENT
* = FOREIGN NUMBER

TTS NMF GmbH
SPARE PARTS LIST

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

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 407-00
DESCRIPTION: INSTALLATION POWER PACK

25.15.10.60.00 1 PC INSTALLATION POWER PACK 5022407
25.15.10.60.01 1 PC DIGITAL MODULE CR203 – ID01 5002203

25.15.10.60.02 1 PC ANALOG MODULE CR2033 – ID03 5002204
25.15.10.60.03 1 PC COMPACT MODULE PWM – ID02 5002197
25.15.10.60.04 2 PC CABLE CAN-BUS M12/M12-0,3m 4243111
25.15.10.60.05 1 PC PLUG-RESISTOR M12-120R 4243112
25.15.10.60.06 4 PC CABLE 5002038
25.15.10.60.07 6 PC CABLE M12/DIN A - CURRENT 4243444
25.15.10.60.08 2 PC CABLE PLUG M12-2m 4243115
25.15.10.60.09 1 PC CONNECT PLUG 5002853
25.15.10.60.10 2 PC PRESSURE TRANSMITTER TYP HT-PD 5002899 5002899
25.15.10.60.11 1 PC TEMPERATURE SENSOR 5002900 5002900
25.15.10.60.12 3 PC CONNECTING CABLE FOR SENSORS 5002905 5002905
25.15.10.60.13 4 PC CONNECTING CABLE FOR PRESSURE 5012873 5012873
SWITCH
25.15.10.60.14 2 PC CABLE ADAPTER 5002254
25.15.10.60.15 2 PC FLAT SOCKET 2079546
25.15.10.60.16 40 PC CABLE TIE 1660206
25.15.10.60.17 1,5 M SPIRAL COILED TUBE 5012560
25.15.10.60.18 2,5 M SPIRAL COILED TUBE 5012561
25.15.10.60.20 12 PC CYLINDRICAL SCREW 1350451
25.15.10.60.21 12 PC SLIDE NUT 1676821
25.15.10.60.22 12 PC SL-WASHER 0725726

TTS NMF GmbH
SPARE PARTS LIST

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

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

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

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

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

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

ORDER NO. 5 002 197-00
DESCRIPTION: COMPACT MODULE

25.15.10.60.03.00. 1 PC COMPACT MODULE 5002197
25.15.10.60.03.02 1 PC COMPACT MODULE 4243105

25.15.10.60.03.03 1 PC PLATE MODULE 5002200 5002200

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 424-00
DESCRIPTION: LIMIT SWITCH FOR WINCHES

25.15.15.00.00 1 PC LIMIT SWITCH FOR WINCHES 5022424
25.15.15.01.00 2 PC LIMIT SWITCH 5002244 5002244

25.15.15.11.00 6 PC HEXAGON-SCREW 0840883
25.15.15.12.00 6 PC SPRING RING 3398003
25.15.15.13.00 2 PC BLIND GASKET 4236998
25.15.15.14.00 1 PC INSTALL SYNC PROXIMITY SWITCHES 5012614
SPARE PARTS LIST

ORDER NO. 5 012 614-00
DESCRIPTION: INSTALL SYNC PROXIMITY SWITCHES

25.15.15.14.00 1 PC INSTALL SYNC PROXIMITY SWITCHES 5012614
25.15.15.14.01 1 PC TERMINALBOX –X51 , CONFURIUS 5012549

ASSEMBLY
25.15.15.14.02 2 PC INITIATOR 2507753
25.15.15.14.03 2 PC CABLE BOX 2096994

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 012 549-01
DESCRIPTION: TERMINALBOX –X51, CONFURIUS ASSEMBLY

25.15.15.14.01.00 1 PC TERMINALBOX –X51, CONFURIUS 5012549

ASSEMBLY
25.15.15.14.01.01 1 PC HOUSING PT100 5012550 5012550
25.15.15.14.01.02 1 PC PLATE TERMINALBOX –X51 5012551 5012551
25.15.15.14.01.101 6 PC TERMINAL 1791261
25.15.15.14.01.102 1 PC TERMINAL 1791263
25.15.15.14.01.103 2 PC TERMINAL BRIDGE 1791265
25.15.15.14.01.104 1 PC END PLATE GR 280-330 1791264
25.15.15.14.01.105 1 PC SIDE ANGLE 209-101 1791302
25.15.15.14.01.106 1 PC TITLE CARD 1666929
25.15.15.14.01.107 4 PC CYL. SCREW 7834532
25.15.15.14.01.108 4 PC SL WASHER 0725726
SPARE PARTS LIST

ORDER NO. 5 022 409-00
DESCRIPTION: CONTROL CABINET

25.15.50.00.00 1 PC CONTROL CABINET 5022409
25.15.50.01.00 1 PC CONTROL CABINET COMPL. 5012807

25.15.50.02.00 1 PC EQUIPMENT PART = M01 5022410
25.15.50.06.00 1 PC STANDARD COMPONENTS 5022417

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 012 807-00
DESCRIPTION: CONTROL CABINET COMPL.

25.15.50.01.00 1 PC CONTROL CABINET COMPL. 5012807
25.15.50.01.01 1 PC CABINET 1800x600x300 5012661

25.15.50.01.02 1 PC CIRCUIT DIAGRAMM POCKET 1350889
25.15.50.01.03 1 PC TYPE PLATE CONTROL CABINET 5012630 5012630
25.15.50.01.04 1 PC PLATE CRANE CONTROL 5012808 5012808
25.15.50.01.05 1 PC PLATE WARNING 1686093 1686093
SPARE PARTS LIST

ORDER NO. 5 012 661-01
DESCRIPTION: CABINET 1800x600x300

25.15.50.01.01.00 1 PC CABINET 1800x600x300. 5012661
25.15.50.01.01.01 1 PC CABINET SERIE SPECIAL 5012662

25.15.50.01.01.03 1 PC DOOR CATCH 5012659
25.15.50.01.01.04 1 PC ASSEMBLY PROFILE 5012660

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 410-00
DESCRIPTION: EQUIPMENT PART =M01

25.15.50.02.00 1 PC EQUIPMENT PART =M01 5022410
25.15.50.02.01 1 PC LOAD BREAKER 5002251 5002251

25.15.50.02.02 1 PC LOAD BREAK SWITCH T3-1 5022144
25.15.50.02.05 1 PC PILOT LIGHT 5022351
25.15.50.02.06 1 PC PILOT LAMP “POWER SUPPLY“ 5022136
25.15.50.02.10 1 PC POWER SUPPLY 5002582
25.15.50.02.11 1 PC MOTOR CIRCUIT BRAEKER 5022350
25.15.50.02.12 1 PC MOTOR CIRCUIT BREAKER 5022161
25.15.50.02.15 1 PC NH-FUSE BREAKER 5022145
25.15.50.02.16 1 PC NH-FUSE 5022349
25.15.50.02.20 3 PC CLAMP 5022152
25.15.50.02.21 3 PC PE-CLAMP 5022153
25.15.50.02.22 2 PC PLATE 5022154
25.15.50.02.23 5 PC CLAMP 5022147
25.15.50.02.24 2 PC PLATE 5022150
25.15.50.02.26 1 PC FUSE 5022149
25.15.50.02.27 7 PC FUSE 5022148
25.15.50.02.30 1 PC CABLE 1608435
25.15.50.02.31 6 PC CABLE 1637432
25.15.50.02.32 4 PC CABLE 5002431
25.15.50.02.40 1 PC TITLE CARD 2350684
25.15.50.02.51 2 M FUSE 5022145
25.15.50.02.52 6 M FUSE 5022146

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 351-00
DESCRIPTION: PILOT LAMP POWER SUPPLY COMPL.

25.15.50.02.05 1 PC PILOT LAMP POWER SUPPLY COMPL. 5022351
25.15.50.02.05.01 1 PC FRONT ELEMENT 5022138

25.15.50.02.05.02 1 PC BULB SOCKET 5022352
25.15.50.02.05.03 2 PC PILOT LAMP 5022141
25.15.50.02.05.04 1 PC SIGN HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 136-00
DESCRIPTION: PILOT LAMP AUX. SUPPLY COMPL.

25.15.50.02.06 1 PC PILOT LAMP AUX. SUPPLY COMPL. 5022136
25.15.50.02.06.01 1 PC FRONT ELEMENT 5022138

25.15.50.02.06.02 1 PC BULB SOCKET 5022139
25.15.50.02.06.03 1 PC PILOT LAMP 5022141
25.15.50.02.06.04 1 PC SIGN HOLDER 5022142

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 437-00

25.15.50.03.01 1 PC CONTACTOR 5022354

25.15.50.03.02 1 PC CONTACTOR 5022355
25.15.50.03.03 1 PC STARPOINT BAR CLAMP 5022356
25.15.50.03.04 1 PC PROTECTIVE COVER 5022131
25.15.50.03.05 3 PC THERMINAL 5022130
25.15.50.03.06 0,5 PC TERMINAL BLOCK 5022357
25.15.50.03.07 2 PC AUXILIARY SWITCH 5022126
25.15.50.03.12 1 PC TIME RELAY 5022358

25.15.50.03.16 1 PC CURRENT TRANSFORMERS 5022359
25.15.50.03.17 1 PC TRANSFORMERS 5022168
25.15.50.03.20 1 PC CONTACTOR 5022156
25.15.50.03.21 1 PC MOTOR CONTACTOR 5022158
25.15.50.03.24 1 PC CONTACTOR 5022155
25.15.50.03.25 1 PC MOTOR CONTACTOR 5022160
25.15.50.03.30 2 PC AUXILIARY SWITCH BLOCK 5022272
25.15.50.03.32 2 PC AUXILIARY SWITCH 5022162
25.15.50.03.35 6 PC BUS BAR 5022163
25.15.50.03.36 2 PC THERMINAL 5022166
25.15.50.03.38 1 PC THERMISTOR RELAIS 5022169
25.15.50.03.50 6 PC TERMINAL BLOCK 5022170
25.15.50.03.51 2 PC CLAMP 1667815
25.15.50.03.52 1 PC CONNECTION PLATE 5022171
25.15.50.03.53 3 M CABLE 1608435
25.15.50.03:54 2 M CABLE 1637432
25.15.50.03.60 6 PC CABLE CLIP 0216411
25.15.50.03.61 3 PC CABLE CLIP 2530908

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 411-00
DESCRIPTION: EQUIPMEMT PART =M03

25.15.50.04.11 1 PC FILTERFAN 5022174

25.15.50.04.13 1 PC THERMOSTAT 5022175
25.15.50.04.14 1 PC HEATING FLH 5022176
25.15.50.04.15 5 PC AUTOMAT 5022178
25.15.50.04.17 1 PC FINAL PLATE 5022438
25.15.50.04.18 2 PC SUPPLY TERMINAL 5022181
25.15.50.04.19 1 PC FINAL PLATE 5022182
25.15.50.04.20 10 M CABLE 1608435
25.15.50.04.21 24 PC CABLE CLIP 1637544
25.15.50.04.24 22 PC TERMINAL CLIP 5022217
25.15.50.04.26 3 PC TERMINAL BRIDGE 5022219

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 412-00

25.15.50.05.01 1 PC PLC R360 CR 0020 5002194

25.15.50.05.02 1 PC CABLE CONNECTOR 4243437
25.15.50.05.10 1 PC TERMINAL 4228649
25.15.50.05.11 75 PC TERMINAL CLIP 5022220
25.15.50.05.12 11 PC SIDE ANGLE 5022221
25.15.50.05.13 1 PC TERMINAL BRIDGE 5022222
25.15.50.05.16 7 PC FM 4-fUSS 5022225
25.15.50.05.20 5 PC SCREEN CLAMP 5022226
25.15.50.05.21 2 PC SCREEN CLAMP 5022227
25.15.50.05.51 4 PC RELAIS 5022367
25.15.50.05.52 1 PC RELAIS 5022365
SPARE PARTS LIST

ORDER NO. 5 002 194-00
DESCRIPTION: PLC R360

25.15.50.05.01.00 1 PC PLC R360 5002194
25.15.50.05.01.02 1 PC PLC R360 4243436

25.15.50.05.01.03 1 PC PLATE CONTROLLER 5002195 5002195

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 417-00
DESCRIPTION: STANDARD COMPONENTS

25.15.50.06.00. 1 PC STANDARD COMPONENTS 5022417
25.15.50.06.01 4 PC HEXAGON-SCREW 7121363

25.15.50.06.04 4 PC CYLINDRICAL-SCREW 1683926
25.15.50.06.05 4 PC HEXAGON-SCREW 1683940
25.15.50.06.06 4 PC HEXAGON-SCREW 7121112
25.15.50.06.07 10 PC HEXAGON-SCREW 1683937
25.15.50.06.08 40 PC COUNTER SUNK SCREW 6705038
25.15.50.06.10 8 PC HEXAGON-NUT 1683741
25.15.50.06.11 12 PC WASHER 1684578
25.15.50.06.15 30 PC HEXAGON-SCREW 1652159
25.15.50.06.17 6 PC HEXAGON-SCREW 0063275
25.15.50.06.19 6 PC SLIDE NUT 1652515
25.15.50.06.20 4 PC SUNK SCREW 1683729
25.15.50.06.24 8 PC HEXAGON-NUT 1683740
25.15.50.06.25 12 PC SL-WASHER 0725726
25.15.50.06.26 12 PC WASHER 1684548
25.15.50.06.30 20 PC SCREW 2088718
25.15.50.06.31 2 M CABLE HOSE 2031738
25.15.50.06.32 2 PC HOLDER CABLE HOSE 2031739
25.15.50.06.40 3 M PROFILRAIL 1652510
25.15.50.06.41 3 M CARRIER RAIL 1665083
25.15.50.06.42 2,5 M CABLE DUCT 1657371
25.15.50.06.43 1,5 M CABLE DUCT 1657370
25.15.50.06.44 1,5 M CABLE DUCT 1657369
25.15.50.06.45 1,5 M CABLE DUCT 2079527
25.15.50.06.50 3 PC EARTHING STRIP 1652483
25.15.50.06.51 5 M CABLE 0337832
25.15.50.06.52 10 M CABLE 1654809
25.15.50.06.53 10 M CABLE 2010796
25.15.50.06.54 25 M CABLE 1656359
25.15.50.06.55 5 M CABLE 1654810
25.15.50.06.60 6,5 M CABLE 1657410
25.15.50.06.62 50 M CABLE 1656357

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 419-01
DESCRIPTION: WORKSHOP INSTALLATION
25.15.60.01.00 70 M CABLE 5002063

25.15.60.02.00 7 M CABLE 5002065
25.15.60.03.00 18 M CABLE 5002068
25.15.60.04.00 90 M CABLE 5002066
25.15.60.05.00 26 M CABLE 5022069
25.15.60.06.00 7 M CABLE 5002070
25.15.60.07.00 6 M CABLE 0625070
25.15.60.10.00 10 M CABLE–QUATTRO 5002121
25.15.60.11.00 14 M CABLE CAN 5002413
25.15.60.12.00 56 M CABLE 1655148
25.15.60.16.00 21 M CABLE 5002412
25.15.60.20.00 1,4 M SHRINK TUBE 5002128
25.15.60.21.00 1 PC REDUCTION 5012064
25.15.60.22.00 0,25 PC SHRINK HOSE BLACK 1655414
25.15.60.23.00 1 PC CABLE GLAND 4236259
25.15.60.24.00 1 PC CABLE GLAND 4236745
25.15.60.25.00 2 PC CONDUIT BUSHING 1360536
25.15.60.26.00 3 M EDGE PROTECTION 0597527
25.15.60.27.00 1 PC PL 3-RUPPER WITH WARP 3 0153691
25.15.60.31.00 10 PC CABLE TIMBLE 0216411
25.15.60.32.00 2 PC CABLE THIMBLE 0511001
25.15.60.33.00 1 PC CABLE THIMBLE 0146964
25.15.60.34.00 1 PC CABLE THIMBLE 0771645
25.15.60.35.00 8 PC CABLE THIMBLE 0038663
25.15.60.36.00 5 PC CABLE SHOE 0039087
25.15.60.39.00 5 PC CABLE END BUSHING 1054398
25.15.60.40.00 8 PC SLEEVE 1054397
25.15.60.41.00 25 PC CABLE END BUSHING 5012555
25.15.60.50.00 2 M CABLE TRAY 0158339
25.15.60.51.00 4 M CABLE TRAY 1660239
25.15.60.52.00 30 PC CABLE TRAY NUT 2012404 2012404
25.15.60.58.00 1 M CABLE CLIP 0924646
25.15.60.60.00 1 PC CU-RAIL 5012308 5012308
25.15.60.61.00 8 PC HEX-SCREW 0056661
25.15.60.62.00 2 PC HEX-SCREW 0067975
25.15.60.63.00 14 PC HEX-NUT 1683742
25.15.60.71.00 5 PC STEEL CABLE JOINT 5002309
25.15.60.72.00 50 PC CABLE TIE 1624720
25.15.60.73.00 50 PC CABLE TIE 1660206
25.15.60.81.00 10 M CABLE 5002333
25.15.60.82.00 10 M CABLE 5002066
25.15.60.83.00 10 M CABLE 1657707
25.15.60.85.00 1 PC CABLE SHOE 0511301
25.15.60.86.00 1 PC CABLE SHOE 0924646
TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 422-00
DESCRIPTION: ELECTRICAL EQUIPMENT CABIN

25.18.00.00.00 1 PC ELECTRICAL EQUIPMENT CABIN 5022422
25.18.02.00.00 1 PC CABINE BUILT-IN 5022230

25.18.10.00.00 1 PC CONTROL DESK LEFT CPL. 5022413
25.18.20.00.00 1 PC CONTROL DESK RIGHT CPL. 5022414
25.18.60.00.00 1 PC WORKSHOP INSTALLATION CABIN 5022422
SPARE PARTS LIST

ORDER NO. 5 022 230-00
DESCRIPTION: CABIN BUILT IN

25.18.02.00.00 1 PC CABINE BUILT-IN 5022230
25.18.02.01.00 1 PC LAMP 5022251

25.18.02.02.00 1 PC BULB 0146181
25.18.02.11.00 1 PC VENTILATOR 2532317
25.18.02.20.00 1 PC SOUNDGENERATOR 1096359

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 413-00
DESCRIPTION: LH. CONTROL DESK COMPL.

25.18.10.00.00 1 PC LH CONTROL DESK CPL. 5022413
25.18.10.01.00 1 PC HOUSING LEFT 5012633

25.18.10.02.00 1 PC DEFA-FAN HEATER 4228061
25.18.10.03.00 1 PC EL. COMPONENTS LH. CTRL DESK 5022415
SPARE PARTS LIST

ORDER NO. 5 012 633-00
DESCRIPTION: HOUSING LEFT

25.18.10.01.00 1 PC HOUSING LEFT 5012633
25.18.10.01.01 1 PC DESK LEFT 5002031 5002031

25.18.10.01.02 1 PC SWITCH CABINET LEFT 2350251 2350251
25.18.10.01.10 4 PC HEX.SCREW 1683942
25.18.10.01.11 4 PC HEX.NUT 0650234
25.18.10.01.13 3 PC CYL-SCREW 1683913
25.18.10.01.14 3 PC HEX-NUT 1683740
25.18.10.01.20 1 PC CABLE GLAND 5002062
25.18.10.01.21 1 PC GLAND NUT 4236264

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 415-00
DESCRIPTION: EL.- COMPONENTS LH. CTRL DESK

25.18.10.03.00 1 PC EL.- COMPONENTS LH. CTRL DESK 5022415
25.18.10.03.01 1 PC CONTROL LEVER SLEW./LUFF. 5022435

25.18.10.03.02 1 PC SELECTOR SWITCH WORKING LIGHT 5022235
25.18.10.03.03 1 PC SELECTOR SWITCH CABIN LIGHT 5022236
25.18.10.03.04 1 PC PUSH BUTTON DECKS LIGHT CPL. 5022237
25.18.10.03.05 1 PC SELECTOR SWITCH CABIN HEATER 5022381
COMPL.
25.18.10.03.06 1 PC SELCTOR SWITCH SREEN WIPER 5022238
25.18.10.03.19 1 PC DUMMY COVER 5022241
25.18.10.03.20 1 PC HEATER PTC 15-CABLE 5022242
25.18.10.03.111 1 M CARRIER RAIL 1665083
25.18.10.03.112 1 M CABLE DUCT 1657369
25.18.10.03.114 6 PC COUNTER SUNK SCREW 6705038
25.18.10.03.115 6 PC HEX.-SCREW 1652159
25.18.10.03.116 6 PC HEX-SCREW 1683937
25.18.10.03.120 46 PC TERMINAL 5022220
25.18.10.03.121 7 PC PROTECTIVE COND.CLAMP 5022250
25.18.10.03.122 3 PC SIDE PLATE 5022221
25.18.10.03.123 3 PC SIDE ANGLE 5022151
25.18.10.03.124 2 PC PLATE HOLDER 5022228
25.18.10.03.125 1 PC TITLE CARD 5022173
25.18.10.03.130 2 M CABLE OELFLEX 1657707
25.18.10.03.131 10 M CABLE 1656357
25.18.10.03.132 12 M CABLE 1656359
25.18.10.03.133 10 PC CABLE STRAP 0840069
25.18.10.03.135 1 PC PLATE 1653236
25.18.10.03.136 1 PC PLATE 1608442

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 235-00
DESCRIPTION: SELECTOR SWITCH WORKING LIGHT

25.18.10.03.02.00 1 PC SEL. SWITCH WORKING LIGHT 5022235
25.18.10.03.02.01 1 PC SELECTOR SWITCH 5022243

25.18.10.03.02.02 1 PC CONTACT HOLDER 5022244
25.18.10.03.02.04 1 PC PLATE HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 236-00
DESCRIPTION: SELECTOR SWITCH CABIN LIGHT

25.18.10.03.03.00 1 PC SELECTOR SWITCH CABIN LIGHT 5022236

25.18.10.03.03.02 1 PC SWITCH CONTACT 5022244
25.18.10.03.03.04 1 PC PLATE HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 237-00
DESCRIPTION: PUSH BUTTON DECKS LIGHT COMPL

25.18.10.03.04.00 1 PC PUSH BUTTON DECKS LIGHT COMPL. 5022237
25.18.10.03.04.01 1 PC PUSH BUTTON 5022243

25.18.10.03.04.04 1 PC PLATE HOLDER 5022142

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 381-00
DESCRIPTION: SELECTOR SWITCH CABIN HEATING

25.18.10.03.05.00 1 PC SELECTOR SWITCH CABIN HEATING 5022381

25.18.10.03.05.04 1 PC PLATE HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 238-00
DESCRIPTION: SELECTOR SWITCH SCREEN WIPER

25.18.10.03.06.00 1 PC SELCTOR SWITCH SREEN WIPER 5022238

25.18.10.03.06.02 1 PC CONTACT SEGMENT 5022245
25.18.10.03.06.04 1 PC PLATE HOLDER 5022142

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 414-00
DESCRIPTION: RH. CONTROL DESK COMPL.

25.18.20.00.00 1 PC RH CONTROL DESK COMPL. 5022414
25.18.20.01.00 1 PC HOUSING RIGHT 5012634

25.18.20.02.00 1 PC EL.- COMPONENTS RH. CTRL DESK 5022416
SPARE PARTS LIST

ORDER NO. 5 012 634-00
DESCRIPTION: HOUSING RIGHT

25.18.20.01.00 1 PC HOUSING RIGHT 5012634
25.18.20.01.01 1 PC CONTROL DESK R.H. 5002032 5002032

25.18.20.01.02 1 PC SWITCH CABINET RIGHT 2350252 2350252
25.18.20.01.10 4 PC HEX.SCREW 1683942
25.18.20.01.11 4 PC HEX.NUT 0650234

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 416-00
DESCRIPTION: ELECTRICAL COMPONENTS R.H. CTRL. DESK

25.18.20.02.00.00 1 PC ELECTRICAL COMPONENTS R.H. CTRL. 5022416

DESK
25.18.20.02.01.00 1 PC CONTROL LEVER HOISTING GEAR 5022436

25.18.20.02.02.00 1 PC LCD-DISPLAY 5002205
25.18.20.02.04.00 1 PC CABINET MODULE 4243438
25.18.20.02.05.00 1 PC CONNECTOR SET FOR CM 4243439
25.18.20.02.10.00 1 PC EMERG-STOP BUTTON 5022257
25.18.20.02.11.00 1 PC KEY-OPERATED BUTTON JIB RESTING 5022259
25.18.20.02.12.00 1 PC PILOT LIGHT FAULT 5022260
25.18.20.02.13.00 1 PC SELECTOR SWITCH OFF/ON 5022384
25.18.20.02.14.00 1 PC BUZZER 5022263
25.18.20.02.15.00 1 PC KEY SWITCH SPREADER OPERATION 5022434
COMPL.
25.18.20.02.16.00 1 PC PILOT LIGHT ALL LANDED COMPL. 5022433
25.18.20.02.17.00 1 PC PILOT LIGHT TWL UNLOCK COMPL. 5022432
25.18.20.02.18.00 1 PC PILOT LIGHT TWL LOCK COMPL. 5022431
25.18.20.02.19.00 1 PC BLIND CAP 5022241
25.18.20.02.20.00 1 PC HEATER 5022242
25.18.20.02.121.00 1 M CARRIER RAIL 1665083
25.18.20.02.131.00 1 M CABLE DUCT 1657369
25.18.20.02.132.00 6 PC COUNTER SUNK SCREW 6705038
25.18.20.02.124.00 6 PC HEX.-SCREW 1652159
25.18.20.02.125.00 6 PC HEX-SCREW 1683937
25.18.20.02.126.00 6 PC CONTACT WASHER 2079806
25.18.20.02.127.00 2 PC CAP SCREW 1683914
25.18.20.02.128.00 2 PC SL-WASHER 0725726
25.18.20.02.129.00 2 PC WASHER 1684548
25.18.20.02.140.00 25 PC TERMINAL 5022220
25.18.20.02.141.00 2 PC TERMINAL 5022250
25.18.20.02.142.00 3 PC SIDE PLATE 5022221
25.18.20.02.143.00 4 PC SIDE ANGLE 5022151
25.18.20.02.144.00 3 PC 5022228
25.18.20.02.145.00 1 PC TITLE CARD 5022173
25.18.20.02.150.00 4,5 M CABLE OELFLEX 5022278
25.18.20.02.151.00 30 M CABLE 1656357
25.18.20.02.152.00 1,5 M CABLE 1656358
25.18.20.02.153.00 1,5 M CABLE 0840069
25.18.20.02.154.00 1 PC EARTHING STRIP 1660053
25.18.20.02.156.00 1 PC RESISTOR 5002107
25.18.20.02.157.00 1 PC PLATE 1653236
25.18.20.02.158.00 1 PC PLATE 1608442

TTS NMF GmbH
SPARE PARTS LIST

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

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

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

ORDER NO. 5 022 257-01
DESCRIPTION: EMERGENCY STOP BUTTON

25.18.20.02.10.00 1 PC EMERGENCY-STOP BUTTON 5022257
25.18.20.02.10.01 1 PC EMERG-PUSH BUTTON 5022254

25.18.20.02.10.02 1 PC CONTACT SEGMENT 5022255
25.18.20.02.10.03 1 PC PROTECTION SHIELD 5022256

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 259-00
DESCRIPTION: KEY-OPERATED BUTTON JIB RESTING

25.18.20.02.11.00 1 PC KEY-OPERATED BUTTON JIB RESTING 5022259
25.18.20.02.11.01 1 PC KEY-OPERATED BUTTON 5022264

25.18.20.02.11.04 1 PC PLATE 5022142
SPARE PARTS LIST

ORDER NO. 5 022 260-00
DESCRIPTION: PILOT LIGHT FAULT

25.18.20.02.12.00 1 PC PILOT LIGHT FAULT 5022260
25.18.20.02.12.01 1 PC PILOT LIGHT 5022266

25.18.20.02.12.04 1 PC PLATE FAULT 5022142
SPARE PARTS LIST

ORDER NO. 5 022 384-00
DESCRIPTION: SELECTOR SWITCH OFF/ON

25.18.20.02.13.00 1 PC SELECTOR SWITCH OFF/ON 5022384
25.18.20.02.13.01 1 PC ILLUMINATED SELECTOR SWITCH 5022385

25.18.20.02.13.04 1 PC PLATE 5022142

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 434-00
DESCRIPTION: SELECTOR SWITCH SPREADER OPERATION COMPL.

25.18.20.02.15.00 1 PC SELECTOR SWITCH SPREADER 5022434

OPERATION COMPL.

25.18.20.02.15.04 1 PC PLATE HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 433-00
DESCRIPTION: PILOT LIGHT ALL LANDED COMPLETE

25.18.20.02.16.00 1 PC PILOT LIGHT ALL LANDED COMPL. 5022433
25.18.20.02.16.01 1 PC PILOT LIGHT 5022266

25.18.20.02.16.04 1 PC PLATE FAULT 5022142
SPARE PARTS LIST

ORDER NO. 5 022 432-00
DESCRIPTION: PILOT LIGHT TWL UNLOCK COMPL

25.18.20.02.17.00 1 PC PILOT LIGHT 5022432
25.18.20.02.17.01 1 PC PILOT LIGHT 5022266

25.18.20.02.17.04 1 PC PLATE FAULT 5022142

TTS NMF GmbH

TTS NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 431-00
DESCRIPTION: PILOT LIGHT TWL LOCK COMPL.

25.18.20.02.18.00 1 PC PILOT LIGHT TWL LOCK COMPL. 5022431
25.18.20.02.18.01 1 PC PILOT LIGHT 5022266

25.18.20.02.18.04 1 PC PLATE HOLDER 5022142
SPARE PARTS LIST

ORDER NO. 5 022 420-00
DESCRIPTION: WORKSHOP INSTALLATION

25.18.60.01.00 4 M CABLE 5002066

25.18.60.02.00 6 M CABLE 1608342
25.18.60.03.00 3 M CABLE 0337832
25.18.60.04.00 8,5 M CABLE 1655148
25.18.60.05.00 4 M CABLE OELFLEX 1657707
25.18.60.10.00 1 PC PLUG MALE 4228204
25.18.60.11.00 5 PC RECEPTACLES 5002255
25.18.60.12.00 4 PC CABLE THIMBLE 0145829
25.18.60.13.00 1 PC GASKET INSERT FOR CABLE GLAND 1654680
25.18.60.20.00 4 PC CYL-SCREW 1683913
25.18.60.22.00 2 PC CYL. SCREW 1683919
25.18.60.25.00 4 PC HOLDER 2062983 2062983
25.18.60.26.00 8 PC HEX. SCREW 1683992
25.18.60.27.00 8 PC WASHER 0063701
25.18.60.28.00 8 PC SPLIT WASHER 0249845
25.18.60.29.00 2 PC HEX. SCREW 0842417
25.18.60.30.00 2 PC HEX. NUT 7832404
25.18.60.31.00 2 PC SPRING RING 3398003

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 155-00
DESCRIPTION: HYDRAULIC SYSTEM COMPL

66.00.00.00.00 1 PC HYDRAULIC SYSTEM COMPL. 5011155
66.01.00.00.00 1 PC HYDRAULIC SYSTEM SLEWING TOWER 5011154

66.15.00.00.00 1 PC HYDRAULIC SYSTEM AGGREGATE MODULE 5011148
66.19.00.00.00 1 PC HYDR.SYSTEM WINCH MODULE 2389309

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 154-00
DESCRIPTION: HYDRAULIC SYSTEM SLEWING TOWER

66.01.00.00.00 1 PC HYDRAULIC SYSTEM SLEWING TOWER 5011154
66.01.02.00.00 1 PC COMPONENTS HYDRAULIC SYSTEM 5010781 5010781

66.01.13.00.00 1 PC HYDR.MOTOR SLEWING GEAR COMPL. 5011150 5011150

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 010 781-00
DESCRIPTION: COMPONENTS HYDRAULIC SYSTEM

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 050-10781-00

66.01.02.01.00 1 PC COOL SYSTEM OIL-AIR 5010440 5010440

SEE SUBSUPPLIER
66.01.02.02.00 2 PC UNION 1331028

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 150-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR COMPL.

66.01.13.00.00 1 PC HYDR.MOTOR SLEWING GEAR COMPL. 5011150
66.01.13.01.00 1 PC HYDR.MOTOR SLEWING GEAR 5011151 5011151

66.01.13.02.00 1 PC HYDR. MOTOR SLEWING GEAR COMPL. 5011152 5011152

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 151-00
DESCRIPTION: HYDR.MOTOR SLEWING GEAR

66.01.13.01.00 1 PC HYDR.MOTOR SLEWING GEAR 5011151 5011151
66.01.13.01.01 1 PC HYDR. MOTOR 5005460

SEE SUBSUPPLIER
ASSEMBYL 66.01.13.01.01
66.01.13.01.02 1 PC SOCKET PIECE 0625708

66.01.13.01.04 4 PC SAE-FLANGE 0727077
66.01.13.01.05 1 PC SCREWING 0070277
66.01.13.01.06 8 PC SAE-FLANGE HALF 0625571
66.01.13.01.07 2 PC SEAL RING 1725417
66.01.13.01.08 8 PC CAP-SCREW 0939137
66.01.13.01.09 8 PC CYL.SCREW 1758053
66.01.13.01.12 16 PC CAP-SCREW 0861764
66.01.13.01.13 4 PC CAP SCREW 0119724
66.01.13.01.14 2 PC T-PIECE 2072544
66.01.13.01.15 2 PC ADAPTER 1397738
66.01.13.01.16 2 PC SEALING RING 1725419
66.01.13.01.17 4 PC THRUST WASHER 1005866
66.01.13.01.18 1 PC UNION 1665715
66.01.13.01.19 1 PC PIPE FILTER 0986373
66.01.13.01.20 1 PC CLOSING COUPLING 1335578
66.01.13.01.21 1 PC SEAL.RING 0029263
66.01.13.01.22 2 PC SAE-Adapter 1627488

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
AXIAL PISTON UNIT F12- 060
PART NO.: 5005460

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5005460
DESIGNATION: AXIAL PISTON UNIT

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5005460
DESIGNATION: AXIAL PISTON UNIT
POS. ORDER-NO. DESCRIPTION QUANTITY REMARK
110 3798562* Barrel Housing Assy Valve Plate 1 Type F

121 3791799 * 1 Type M
130 3793563 * Hex socket Plug Assy 1 For F-Housing "
211 3799676* Bearing Housing 1 Type I "See SI 97/05"
225 925258* O-Ring 1 Nitril
231 3796201* Seal Carrier 1 Type N, Nitril LP
233 117852* Shaft Seal 1
237 914548* Retaining Ring 1
238 914534* Retaining Ring 1
310 3799688* Shaft assy 1 Type D "See SI 97/05"
411 3797719* Cylinder Barre 1
430 3709840* Barrel Support 1 Pump version Not available
440 3709470* Piston Assy 7 see SI 08/02
442 3795377* Piston Ring 21
452 3799822* Ring Gear 1
460 184660* Tap Rol Bearing 1
470 118770* Tap Rol Bearing 1
476 37996* Spacer Washer 2
488 37936* Shim 2
491 37936* Hex Socket Screw 4
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

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

66.01.13.01.02.00 1 PC SOCKET PIECE. 0625708
66.01.13.01.02.01 1 PC SOCKET PIECE ZV206/22/183 5006853

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5011152
DESCRIPTION: HYDR. MOTOR SLEWING GEAR COMPL.

66.01.13.02.01 1 PC HYDR. MOTOR 5005460

SUBSUPPLIER SEE
66.01.13.02.02 1 PC SOCKET PIECE 0625708
66.01.13.02.03 1 PC LOCK SCREW 1009480
66.01.13.02.04 8 PC SAE-FLANGE 0727077
66.01.13.02.05 1 PC SCREWING 0070277
66.01.13.02.06 2 PC T-PIECE 1656540
66.01.13.02.07 2 PC SEAL RING 1725417
66.01.13.02.08 16 PC CAP-SCREW 0939137
66.01.13.02.09 8 PC CAP SCREW 6220282
66.01.13.02.13 4 PC CAP SCREW 0119724
66.01.13.02.14 4 PC THRUST WA 1005866
66.01.13.02.22 2 PC SAE-ADAPTER 1627448 1627448

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 0 625 708-00

66.01.13.02.02.00 1 PC SOCKET PIECE. 0625708

66.01.13.02.02.02 1 PC CONN.-NUT A2L 22 0010699
66.01.13.02.02.03 1 PC TAPER-BUSH L22-ST 0010695

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5-011 153-00
DESCRIPTION: HYDR. MOTOR SLEWING GEAR COMPL.

66.01.13.03.01 1 PC HYDR. MOTOR 5005460

SUBSUPPLIER SEE
66.01.13.03.02 1 PC SOCKET PIECE 0625708
66.01.13.03.04 8 PC SAE-FLANGE 0727077
66.01.13.03.05 1 PC SCREWING 0070277
66.01.13.03.07 2 PC SEALING RING 1725417
66.01.13.03.08 16 PC CAP-SCREW 0939137
66.01.13.03.11 4 PC THRUST WASHER 1005866
66.01.13.03.13 4 PC CAP SCREW 0119724

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 0 625 708-00

66.01.13.03.02.00 1 PC SOCKET PIECE. 00625708

66.01.13.03.02.02 1 PC CONN.-NUT A2L 22 0010699
66.01.13.03.02.03 1 PC TAPER-BUSH L22-ST 0010695

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5011148
DESCRIPTION: HYDRAULIC SYSTEM AGGREGATE MODULE

66.15.00.00.00 1 PC HYDRAULIC SYSTEM AGGREGATE MODULE 5011148
66.15.01.00.00 1 PC HYDRAULIC AGGREGATE COMPL 5011147

66.15.20.00.00 1 PC HYDRAULICTANK COMPONENTS 5005657 5005657
66.15.21.00.00 1 PC PUMPAGGREGAT 5001106 5001106

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 147-00
DESCRIPTION: HYDRAULIC AGGREGATE COMPL

66.15.01.00.00 1 PC HYDRAULIC AGGREGATE COMPL. 5011147
66.15.01.01.00 1 PC DISTRIBUTION GEAR I = 0,65 5005264 5005264

66.15.01.02.00 1 PC FASTENING PARTS F. DISTRIBUTION GEAR 2093380 2093380
66.15.01.03.00 3 PC DAMPER 2067961 2067961
66.15.01.04.00 1 PC HYDRAULIC POWER UNIT 5011141 5011141

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 264-04
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

TTS-NMF GmbH
SARE PARTS LIST

ORDER NO. 5 005 264-04
DESCRIPTION: DISTRIBUTION GEAR I=0,65(440V-60HZ)

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

66.15.01.01.02 1 PC COVER 2441628 2441628
66.15.01.01.03 1 PC SPUR WHEEL Z-66 MN-3,5 Z-66 Mn-3,5 4221591 4221591
66.15.01.01.04 3 PC SPUR WHEEL Z-43 MN-3,5 Z-43 Mn-3,5 4221593 4221593
66.15.01.01.05 3 PC HOLLOW SHAFT 4221598 4221598
66.15.01.01.06 3 PC WAVE DISK 4221595 4221595
66.15.01.01.07 1 PC WAVE DISK 4221594 4221594
66.15.01.01.08 3 PC CENTER BUSHING 4221596 4221596
66.15.01.01.09 1 PC SPACER 4221597 4221597
66.15.01.01.10 1 PC O-RING 4228224
66.15.01.01.11 3 PC O-RING 4228223
66.15.01.01.12 1 PC O-RING 4228240
66.15.01.01.13 1 PC O-RING 0460685
66.15.01.01.14 3 PC O-RING 0830401
66.15.01.01.15 1 PC V-RING 0750367
66.15.01.01.16 1 PC OIL SIGHT GLAS 1655840
66.15.01.01.17 9 PC STUD BOLT 5006664
66.15.01.01.18 12 PC STUD BOLT 5006665
66.15.01.01.19 1 PC HEXAGON SCREW 5006666
66.15.01.01.20 3 PC HEXAGON SCREW 0056638
66.15.01.01.21 21 PC HEXAGON NUT 0057136
66.15.01.01.22 21 PC WASHER 0056993
66.15.01.01.23 1 PC LOCKING BOLT DISK 4228235
66.15.01.01.24 3 PC LOCKING BOLT DISK 2535252
66.15.01.01.25 4 PC SPRING-PIN 0054166

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 093 380-02
DESCRIPTION: FASTENING PARTS F. DISTRIBUTION GEAR

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

66.15.01.02.02 1 PC UNION 0982729
66.15.01.02.03 1 PC SCREWING 0033589
66.15.01.02.04 0,3 M PIPE 5009300 5009300
66.15.01.02.06 8 PC WASHER 0056993
66.15.01.02.07 8 PC HEXAGON SCREW 0056683

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 067 961-01
DESCRIPTION: DAMPER

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

66.15.01.03.09 1 PC HEXAGON SCREW 7120794
66.15.01.03.10 1 PC HEXAGON NUT 0032975
66.15.01.03.11 1 PC HEXAGON NUT 1673943
66.15.01.03.12 2 PC WASHER 2479257
66.15.01.03.14 1 PC WASHER 0034624

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 141-01
DESCRIPTION: HYDRAULICAGGREGAT

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 141-01

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 141-01
66.15.01.04.00 1 PC HYDRAULICAGGREGAT 5011141 5011141
66.15.01.04.01 1 PC VARIABLE DISPLACEMENT PUMP A4V G140 5007001

SEE SUBSUPPLIER
ASSEMBLY 66.15.01.04.01
66.15.01.04.02 1 PC VARIABLE DISPLACEMENT PUMP A4V G 125 2530269
SEE SUBSUPPLIER
ASSEMBLY 66.15.01.04.02
66.15.01.04.03 1 PC VARIABLE DISPLACEMENT PUMP A4V G 125 5007000
SEE SUBSUPPLIER
ASSEMBLY 66.15.01.04.03
66.15.01.04.04 4 PC PRESSURE SWITCH 5010113
1 PC VARIABLE DISPLACEMENT PUMP A4V G 125
66.15.01.04.05 SEE SUBSUPPLIER 5001937
ASSEMBLY 66.15.01.04.05
66.15.01.04.06 1 PC PUMP SUPPORT PLATE SAE-B 5001939
SEE SUBSUPPLIER
ASSEMBLY 66.15.01.04.06
66.15.01.04.17 4 PC REDUCER SCREW JOINT 5011341
66.15.01.04.16 11 PC SHEET STEEL SIGN 0303742
66.15.01.04.19 3 PC MEASURING CONNECTION 1709799
66.15.01.04.25 2 PC SCREWED COUPL. 1652183
66.15.01.04.27 4 PC SAE-SCREWED FLANGE 1654307
66.15.01.04.28 8 PC UNION 1331025
66.15.01.04.29 3 PC TUBE FITTING 1768191
66.15.01.04.30 6 PC TRANSITION PIECE 1665757
66.15.01.04.31 7 PC UNION 1636006
66.15.01.04.32 2 PC UNION 0205786
66.15.01.04.33 2 PC UNION 1636655
66.15.01.04.34 8 PC UNION 8411057
66.15.01.04.35 1 PC UNION 1665749
66.15.01.04.36 1 PC UNION 0304986
66.15.01.04.37 2 PC ADAPTER SOCKET SLEEVE 0986672
66.15.01.04.38 6 PC UNION 1637351
66.15.01.04.39 4 PC UNION 1307809
66.15.01.04.41 3 PC UNION 1331029
66.15.01.04.42 11 PC CABLE CLAMP 0661868
66.15.01.04.43 1 PC UNION 1636028
66.15.01.04.63 12 PC SEALING RING 1725419
66.15.01.04.64 6 PC MEASURING SOCKET 0310324 0310324
66.15.01.04.65 1 PC UNION 1331028
66.15.01.04.68 4 PC SEALING RING 1725417
66.15.01.04.69 16 PC CYLINDRICAL – SCREW 0216259
66.15.01.04.81 48 PC CAP-SCREW 0861764
66.15.01.04.83 2 PC UNION 0153812
66.15.01.04.85 6 PC LOCK SCREW 1406392
66.15.01.04.87 6 PC SAE-ELBOW 2072550 2072550
66.15.01.04.88 2 PC UNION 0592748
66.15.01.04.89 2 PC WASHER 0080731
TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG 125
PART-NO.: 5 007 001

TTS-NMF GmbH

TTS-NMF GmbH
INDEX
VAR. DISPL. PUMP A4VG 125
ROTARY GROUP,
CONTROL, HYDRAULIC
PORT PLATE WITH VALVES
PUMP COVER
CONTROL MODUL

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 902123413
DESCRIPTION: VAR. DISPL. PUMP A4VG 125
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902123413*
1 902123413* VAR. DISPL. PUMP A4VG 125 1 PC
1 902087433* ROTARY GROUP 1 PC L

2 902012015* CONTROL, HYDRAULIC 1 PC L
3 909609518* PORT PLATE WITH VALVES 1 PC L
4 902087754* PUMP COVER 1 PC L
5 902113914* CONTROL MODULE 1 PC L
10 902015532* HOUSING 1 PC L
13 902118633* JOINT PIN 2 PC
14 909405732* DOWEL PIN 1 PC
20 909153861* LOCKING SCREW 1 PC D
25 909085545* O-RING 1 PC D
28 909426700* ORIFICE 2 PC D
31 909154427* CLAMPING PIN 2 PC
46 909154982* THREADED PIN 1 PC D
47 909087405* SEAL LOCK NUT 1 PC D
49 909426707* ORIFICE 1 PC
98 902095530* SEAL KIT, COMPLETE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902087433*
DESCRIPTION: ROTARY GROUP
1 R902087433* ROTARY GROUP 1 PC
1 R902105942* ROTARY GROUP, HYDR. SECTION 1 PC L

2 R902103381* CONTROL PLATE 1 PC
12 R909445122* CRADLE 1 PC
13 R909449034* SLIDE RING 1 PC
14 R909921000* DRIVE SHAFT 1 PC
17 R909421418* WIRE 2 PC
26 R902066594* BEARING LINER (PAIR) 1 PC
31 R902603914* PLAIN ROLLER BEARING 1 PC
32 R909830578* CRADLE BEARING ASSEMBLY (SET) 1 PC
36 R909084416* RETAINING RING 1 PC
38 R902601821* SHAFT SEAL RING 1 PC D
98 R902002391* SEAL KIT DRIVE SHAFT 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902105942*
DESCRIPTION: ROTARY GROUP, HYDR. SECTION
1 R902105942* ROTARY GROUP, HYDR. SECTION 1 PC
1 R902105527* CYLINDER WITH BUSH 1 PC

2 R902076829* PISTON-SLIPPER PAD 9 PC
11 R909921720* CUP-SPRING STACK 1 PC
20 R909432505* SHIM 1 PC
20 R909432506* SHIM 1 PC
20 R909432507* SHIM 1 PC
20 R909432508* SHIM 1 PC
24 R909921719* RETAINING PLATE 1 PC
25 R909432264* RETAINING BALL 1 PC
27 R902105941* SHIM 2 PC
29 R909435465* PRESSURE SPRING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902012015*
DESCRIPTION: CONTROL, HYDRAULIC
1 R902012015* CONTROL, HYDRAULIC 1 PC
1 R902025586* POSITIONING PISTON COMPLETE 1 PC L

3 R902010745* COVER 1 PC
4 R902010746* COVER 1 PC
16 R909157477* HEXAGON NUT 1 PC
17 R909083038* SOCKET-HEAD SCREW 8 PC
20 R909085360* O-RING 2 PC D
21 R909432790* THREADED PIN 2 PC
22 R909152459* SEAL LOCK NUT 2 PC D
30 R902600839* GUIDE RING 2 PC
31 R902600272* ROD SEAL KIT 2 PC D
98 R902002374* SEAL KIT HYDR. CONTROL 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902025586*
DESCRIPTION: POSITIONING PISTON COMPLETE
1 R902025586* POSITIONING PISTON COMPLETE 1 PC
1 R902010570* POSITIONING PISTON 1 PC

2 R909449241* ROD 1 PC
5 R902020493* RING 2 PC
5 R902013493* RING 2 PC
5 R902013494* RING 2 PC
5 R902013495* RING 2 PC
5 R902013496* RING 2 PC
5 R902013497* RING 2 PC
5 R902013498* RING 2 PC
5 R902029756* RING 2 PC
5 R902029757* RING 2 PC
5 R902043149* RING 2 PC
6 R902600767* ASSEMBLY RING 2 PC
7 R909652048* SPRING COLLAR 2 PC
19 R909086333* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909609518*
DESCRIPTION: PORT PLATE WITH VALVES
1 R909609518* PORT PLATE WITH VALVES 1 PC
1 R902603817* VALVE 1 PC L
2 R909434856* PRESSURE RELIEF VALVE 1 PC L
3 R909433834* PRESSURE OVERRIDE VALVE 1 PC L
5 R909651090* PORT PLATE 1 PC
9 R909830217* O-RING 1 PC D
11 R909831320* DOUBLE BREAKE OFF-PLUG 1 PC D
13 R909154024* LOCKING SCREW 4 PC D
26 R909086333* O-RING 2 PC D
43 R909432774* BUSH 1 PC
44 R909432773* BEARING BUSHING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902603817*
DESCRIPTION: VALVE
1 R902603817* VALVE 1 PC
1 R901162844* PRESSURE RELIEF VALVE 1 PC

98 R961000764* SEAL KIT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909434856*
DESCRIPTION: PRESSURE RELIEF VALVE
1 R909436167* LOCKING SCREW 1 PC

2 R909449622* ADJUSTING SCREW 1 PC
3 R909435899* VALVE PISTON 1 PC
8 R909083761* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909433834*
DESCRIPTION: PRESSURE OVERRIDE VALVE
1 R909433834* PRESSURE OVERRIDE VALVE 1 PC

2 R909446552* VALVE BUSHING 1 PC
3 R909432301* CONTROL PISTON 1 PC
4 R909432163* PISTON 1 PC
6 R909432775* POPPET SEAT 1 PC
10 R909083757* O-RING 1 PC D
15 R909086380* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902019663*

2 R909409929* PISTON 1 PC
4 R909409819* GUIDE BUSHING 1 PC
5 R909449463* PLUG 1 PC
8 R909409822* LOCKING BOLT 1 PC
11 R909153402* SHIM 1 PC
11 R909150369* SHIM 1 PC
17 R909084890* O-RING 1 PC D
18 R909084890* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902087754*
DESCRIPTION: PUMP COVER
1 R902087754* PUMP COVER 1 PC

7 R909157881* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902113914*
DESCRIPTION: CONTROL MODUL
1 R902113914* CONTROL MODULE 1 PC
1 R902115150* CONTROL MODULE 1 PC L

2 R902603440* PROPORTIONAL SOLENOID 2 PC
3 R902602623* PLUG SOCKET 1 PC
98 R902002418* SEAL KIT CONTROL MODULE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902115150*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902115150*
1 R902115385* HOUSING 1 PC
3 R902106775* CONTROL PISTON WITH CYL. PIN 1 PC
4 R902050396* LEVER PAIR 1 PC
6 R902067212* ECCENTRIC 1 PC
7 R902107488* RING 1 PC
8 R902044854* SHIM 1 PC
9 R902113679* FEEDBACK LEVER WITH NEEDLE ROLLER 1 PC
10 R909651478* GASKET 1 PC D
11 R909443201* COVER 1 PC D
12 R902063327* DRAW SPRING 1 PC D
18 R902603311* FILTER DISK 1 PC
20 R902067214* SHIM 1 PC
20 R902067215* SHIM 1 PC
20 R902067217* SHIM 1 PC
20 R902067218* SHIM 1 PC
20 R902067219* SHIM 1 PC
20 R902067220* SHIM 1 PC
20 R902067232* SHIM 1 PC
21 R909083021* SOCKET-HEAD SCREW 2 PC D
24 R902602838* SEAL PLUG 2 PC
25 R902603136* SEAL PLUG 1 PC
26 R909087338* CYLINDER PIN 1 PC D
27 R909086380* O-RING 1 PC D
28 R902600641* O-RING 1 PC D
29 R909086523* O-RING 2 PC D
30 R909153668* O-RING 1 PC D
31 R909086333* O-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG125 + A4VG28
PART-NO.: 2 530 269
ASSEBLYGROUP 66.15.01.04.02
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902125484*
DESCRIPTION: VAR. DISPL. PUMP A4VG125+A4VG28

R902125484* VAR. DISPL: PUMP A4VG125+A4CG28 1 PC
1 R902123400* VAR. DISPL. PUMP A4VG125 1 PC L
2 R902110592* VAR. DISPL. PUMP A4VG28 1 PC L
20 R909430409* WASHER 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902123400
DESCRIPTION: VAR. DISPL. PUMP A4VG125

R902123400* VAR. DISPL. PUMP A4VG125 1 PC
1 R902087433* ROTARY GROUP 1 PC L
2 R902012015* CONTROL HYDRAULIC 1 PC L
3 R909609518* PORT PLATE WITH VALVES 1 PC L
4 R902085974* PUMP SUPPORT PLATE 1 PC L
10 R902015532* HOUSING 1 PC
13 R902118633* JOINT PIN 2 PC
14 R909405732* DOWEL PIN 1 PC
25 R909085545* O-RING 1 PC D
28 R909426700* ORIFICE 2 PC D
31 R909154427* CLAMPING PIN 2 PC
46 R909154982* THREADED PIN 1 PC D
47 R909087405* SEAL-LOCK-NUT 1 PC D
49 R909426707* ORIFICE 1 PC
98 R902095530* SEAL KIT, COMPLETE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902087433*

R902087433* ROTARY GROUP 1 PC

12 R909445122* CRADLE 1 PC
17 R909421418* WIRE 2 PC
38 R902601821* SHAFT SEALING RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902105942*

R902105942* ROTARY GROUP, HYDR. SECTION 1 PC

2 R902076829* PISTON-SLIPPER OAD 9 PC
20 R909432505* SHIM 1 PC
20 R909432506* SHIM 1 PC
20 R909432507* SHIM 1 PC
20 R909432508* SHIM 1 PC
27 R902105941* SHIM 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902012015*

R902012015* CONTROL, HYDRAULIC 1 PC

3 R902010745* COVER 1 PC
4 R902010746* COVER 1 PC
20 R909085360* O-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902025586*
DESCRIPTION: POSITIONING PISTON COMPL.


2 R909449241* ROD 1 PC
5 R902020493* RING 2 PC
5 R902020494* RING 2 PC
5 R902020495* RING 2 PC
5 R902020496* RING 2 PC
5 R902020497* RING 2 PC
5 R902020498* RING 2 PC
5 R902029756* RING 2 PC
5 R902029757* RING 2 PC
5 R902043149* RING 2 PC
19 R909086333* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909609518*

1 R909609518* PORT PLATE WIZH VALVES 1 PC
1 R902603817* VALVE 1 PC L
9 R909830217* O-RING 1 PC D
11 R909831320* DOUBLE BREAK-OFF PIN 1 PC D
26 R909086333* O-RING 2 PC D
43 R909432774* BUSH 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R9022603817*
DESCRIPTION: VALVES

1 R902603817* VALVE 1 PC

1 R961000764* SEAL KIT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909434856*


8 R909083761* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909433834*


4 R909432163* PISTON 1 PC
10 R909083757* O-RING 1 PC D
15 R909086380* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902019663*


2 R909409929* PISTON 1 PC
4 R909409819* GUIDE BUSHING 1 PC
5 R909449463* PLUG 1 PC
8 R909409822* LOCKING BOLT 1 PC
11 R909150369* SHIM 1 PC
11 R909153402* SHIM 1 PC
17 R909084890* O-RING 1 PC D
18 R909084890* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902085974*
DESCRIPTION: PUMP SUPPORT PLATE

1 R902085974* PUMP SUPPORT PLATE 1 PC
1 R902081911* INTERMEDIATE FLANGE 1 PC

5 R902013171* THROUGH DRIVE COUPLING 1 PC
12 R909157881* O-RING 1 PC D
20 R909154589* O-RING 1 PC D
98 R902002413* SEAL KIT INTERNAL GEAR PUMP 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902113914*
DESCRIPTION: CONTROL MODULE


L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902115150*

1 R902115385* HOUSING 1 PC
6 R902067212* ECCENTRIC PIN 1 PC
7 R902107488* RING 1 PC
8 R902044854* SHIM 1 PC
10 R909651478* GASKET 1 PC D
11 R909443201* COVER 1 PC D
20 R902067214* SHIM 1 PC
20 R902067215* SHIM 1 PC
20 R902067216* SHIM 1 PC
20 R902067217* SHIM 1 PC
20 R902067218* SHIM 1 PC
20 R902067219* SHIM 1 PC
20 R902067220* SHIM 1 PC
20 R902067232* SHIM 1 PC
20 R902067213* SHIM 1 PC
24 R902602838* SEAL PLUG 2 PC
25 R902603136* SEAL PLUG 1 PC
27 R909086380* O-RING 1 PC D
28 R902600641* O-RING 1 PC D
29 R909086523* O-RING 2 PC D
30 R909153668* O-RING 1 PC D
31 R909086322* O-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
*= FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902110592*

1 R902110592* VAR. DISPL. PUMP A4VG 28 1 PC

2 R902039532* CONTROL, HYDRULIC 1 PC L
4 R902064015* PUMP COVER 1 PC L
10 R902007055* HOUSING 1 PC
13 R902114380* JOINT PIN 1 PC
14 R909405732* DOWEL PIN 1 PC
25 R909083761* O-RING 1 PC D
28 R909156493* ORIFICE 2 PC D
31 R909156579* CLAMPING PIN 2 PC D
49 R909156497* ORIFICE 1 PC
86 R909415314* DOUBLE BREAK-OFF PIN 1 PC
94 R909607200* ORIFICE SCREW COMPL. 1 PC L
98 R902095522* SEAL KIT, COMPLETE. 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902199517*


12 R909651164* CRADLE 1 PC
17 R909408786* WIRE 1 PC
18 R909443447* JOINT PIN 1 PC
19 R909444491* WIRE 1 PC
37 R902600141* RETAINING RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902079199*


20 R909432999* SHIM 1 PC
20 R909435000* SHIM 1 PC
20 R909435001* SHIM 1 PC
20 R909435002* SHIM 1 PC
27 R909922004* WASHER 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902039532*

R902039532* CONTROL, HYDRAULIC 1 PC

3 R902015596* COVER 1 PC
4 R902015597* COVER 1 PC
20 R909083784* O-RING 2 PC D
30 R902600836* GUIDE RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902035975*

1 R902035975 POSITIONING PISTON COMPLETE 1 PC

2 R909449237* ROD 1 PC
5 R902015508* RING 2 PC
5 R902013493* RING 2 PC
5 R902015508* RING 2 PC
5 R902015509* RING 2 PC
5 R902015510* RING 2 PC
5 R902015511* RING 2 PC
5 R902015512* RING 2 PC
5 R902015514* RING 2 PC
5 R902015513* RING 2 PC
8 R909445782* SPACER RING 2 PC
19 R909085709* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.R902003293*


9 R913002054* O-RING 1 PC D
11 R909831318* DOUBLE BREAK-OFF PLUG 3 PC D
13 R909831319* DOUBLE BREAK-OFF PLUG 2 PC D
26 R909085709* O-RING 2 PC D
41 R909415314* DOUBLE BREAK-OFF PLUG 1 PC
43 R909651184* BUSH 1 PC
98 R902002397* SEAL KIT PORT PLATE WITH VALVES 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902016398*


2 R902010478* VALVE COLLAT 1 PC
3 R902010477* VALVE SPINDLE 1 PC
4 R902016288* SPRING LOADING NUT 1 PC
6 R909425925* SPRING, CONE-SHAPED 1 PC
9 R909083761* O-RING 1 PC D
10 R909831768* BACK-UP RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902037600*


5 R902601678* STEEL SEALING RING 1 PC D
6 R909152694* O-RING 1 PC D
7 R909150370* SHIM 1 PC
7 R909153402* SHIM 1 PC
7 R909150369* SHIM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909447281*


4 R909432163* PISTON 1 PC
10 R909083752* O-RING 1 PC D
15 R909086380* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902016402*


2 R909444989* VALVE COLLAR 1 PC
3 R902010477* VALVE SPINDLE 1 PC
4 R902016288* SPRING LOADING NUT 1 PC
6 R909425925* SPRING, CONE-SHAPED 1 PC
9 R909083761* O-RING 1 PC D
10 R909831768* BACK-UP RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902064015*


5 R909830379* KANTSEAL-RING 1 PC D
98 R902002410* SEAL KIT GEAR PUMP 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902107017*


L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902107471*

1 R902107404* HOUSING 1 PC
6 R902133883* ECCENTRIC PIN 1 PC
8 R902044854* SHIM 1 PC
10 R902603830* GASKET 1 PC D
11 R902107492* COVER WITH FILTER 1 PC
12 R902068150* DRAW SPRING 1 PC
13 R902603829* GASKET 1 PC D
14 R902603044* SEAL PLUG 2 PC
23 R902064222* SHIM 1 PC
23 R902051255* SHIM 1 PC
23 R902051254* SHIM 1 PC
23 R902051253* SHIM 1 PC
23 R902051252* SHIM 1 PC
23 R902051256* SHIM 1 PC
27 R909086301* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
*= FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909607200*
DESCRIPTION: ORIFICE SCREW COMPL.

1 R909607200* ORIFICE SCREW 1 PC
1 R902051030* ORIFICE SCREW 1 PC

2 R909447806* ORIFICE 1 PC L
3 R909083380* RETAINING RING 1 PC D
4 R900012473* SEAL RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R909447806*
DESCRIPTION: ORIFICE

12 R902037856* ORIFICE 1 PC
15 R909439645* ORIFICE 1 PC
20 R909436840* ORIFICE 1 PC
23 R909424299* ORIFICE 1 PC
27 R909436300* ORIFICE 1 PC
29 R909413895* ORIFICE 1 PC
31 R909431470* ORIFICE 1 PC
32 R909413042* ORIFICE 1 PC
33 R909418443* ORIFICE 1 PC
34 R909432478* ORIFICE 1 PC
35 R909421451* ORIFICE 1 PC
36 R909431782* ORIFICE 1 PC
37 R909416695* ORIFICE 1 PC
38 RR09431595* ORIFICE 1 PC
39 R909432479* ORIFICE 1 PC
40 R909408026* ORIFICE 1 PC
41 R909413816* ORIFICE 1 PC
42 R909415274* ORIFICE 1 PC
43 R909432480* ORIFICE 1 PC
44 R909408027* ORIFICE 1 PC
45 R909421848* ORIFICE 1 PC
46 R909417007* ORIFICE 1 PC
47 R909405619* ORIFICE 1 PC
48 R909412633* ORIFICE 1 PC
49 R909430745* ORIFICE 1 PC
50 R909417025* ORIFICE 1 PC
51 R909413327* ORIFICE 1 PC
52 R909405975* ORIFICE 1 PC
53 R909413934* ORIFICE 1 PC
54 R909418163* ORIFICE 1 PC
55 R909405617* ORIFICE 1 PC
56 R909412748* ORIFICE 1 PC
57 R909411438* ORIFICE 1 PC
58 R902013917* ORIFICE 1 PC
59 R909430828* ORIFICE 1 PC
60 R909410920* ORIFICE 1 PC
61 R909445937* ORIFICE 1 PC
62 R909431101* ORIFICE 1 PC
63 R902139456* ORIFICE 1 PC
64 R909408665* ORIFICE 1 PC
67 R909421856* ORIFICE 1 PC
69 R909416256* ORIFICE 1 PC
70 R902053002* ORIFICE 1 PC
71 R902056449* ORIFICE 1 PC
74 R909417704* ORIFICE 1 PC
77 R902029162* ORIFICE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER
TTS-NMF GmbH
SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG 125
PART-NO.: 5 007 000

TTS-NMF GmbH

TTS-NMF GmbH
INDEX
VAR. DISPL. PUMP A4VG 125
ROTARY GROUP,
CONTROL, HYDRAULIC
PORT PLATE WITH VALVES
PUMP COVER
CONTROL MODUL

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R02123403*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R02123403*
1 R02123403* VAR. DISPL. PUMP A4VG 125 1 PC

2 R02012015* CONTROL, HYDRAULIC 1 PC L
4 R02087754* PUMP COVER 1 PC L
10 R02015532* HOUSING 1 PC L
13 R02118633* JOINT PIN 2 PC
14 R09405732* DOWEL PIN 1 PC
25 R09085545* O-RING 1 PC D
28 R09426700* ORIFICE 2 PC D
31 R09154427* CLAMPING PIN 2 PC
49 R09426707* ORIFICE 1 PC
98 R02095530* SEAL KIT, COMPLETE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902087433*

12 R909445122* CRADLE 1 PC
17 R909421418* WIRE 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902105942*

20 R909432505* SHIM 1 PC
20 R909432506* SHIM 1 PC
20 R909432507* SHIM 1 PC
20 R909432508* SHIM 1 PC
27 R902105941* SHIM 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902012015*
1 R902012015* CONTROL, HYDRAULIC 1 PC

3 R902010745* COVER 1 PC
4 R902010746* COVER 1 PC
20 R909085360* O-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902025586*
DESCRIPTION: POSITIONING PISTON COMPLETE

2 R909449241* ROD 1 PC
5 R902020493* RING 2 PC
5 R902013493* RING 2 PC
5 R902013494* RING 2 PC
5 R902013495* RING 2 PC
5 R902013496* RING 2 PC
5 R902013497* RING 2 PC
5 R902013498* RING 2 PC
5 R902029756* RING 2 PC
5 R902029757* RING 2 PC
5 R902043149* RING 2 PC
19 R909086333* O-RING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909609515*
1 R902603817* VALVE 2 PC L
9 R909830217* O-RING 1 PC D
26 R909086333* O-RING 2 PC D
43 R909432774* BUSH 1 PC
98 R902002401* SEAL KIT PORT PLATES WITH VALVES 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902603817*
DESCRIPTION: VALVE
1 R902603817* VALVE 1 PC

98 R961000764* SEAL KIT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909434856*
1 909434856* PRESSURE RELIEF VALVE 1 PC
1 909436167* LOCKING SCREW 1 PC

2 909449622* ADJUSTING SCREW 1 PC
3 909435899* VALVE PISTON 1 PC
4 902010336* SPRING COLLAR 1 PC
5 909440765* PRESSURE SPRING 1 PC
8 909083761* O-RING 1 PC D
9 909153271* SEAL LOCK NUT 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909433834*

4 R909432163* PISTON 1 PC
10 R909083757* O-RING 1 PC D
15 R909086380* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902087754*

7 R909157881* O-RING 1 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902113914*

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902115150*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:R902115150*
1 R902115385* HOUSING 1 PC
6 R902067212* ECCENTRIC 1 PC
7 R902107488* RING 1 PC
8 R902044854* SHIM 1 PC
10 R909651478* GASKET 1 PC D
11 R909443201* COVER 1 PC D
20 R902067214* SHIM 1 PC
20 R902067215* SHIM 1 PC
20 R902067217* SHIM 1 PC
20 R902067218* SHIM 1 PC
20 R902067219* SHIM 1 PC
20 R902067220* SHIM 1 PC
20 R902067232* SHIM 1 PC
24 R902602838* SEAL PLUG 2 PC
25 R902603136* SEAL PLUG 1 PC
27 R909086380* O-RING 1 PC D
28 R902600641* O-RING 1 PC D
29 R909086523* O-RING 2 PC D
30 R909153668* O-RING 1 PC D
31 R909086333* O-RING 2 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
VAR. DISPL. PUMP

A4VG28
PART-NO.: 5 001 937

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 937
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 937
0005001937* VAR. DISPL. PUMP A4VG28 (R902105244* 1 ST L
1 R902084722* ROTARY GROUP 1 ST L

2 R902039632* CONTROL HYDRAULIC 1 ST L
3 R902014750* PORT PLATE WITH VALVES 1 ST L
4 R902064015* PUMP SUPPORT PLATE 1 ST L
5 R902107017* CONTROL MODULE 1 ST L
10 R902007055* HOUSING 1 ST
13 R909445118* JOINT PIN 2 ST
14 R909405732* DOWEL PIN 1 ST D
20 R909151694* LOCKING SCREW 60NM 1 ST D
25 R909083761* O-RING 1 ST D
27 R909831318* DOUBLE BREAK-OFF PIN 1 ST D
28 R909156493* ORIFICE 3NM 2 ST D
31 R909156579* CLAMPING PIN 2 ST D
37 R909086351* THREADED PIN 1 ST D
46 R909154981* THREADED PIN 1 ST
47 R909153271* SEAL-LOCK-NUT 44NM 1 ST D
49 R909156497* ORIFICE 3NM 1 ST
86 R909415314* DOUBLE BREAK-OFF PIN 1 ST L
98 R902095522* SEAL KIT COMPL. 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902084722*

R902084722* ROTARY GROUP 1 ST L
1 R902079199* ROTARY GROUP HYDR. PART 1 ST L
2 R902084700* CONTROL PLATE 1 ST
12 R909651164* CRADLE 1 ST
13 R909444490* SLIDE RING 1 ST
14 R909651163* DRIVE SHAFT 1 ST
17 R909408786* WIRE 1 ST
18 R909443447* JOINT PIN 1 ST
19 R909444491* WIRE 1 ST
23 R909401842* ROLLER 2 ST
26 R902066592* BEARING LINER (PAIR) 1 ST
31 R909156605* PLAIN ROLLER BEARING 1 ST
32 R909830517* CRADLE BEARING ASSEMBLY (SET) 1 ST
36 R909083355* RETAINING RING 1 ST
37 R902600141* RETAINING RING 2 ST D
38 R902601818* SHAFT SEALING RING 1 ST D
98 R902002386* SEALKIT ROTARY GROUP 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902079199*
DESCRIPTION: ROTARY GROUP HYDR. PART

R902079199* ROTARY GROUP HYDR. PART 1 ST L
1 R902037329* CYLINDER WITH BUSH 1 ST
2 R909431514* PISTON 9 ST
11 R909444151* SPRING COLLAR 1 ST
20 R909435000* SHIM 1 ST
20 R909435001* SHIM 1 ST
20 R909432999* SHIM 1 ST
20 R909435002* SHIM 1 ST
24 R909443284* RETAINING PLATE 1 ST
25 R909431343* RETAINING BALL 1 ST
27 R909922004* WASHER 2 ST
29 R909921997* PRESSURESPRING 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902039532*

R902039532* CONTROL HYDRAULIC 1 ST L
1 R902035975* POSITIONING PISTON COMPL. 1 ST L
3 R902015596* COVER 1 ST
4 R902015597* COVER 1 ST
16 R909154918* HEXAGON NUT 1 ST
17 R909083019* SOCKET HEAD SCREW 8 ST
20 R902600658* O - RING 2 ST D
22 R909152707* SEAL-LOCK-NUT 22NM 2 ST D
30 R902600836* RING 2 ST D
31 R902600192* TURCON – GLYD - RING 2 ST D
98 R902002370* SEAL KIT CONTROL HYDRAULIC 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902035975*

R902035975* POSITIONING PISTON COMPL 1 ST L
1 R902016078* POSITIONING PISTON 1 ST
2 R909449237* ROD 1 ST
5 R902013493* RING 2 ST
5 R902015509* RING 2 ST
5 R902015510* RING 2 ST
5 R902015511* RING 2 ST
5 R902015512* RING 2 ST
5 R902015508* RING 2 ST
5 R902015514* RING 2 ST
5 R902015513* RING 2 ST
6 R902600489* RING 2 ST
8 R909445782* DISTANCE RING 2 ST
9 R909436327* PRESSURE SPRING 2 ST
19 R909085709* O-RING 1 ST D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902014750*

R902014750* PORT PLATE WITH VALVES 1 ST L
1 R902016398* PRESSURE RELIEF VALVE 10Nm 1 ST L
2 R902037600* PRESSURE RELIEF VALVE 70NM 1 ST L
3 R909447281* PRESSURE OVERRIDE VALVE 35NM 1 ST L
5 R909651058* PORT PLATE 1 ST
7 R909083099* SOCKET-HEAD SCREW 130NM 4 ST
8 R909084164* CYLINDER PIN 2 ST D
9 R909085364* O - RING 1 ST D
14 R909154024* LOCKING SCREW 5NM 1 St D
26 R909085709* O-RING 2 ST D
41 R909415314* DOUBLE BREAK-OFF PIN 1 ST
43 R909651184* BUSH 1 ST
44 R909439437* BEARING BUSHING 1 ST
98 R902002397* SEAL KITPORT PLATE WITH VALVES 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:. R902016398*

R902016398* DRUCKBEGRENZUNGSVENTIL 1 ST L
1 R909445618* LOCKING SCREW 1 ST
2 R902020478* VALVE COLLAT 1 ST
3 R902010477* VALVE SPINDLE 1 ST
4 R902016288* SPRING LOADING NUT 1 ST
6 R909425925* SPRING, CONE-SHAPED 1 ST
9 R909083761* O-RING 1 ST D
10 R909831768* BACK-UP RING 1 ST D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.:. R902037600*

R902037600* PRESSURE RELIEF VALVE 1 ST L
2 R909435899* VALVE PISTON 1 ST
5 R902601678* STEEL SEALING RING 1 ST
6 R909152694* O-RING 1 ST D
7 R909150370* SHIM 1 ST
7 R909153402* SHIM 1 ST
7 R909150369* SHIM 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R909447281*

R909447281* PRESSURE OVERRIDE VALVE 1 ST L
2 R909425951* VALVE BUSHING 1 ST
3 R909432162* CONTROL PISTON 1 ST
4 R909432163* PISTON 1 ST
5 R909432164* VALVE PISTON 1 ST
6 R909436284* POPPET SEAT 1 ST
9 R909432167* ADJUSTING SCREW 1 ST
10 R909083752* O-RING 1 ST D
14 R909152707* SEAL-LOCK-`NUT 1 ST D
15 R909086380 O-RING 1 ST D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902064015*

R902064015* PUMP COVER 1 ST L
1 R902063317* PUMP COVER 1 ST
5 R909830379* KANTSEAL-RING 1 ST
6 R909083036* SOCKET-HEAD SCREW 1 ST
98 R902002410* SEAL KIT PUMP COVER 1 ST D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902107017*

R902107017* CONTROL MODULE 1 ST L
1 R902107471* CONTROL MODULE 1 ST L
2 R902603440* PROPORTIONALVALVE 2 ST
3 R902602623* PLUG BOX 1 ST
4 R902602622* PLUG BOX 1 ST
98 R902002395* SEAL KIT CONTROL MODULE 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902107471*
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R902107471*

R902107471* CONTROL MODULE 1 ST L
1 R902107404* HOUSING 1 ST
3 R902107090* CONTROL PISTON WITH CYL. PIN 1 ST
4 R902055588* LEVER PAIR 1 ST
6 R902053346* ECCENTRIC PIN 1 ST
8 R902044854* WASHER 1 ST
9 R902042752* LEVER PAIR 1 ST
10 R902050037* GASKET 1 ST D
11 R902107492* COVER WITH FILTER 1 ST
12 R902068150* DRAW SPRING 1 ST
13 R902066611* GASKET 1 ST D
14 R902603044* PLUG 2 ST
15 R909085831* SOCKET-HEAD SCRE 10,4NM 4 ST D
16 R909087338* CYLINDER PIN 2 ST D
21 R909083207* SOCKET-HEAD SCRE 10,4NM 1 ST
23 R902064222* SHIM 1 ST
23 R902051252* SHIM 1 ST
23 R902051255* SHIM 1 ST
23 R902051254* SHIM 1 ST
23 R902051256* SHIM 1 ST
23 R902051253* SHIM 1 ST
25 R909151552* NEEDLE ROLLER 1 ST
27 R909086301* O – RING 1 ST D
28 R902601243* SOCKET-HEAD SCREW 6,1NM 8 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
PUMP SUPPORT PLATE

SAE - B
PART-NO.: 5 001 939

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02078022*
DESCRIPTION: PUMP SUPPORT PLATE

1 0005001939* INTERMEDIATE FLANGE 1 ST
5 R902013171* THROUGH DRIVE COUPLING 1 ST
10 R909086573* SOCKET-HEAD SCREW 130NM 4 ST
12 R909157881* O-RING 1 ST D
20 R909154589* O-RING 1 ST D
98 R902002413* SEAL KIT 1 ST
ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO5 005 657-02

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

SEE SUBSUPPLIER
ASSEMBLY 16.66.20.01.00
66.15.20.03.00 1 PC CONTROL STATION FILTER 5001119

SEE SUBSUPPLIER
ASSEMBLY 66.15.20.03.00
66.15.20.04.00 1 PC NIVEAU SWITCH 5006331

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO5 005 657-02

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 005 657-02


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

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

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

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

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

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

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

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

15.66.21.00.00 1 ST PUMP AGGREGAT COMPL. 5001106 5001106
15.66.21.01.00 1 ST TANK COVER 5001105 5001105

15.66.21.02.00 1 ST PUMP UNIT 5001110 5001110
SEE SUBSUPPLIER
15.66.21.03.00 1 ST SEAL 5001115 5001115
15.66.21.04.00 1 ST SEAL 5001114 5001114
15.66.21.05.00 4 ST STUD BOD 0301702
15.66.21.06.00 10 ST HEXAGON NUT 0057130
15.66.21.07.00 10 ST WASHER 0063701
15.66.21.08.00 18 ST HEXAGON SCREW 0057127
15.66.21.09.00 18 ST WASHER 0056988
15.66.21.10.00 1 ST O-RING 0936425
15.66.21.11.00 6 ST STUD BOLD 0303774
15.66.21.12.00 6 ST HEXAGON SCREW 0056672

TTS-NMF GmbH
SPARE PARTS LIST

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

15.66.21.01.00 1 ST TANK COVER WITH PUMP CARRIER 5001105 5001105
15.66.21.01.01 1 ST PLATE 0050966

15.66.21.01.02 1 ST PLATE 2053639
15.66.21.01.03 1 ST UNION 0215051
15.66.21.01.04 1 ST UNION 0304890
15.66.21.01.05 1 ST UNION 0924291

TTS-NMF GmbH

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

TTS-NMF GmbH
SPARE PARTS LIST

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

TTS-NMF GmbH
SPARE PARTS LIST

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

5 001 110 FUEL FEED AND CONTROL PUMP 1 PC L
1 1427183* THREE PHASE MOTOR 1 PC

2 1421506* AXIAL PISTON PUMP K3VL80 1 PC
3 1421507* GEAR PUMP ALP3A 1 PC
4 1428125* PUMP CARRIER 1 PC
5 1337223* COUPLING 1 PC
8 1241164* CYLINDRICAL SCREW 6 PC
9 1315354* HEXGON SCREW 2 PC
10 1421957* NO RETURN VALVE 1 PC
11 1240026* HALF-FLANGE 4 PC
12 1423337* HYDR. HOSE 1 PC
SEE LIST OF LMG HYDRAULIC HOSES
14 1421562* UNION 1 PC
15 1054529* HYDR. PIPE 1M
16 1239873* UNION 1 PC
17 1421634* HYDR. HOSE 1 PC
18 1421563* TANK UNION 1 PC
19 1421565* TANK UNION 1 PC
22 1421960* HYDR. HOSE 1 PC
25 1421960* O-RING 1 PC
26 1241212* HEXGON NUT 2 PC
27 1424506* WASHER 2 PC
28 1241238* WASHER 6 PC
29 1239677* SPRING RING 2 PC
33 1054469* HYDR. PIPE 1M
34 1240128* PLATE SIGN 1 PC
35 1124405* PLATE SIGN 1 PC
36 1421965* HOLDER 2 PC
38 1421966* HOSECLAMP 2 PC
44 1241206* SEALING RING 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 309-00
DESCRIPTION: HYDR.SYSTEM WINCH MODULE

66.19.00.00.00 1 PC HYDR.SYSTEM WINCH MODULE 2389309
66.19.02.00.00 1 PC COMPONENTS HYDR. WINCH MODULE 2389310 2389310

66.19.10.00.00 1 PC HYDR. MOTOR HOISTING GEAR COMPL. 2389311 2389311
66.19.11.00.00 1 PC HYDR.MOTOR LUFFING GEAR COMPL. 2532751 2532751

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 310-00
DESCRIPTION: COMPONENTS HYDR.SYSTEM WINCH MODULE

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

66.19.02.02.00 2 PC UNION 1636004
66.19.02.03.00 2 PC UNION 1338218
66.19.02.04.00 2 PC TRANSIT.MUFF CONNECT.PIECE 0665861
66.19.02.05.00 2 PC UNION 1665742
66.19.02.06.00 2 PC BRAKE FILTER 1637770

TTS-NMF GmbH
SPARE PARTS LIST

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

HYDRAULIC MOTOR HOISTING GEAR

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

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

TTS-NMF GmbH
SPARE PARTS LIST
ADJUSTABLE OIL MOTOR

A6VM 200
PART-NO: 2 532 117

TTS-NMF GmbH
SPARE PARTS LIST

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

1 4 532 117 ADJUSTABLE OIL MOTOR A6VM 200/63 ( 09604650* ) 1 PC L
2 09604644* CONTROL 1 PC L
5 09921682* HOUSING 1 PC
8 01466223 LOCKING SCREW 1 PC D
9 00012532 RETAINING RING 1 PC
10 09831663* SHAFT SEAL RING 1 PC D
11 09832084* BACK-UP PLATE 1 PC
12 09157314* O-RING 1 PC D
17 09446862* THREADED PIN 2 PC
18 01401644 SEAL-LOCK-NUT 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09603916*

1 09603992* ROTARY GROUP, HYDR. SECTION 1 PC L
2 09921774* DRIVE SHAFT 1 PC
3 09651659* SHIM 1 PC
7 09086744* RETAINING RING 1 PC
10 09157196* TAPERED-ROLLER BEARING 1 PC
11 09157197* TAPERED-ROLLER BEARING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09603992*

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02021906*
DESCRIPTION: PISTON WITH PISTON RINGS

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09604644*
DESCRIPTION: CONTROL

1 09604634* CONTROL PART 1 PC L
2 09603769* COVER 1 PC L
3 09921414* PORT PLATE 1 PC
4 09921435* POSITIONING PISTON 1 PC
5 09424057* POSITIONING TRUNNION 1 PC
7 09652204* PISTON 1 PC
10 09422894* VALVE GUIDE 2 PC
11 09426662* BOLT 2 PC
13 09412756* BUSH 2 PC
15 09083131* SOCKET-HEAD SCREW 215NM 8 PC
19 09830726* O-RING 2 PC D
20 09085577* O-RING 6 PC D
21 09086487* O-RING 2 PC D
23 09831057* SOCKET-HEAD SCREW E 150NM 1 PC
24 09832146* SQUARE RING 3 PC D
26 00218305 CYLINDER PIN 2 PC
28 09831318* DOUBLE BREAK-OFF PIN 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09604634*
DESCRIPTION: CONTROL PART

1 02000313* CONTROL HOUSING 1 PC
2 09412246* CONTROL BUSH 1 PC
3 09921942* CONTROL PISTONV 1 PC
4 09651119* ADJUSTING BUSHING 1 PC
14 09085560* O-RING 1 PC D
15 00013445 SOCKET-HEAD SCREW 25NM 4 PC
16 09153930 LOCKING SCREW 30NM 1 PC D
21 00900778 SEAL-LOCK-NUT 10NM 1 PC D
22 09831317 DOUBLE BREAK-OFF PIN 5 PC
25 02600646* O-RING 1 PC D
27 09441694* PROPORTIONAL SOLENOID 1 PC L
28 00765885 PLUG BOX 1 PC
40 09440571* CONTROL PISTON 1 PC
41 02000492* CONTROL BUSH 1 PC
48 09152686* O-RING 1 PC D
49 09157764* SEAL-LOCK-NUT 11NM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09441694*
DESCRIPTION: PROPORTIONAL SOLENOID

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09603769*
DESCRIPTION: COVER

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 09446625*
DESCRIPTION: THROTTLE PIN

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

ORDER NO. 09446862*
DESCRIPTION: THREADED PIN

L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 532 751-03
DESCRIPTION: HYDR.MOTOR LUFFING GEAR COMPL.

66.19.11.00.00 1 PC HYDR.MOTOR LUFFING GEAR COMPL. 2532751 2532751
66.19.11.01.00 1 PC AXIAL PISTON UNIT 1600828

SEE SUBSUPPLIER
ASSEMBLY 66.19.11.01
66.19.11.02.00 1 PC SOCKET PIECE 0625708
66.19.11.05.00 1 PC THREAD JOINT VSTI 0986982
66.19.11.06.00 1 PC SCREWING 0070277
66.19.11.07.00 16 PC CAP-SCREW 0861764
66.19.11.08.00 4 PC HEXAGON SCREW 0056679
66.19.11.09.00 4 PC THRUST WASHER 0153212
66.19.11.10.00 1 PC ADAPTER 90GR 1397693 1397693
66.19.11.11.00 3 PC SEALING RING 1725419
66.19.11.12.00 1 PC SAE-ADAPTER 2072550 2072550
66.19.11.13.00 1 PC LOCK SCREW 1406392
66.19.11.14.00 1 PC UNION 1312318
66.19.11.15.00 1 PC UNION VSTI 1637351
66.19.11.16.00 1 PC CHAK VALVE 1636493

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
AXIAL PISTON UNIT

A2FM 125/61W
PART-NO.: 1 600 828

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 1 600 828
DESCRIPTION: AXIALPISTON UNIT A2FM 125/61W

1 600 828 AXIAL PISTON UNIT A2FM 125/61W ( 09409634* ) 1 PC L
3 02038551* HOUSING 1 PC
4 09409552* PORT PLATE 1 PC
6 09154986* O-RING 1 PC D
7 00056714 SOCKET HEAD SCREW 87NM 2 PC
10 00013461 SOCKET HEAD SCREW 87NM 4 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02027409*

1 02027409* ROTARY GROUP, HYDR. SECTION 1 PC L
2 02027404* DRIVE SHAFT WITH BEARING 1 PC L
4 01419143 LOCKING RING 1 PC D
14 09831178* SHAFT SEALING RING 1 PC D
15 09086636* O-RING 1 PC D
17 01415525 ADJUSTMENT SHIM 2 PC
18 01415526 ADJUSTMENT SHIM 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02027407*

1 09421310* CYLINDER 1 PC
2 09650836* CONTROL LENS 1 PC
3 02027352* CENTER PIN 1 PC
4 02031679* PISTON WITH PISTON RINGS 7 PC L
5 01419144 WASHER 1 PC
11 09444064* RETAINING PLATE 1 PC
12 09831108* PAN HEAD SCREW WITH TROX 7 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02031679*
DESCRIPTION: PISTON WITH PISTON RINGS

1 02028625* PISTON 1 PC
2 09831892* STEEL SEALING RING 2 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02027404*
DESCRIPTION: DRIVE SHAFT WITH BEARING

2 02027338* DRIVE SHAFT 1 PC
3 09430091* BEARING RING 1 PC
6 02027403* RETAINING WASHER 1 PC L
10 09154382* CONICAL ROLLER BEARING 1 PC
11 00900241 CONICAL ROLLER BEARING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 02027403*
DESCRIPTION: RETAINING WASHER

1 09921494* RETAINING WASHER 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 0 625 708-00

66.19.11.02.00 1 PC SOCKET PIECE. 00625708
66.19.11.02.01 1 PC SOCKET PIECE ZV206/22/183 5006853

66.19.11.02.02 1 PC CONN.-NUT A2L 22 0010699
66.19.11.02.03 1 PC TAPER-BUSH L22-ST 0010695

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 243-00
DESCRIPTION: ADDITIONAL EQUIPMENT

80.00.00.00.00 1 PC ADDITIONAL EQUIPMENT 5011243
80.25.00.00.00 1 PC SPECIAL EQ. POWER SWIVEL / SPREADER 5022423

80.50.00.00.00 1 PC ADDITIONAL LOAD TURNING DEVICE 5011253 5011933
S PC
80.62.00.00.00 1 T LOAD TURNING DEVICE SWL 39,4T 5011234 5011234
SEE SUBSUPPLIER
80.66.00.00.00 1 PC HYDRAULIC ADDITIONAL EQUIPMENT 5011358

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 423-00
DESCRIPTION: SPECIAL ELECTRICAL EQUIPMENTS

80.25.00.00.00 1 PC SPECIAL ELECTRICAL EQUIPMENTS 5022423
80.25.01.00.00 1 PC CABINET FOR SPECIAL EQUIPMENT 5022428

80.25.02.00.00 1 PC REELING CABLE WITH ACCESSORIES 5022429
80.25.60.00.00 1 PC INSTALLATION SPECIAL EQUIPMENT 5022430

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 428-00
DESCRIPTION: CABINET FOR SPECIAL EQUIPMENTS

80.25.01.00.00 1 PC CABINET SPECIAL EQUIPMENTS 5022428
80.25.01.01.00 1 PC CABINET 5002704

80.25.01.02.00 4 PC CABINET HOLDER 5002705
80.25.01.03.00 1 PC DOORFASTERNER 5002706
80.25.01.04.00 1 PC HEATING CONTROL CABINET 5022242
80.25.01.05.00 1 PC PLATE WARNING 5012830 5012830
80.25.01.06.00 1 PC SHILD CARGO GEAR CONTROL 2350870 2350870
80.25.01.07.00 1 PC CABLE BRACKET 4234982
80.25.01.08.00 1 PC GLAND NUT 4236261
80.25.01.09.00 1 PC CABLE UNIT 4236258
80.25.01.10.00 1 PC GLAND NUT 4236262
80.25.01.11.00 2 PC CABLE UNIT 4236259
80.25.01.12.00 2 PC GLAND NUT 4236263
80.25.01.13.00 2 PC CABLE UNIT 4236260
80.25.01.14.00 2 PC GLAND NUT 4236264
80.25.01.15.00 1 PC TRANSFORMER 5002690
80.25.01.18.00 2 PC CONTACTOR 4KW 5022426
80.25.01.19.00 1 PC REVERSING WIRES 5022446
80.25.01.20.00 2 PC CONTACTOR 7,5 KW 5022450
80.25.01.21.00 2 PC SOCKET P2RF-08-S 5022363
80.25.01.22.00 1 PC RELAY G2R-1-SN024DC 5022132
80.25.01.23.00 1 PC RELAY G2R-2-SN230AC 5022362
80.25.01.24.00 4 PC RELAY G2RV-SL700-230AC 5022365
80.25.01.25.00 1 PC MOTOR CIRCUIT BREAKER 2,5-4A 5022161
80.25.01.26.00 1 PC CONTACT GV AN11 5022162
80.25.01.28.00 2 PC CIRCUIT BREAKER C60H 2P C16A 5022427
80.25.01.29.00 3 PC AUX. SWITCH C60 SERIES 5022439
80.25.01.30.00 1 PC CIRCUIT BREAKER C60H 2P C4A 5022425

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 428-00
DESCRIPTION: CABINET FOR SPECIAL EQUIPMENTS

80.25.01.31.00 1 PC CONNECTION BAR 5022444

80.25.01.32.00 2 PC END COVER PS-ENDPS 5022445
80.25.01.33.00 2 PC SUPPLY TERMINAL 1488535 5022447
80.25.01.34.00 13 PC RELAY G2RV-SL700-25VDC 5022367
80.25.01.104.00 10 PC SCREW 2088718
80.25.01.111.00 1,5 M CARRIER RAIL 35x15 1655083
80.25.01.112.00 0,6 M CABLE DUCT 1657371
80.25.01.113.00 2 M CABLE DUCT 1657370
80.25.01.114.00 0,5 M CABLE DUCT 1657369
80.25.01.120.00 30 PC TERMINAL ZDU 2.5-2/3AN 5022220
80.25.01.121.00 6 PC TERMINAL ZPE 2.5-2/3AN 5022250
80.25.01.122.00 2 PC SIDE PLATE 5022221
80.25.01.123.00 6 PC SIDE ANGLE 5022151
80.25.01.124.00 3 PC MARKER SCHT 5S 5022228
80.25.01.125.00 30 PC TERMINAL ZDU 4 5022170
80.25.01.126.00 2 PC TERMINAL ZPE 4 5022172
80.25.01.127.00 1 PC SIDE PLATE ZAP/TW$ DB 5022171
80.25.01.128.00 3 PC TERMINAL ZDU 35 5022448
80.25.01.129.00 1 PC TERMINAL ZDU 35 5022449
80.25.01.130.00 1 PC MARKER DEK 5 5022173
80.25.01.131.00 1 PC MARKER DEK 6 5022229
80.25.01.150.00 4 M ISO WIRE A25 1636826
80.25.01.151.00 2 M ISO WIRE A2,5 5002431
80.25.01.154.00 10 M ISO WIRE 2010796
80.25.01.156.00 10 M LINE 1656357
80.25.01.157.00 15 M LINE 1656358
80.25.01.158.00 3 M LINE 1656359

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 022 429-00
DESCRIPTION: REELING CABLE WITH ACCESSORIES

80.25.02.00.00 1 PC REELING CABLE WITH ACCESSORIES 5022429
80.25.02.01.00 92 M DRUM CABLE CORDAFLX 5022451

80.25.02.02.00 1 PC CHINESE FINGERS 5002934
80.25.02.03.00 1 PC SHRINK DOWN PLASTIC TUBING 1636779
80.25.02.04.00 1 PC SHRINK DOWN PLASTIC TUBING 1636780
80.25.02.05.00 1 PC CLAMP 0766405
80.25.02.06.00 2 PC SHACKLE 0157673
80.25.02.07.00 2 PC SHACKLE 0159554
80.25.02.13.00 1 PC SOCKET 1627744
80.25.02.14.00 1 PC CABLE GLAND 3398416
80.25.02.14.00 1 PC CONTACT INSERT 5009694
80.25.02.16.00 1 PC MOUNTING TOOL 5002885
SPARE PARTS LIST

ORDER NO. 5 022 430-00
DESCRIPTION: INSTALLATION SPECIAL EQUIPMENT

80.25.60.00.00 1 PC INSTALLATION SPECIAL EQUIPMENT 5022430
80.25.60.01.00 3 M CABLE TRY 0158339

80.25.60.02.00 12 M CABLE TRY 2012404 2012404
80.25.60.04.00 1 PC CABLE GLAND 1660699
80.25.60.05.00 1 PC CABLE GLAND 1636174
80.25.60.07.00 8 PC STEEL CABLE JOINT 5002309
80.25.60.08.00 30 PC CABLE TIE 1624720
80.25.60.11.00 1 PC DRUM CABLE CORDAFLEX 5022451
80.25.60.12.00 11 M CABLE IEC 60092 5002066
80.25.60.31.00 11 M CABLE IEC 60092 5002333
80.25.60.32.00 11 M ISO. WIRE A25 1636826
80.25.60.33.00 11 M CABLE –OELFL 3333838
80.25.60.34.00 11 M CABLE –OELFL 5012261
80.25.60.35.00 1 PC PLUG 1624266
80.25.60.36.00 4 PC HEXAGON SCREW 0650450
80.25.60.37.00 4 PC HEXAGON NUT 0650141
80.25.60.38.00 4 PC WASHER 0650452

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 253-00
DESCRIPTION: ADDITIONAL LOAD TURNING DEVICE

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 253-00

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 253-00

80.50.00.00.00 1 ST AADDITIONAL LOAD TURNING DEVICE 5011253 5011253
80.50.01.00.00 1 ST CABLE DRUM COMPL. 2389208 2389208

80.50.03.00.00 3 ST BRACKET 2044228 2044228
80.50.05.00.00 1 ST TENSION ROPE WINCH 5006084
SEE SUBSUPPLIER
80.50.06.00.00 1 ST ROPE PULLEY COMPL. 2044982 2044982
80.50.07.00.00 1 ST ROPE PULLEY COMPL. 2044713 2044713
80.50.10.00.00 3 ST CABLE REEL DIA 530 2370411 2370411
80.50.11.00.00 24 ST HEXAGON SCREW 0056677
80.50.12.00.00 24 ST WASHER 0056992
80.50.13.00.00 8 ST HEXAGON SCREW 0054431
80.50.14.00.00 8 ST WASHER 1665160
80.50.19.00.00 4 ST HEXAGON SCREW 0108533
80.50.20.00.00 8 ST WASHER 0056992
80.50.21.00.00 4 ST SPRING WASHER 0725735
80.50.22.00.00 4 ST HEXAGON NUT 0057133
80.50.23.00.00 65 M ROPE 1655183
80.50.24.00.00 6 M CHAIN 0630631
80.50.25.00.00 1 ST GROMMET 0887856
80.50.26.00.00 1 ST WIRE ROPE GRIP 0842015
80.50.27.00.00 6 ST SHACKLE 0305085
80.50.28.00.00 1 ST SHACKLE 5004084
80.50.29.00.00 4 ST RING BOLT 0052693

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 208-00
DESCRIPTION: CABLE REAL COMPL.

80.50.01.00.00 1 ST CABLE REAL COMPL. 2389208 2389208
80.50.01.01.00 1 ST CABLE REAL 2389206 2389206

SEE SUBSUPPLIER
ASSEMBLY 80.50.01.01.00
80.50.01.02.00 1 ST MULTI DISC BRAKE 1655132 1655132
SEE SUBSUPPLIER
ASSEMBLY 80.50.01.02.00
80.50.01.03.00 6 ST HEXAGON SCREW 0056639
80.50.01.04.00 6 ST HEXAGON NUT 0057133
80.50.01.05.00 6 ST WASHER 0056992

TTS-NMF GmbH
AND
SPARE PARTS LIST
CABLE DRUM
PART-NO.: 2 389 206

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 206
DESCRIPTION: CABLE DRUM

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 389 206
DESCRIPTION: CABLE DRUM

2 389 206 CABLE DRUM KFM7/12R SERIAL-NO. 175 464 - 469 1 PC L
01 X5751 – 0014* GEARBOX i = 1:26 1 PC

02 F-171-21-00-3-2* DRUM FLANGE 1 PC
03 F-0200-40-00-1-3* DRUM BODY 700 x 1200 x 250mm 1 PC
04 X03-04-003-0-00-4-5* STRAIN RELIEF CLIP 1 PC
05 X06-02-038-0-00-3-3* HOUSING 1 PC
06 X06-04-017-1-00-3-7* CABLE ENTRY 1 PC
07 X6020-1013* GLAND M63x1,51 PC
08 X06-03-064-0-00-4-0* MOUNTING RAIL1 PC
X6501-0010* TERMINAL STRIP EK 2.5 mm² 1 PC
X6501-0002* TERMINAL STRIP SAK 2.5 mm² 29 PC
X6502-0001* END ANGLE 2 PC
09 X01-02-028-1-00-3-3* COVER 1 PC
10 X06-07-026-0-00-3-0* CIRCLIP RING 1 PC
11 X06-02-058-0-00-3-3* HOUSING 1 PC
12 X6020-1004* GLAND M50x1,51 PC
13 X6000-0001* HEATING 33W 1 PC
14 X01-02-099-1-00-4-3* COVER 1 PC
15 X06-07-026-0-00-3-4* CIRCLIP RING 1 PC
16 X07-10-015-0-00-4-1* SLIP RING CARRIER 1 PC
17 G-1662-16-00-4-0* SLIP RING EARTH; 36 A 1 PC
18 G-1662-15-00-4-0* SLIP RING PHASE; 36 A 29 PC
19 X41-12-106-0-00-3-0* BRUSH HOLDER EARTH; 36 A 1 PC
20 X41-12-107-0-00-3-0* BRUSH HOLDER PHASE; 36 A 29 ST
OIL QUANTITY: 2,8 LTR. SYNTHETIC OIL SHELL-TIVELLA
When ordering spare parts, please state our order- and our serial number, to avoid wrong
deliveries. The order- and our serial number are on the type plate on the drum.
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
1. Maintenance instruction
INDEX
1. MAINTENANCE INSTRUCTION 14
1.1 ASSEMBLY OF THE CABLE REELING DRUM 15
1.2 MOUNTING OF THE CABLE REELING DRUM 15
1.3 CONNECTING THE PAYOUT CABLE 15
1.4 CONNECTING OF THE MAIN POWER CABLE 15
1.5 CHECK BEFORE COMMISSIONING 16
1.6 MAINTENANCE OF THE CABLE REELING DRUM 16
1.7 LIABILITY FOR FAULTS 17
1.8 ENCLOSURE 17

TTS-NMF GmbH
ATTENTION: TECHNICAL OPERATIONS SHOULD ONLY BE CARRIED

OUT BYQUALIFIED TECHNICAL PERSONNEL!
1 ASSEMBLY OF THE CABLE REELING DRUM

The cable reeling drum is constructed for heavy duty. The construction consists of the following main parts
which are apparent of the spare parts drawing 2122-1002_ETZ. The
drum body (3) is install to the drum flange (2) onto the hollow shaft of the gearbox (1). On
the opposite side of the drum body (3) the slip ring body with its slip rings and brush holder
unit is installed. The driving of the drum body (3) are given through a electric break motor
with an intermediate coupling, an magnetic coupling and a gearbox (1) on the drum body
(3) (the drive unit is supplied by the costumer). The heating (13) prevent the accumulation
of the condensation water inside the slip ring housing (heating must run in continuous operation).
2 MOUNTING OF THE CABLE REELING DRUM

The gear box of the cable reeling drum is provided with 6 pieces of borings, bore-size
approx. ø= 17mm. The cable reeling drum will be installed firmly at these borings with the
appropriate screws at the intended location.
NOTE: When assembling of the cable reeling drum it is to be made certain that the mounting
console is even.
NOTE: Please consider the torque of the screws (see B+E 00 069).
NOTE! PLEASE CONSIDERED THE OPERATING MANUAL AND HANDLING INSTRUCTIONS

OF THE CABLE MANUFACTURE!!!
3 CONNECTING THE PAYOUT CABLE

Remove the cover (9) from the drum body (3) and the slip ring cover (14). The reeling cable
goes through the gland (7) at the drum body (3) and connected to each terminal strip (8).
Afterwards tighten the compression gland (7), thereby ensuring stain-relief and a good seal
onto the cable and replace the slip ring cover (9), too. Start now to coil on the cable including 2 safety windings
for strain relief onto the drum body (3).
Coiling on the cable onto the drum:
Lay the cable non-twisted onto the ground. Coil on the cable layer by layer by turning the
drum body (3).
4 CONNECTING OF THE MAIN POWER CABLE

Remove the slip ring cover (14). The main power cable, coming from the distribution box
through the gland (12) at the slip ring housing (11) and is fixed to the brushes.
NOTE: The 1st, slip ring (17) nearest the axle is always earth ╧.
Replace the slip ring cover (14) and tighten the compression gland (12), thereby ensuring
stain-relieved and a good seal onto the cable.

TTS-NMF GmbH
5 CHECK BEFORE COMMISSIONING

Before the drum is put into operation, we recommend the following check:
a.) NOTE: Protective motor switch is always necessary.
b.) Check terminal block for proper sealing.
c.) Check slip ring unit for dampness, no moisture must be present.
d.) Check brush holders for proper contacts to slip rings.
e.) Rotation must be smooth.
f.) Grease slip rings slightly with contact grease.
6 MAINTENANCE OF THE CABLE REELING DRUM

A.) WEAR PARTS
The brush holders/collector and slip rings/plane slip rings are subject to a natural wear and
are depending upon need to be replaced. The brush bearing surfaces are to be cleaned
and the mobility of the pendulum brush holders are to examine (with wire brush holding the
pressure * is to the slip rings to examine), if necessarily should take place a cleaning or an
exchange (during 2/3 wear of the brush coals). After cleaning of the slip rings these should
be injected with contact spray. You receive the for this necessary special spray over our
spare part sales. It is to be made certain that the slip rings are always clean and no brush
coal dust at the slip rings set (flash over). After running in (after commissioning for the first
time after 3 months) of the brush coals the brush coal dust in the slip ring area is to be removed. You have to
made weekly maintenance in the running-in period (approx. 4-8
weeks) after commissioning. That’s important to ensure correct function further on. Afterwardsin regular in-
tervals (every 6 months and/or depending upon turnings of the slip rings)
repeat this procedure. If you fall into no pattern, please you request a maintenance plan
from us (with description of your data e.g. turnings, layer duration, travel speed). The inserted grooved ball
bearings are by the factory plentifully provided with camp fat, so that a
greasing is necessary only in larger time intervals. It is to be made certain by the customer
that the steel flange is closely screwed on and the cable entry is well after IP54 (IP65)
sealed.
Pressure* = when easy one-sided taking from 3-4 mm off should set itself the hook again
well on the slip ring course. If this effected can take place re-bent and/or must an exchange.
The electrical connection must be done according to VDE 0100 - 0113 resp. IEC-Nr.: 204-
1:1992 or CENELEC.
D.) GEARBOX
lubrication of the gearbox

Gearboxes are delivered with the suitable lubrication according to the mentioned operation
condition.
OIL FILLING
In Gearbox, the oil has to be replaced according to the working hours after about 10.000
working hours. It is recommended, that the oil should be drained shortly after having stopped
the gear. If possible, refill the gear with the same type of oil.
Type of oil: Shell-Tivella

Temperature range: -40°C to +170°C
Oil quantity: 2.8 liter
IT IS IMPORTANT TO CARRY OUT THE CHANGING OF THE OIL UNDER CLEAN CONDITIONS.

TTS-NMF GmbH
Maintenance of the gearbox

All roller bearings are well dimensioned and lubricated with high quality lubrication. Therefore
a long service life is expected. The gearbox housing is dust-tight and Hose proofed
and can be installed in any position.
SEAL RINGS, BEARINGS AND OIL ARE SUBJECT TO NORMAL WEAR.
We recommend the following maintenance

At normal load and temperature conditions the lubrication should be renewed after 10.000
working hours. But because the lubrication gets old while the drum is switched off, the lubrication should be
changed after 3 years, not depending on the working hours.
7 LIABILITY FOR FAULTS

If any alterations or repairs to the cable reeling drum are done by anyone else within the
time of warranty, we do not take any further liability for faults.
NOTICE
According the EC recommendation 89/392/EEC, we point out that rotating parts have to be
secured against danger of accident.
8 ENCLOSURE
General security for motor reeling drums B+E 00 049
Screws / tightening torque B+E 00 069

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
MULTI DISK BRAKE
PART-NO.: 1 655 132

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 1 655 132-00
DESCRIPTION: MULTI DISK BRAKE

1 655 132 MULTI DISK BRAKE 1 ST L
1 FLANGE 1 ST
2 CYLINDER 1 ST
3 PISTON 1 ST
4 RING HOUSING 1 ST
5 OUTER PLATE 8 ST
6 INNER PLATE 7 ST
7 SPRING 16 ST
9 SQUARE RING 1 ST
10 SQUARE RING 1 ST
11 TEFLON BBACK-UP RING 1 ST
15 SCREW 2 ST
16 SCREW PLUG 1 ST
19 HUB 1 ST
20 STOP PLATE 1 ST
21 SCREW 2 ST
22 SCREW 6 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
WINCH MODULE
PART-NO.: 5 006 084

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 084
ZHP 4.13 5006084 ROPE WINCH ( 04.13 1068480*) 101 - 108
4.13 1068480* INSTALLATION DRAWING

00001068480* ROPE WINCH SERIAL NO. 101 - 108
00001075223* GEAR
60193001430* ROPE DRUM
60193001098* FLANGE
00001075225* DRIVE
60193001433* WINCH SUPPORT
00192001263* HYDR. MULTIPLE DISC BRAKE
190000550* INSTALLATION INSTRUCTION

190000204* MAINTENANCE INSTRUCTION
190000315* RECOMMENDATION FOR LUBRICANTS
190000781* GEARBOX INSPECTION
190000159* TIGHTENING TORQUES
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 084
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 084
5006084 WINCH MODULE COMPL.(04.13 1068480) SERIE 101-108 1 ST
01 00001075223* GEAR 1 ST L
21 60193001430* ROPE DRUM 1 ST L
22 6019300^098* FLANGE BEARING 1 ST L
24 0000^075225* DRIVE 1 ST L
40 60193001433* WINCH SUPPORT 1 ST L
WEIGHT: 66,0 KG OIL QUANTITY: 04131068480 : 0,5 LTR.
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001075223*
DESCRIPTION: GEAR
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001075223*
DESCRIPTION: GEAR

1 00001075223* GEAR 1 ST L
1/ 1 00001075224* OUTPUT DRIVE 1 ST L

1/ 1/ 1 60241300279* PLANETARY CARRIER 1 ST
1/ 1/ 3 00001049758* INNER WHEEL BODY 1 ST
1/ 1/ 6 60241300264* BEARING FLANGE 1 ST
1/ 1/ 11 60241300259* COVER 1 ST
1/ 1/ 24 60411230024* CYLINDRICAL SCREW 3 ST
1/ 1/ 31 60441100036* SHAFT SEALING RING 1 ST D
1/ 1/ 41 60442000004* PROFILED CORD 0,6 M D
1/ 1/ 42 60541000089* O-RING 1 ST
1/ 1/ 51 60453300211* CYLINDER ROLLER BEARING 1 ST
1/ 1/ 53 60453000034* GROOVED BALL BEARING 1 ST
1/ 1/ 61 60403100041* CIR CLIP / LOCKING RING 1 ST
1/ 1/ 63 00001009883* CIR CLIP / SNAP RING 2 ST
1/ 1/ 64 60503200089* CIR CLIP / SNAP RING 1 ST
1/ 1/ 95 60414030011* SCREW PLUG 3 ST
1/ 1/ 96 60441000207* FLAT SEALING RING 3 ST D
1/ 1/ 454 60441100118* SHAFT SEALING RING 1 ST D
1/ 11 60100402054* PLANETARY STAGE 1 ST L

1/ 11/ 3 60241300261* SUN WHEEL 1 ST
1/ 21 60100501551* PLANETARY STAGE 1 ST L

1/ 21/ 3 60241300277* SUN WHEEL 1 ST
1/ 24 60100010166* PLANET CARRIER 1 ST L

1/ 24/ 1 60241300280* PLANET CARRIER 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193001430*

21 60193001430* ROPE RUM 1 ST L
21/ 1 60241300323* ROPE DRUM 1 ST
21/ 5 60234400030* ROPE WEDGE 1 ST
21/ 17 60541800021* STOPPER 2 ST
21/ 21 60411230060* CYLINDRICAL SCREW 12 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193001098*

22 60193001098* FLANGE BEARING 1 ST L
22/ 1 60241300258* FLANGE 1 ST
22/ 4 60403200044* CIRCLIP / LOCKING RING 1 ST
22/ 6 60453000269* GROOVED BALL BEARING 1 ST
22/ 8 60241300272* COVER 1 ST
22/ 12 60417000090* SLOTTED PIN 2 ST
22/ 27 60541800154* STOPPER 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001075225*
DESCRIPTION: DRIVE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 00001075225*
DESCRIPTION: DRIVE

24 00001075225* DRIVE 1 ST L
24/ 1 60193001432* DRIVE SLEEVE 1 ST
24/ 7 60230000465* MOTOR FLANGE 1 ST
24/ 25 60411130452* HEXAGON SCREW 4 ST
24/ 48 60503200059* CIRCLIP / SNAP RING 1 ST
24/ 59 60541000019* O-RING 1 ST
24/ 60 60414030001* SCREW PLUG 1 ST
24/ 61 60441000207* FLAT SEALING RING 1 ST
24/ 66 60242400138* COVER 1 ST
24/ 67 60541800004* STOPPER 2 ST
24/ 69 60543400040* AIR FILTER 1 ST
24/ 75 60402100337* PRESSURE SPRING 10 ST
24/ 76 60402100338* PRESSURE SPRING 10 ST
24/ 79 60404130009* DISC 4 ST
24/ 95 60506701101* OIL PRESSURE UNIT 1 ST
24/ 96 60241300265* DISC HOUSING 1 ST
24/ 97 60506700084* OUTER DISC 12 ST
24/ 98 60506700085* INNER DISC 11 ST
24/ 122 60414030002* SCREW PLUG 1 ST
24/ 123 60441000208* LAT SEALING RING 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 192001283*
DESCRIPTION: DRIVE
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 60193001433*

40 60193001433* WINCH SUPPORT 1 ST L
40/ 1 60241300324* WINCH SUPPORT 1 ST
40/ 2 60411130454* HEXAGON SCREW 6 ST
40/ 4 60421100475* HEXAGON SCREW 12 ST
40/ 5 60240700289* DISC 12 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
190000330*
GENERAL
Please also note the indication in our installation drawings:
The rope winch is supplied completely assembled
Before assembling, verify your steel construction according to our installation drawing.
The screw-on-surfaces have to be worked properly to the same level.
Strength classes and torque moments for screw see installation drawing.
Assembly
Put rope winch unit with winch support into steel frame.
Fix winch support with screws.
Connect brake line( see installation drawing )
Release hydraulically multiple disc brake.
Remove transport cover of the motor flange.
Before montage of the motor we recommend to treat the surface of the output shaft of the motor and
the profile of the drive sleeve in the drive unit with “Optimoly Paste White T” against fretting corrosion.
Check rope winch with running motor as to unction.
Check above all the control and unction o the holding brake and the drive motor.
Introduce the rope and draw in the rope key.
The rope must be wound up with at least 10% o the nominal rope pull.
* = FOREIGN NUMBER

TTS-NMF GmbH
190000204
Lubrication
Oil filling ex factory : AVIA gear oil Hypoid 90 EP
Choice according to DIN : DIN 51502 resp. API GL5
sticker.

Recommendation for maintenance intervals

First oil change after 200, then after each 1000 service hours, but at least once a year.
* = FOREIGN NUMBER

TTS-NMF GmbH
19000315*
RECCOMENDATION FOR LUBRICANTS

Choice list
CHOOSEN ACCORDING TO CHOOSEN ACCORDING TO CHOOSEN ACCORDING TO

API GL 5 DIN 51502 DIN 51502
OIL, SAE 90 OIL, DIN 51517 – CLP 220 GREASE, DIN 51825 – KP2K
AVIA GEAR OIL

HYPOID 90 EP
CASTROL SPHEEROL
EPL 2 GREASE
ESSO GEAR OIL

GX-D90
FUCHS GEAR OIL

RENOGEAR HYPOID 90

* = FOREIGN NUMBER

TTS-NMF GmbH
190000158
GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Why oil analyses ?

charges.
Simple surveillance:
metals, dirt etc.
construction part.
damage of the gear.
* = FOREIGN NUMBER

TTS-NMF GmbH
190000781
Taking of an oil sample

level.
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
190000159
TIGHTENING TORQUES
Tightening torques for fixing screws M 4 to M 36 and for strength classes 8.8, 10.9
and 12.9 at a coefficient of friction 0,125.
8.8 10.9 12.9
M4 = 2,7 Nm 3,8 Nm 4,6 Nm
M5 = 5,5 Nm 8,0 Nm 9,5 Nm
M6 = 9,5 Nm 13,0 Nm 16,0 Nm
M8 = 23,0 Nm 32,0 Nm 39,0 Nm
M 10 = 46,0 Nm 64,0 Nm 77,0 Nm
M 12 = 80,0 Nm 110,0 Nm 135,0 Nm
M 14 = 125,0 Nm 180,0 Nm 215,0 Nm
M 16 = 195,0 Nm 275,0 Nm 330,0 Nm
M 18 = 270,0 Nm 390,0 Nm 455,0 Nm
M 20 = 385,0 Nm 540,0 Nm 650,0 Nm
M 22 = 510,0 Nm 720,0 Nm 870,0 Nm
M 24 = 660,0 Nm 930,0 Nm 1100,0 Nm
M 27 = 980,0 Nm 1400,0 Nm 1650,0 Nm
M 30 = 1350,0 Nm 1850,0 Nm 2250,0 Nm
M 36 = 2350,0 Nm 3300,0 Nm
 The indicated tightening torques are maximum values.

 Screws secured by Loctite Type 242.
 Fitting surfaces sealed by Loctite Type 640.
 Surfacing on brake sealed by Loctite Type 573.
 Screwing of the tubing and the connection surfaces of the drive motor to the gear are sealed
with Loctite Type 572.
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 044 982-01
DESCRIPTION: ROPE PULLEY COMPL.

80.50.06.00.00 1 ST ROPE PULLY COMPL. 2044982 2044982
80.50.06.01.00 1 ST BEARING PEDESTAL 2055074 2055074

80.50.06.02.00 1 ST COMPONENTS 2055095

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 055 095-00
DESCRIPTION: COMPONENTS ROPE PULLEY

80.50.06.02.00 1 ST COMPONENTS ROPE PULLEY 2055095 2055095
80.50.06.02.01 1 ST PIN 2044712 2044712

80.50.06.02.03 1 ST WASHER 0056996
80.50.06.02.04 1 ST LOCKING NUT 0925476

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 044 713-00
DESCRIPTION: ROPE PULLEY COMPL.

80.50.07.00.00 1 ST ROPE PULLY COMPL. 2044713 2044713
80.50.07.01.00 1 ST BEARING PEDESTAL 2044545 2044545

80.50.07.02.00 1 ST COMPONENTS 2044733

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 044 733-00
DESCRIPTION: COMPONENTS ROPE PULLEY

80.50.07.02.00 1 ST COMPONENTS ROPE PULLEY 2044733 2044733
80.50.07.02.01 1 ST PIN 2044712 2044712

80.50.07.02.03 1 ST WASHER 0056996
80.50.07.02.04 1 ST LOCKING NUT 0925476

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
LOAD TURNING DEVICE SWL 44,4T

CS10040
PART-NO.: 5 011 234

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00
DESCRIPTION: LOAD TURNING DEVICE CS10040 SWL 44,4T
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

5 011 234 LOAD TURNING DEVICE SWL 39,4T 1 ST L
1 CS 10040* STEEL STRUCTURE 1 ST
2 HYROS 25* CABLE CRAMP 2 ST
4 WASHER 4 ST
5 15002* COVER 2 ST
6 CABLE ENTRY 1 ST
7 CS10027* FORK BRACKET 1 ST
8 15003* BUSH 1 ST
9 CABLE ENTRY 3 ST
10 CABLE 1 ST
11 HYDRAULIC HOSE 2 ST
13 WASHER 4 ST
14 15004* COVER 1 ST
15 EL CONTAKT 1 ST
16 CABLE 1 ST
17 WK6U* CONNECTION PLINTH 4 ST
18 TS 32* PLINTH BRACKET 1 ST
19 15005* ROTATION STOP 1 ST
20 GREASE NIPPLE 1 ST
21 COTTER PIN 1 ST
23 WASHER 2 ST
24 15007* NUT 1 ST
25 15006* SHAFT 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

400097* BALL RING GEAR CS10040 1 ST L
1 PIPE COUPLING 2 ST
2 GREASE HOSE 2 ST
5 11080* BALL RING GEAR 2 ST
9 GREASE HOSE 1 ST
11 GREASE NIPPLE 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

400099* HYDRAULIC UNIT CS10040 1 ST L
1 1A90L-41,5* ELECTRIC MOTOR 1 ST
2 SCREW 4 ST
3 Fly1.2150 AD* ADAPTER PLATE 1 ST
4 SCREW 4 ST
5 SPACING SLEEVE 4 ST
7 Fly1.2211 M* SHAFT COUPLING 1 ST
8 Fly1.2211 PDC* SHAFT COUPLING 1 ST
10 Fly1.3,7 TO DE* VALVE BLOCK 1 ST
11 O-RING 1 ST
12 O-RING 1 ST
13 M1 B3,6 530021* GEAR PUMP 1 ST
14 WASHER 4 ST
16 265/205/8L* OIL TANK 1 ST
17 U 018182* AIR FILTER 1 ST
18 O-RING 1 ST
19 NUT 1 ST
20 GASKET 1 ST
21 LEVEL GLASS 1 ST
22 NUT 4 ST
24 11076* PILOTED CHECK VALVE 2 ST
25 11077* PRESSURE VALVE 2 ST
26 11078* CHECK VALVE 2 ST
28 O-RING 2 ST
29 11079* SUCTION STRAINER 1 ST
30 BRACKET 1 ST
31 WASHER 4 ST
33 WASHER 2 ST
35 WASHER 2 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

400096* HYDRAULIC MOTOR BLOCK CS10040 1 ST L
1 SVO8-25M-O-N-OO* DIRECTION VALVE 1 ST
2 AG-23DV A.C.* SOLENOID 230/60Hz 1 ST
4 VALVE BLOCK 1 ST
5 PIPE 1 ST
6 T370-2-25-NAN-HP_SEAL* HYDRAULIC MOTOR 1 ST
10 PIPE COUPLING 2 St
11 MEASURING NIPPLE 2 ST
12 RDDA-LAN* DIRECT ACTING RELIEF VALVE 2 ST
13 YVB* VALVE BLOCK 1 ST
15 O-RING 2 ST
17 T16-25* PINION GERA 1 ST
21 WASHER 2 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

400102* HYDRAULIC DIAGRAM CARGO TURNER CS10040
1 HYDRAULIC MOTOR
2 DIRECTION VALVE
3 VALVE BLOCK
4 DIRECT ACTING RELIEF VALVE
5 MEASSURING NIPPLE
6 VALVE BLOCK
7 PILOTED CHECK VALVE
8 RELIEF VALVE
9 GEAR PUMP
10 ELECTRIC MOTOR
11 CHECK VALVE
12 AIR FILTER
13 SUCTION STRAINER
14 LEVEL GLASS
15 OIL TANK
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: 5 011 234-00

400016* CONNECTION DIAGRAM CS-10040
1 309.012.000.554.000* ODU CHASSI 1 ST
309.800.150.030.151* PIN INSERT COMPL.
2 WK6U* CONNECTION PLINTH 29 ST
3 WK6 SL/35* CONNECTION PLINTH GND 4 ST
4 309.012.000.554.000* ODU CHASSI 1 ST
309.703.150.024.00* PIN INSERT COMPL.
5 230V/60Hz* SOLENOID 1 ST
6 440V/60Hz 1,8 kW* ELECTRIC MOTOR 1 ST
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
LOAD TURNING DEVICE SWL 44,4T

CS10040
INSTRUCTION MANUALS

TTS-NMF GmbH
General information
There are two types of machine regulations, within the domain of the National Board of Occupational Safe-
ty
and Health; directives for the product and directives for the working environment. The intentions of the
instructions are to make uniform the product requirements in each country in order to eliminate the so-
called
trade barriers. This agreement to conformity makes the technical requirements of the products the same in
all member countries. The intention of regulating the working environment is that no country will gain unfair
business advantages by maintaining a poor working environment (making their products cheaper than
products of other countries by risking the health and safety of their employees). In the machine regulations
there are three different parties; the manufacturer, the company and the operator. The manufacturer or his
agent is responsible for the machine meeting the minimum requirements, the implication of this is that the
machine is to accompanied by instructions for use. The company/ the user is required to train the
driver/operator so he can use the machine properly. The driver/ operator is to follow the rules and
instructions necessary for him to protect himself and others from accidents and to run the machine prop-
erly.
EXPLANATION OF SYMBOLS
The instructions contain important information, which is to be understood by all users, prior to putting the
machine in use. Therefore we have placed symbols in the instructions where we particularly want to focus
your attention.
CAUTION ADVICE
Vital information warning for Vital information on how to Advice on operation, care and
incident which can result in prevent personal and maintenance of the machine.
personal injury if instructions equipment damage.
are not followed.
EXPLANATION OF DECALS
Decals conveying vital information are placed in strategic areas on the machine. The users of the machine
must understand what the decals mean before they operate the machine.
Wear protective,
Warning! Danger of helmet, ear protectors,
getting crushed. protective goggles and
visor.
Prior to using, study the

safety regulations in the Wear durable,.
manual. non-slip gloves.
Wear reinforced
boots with nonslip
soles

TTS-NMF GmbH
SAFETY REGULATIONS
The following list of safety regulations is an excerpt from the general safety precautions which we want to
emphasize. Our intention is to make the personnel aware of the risks and dangers when the cargo-turner is
in operation.
1. Study and learn the meaning of all the warning symbols, safety precautions and instructions
in the manual. Study and learn the meaning of all the decals on the machine. See that you
fully understand the instructions before you start operating the cargo-turner.
2. Report all incidents and accidents to the responsible foreman.
3. If possible, use protective gloves, reinforced boots and protective goggles to protect your
hands, feet and eyes from getting cut or crushed; and to protect them from solvents, grease and oil.
4. Permit no unauthorized or under-aged persons in the working area.
5. Warning, prohibiting and informative decals must not be concealed, changed or damaged.
6. Do not climb onto the instrument or allow anyone else to.
7. Check the instrument for damage before each use. Repair damage before using the instrument.
8. Do not allow untrained personnel to start or use any of the equipment without the guidance
of a trained operator.
PRODUCT INFORMATION
Cargo-turner is used to efficiently hoist cargo and place it exactly where the crane operator wants its. It can
be used for all types of lifting equipment; on cranes, in docks or on ships. Use of the cargo-turner increases
efficiency by reducing the amount of time required for loading and unloading which also reduces operating
costs and risk of accidents.
PUTTING INTO OPERATION

It is important that everyone who is to use the cargo-turner is given the opportunity to read through the
instructions with an instructor or another trained person.
FOR THE INTRODUCTION WE RECOMMEND THAT YOU:

ADVICE
1. Go through the instructions carefully to determine possible difficulties.
2. Check that all safety devices are in place.
3. Make sure that the lighting is satisfactory.
UNAUTHORIZED PERSONNEL MUST NOT BE WITHIN THE WORKING AREA

WHEN THE CARGO-TURNER IS IN OPERATION

TTS-NMF GmbH
MOUNTING
The crane on which the cargo-turner is to be mounted must be approved (been granted a test hoisting
certificate) and must meet the prevalent rules and regulations.
1. Check that the lighting is satisfactory and that the cargo-turner is standing steadily.
2. Fit the lockings and connect the supply current. Prior to the test run check the lockings.
3. During the test run and operation of the cargo-turner nobody is permitted in the working area.
4. Never hoist a load above or near people and make sure that the operator has a good view of the
working area.
DISMOUNTING
1. Make sure that lighting is satisfactory.
2. While dismounting the cargo-turner is to be placed in it’s transport frame.
3. Remove the lockings and disconnect the supply current.
PRIOR TO REMOVING THE INSPECTION

COVER, THE OPERATOR MUST BE
CERTAIN THAT THE POWER SUPPLY
IS DISCONNECTED.
BE CAREFUL! DANGER OF GETTING
CRUSHED. (SEE PICTURE 1)
Picture 1
SPARE PARTS
When replacing damaged parts make sure that they are approved by the manufacturer.
CARE AND MAINTENANCE

1. The purpose of all service and repair should be to maintain or
restore the cargo-turner to original function. If the function
of the machine is altered, the party responsible for the
alteration will be held liable according to the Machine Directive.
2. The person who repairs and services the machine must be
knowledgeable about the machine.
3. The person responsible for operating the machine must know
when and how the machine is to be serviced.
4. The machine is to be serviced only when lighting is satisfactory
lighting.
This high quality cargo-turner has a long life of high function despite strenuous tasks and a difficult
environment to function in.
To get the most out of the cargo-turner functionally and economically it must be maintained and serviced
properly.

TTS-NMF GmbH
HYDRAULIC AGGREGATE
AFTER 8 HOUR OF USE...
* Check oil level (level should be between the marks on the oil gauge).
* Check for leaks.
* Check that the hydraulic couplings and anchor bolts for the hydraulic aggregate,
hydraulic oil tank and hydraulic motor are tightened.
* Check hydraulic hoses.
* Make sure electric cables and plugs are not broken and are clean.
* Grease slewing ring gear and pinion
Check hydraulic pressure.

To check maximum working pressure, the
rotating part must go to stop. At this time
the pressure should be 80 bar.
(see picture 2 Pressure measurement).
Picture 2
* Change the hydraulic oil

DISMOUNTING OF HYDRAULIC UNIT
1. Check that lighting is satisfactory. Prior to open the inspection cover the operator must be certain that
the supply current is disconnected.
2. Open the inspection covers on both sides of the Cargo-Tuner
3. Disconnect the electric cable from the electric motor.
4. Disconnect all hydraulic hoses.
5. Screw off the bolts on the fastening plate of the hydraulic unit. Remove the fastening plate with the
hydraulic unit from the Cargo-Tuner.
CHANGE OF HYDRAULIC OIL
1. Check that lighting is satisfactory. Prior to opening the inspection cover the operator must be certain
that supply current is disconnected.
2. Dismount the hydraulic unit.
3. . Screw off the fastening of the hydraulic plate.
4. Drain oil tank through filling hole to collecting pail for waste oil.
5. Unscrew the oil tank from the hydraulic block.
6. Clean inside of oil tank, check the sealing between oil tank and block before mounting it back.
7. Fill new hydraulic oil through filling hole to correct level.
8. Check for leakage between block / oil tank before the hydraulic unit is fitted to the Cargo-Tuner.

TTS-NMF GmbH
Clean all equipment after each commission. Inspect equipment for damage
ADVICE and repair any possible damage so that it is operable for the next
commission.
Make sure that electric plug is not broken and is clean.
CAUTION When handling grease and oil great caution should be exercised.
Avoid skin contact.
The oil tank holds approximately 5,0 L.
Type of hydraulic oil: Shell Tellus T 32 S

BP Bartran HV 32
ESSO Univis N 32
Mobil Flowrex SHS 32
ANNUAL MAINTENANCE
1. Clean equipment thoroughly.
2. Inspect for wear and tear.
3. Exchange damaged parts, touch- up damaged areas and give anti-corrosive treatment.
4. Lubricate all bearings.
5. Renew test hoisting certificate according to regulations.
CONDITIONS OF GUARANTEE:
The guarantee does not cover damage that has occurred due to misuse or because repairs have been
carried out incorrectly. The guarantee is also invalid if other than original parts have been used to repair the
machine. The guarantee is also invalid if the instructions in the instruction manual have not been adhered to.
TECHNICAL SPECIFICATIONS
Type CS10040
Serial No. 40093, 40094
Build year. 02-2008
Lifting capacity 39,4 ton SWL
Weight 600 kg
Electric motor 440 V 60 Hz 1,8 kW IP55
Working pressure 80 Bar
Rotation torque. 2600 Nm
Rotation speed 2.4 - 3.0 rev/min

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 173-00
DESCRIPTION: HYDR. SYSTEM ADDITIOANL EQUIPMENT

80.66.00.00.00 1 PC HYDR.SYSTEM ADDITIONAL EQUIPMENT 5011358
80.66.01.00.00 1 PC HYDRAULIC LOADSTABILIZING 5011357

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 357-00
DESCRIPTION: HYDRAULIC SYSTEM AUXILLIARY EQUIPMENT

80.66.01.00.00 1 HYDRAULIC SYSTEM AUXILLIARY 5011357

EQUIPMENT
80.66.01.01.00 1 PC COMPONENTS HYDRAULIC SYSTEM 5006690

AUXILLIARY EQUIPMENT
80.66.01.03.00 1 PC HYDRAULIC MOTORS COMPL. 5006175

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 690-03

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 690-03

80.66.01.01.01 1 PC VALVE BLOCK 5001121 5001121

SEE SUBSUPPLIER
ASSEMBYL 66.80.01.01.01
80.66.01.01.03 1 PC AXIAL PISTON 1606188
SEE SUBSUPPLIER
ASSEMBYL 66.80.01.01.03
80.66.01.01.04 1 PC ADAPTER 2072712
SEE SUBSUPPLIER
ASSEMBYL 66.80.01.01.04
80.66.01.01.05 1 PC SOCKET 1636032
80.66.01.01.06 2 PC SAE-FLANGE HOLDER 0566762
80.66.01.01.07 2 PC SAE-FLANGE 0842973
80.66.01.01.08 4 PC CAP SCREW 5006706
80.66.01.01.09 4 PC CAP-SCREW 5006707
80.66.01.01.10 1 PC NON-RETURN VALVE 3330344
80.66.01.01.11 1 PC UNION 1312318
80.66.01.01.12 2 PC UNION 0249224
80.66.01.01.13 1 PC UNION 0092671
80.66.01.01.14 1 PC UNION 1307804
80.66.01.01.15 1 PC MEASURING SOCKET 1650091
80.66.01.01.16 1 PC UNION 1636030
80.66.01.01.17 1 PC UNION 1654183
80.66.01.01.18 2 PC UNION 1307806
80.66.01.01.19 2 PC NON-RETURN VALVE 0068935
80.66.01.01.20 1 PC UNION 0887848
80.66.01.01.21 1 PC NOZZLE 1939789
80.66.01.01.22 1 PC UNION 8411057
80.66.01.01.23 1 PC UNION 1983889
80.66.01.01.24 1 PC FITTING 1991910
80.66.01.01.26 4 PC HEXAGON SCREW 0056668
80.66.01.01.27 2 PC HEXAGON SCREW 0054431
80.66.01.01.31 1 PC UNION 1636020
80.66.01.01.32 6 PC WASHER 0063701
80.66.01.01.35 1 PC PRESSURE SWITCH 1652152
80.66.01.01.36 1 PC RUBBER CAP 0625431
80.66.01.01.45 5 PC CLIP 1389991
80.66.01.01.48 20 PC CABLE TIE 1624720
80.66.01.01.49 4 PC CAP SCREW 933422
80.66.01.01.50 1 PC SEALING RING 1725417
80.66.01.01.51 1 PC SEALING RING 1725419
80.66.01.01.53 1 PC UNION 1665730
80.66.01.01.88 1 PC RETAINING PLATE 5001109 5001109
80.66.01.01.89 3 PC HEXAGON SCREW 0056668
80.66.01.01.90 3 PC WASHER 3330361
80.66.01.01.91 3 PC HEX.-NUT 0057130

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
VALVE BLOCK
PART-NO.: 5 001 121

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 121
DESCRIPTION: VALVE BLOCK
L = ASSEMBLY GROUP
D = SEALING ELEMENT
 = FOREIGN NUMBER

 ASSEMBLY GROUP 80.66.01.01.01
TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 001 121
DESCRIPTION: VALVE BLOCK

5 001 121 VALVE BLOCK LT 30L36.0 1 PC L
1 1421624* BLOCK LT 30L36.0 1 PC
2 1239411* PLUG 5 PC
3 1239261* PLUG 2 PC
4 1231342* PRESSURE FILTER (FLANGE DESIGN) 1 PC
5 1240064* 4/2 WAY SOLENOID VALVE 1 PC
8 1233544* PRESSURE RELIEF VALVE 2 PC
9 1241604* MEASURE CONNECTION PIECE 5 PC
10 1135727* THREAD JOINT 5 PC
13 1239317* NUT 4 PC
14 1239373* STUD BOLT 4 PC
15 1238484* O-RING 2 PC
16 1238509* O-RING 2 PC
17 1238500* O-RING 5 PC
18 1238536* O-RING 5 PC
19 1240995* EXPANDER 17 PC
20 1243997* BALL VALVE DN 04-06 2 PC
21 1240470* BALL VALVE DN 10 5 PC
22 1241609* KEY FOR BALL VALVE 7 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
VAR. DISPL. PUMP

A10VO 28 DR /30
PART-NO.: 1 606 188

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 1 606 188
DESCRIPTION: VAR. DISPL. PUMP A10VO 28 DR /31

1 505 188 VAR. DISPL. PUMP A10VO 28 DR /31 1 PC L
1 R910906325* G A10VO 28 DR /31R-PSC61N00 1 PC L
2 R910907095* CONTROL VALVE 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

DESCRIPTION: G A10VO 28 DR /31R-PSC61N00

TTS-NMF GmbH
SPARE PARTS LIST

DESCRIPTION: G A10VO 28 DR /31R-PSC61N00

R910906325* G A10VO 28 DR /31R-PSC61N00 1 PC L
2 R910911162* ADJUSTING PIECE 1 PC L
5 R910915773* PUMPING HOUSING 1 PC
7 R910960813* SWASHPLATE 1 PC
11 R910744158* SHIM 1 PC
12 R902400789* ADJUSTMENT SHIM 1 PC
15 R910730068* TAPERED-ROLLER BEARING 1 PC
16 R902400788* TAPERED-ROLLER BEARING 1 PC
17 R910902778* BEARING-LINER 2 PC
20 R910794325* SHAFT SEALING RING 1 PC D
22 R910730041* O-RING 1 PC D
23 R910102075* O-RING 4 PC D
33 R910707481* CYLINDER PIN 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902439597*

R902439597* ROTARY GROUP 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902439601*

R902439601* ROTARY GROUP 1 PC L
1 R902433667* PISTON 9 PC
2 R902407325* CYLINDER 1 PC
4 R902434998* RETAINUNG PLATE 1 PC
7 R910924891* SPRING 1 PC
9 R902464162* PRESSURE PIN 3 PC
10 R902400716* SEEGER-V-RING 1 PC
11 R902400717* BACK-UP-PLATE 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R910911162*
DESCRIPTION: ADJUSTING PIECE

R910911162* ADJUSTING LATE 1 PC L
2 R910910646* PISTON GUIDE 1 PC
3 R910908999* OPPOSED PISTON 1 PC
4 R910737283* PISTON GUIDE 1 PC
6 R910799041* SPRING 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO.: R910907095*
DESCRIPTION: CONTROL VALVE

R910907095* CONTROL VALVE 1 PC L
1 R910912797* ZVK POSITIONING VALVE A10 DR 1 PC
2 R910515078* O-RING 3 PC D
3 R910900443* SOCKET-HEAD SCREW 15,5NM 4 PC D
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
PUMP SUPPORT PLATE

SAE – B (KO2)
PART-NO.: 2 072 712

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 2 072 712*
DESCRIPTION: PUMP SUPPORT PLATE SAE-B (KO2)

0002072712* PUMP SUPPORT PLATE SAE-B (KO2) 1 PC L
1 R902071458* INTERMEDIATE FLANGE 1 PC
5 R902083677* THROUGH DRIVE COUPLING 1 PC
10 R909086573* SOCKET-HEAD SCREW 130NM 4 PC
12 R909157881* O-RING 1 PC D
17 R909086218* O-RING 1 PC D
20 R909152589* O-RING 1 PC D
89 R902260977* FLANGE COVER COMLETE 1 PC LD
ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. R902602977*
DESCRIPTION: FLANGE COVER COMPLETE

R902602977* FLANGE COVER COMPLETE 1 PC L
1 R902603694* FLANGE COVER 1 PC L
2 R909083705* HEXAON SCREW 2 PC
SPARE PARTS LIST

ORDER NO. R902603694*
DESCRIPTION: FLANGE COVER

R902603694* FLANGE COVER 1 PC
1 R902602982* FLANGE COVER 1 PC
2 R902603199* GASKET 1 PC
ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 175-00
DESCRIPTION: HYDRAULIC MOTOR COMPL.

80.66.01.03.00 1 PC HYDRAULIC MOTOR COMPL. 5006175
80.66.01.03.01 1 PC HYDRAULIC MOTOR COMPL.. 5006177 5006177

80.66.01.03.02 1 PC HYDRAULIC MOTOR COMPL. 5006178 5006178

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 177-00
DESCRIPTION: HYDR. MOTOR COMPL.

80.66.01.03.01.00 1 PC HYDR. MOTOR COMPL. 5006177 5006177
80.66.01.03.01.01 1 PC HYDR. MOTOR 5006079

SUBSUPPLIER SEE
80.66.01.03.01.02 1 PC UNION 1665742
80.66.01.03.01.03 2 PC UNION 1654512
80.66.01.03.01.04 1 PC VSTI-R1/2-ED 1398507
80.66.01.03.01.05 1 PC TRANSIT.MUFF CONNECT:PIECE 0665861
80.66.01.03.01.06 1 PC UNION 1312318
80.66.01.03.01.07 1 PC UNION 0887848
80.66.01.03.01.08 2 PC UNION 1307809
80.66.01.03.01.09 1 PC UNION 1983889
80.66.01.03.01.10 1 PC NOZZLE 1939789
80.66.01.03.01.11 4 PC HEX-SCREW 0842733
80.66.01.03.01.12 1 PC BRAKE FILTER 1637770
80.66.01.03.01.14 1 PC UNION 1636004
80.66.01.03.01.15 1 PC UNION 5006205
80.66.01.03.01.16 1 PC UNION 1665705
80.66.01.03.01.22 1 PC UNION 0153812
80.66.01.03.01.23 1 PC UNION 1312010

TTS-NMF GmbH

TTS-NMF GmbH
SPARE PARTS LIST
HYDRAULIC MOTOR
SCM 012
PART-NO.: 5 006 079

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
DESCRIPTION: HYDRAULIC MOTOR SCM 012 ISO
FIGURE 1

0005006879 HYDRAULIC MOTOR SCM 012 ISO 1 PC L
1,2,3 FIGURE 1 SHAFT SEAL KIT M-012/-64 ISO 1 PC
4,5 FIGURE 2 KEY 1 PC
6,7,8,9 FIGURE 2 REPAIR KIT M-017 ISO FRONT 1 PC
10 FIGURE 3 PLUG G ½” 1 PC
11 FIGURE 3 ANGULAR HOUSING M-012/-34 1 PC
12 FIGURE 3 SPRING PIN M-012/-17 1 PC
13 FIGURE 3 CYLINDRICAL SCREW 8 PC
14 FIGURE 3 PLUG G ½” PLASTIC 1 PC
15 FIGURE 3 PISTON SC/-M 012/025 5 PC
16,17 FIGURE 4 REPAIR KIT M-012 ISO BACK 1 PC
18,19,20 FIGURE 5 SEAL KIT M-012/-34 ISO 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
FIGURE 2

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
FIGURE 3

4 0000091945* KEY 8x7x32 1 PC
5 0000091944* KEY 6x6x32 1 PC
6 0000050566* REPAIR KIT M-012/-17 ISO A F 1 PC
7 0000050567* REPAIR KIT M-012/-17 ISO B F 1 PC
8 0000050568* REPAIR KIT M-012/-17 ISO C F 1 PC
9 0000050569* REPAIR KIT M-012/-17 ISO D F 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
FIGURE 4

10 0000050337* PLUG G ½” 1 PC
11 0000030230* ANGULAR HOUSING M-012/-34 1 PC
12 0000020337* SPRING PIN M-012/-17 1 PC
14 0000091372* PLUG G ½” PLASTIC 1 PC
15 0000050280 PISTON SC/-M 012/025 5 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
FIGURE 5

16 0000050489* REPAIR KIT M-012 ISO S B 1 PC L
17 0000050570* REPAIR KIT M-012 ISO K B 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 079
FIGURE 6

18 0000050547* REPAIR KIT M-012/-34 N ISO 1 PC L
19 0000050548* REPAIR KIT M-012/-34 H ISO 1 PC L
20 0000050549* REPAIR KIT M-012/-34 V ISO 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 178-00
DESCRIPTION: HYDR. MOTOR COMPL.

80.66.01.03.02.00 1 PC HYDR. MOTOR COMPL. 5006178 5006178
80.66.01.03.02.01 1 PC HYDR. MOTOR 5006080

SUBSUPPLIER SEE
80.66.01.03.02.02 1 PC UNION 1665742
80.66.01.03.02.03 2 PC UNION 1654512
80.66.01.03.02.04 1 PC VSTI-R1/2-ED 1398507
80.66.01.03.02.05 1 PC TRANSIT.MUFF CONNECT:PIECE 0665861
80.66.01.03.02.06 1 PC UNION 1312318
80.66.01.03.02.07 1 PC UNION 0887848
80.66.01.03.02.08 2 PC UNION 1307809
80.66.01.03.02.09 1 PC UNION 1983889
80.66.01.03.02.10 1 PC NOZZLE 1939789
80.66.01.03.02.11 4 PC HEX-SCREW 0842733
80.66.01.03.02.12 1 PC BRAKE FILTER 1637770
80.66.01.03.02.14 1 PC UNION 1636004
80.66.01.03.02.15 1 PC UNION 5006205
80.66.01.03.02.16 1 PC UNION 1665705
80.66.01.03.02.22 1 PC UNION 0153812
80.66.01.03.02.23 1 PC UNION 1312010

TTS-NMF GmbH
SPARE PARTS LIST
HYDRAULIC MOTOR
SCM 017
PART-NO.: 5 006 080

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 1

1,2,3 FIGURE 1 SHAFT SEAL KIT M-012/-64 ISO 1 PC
4,5 FIGURE 2 KEY 1 PC
6,7,8,9 FIGURE 2 REPAIR KIT M-017 ISO FRONT 1 PC
10 FIGURE 3 PLUG G ½” 1 PC
11 FIGURE 3 ANGULAR HOUSING M-012/-34 1 PC
12 FIGURE 3 SPRING PIN M-012/-17 1 PC
13 FIGURE 3 CYLINDRICAL SCREW 8 PC
14 FIGURE 3 PLUG G ½” PLASTIC 1 PC
15 FIGURE 3 PISTON SC/-M 017/034 5 PC
16,17 FIGURE 4 REPAIR KIT M-017 ISO BACK 1 PC
18,19,20 FIGURE 5 SEAL KIT M-012/-34 ISO 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 2

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

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 3

4 0000091945* KEY 8x7x32 1 PC
5 0000091944* KEY 6x6x32 1 PC
6 0000050566* REPAIR KIT M-012/-17 ISO A F 1 PC
7 0000050567* REPAIR KIT M-012/-17 ISO B F 1 PC
8 0000050568* REPAIR KIT M-012/-17 ISO C F 1 PC
9 0000050569* REPAIR KIT M-012/-17 ISO D F 1 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 4

10 0000050337* PLUG G ½” 1 PC
11 0000030230* ANGULAR HOUSING M-012/-34 1 PC
12 0000020337* SPRING PIN M-012/-17 1 PC
14 0000091372* PLUG G ½” PLASTIC 1 PC
15 0000050280 PISTON SC/-M 017/034 5 PC
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 5

16 0000050491* REPAIR KIT M-017 ISO S B 1 PC L
17 0000050571* REPAIR KIT M-017 ISO K B 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 006 080
FIGURE 6

18 0000050547* REPAIR KIT M-012/-34 N ISO 1 PC L
19 0000050548* REPAIR KIT M-012/-34 H ISO 1 PC L
20 0000050549* REPAIR KIT M-012/-34 V ISO 1 PC L
L = ASSEMBLY GROUP
D = SEALING ELEMENT
* = FOREIGN NUMBER

TTS-NMF GmbH
SPARE PARTS LIST

ORDER NO. 5 011 312-00
DESCRIPTION: TECHNICAL DOKUMENTS

97.00.00.00.00 1 PC TECHNICAL DOKUMENTS 5011312
97.01.00.00.00 1 PC TECHNICAL DOKUMENTATION 5011313
97.01.01.00.00 1 PC DECK-CRANE 5327327 5327327

97.01.02.00.00 1 PC CRANE ARRANGEMENT 5327323 5327323
97.01.05.00.00 1 PC ASSEMBLY INSTRUCTION 5011306 5011306
97.25.00.00.00 1 PC ELECTRIC DOKUMENTATION 6011314
97.25.01.00.00 1 PC ELECTRIC DIAGRAM 5022372 5022372
97.66.00.00.00 1 PC HYDRAULIC DOKUMENTATION 5011315
97.66.01.00.00 1 PC HYDRAULIC DIAGRAM 5011156 5011156

97.66.02.00.00 1 PC LIST OF PARTS FOR HYDR. DIAGRAM 5011157 5011157
97.66.03.00.00 1 PC LIST OF HOSES 5011158 5011158
97.66.04.00.00 1 PC HYDRAULIC DIAGRAM ADDITIONAL 5011316 5011316
EQUIPMENT
97.66.05.00.00 1 PC LIST OF PARTS FOR HYDR. DIAGRAM 5011317 5011317
ADDITIONAL EQUIPMENT
97.66.06.00.00 1 PC LIST OF HOSES ADDITIONAL 5011318 5011318
EQUIPMENT

TTS-LMG Marine Cranes GmbH
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
SACH - NR. : / PART - NO. : 5 011 157 Index 00
AUFLISTUNG
LIST OF PARTS
zum
for
HYDRAULIKSCHEMA
HYDRAULIC DIAGRAM
SACH - NR. : / PART - NO. : 5 011 157
KRAN - TYP : / CRANE TYPE : KL 45T – 29M

BAU - NR. : / COMM. NO. : 83156, 83157, 83158, 83159
Auflistung z. Hydraulikschema Ident No. : 5 011 157

Bau 83156, 83157, 83158, 83159 22.08.20136 1/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Pos. im Hydro-Schema Menge Benennung LMG-Sach-Nr. Bemerkung
Type
Item in hydr. diagram Qty. Designation Ref.-No. Remarks
1.0 Hubwerk
Hoisting gear
2.0 Wippwerk
Luffing gear
3.0 Drehwerk
Slewing gear
4.0 Speiseölkreis
Feed oil circuit
5.0 Ölkühler-Kreislauf
Oil cooler circuit
6.0 Hydrauliköltank
Hydraulicoiltank
7.0 Füllhandpumpe
filling pump
8.0 Handpumpe für Notbetrieb
Manual pump for emergency operation

Bau 83156, 83157, 83158, 83159 22.08.20136 2/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
1.0 1 Hubwerk
Hoisting gear)
1.1 1 Verstellpumpe 5 007 001 A4VG 125 EP2DM1 / 32R
Var. displacement pump
1.5 1 Verstellmotor 2 532 117 A6VM 200 EP2D/63W
Var. displacement motor
1.15 1 Filter 1 637 770 14300-40299
Filter
1.16 1 Rückschlagventil 1 636 493 RHZ 16
Check valve
1.23 1 Drucksensor 5 002 899 HT-PD
Pressure sensor
1.24 1 3/2 Wegeventil Item in GS04-30-10N
3/2 Way valve 5 001 119
1.27 1 Druckschalter 5 010 113 0122-407-01-1-600 7 bar
Pressure switch
1.28

Bau 83156, 83157, 83158, 83159 22.08.20136 3/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
2.0 1 Wippwerk
Luffing gear
2.1 1 Verstellpumpe Pump 1 in A4VG 125 EP2DM1/32R
Var. displacement pump 2 530 269
2.2 1 Verstellpumpe Pump 2 in A4VG 28 EP2DM1 / 32R
Var. displacement pump 2 530 269
2.4 1 Durchtrieb is in
Flange 2 530 269
2.5 1 Axialkolbeneinheit 1 600 828 A2FM125 / 63W
Axial piston unit
2.15 1 Filter 1 637 770 14300-40299
Filter
2.16 1 Rückschlagventil 1 636 493 RHZ 16
Check valve
2.23 1 Drucksensor 5 002 899 HT-PD
Pressure sensor
3/2 Way valve 5 001 119
2.27 1 Druckschalter 5 010 113 0122-407-01-1-600 (7 bar)
Pressure switch
2.28

Bau 83156, 83157, 83158, 83159 22.08.20136 4/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
3.0 1 Drehwerk
Slewing gear
3.3 1 Durchtrieb 5 001 939 SAEB / B-B (K04)
Flange
3.4 3 Axialkolbeneinheit 5 005 460 F12-60
Axial piston unit
3.12 1 Druckschalter 5 010 113 0122-407-01-1-600 7bar
Pressure switch
3.13
3.15 1 Filter 1 637 770 14300-40299

Filter
3/2 Way valve 5 001 119
3.27 1 Druckschalter 5 010 113 0122-407-01-1-600 (7 bar)
Pressure switch
3.28

Bau 83156, 83157, 83158, 83159 22.08.20136 5/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
4.0 1 Speiseölkreislauf
Feed oil circuit
4.1 1 Speiseöl- und Steuerölpumpe Pump 1 in K3VL80
Feed and control oil pump 5 001 110
4.2 1 Drehstrommotor Motor in 9 kW, 440 V - 60Hz
three phase motor 5 001 110
4.3 1 E-Motor 5 012 805 160 kW 440V - 60Hz
Elect. motor
4.9 1 Steuerstation Filter 5 001 119 LT-10-88.0-K
control station filter.
4.9.1 1 Filter Item in 374A-3E50-TL110/123
Filter 5 001 119
4.9.1.1 1 Wartungsanzeige 1 654 621 FF 3468
Maintenance indicator
4.9.1.2 1 Filtereinsatz 0 690 443 370-L-110A
Filter cartridge
4.9.2 1 Drosselventil Item in NV08-20A-O-N
Throttle valve 5 001 119
4.24 1 3/2 Wegeventil 5 001 137
3/2 Way valve (Item in 5 001 119)

Bau 83156, 83157, 83158, 83159 22.08.20136 6/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
5.0 1 Ölkühler-Kreislauf
Oil cooler circuit
5.1 1 Kühlölpumpe Pump 2 in ALP3 A-D-94-S1-A
Cooling oil pump 5 001 110
5.3 1 Filter-Leckölblock 5 001 120 LT-35D38.1-K
Filter-leak oil block
5.3.1 1 Filter Item in 274-A-2N35-TL110/123
Filter 5 001 120
5.3.1.1 1 Filtereinsatz 2 548 583 270-L-123A
Filter cartridge
5.3.2 1 Rückschlagventil Item in Hy5300034 1 bar
Check valve 5 001 120
5.5 1 Temperatursensor 5 002 900
Temperature sensor
5.8 1 Ölkühler kompl. 5 010 440 507100064
Oil cooler compl.
5.8.2 1 E-Motor Item in IMB14C140-90L
Elect.-motor 5 010 440

Bau 83156, 83157, 83158, 83159 22.08.20136 7/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
5.8.3 1 Ölkühler Item in 507100064
oil cooler 5 010 440

Bau 83156, 83157, 83158, 83159 22.08.20136 8/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
6.0 1 Hydrauliktank
Hydraulictank
6.1 2 Ölstansanzeige 1 655 840 R1“ - 530
Oil gauge
6.2 1 Belüftungsfilter 0 156 729 BF 25 S130 – F00
Venting filter
6.3 1 Kugelhahn 1 367 718 KN 25.225 B1
Ball cock
6.4 1 Leitungsfilter 0 986 373 7SL45/21 P10 R-00P
Line filter
6.4.1 1 Filtereinsatz 0 303 628 8.7SL45/21 P10 P
Filter cartridge
6.5 1 Verschlußkupplung 1 335 578 DN19 Nr.. 05014
Locking coupling LP-019-0-WR 026
6.8 1 Kugelhahn 0 830 538 KN 25.312-B1
Ball cock

Bau 83156, 83157, 83158, 83159 22.08.20136 9/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
7.0 1 Füllhandpumpe 0 478 065
Manual filling pump

Bau 83156, 83157, 83158, 83159 22.08.20136 10/11
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
8.0 1 Handpumpe für Notbetrieb 5 001 738
Manual pump
(Lagerung im Store)
(To be kept in store)

Bau 83156, 83157, 83158, 83159 22.08.20136 11/11
Anschlußform der Schlaucharmatur

nach DIN 20078
Sach.-Nr.:
Part.-No.: 5 011 158 - 01 SCHLAUCHLISTE FÜR
HYDRAULIKSCHEMA Blatt:
List of hoses Hydraulic diagram
CH 90 1 von 4
Pos im Gegenstand / für / Ident Nr. /

Schema Object for Ident No
1.01 DN08x5350 -N/N90 -1SN TOWER 2 536 028
1.03 DN12x950 -P/P90 -1SN TOWER 2 072 987
1.05 DN16x1950 -N/N90 -1SN SCAFFOLD 2 536 015
1.07 DN20x1200 -N/N90 -1SN TOWER 2 028 319
1.08 DN25x1500 -N/N -1SN SCAFFOLD 5 004 813
1.09 DN32x7700 -S/S45 -4SH TOWER 2 536 001
1.10 DN32x7800 -S/S90 -4SH TOWER 2 536 002
1.11 DN10x5000 -N/N90 -1SN TOWER 2 536 127
2.01 DN08x4150 -N/N90 -1SN TOWER 2 072 985
2.02 DN12x1000 -P/P90 -4SP SCAFFOLD 2 536 226
2.03 DN12x1700 -P/P90 -1SN TOWER 2 072 988
2.07 DN20x1700 -N/N90 -1SN TOWER 4 221 028
2.09 DN32x7300 -S/S90 -4SH TOWER 2 535 921
2.10 DN32x7400 -S/S90 -4SH TOWER 2 536 000
Sach.-Nr.:
CH 90 2 von 4

3.01 DN08x5550 -N/N90 -1SN TOWER 2 072 986
3.02 DN06x1300 -N/N90 -1SN TOWER 2 072 984
3.03 DN06x4100 -N/N90 -1SN TOWER 5 004 972
3.09 DN20x1100 -N/N -1SN TOWER 2 072 990
3.10 DN20x700 -N/N -1SN TOWER 2 072 989
3.11 DN20x4500 -N/N90 -1SN TOWER 5 004 973
3.15 DN32x5850 -S/S -4SH TOWER 5 011 355
3.16 DN32x4850 -S/S90 -4SH TOWER 2 056 850
3.19 DN20x900 -S/S90 -4SH TOWER 2 072 993
3.20 DN20x900 -S/S90 -4SH TOWER 2 072 993
Sach.-Nr.:
CH 90 3 von 4

3.21 DN20x4700 -S/S90 -4SP TOWER 5 004 974
3.22 DN20x4700 -S/S90 -4SP TOWER 5 004 974
4.12 DN25x1800 -R/N90 -1SN SCAFFOLD 5 004 815
4.13 DN25x5800 -N/N90 -1SN TOWER 2 072 996
4.14 DN25x5600 -N/N90 -1SN TOWER 2 072 995
4.17 DN50x1000 -R/R90 -1SN SCAFFOLD 2 536 022
4.22 DN32x1050 -R90/N -1SN SCAFFOLD 2 536 025
Sach.-Nr.:
CH 90 4 von 4
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
AUFLISTUNG
LIST OF PARTS
zum
for
HYDRAULIKSCHEMA
HYDRAULIC DIAGRAM
SACH - NR. : / PART - NO. : 5 011 317
KRAN - TYP : / CRANE TYPE : KL 45T – 29M

BAU - NR. : / COMM. NO. : 83156, 83157, 83158, 83159

Bau 83156, 83157, 83158, 83159 22.08.20136 1/5
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
10 Hydraulik – Laststabilisierungswinde
Hydraulic – Tension winch drive
11.0 Hydraulik – Kabeltrommel
Hydraulic – cable drum drive

Bau 83156, 83157, 83158, 83159 22.08.20136 2/5
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________

Type
10.0 Hydraulik – Laststabilisierungswinde
10.1 1 Verstellpumpe 1 606 188 A10V28
10.1.1 1 Adapter 2 072 712 SAE-B (K02)
10.2 1 Ventilblock 5 001 121 LT30L36.0-K

Valve block
10.2.1 1 Druckfilter 175A-4N35-BL 110
Pressure filter
10.2.2 1 Kugelhahn BKH-DN10
Ball cook
10.2.3 1 Druckschalter 1652152 0163-407-01-1-025 / 20bar
Pressure switch
Ball cook
10.2.5 1 Rückschlagventil D02 B2 0,2N
Check-valve
10.2.6 1 Kugelhahn BKH-DN4-6
Ball cook

Bau 83156, 83157, 83158, 83159 22.08.20136 3/5
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
10.2.7 1 Druckbegrenzungsventil
Pressure relief valve
Ball cook
10.2.9 1 Rückschlagventil
Check-valve
10.3 1 Axialkolbeneinheit 5 006 079 M-012W/NI4AGK
Axial pisten unit

Bau 83156, 83157, 83158, 83159 22.08.20136 4/5
HYDRAULISCHE ANLAGE
_______________________________________________________________________________________________________________
Type
11.0 Hydraulik – Laststabilisierungswinde
Ball cook
11.2.2 1 4/2 Wegeventil EDH 12/42-08
4/2 way valve
11.2.3 1 Rückschlagventil D02 B2 2,1N 2,5bar
Check-valve
11.2.4 1 Druckbegrenzungsventil
Pressure relief valve
11.2.5 1 Kugelhahn M-012W/NI4AGK
Ball cook
Ball cook
10.3 1 Axialkolbeneinheit 5 006 080 M-017W/NI4AGK
Axial pisten unit

Bau 83156, 83157, 83158, 83159 22.08.20136 5/5
Anschlußform der Schlaucharmatur

nach DIN 20078
Sach.-Nr.:
Part.-No.: 5 011 318-01 SCHLAUCHLISTE FÜR
CH 90 1 von 3

10.01 DN20x4700 -N/N90 -1SN TOWER 2 536 856
10.02 DN06x500 -P90/N10L -1SN TOWER 5 006 204
10.03 DN08x3500 -N/N90 -1SN TOWER 2 536 856
10.04 DN12x3500 -P/P90 -1SN TOWER 2 536 152
10.05 DN12x5450 -P/P -1SN TOWER 5 011 353
10.06 DN112x3500 -P/P90 -1SN TOWER 2 536 152
10.07 DN12x5200 -P/P -1SN TOWER 2 536 143
10.08 DN08x5200 -N/N -1SN TOWER 2 536 134
10.09 DN16x1450 N/N90 -1SN TOWER 5 004 292
10.10 DN12x5200 -N/N -1SN TOWER 5 011 354
10.11 DN25x600 -N/R32 -SAE100R4 TOWER 5 004 288
10.12 DN16x950 -N/N90 -1SN TOWER 2 536 495
10.13 DN16x1400 N/R20 90° -1SN TOWER 5 004 291
10.19 DN08x5250 -N/N90 -1SN TOWER 2 536 029
10.20 DN12x5200 -P/P -1SN TOWER 2 536 143
10.21 DN112x5400 -P/P90 -1SN TOWER 5 011 353
10.22 DN12x1400 -P/P90 -1SN TOWER 2 536 581
10.23 DN12x1400 P/P90 -1SN TOWER 2 536 581
10.24 DN08x1400 -N/N90 -1SN TOWER 1 605 605
10.25 DN06x500 -P90/N10L -1SN TOWER 5 006 204
Sach.-Nr.:
CH 90 2 von 3

10.26 DN08x1600 -N/N90 -1SN TOWER 5 004 583
10.27 DN06x500 -P10S/N10L -1SN TOWER 5 004 588
Sach.-Nr.:
CH 90 3 von 3
TTS-NMF GmbH
83158 - ASSEMBLY INSTRUCTION
7. ASSEMBLY INSTRUCTION
Crane type: KL 45 T – 29 M
Crane No.: 83158
Date: 08.2013
TTS NMF GmbH

Biedenkamp 13b
D-21509 Glinde
Germany
Telephone: +49 40 554 361 833
Mobil +49 172 4511400
E-mail: dwiechern@nmf-crane.de
Please state the crane no. and type (see data plate) with all enquiries. PART – NO.: 5 011 306
ASSEMBLY INSTRUCTION 83158 83158 Ind. 00 / 10-2013 7-1

TTS-NMF GmbH
83158. . ASSEMBLY INSTRUCTION
ASSEMBLY INSTRUCTION
INDEX
7. ASSEMBLY INSTRUCTION 1
7.1 ASSEMBLY INSTRUCTION 2
7.2 ASSEMBLY AND PUTTING INTO SERVICE OF THE CRANE 3
7.3 PREPARATION OF FOUNDATION COLUMN 5
7.4 UNLOADING AND PUTTING UP CRANE TOWER 7
7.4.1 UNLOADING OF CRANE TOWER 7
7.4.2 PUTTING THE CRANE UPRIGHT 8
7.5 FILLING OF THE GEAR REDUCERS AND THE HYDRAULIC 9
7.6 MOUNTING OF CRANE TOWER 10
7.7 FITTING THE ACCESS LADDER INTO THE FOUNDATION COLUMN/CRANE
TOWER 11
7.8 SCHEMATIC DIAGRAM OF CONNECTION 11
7.9 FITTING THE JIB 12
7.10 REEVING OF ROPES 13
7.10.1 ROPE LAYOUT FOR LUFFING GEAR: 14
7.10.2 ROPE LAYOUT FOR MAIN HOISTING GEAR: 14
7.10.3 ROPE LAYOUT FOR LOADSTABILIZING GEAR AND CABLE 15
7.10.4 HOISTING AND LUFFING ROPE END FASTENINGS ON THE WINCHES: 16
7.10.5 HOISTING AND LUFFING ROPE END FASTENINGS ON CRANE AND JIB 16
7.11 ASSEMBLY OF THE COMPLETE CRANE 17
7.12 FITTING THE REMAINING PLATES 18
7.13 INSTALLATION OF REMAINING COMPONENTS 18
7.14 LUBRICANTS RECOMMENDATION 19
7.15 TERMINAL CONNECTING PLAN 20
7-2 Ind. 00 / 10-2013 83158 ASSEMBLY INSTRUCTION 83158

TTS-NMF GmbH
ASSEMBLY AND PUTTING INTO SERVICE OF THE CRANE

The following instructions will enable the yard personnel to erect the crane and prepare it for commissioning.
The duration and the scope of work to be performed by TTS-LMG Marine Cranes GmbH personnel are
defined in the supply contract. Any extra cost exceeding the contract provisions shall be borne by the con-
tract partner having incurred such cost.
It is therefore in the yard’s own interest to ensure that erection and commissioning of the crane proceed
smoothly and make the respective preparations beforehand.
FOR THE ERECTION, THESE PREPARATIONS ARE:
7.2.1 The foundation column upper part to be welded to the foundation column lower part following the
weld seam preparation and in accordance with the actualfoundation column drawing.
Execution and testing of all weld seams in conformity with the rules and regulations of the respective
classification society, and to the satisfaction and with the approval of the local inspector of that
society.
7.2.2 It is imperative to keep the planeness specified in chapter 7.3 when welding the foundation column
upper part. Check that planeness is correct.
7.2.3 0,6 Mpa (6bar) air supply shall be available for the erection tools.
7.2.4 Crane capacities to cope with the loads mentioned in the erection instructions shall be available.
7.2.5 A horizontal support must be provided for the jib.
7.2.6 Work platforms for tightening the fastening screws should be prepared.
7.2.7 A trestle or a rotary plate for picking up the rope spools and a auxiliary rope (250m) as well as a rope
stocking shall be provided.
7.2.8 The ship’s mains for uninterrupted current supply to the crane is operative.
7.2.9 The ship can be ballasted if necessary, in order to allow mounting the crane on an even keel.
FOR PUTTING THE CRANE INTO SERVICE AND FOR THE ACCEPTANCE TESTS, IT SHOULD BE
ENSURED THAT:
7.2.10 The ship’s mains for uninterrupted current supply to the crane is operative.
7.2.11 The ship can be ballasted if necessary, in order to allow mounting the crane on an even keel.
7.2.12 The hatch covers can be opened if requested, in order to be able to set the bottom position of the
hook.
ATTENTION:
It should be ensured that no current is led over the slewing assembly or other bearings when welding.
The ground connection is to be made immediately next to the point of welding in order to avoid any damage
to the electronic components.

TTS-NMF GmbH
7.2.13 YARD SCOPE OF WORK
- Putting the crane tower upright - raising it from the horizontal into the vertical position
- Assembling the slipring body including making of all electrical connections to the ship and the
crane tower
- Fitting the venting mushrooms to the gear reducers and the hydraulic oil tank, filling in oil if
necessary
- Putting the crane (crane tower) on the foundation column
- Bolted connection between crane tower and foundation column
- Bolted connection between crane tower and jib
- Assembly of access ladder
- Assembly and electrical connection of jib light, switch, inside lighting and possible further deck
lights and additional lanterns
- Reeving the hoisting and the luffing ropes
- Making ready of test weight acc. to test programme
- Lubricating work acc. to lubrication plan (see operating manual)
- Preparation of vessel for functional and overload tests
- Acceptance by classification society
7.2.14 TTS-NMF SCOPE OF WORK
- General erection supervision

- Commissioning of the crane
- Setting the limit switches
- Carrying out functional tests in accordance with test program
CONTACT TTS-NMF GMBH WELL AHEAD OF TIME TO REQUEST

DELEGATION OF TTS-LMG PERSONNEL.:
TTS NMF GmbH

Biedenkamp 13b
D-21509 Glinde
Germany
Telephone: +49 40 554 361 833
Mobil +49 172 4511400
E-mail: dwiechern@nmf-crane.de
Please state the crane no. and type (see data plate) with all enquiries.

TTS-NMF GmbH
PREPARATION OF FOUNDATION COLUMN

- Clean and degrease contact surfaces (fig. 2) (free from grease, rust and paint residues).
The contact surface for the slewing assembly must be cleaned over the entire circumference.
On the bottom, only the contact surfaces for washers need to be cleaned.
Fig. 2
- Check evenness with ruler over the entire diameter. Inform TTS-LMG if the
evenness indicated in fig. 3 is not kept.
- Fit slip - ring body and connect to ship’s system and to the crane tower.See.
terminal connecting plan ref. no. 5 022 372 in Appendix. Holes for entering the
cables for connection to the ship’s mains will have to be made in the bottom
locking plates of the slipring body(cable inlets are not TTS-LMG supply). The
diameters of the bore holes depend on the cable diameters and
consequently, the cable gland diameters. The number of cables to be
connected can be seen on the connecting plan in the annex. Glue plates on
the slipring body (cf. fig.3) before connecting it. The slipring body is best
positioned by lowering it through the access hatch in the foundation column
intermediate floor before the crane is erected. It is then bolted to the
intermediate floor from below (fig. 4).
- Put access ladder (fig. 3) and fastening material for erection of the crane into
the foundation column before the crane tower is put on. The ladder is fitted
after the deck crane has been mounted on the foundation column.

TTS-NMF GmbH
Fig. 3
Fig. 4
Fig. 5

TTS-NMF GmbH
UNLOADING AND PUTTING UP CRANE TOWER

Timbers for unloading the crane tower and putting it upright should be adequately dimensioned.
Timbers should provide an even surface when the tower is put upright so that contact is close.
7.1.1 UNLOADING OF CRANE TOWER
Fig. 6

TTS-NMF GmbH
7.1.2 PUTTING THE CRANE UPRIGHT
Fig. 7
Fig. 8

TTS-NMF GmbH
FILLING OF THE GEAR REDUCERS AND THE HYDRAULIC

Remove blind plugs from gear reducers (hoisting, luffing and slewing gear reducer) and from hydraulic tank.
Replace by respective venting mushrooms (fig.9). Check the fillings and top up, if necessary.
Fillings: Main hoisting gear winch: 1x 16 Litres

Loadstabilizing winch: 1x 0,5 Litres
Luffing gear winch: 1x 16 Litres
Slewing gear reducer 3 pces a12 Ltr. 36 Litres
Cable drum 5 Litres Syntethic oil
Hydraulic tank 1x 500 Litres
remaining hydr. equipment 1x 70 Litres
Fig. 9

TTS-NMF GmbH
MOUNTING OF CRANE TOWER

 Lift the crane tower above the foundation column, distance abt. 5-10mm. Position bore holes on top
of one another with the help of guide mandrils and screw in the stud bolts. All stud bolts must have
been screwed in before the crane tower is put on fully.
Before hinge the tower, assembly the locking device segments
 Set the dimension for screwing-in the stud bolts acc. to fig. 10.
 Before unslinging the crane tower from the erection crane, all stud bolts must be screwed in, and
each stud bolt on the circumference must have been tightened with an impact screw driver.
 After completion of the erection the pre-stressing force on all the bolts is checked once again, drive out
the locking pins and re-tightened if necessary.
 After the tower has been taken from the erection crane, the bolts are lengthened with the specified
pre-stress crosswise (see fig. 10).
NOTE:
Place down crane tower in a way to allow jib to be put into the support.
Fig. 10

TTS-NMF GmbH
FITTING THE ACCESS LADDER INTO THE FOUNDATION

COLUMN/CRANE TOWER
Weld the ladder with the fastening plates to the bottom of the crane tower base plate.
Weld the pin for driving the slipring body after adjusting it.
Fig. 11
SCHEMATIC DIAGRAM OF CONNECTION

After the crane tower and the ladder have been fitted, the supply cables having come up into the tower are
led to the slipring body and the light switch over the ladder string piece (fig.11). The cables are then cut to
the correct size and connected to the slipring body fitted with cables lugs. (Connecting diagram ref. no.
5 022 372 in the annex). After erection work has been completed and tests have been successfully conclu-
ded, the slipring body must be sealed by grouting it in.
Fig. 12

TTS-NMF GmbH
FITTING THE JIB

Before mounting the jib, the jib and alarm lamps must be installed and electrically connected. If there is no jib
rest on board the ship, a provisional support must be made.
The jib bearings have already been fastened on the crane tower, therefore the jib will only have to be fitted to
the bearings (fig.13). The contact surfaces (fig. 14) must be cleaned and degreased (free from grease, rust,
and paint residues). The thread and the contact surfaces of the fastening screw heads must be greased
with MOS2.
Fig. 13
Fig. 14

TTS-NMF GmbH
After jib has been fitted, electrical connections must be made. The cables on the jib must all be guided to the
distributor boxes near the jib bearing on the crane tower (fig. 15) and connected there. Earthing must also be
installed between jib and crane tower. See connecting diagram ref. no. 5002270 in the annex.
Distributot box earthing
Cable connection
Fig. 15
REEVING OF ROPES
Use a thin auxiliary rope (abt. 250 m) attached to the hoisting and luffing ropes for reeving the ropes in. Pull
at the auxiliary rope until the hoisting or luffing rope reaches the rope drum, starting with the luffing rope. The
hook block should be in upright position when the hoisting rope is reeved in.
2 Luffing rope 34x185m long
1 Hoisting rope 34x207m long
ATTENTION!
Pull ropes off the reel, otherwise they might twist.
Fig. 16

TTS-NMF GmbH
7.1.3 ROPE LAYOUT FOR LUFFING GEAR:
Fig. 17
7.1.4 ROPE LAYOUT FOR MAIN HOISTING GEAR:
Fig. 18

TTS-NMF GmbH
7.1.5 ROPE LAYOUT FOR LOADSTABILIZING GEAR AND CABLE
Electro cable
Y
Rope loadstabilizing 10
W
DETAIL Y
Cabel
Rope loadstabilizing
Fig. 20

TTS-NMF GmbH
7.1.6 HOISTING AND LUFFING ROPE END FASTENINGS ON THE WINCHES:

After the ropes have been reeved in and fastened acc. to fig. 20, fit screw retention (retention wire through
screw heads).
5 hex. Socket head cap srews M20-8.8

distributed over circumference Z
tightening torque Ma = 385Nm
fig. 21
7.1.7 HOISTING AND LUFFING ROPE END FASTENINGS ON CRANE AND JIB
Beat sleeves into rope thimbles before fitting thimbles on the pin
Hoisting rope end fastening

on crane tower hexagon screw ISO 4014 – M10x125
adjusting ring
sleeve
Luffing rop end fastening

on Jib
Fig. 22

TTS-NMF GmbH
ASSEMBLY OF THE COMPLETE CRANE

In case the crane is pre-assembled on the quayside, proceed as follow:
1. Put the crane tower upright acc. to items 3.0 – 3.2 of these assembly instructions.
2. Fill the gearboxes and the hydraulic plant with oil acc. to item 4.0 (if this has not been
done before delivery.
3. Fit the jib acc. to item 8.0
4. Reeve in the hoisting and luffing rope acc. to item 9.0
After pre-assembly has been completed, see to all the preparatory work described under
item 2.0.
Slinging crane to yard crane:

Main slinging point is a 50t-eye of the crane tower.
In addition, 2 slinging ropes for the two eyes on the jib are needed for balancing the crane
when it is put on the foundation column(see fig. 22].
Fig. 23
Assembly crane acc. to items 5.0 to 7.0

Work off items 11.0 and 13.0.

TTS-NMF GmbH
FITTING THE REMAINING PLATES

Plates installed at the inside door foundation column
fig. 24
Plate installed the wall closed by

hatchcover
Fig. 25
INSTALLATION OF REMAINING COMPONENTS

The fire extinguisher and the rope-down device will be installed in the crane driver’s cabin right at the end of
the erection.

TTS-NMF GmbH
LUBRICANTS RECOMMENDATION
Fig. 26

TTS-NMF GmbH
TERMINAL CONNECTING PLAN

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS-NMF GmbH

TTS 83158 englisch Operating Instruction+Spare Parts List - копия PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

TTS 83158 englisch Operating Instruction+Spare Parts List - копия PDF

Загружено:

Авторское право:

Доступные форматы

TTS NMF GmbH

SINGLE DECK CRANE KL 45T – 29M

TTS YARD-NO. : 83158

TTS NMF GmbH

© Copyright by TTS-LMG Printed in Germany

5. SPECIFICATION OF THE ELECTRICAL

6. SPARE PARTS LIST

PREFACE 83158 83158 Ind. 00 / 10-2013 1-1

1-2 Ind. 00 / 10-2013 83158 PREFACE 83158

PREFACE 83158 83158 Ind. 00 / 10-2013 1-3

TTS NMF GmbH

1-4 Ind. 00 / 10-2013 83158 PREFACE 83158

1.2 SAFETY REGULATIONS – GENERAL REMARKS

PREFACE 83158 83158 Ind. 00 / 10-2013 1-5

1.3 EXPLANATION OF SAFETY SIGNS

1.3.1 PROHIBITION SIGNS

Fire, exposed flame and smoking prohibited Do not operate switch

No unauthorised access Prohibited for persons with pacemaker

1.3.2 WARNING SIGNS

Warning of hanging load Warning of electro – magnetic field

Warning of high voltage Danger of falling

1.3.3 MANDATORY SIGNS

Wear eye protection Wear safety gloves Wear safety protection

Wear safety helmet Wear safety boots Wear ear protection

PREFACE 83158 83158 Ind. 00 / 10-2013 1-7

1.3.4 RESCUE SIGNS

First aid Fire extinguisher

1-8 Ind. 00 / 10-2013 83158 PREFACE 83158

1.4 SAFETY DEVICES – GENERAL REMARKS

1.4.3 LIMIT SWITCHES

1.4.4 SAFETY DEVICES

THE CHECKS MUST CONSIST OF AN INSPECTION AND A FUNCTION CHECK.

PREFACE 83158 83158 Ind. 00 / 10-2013 1-9

1.5 SAFETY REGULATIONS

1.5.1 FIRE EXTINGUISHING SYSTEM / FIRE EXTINGUISHERS

Portable fire extinguishers: dry powder extinguishers

Extinguishing agent: 5 kg ABC powder

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 CASE OF FIRE:

Move to a Warn endangered persons. Remove the injured and

1-10 Ind. 00 / 10-2013 83158 PREFACE 83158

FIRE EXTINGUISHING SYSTEM/FIRE EXTINGUISHERS

RULE NO. 1 IN FIREFIGHTING IS:

SAVING HUMAN LIFE IS MORE IMPORTANT THAN FIGHTING THE FIRE.

CORRECT USE OF FIRE EXTINGUISHERS:

PREFACE 83158 83158 Ind. 00 / 10-2013 1-11

1.5.2 OPERATING INSTRUCTION FOR EMERGENCY EXIT WITH

TAKE SAFETY HARNESS OUT OF BAG AT THE CABIN WALL.

TAKE LEVER BRAKE OUT OF THE BAG

HINGE THE GRATING UP FORWARD AND OPEN BOTTOM

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

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

Replace rope after 4-5 years

1-12 Ind. 00 / 10-2013 83158 PREFACE 83158

DESCRIPTION 83158 83158 Ind. 00 / 10-2013 2-1

2.1.1 CRANE TOWER

2.1.2 CRANE CABIN

2.1.4 SLEW ASSEMBLY

2.1.5 HYDRAULIC SYSTEM

2.1.6 HOISTING AND LUFFING GEARS