NMF

Instruction manual
Deck crane

Type: DK II 60016/40025/34028

Order no.: 80449

Build no.: 786

Year of construction: 2007

Edition 1. 12. 2007

Neuenfelder Maschinenfabrik GmbH

Neuenfelder Fährdeich
21129 Hamburg
Tel.: 040 / 7451102
Fax: 040 / 74511867
e-mail: info@nmf-crane.de
Internet: www.nmf-crane.com
 Instruction Manual
Board crane type DK II NMF
Table of contents
1. December, 2007

1 About this instruction manual

1.1 ......................Manufacturer ..................................................................................................... 1-9
1.2 ......................Operator's duty of care ...................................................................................... 1-9
1.3 ......................Terms, abbreviations and symbols.................................................................. 1-10
1.4 ......................Technical changes .......................................................................................... 1-11
1.5 ......................Guarantee ....................................................................................................... 1-11
1.6 ......................Copyright ......................................................................................................... 1-11
1.7 ......................Hydraulic symbols ........................................................................................... 1-13
1.7.1...............Pumps/ Hydro motors...................................................................................... 1-13
1.7.2...............Cylinders ......................................................................................................... 1-13
1.7.3...............Way valves ...................................................................................................... 1-14
1.7.4...............Triggering type for way valves......................................................................... 1-15
1.7.5...............Throttling way valves ....................................................................................... 1-16
1.7.6...............Pressure valves ................................................................................................ 1-17
1.7.7...............Flow control valves.......................................................................................... 1-18
1.7.8...............Non-return valves ............................................................................................ 1-18
1.7.9...............Pipe connections ............................................................................................. 1-19
1.7.10............. Others ............................................................................................................ 1-19
2 Safety
2.1 ......................Intended use...................................................................................................... 2-1
2.2 ......................General safety instructions ................................................................................ 2-1
2.3 ......................Personnel requirements .................................................................................... 2-1
2.4 ......................Symbols on the crane........................................................................................ 2-1
2.5 ......................Warning signals during crane operation............................................................ 2-1
2.6 ......................Safety devices on the crane and functional tests thereof.................................. 2-2
2.6.1...............Control levers .................................................................................................... 2-2
2.6.2...............Pressure switches ............................................................................................. 2-2
2.6.3...............Hoisting gear pressure sensor .......................................................................... 2-2
2.6.4...............Hydraulic overload protection............................................................................. 2-3
2.6.5...............Limit switches .................................................................................................... 2-3
Neuenfelder Maschinenfabrik GmbH

2.7 ......................Hazards and behaviour in case of danger......................................................... 2-3

2.7.1...............Noise hazards ................................................................................................... 2-3
2.7.2...............Hazards stemming from "residual" energies: .................................................... 2-3
2.7.3...............Behaviour in case of danger.............................................................................. 2-4
2.7.4...............Behaviour in critical situations ........................................................................... 2-4
2.7.5...............Emergency exit.................................................................................................. 2-4

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NMF Board crane type DK II

3 Crane description
3.1...................... Technical data ................................................................................................... 3-1
3.2...................... .Construction...................................................................................................... 3-3
3.2.1 .............. General .............................................................................................................. 3-4
3.2.2 .............. Pump unit........................................................................................................... 3-4
3.2.3 .............. Hoisting gear...................................................................................................... 3-4
3.2.4 .............. Luffing gear........................................................................................................ 3-4
3.2.5 .............. Slewing gear ...................................................................................................... 3-4
3.2.6 .............. Gear oil cooler ................................................................................................... 3-4
3.2.7 .............. Hydraulic oil coolers........................................................................................... 3-5
3.2.8 .............. Heating .............................................................................................................. 3-5
3.2.9 .............. Slack rope switch............................................................................................... 3-5
3.2.10 ............ Gear cam limit switch......................................................................................... 3-5
3.2.11 ............ Slip ring assembly.............................................................................................. 3-5
3.2.12 ............ Load measurement system ............................................................................... 3-6
3.2.13 ............ Pressure transducer .......................................................................................... 3-6
3.3...................... Hydraulic functions ............................................................................................ 3-7
3.3.1 .............. General .............................................................................................................. 3-7
3.3.2 .............. Starting the pump unit........................................................................................ 3-7
3.3.3 .............. Ventilation .......................................................................................................... 3-7
3.3.4 .............. Heating / cooling ................................................................................................ 3-7
3.3.5 .............. Electro-hydraulic control system functionality ................................................... 3-8
3.3.6 .............. Hoisting gear..................................................................................................... 3-10
3.3.6.1 ...... Idling ................................................................................................................. 3-10
3.3.6.2 ...... Hoisting the 60t nominal load ........................................................................... 3-10
3.3.6.3 ...... Hoisting the 40t nominal load ........................................................................... 3-10
3.3.6.4 ...... Fast speed (0-22t) ............................................................................................ 3-10
3.3.6.5 ...... Lowering the load ............................................................................................. 3-10
3.3.6.6 ...... Hydraulic overload disconnect.......................................................................... 3-12
3.3.7 .............. Luffing gear...................................................................................................... 3-12
3.3.7.1 ...... "Luffing up" ...................................................................................................... 3-12
3.3.7.2 ...... "Luffing down" .................................................................................................. 3-12
3.3.8 .............. Slewing gear .................................................................................................... 3-13
3.3.8.1 ...... Slewing "right" - "left" ........................................................................................ 3-13
3.4...................... Electrical equipment ........................................................................................ 3-15
3.4.1 .............. Electronic regulator cards ................................................................................ 3-15
3.4.1.1 ...... 4-channel current regulator card....................................................................... 3-15
3.4.2 .............. Fault indicator cards ......................................................................................... 3-18
3.4.3 .............. Switches in the switch box................................................................................ 3-19
3.4.3.1 ...... "TEST OPERATION" switch ............................................................................. 3-19
3.4.3.2 ...... "RESET" switch ................................................................................................ 3-19

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Board crane type DK II NMF
3.4.3.3 ......."BRIDGE HOISTING GEAR BRAKE PRESSURE SENSOR" switch .............. 3-19
1. December, 2007

3.4.3.4 ......."BRIDGE LUFFING GEAR BRAKE PRESSURE SENSOR" switch ................ 3-19
3.4.3.5 .......„TEST LOAD" switch ........................................................................................ 3-19
3.4.4...............Jib winch, hoisting winch and auxiliary hoisting winch speed monitoring........ 3-19
3.4.5...............Brake relay monitoring .................................................................................... 3-20
3.5 ......................Test operation ................................................................................................. 3-23
3.5.1...............Testing the current regulator cards during test operation:............................... 3-23
3.5.2...............Testing the brake release potentiometer and solenoid valve: ......................... 3-23
3.6 ......................Load master/load measurement system (DMSA) ........................................... 3-25
3.7 ......................PS2-200 Compact PLC ................................................................................... 3-29
3.7.1...............Construction .................................................................................................... 3-29
3.7.2...............Elements ......................................................................................................... 3-29
3.7.3...............Setting the bus termination resistors ............................................................... 3-31
3.7.4...............Operating states of the PLC ............................................................................ 3-32
3.7.5...............Test/initial operation ........................................................................................ 3-34
4 Operation
4.1 ......................Safety instructions ............................................................................................. 4-1
4.2 ......................Personnel requirements .................................................................................... 4-1
4.3 ......................Operating range of the crane ............................................................................ 4-2
4.4 ......................Operation........................................................................................................... 4-3
4.4.1...............Crane cab.......................................................................................................... 4-3
4.4.2...............Control panels ................................................................................................... 4-4
4.5 ......................Starting up ......................................................................................................... 4-6
4.5.1...............Before starting up .............................................................................................. 4-6
4.5.2...............Switching on ...................................................................................................... 4-6
4.5.3...............During operation................................................................................................. 4-7
4.5.4...............Setting the load steps........................................................................................ 4-7
4.5.5...............Switching on 0-22t fast speed ........................................................................... 4-7
4.6 ......................Switching off ...................................................................................................... 4-8
4.7 ......................Emergency shutdown of the crane.................................................................... 4-8
5 Maintenance and repair
5.1 ......................General safety instructions ................................................................................ 5-1
5.1.1...............Prior to maintenance and repair ........................................................................ 5-1
Neuenfelder Maschinenfabrik GmbH

5.1.2...............When working on electrical equipment.............................................................. 5-1

5.1.3...............When working on hydraulic systems and equipment ........................................ 5-1
5.1.4...............Environmental protection................................................................................... 5-1
5.1.5...............After maintenance and repair ............................................................................. 5-2
5.1.5.1 .......Before starting the crane, do the following: ........................................................ 5-2
5.1.6...............Personnel requirements .................................................................................... 5-2
5.1.6.1 .......When working on electrical equipment............................................................... 5-2
5.1.6.2 .......When working on hydraulic equipment .............................................................. 5-2

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NMF Board crane type DK II

5.1.7 .............. Functional check and safety inspection ............................................................. 5-2

5.2...................... Maintenance schedule....................................................................................... 5-4
5.3...................... Lubricant table ................................................................................................... 5-8
5.4...................... Lubrication chart ................................................................................................ 5-9
5.4.1 .............. Symbols ............................................................................................................. 5-9
5.4.2 .............. Lubrication schedule......................................................................................... 5-10
5.5...................... Images of the lubrication points ....................................................................... 5-11
5.5.1 .............. Door hinge lubrication points ............................................................................ 5-12
5.5.2 .............. Electric motor.................................................................................................... 5-13
5.5.3 .............. Slewing ring ..................................................................................................... 5-13
5.5.4 .............. Jib sheaves....................................................................................................... 5-14
5.5.5 .............. Crane housing sheaves ................................................................................... 5-14
5.5.6 .............. Bottom hook block ........................................................................................... 5-15
5.5.7 .............. Slewing gear .................................................................................................... 5-16
5.5.8 .............. Winch................................................................................................................ 5-17
5.6...................... Maintenance and repair ................................................................................... 5-18
5.6.1 .............. Crane cleaning................................................................................................. 5-18
5.6.2 .............. Lubrication ....................................................................................................... 5-18
5.6.3 .............. Changing the oil............................................................................................... 5-18
5.6.4 .............. Gearbox ........................................................................................................... 5-18
5.6.5 .............. Gearbox inspection.......................................................................................... 5-18
5.6.6 .............. Pump drive unit................................................................................................ 5-19
5.6.7 .............. Filters ............................................................................................................... 5-20
5.6.7.1 ...... Gear oil cooler filter........................................................................................... 5-20
5.6.7.2 ...... Changing the hydraulic oil ................................................................................ 5-20
5.6.7.3 ...... Changing the hydraulic oil filter......................................................................... 5-20
5.6.8 .............. Bottom hook block ............................................................................................ 5-23
5.6.9 .............. Slewing ring ...................................................................................................... 5-24
5.6.10 ............ Slip ring assembly............................................................................................ 5-27
5.6.11 ............ Slack rope switch apparatus............................................................................ 5-28
5.7...................... Rope maintenance, care and discard criteria .................................................. 5-29
5.7.1 .............. Cleaning and greasing of ropes....................................................................... 5-29
5.7.2 .............. Monitoring ........................................................................................................ 5-29
5.7.3 .............. Rope replacement ........................................................................................... 5-31
5.7.4 .............. Discard criteria................................................................................................. 5-31
5.8...................... Disc brake........................................................................................................ 5-35
5.8.1 .............. Description....................................................................................................... 5-35
5.8.2 .............. Connections..................................................................................................... 5-35
5.8.3 .............. Pressure media................................................................................................ 5-37
5.8.4 .............. Operation ......................................................................................................... 5-37
5.8.5 .............. Manually lifting in emergencies........................................................................ 5-37

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Board crane type DK II NMF
5.8.6...............Brake maintenance ......................................................................................... 5-37
1. December, 2007

5.8.7...............Dismounting and mounting.............................................................................. 5-37

5.8.8...............Malfunctions .................................................................................................... 5-39
5.9 ......................Lifting the brakes in an emergency ................................................................. 5-40
5.9.1...............Hoisting gear ................................................................................................... 5-40
5.9.1.1 .......Connect the brake lift hand pump as follows:................................................... 5-42
5.9.2...............Jib..................................................................................................................... 5-43
5.9.3...............Slewing gear.................................................................................................... 5-43
5.10 ....................Gear cam limit switch ...................................................................................... 5-47
5.10.1.............Limit switch settings ......................................................................................... 5-48
5.10.2.............The following steps need to be taken:............................................................. 5-48
5.11 ....................How do I replace a PLC? ................................................................................ 5-53
5.11.1.............Changing the battery ....................................................................................... 5-53
6 Spare parts
6.1 ......................Ordering spare parts ......................................................................................... 6-1
6.1.1...............How to order spare parts .................................................................................... 6-2
6.2 ......................Spare parts ........................................................................................................ 6-3
7 Table of figures
8 Spare parts catalogue
9 Drawings + parts lists
Neuenfelder Maschinenfabrik GmbH

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NMF Board crane type DK II

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Board crane type DK II NMF

Illustrations
1. December, 2007

Fig. 1 Overview ............................................................................................. 3-3

Fig. 2 Pump diagram ..................................................................................... 3-9
Fig. 3 Half load functionality ....................................................................... 3-11
Fig. 4 Current regulator card ....................................................................... 3-15
Fig. 5 Fault indicator card............................................................................ 3-18
Fig. 6 Switches ............................................................................................ 3-21
Fig. 7 Control lever diagram ........................................................................ 3-24
Fig. 8 Load master ...................................................................................... 3-26
Fig. 9 Indicator display ................................................................................ 3-27
Fig. 10 Operating range of the crane .............................................................. 4-2
Fig. 11 Crane cab............................................................................................ 4-3
Fig. 12 Right control panel .............................................................................. 4-4
Fig. 13 Left control panel................................................................................. 4-5
Fig. 14 Roof hatch grease nipple .................................................................. 5-12
Fig. 15 E-Motor.............................................................................................. 5-13
Fig. 16 Gear rim ............................................................................................ 5-13
Fig. 17 Sheave Jib......................................................................................... 5-14
Fig. 18 sheave crane upperpart .................................................................... 5-14
Fig. 19 Bottom hook block............................................................................. 5-15
Fig. 20 Slewing gear...................................................................................... 5-16
Fig. 21 Winch ................................................................................................ 5-17
Fig. 22 Filters................................................................................................. 5-22
Fig. 23 Slack rope switch .............................................................................. 5-28
Fig. 24 Brake components ............................................................................ 5-35
Fig. 25 Disc brake ......................................................................................... 5-36
Fig. 26 .......................................................................................................... 5-38
Fig. 27 By-pass ball cock .............................................................................. 5-41
Fig. 31 Solenoid valve block connections ..................................................... 5-44
Fig. 32 Brake lift hand pump ......................................................................... 5-45
Fig. 33 Multi-function valve............................................................................ 5-46
Fig. 34 Cam switch........................................................................................ 5-47
Fig. 35 Hoisting gear limit switch settings ..................................................... 5-50
Neuenfelder Maschinenfabrik GmbH

Fig. 36 Luffing gear limit switch settings........................................................ 5-51

Fig. 37 Jib position ........................................................................................ 5-52
Fig. 38 Pump unit ............................................................................................ 7-1
Fig. 39 Load measurement system ( siehe Seite 11, Absatz 2.18) ...................... 7-2
Fig. 40 Crane cabin emergency exit................................................................ 7-3
Fig. 41 Fault indicator card.............................................................................. 7-4
Fig. 42 Current regulator card ......................................................................... 7-5
Fig. 43 Gear oil cooler ..................................................................................... 7-6
Fig. 44 Reset - test - test load switches .......................................................... 7-7

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NMF Board crane type DK II

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Board Crane type DK II NMF
1 About this instruction manual
December, 2007

1.1 Manufacturer
The manufacturer of this crane is NMF Neuenfelder Maschinenfabrik GmbH.
The address is:
NMF Neuenfelder Maschinenfabrik GmbH
Neuenfelder Fährdeich 120
21129 Hamburg
You can contact us at:
Telephone +49 40 7451-102
Fax +49 40 7451-1867
E-mail info@nmf-kran.de

1.2 Operator's duty of care

The operator must ensure that:
• The crane is only used in accordance with its intended purpose ( siehe Seite 2-1, Absatz
2.1).
• The crane is only operated in a fault-free, fully functional condition,
• The safety devices are checked at regular intervals to verify their operational reliability,
• Personal protective clothing and equipment are provided for the operating, maintenance
and repair personnel, and that these are worn and/or used,
• The instruction manual is always complete and legible, and available at the crane's
usage site,
• Only sufficiently qualified and authorised personnel operate, maintain and repair the
crane,
• This personnel is regularly trained in all pertinent aspects of operational safety and envi-
ronmental protection and is familiar with the instruction manual and, in particular, the
safety instructions included in this manual,
• All safety instructions and warning notices on the crane are legible and have not been
removed.
In addition to the operating manual, operating instructions relating to the Framework Direc-
tive on Health and Safety at Work and the Use of (Work) Equipment Directive are also to be
provided.
Neuenfelder Maschinenfabrik GmbH

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 Instruction manual
NMF Board Crane type DK II

1.3 Terms, abbreviations and symbols

All numbers in square brackets correspond to the circled numbers in the hydraulic diagram.
The terms used in this instruction manual are explained in (see page 1-10, Table 1).

Term / abbreviation Meaning

NMF Neuenfelder Maschinenfabrik GmbH

Operator Company or person responsible for use of the crane

Table 1: Terms and abbreviations

Together with the safety instructions, the safety symbols are intended to draw attention to
residual risks when handling the crane. These residual risks are related to:
• People
• The crane
• Other objects and items
• The environment.
This instruction manual makes use of the safety symbols described in (see page 1-10, Table
2).

Symbols Explanation

NOTE
Information that is important for operating this product.

CAUTION
Hazards that can damage the equipment and/or other crane sys-
tem components, but which do not pose a threat to life and limb

DANGER
Hazards that pose a threat to life and limb, and/or additional haz-
ards that can damage the equipment and/or other crane system
components.

Table 2: Symbols

Please note that a safety symbol can never replace the text of safety instructions. For this
reason, always read the safety instructions fully and thoroughly!

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Board Crane type DK II NMF
1.4 Technical changes
December, 2007

For safety reasons, no unauthorised changes are to be made to the crane - this also applies
to welding work on load bearing parts. All planned changes must be approved in writing by
Neuenfelder Maschinenfabrik GmbH.
We reserve the right to implement technical changes that improve this product. There may
be slight differences between the illustrations in this instruction manual and the actual
design.

1.5 Guarantee
Unless otherwise stipulated in the contract, any warranty claims shall be dealt with in
accordance with the Neuenfelder Maschinenfabrik GmbH "General Terms and Conditions
for Supplies and Services", which became applicable at the time the contract was con-
cluded.
The Neuenfelder Maschinenfabrik GmbH guarantee will become void if:
• The product is modified without our consent,
• This instruction manual is disregarded,
• Replacement parts or additional devices not supplied or approved by us have been fit-
ted or removed,
• The crane is overloaded, e.g. the load capacity is exceeded,
• The crane is not used in accordance with its designed purpose, e.g. oblique hoisting,
• The technical data stipulated in ( siehe Seite 3-1, Absatz 3.1) are exceeded or not
reached,
• The product is handled improperly.

1.6 Copyright
The copyright for this instruction manual and the illustrations remains with Neuenfelder
Maschinenfabrik GmbH. The readers of the instruction manual and illustrations may only
use them for the intended purposes. These documents are not to be handed over or dis-
closed to third parties without our express written consent. Any reproduction (including indi-
vidual details) is prohibited. Noncompliance will be subject to prosecution.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 About this instruction manual 1-11

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NMF Board Crane type DK II

1-12 About this instruction manual Copyright © 2005

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 Instruction manual
Board Crane type DK II NMF
1.7 Hydraulic symbols
December, 2007

1.7.1 Pumps/ Hydro motors

Pumps
-with one direction of flow

Pumps
-with two directions of flow

Hydraulic motor
-with one direction of flow

Hydraulic motor
-with two directions of flow

1.7.2 Cylinders

Cylinder
-single-acting
Neuenfelder Maschinenfabrik GmbH

-single-acting with spring return

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NMF Board Crane type DK II

1.7.3 Way valves

Way valves are valves with different flow paths.

They are characterized through:
-Number of switching positions; representation by an
appropriate number of quadrants,
Marking through 0, a, b
-Number of the connections and
linkages within the switching positions;
representation through lines and arrows

Marking of the connections by letters

(at the basic position 0)
P pump, pressure
T tank, return
A, B user
X, Y, Z control line
L leak oil,
Description e.g.
4/3 way valve

number of the switching positions

number of connection

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Board Crane type DK II NMF
1.7.4 Triggering type for way valves
December, 2007

directly working

Reel/tappet

hand lever
with spring return

electromagnetic triggering
with spring centring

electromagnetic triggering
with spring return

hydraulically triggering
with spring return

servo-controlled detailed

-hydraulically operated
electro magnetically controlled
-larger way valve are operated
hydraulically by a pilot valve.
the pilot valve operated electrically

simplified

In this valve both triggering are in one,

on the side directly working and
the other side servo-controlled,
Neuenfelder Maschinenfabrik GmbH

Description:
3/4 way-valve, constantly variable

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NMF Board Crane type DK II

1.7.5 Throttling way valves

Throttling way valves (servo valve);

Way valve with stepples transition
between the switching positions during
variable throttle effect.
Representation by parallel line over
the entire length

Hydraulically controlled
proportional-way valve

electro-hydraulically controlled
proportional-way valve

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Board Crane type DK II NMF
1.7.6 Pressure valves
December, 2007

-Pressure relief valve

direct acting
normally closed,
opens with reaching adjusted
inlet pressure

-Pressure relief valve

pilot operated
Control oil outlet intra

-Pressure reducing valve

direct acting
-Pressure regulating valve or
Pressure regulator
normally opened, closes with reaching
adjusted outlet pressure

pilot operated sequence valve,

a hydraulic connection switches
with reaching the adjusted pressure

-Pressure switch
an electric contact switches with
reached the adjusted pressure
Neuenfelder Maschinenfabrik GmbH

-Pressure emitter
an electric contact switches with
reaching the adjusted pressure
to the PLC

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NMF Board Crane type DK II

1.7.7 Flow control valves

-Throttle
firm resp. adjustable

-aperture
short throttle way

1.7.8 Non-return valves

-non-return valve
with recoil spring

-non-return valve
with adjustable throttle

-shuttle valve

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Board Crane type DK II NMF
1.7.9 Pipe connections
December, 2007

-Main pipe

-Control and leak oil pipe

-Flexible hoses

-Pipe connection

-Crossed lines without connection

1.7.10 Others

Filter

Heating

Cooler

Manometer
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

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Board Crane type DK II NMF
2 Safety
December, 2007

2.1 Intended use

The Type DK II deck crane is intended as a loading device for the loading and unloading of
heavy cargo, consignments and containers onto and from ships.

2.2 General safety instructions

The design and construction of Neuenfelder Maschinenfabrik GmbH products encom-
passes a risk analysis, a careful selection of the harmonised standards that are to be com-
plied with, as well as further technical specifications. They therefore reflect the state of the
art and guarantee the highest possible degree of safety.
This level of safety is only achieved if all of the required measures are taken. It is therefore
part of the crane operator's duty of care to plan these measures and ensure they are exe-
cuted correctly ( siehe Seite 1-1, Absatz 1.2).

2.3 Personnel requirements

Personnel operating the crane must:
• Be trained, inducted and authorised,
• Be familiar with the instruction manual and act in accordance with it,
• Confirm with their signature that they have understood the instruction manual.
In particular, personnel must be inducted in and familiar with the following activities:
• Emergency shutdown of the crane ( siehe Seite 4-8, Absatz 4.7),
• Exit from the crane cab via the escape hatch using a ladder or a descent line ( siehe
Seite 2-4, Absatz 2.7.5).
• Emergency lowering of the load and jib ( siehe Seite 5-40, Absatz 5.9),
• Behaviour in critical situations, e.g. heeling and trimming ( siehe Seite 2-4, Absatz 2.7.4).
The operating personnel’s specific areas of authority must be clearly defined.

2.4 Symbols on the crane

Always keep all safety and operating instruction signs on the crane in a clearly legible state.
Replace any damaged or illegible signs immediately.

2.5 Warning signals during crane operation

Acoustic warning signals

Neuenfelder Maschinenfabrik GmbH

• Horn
Optical warning signals
• Warning lamps on the left control panel

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2.6 Safety devices on the crane and functional tests thereof

2.6.1 Control levers

The control levers are spring loaded and automatically return to the neutral position when
released. The hoisting, luffing and slewing gear brakes are spring loaded and generally
engaged. They are released only when the corresponding control lever is operated.
The brakes engage automatically in the following cases:
• The control levers are at the neutral position,
• The system loses pressure (in this case, the pump unit is switched off immediately),
• During a power failure
• In case of overload,
• The outreach limit for the different load levels is reached,
• The slack rope switch is activated while the hoisting gear is "lowering".

2.6.2 Pressure switches

A pressure switch is installed in each high-pressure line to monitor the feed pressure.
• [4.4] luffing down,
• [5.4] slewing,
• [3.4] hoisting,
These pressure switches turn the pump unit off immediately if there is a loss of pressure in
the feed line. A float switch in the hydraulic oil tank also switches off the pump unit if there
is insufficient oil. This prevents the pumps from running dry.
If the crane switches off because a pressure switch opens or a gear oil cooler fails:
• The crane operator cannot restart the crane.
• A hose may have burst.
• Carry out a visual inspection of the hydraulic system before restarting the crane. If you
do not find any defects, press the "Reset" button in the switch box. Then restart the
crane.

2.6.3 Hoisting gear pressure sensor

The load pressure switch [3.15] in the hoisting line stores the most recent working pressure
and only opens the hoisting winch brake during the next operation when this pressure is
reached again.

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Board Crane type DK II NMF
2.6.4 Hydraulic overload protection
December, 2007

The entire hydraulic oil system is protected from excess pressure by pressure relief valves.
A load pressure switch is installed in the hoisting gear's hoisting pipe.
[3.5] 22-40t hoisting/lowering
[3.6] 60t hoisting/lowering
In case of overload:
Nominal load: Stop: Hoisting the hoisting gear, luffing up, luffing down
Only lowering is possible
Fast speed: Hoisting the hoisting gear, luffing up, luffing down
only lowering is possible; the switching valves lose power.
The hoisting gear functions at full load capacity.
• The load pressure switch switches off the function in use,
• The pump unit continues to run,
• The hoisting winch brake engages immediately,
• The hoisting gear pump [3.0] swings to "0".

2.6.5 Limit switches

Limit switches limit the hoisting and luffing gears to the operating ranges of the individual
load levels ( siehe Seite 5-49, Absatz 5.10). When these limits are reached, the relevant func-
tion is switched off and the brakes engage. A reverse operation is possible, however. These
limit switches only affect the functioning of the pumps; i.e., the electric motor continues to
run at a constant speed, but only at idle capacity.
When crane operations resume, current peaks are avoided thanks to the centrifugal mass
of the electric motor and the pumps, and the smoothly operating hydraulics.

2.7 Hazards and behaviour in case of danger

2.7.1 Noise hazards

Depending on local conditions, there may be elevated sound pressure levels outside of the
crane cab, which can result in deafness, a loss of balance or reduced alertness.
If this occurs, use personal protective equipment.
Please remember that when the crane is operating, verbal communication is impaired, as is
the ability to hear acoustic signals, e.g. warning signals etc..

2.7.2 Hazards stemming from "residual" energies:

Neuenfelder Maschinenfabrik GmbH

Please note that various form of energy may still exist even after the crane has been
switched off or is at a standstill, such as:
• When the jib or a load is raised
• In hydraulic pressure pipes
• In live power cables
Please advise personnel accordingly during the induction.

Copyright © 2005 Safety 2-3

 Instruction manual
NMF Board Crane type DK II

2.7.3 Behaviour in case of danger

In case of danger, press the emergency stop button immediately ( siehe Seite 4-8, Absatz
4.7).
In case of fire, switch off the crane immediately using the main switch.
Please follow special procedures when fighting fires involving:
• Operating fluids (hydraulic oil, lubricants),
• Electrical wires.

2.7.4 Behaviour in critical situations

Critical situations arise when heeling exceeds 3°.

Optical and acoustic signals give warning when the crane enters this critical state.
Take the following corrective actions:
• Luff the jib up,
• Slew the crane over the centre of the ship using the shortest route possible,
• Set down the load,
• Determine the cause of the heavy heeling.

2.7.5 Emergency exit

In case of an emergency, leave the crane via the emergency exit in the crane cab.
• Use the external ladder fitted to the crane (if present).
• Or use the emergency descending device in the crane cab see (Chapter 7, Ersatzteilkata-
log, Page 7-1).

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Board Crane type DK II NMF
3 Crane description
December, 2007

3.1 Technical data

The DK II board crane is a loading device. The technical data is summarised in (see page
3-1, Table 3)

Feature Value

Crane
Crane type DK II 60016/40025
Capacity (SWL) follow load step 60tons,40tons;34tons,22tons
eligible over key switch
Outreach
SWL 60tons 4,0 - 16,0m
SWL 40tons 3,0 - 25,0m
SWL 34tons 3,0 - 25,0m
SWL 22tons 3,0 - 28,0m
Lifting height ca. 37,5m
Luffing 70s
Hoisting speed
SWL 60tons 0 - 13,0 m/min
SWL 40tons 0 - 16,0 m/min
SWL 34tons 0 - 16,0 m/min
SWL 22tons 0 - 25,0 m/min
Slewing speed SWL 0-40tons 0 - 0,8 U/min
Slewing speed SWL 0-60tons 0 - 0,4 U/min
Slewing range 360°
Specification 60 tons load and 16 m outreach at +/- 5° heeling and
simultaneous trim of +/- 2°
Half load stage 0 - 22 tons load with double hoisting speed
(0 - 25 m/min)

Voltage
Nominal Voltage (U) 400 V / 50 Hz
Motor speed (n) 1,475 r/min
Mounting power 160 kW
Max. input, temporarily 270 kW
Neuenfelder Maschinenfabrik GmbH

Auxiliary supply 230 V / 50 Hz

Heating ___ kW
Total lighting ___ kW
Main pump motor

Table 3: Technical Data

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 Instruction manual
NMF Board Crane type DK II

Feature Value

Type 280 S4
Manufacturer ___
Performance 160 kW
System of protection, insulation IP 23
class
Structural shape Standstill heating with three posistors
Miscellaneous Star-delta start-up

Fan motors
Maximum input 2.5 kW

Table 3: Technical Data

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 Instruction manual
Board Crane type DK II NMF
3.2 .Construction
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 1: Overview

Copyright © 2005 Crane description 3-3

 Instruction manual
NMF Board Crane type DK II

3.2.1 General

All working motions are continuously adjustable from zero to maximum speed and can take
place simultaneously. With a nominal load, an electric load limiter reduces the control cur-
rent to the pump control for the hoisting, slewing and luffing gear, depending on the electric
motor's power input. These speeds are reduced, keeping the electric motor's power input
constant.

3.2.2 Pump unit

A pump unit is mounted on the crane housing. It consists of an electric motor, a pump drive
unit and three hydraulic pumps.
The electric motor powers the pumps via the pump distribution gear. The pump unit supplies
the hoisting, slewing and luffing gear with pressure oil.
The hydraulic pumps are variable, reversible high-pressure axial piston pumps. The are
connected to the hydraulic motors by means of high-pressure hoses.

3.2.3 Hoisting gear

The hoisting gear is built into the crane housing and consists of the winch drum, the winch
gear and a hydraulic motor. The winch gear is built in to the winch drum; the hydraulic
motors are flanged onto the winch drum.
The hydraulic motor is a axial piston bent axis motor with spherical pistons. These start with
maximum displacement volume and therefore with maximum start moment.

3.2.4 Luffing gear

The luffing gear is constructed in the same way as the hoisting gear.

3.2.5 Slewing gear

The slewing drive consists of three slewing gears that are mounted on the floor of the crane.
Each slewing gear engages with the gear rim of the roller-bearing turntable via a gear wheel,
thereby transmitting the slewing motion to the crane. An axial piston fixed displacement
motor is mounted on each of the slewing gears.

3.2.6 Gear oil cooler

The gear oil cooler is an oil-air cooler that cools the gear oil in the pump drive unit see (Chap-
ter 7, Ersatzteilkatalog, Page 7-1).
It starts up when the hydraulic oil temperature reaches 20 °C.
The gear oil cooler has an oil filter that must be changed in accordance with the mainte-
nance cycle ( siehe Seite 5-4, Absatz 5.2).

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Board Crane type DK II NMF
3.2.7 Hydraulic oil coolers
December, 2007

The hydraulic oil coolers are oil-air coolers that are built into the return lines of the hydraulic
system.
The spring-loaded vent flap [2.7] is opened hydraulically when the pump unit is started. The
oil-air cooler starts up at an oil temperature of >40 °C. The heated air exits through the open
vent flap. All functions are switched off when the oil temperature exceeds 85 °C. The pump
unit and the oil-air-cooler continue to run.

3.2.8 Heating

Electric heating elements are installed in the hydraulic oil tank and the crane housing. A
room thermostat controls the room heating. A thermal sensor monitors the oil temparature
in the oil tank. The tank heating runs constantly when the oil temperature is below 20°. The
tank heating is switched off at about 22° C.

3.2.9 Slack rope switch

The moment the hoisting gear rope begins to slacken toward the crane column so that the
rope threatens to jump out of the grooves, the inductive proximity switch is actuated by the
rocker. This immediately switches off the hoisting gear if it is in “lowering” mode. “Hoisting”
is still possible.
Check that the rope is positioned correctly before proceeding.

3.2.10 Gear cam limit switch

A gear cam limit switch is fitted to each winch gear.

These limit switches have a variable number of cams, which are actuated as required by the
operating conditions of the crane. ( siehe Seite 5-49, Absatz 5.10)

CAUTION
The limit switches are only to be operated, serviced and repaired by
authorised, trained and inducted personnel.
This personnel must have read and understood the complete instruction
manual and must also have received special training about possible hazards
( siehe Seite 5-49, Absatz 5.10).

3.2.11 Slip ring assembly

Neuenfelder Maschinenfabrik GmbH

The slip ring assembly transmits power from the fixed part of the crane (foundation) to the
slewing part of the crane, allowing the crane to rotate without restriction.
Due to its enclosed design, the slip ring assembly is splash-proof. It is fitted to the rotary
union and can be accessed by opening the cover.

Copyright © 2005 Crane description 3-5

 Instruction manual
NMF Board Crane type DK II

CAUTION
Prior to opening the slip ring assembly cover:
• Switch the power off,
• Prevent unauthorised activation of the power.

3.2.12 Load measurement system

The load is measured via a load measuring pin that is located in the hoisting winch. The load
is displayed on a display screen in the cabin.
Do not, under any circumstances, hit the load measuring pin with a hammer or other tool in
order to push it into the hole. Failure to heed this warning can cause mechanical damage to
the load measuring pin, resulting in wrong measurements.
If it is determined that this warning was not heeded, the guarantee no longer applies.
The load measurement system can be deactivated using a key switch in the switch box. (see
item 52, page 7-2) The load measuring pin is then bridged electronically and electronic load
measurement is deactivated. This does not affect the hydraulic overload monitoring system.

CAUTION
If the load measurement system is deactivated, the load master does not switch off
the crane in case of overload.

3.2.13 Pressure transducer

The pressure transducers [3.15] and [4.15] in the hoisting line store the most recent working
pressure, and open the winch brake during the next operation only when this pressure is
reached again.

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Board Crane type DK II NMF
3.3 Hydraulic functions
December, 2007

The numbers in brackets relate to the diagram with the serial number 840-4900-28(1)

3.3.1 General

The crane drives work electro-hydraulically and in a closed circuit. The electric motor [1.0]
drives the reversible axial piston pumps [3.0-5.0] via a drive unit [1.1]. The pump unit [1] is
mounted flexibly and is connected to the consumers by means of high-pressure hoses.
Each axial piston pump [3.0-5.0] has an integrated control and feed pump with external suc-
tion [2.0].
The oil flow feed controls of the axial piston pumps [3.0-5.0] are reversed by electro-hydrau-
lic proportional valves via manual control levers and current regulator cards.
Pressure relief valves protect the entire system, including each of the individual functions,
from overload.
In addition, electro-hydraulic pressure switches are mounted in each pressure pipe to mon-
itor the feed pressure. If there is a loss of pressure or a line ruptures, these pressure
switches cut the control current; the electric motors [1.0] switch off immediately.
The float switch [2.5] in the hydraulic oil tank [2.8] also shuts down the entire system if there
is a loss of oil. This protects the pumps [3.0, 4.0 and 5.0] from running dry and prevents
greater oil losses.

3.3.2 Starting the pump unit

The electric motor [1.0] has a star/delta starter. The gear oil cooler [1.2] starts up when the
oil temperature exceeds 20 °C. Power is supplied to the 4/2-way directional control valve
[2.2], which blocks the depressurised flow of control and feed oil from the control and feed
pumps [2.0].
When all of the pressure switches [3.4, 4.4, 5.3 and 5.4] in the pipes are actuated by the
feed pressure, the green pilot lamp lights up. The vent flaps [2.7] are opened automatically
by the control pressure. When the is crane operated, heated hydraulic oil is fed to the
hydraulic oil tank [2.8] through the flush valves [2.1] at a rate of about 20 l/min. The control
and feed pumps [2.0] feed cooled hydraulic oil back in through the combined pressure relief
valves with feed valves [3.1, 4.1 and 5.2]. The pressure oil ejected from the pressure relief
valves [2.1] of the control and feed pumps [2.0] flows back into the hydraulic oil tank [2.8].

3.3.3 Ventilation

The spring-loaded vent flap [2.7] is automatically opened hydraulically when the pump unit
is started.
Heat from oil and air warmed to more than 40°C during crane operation is discharged
through the open vent flap [2.7] by the oil-air coolers [2.6], which start automatically.
Neuenfelder Maschinenfabrik GmbH

3.3.4 Heating / cooling

Electric heating elements are installed in the hydraulic oil tank [2.8] and the crane housing.
A room thermostat controls the room heating, which is switched off when the ambient tem-
perature reaches 20° C.

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NMF Board Crane type DK II

A thermal sensor monitors the oil temperature in the hydraulic oil tank. The tank heating [2.4]
switches on when the oil temperature drops below 20° C. When the oil temperature reaches
22°C, the tank heating [2.4] switches off; the oil-air coolers [2.6] switch on at 40° C.
In the event that the oil temperature reaches 85°C, the controls are deactivated and none of
the functions work. The pump units and oil-air cooler [2.6] continue running; the vent flaps
[2.7] remain open.

3.3.5 Electro-hydraulic control system functionality

An external electrical input signal at the pressure pilot valve [2.1.1] on the solenoid controls
the servo valve [2.1.2]. The pressure pilot valve [2.1.1], which functions on the nozzle-flap-
per (swashplate) principle, generates a hydraulic differential pressure that is proportional to
the electrical input signal.
The servo valve [2.1.2] converts the eletrical input signal into a position-controlling output
signal. This position-controlling signal determines the variable displacement pump's pivot
angle.
The variable displacement pump's displacement volume is proportional to the electrical
input signal. A mechanical feedback mechanism at the swashplate fixes the pre-selected
swashplate position, thus stabilising the pre-selected displacement volume. This makes
operation of the crane functions fast, precise and safe.

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Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 2: Pump diagram

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 Instruction manual
NMF Board Crane type DK II

3.3.6 Hoisting gear

Das Hubwerk [3] besteht aus einer Winde und einem verstellbaren Hubwindenmotor [3.11].
The variable hoisting gear pump [3.0] and the variable hoisting winch motor [3.11] work in a
closed circuit.

3.3.6.1 Idling

The motor's swashplates are set to maximum displacement volume, i.e., low speed, high
torque ==> low winch speed. Power is not supplied to electro-solenoid valves [3.8, 3.10].

3.3.6.2 Hoisting the 60t nominal load

Set the key switch to (4) "0", 60t.

The hoisting gear pump swings from the "0" position in proportion to the deflection of the
control lever, and begins to deliver pressure oil. The solenoid valve is not actuated. The
motor runs with max. displacement volume, ==> max torque, ==> low winch speed.

3.3.6.3 Hoisting the 40t nominal load

Set the key switch to (4) "1", 40t.

This has the same functionality as described in ( siehe Seite 3-10, Absatz 3.3.6.2).

3.3.6.4 Fast speed (0-22t)

Set the key switch (5) to "ON".

The solenoid valves [3.8 and 3.10] are actuated, which reduces the hoisting gear motor's
pivot angle via the servo valve [3.17]. This means that the motor runs at a low displacement
volume, low torque and high speed.
If the load moment or the reduced motor pivot angle cause the system pressure to rise, the
motor swings to a wider angle when the value set at the pressure switch [3.16] is reached.
The abnormal pressure is reduced by increasing the displacement volume, which causes a
reduction in pressure.
If the load to be hoisted exceeds 22t, the hoisting gear brake [3.9] opens, but then engages
again immediately. The rising pressure in the hoisting pipe actuates the load pressure
switch [3.5]. The directional control valve [3.8] and the electronic pump control [3.1.1] lose
power. Bring the control lever to the "0" position immediately, otherwise the hoisting gear
will operate jerkily. Set the load step switch to the nominal load.

3.3.6.5 Lowering the load

The lowering process works like the hoisting process.

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Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 3: Half load functionality

Copyright © 2005 3-11

 Instruction manual
NMF Board Crane type DK II

3.3.6.6 Hydraulic overload disconnect

A hydraulic pressure limitation valve [3.1.1 - 5.1.1] is mounted on each axial piston pump
[3.0 - 5.0]. These are connected to the high pressure pipes. They are set slightly higher than
the electro-hydraulic load pressure switches [3.5 and 3.6] in the hoisting gear system.
Pressure limitation valves [3.1.1 - 5.1.1] on pumps [3.0 - 5.0] are set lower than pressure
relief valves [3.1 and 5.1].
In case of overload, the system pressure forces the corresponding pressure limitation valve
[3.1.1 - 5.1.1] into the neutral position. The pump adjustment control oil flows through the
pressure limitation valve; it is pre-stressed to about 2.2 bar. The spring tension forces the
axial piston pump toward the "0" position. This causes it to feed only as much pressure as
is needed to hold the load, since the corresponding brake does not engage in this case.
In case of overload:
Nominal load
Stop: Hoisting the hoisting gear, luffing up, luffing down
Only lowering is possible

Fast speed:
Stop: Hoisting the hoisting gear, luffing up, luffing down
only lowering is possible; the switching valves [3.10] lose power.
The hoisting gear functions at the full load step.
Bring the control lever to the "0" position immediately and select the corresponding load
step.

3.3.7 Luffing gear

3.3.7.1 "Luffing up"

The directional control valve [4.6] receives power when the luffing gear control lever is
deflected. The control pressure that is released opens the luffing winch brake [4.7].
The luffing up speed is reduced when the jib angle exceeds 70°, and stops completely at
min. outreach. Directional control valve [4.6] loses power and the luffing winch brake [4.7]
engages; it is still possible to luff down. In case of overload, the pressure limitation valve
[4.1] signals the luffing winch pump [4.0] ( siehe Seite 3-12, Absatz 3.3.6.6).

3.3.7.2 "Luffing down"

The luffing down functionality is the same as luffing up. It is limited at maximum outreach by
a limit switch.

IMPORTANT NOTE
Activate the "Jib in park position" switch only to place the jib on the jib rest. If this
key switch is activated, none of the limit switches work except for the 0° jib angle limit
switch, which switches off the luffing down function. At least 3 safety wraps remain
on the luffing winch drum. It is still possible to luff up, however.

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Board Crane type DK II NMF
3.3.8 Slewing gear
December, 2007

3.3.8.1 Slewing "right" - "left"

When the slewing control lever is deflected, the control valve [5.5] receives power and the
slewing gear brakes [5.7] are released. When the control lever is returned to "0", the slewing
gear pump [5.0] returns to "0" first. After this, the slewing gear brakes [5.7] close slowly, in
dependence on an electronic time relay. This brings the crane to a smooth stop. In case of
overload, that is, slewing against the heel with a load and high outreach, the pressure limi-
tation valve [5.1] signals the slewing gear pump [5.0].
( siehe Seite 3-12, Absatz 3.3.6.6). Shift the control lever to "0" and luff the jib up to reduce
heeling.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 3-13

 Instruction manual
NMF Board Crane type DK II

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 Instruction manual
Board Crane type DK II NMF
3.4 Electrical equipment
December, 2007

3.4.1 Electronic regulator cards

3.4.1.1 4-channel current regulator card

Illustration 4: Current regulator card

Short description
Magnetic current regulator card for controlling proportional valves.
The card has a total of four PWM outputs, of which up to two can be active at the same time.
A control lever potentiometer triggers on set values.
Functions:
Neuenfelder Maschinenfabrik GmbH

• Individual operation of pump 1, pump 2 or both pumps.

• Normal operation, creep speed 1, creep speed 2
• Synchronised operation, as master for second crane.
• Synchronised operation, as slave for second crane.
• Parametrised operation, operation by means of the buttons on the front plate
• Extended parametrised operation via laptop / RS232.
• Load limiter.

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 Instruction manual
NMF Board Crane type DK II

Technical data:
• Supply voltage: 24 V DC (18-32 V) residual ripple max. 5 %
• Output current range: 10 - 999 mA (PWM 122 Hz)
• Five ramp generators, durations of up to 10 sec from I minÞ I max, or I max Þ I min
• Power supply for control lever: ±15 V DC
• Incremental sensor connection (24 V DC) for Gemini operation
• RS 485 interface for Gemini operation
• Ten inputs (24 V DC) for selecting functions
• Two AC inputs for converter (10 V AC)·
• Status display (2x16 characters)
Mechanics:
Eurocard (100x160 mm) Front:12 HP, 3 U

1. UP (RIGHT) I MIN. MA ANFANGSSTROM FÜR HEBEN (RECHTS)

2. UP (RIGHT) I MAX. MA MAXIMALSTROM FÜR HEBEN (RECHTS)
3. UP (RIGHT) I MIN. 1 MA MAXIMALSTROM SCHLEICHGANG 1 FÜR HEBEN(RECHTS)
4. UP (RIGHT) I MAX. 2 MA MAXIMALSTROM SCHLEICHGANG 2 FÜR HEBEN(RECHTS)
5. DOWN (LEFT) I MIN. MA ANFANGSSTROM FÜR SENKEN (LINKS)
6. DOWN (LEFT) I MAX. MA MAXIMALSTROM FÜR SENKEN (LINKS)
7. DOWN (LEFT) I MIN. 1 MA MAXIMALSTROM SCHLEICHGANG 1 (SENKEN (LINKS)
8. DOWN (LEFT) I MAX. 2 MA MAXIMALSTROM SCHLEICHGANG 2 (SENKEN (LINKS)
9. UP SPEED UP SEK RAMPENZEIT FÜR HEBEN (RECHTS) BESCHLEUNIGEN
10. UP SLOW DOWN SEK RAMPENZEIT FÜR HEBEN (RECHTS) BREMSEN
11. DOWN SPEED UP SEK RAMPENZEIT FÜR HEBEN (RECHTS) BESCHLEUNIGEN
12. DOWN SLOW DOWN SEK RAMPENZEIT FÜR HEBEN (RECHTS) BREMSEN
13. OVERLOAD THRESHOLD V EINGRIFFSWERT DER LEISTUNGSREGELUNG
14. ATTACK REACTING / BEGINN DER LEISTUNGSREGELUNG
15. RELEASE FADING / ABKLINGEN DER LEISTUNGSREGELUNG

Operating instructions
If the authorisation signal is not supplied, you can enter parameter mode by pressing the
ENTER button. The upper line of the display shows the parameter number and the abbrevi-
ation for the slewing direction. The lower line shows the abbreviation for the value to be
edited on the left and the current value on the right, along with the abbreviation for the
dimension. To modify the value, press the ENTER button. EDIT appears in the upper line.
Use the arrow keys to increase or decrease the value. You can make extensive changes
quickly using the auto-repeat function. Press ENTER again to save the value. EDIT disap-
pears again, and you can scroll to another parameter number using the arrow keys (you can
also use auto-repeat here). If you want to save the old value again instead of the new value,
simply press the ESC button. Exit the parameter menu by pressing ESC.

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Board Crane type DK II NMF
Notes on settings
December, 2007

1. Maximum current
Here you can set the current that is made available when the control lever is pushed
all the way forward.
N: Value for normal operation
S1: Creep speed 1
S1: Creep speed 2
2. Minimum current
Input current for the hydraulic system (when winches begin rotating); also the value
for the pressure increase.
3. Control lever in neutral position
Mimimum control lever deflection needed to start.
4. Ramping
Increase ramp times (in seconds) for the current value.
5. Synchronous regulator
P-part: Regulator for dual use.
Synchronous warning: Maximum allowed divergence.
6. Hydraulic overload
Reaction value for reacting and subsiding: the higher this value is, the more slowly
(from V 1.07) the changes in current are carried out. Limit: Converter current (V AC)
setting at which the load limiter is activated.
7. Current regulation
Damping: Adjustment of solenoid valve currents. The set value (9) should generally
not be changed. Start factor: Value for the PWM controller after a restart. The default
value (52) is optimal for the solenoid valves in use and should only be changed if the
solenoid valve current rises too slowly after a restart or if a massive overshoot is
detected.
Neuenfelder Maschinenfabrik GmbH

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 Instruction manual
NMF Board Crane type DK II

3.4.2 Fault indicator cards

Any faults that occur during operation of the crane are indicated acoustically and optically:
• Acoustically with the horn,
to turn off the horn, press the "Acknowledge alarm" button on the door of the switch
box.
• Optically by means of the "FAULT" lamp on the left control panel and the LEDs on the
fault indicator card.
If a fault occurs, the corresponding fault indicator card LED lights up. After the fault is
acknowledged (by pressing the button), the lamp remains lit until the fault is eliminated.

Fault indicator card

Reset button

Illustration 5: Fault indicator card

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Board Crane type DK II NMF
3.4.3 Switches in the switch box
December, 2007

3.4.3.1 "TEST OPERATION" switch

(siehe Seite 21, Abb. 6)

During "test operation", all electrical components of the crane system are operational. The
electric motor and the hydraulic pumps do not run. "Test operation" primarily serves to find
faults.

3.4.3.2 "RESET" switch

(siehe Seite 21, Abb. 6)

If the crane switches off due to a pressure switch or because the gear oil cooler fails, the
operator cannot restart the crane.
A hose may have burst. The hydraulic system should be inspected visually before the next
start. If no defects are detected during the inspection, press the "Reset" button in the switch
box. The crane can then be restarted.

3.4.3.3 "BRIDGE HOISTING GEAR BRAKE PRESSURE SENSOR" switch

If the pressure sensor [3.15] is defective, it can be bridged using this switch.

3.4.3.4 "BRIDGE LUFFING GEAR BRAKE PRESSURE SENSOR" switch

If the pressure sensor [4.15] is defective, it can be bridged using this switch.

3.4.3.5 „TEST LOAD" switch

This switch is located in the switch box (see illustration 6, page 3-21).
The switch should only be activated when the crane is to be subjected to a load test.

3.4.4 Jib winch, hoisting winch and auxiliary hoisting winch speed monitoring

The boom and hoisting gear winches are fitted with speed monitors. Should a drive fault
cause the speed to exceed the maximum allowable value, the brakes are forced to engage.
The "FAULT" lamp on the left control panel Crane cab, Seite 3 lights up, along with the
"Winch overspeed", "Jib winch overspeed" or "Auxiliary hoisting winch overspeed" lamps at
the switch box. The crane operator cannot restart the winch. Eliminate the fault by pressing
the "Reset overspeed" button (siehe Seite 4, Abb. 54).
If the crane is stopped frequently due to overspeed conditions and no drive fault is found,
overspeed monitoring can be deactivated.
Neuenfelder Maschinenfabrik GmbH

NOTE:
Overspeed monitoring may only be deactivated with the manufacturer's permission.

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3.4.5 Brake relay monitoring

For safety reasons, the solenoid valves of the hoisting, slewing and luffing gear brakes are
triggered by 2 relays situated in a row. This arrangement guarantees the greatest possible
security. Should a relay bond and the contact no longer open, the second relay still switches
the brake off safely. The relays are monitored by the PLC. The relays are checked 0.5 sec.
after the brake is released. If a relay still has a closed contact, the crane operator receives
a fault message. The switch box shows which brake is faulty.

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December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 6: Switches

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3.5 Test operation
December, 2007

Hydraulic pressure is not built up during test operation. The main motor and oil cooler are
not started. This makes it possible to test the electrical connections to the actuators and sen-
sors and the input signals to the current regulator cards.
1. Switch off the crane and switch on the "Test operation" switch in the switch box.
2. The crane is now in "Ready for operation" mode (which is normally only the case
when the main motor is running).
3. The load measurement system DMSA (optional) is activated.
4. Feed pressure and pressure switches cannot be tested as pressure has not been
built up.
5. Testing the PLC inputs and outputs:
It is possible to test all sensors and actuators that are connected to the PLC. These
are displayed by the PLC's input and output module LEDs.
Find the sensor or actuator you want to test in the circuit diagram (e.g. load level
pressure switch). Disconect the pressure switch plug. The LEDs on the correspond-
ing PLC input module will go out (check this using the circuit diagram), and the over-
load alert LED on the PLC output module will light up (if the corresponding load level
is selected).

3.5.1 Testing the current regulator cards during test operation:

The control levers are used to test the modulation of the corresponding current regulator
card.
• When a control lever is shifted (contact 1/2 indicates the direction), the measured cur-
rent displayed by the current regulator card rises to a median, fixed value. The direction
(up/down) is also displayed. (see illustration 7, page 3-24)
• The corresponding pump valve is triggered.
• If the value on the display remains at 0, check contacts 1/2 at the control lever.

3.5.2 Testing the brake release potentiometer and solenoid valve:

• In addition to the "Test operation" switch, switch on the "Bridge pressure sensor" switch
for the hoisting gear or the jib (see illustration 6, page 3-21).
When the control lever is shifted, the measured current rises, depending on control lever
deflection (potentionmeter 3), up to the maximum value.
• If the median, fixed value is displayed even when the control lever is deflected to maxi-
mum and the "Bridge pressure sensor" switch is activated, check potentiometer 3 at the
control lever.
• The corresponding brake valve must also receive a signal when the control lever is
deflected. (LED indication at the solenoid valve).
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

Illustration 7: Control lever diagram

After testing, make absolutely sure that the "Test operation" and "Bridge pressure
sensor" switches for the hoisting gear and jib in the switch box are switched off
again.

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3.6 Load master/load measurement system (DMSA)
December, 2007

The load measurement system consists of the load master (DMSA) in the switch box (siehe
Seite 26, Abb. 8), the display in the cabin (siehe Seite 27, Abb. 9) and the load measuring pin
in the rope end connection.
In case of overload, the load measuring system switches off the corresponding crane func-
tion.
In case of overload:
Nominal load
Stop: Hoisting the hoisting gear, luffing up, luffing down
Only lowering is possible

Half load step

Stop: Hoisting the hoisting gear, luffing up, luffing down
only lowering is possible; the switching valves lose power.
The hoisting gear functions at the full load step.
The load master emits a warning if heeling is > 5°.
The DMSA receives an electrical signal from the load measuring pin, evaluates this signal
working together with the PLC, and displays the result in the cabin.
The load measurement system can be deactivated using a switch in the switch box. The
load measuring pin is then bridged electronically and electronic load measurement is deac-
tivated.
It is not possible to switch to half load when the load measuring system is bridged. In this
case, the crane only works in full load steps.
This does not affect the hydraulic overload monitoring system.

CAUTION
If the load measurement system is deactivated, the load master does not switch off
the crane in case of overload.
Neuenfelder Maschinenfabrik GmbH

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1 = Parameter mode -
only for setting parame-
ters 2
2 = Running - switch
position for crane opera- 1 3
tion 5
3 = Deactivate alarms
and warnings - switches
off the load measurment
4
system
6
4 = Fuses - the LED
goes out if a fuse is
defective
5 = Display and manual
parameter entry
6 = PC connection
CAUTION
Parameter settings and adjustments may only be made by
authorised personnel.

Illustration 8: Load master

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December, 2007

Permissible load Load on the hook Outreach

Display during normal operation

Load step Heeling

The display blinks if there is an

error or overload at the DMSA.
If the overload originates from the
pressure switches, this is not dis-
played by the DMSA.

Display when the load measure-

ment system (DMSA) is switched
off

The display blinks if the load

measuring pin is defective
Neuenfelder Maschinenfabrik GmbH

Illustration 9: Indicator display

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3.7 PS2-200 Compact PLC
December, 2007

A complete description is available in see (Chapter 7, Ersatzteilkatalog, Page 7-1).

3.7.1 Construction

6. 24 V DC power supply
7. "High speed counter" input (alternative to I 0.0), 3kHz
8. Alarm input (alternative to I 0.1)
9. 8 24 V DC digital inputs and 24 V DC power supply for the outputs
10. Plug-in screw terminal
11. Status display for inputs
12. Status display for outputs
13. 6 24 V DC/0.5A digital outputs; short-circuit proof and overload protected analog
inputs U0, U1 (0 to 10 V), 1 analog output U10 (0 to 10 V)
14. Suconet K interface
15. Set point potentiometers P1, P2
16. Switch S1 for bus termination resistors
17. Programming device interface (PRG)
18. Memory module
19. Status display for the PLC
Neuenfelder Maschinenfabrik GmbH

3.7.2 Elements

1. Power supply unit

The PS4-200 is operated with a rated voltage of 24 V DC. The power supply connection is
protected against polarity reversal. The 24 V connection enables the PLC in the switch box
to be supplied with standard voltages in accordance with industry standards (IEC).

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2. "High speed counter" input

You can count pulses at up to 3 kHz via digital input I 0.0, irrespective of the cycle time. The
up counter is capable of processing square-wave pulses with a pulse/pause ratio of 1.
3. Digital inputs
The PLC has eight digital inputs. They are galvanically isolated from the CPU. The inputs
are designed for 24 V DC. The input delay of typically 55 µs ensures short response times
(e.g. for direct peripheral scans and alarm evaluations). Inputs I 0.0 to I 0.7 can be
addressed in bit or byte format with peripheral I/O commands.
4. Status display for digital inputs
LEDs (light-emitting diodes) display the physical states of the inputs as well as the diagnos-
tic status word.
5. Status display for outputs
The LEDs (light-emitting diodes) display the logical states of the outputs. Outputs Q 0.6 and
Q 0.7 are used only as a LED display.
6. Digital/analog outputs, analog inputs
Digital outputs:
The PS4-200 has six 24V/0.5A digital outputs. They are galvanically isolated from the CPU
and are protected against short circuits and overloads. Up to four outputs can be connected
in parallel.
Outputs Q 0.0 to Q 0.5 can be addressed either in bit or byte format with peripheral
commands.
Analog inputs/outputs:
The PLC has two analog inputs and one analog output. The signal range is 0 to 10 V. The
resolution of the inputs is 10 bits (1024 increments); that of the output is 12 bits (4096 incre-
ments).
7. Switch S1 for bus termination resistors
Use switch S1 to set the bus termination resistors for the first and last physical stations.
8. Memory modules
The PS4-200 has 32 KB of internal, battery-backed RAM. The memory is subdivided into a
data memory and a user program memory.
9. Status display for the PLC
The “Ready”, “Run”, “Not Ready” and “Battery” LEDs show the state of the PLC.

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December, 2007

1. Back-up battery
2. Reset button
3. Multi-pin connector for local expansion modules
4. Operating mode selector switch
About 1. back-up battery
The battery backs up the internal RAM and the real-time clock.
The back-up battery must only be replaced with the power supply switched on, or
data will be lost.
About 2. and 4. operating mode selector switch/reset button
You can select the “Halt” (stop), “Run” and “Run M-Reset” modes with the operating mode
selector switch. The selected mode is activated when you press the Reset button.
About 3. multi-pin connector for local expansion modules
The multi-pin connector provides an interface for connecting local LE4 expansion modules.

3.7.3 Setting the bus termination resistors

Set the bus termination resistors on the module for the first and last physical stations in a
line. To do this, set both S1 switches to the “ON” position. Both switches must be set to the
“OFF” position for all other stations.
Neuenfelder Maschinenfabrik GmbH

Figure 9: Bus termination resistors activated

In order for the PLC to function correctly the two S1 switches must be set to the same
position (“ON” or “OFF”).

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3.7.4 Operating states of the PLC

The PLC can have the following operating states: “Run”, “Ready”, “Not Ready”.
Communication with a PC is possible in all three operating states. This means, for
example, that the current status of the PLC and the real-time clock can always be
read.
Ready
The “Ready” status means the following:
A user program is loaded in the PLC;
The user program is not running;
The outputs are reset and disabled;
The PLC is switched to “Ready” status:
If the “Reset” button is pressed when the operating mode selector switch is set to
“Halt”;
After the power supply is switched on when the operating mode selector switch is set
to “Halt”;
By means of the programming software via the PC;
In slave mode, if the master switches to “Halt” (stop) status and you have set the
“remote control” function to ON when setting the slave parameters in the Sucosoft
Topology Configurator;
If the tab of the memory module is pulled out.
Run
“Run” status means that the user program is running cyclically.
The PLC is switched to “Run” status:
If the “Reset” button is pressed when the operating mode selector switch is set to
“Run” or “Run M-Reset”;
After the power supply is switched on when the operating mode selector switch is set
to “Run” or “Run M-Reset”;
By means of the programming software via the PC.
Not Ready
The user program does not run in “Not Ready” status.
The PLC is switched to “Not Ready” status:
If there is no program loaded in the PLC;
As a result of a hardware error or a serious error in the user program (e.g. cycle time
violation).
Once the error has been rectified and confirmed, you can exit the “Not Ready” status as fol-
lows:
By pressing the “Reset” button; if the operating mode selector switch is set to “Run M-
Reset”, the PLC will be switched to “Run” status;
By switching the power supply off and then on again; if the operating mode selector
switch is set to “Run M-Reset” the PLC will be switched to “Run” status;
By means of the programming software via the PC.

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December, 2007

Legend for Table 13:

1) If the programs in the memory module and the RAM are not the same, the program in the
memory module is copied to the RAM.
2) If the start condition is set to "Halt" in the system parameter settings, the PLC is switched
to "Not Ready" status after a user program is transferred to the PLC or the memory module
is booted. A cold start is required in this case.
Neuenfelder Maschinenfabrik GmbH

Mounting and dismounting individual modules ( siehe Seite 5-53, Absatz 5.11)
Whenever the PLC is started – by switching on the power or pressing the “Reset” button, or
via the PC – the backup program is compared with the program in the RAM. If the programs
are not the same, the program in the memory module (backup program) is copied to the
RAM.
If the user program in the memory module is defective, it is updated, provided that the user

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NMF Board Crane type DK II

program in the RAM is valid. An update is also carried out every time the user program is
transferred from the PC to the PLC.

3.7.5 Test/initial operation

Status display
The coloured LEDs (light-emitting diodes) enable fast and simple diagnostics of the PLC
functions. The input/output states are easy to monitor.

1) CAUTION!
Data may be lost if the battery does not supply sufficient power. Always replace the
battery with the power supply switched on!

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4 Operation
December, 2007

4.1 Safety instructions

Before operating the crane, familiarise yourself with:
• The instruction manual,
• The crane's operational and control elements,
• The crane's immediate environment,
• The crane's safety devices,
• Measures to be taken in case of emergencies.

4.2 Personnel requirements

The crane may only be operated by trained, inducted and authorised persons. These per-
sons must be familiar with the instruction manual and act in accordance with it. The operat-
ing personnel’s specific areas of authority must be clearly defined.
Operating personnel in training may only work on the crane under the supervision of an
experienced person. Successful completion of the induction should be confirmed in writing.
All control and safety devices must only be operated by persons with suitable training.
All persons who work on the crane must read the instruction manual and confirm with their
signature that they have understood it.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

4.3 Operating range of the crane

Illustration 10: Operating range of the crane

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4.4 Operation
December, 2007

4.4.1 Crane cab

The crane's operating controls are located in the cab.

Lastanzeige

Electronic pressure switch

Hydraulic pressure switch indicator

for pressure in the hydraulic system
Neuenfelder Maschinenfabrik GmbH

Illustration 11: Crane cab

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NMF Board Crane type DK II

4.4.2 Control panels

The control levers are sensitive and can be adjusted continuously.

3
5

2 7
9

3
6
8
10

1 PUSH BUTTON „BY-PASS FAST SPREED 22t STEP“

2 CONTROL LEVER
3 PUSH BUTTON „HORN“
4 KEY SWITCH „LOAD STEEP“
1=34t;
2=40t;
3=60t;
4= AUTOMATIC“
5 KEY SWITCH „LOAD STEEP 22t ON/OFF“
6 KEY SWITCH „JIB IN PARKPOSITON
7 SWITCH „LIGHT CABIN“
8 SWITCH „WARNING LIGHT JIB“
9 SWITCH „FLOOD LIGHT“
10 SWITCH „WINDOWS SCREEN WIPER“

Illustration 12: Right control panel

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Board Crane type DK II NMF
December, 2007

1
2 3

4
6
8 2
10

12
5
7
9
11

1 NO FUNCTION
2 LUFFING/SLEWING GEAR CONTROL LEVER
3 "EMERGENCY STOP" BUTTON
4 "FAULT" LAMP
5 "HEELING 5°" LAMP
6 "WARNING OVERLOAD" LAMP
7 "OVERLOAD" LAMP
8 "MOTOR OFF" BUTTON
9 "MOTOR ON" BUTTON
10 "OIL COOLER IN OPERATION" LAMP
11 "READY FOR OPERATION" LAMP
12 SOCKET 220V
Neuenfelder Maschinenfabrik GmbH

Illustration 13: Left control panel

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NMF Board Crane type DK II

4.5 Starting up

4.5.1 Before starting up

Before every start

• Make sure all safety devices are present and ensure they are functioning.
• Inspect the crane for signs of visible damage. Remedy any defects found and report
these to your supervisor or the crane operator.
• Ensure that only authorised persons are in the crane operation area, and that starting
the crane does not endanger any other people.
• Remove all objects and other material not required for operating the crane from the
crane operation area.
• Check the oil level in the hydraulic oil tank. Oil must be visible in the lower viewing glass.
• Check that all shut-off cocks are open, and open them if necessary.
• Check that the oil drain valve is closed.
• Operate the crane only if it is in fault-free condition.

4.5.2 Switching on

1. Turn on the main switch in the machine room.

2. Start the pump unit. The green pilot lamp on the left control panel lights up after about
10 seconds.
3. Check that the vent flap is open.
4. Switch to load step 60t using the key switch on the right control panel.
5. Luff the jib down completely and check that the luffing gear stops without difficulty
when it reaches its maximum position.
6. "Hoist" the hoisting gear. The bottom hook block should stop about 1 m under the jib
head.
7. Luff the jib up completely and check that it stops when it reaches its minimum posi-
tion.
8. Remove the key from the "Jib in park position" key switch to prevent operator error
during loading operations.

NOTE
The luffing up speed is automatically reduced by half when the jib angle exceeds 70°.

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4.5.3 During operation
December, 2007

• Do not remove or disable any of the safety devices.

• You and all other operating personnel should remain within their specified work areas.
• Make sure that unauthorised persons do not enter the crane operation area.
• Never swing loads over people.
• Use the load step switch to set a new load step only when the hook is not carrying a
load.
• Oblique hoisting with the hoisting rope is not permitted.
Give a warning signal.
• Activate the "Jib in park position" switch only to place the jib on the jib rest.
• CAUTION None of the other limit switches will function when you do this.
• It is imperative to avoid slack rope.

4.5.4 Setting the load steps

The load steps are set using the right control panel ( siehe Seite 4-4, Absatz 4.4.2).

NOTE:
The load step may only be changed when there is no load on the hook. If the load on the
hook exceeds the selected load step, the crane switches off in "hoisting" mode. It can still
be operated in "lowering" mode.

4.5.5 Switching on 0-22t fast speed

Fast speed may only be used for loads from 0 - 22 t. The hoisting speed is then
between 0 - 25 m/min..
Use the key switch on the right control panel to switch on fast speed, and the white button
on the hoisting gear control lever to operate it ( siehe Seite 4-4, Absatz 4.4.2). Press the white
button within 5 seconds and begin operating, otherwise the crane is automatically switched
back to nominal load. When fast speed is switched on, you must press the white button each
time you return the control lever to "0". If the load to be hoisted exceeds 22t, the hoisting
gear brake opens, but then engages again immediately. Move the control lever to "0" imme-
diately. Set the key switch to the max. load step.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

4.6 Switching off

Shutting the crane down

1. Slew the crane into the locking position, park the jib and lock the crane.
2. Extend the jib to maximum outreach. Activate the "Lay down jib crane" key and
continue holding the key in this position. Place the jib in the jib rest and relieve the
luffing wire a little.
3. Switch the pump unit off.
4. Check that the vent flap is closed.
5. Close the cab windows and ventilator.
6. Turn off the main switch in the machine room.
7. Do not switch off the auxiliary supply.

4.7 Emergency shutdown of the crane

Three emergency stop buttons are installed in the crane and its housing:
• On the ladder at the crane's access door (upper part of foundation)
• At the switch box
• On the right control panel

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Board Crane type DK II NMF
5 Maintenance and repair
December, 2007

5.1 General safety instructions

5.1.1 Prior to maintenance and repair

1. Take the crane out of operation.

2. Switch off the central power supply using the master switch.
3. Lock the master switch and put up a warning sign to prevent it being switched on
again.
4. Block access to the crane's operation area and ensure that no unauthorised persons
are within it.
5. Ensure that lifting and load-bearing equipment appropriate for replacing larger crane
parts is available.
6. Replace all defective crane parts immediately.
7. Use only original NMF spare parts.

5.1.2 When working on electrical equipment

Check electrical equipment regularly:

• Tighten loose connections.
• Replace damaged wires or cables immediately.
Always keep the switch box and all electrical supply units locked. Access to these is only
permitted to authorised persons using a key or special tool.
Never clean electrical equipment with water or similar fluids.

5.1.3 When working on hydraulic systems and equipment

Before starting work, depressurise all hydraulic systems / system parts.

Hose lines should always be replaced during repairs as a preventive maintenance measure
- even if no damage is discernable.

5.1.4 Environmental protection

When working on and with the crane, be sure to observe all regulations pertaining to waste
avoidance, recycling and disposal.
In particular, when carrying out assembly and maintenance work and when taking the crane
out of operation, take care that substances which may contaminate ground water, such as
greases, oils, coolants, solvent-based cleaning fluids, etc., do not damage the environment.
Neuenfelder Maschinenfabrik GmbH

Such substances should be collected, stored, transported and disposed of in suitable recep-
tacles.

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NMF Board Crane type DK II

5.1.5 After maintenance and repair

5.1.5.1 Before starting the crane, do the following:

• Check that all screws and bolts that were loosened are now tightly secured.
• Check that all protective devices, covers, filters, limit switches and pressure switches
that were removed are replaced correctly.
• Make sure that all tools, materials and other equipment that was used are removed from
the operating area.
• Clean the operating area and remove any fluids or similar substances that may have
spilled.
• Make sure all safety devices are present and ensure they are functioning in a fault-free
manner.
• Check all of the functions as well as the limit switches for the individual load levels with
no load.

5.1.6 Personnel requirements

5.1.6.1 When working on electrical equipment

All work on the crane's electrical equipment must only be carried out by qualified electri-
cians.
When carrying out work on live crane parts or wires, a second person who can turn off the
master switch in an emergency must always be present.

5.1.6.2 When working on hydraulic equipment

All work on the crane's hydraulic equipment must only be carried out by qualified specialists.

5.1.7 Functional check and safety inspection

The functional check and safety inspection is to be carried out in accordance with the guide-
lines issued by the relevant classification society. Please ask the manufacturer to send a
specialist, if needed.
Carry out the following inspections:
1. Visually inspect the steel structure for signs of possible damage.
2. Inspect the main welding seams on the foundation and the crane for cracks.
3. Inspect the ropes for wire breakage.
4. Inspect the sheaves for damage and wear at the bottom of the grooves, and verify
free movement.
5. Check that the hook and swivel move freely.
6. Check the limit switch settings.
7. Check the nominal speed of the individual functions while the crane is idling.
8. Test the system at nominal load.
9. Measure the system pressures of the individual functions and compare them with the
pressures prescribed in the hydraulic diagram; correct these if required.

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10. Carry out a braking manoeuvre that includes all movements, including activation of
December, 2007

the emergency stop button. The brakes should engage immediately and hold the
load without fault.
11. If required, secure misaligned pressure relief valves, pressure switches etc., or mark
their position with marking paint.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.2 Maintenance schedule

Maintenance is deemed to be the regular inspection and care of the crane to ensure fault-
free operation.
The table below shows the maintenance intervals.
A maintenance overview is provided in the lubrication chart ( siehe Seite 5-9, Absatz 5.4).

Interval Part Activity

Before every operation or Crane - visual inspection

after each sea journey Hydraulic oil tank - check oil level
Gears: - check oil level;
(winch gear, slewing gear, pump drive unit gear) see instructions (siehe Seite 16, Abb. 20);
(siehe Seite 17, Abb. 21)
The oil volume is specified on the type
plate and in the lubricant table ( siehe
Seite 5-8, Absatz 5.3)
Filter service indicator - check filter service indicator,
replace the filter cartridge if necessary (see
"Filter" instructions see (Chapter 7,
Ersatzteilkatalog, Page 7-1)).
Limit switches - test all limit switch settings and check that
they are functioning correctly (see section
( siehe Seite 5-50, Absatz 5.10.2)).
Slack rope switch (optional) - functional test ( siehe Seite 5-28, Absatz
5.6.11)
Weekly gear rim - lubricate sufficiently
Monthly Visual inspection - pay particular attention to the ropes,
sheaves, rope end connections and safety
harness.
Bottom hook block - visual inspection: hook, sheave, swivel,
shackle, roller bearing; check tightness of
all bolts. ( siehe Seite 5-23, Absatz 5.6.8)
Every three months Crane - cleaning
Crane ropes - lubrication, greasing
Rope end connection, swivel - lubrication, greasing
Sheaves - lubrication, greasing
Winch bearing - lubrication, greasing

Table 4:

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December, 2007

Interval Part Activity

Every six months Slip ring assembly - visual inspection (see item 5.6.10, page
5-27)
Oil cooler - visual inspection; cleaning if required see
(Chapter 7, Ersatzteilkatalog, Page 7-1)
Bolt connections - check the tightness of all bolts, especially
in rope end connections, jib base and bot-
tom hook block.
Slewing ring - inspect the seals
Yearly Crane - functional check and safety inspection
(see item 5.1.7, page 5-2)
Gear brakes - check brakes for leakages
(winch gear, slewing gear) - check braking torque
- inspect brake discs
( siehe Seite 5-35, Absatz 5.8)
Hydraulic system - hydraulic oil sample analysis (oil tank)
Slewing ring - grease sample:
examine extruded grease for abraded par-
ticles
- have manufacturer examine lubricant
sample. (see item 5.5.3, page 5-13)
Bottom hook block - inspection by an expert
(see item 5.6.8, page 5-23)
Initially after 50 hours of Hydraulic system - change filters
operation (see item 5.6.7.3, page 5-20)
Gear oil cooler - change filters
(see item 5.6.7.1, page 5-20)
Slewing ring (roller bearing) - relubricate
(see item 5.5.3, page 5-13)
Initially after 100 hours Slewing ring - check the tightness of bolts and nuts
of operation (see item 5.5.3, page 5-13)
Pumps - visual inspection; leakages
Initially after 200 hours Gears: - oil change
(winch gear, slewing gear, pump drive unit gear)
of operation

Table 4:
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

Interval Part Activity

Every 500 hours of oper- Hydraulic system - change filters

ation or every six months (see item 5.6.7, page 5-20),
Hydraulic system - hydraulic oil sample analysis (oil tank)
Gear oil cooler - change filters
Gear oil sample - gear oil sample analysis
(hoisting gear, luffing gear, slewing gear and pump
drive unit gear)

Oil cooler - visual inspection; cleaning if required

Ropes, rope connections - inspect ropes and rope end connections
for damage
- inspect ropes in accordance with the
guidelines issued by the relevant classifica-
tion society.
- see section
Sheaves - inspect for signs of wear, check tightness
of bolts
Bottom hook block - visual inspection: hook, sheave, swivel,
shackle, roller bearing
(see item 5.5.6, page 5-15)
Slack rope switch (optional) - inspect sheave for damage (see item
5.6.11, page 5-28)
Electrical equipment including slip - ( siehe Seite 3-15, Absatz 3.4)
ring assembly
Cab heating - functional test
Crane housing, foundation, jib - inspect welding seams for cracks
Slewing ring - inspect the seals
Slewing gear and gear rim - check backlash
Cable drum (optional) - inspect electrical connection, slip ring
assembly, brake, brush holder
Initially after 800 hours Hydraulic system - oil change
of operation - hydraulic oil sample analysis

Every 1000 hours of Gearbox - oil change

(winch gear, slewing gear, pump drive unit gear)
operation
Entire crane - inspection by the NMF service depart-
ment is recommended
Every 1500 hours of Hydraulic system - oil change
operation - gear oil sample analysis
At least once a year Hydraulic system - change filters
Gear oil cooler - change filters
Gear brakes - remove motor and brake to check input
(winch gear, slewing gear) side spline shaft ( siehe Seite 5-35,
Absatz 5.8)

Table 4:

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December, 2007

Interval Part Activity

Every two years Hydraulic oil tank - drain oil via drain valve, clean tank
- check correct functioning of float switch
- inspect vent valve
- refill with new oil; see lubricant list
- change oil filter
Every three years Gearbox Inspection of gears
(see item 5.6.5, page 5-18)
At class renewal or every Slewing ring - re-tighten bolts with sufficient torque
5 years (see item 5.5.3, page 5-13)
If necessary, contact the NMF service
department.
Ropes - rope inspection; check discard criteria
( siehe Seite 5-29, Absatz 5.7)
Crack testing - the inspector may request that connec-
tions of all kinds be inspected for cracks
using appropriate procedures

Table 4:

NOTE
Please also refer to the spare parts documentation (see item 6, page 6-1).
Neuenfelder Maschinenfabrik GmbH

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Board Crane type DK II NMF

5.3 Lubricant table

Neuenfelder Schmierstofftabelle für Schiffshilfsmaschinen
NMF Maschinenfabrik GmbH
21129 Hamburg Table of Lubricant for Hull Auxiliaries
BEDINGUNGEN / CONDITIONS 2006
Außentemp. x)
Viskosität Hydraulikanlagen in:
Outdoor Pourpoint ELF BP Castrol Exxonmobil SHELL FAMM Füllmenge
Viscosity Hydr. Equipm. Installed in:
temp. Oil Quantity
Tief -20°C Bordkran/Deck Crane 1000 l
Low Lastdrehvorrichtung
l
Univis Rando oil Load Turning Devise
Visga Bartran Hyspin N 46 Tellus oil HDZ 46 Spannwinde
l
46cST/40°C <-15° 46 HV46 AWH-M 46 Nuto T 46 HD46 Span winch
ISO VG 46 Vitam H 46 Rudermaschine
l
HF 46 Mobil DTE Steering Gear
Normal 45°C 15 M Sonstige hydr. Anlagen
l
Normal Other hydr. Drives
Tief -30°C Hubwindengetriebe x ) 17,0 l
1
Low Cargo Winch Gear
Hangerwindengetriebe x ) 16,0 l
1
Spartan Omala Topping Winch Gear
SEP HD Drehwerksgetriebe 1
l
x )3x13,5
220 220 Turning Gear
. Hilfswindengetriebe l
220cST/40°C <-25° C Epona Enersyn Alphasyn Mobil Tivela Pinnacle Auxiliary Winch Gear
ISO VG 220 SA 220 HTX HG SHC 630 WB Marine Bootswindengetriebe l
Synthetical 220 220 220 GEL Boat Winch Gear
PAO Oil 220 Kabeltrommelgetriebe l
Cable drum gear
Sonstige Getriebe l
Other Gears
Normal 45°C Pumpenverteilergetriebe x ) 7,5 l
1
Normal Pump Distribution Gear
Achtung: Synthetisches Getriebeöl auf PAO- Energrease Spheerol MobilTac Alvania Offene Zahnradgetriebe 30 kg
Basis darf nicht mit synthetischen Getriebeöl auf MP-MG2 SX2 375 NC EP2 OpenToothed Gearings
Polyglykolbasis gemischt werden. CERANA Energrease Spheerol Mobilarma Rhodina Novatex
Ölwechsel und Fettschmierintervalle siehe AD MP-MG 2 SX2 798 Grease EP2 Seile
Wartungsanleitung 50 kg
Mobil Grease EP Novatex Rope
XHP 222 FK10
Attention: Synthetically gear oil on PAO-base CERANA Energrease Spheerol Mobil Grease Alvania
may not be mixed with synthetically gear oil on VR2 MP-MG 2 SX2 XHP 222 RL Lager(Fettschmierung)
polyglycol base Mobilith Bearings (Grease Lubrication) 30 kg
Oil change and greasing intervals see SHC 460
maintenance instruction.
x) für einen Kran/for one crane
Erzeugnis/Produkt Auftrag/Order NB/Hull No.
x1)Werksfüllung/filling in the factory Deckskran
R 02/06

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Board Crane type DK II NMF
5.4 Lubrication chart
December, 2007

5.4.1 Symbols

see (Chapter 8, Zeichnungen + Ersatzteillisten, Page 8-1)drawing 845-0500-00(1)

Check hydraulic oil ISO VG 46 a before each use; weekly

Check hydraulic oil ISO VG 220 b every 100 hours; monthly

Gear rim grease c every 200 hours; every 3 months

NLGI 2 grease d every 500 hours

Rope grease e every 1000 hours

Oil inlet f yearly or every 1500 hours

Oil drain valve

Check dipstick

Check oil level viewing glass

Check filter; change filter after the

first 50 hours

Change hydraulic oil

first oil change after 800 hours

Change gear oil

first oil change after 200 hours

Vent valve
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.4.2 Lubrication schedule

Pos. Part a b c d e f

(see illustration 14, page 5-12) Door, hatch, hinges

(see illustration 15, page 5-13) Electric motor
(see illustration 16, page 5-13) Gear rim, pinion, slewing gear
(see illustration 17, page 5-14) Sheaves - jib
(see illustration 18, page 5-14) Sheaves - crane housing
Rope end connections at jib and
crane housing (optional)
(see illustration 19, page 5-15) Bottom hook block, swivel,
sheave
(see illustration 20, page 5-16) Slewing gear
(see illustration 21, page 5-17) Hoisting winch, luffing winch
(see item 5.7, page 5-29) All ropes
(see item 5.6.6, page 5-19) Pump distribution gear
Oil tank
(see item 5.6.7.3, page 5-20) Hydraulic oil filter
(see item 5.6.7.1, page 5-20) Gear oil cooler
Hydraulic oil tank vent valve
Locking cylinder (optional)
Cable drum (optional)

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Board Crane type DK II NMF
5.5 Images of the lubrication points
December, 2007
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.5.1 Door hinge lubrication points

Illustration 14: Roof hatch grease nipple

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Board Crane type DK II NMF
5.5.2 Electric motor
December, 2007

Upper motor bearing grease nipple

Lower motor bearing grease nipple

Illustration 15: E-Motor

5.5.3 Slewing ring

Grease nipple: slewing gear

Grease: gear rim

Neuenfelder Maschinenfabrik GmbH

Illustration 16: Gear rim

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NMF Board Crane type DK II

5.5.4 Jib sheaves

Jib head sheave grease nipple

both sides
Grease

Illustration 17: Sheave Jib

5.5.5 Crane housing sheaves

Grease nipples
Grease

Rope end connection

Grease nipples
Grease

Illustration 18: sheave crane upperpart

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Board Crane type DK II NMF
5.5.6 Bottom hook block
December, 2007

Grease nipples
Grease

Illustration 19: Bottom hook block

Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.5.7 Slewing gear

Oil level viewing glass

Oil inlet

Illustration 20: Slewing gear

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Board Crane type DK II NMF
5.5.8 Winch
December, 2007

Oil inlet
Grease nipples Oil dipstick

Oil drain valve

Illustration 21: Winch

Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.6 Maintenance and repair

5.6.1 Crane cleaning

• Grease all exposed parts to prevent corrosion.

• Make sure all bolt connections are tight and check for leaks in the line system.
• Do not repair damaged pipes and hoses - they must be replaced.

5.6.2 Lubrication

Use the lubricants listed in ( siehe Seite 5-8, Absatz 5.3).

5.6.3 Changing the oil

CAUTION
Only change the oil:
• When the gears are at a standstill
• While still warm after operation.

1. Remove the ventilation filter.

2. If the ambient temperature is low:
Rinse with a small amount of fresh, warm oil to remove abraded particels and con-
taminants.
3. Fill to the oil volume specified on the type plate.

5.6.4 Gearbox

The gears have splash lubrication. The roller bearing at the gearbox output is filled with
grease. As this is a lifetime lubrication, it is not necessary to refill or replace it.

5.6.5 Gearbox inspection

To ensur the highest degree of reliability, we recommend sending the gearbox to the
manufacturer for servicing when inspection or repairs are due. As a preventative
measure to increase safety, we recommend a visual inspection of the gearbox (inside
! and out) every three years.
Inspecting the colour of the used oil
If the used oil is dark or black:
• Temperatures of over 100 °C were reached during operation. This causes the oil to age
more quickly and decreases its lubricity.
• Change the oil at shorter intervals.
If the used oil is cloudy:

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Board Crane type DK II NMF
• Water penetration may have taken place.
December, 2007

• Change the oil immediately. When doing so, clean the gearbox by flushing it repeatedly
with fresh oil.
• We recommend removing the gearbox and examining the parts for signs of corrosion.
Checking the oil level
Compare the amount of oil drained off with the specified oil quantity.
Check for insoluble contaminants
We recommend checking for contaminants in accordance with DIN 51592. In this proce-
dure, the sample is dissolved in pure benzene, warmed slightly if required, and passed
through a fine-pored benzene-proof membrane filter. The residue is washed, dried and
weighed to determine the contaminant level.
The maximum permissible contaminant level is approx. 0.15 % of the total gearbox oil vol-
ume. However, these contaminants may only consist of fine abrasion particles no larger
than 25 µm.
If this value is not exceeded, the gearbox can be taken into operation after the oil change.
If larger particles (over 25 µm) or flakes from the tooth flank are detected, the gearbox must
be removed - regardless of contaminant level. Visually inspect the tooth flanks of the gear
rims, especially the large sun gear of the output planetary gear step.

5.6.6 Pump drive unit

Cleaning
• Clean the outside of the gearbox.
• Check for leakages or loosened bolts.
• Take oil samples. The presence of larger abraded metal particles in the oil or near the
drain plug indicates increased wear or incipient damage. If this is the case, inspect the
gearbox carefully.

Changing the oil

• When changing the oil for the first time, clean the gearbox by flushing it with fresh oil.
• Clean the ventilation filter and the magnetic plug on the drain plug each time you
change the oil.
The markings on threaded dipsticks apply when the disptick is not screwed in.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

The markings apply when the dipstick is inserted fully (but not screwed closed).

5.6.7 Filters

5.6.7.1 Gear oil cooler filter

see (Chapter 7, Ersatzteilkatalog, Page 7-1)

Cleaning and replacing the oil filter cartridge
1. Unscrew the filter housing and remove it.
2. Take out the dirt trap and cartridge.
3. Empty the accumulated sludge into a used oil container.
4. Pull the element out of the dirt trap.
5. Clean the trap.

CAUTION
Wash only elements made of wire mesh (type 25 W) in cleaning fluid.

6. Insert a new cartridge with dirt trap into the filter housing.

5.6.7.2 Changing the hydraulic oil

We recommend having oil samples analysed by the supplier. The supplier will then provide
information on the condition of the oil and will recommend a date for changing it.

5.6.7.3 Changing the hydraulic oil filter

Display
The filters have an optical clog indicator. see (Chapter 7, Ersatzteilkatalog, Page 7-1)
Changing the element
The element should generally be changed when the clog indicator is activated during normal
operating conditions. If the clog indicator is activated only when cold starting, the element
does not need to be changed.
The intervals may be shorter when the crane is first taken into operation, after repairs, after
oil changes, etc..
1. Switch the crane off.
2. Depressurise the filter.

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CAUTION
December, 2007

If the filter is not depressurised before the work is carried out, it may empty suddenly,
which risks injury and material damage. The threads of the filter housing may seize
up if the filter is not depressurised or there are dirt particles in the threads.

3. Unscrew the filter housing (2) and remove it.

4. Dispose of the fluid in a suitable container. Do not re-use this fluid in the crane.
5. Remove the element (3).
6. Examine the surface of the element for traces of dirt and larger particles. Their pres-
ence may indicate damage to components.
7. Replace or clean the element (3) as needed.

CAUTION
Only clean elements made made of wire mesh (W) or metal fleece (V). Do not clean
elements made of BETAMICRON E-2 (BH/HC, BN/HC, BH and BN) filter material.

8. Clean the inside of the housing (2). Make sure that the clean side is not contami-
nated.
9. Examine the filter, especially the sealing surfaces and threads, for signs of mechani-
cal damage. Replace the parts if needed.
10. Check the O-ring (4) on the housing (2). Replace the O-ring if it is damaged.
11. Coat the filter threads and sealing surfaces and the element O-ring (3) with fresh
lubricant.
12. Make sure that the new element is of the same specification as the one being
replaced.
13. Mount the element on the trunnion. Screw the housing (2) in fully.
14. Check the filter for leakage.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

NOTE
Replace one-way filter elements and dirty Betamicron N-2 (BN, BN/HC) and
Betamicron 9H-2 (BH, BH/HC) elements only with new elements.

Illustration 22: Filters

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Board Crane type DK II NMF
5.6.8 Bottom hook block
December, 2007

1. Maintenance
Inspection and lubrication intervals depend on the number of operating hours, the conditions
of use, the operating conditions and the user's considered judgement. The following guide-
lines apply for normal use:
2. Inspection
Each bottom hook block must be inspected by an expert at least once a year. Inspect the
following regularly:
• Wear to the side plates, sheave surfaces, axes, bushings and bearings;
• Any deformation of bottom hook block parts;
• Sheave fit and play;
• Tightness of nuts, bolts and other fastening elements;
• Corrosion;
• Cracks in welding seams.
The user or owner should contact NMF if repairs are required.
3. Lubrication
Grease specification: ( siehe Seite 5-8, Absatz 5.3)
• Sheave bearings:
Roller bearings: daily with continuous use or every 14 days with periodic use.
• Thrust bearing at hook:
Roller bearings: monthly with periodic use.
4. Permissible load
Ensure that the permissible load, Safe Working Load (SWL) or Working Load Limit (WLL)
specified on the bottom hook block is not exceeded.
5. Warning
• Do not pull diagonally.
• Apply load gradually without jerking.
• Do not load only one side of a double hook.
• Maximum pull on hoist lugs = 1/3 SWL.
• Do not carry out welding work on bottom hook block parts.
• Keep your hands away from the sheaves and other moving parts.
• In areas where loads are transported, or loads are moved using the bottom hook block,
personnel must wear personal protective clothing.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

5.6.9 Slewing ring

Lubrication and maintenance

The first re-lubrication of the raceway and lubrication of gears must follow mounting imme-
diately. Lubricants to be used for this and every subsequent lubrication are listed in lubricant
table ( siehe Seite 5-8, Absatz 5.3). These raceway lubricants are solely KP 2 K lubricants,
i.e. lithium-saponified NLGI Grade 2 mineral oils with EP additives. The raceway lubricants
in the lubricant list can be mixed with one another. The grease filling prevents friction, acts
as a sealant and protects against corrosion. Lubrication should therefore be so generous
that a collar of fresh grease builds up around the entire circumference of the bearing gaps
and seals. Rotate the bearing when re-lubricating it.
Lubricants
Lubricant-specific queries should be directed to the manufacturer. The greases listed in the
lubricant table are approved for these large roller bearings and have been tested for com-
patibility with the materials we use for spacers and seals.
Maintenance personnel must determine individual consumption rates by regularly checking
the lubrication state of the raceways and gears.
Raceway lubrication intervals
Select an interval that fits the operating conditions.
Generally about every 100 operating hours; roller
bearings every 50 operating hours.
Shorter lubrication intervals:
• In the tropics, with high humidity, in very dusty and
dirty environments, with severe variations in tem-
parature and with continuous slewing.
• If there are idle periods between the time the bear-
ing is mounted and the equipment is brought into
use, appropriate maintenance measures must be
taken, e.g. re-lubrication under rotation within at
least 3 months and at further intervals of 3 months.
• If the equipment is not in use for a longer period,
re-lubrication is essential both before and after the
equipment is taken out of use. This applies especially to winter breaks. When cleaning
the equipment, it is essential to ensure that cleaning agents do not damage the seals or
penetrate the raceways. Check the seals every 6 months.
Gear lubrication intervals
Before being taken into operation, the gear and pinion must be adequately lubricated using
one of the gear greases listed in the lubricant table. We recommend weekly gear lubrication.
There must always be a sufficient layer of grease on the gear.
Inspection of bolts
During mounting or installation, the stud bolts are tightened twice using a clamping cylinder
that applies appropriate torque (traction) to the bolt.
It is necessary to ensure a sufficiently high bolt preload force throughout the lifespan of the
slewing ring. Based on our experience with compensating for settling effects, we recom-
mend regular tightening of the bolts using sufficient tightening torque. Inspection is possible
only by gently tapping the nuts. If gentle tapping of a nut produces an abberant sound, the
nut must be hammered tight using a bump key and hammer.

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Board Crane type DK II NMF
Inspection of the raceway
December, 2007

Large roller bearings are supplied with bearing clearances that guarantee good running con-
ditions and functionality. We recommend taking a base measurement before bringing the
equipment into operation. After a longer period of operation, the bearing clearances
increase. It is therefore necessary to check for such axial movement or settling at regular
intervals.
We recommend measuring bearing wear to assess the condition of the bearing. A change
in the axial motion indicates raceway wear. This can be assessed by measuring settlement
regularly.
Settlement measurement
Settlement can be measured when the focal point of the combined loads lies within the track
diameter of the bearing. This load principle is illustrated in Figure 26. Settlement can only
be measured if a base value is established when the equipment is first taken into operation.
The bolt connection must be tightened correctly. Assuming fixed jib positioning, measure-
ments are taken at various positions on the circumference. The measurement is made
between the lower connecting structure and the bearing ring that is bolted to the upper struc-
ture.
The measurement values derived in this way are listed in a table and compared to the base
measurement (Figure 28). Settlement measurements should be taken at intervals of no
more than twelve months, and always under the same conditions. The measurement inter-
vals should be shortened if the equipment is under strong wear. If the difference between
the current measurement and the base measurement exceeds the maximum values, please
contact NMF.
Neuenfelder Maschinenfabrik GmbH

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NMF Board Crane type DK II

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5.6.10 Slip ring assembly
December, 2007

CAUTION
Prior to opening the slip ring assembly cover
• Switch the power off,
• Prevent unauthorised activation of the power

1. The entire slip ring assembly including the brush holders and insulation material must
be dry and free of dust and grease.
Remove the output from the carbon contacts carefully.
Smooth any oxidised areas on the running surfaces with a fine emery cloth.
2. Inspect the mobility and contact pressure of the brush holder's joint arms by lifting
them.
Replace stiff joint arms and brush holders with insufficient contact pressure with new
parts.
Make sure that all brush holders are aligned to the centre of the slip ring.

CAUTION
The brush holder joints and the ring surface should not be greased or oiled under any
circumstances.

3. Replace heavily worn carbon contacts and carbons with burns with new ones.
The carbon contacts should never be worn down to more than 1/3 of their original
length.
If new carbon contacts are required, both brush holder carbons need to be replaced
with the carbon contacts of the same manufacture.
As service life of the carbons depends on the operating times and the slip ring assem-
bly speed, it is not possible to specify fixed replacement intervals.
To ensure a large contact surface, new carbon contacts should be ground to fit the
ring radius. This is done by placing a piece of emery cloth on the ring surface and pull-
ing it back and forth underneath the new carbons several times, which grinds the ring
radius into the carbon. The resulting dust must be removed.
4. Check that the connection cables are firmly connected to the ring and the brush hold-
ers. Tighten the bolts if needed.
5. Check that the shaft seal, cable connections and rubber profile seal are impermea-
ble. Replace defective parts immediately to prevent moisture penetration.
Neuenfelder Maschinenfabrik GmbH

6. Screw the housing cover back on so that it fits tightly.

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NMF Board Crane type DK II

5.6.11 Slack rope switch apparatus

Setting switch 2
1. Loosen the clamping bolt (1.1).
2. Lower the hook to the deck and run out some slack rope.
3. Turn switch cam 1 in the direction of the arrow with 1 cm clearance past switch 2 until
the red pilot lamp goes out. Tighten clamping bolt (1.1).
4. Repeat the lowering process.
When "lowering", the hoisting gear must switch off without difficulty when the hook is
resting. Make sure the rope layers do not cross over one another.

Illustration 23: Slack rope switch

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5.7 Rope maintenance, care and discard criteria
December, 2007

NOTE
Maintaining the ropes at regular intervals ensures safe operation of the crane and
increases rope life significantly. Under identical test conditions, well-greased ropes
permit four times as many reverse bending cycles as ungreased ropes.

5.7.1 Cleaning and greasing of ropes

Crane ropes are moving and slightly twisting parts. During operation, they cause friction at
the sheaves and rope drums.
1. Clean heavily soiled wire ropes by brushing them. If the soiling is extremely heavy or
the rope grease has resinified, clean the ropes, sheaves and rope drums with a non-
caustic degreaser and dry them afterwards.
2. Take special care to grease the ropes at the bending zones (drums and sheaves).
The lubricants to be used are listed in ( siehe Seite 5-8, Absatz 5.3). Lubricants used
for re-greasing must be compatible with the original lubricant.

CAUTION
Make sure that when unwinding the rope, 3 safety wraps remain on the rope drums.
Grease the ropes again with a suitable rope grease and operate the crane without a
load for a few work cycles to distribute the grease evenly.

If the lowermost layers on the drum are used infrequently or not at all, they must be unwound
and rewound with sufficient pre-tension from time to time. A rope works most economically
when its entire length is always used. For this reason, it is recommended that an appropriate
rope length be used for longer crane operations.
If sections of the rope are subject to very different workloads, the rope can be reversed after
a certain period of operation. Rope life can be noticeably extended by attaching the formerly
free end of the rope to the drum, so that the portion previously exposed to less wear is now
positioned in the higher use zone, while the more worn portion of the rope is positioned so
that it receives less wear.
If the wear occurs mainly in multi-layer spooling on the Lebus drum, rope life can be
extended by shortening the rope by a length corresponding to 1/3 of the drum diameter. This
can only be done twice.

5.7.2 Monitoring
Neuenfelder Maschinenfabrik GmbH

If needed, the wire ropes and rope end connections should be inspected visually for signs
of damage on a daily basis. Any irregularities discovered in this way must be reported to the
appropriate decision maker.
Wire ropes must be inspected regularly by trained personnel to ensure they are in a safe
operational condition. The intervals between these inspections must be short enough for
damage to be identified at an early stage. For this reason, the intervals should be shorter
than usual in the first few weeks after a rope is installed as well as after the first signs of wire

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NMF Board Crane type DK II

breakage are detected. The intervals should also be shortened (to hours if necessary) if the
rope is subjected to unusually high loads or if non-visible damage to the rope is suspected.
Such an inspection should also be carried out when the crane is taken into operation after
a longer stillstand period, as well as each time there is a rope-related accident or damage.
During this inspection, particular attention should be paid to the portions of the rope that run
over the sheaves or that are near equaliser sheaves, suspensions or connections.
Ropes are designed in such a way that when the first wire breakage appears, it is safe to
continue using the rope until a new one is installed.
The operational safety of the ropes can be judged according to the following criteria:
• Type and number of wire breakages,
• Position and chronological sequence of wire breakages,
• Reduction in rope diameter during the period of operation,
• Corrosion,
• Abrasion,
• Rope deformations,
• Heat-related damage,
• Time elapsed since installation.
Special attention must be paid to the beginnings of any changes in rope behaviour.

CAUTION
There is a serious risk of rope damage if the rope lines strike one another above the
hook block. This is always caused by additional torsion in the rotation-resistant
hoisting rope, which may originate from a number of factors and faults, but may also
be caused by exceptional stretching of the hoisting rope during heavy operation.
Compensating for such additional rotation requires extreme caution and expertise.

Untwisting the hook block with a rotation-resistant fixed point rope:

1. Set the hook block down.
2. Determine the direction of twist.
3. Detach the rope from the fixed point.
4. Carefully turn the rope by 180-360 degrees so that the hook block twist is compen-
sated for. If needed, simulate the correct direction of twist using a piece of string.
5. Reattach the rope at the fixed point.
6. Carefully lift the hook block and carry out several trial operations with no load on the
hook, using the hook block and a crane trolley, if available.
7. Repeat if necessary.
When doing this, make sure the twist is applied to the longest possible free length of rope.
The load-free trial operations distribute the twist onto the entire length of the rope.

CAUTION
Do not under any circumstances twist a short length of rope, as this can damage the
rope structure permanently.

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Board Crane type DK II NMF
If the hoisting rope was operated with an open swivel, untwisting can be achieved by oper-
December, 2007

ating the trolley several times with no load on the hook. If this is not successful, follow the
same procedure given for ropes with a fixed point, i.e., if there is no swivel or the rope is
already damaged or the cause of twisting cannot be eliminated.
The rope end connections and suspensions must also be inspected to ensure they are in a
correct, functional condition. The individual elements of the rope drive unit, drums and
sheaves should turn freely in their bearings, and the grooves should not show an imprint of
the rope surface.

5.7.3 Rope replacement

To avoid having to adjust the limit switch settings, follow these instructions when replacing
a rope.
Please note that the service life of a rope is influenced by many different factors. The most
common of these are internal friction and corrosion. A rope must nevertheless be replaced
after about 5-6 years.
1. Bring the crane into the jib park position.
2. Pull slightly on the hoisting and luffing ropes.
3. Count the number of wraps on the hoisting and luffing winches.
4. Make a note of the number of wraps.
5. Remove the limit switch from the winch and secure it. Do not twist the shaft of the
switch.
6. Now replace the rope.
7. After the new rope is installed, count the wraps. The number of wraps must match
Pos. 4. Reinstall the limit switch.
8. For safety reasons, check all limit switch settings.

5.7.4 Discard criteria

In the interest of safety during hoisting operations, the wire rope must be replaced in a timely
manner. The criteria listed in ( siehe Seite 5-29, Absatz 5.7.2) below form the basis for deter-
mining when a wire rope should be replaced, depending on the scope of the damage. Con-
tinued operation of the hoisting equipment can be dangerous.
1. Type and number of wire breakages
The way rope drives are designed makes wire ropes not durable. For this reason, wire
breakages occur during operation.
At the latest, a wire rope should be replaced when one of the various visible wire breakages
listed in the table on page 3 is detected at any point.
2. Position of the wire breakages
Neuenfelder Maschinenfabrik GmbH

If wire breakage clusters form, the wire rope must be replaced. The wire rope must be
replaced immediately if a strand breaks.
Chronological order of wire breakages
In important cases it may be advisable to determine the number of wire breakages occurring
over a period of time. This makes it possible to estimate future breakage increases and to
determine the likely replacement date.

Copyright © 2005 5-31

 Instruction manual
NMF Board Crane type DK II

Please note that wire breakages occur only after a certain period of operation, and then
increase at an increasingly faster rate.
3. Reduction in rope diameter during the period of operation
The wire rope must be replaced if structural changes cause a reduction in diameter of 15%
or more compared to the specified size in longer sections of the wire rope.
A prerequisite here is that the new wire rope must still fall within the tolerances specified in
DIN 3055 to DIN 3070, even if the wire rope is not of a standard design.
4. Corrosion
Corrosion is especially likely to occur when operating in a sea water atmosphere or in a cor-
rosive atmosphere and with ropes that are installed for longer periods in exposed conditions.
Corrosion of the outer rope wires can be detected by means of visual inspection. Corrosion
of inner wires, which cannot be seen, is difficult to determine.
Corrosion reduces the static breaking strength of the wire rope due to a reduction in its
metallic cross-section, along with reduced operational capacity due to corrosion pits.
If the rope diameter is reduced by 10% or more compared to the specified size, it should be
replaced even if no wire breakage is found.
5. Abrasion
Abrasion of the wire rope occurs as "internal abrasion", caused by the motion of strands and
wires rubbing against one another during bending, and as "external abrasion" caused by
motion between the rope and sheaves (e.g. due to slipping of the rope during starting and
braking) or as a result of the rope dragging on the ground or along the items to be hoisted.
Abrasion is encouraged by dust and by insufficient or no lubrication.
Abrasion reduces the static breaking strength of the wire rope due to a reduction in its metal-
lic cross-section, along with reduced operational capacity due to wear chamfer.
If the rope diameter is reduced by 10% or more compared to the specified size, it should be
replaced even if no wire breakage is found.
6. Rope deformations
Rope deformations are visible changes in the rope surface. The most important of these
deformations can be characterised by their appearance:
corkscrew-type deformartions, necking,
bird cages, flattening,
wire looping, curl-shaped deformations,
loosening of individual wires or strands, kinks and knots, buckling.
Deformations normally result in a loosening of the rope structure, at least in the vicinity of
the deformation. In the case of a corkscrew-type deformation, the axis of the rope forms a
helix when it is not bearing a load.

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Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 5-33

 NMF
Instruction manual
Deck crane type DK II

A n z a h l d e r s ic h tb a re n D ra h tb rü c h e b e i A b la g e re ife
T rie b w e rk s g ru p p e n T rie b w e rk s g ru p p e n
A n z a h l d e r tra g e n d e n 1E m , 1D m, 1C m , 1B m 1A m 2 m, 3 m , 4 m , 5 m
D rä h te in d e n A u ß e n litz e n K re u zs c h la g G le ic h s c h la g K re u zs c h la g G le ic h s c h la g
3
d e s D ra h ts e ile s ) A u f e in e r L ä n g e A u f e in e r L ä n g e A u f e in e r L ä n g e A u f e in e r L ä n g e
von von von von
6d 30d 6d 30d 6d 30d 6d 30d
B is 5 0 2 4 1 2 4 5
5 1 b is 7 5 3 6 2 3 6 12 3 6
7 6 b is 1 0 0 4 8 2 4 5 16 4 ~8
1 0 1 b is 1 2 0 6 10 2 6 10 19 ~ 10
1 2 1 b is 1 4 0 6 11 3 6 11 22 6 11
1 4 1 b is 1 6 0 6 13 3 6 13 26 6 13
1 6 1 b is 1 8 0 7 14 4 7 14 29 7 14
1 8 1 b is 2 0 0 8 16 4 8 16 12 8 16
2 0 1 b is 2 2 0 9 18 4 9 18 35 9 18
2 2 1 b is 2 4 0 10 19 5 10 19 38 10 19
2 4 1 b is 2 6 0 10 21 5 10 21 42 10 21
2 6 1 b is 2 8 0 1 1 22 6 11 22 45 11 22
2 8 1 h i.3 0 0 12 24 6 13 24 48 12 24
4
über 300 ) 0 .0 4 n 0 .0 8 *rn 0 ,0 1 *n 0 .0 4 *n 0 .0 8 *n 0 ,1 6 *n 0 .0 4 *n 0 .0 8 *n
B e i S e ilk o n s tru k tio n e n m it b e s o n d e rs d ic k e n D rä h te n in d e r A u ß e n la g e d e r A u ß e n litz e , z . b . R u n d litz e n s e il
6 x 1 9 S e a le n a c h D IN 3 0 5 8 o d e r R u n d litz e n s e il 6 x 1 9 S e a le n a c h D IN 3 0 6 2 , is t d ie A n z a h l s ic h tb a re r
D ra h tb rü c h e b e i A b la g e re ife u m 2 Z e ile n n ie d rig e r a ls n a c h d e n T a b e lle n w e rte n a n zu n e h m e n .
T rie b w e rk s g ru p p e n n a c h D IN 1 5 0 2 0 B la tt 1
d D ra h ts e ild u rc h m e s s e r
3 ) F ü lld rä h te w e rd e n n ic h t a ls tra g e n d a n g e s e h e n .
B e i D ra h ts e ile n m it m e h re re n L itz e n la g e n g e lte n n u r d ie L itz e n d e r ä u ß e rs te n L itz e n la g e n a ls
„A u ß e n litz e n “.

4 ) D ie e rre c h n e te n Z a h le n s in d a u fzu ru n d e n .

Table 5: Discard criteria for wire ropes

34
 Instruction manual
Board Crane type DK II NMF
5.8 Disc brake
December, 2007

The multiple disc brakes are mounted as a compact unit between the motor and the gear-
box.

Illustration 24: Brake components

5.8.1 Description

With hydraulically controlled, spring loaded brakes, a set of coil springs presses the disc
assembly together. The annular housing (2) with toothing to engage the outer discs (5),
along with the piston (1/1) and cylinder (1/2), are combined in one unit (see Figure 7). This
brake component is secured to the gearbox with bolts (12). The disc carrier (4) has toothing
to engage the inner discs (6), and is connected to the shaft to be braked. The brake is
released using oil pressure.

5.8.2 Connections

The brake has connections for the intake of the pressure medium. These are connected to
the pressure feed pipe of the hydraulic system. For the dimensions and positions of these
connections please refer to the installation drawing (or the installation drawing in see (Chap-
Neuenfelder Maschinenfabrik GmbH

ter 7, Ersatzteilkatalog, Page 7-1)).

Loosening or removing pressurised hydraulic lines or connections can be life-threat-
! ening. For this reason, make sure that when working on the brake (mounting, dis-
mounting), the brake and all related hydraulic lines are depressurised.

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NMF Board Crane type DK II

Illustration 25: Disc brake

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Board Crane type DK II NMF
5.8.3 Pressure media
December, 2007

Hydraulic oil is required to release the brake. The viscosity should be 32 to 68 cSt at 40°C.
Recommended oil grades are listed in see (Chapter 7, Ersatzteilkatalog, Page 7-1).

5.8.4 Operation

The brakes are designed for max. 320 bar operating pressure. The minimum release pres-
sure required is specified on the type plate.
Never operate the brake at pressures in higher than 250-320 bar, as this risks break-
ing the bolts or the circlips. The brake should also not be operated at a low release
pressure, as it is not a dynamic brake and could be damaged by doing so.
!
5.8.5 Manually lifting in emergencies

If the hydraulic system fails or when maintenance work is to be carried out, the brake can
be lifted manually. A manually operated hydraulic pump can be attached to the brake's pres-
sure oil connection for this purpose. The brake should be pressurised to the required lifting
pressure - see emergency lowering see (Chapter 5.9, Lifting the brakes in an emergency,
Page 5-40).

5.8.6 Brake maintenance

The brake adjusts itself automatically.

Leakage of small quantities of oil from the pistons is unavoidable at high pressures and with
frequent switching.
The discs must be replaced when worn. Wear becomes noticeable when braking torque is
no longer achieved. The coated discs are then worn down to the ground of the oil and dust
separation grooves. This makes the output or the oil stick between the discs and reduces
braking torque. Insert the discs in the correct order.
All sealing elements must be replaced when replacing the seals, not just the damaged seal,
i.e., seals must be replaced in sets.
It is imperative that the brake's hydraulic connections are not pressurised. Before dismount-
ing the brake, lift it manually as described in section 7.5 see (Chapter 5.8.7, Dismounting and
mounting, Page 5-37).

5.8.7 Dismounting and mounting

The flange (1/3) is under spring pressure. When the bolts (12) are loosened, it may suddenly
Neuenfelder Maschinenfabrik GmbH

come off. For this reason, the brake should be lifted manually before it is dismounted. Insert
two bolts of sufficient length with nuts into the threaded holes in the piston (1/1) located at
180° to each other (see Figure 7.7). Draw the piston toward the flange (1/3) by turning each
nut alternately by a half turn (avoid tilting the piston!). Then unscrew the bolts (12) and
remove the closed brake from the gearbox.

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NMF Board Crane type DK II

Illustration 26:

Further disassembly: Remove two bolts (1/7). It is now possible to pull the flange (1/3) with
the piston (1/1) out of the cylinder (1/2). When replacing the innner and outer seals, make a
note of how the seals are positioned to ensure they are reinstalled in the same way. Do not
damage the chrome-plated, super-finished piston slide faces in any way. Ensure complete
cleanliness! (Do not use any steel wool or abrasive cleaning agents). When replacing the
discs, place the annular housing (2) on the centre of the gearbox first. Then assemble the
disc assembly. Make absolutely sure that the discs are assembled correctly, as this is crucial
to the braking torque. Please refer to the "technical data sheet" in the appendix for the cor-
rect disc assembly. Should it be necessary to remove the flange (1/3) from the piston (1/1),
loosen the nuts on the emergency lifting bolts alternately. Never unscrew the emergency lift-
ing bolts unless the springs between the piston and flange are completely released (risk of
accident!).
The brake is re-assembled in the reverse order.
BEFORE RE-ASSEMBLING THE DISCS, DIP THEM IN OIL.
Please make sure that foreign lubricants (mounting lubricants, greases, lubricating pastes,
etc.) do not contaminate the disc housing, as this has a significant impact on the friction
! coefficient between the disc pairs and may cause the brake to stop functioning correctly.
Replacement discs are supplied in sets. The discs and the brake are described on the pack-
aging along with the size and number of discs. Discs do not bear serial numbers for func-
tional reasons.

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Board Crane type DK II NMF
5.8.8 Malfunctions
December, 2007

Braking torque decreases or is too low

• Check whether the discs are assembled correctly.
• Replace the disc assembly if excessively worn.
• Use a dry run to check whether leakage oil may have escaped.
Brake becomes warm
•Make sure there is sufficient lifting pressure.
•The brake may be under constant input pressure.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 5-39

 Instruction manual
NMF Board Crane type DK II

5.9 Lifting the brakes in an emergency

If there is a total power failure, the load can be lowered if necessary.
The steps to be taken in this case are described on the following pages.
IMPORTANT NOTE
The working lines A and B between the pump and the winch motor should not be dis-
mounted or connected with one another under any circumstances, since the load will enter
a free-fall when the brake lift hand pump is used to open the disc brake. Doing so is life-
threatenting and can result in extensive material damages.

5.9.1 Hoisting gear

To do this, it is necessary to:

1. Open the "bypass" ball cock (6.0). (see illustration , page 5-44)
2. Loosen the wheel at the choke (6.1) by one turn.(see illustration , page 5-44)
3. Lift the brake in question carefully using the brake lift hand pump.(see illustration 32,
page 5-45)

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Board Crane type DK II NMF
December, 2007

Ball cock

Throttle

Attach the hand lever only in emergencies.

Neuenfelder Maschinenfabrik GmbH

Illustration 27: By-pass ball cock

CAUTION
If there is a load on the hook, the load begins to lower at a brake lift pressure of 3-4
bar. Braking torque is reduced by 30% when there is a load on the hook.

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 Instruction manual
NMF Board Crane type DK II

5.9.1.1 Connect the brake lift hand pump as follows:

1. Find the hydraulic block (see illustration 31, page 5-44) and the hoisting gear brake
marking.
2. Dismount brake line 5, which connects the hoisting gear brake to the solenoid
valve.(see item 31, page 5-44)
3. Connect hose 2 of the brake lift hand pump (see illustration 32, page 5-45) to brake
line 5.
4. Close off the connection to the hoisting gear solenoid valve with a screw plug.
5. Close pressure release valve 5 on the brake lift hand pump and check the oil level in
the pump tank. (see item 32, page 5-45)
6. Carefully increase the pressure at the hand pump until the winch drum begins to turn
slowly (max. 2-3 rpm). If the winch drum turns faster, immediately open pressure
release valve 5 on the brake lift hand pump.
7. Recreate the original conditions once the load is lowered.
•Close the ball cock (6.0) again and secure it.
•Tighten the wheel at the choke (6.1) again.

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Board Crane type DK II NMF
5.9.2 Jib
December, 2007

1. Find the hydraulic block (siehe Seite 44, Abb. 31) and the luffing gear brake marking.
2. Dismount brake line 4, which connects the luffing gear brake to the solenoid valve
(siehe Seite 44, Abb. 31).
3. Connect hose 2 of the brake lift hand pump (siehe Seite 45, Abb. 32) to brake line 4.
4. Close off the connection to the luffing gear solenoid valve with a screw plug.
5. Close pressure release valve 5 on the brake lift hand pump and check the oil level in
the pump tank (siehe Seite 45, Abb. 32).
6. Open multi-function valves 4.1 and 4.2 at the pump (siehe Seite 46, Abb. 33).
7. Carefully increase the pressure at the hand pump until the winch drum begins to turn
slowly (max. 2-3 rpm). If the winch drum turns faster, immediately open pressure
release valve 5 on the brake lift hand pump.
8. Recreate the original conditions once the jib is lowered.

CAUTION
The tare weight of the jib causes it to start lowering at a brake lifting pressure of 3-4
bar. This reduces braking torque by 30%.

5.9.3 Slewing gear

1. Find the hydraulic block (siehe Seite 44, Abb. 31) and the slewing gear brake mark-
ing.
2. Close the ball cock (1).
3. Remove the screw plug below the ball cock.
4. Connect the hand pump hose to the threaded connection.
5. Close pressure release valve 5 on the brake lift hand pump and check the oil level in
the pump tank (siehe Seite 45, Abb. 32).
6. Open multi-function valves 5.1 and 5.2 at the pump (siehe Seite 46, Abb. 33).
7. Increase the pressure at the hand pump. The brakes are opened fully at 20 bar; the
slewing gears move freely. The crane can now be turned using an external winch.
8. To engage the brake, open pressure release valve 5 on the brake lift hand pump.
9. Recreate the original conditions once these steps have been taken.
CAUTION
Keep an eye on ship heeling/trimming when lifting the brake.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 5-43

 Instruction manual
NMF Board Crane type DK II

3.18
3.10

3.8 4.6 5.5 2.2

1
6
opened
4

The ball cock is always open. Close the ball cock only when attaching the hand pump.

Abbildung 31: Solenoid valve block connections

1. =Measurement connections
2. =Connection hose from change valve to hydraulic motor
3. =Slewing gear brake hose
4. =luffing gear brake hose
5. =hoisting gear brake hose
6. Ball cock slewing gear motor (only closed in emergenca operating)
3.8 Solenoid valve for the hoisting gear brake
3.18 Change valve for hoisting gear 40t
3.10 Change valve for hoisting gear 22t
4.6 Solenoid valve for the luffing gear brake
5.5 Solenoid valve for the slewing gear brake
2.2 Solenoid valve for the bypass

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Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Abbildung 32: Brake lift hand pump

Copyright © 2005 5-45

 Instruction manual
NMF Board Crane type DK II

Abbildung 33: Multi-function valve

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Board Crane type DK II NMF
5.10 Gear cam limit switch
December, 2007

The limit switch is only to be operated, serviced and repaired by authorised, trained
and inducted personnel.

MAINTENANCE

When carrying out service and maintenance work, take note of the chapter on safety instruc-
tions.
Maintenance or inspection work is generally not required at the limit switch. Do not remove
dust deposits from the contacts with compressed air, as this causes the dust to penetrate
more deeply into the contacts, which can be detrimental to the switching capacity.
Do not clean the limit switch with benzene. Replace the cover seal after opening the
cover, or after a longer period of operation.

CONTACT ADJUSTMENT

An adjustable cam disc set, consisting of cam discs (6) and (7), is assigned to each contact.
The cam disc set with the selector shaft are held in the selector shaft groove by means of a
ring (2) using the toothing of the cam disc (6) and a lobe.
The cam disc part (7) can be adjusted continuously by turning the self-locking bolt (8) radi-
ally. An extremely fine adjustment is possible depending on the direction the screwdriver is
turned in.
To reach the bolt (8) with the screwdriver, loosen the nut (3) a little. The corresponding cam
disc set can then be adjusted radially without affecting the other cam disc sets.
The cam disc (7) is designed in such a way that one operative path and one overrun path
are available. No damage is caused if the overrun path is exceeded. However, the contact
is opened or closed again.
Neuenfelder Maschinenfabrik GmbH

Illustration 34: Cam switch

Copyright © 2005 Gear cam limit switch 5-47

 Instruction manual
NMF Board Crane type DK II

5.10.1 Limit switch settings

Initial position:
Jib is in park position
Luffing gear cam switches WW0, WW1, WW2 and WW3 switch when luffing down.
Luffing gear cam switches WW5, WW6 and WW7 swtich when luffing up.
Hoisting gear cam switches HW1, HW2, HW3 and HW4 switch during hoisting.
Hoisting gear cam switch HW6 switches during lowering.
Rotation direction A on the gear side = lowering,
Rotation direction B on the gear side = hoisting,
The rotation direction is reversed on the cam disc side,
(see illustration 35, page 5-50), (see illustration 36, page 5-51)

5.10.2 The following steps need to be taken:

1 Jib is in park position.

Turn cam WW0 at the luffing gear limit switch in direction "B" until LED
8 goes out at 1A14. (see illustration 36, page 5-51)

2 Measure the maximum outreach from the middle of the crane's pivot
point to the middle of the hook.
Luff the jib up to the measured point (maximum outreach).
Turn cam WW1 at the luffing gear limit switch (see illustration 36, page 5-
51) in direction "B" until LED 9 goes out at 1A14.

3 Move the bottom hook block to about 1m unter the jib head.
Turn cam HW1 at the hoisting gear limit switch in direction A until LED
0 goes out at 1A14.

4 Turn cam HW2 at the hoisting gear limit switch (see illustration 35, page 5-
50) in direction A until LED 1 goes out at 1A14, then immediately turn
it in direction B so that LED 1 lights up again.

5 Run-on stage for bottom hook block

Measure an outreach of 25 m from the middle of the crane's pivot point
to the middle of the hook.
Luff the jib up to the measured point.
Turn cam WW1 at the luffing gear limit switch in direction B until LED
10 lights up at 1A14.

6 Move the bottom hook block to about 1m under the jib head again.
Turn cam HW3 at the hoisting gear limit switch in direction A until LED
2 goes out at 1A14.

7 Run-on stage for bottom hook block

Measure an outreach of 16 m from the middle of the crane's pivot point
to the middle of the hook.
Luff the jib up to the measured point.
Turn cam WW3 at the luffing gear limit switch in direction B until LED

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 Instruction manual
Board Crane type DK II NMF
11 lights up at 1A14.
December, 2007

Move the bottom hook block to about 1m under the jib head again.
Turn cam HW4 at the hoisting gear limit switch in direction A until LED
3 goes out at 1A14.

8 The hoisting gear rope is wound onto the drum in a second layer.
Turn cam HW6 at the hoisting gear limit switch in direction A until LED
4 goes out at 1A12.

9 Measure an outreach of 6m from the middle of the crane's pivot point

to the middle of the hook.
Luff the jib up to the measured point (6m).
The jib's reduced speed zone of 6.0m - 3.5m begins here.
Turn cam WW5 at the luffing gear limit switch in direction A until LED
13 goes out at 1A14.

10 Measure an outreach of 4.0m from the middle of the crane's pivot

point to the middle of the hook.
Luff the jib up to the measured point.
Turn cam WW6 at the luffing gear limit switch in direction A until LED
15 goes out at 1A14

11 Measure an outreach of 3.0m from the middle of the crane's pivot

point to the middle of the hook.
Luff the jib up to the measured point.
Turn cam WW7 at the luffing gear limit switch in direction A until LED
15 goes out at 1A14.

12 Move the bottom hook block down until the hook is about 1m above
the double bottom. A minimum of 3 safety wraps must remain on the
hoisting gear drum.
Turn cam HW6 in direction B until LED 5 goes out at 1A14.

13 Run the luffing and hoisting gears through after adjusting the limit
switches.
When luffing down the jib and turning off the hoisting gear, make sure
the jib does not touch the bottom hook block.
When luffing the jib down from its upper position, the jib switches off
at 25m outreach. The jib can only be brought to maximum outreach
when the bottom hook block is being lowered.

14 Slew the crane into the park position.

Activate the "Jib in park position" switch to bring the jib into park
position.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 Gear cam limit switch 5-49

 Instruction manual
NMF Board Crane type DK II

HW3HW2

HW6 HW4 HW1

B
B

Illustration 35: Hoisting gear limit switch settings

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 Instruction manual
Board Crane type DK II NMF
December, 2007

B WW7 WW5 WW3 WW1

WW6 WW2 WW0 B

1A5
Neuenfelder Maschinenfabrik GmbH

Illustration 36: Luffing gear limit switch settings

Copyright © 2005 Gear cam limit switch 5-51

 Instruction manual
NMF Board Crane type DK II

Illustration 37: Jib position

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 Instruction manual
Board Crane type DK II NMF
5.11 How do I replace a PLC?
December, 2007

Description of the devices (PLC)

PS 4-201-MM1
EM 4-201-DX2
LE 4-116-DX1
LE 4-116-XD1
One of these devices needs to be replaced if 24 VDC is supplied at the input but the input
LED does not light up.
If an output LED lights up but 24 V DC is not supplied at the output. Before proceeding,
make sure the power supply for the outputs works.
The PS4 must also be replaced if the POWER LED is no longer lit when power is supplied
to the device.
If the RUN LED is blinking, the PS4 or one of the EM4/LE4 units may be defective.
Disconnect the power supply before replacing any device.
PS4:
Disconnect the power supply wiring. (see Figure 1 on the next page).
Open the cover of the input and output terminals (see Figure 2). Do not disconnect the wires.
Pull on the cover to disconnect the plug-in screw terminal (see Figure 3).
Once the new PS4 is installed, insert the program memory. (see Figure 4-6).
EM4:
Disconnect the power supply wiring (see Figure 7).
Open the input terminal cover (see Figure 8). Do not disconnect the wires.
Pull on the cover to disconnect the plug-in screw terminal (see Figure 9). Open the cover in
the middle and disconnect the data cable for the next LE (see Figure 10). Now disconnect
the data cable plug from socket 1 (see Figure 11). This data cable connects the PS4 with
the EM4.
Once you have disconnected all cables, you can remove the EM4 from the top hat rail.
Before switching on the new EM4, set the coding switches according to the instructions in
the circuit diagram (see Figure 12).
LE4:
Open the cover of the input and output terminals (see Figure 13).
Do not disconnect the wires.
Pull on the cover to disconnect the plug-in screw terminal (see Figure 14). Open the cover
in the middle and disconnect the data cable for the other LE4 (see Figure 15).
You can now remove the device from the top hat rail.
Neuenfelder Maschinenfabrik GmbH

5.11.1 Changing the battery

(see Fig.16)
To prevent data loss, change the battery only when the crane is switched on.

Copyright © 2005 How do I replace a PLC? 5-53

 Instruction manual
NMF Board Crane type DK II

When changing the battery:

Pull the plug only when switched on!
CAUTION
Change the battery every year!!!
Verify the the battery change with a signature and date.

5-54 How do I replace a PLC? Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
December, 2007

Fig. 1
PS4 Fig. 2

Fig. 3 Fig. 4
memory card switch to position 3

Fig. 5 Fig. 6

insert memory card

break button
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 How do I replace a PLC? 5-55

 Instruction manual
NMF Board Crane type DK II

EM4 Fig. 7 Fig. 8

Fig. 9 Fig. 10

Fig. 11 Fig. 12

Coding switche

5-56 How do I replace a PLC? Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
December, 2007

Fig. 13 Fig. 14

Fig. 15 Fig. 16

Battery
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 How do I replace a PLC? 5-57

 Instruction manual
NMF Board Crane type DK II

5-58 How do I replace a PLC? Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
6 Spare parts
December, 2007

6.1 Ordering spare parts

Use only original NMF spare parts, as these parts have been designed especially for this
crane. It cannot be guaranteed that parts from other sources are designed and manufac-
tured in a way that meets operational demands and safety requirements.
The depictions of the spare parts are our property and are protected by copyright in accord-
ance with the legal provisions. They may only be used and employed with our written con-
sent, especially if they are to be made available to a third party. Objects manufactured on
the basis of these depictions may only be photographed with our written consent. Unauthor-
ised use or employment will be prosecuted under civil and penal law.
Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 Spare parts 6-1

 Instruction manual
NMF Board Crane type DK II

6.1.1 How to order spare parts

Ersatzteilbestellanleitung/How to order spare parts

Für die Bestellung von Ersatzteilen sind folgende Angaben erforderlich:
When ordering spare parts the following data are necessary:

Auftrags-Nr./Order -No.
Erzeugnis/Product Siehe Typenschild/See type plate
Typ/Type

Zeichnungs-Nr. Teil Benennung Menge

Drawing -No. Part Denomination Quantity
879-4900-01(0) 20 4/2 Wegeventil 1 Stück
4/2 Way solenoid valve 1 piece

P10P
Diese Darstellung(Zeichnung, Skizze, Fotografie, Plan ,Liste u.a.) ist unser Eigentum
und nach Maßgabe der gesetzlichen Bestimmungen urheberrechtlich geschützt. Sie darf
ohne unsere schriftliche Einwilligung weder benutzt noch verwertet, insbesondere nicht
Dritten zugänglich gemacht werden. Aufgrund dieser Darstellung hergestellte
Gegenstände dürfen ohne unsere schriftliche Einwilligung nicht fotografiert werden . Die
unbefugte Benutzung oder Verwertung hat zivil- und gegebenenfalls auch strafrechtliche
Folgen.
We have the proprietary right in this presentation (drawing, sketch, photo, plan,
statement etc.) which is copyrighted according to provision of law. Without written
consent it must neither be used or exploited nor made available to third parties. Photos
from the goods manufactured according to this presentation must not be taken without
our written consent. The unauthorised use or exploitation is liable to civil or - should the
case occur- penal prosecution.

6-2 Spare parts Copyright © 2005

korr-Schi/ho2007
Reserveteilliste / Spare parts list Auftrag/Order: 80449

Artikelnummer/Item-No. Benennung/Designation: Zeichungsnr./Drawing-No.

860-9900-00 Reserveteile / Spare parts 860-9900-00(4)
/

Pos/ Artikelnummer/ Menge/ Benennung/

Item Item-No. Qty. Designation

Ersatzteil: / Spare part

01 1,00 1,00 Handhebelfettpresse
Manual grease gun

02 1250ft010 1,00 1,00 HANDHEBEL-FETTPRESSE 75/PK

Manual grease gun

03 1250ft011 1,00 1,00 SCHLAUCH 160/L 300 MM LANG

hose

04 1250ft005 1,00 1,00 KUPPLUNG 521A F.FLACHKOPFNIPP.

coupling

05 1680mn003 1,00 1,00 GLYCERIN-MANOMETER

pressure manometer

06 1680mn005 1,00 1,00 GLYCERIN-MANOMETER

pressure manometer

07 1681mn202 2,00 1,00 MANOMETERMESSSCHLAUCH DN2

hose for gauge connection

08 1440gu200 1,00 1,00 EINZIEHWERKZEUG FÜR KEDER

tool for windows pane

09 1855ph310 1,00 1,00 BREMSLÜFTHANDPUMPE

manual pump of brake

10 1440gu154 1,00 6,00 KEDER (EINREIßFÜLLER) F. KLEMM

filler profile

11 1440gu155 1,00 6,00 KLEMMPROFIL

rubber profile

12 1980sl001 1,00 1,00 SEILEINZIEHSTRUMPF

wire rigging socks

13 3000ft004 10,00 1,00 SHELL ALVANIA FETT RL 2

grease SHELL RL2

14 3000sn004 10,00 1,00 FLACHKOPFSCHMIERNIPPEL M 1,

flat grease nipple M 10x1

15 2600vt039 1,00 1,00 4/2 W.-VENTIL, ELEKTR.BETÄTIGT

4/2- directional control valve, electric actuated

16 2423or011 10,00 1,00 O-Ring/o-ring für 4D01

o-ring for 4D01

Datum/date: 01.12.2007 12:37:43 Seite/ Side: 1 von/of 5

Reserveteilliste / Spare parts list Auftrag/Order: 80449

Artikelnummer/Item-No. Benennung/Designation: Zeichungsnr./Drawing-No.

860-9900-00 Reserveteile / Spare parts 860-9900-00(4)
/

Pos/ Artikelnummer/ Menge/ Benennung/

Item Item-No. Qty. Designation

Ersatzteil: / Spare part

17 1262fi321 2,00 1,00 FILTERERSATZELEMENT
filter element

18 1262fi200 2,00 1,00 ERSATZPATRONE 0160 MG 010 P

spin-on filter element

19 2423or001 5,00 1,00 O-Ring 8x2 NBR 70

o-ring for HD-hose

20 2423or002 5,00 1,00 O-Ring 9x2 NBR 70

o-ring for HD-hose

21 2423or003 5,00 1,00 O-Ring 13x2 DN 12

o-ring for HD-hose

22 2423or004 5,00 1,00 O-Ring 17x2,5; NBR 70

o-ring for HD-hose

23 2423or005 5,00 1,00 O-Ring 22x2,5

o-ring for HD-hose

24 2423or006 5,00 1,00 O-Ring 27x2,5 NBR 70

o-ring for HD-hose

25 2423or007 5,00 1,00 O-Ring 35x2,5 DN 32

o-ring for HD-hose

26 2423or008 5,00 1,00 O-Ring 48x3; NBR 70

o-ring for HD-hose

27 2423or009 5,00 1,00 O-Ring 32,92x3,53 (SAE 1")

o-ring for HD-hose

28 2423or010 5,00 1,00 O-Ring 37,69x3,53 (SAE 1 1/4")

o-ring

29 g08sa3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

30 g12sa3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

31 g16sa3cx 4,00 1,00 Ermeto-Verschraubung/ fitting

Ermeto-fitting

32 g20sa3cx 4,00 1,00 Ermeto-Verschraubung/ fitting

33 g22la3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

Datum/date: 01.12.2007 12:37:43 Seite/ Side: 2 von/of 5

Reserveteilliste / Spare parts list Auftrag/Order: 80449

Artikelnummer/Item-No. Benennung/Designation: Zeichungsnr./Drawing-No.

860-9900-00 Reserveteile / Spare parts 860-9900-00(4)
/

Pos/ Artikelnummer/ Menge/ Benennung/

Item Item-No. Qty. Designation

Ersatzteil: / Spare part

34 g25sa3cx 4,00 1,00 Ermeto-Verschraubung
Ermeto-fitting

35 g28la3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

36 g30sa3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

37 g35la3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

38 g38sa3cx 4,00 1,00 Ermeto-Verschraubung

Ermeto-fitting

39 g42la3cx 4,00 1,00 Ermeto-Verschraubung

40 1343fl330 2,00 1,00 SAE-VERSCHLUßFLANSCH AFC-404M

closing flange

41 vka38a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

41 1343fl350 2,00 1,00 SAE-VERSCHLUß-GEGENFLANSCH

close flange

42 vka08a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

43 vka12a3c 4,00 1,00 Ermeto-Verschraubung

blanking plug for cones

44 vka16a3c 4,00 1,00 Ermeto-Verschraubung/ fitting

blanking plugs for cones

45 vka20a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

46 vka22a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

47 vka25a3c 4,00 1,00 Ermeto-Verschraubung

blanking plug for cones

48 vka28a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

49 vka30a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

Datum/date: 01.12.2007 12:37:43 Seite/ Side: 3 von/of 5

Reserveteilliste / Spare parts list Auftrag/Order: 80449

Artikelnummer/Item-No. Benennung/Designation: Zeichungsnr./Drawing-No.

860-9900-00 Reserveteile / Spare parts 860-9900-00(4)
/

Pos/ Artikelnummer/ Menge/ Benennung/

Item Item-No. Qty. Designation

Ersatzteil: / Spare part

50 vka35a3c 4,00 1,00 Ermeto-Verschraubung
blanking plugs for cones

51 vka42a3c 4,00 1,00 Ermeto-Verschraubung

blanking plugs for cones

52 dn08-003-gl 1,00 5.000,00 HD-Schlauch DN8-2SN

hose line
840-4900-28(1) Pos. 61
53 dn12-002-gl 1,00 5.000,00 HD-Schlauch DN12-2SN
hose line
840-4900-28(1) Pos. 67
54 dn16-002-gl 1,00 2.500,00 HD-Schlauch DN16-2SN
hose line
840-4900-28(1) Pos. 71
55 dn20-003-gl 1,00 2.600,00 HD-Schlauch DN20-2SN
hose line
840-4900-28(1) Pos. 75
56 dn32-012-gl 1,00 4.400,00 HD-Schlauch DN 32-4SH
hose line
840-4900-28(1) Pos. 83
57 dn20-007-gl 1,00 1.200,00 HD-Schlauch DN20-4SP
hose line
840-4900-28(1) Pos. 80

58 dn40-008-gl 1,00 1.700,00 HD-Schlauch DN40-4SH

hose line
840-4900-28(1) Pos. 85
59 1810pr017 1,00 1,00 STROMREGELKARTE SRK 04
Current regulator print card

60 1170es010 1,00 1,00 KOMPAKTSTEUERUNG PS4-201-MM1

Spare appliance

61 1170es012 2,00 1,00 SPEICHERMODUL ZB4-128-SF1

flash memory modul

62 1420gr001 1,00 1,00 GLEICHRICHTER B 250-25

Rectifier

63 1650le901 1,00 1,00 NAV - LAMPE HD

sodium lamp

64 1800pt008 1,00 1,00 POTENTIOMETER B5 MIT PLATINE

Potentiometer

65 2364su732 1,00 1,00 Schaltkontakte DIL4AM145-XCT

contact switchcontacts

Datum/date: 01.12.2007 12:37:43 Seite/ Side: 4 von/of 5

Reserveteilliste / Spare parts list Auftrag/Order: 80449

Artikelnummer/Item-No. Benennung/Designation: Zeichungsnr./Drawing-No.

860-9900-00 Reserveteile / Spare parts 860-9900-00(4)
/

Pos/ Artikelnummer/ Menge/ Benennung/

Item Item-No. Qty. Designation

Ersatzteil: / Spare part

66 2364su726 2,00 1,00 Hauptschaltstücke DIL M250-XCT
contacts

67 1055bt003 10,00 1,00 GLÜHLAMPE 30 V BA 9S

bulb

Datum/date: 01.12.2007 12:37:43 Seite/ Side: 5 von/of 5

 Instruction manual
Board Crane type DK II NMF
7 Table of figures
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 38: Pump unit

Copyright © 2005 Table of figures 3-1

 Instruction manual
NMF Board Crane type DK II

Illustration 39: Load measurement system ( siehe Seite 25, Absatz 3.6)

3-2 Table of figures Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
December, 2007

Illustration 40: Crane cabin emergency exit

Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 Table of figures 3-3

 Instruction manual
NMF Board Crane type DK II

Illustration 41: Fault indicator card

3-4 Table of figures Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 42: Current regulator card

Copyright © 2005 Table of figures 3-5

 Instruction manual
NMF Board Crane type DK II

Filters

Illustration 43: Gear oil cooler

3-6 Table of figures Copyright © 2005

korr-Schi/ho2007
 Instruction manual
Board Crane type DK II NMF
December, 2007
Neuenfelder Maschinenfabrik GmbH

Illustration 44: Reset - test - test load switches

Copyright © 2005 Table of figures 3-7

 Instruction manual
NMF Board Crane type DK II

3-8 Table of figures Copyright © 2005

korr-Schi/ho2007
 Betriebsanleitung
Bordkran Typ: DK II NMF
8 Spare parts catalogue
December, 2007

Seq Part Type NMF part no.

. no.

1 Variable axial piston pump for hoisting gear 90R180 1831pa430

2 Variable axial piston pump for slewing gear 90R130 1831pa425
3 Variable axial piston pump for luffing gear 90R130 1831pa452
4 Variable axial piston motor A6VM250HD1D/63W2-VZB157 1702mh152
5 Constant axial piston motor A2FM 160/61W-VZB04 1702mh031
6 Constant axial piston motor F12-060 1702mh020
7 Hoisting winch ZHP 4.29 10749 1391t8621-lr
8 Luffing winch ZHP 4.29 10740
9 Slewing gear drive RE 2523 Z1P 141,44 F604 PAM 1396gt2523-bv
10 Oil cooler 2000.001.0000 1391gt335
11 Gear oil cooler OKAF-R2S 1587KU001
12 Pump distribution gear i=0,726; 4387.24 1588KU005
13 Solenoid valve 4D01 1392GT114
14 Pipe filter for hydraulic system E 2.460 H 20 2600VT039
15 Cabin NG 1262FI320
16 Descending device AG10 1540kb003
17 Bottom hook block SWL 80t 1920rt005
18 Compact PLC SPS-PS-4 1610ld724-lr

Tabelle 6: Spare parts list

Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 Spare parts catalogue 1

 Betriebsanleitung
NMF Bordkran Typ: DK II

2 Spare parts catalogue Copyright © 2005

 Genuine Parts
Original
Ersatzteile

Series 90

180 cc - Axial Piston

Pump
Service Parts Manual

BLN-2-41695 May, 1997

 Series 90
saueContents Genuine Parts
180 cc Pump
BLN-2-41695
Original
Ersatzteile May, 1997

Unit and Service Parts Identification ............................................................................................................... 3-4

Order Code ...................................................................................................................................................... 5
Housing .......................................................................................................................................................... 6-7
Swashplate ..................................................................................................................................................... 6-7
Displacement Limitation ................................................................................................................................. 8-9
End Cap ...................................................................................................................................................... 10-13
Charging System ........................................................................................................................................ 14-15
Auxiliary Mounting Flange .......................................................................................................................... 16-21
Charge Pressure ........................................................................................................................................ 22-23
Shaft ........................................................................................................................................................... 22-23
Control ........................................................................................................................................................ 24-29
Filtration ...................................................................................................................................................... 30-31
High Pressure Regulation ........................................................................................................................... 32-33
Orifice ......................................................................................................................................................... 34-35
Rotating Group ........................................................................................................................................... 36-37
Valve Plate ................................................................................................................................................. 36-37
Special Hardware/Side Cover .................................................................................................................... 36-37
Overhaul Kit .................................................................................................................................................... 38
SB-9507 ...................................................................................................................................................... 40-41
SB-9625 ...................................................................................................................................................... 42-43
SB-9711 ...................................................................................................................................................... 44-45
SB-9713 ...................................................................................................................................................... 46-47
SB-9714 ...................................................................................................................................................... 48-49

Copyright 1997 Sauer-Danfoss. All rights reserved.

Contents subject to change. Information contained herein should be confirmed before placing orders.
2
Printed in U.S.A.
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Parts Identification

The following information and procedure is used to identify the module group, item number, manufactured date,
part number, and part name of the parts included in the Series 90 Pump.

The parts listed include all parts which may be used when performing either "Minor Repairs", "Major Repairs", or
"Conversions" on the Series 90 Pump.

- Nameplate -

Each pump will have a nameplate affixed to the housing. The

name plate will include the following information.

Model Code Ames, Iowa, U.S.A. NeumŸnster, Germany

The Sauer-Danfoss model code completely defines the Model Code Typ

specific unit and must be used when ordering the complete unit 90L180 MA 1 C
for the first time or for ordering parts to service the product. 8 S 3 F1 H 03
NNN 35 35 24
Model Number Model No. Ident Nr
The Sauer-Danfoss model number is used by the factory in 9820107
manufacturing. On repeat orders, a complete unit can also be A - 92 - 26 - 12345
ordered by the model mumber. Serial No. Fabr Nr
MADE IN U.S.A.

Serial Number
The Sauer-Danfoss serial number is used to identify the
manufacturing location, manufacturing date and the unit se-
Ames, Iowa, U.S.A. NeumŸnster, Germany
quence in the build. The serial number is also used to identify Model Code Typ
the unit's warranty time period. 90L180 MA 1 C
Identification Number 8 S 3 F1 H 03
Pumps manufactured in Germany will have an identification NNN 35 35 24
Model No. Ident Nr
number instead of a model number.
123456
N - 92 - 26 - 12345
Serial No. Fabr Nr
The letter code indicates the location of original manufacture MADE IN GERMANY
(assembly). "A" indicates the unit was originally assembled
in Ames, Iowa, USA. "N" indicates the unit was originally
assembled in NeumŸnster, Germany.

The first number (2 digits) indicates the year of manufacture.

("92" would indicate the unit was manufactured in 1992)

The second number (2 digits) indicates the calender week of

manufacture.

The third number (5 digits) is a sequential number used to

identify a specific unit.

3
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Date Code

The date code is defined as the year and week of manufacture. The same reference number may list more than
one part number. This indicates that there is more than one configuration for that reference number. You will see
that there are different date codes for the different part numbers. Find the date code of your unit via the name-
plate to determine which service part number you need to order.

EXAMPLE: The service part desired is Item E10.

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model
E10 92-19 → 746107 Side cover (SB-9203) 1
" 89-41 → 92-18 340133 Side cover 1

All units using this module group with a date code of 89-41 and up to and including 92-18 must use part number
340133. All units with a date code of 92-19 and up must use part number 746107.

Service Bulletins

A Service Bulletin Number (SB- _ _ _ _) may follow the Description of the part you desire. You must read that
Service Bulletin prior to ordering that part. A copy of each of these Service Bulletins, as of the print date of this
bulletin, are included at the end of this manual. Service Bulletins contain more detailed information such as
interchangeability, what additional parts are involved, etc. It is suggested that you add additional Service Bulletins
to this manual as you receive them.

Procedure to Identify a Given Part/Part Number

General
The modular design of Series 90 units results in a simplified Service Parts List and Part Identification Procedure.

The same item numbers are used for same part description on all units within a product type. (Example: The shaft
seal - Item Number L40 has the same item number on all variable displacement pumps.)

All Item Numbers begin with a letter. The letter identifies a particular module. (Example: any items beginning with
K relate to the charge relief valve; items beginning with L relate to the input shaft components, etc.)

Example of a Part Identification

The nameplate on a Series 90 pump has an Order Code of 90L180 MA 1 C 8 S 3 F1 H 03 NNN 35 35 24. Use
the following procedures to determine the part number of the filtration kit used on this pump.

1) Referring to the input shaft module in the Model Code (see page 5), the shaft option for this unit is identified by
the code F1 (90L180 MA 1 C 8 S 3 F1 H 03 NNN 35 35 24)
2) Referring to the Service Parts List, find the shaft group. Next find the order code that relates to this unit, which
is F1. The shaft is found to be item L1 and part number 772590.

4
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

R M P J G N F L H T W Y Z K
90 L 1 8 0 MA 1 C 8 S 3 F1 H 03 NNN 35 35 24

Charge
Series Pressure Setting

Rotation High Pressure Setting

Port A

Pump Size (cc) High Pressure Setting

Port A

Control Type Special Hardware Features

Pressure Regulation Control Orifice

Auxilary Mounting Pad Charging System

End Cap Ports Input Shaft

Filtration Displacement Limitation

5
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Common Parts

B80
B80A

B83A

B70
B83
B70A
B82
B82A

D75 B50
M14
D70
D65 B20
D55 D85 B20
B10

D10 D80 B50

D86
D95 D87A
D87
B30

D60
D80
D70 D50 Enlarged Bold type item numbers
are recommended parts to be
D75 stocked for servicing

6
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

Common Parts
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
B10 94-20 → 789438 Housing assembly 1
B20 94-20 → 648550 (9004800-1904) Pin 2
B30 94-20 → 746313 Cradle bearing assembly 1
B50 94-20 → 001289 (9004800-3708) Pin 2
B70 94-20 → 515965 (9005110-5600) Plug 2
B70A 94-20 → 085043 (9004201-3700) O-ring 2
B80 94-20 → 676734 (9005110-9500) Plug 1
B80A 94-20 → 093823 (9004201-9200) O-ring 1
B82 94-20 → 515965 (9005110-5600) Plug 2
B82A 94-20 → 085043 (9004201-3700) O-ring 2
B83 94-20 → 515965 (9005110-5600) Plug 2
B83A 94-20 → 085043 (9004201-3700) O-ring 2
D10 94-20 → 746339 Servo arm assembly 1
D50 94-20 → 770362 Swashplate 1
D55 94-20 → 746362 Screw 1
D60 94-20 → 745703 Swashplate guide 1
D65 94-20 → 504494 Screw 1
D70 94-20 → 127464 Washer 2
D75 94-20 → 333369 Spiral head pin 2
D80 94-20 → 700948 Cage locator link 2
D85 94-20 → 500449 Screw 1
D86 94-20 → 770594 Pin 1
D87 94-20 → 504519 Plug 1
D87A 94-20 → 039297 (9004201-1200) O-ring 1
D95 94-20 → 746396 Spring 1
M14 94-20 → 747451 Feedback link (SB-9625) 1

Bold Items indicate recommended parts to be stocked for servicing

7
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Displacement Limitation

F70
F34
F35 F80
S01
F60

F60
F40
F50

F40
F50
S03

F103

F12 F11

F20
F11
F12 S02
Enlarged Bold type item numbers
are recommended parts to be
stocked for servicing F50
F40

F70 F60
F80
F50
F40

F35
F60
S04
F34

8
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

F: Displacement Limitation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
F103 94-20 → 509288 Servo piston assembly 1
F11 94-20 → 755264 O-ring 2
F12 94-20 → 507801 Piston ring 2
F20 94-20 → 746479 Slider block 1

3 S02 94-20 → 8510150 Servo piston kit - no limitation 1

F40 94-20 → 092742 (9004104-1520) O-ring 1
F50 94-20 → 755272 O-ring 1
F60 94-20 → 507205 Screw 4
S03 94-20 → 8510150 Servo piston kit - no limitation 1
F40 94-20 → 092742 (9004104-1520) O-ring 1
F50 94-20 → 755272 O-ring 1
F60 94-20 → 507205 Screw 4

4 S01 94-20 → 8510151 Servo piston kit - adjustable 1

F34 94-20 → 755033 Set screw 1
F35 94-20 → 649822 Seal nut 1
F40 94-20 → 092742 (9004104-1520) O-ring 1
F50 94-20 → 755272 O-ring 1
F60 94-20 → 507205 Screw 4
F70 94-20 → 394312 Plug 1
F80 94-20 → 084640 Seal ring 1
S04 94-20 → 8510151 Servo piston kit - adjustable 1
F34 94-20 → 755033 Set screw 1
F35 94-20 → 649822 Seal nut 1
F40 94-20 → 092742 (9004104-1520) O-ring 1
F50 94-20 → 755272 O-ring 1
F60 94-20 → 507205 Screw 4
F70 94-20 → 394312 Plug 1
F80 94-20 → 084640 Seal ring 1

Bold Items indicate recommended parts to be stocked for servicing

9
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

End cap

G513A G542 G533

G513 G523 G533A
G523 G563
G523A
G903
G523A
G563A
G543
G93 G543A G303

G20
G953 G95
G95
G573A

G573
G40 G043
G93
G903
G563A
G523A G563
G95
G95 G523 G553A
G553
G963
G078

G068
G558
G088
G568

G568A
G558A G908

G93
G95 G308
G958 G95 G20
G40
G93

G95 Enlarged Bold type item numbers

are recommended parts to be
G95 stocked for servicing
G048
G968 G908 G568A
G558A
G558 G568

10
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

G: End Cap Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
G93 94-20 → 713818 (8800565) Lifting bracket 2
G95 94-20 → 505479 Washer 4

3 & 83 G043 94-20 → 752006 End cap, twin ports 1

G20 94-20 → 303693 Journal bearing 1
G40 94-20 → 303651 Bushing 1
G303 94-20 → 504417 End cap gasket (SB-9713) 1
G513 94-20 → 765990 (9005100-3700) Plug 1
G513A 94-20 → 039297 (9004201-1900) O-ring 1
G523 94-20 → 504519 Plug 3
G523A 94-20 → 039297 (9004201-1200) O-ring 3
G533 94-20 → 681296 (9005110-7500) Plug 1
G533A 94-20 → 001131 (9004201-5000) O-ring 1
G542 94-20 → 787838 Set screw 1
G543 94-20 → 515965 (9005110-5600) Plug 1
G543A 94-20 → 085043 (9004201-3700) O-ring 1
G553 94-20 → 515965 (9005110-5600) Plug 1
G553A 94-20 → 085043 (9004201-3700) O-ring 1
G563 94-20 → 046151 (9005100-5600) Plug 2
G563A 94-20 → 085043 (9004201-3700) O-ring 2
G573 94-20 → 504519 Plug 1
G573A 94-20 → 039297 (9004201-1200) O-ring 1
G903 94-20 → 085183 Screw 2
G953 94-20 → 675900 Screw 1
G963 94-20 → 290502 Screw 1

8 & 80 G048 94-20 → 501471 End cap, twin ports 1

G20 94-20 → 303693 Journal bearing 1
G40 94-20 → 303651 Bushing 1
G068 94-20 → 364281 Housing assembly 1
G078 94-20 → 694356 (9007314-0608) Screw 4
G088 94-20 → 689117 Gasket 1
G308 94-20 → 504417 End cap gasket (SB-9713) 1
G558 94-20 → 515965 (9005110-5600) Plug 2
G558A 94-20 → 085043 (9004201-3700) O-ring 2
G568 94-20 → 046151 (9005100-5600) Plug 2
G568A 94-20 → 085043 (9004201-3700) O-ring 2
G908 94-20 → 085183 Screw 2
G958 94-20 → 290502 Screw 1
G968 94-20 → 675900 Screw 1

Bold Items indicate recommended parts to be stocked for servicing

11
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

End cap

G078

G068
G558
G088
G568

G568A
G558A G908
G93
G95 G308
G958 G95 G20

G93 G95

G95 G40
G048
G908 G568A
G968 G558A
G558 G568

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

12
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

G: End Cap Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
G93 94-20 → 713818 (8800565) Lifting bracket 2
G95 94-20 → 505479 Washer 4

8H G048 94-20 → 510441 End cap, twin ports 1

G20 94-20 → 303693 Journal bearing 1
G40 94-20 → 303651 Bushing 1
G068 94-20 → 364281 Housing assembly 1
G078 94-20 → 694356 (9007314-0608) Screw 4
G088 94-20 → 689117 Gasket 1
G308 94-20 → 504417 End cap gasket (SB-9713) 1
G558 94-20 → 515965 (9005110-5600) Plug 2
G558A 94-20 → 085043 (9004201-3700) O-ring 2
G568 94-20 → 046151 (9005100-5600) Plug 2
G568A 94-20 → 085043 (9004201-3700) O-ring 2
G908 94-20 → 085183 Screw 2
G958 94-20 → 290502 Screw 1
G968 94-20 → 675900 Screw 1

Bold Items indicate recommended parts to be stocked for servicing

13
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Charging System

H06L
H05L H90LA
H50 H90L

H80
H60
H70 H40

H50

H05

H80

H70

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

14
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

H: Charging System Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
H H05 94-20 → 503517 Charge pump, 34 cc (SB-9507) 1
H40 94-20 → 750133 Pin 1
H50 94-20 → 503519 Charge pump shaft (SB-9714) 1
H60 94-20 → 734608 Key 1
H70 94-20 → 303644 Retaining plate 1
H80 94-20 → 378083 Screw 6

J H05 94-20 → 503518 Charge pump, 47 cc (SB-9507) 1

H40 94-20 → 750133 Pin 1
H50 94-20 → 503519 Charge pump shaft (SB-9714) 1
H60 94-20 → 734608 Key 1
H70 94-20 → 303644 Retaining plate 1
H80 94-20 → 378083 Screw 6

L H05L 94-20 → 339762 Charge pump spacer 1

H06L 94-20 → 711218 Distance plate 1
H50 94-20 → 503519 Charge pump shaft (SB-9714) 1
H70 94-20 → 303644 Retaining plate 1
H80 94-20 → 378083 Screw 6
H90L 94-20 → 676734 (9005110-9500) Plug 1
H90LA 94-20 → 093823 (9004201-9200) O-ring 1

Bold Items indicate recommended parts to be stocked for servicing

15
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Auxiliary Mounting

J15

J10
J30

J90
J50
J92 J60

J95
J70
J80
J15
'A' & 'AB' J
J10
J30

J90 J50

J95 J60

J70 J15
J92 J80
J
'B' & 'BC' J30 J10

J50
J60

J90
J95 J70
J80
J92 Enlarged Bold type item numbers
J
are recommended parts to be
'C' & CD stocked for servicing

16
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
A & AB J 94-20 → 8510100 Aux. mtg. A flange kit, 9 tooth 1
J10 94-20 → 766964 Coupling 1
J15 94-20 → 501402 Cover assy., CW 1
" 94-20 → 501401 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505136 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 726950 (9004104-0420) O-ring 1
J92 94-20 → 545475 (9802336) Cover plate 1
J95 94-20 → 012203 (9007200-3714) Screw 2

B & BC J 94-20 → 8510101 Aux. mtg. B flange kit, 13 tooth 1

J10 94-20 → 767566 Coupling 1
J15 94-20 → 501402 Cover assy., CW 1
" 94-20 → 501401 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505132 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 726935 (9004104-0450) O-ring 1
J92 94-20 → 689091 (4460370) Cover plate 1
J95 94-20 → 647248 (9007200-5021) Screw 2

C & CD J 94-20 → 8510102 Aux. mtg. C flange kit, 14 tooth 1

J10 94-20 → 768523 Coupling 1
J15 94-20 → 501402 Cover assy., CW 1
" 94-20 → 501401 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505139 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 726943 (9004104-0490) O-ring 1
J92 94-20 → 307363 (8800406) Cover plate 1
J95 94-20 → 647248 (9007200-5021) Screw 4
Bold Items indicate recommended parts to be stocked for servicing

17
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Auxiliary Mounting

J80N

J40N
J15N

J30
'N' & 'NN'

J15

J10
J30

J90
J50

J95
J60
J92

J80 J70
J15
'D' & 'DE' J
J10
J30

J90
J50
J60
J95
J
J92 J70
J80
'E' & 'EF'
'H' & 'EG'
Enlarged Bold type item numbers
are recommended parts to be
stocked for servicing

18
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
D & DE J 94-20 → 8510103 Aux. mtg. D flange kit, 13 tooth 1
J10 94-20 → 768564 Coupling 1
J15 94-20 → 503663 Cover assy., CW 1
" 94-20 → 503666 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 767681 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 726927 O-ring 1
J92 94-20 → 338400 Cover plate 1
J95 94-20 → 338426 (9007200-7524) Screw 4

E & EF J 94-20 → 8510104 Aux. mtg. E flange kit, 13 tooth 1

J10 94-20 → 768564 Coupling 1
J15 94-20 → 503663 Cover assy., CW 1
" 94-20 → 503666 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505141 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 505068 O-ring 1
J92 94-20 → 750422 Cover plate 1
J95 94-20 → 338426 (9007200-7524) Screw 4

H & EG J 94-20 → 8510105 Aux. mtg. E flange kit, 27 tooth 1

J10 94-20 → 751701 Coupling 1
J15 94-20 → 503663 Cover assy., CW 1
" 94-20 → 503666 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505141 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 505068 O-ring 1
J92 94-20 → 750422 Cover plate 1
J95 94-20 → 338426 (9007200-7524) Screw 4

N & NN J15N 94-20 → 501400 Charge pump cover 1

J30 94-20 → 303651 Bushing 1
J40N 94-20 → 916940 O-ring 1
J80N 94-20 → 308734 Screw 4
Bold Items indicate recommended parts to be stocked for servicing

19
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Auxiliary Mounting

J15

J10
J30

J90 J50

J95 J60

J70
J92 J80
J
'V' & 'BB'

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

20
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
V & BB J 94-20 → 8510106 Aux. mtg. B-B flange kit, 15 tooth 1
J10 94-20 → 773739 Coupling 1
J15 94-20 → 501402 Cover assy., CW 1
" 94-20 → 501401 Cover assy., CCW 1
J30 94-20 → 303651 Bushing 1
J50 94-20 → 505068 O-ring 1
J60 94-20 → 505132 Flange adaptor 1
J70 94-20 → 279729 Washer 4
J80 94-20 → 750414 Screw 4
J90 94-20 → 726935 (9004104-0450) O-ring 1
J92 94-20 → 689091 (4460370) Cover plate 1
J95 94-20 → 647248 (9007200-5021) Screw 2

Bold Items indicate recommended parts to be stocked for servicing

21
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Charge Releif/Shaft

K90

K10

K50
K90
K50 K10
K70 K70
K80
K80

L70
L30
L40
L50

L20
L10 L60

L34

L1 L32
L31

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

22
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

K: Charge Pressure Setting

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
00-30 K10 94-20 → 343095 Plug assembly 1
K50 94-20 → 001156 (9004201-7500) O-ring 1
K70 94-20 → 709469 Spring 1
K80 94-20 → 343087 Poppet 1
K90 94-20 → 343848 Nut 1
L10 94-20 → 746487 Roller bearing 1
L20 94-20 → 392233 Retaining ring 1
L30 94-20 → 303503 Seal carrier 1
L31 94-20 → 392712 Support shim 1
L32 94-20 → 373563 Shim 1
L34 94-20 → 510018 Seal assembly 1
L40 94-20 → 673525 (9008000-0114) Lip seal 1
L50 94-20 → 509353 O-ring 1
L60 94-20 → 303529 Retainer plate 1
L70 94-20 → 009159 Screw 3

L: Shaft Group
C8 L1 94-20 → 748863 Shaft, 27 tooth spline 1

F1 L1 94-20 → 772590 Shaft, 13 tooth spline 1

Bold Items indicate recommended parts to be stocked for servicing

23
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Control

M87
W702
0030
M90 0030

W701

Q130 M9D

W701A M10

A B
D
T

M93D M11
(included in D) M90
M87

M90 M1C

M87

M11
M9E M98E

M97
M96

M95

M1E
M11

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

24
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
CB M11 94-20 → 790345 (8800923) Control gasket 1
M1C 94-20 → 501097 Cover plate 1
M87C 94-20 → 592386 Seal Washer 1
M90C 94-20 → 693341 (9007314-0606) Screw 6
(Feedback link on Swashplate)
DD D 94-20 → 8510146 Control kit, 3 position sol. ,24v 1
M11 94-20 → 790345 (8800923) Control gasket 1
M87 94-20 → 592386 Seal Washer 1
M90 94-20 → 693341 (9007314-0606) Screw 6
M93 94-20 → 509167 Orifice 1
M9D 94-20 → 549907 Control,3 position sol.,24v 6
Q130 94-20 → 504093 O-ring kit 1
W701 94-20 → 048413 O-ring 4
W702 94-20 → 141135 Screw 4
0030 94-20 → 711242 O-ring 2
EA E 94-20 → 8510153 EDC kit w/MS conn. 1
M11 94-20 → 790345 (8800923) Control gasket 1
M1E 94-20 → 500726 (MCV111B1802) EDC 1
M9E 94-20 → 701417 (MCV110A1017) PCP type 3 oil filled, MS conn. 1
M87E 94-20 → 592386 Seal Washer 1
M90E 94-20 → 692889 (9007314-0611) Screw 6
M95E 94-20 → 318337 (9004104-0120) O-ring 2
M96E 94-20 → 011304 (9004104-0140) O-ring 1
M97E 94-20 → 318345 (9004104-0240) O-ring 1
M98E 94-20 → 067678 (9007315-0504) Screw 4

EN E 94-20 → 8510154 EDC kit w/MS conn. 1

M11 94-20 → 753806 (K11420) Control gasket 1
M1E 94-20 → 507440 (MCV114A1807) EDC2 w/MS conn. 1
M9E 94-20 → MCV116A3501 PCP,type 3, MS conn. 1
M87E 94-20 → 592386 Seal Washer 1
M90E 94-20 → 692889 (9007314-0611) Screw 6
M95E 94-20 → 318337 (9004104-0120) O-ring 2
M96E 94-20 → 011304 (9004104-0140) O-ring 1
M97E 94-20 → 318345 (9004104-0240) O-ring 1
M98E 94-20 → 067678 (9007315-0504) Screw 4

Bold Items indicate recommended parts to be stocked for servicing

25
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Control

M90

M87
M90H
M9E M98E

M97 M1H
M96

M95 H M11

M1E
M11

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

26
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
HD H 94-20 → 8510164 HDC kit 1
M11 94-20 → 501665 Control gasket 1
M1H 94-20 → 503183 (MCV115C1309) HDC 1
M87H 94-20 → 592386 Seal Washer 1
M90H 94-20 → 692889 (9007314-0611) Screw 6

HF H 94-20 → 8510157 HDC kit 1

M11 94-20 → 753806 (K11420) Control gasket 1
M1H 94-20 → MCV115A1803 HDC 1
M87H 94-20 → 592386 Seal Washer 1
M90H 94-20 → 692889 (9007314-0611) Screw 6

KA E 94-20 → 8510155 EDC3 kit 1

M11 94-20 → 790345 (8800923) Control gasket 1
M1E 94-20 → 506936 (KVEAB1802) EDC 1
M9E 94-20 → MCV116F4201 PCP, type 4, MS conn. 1
M87E 94-20 → 592386 Seal Washer 1
M90E 94-20 → 692889 (9007314-0611) Screw 6
M95E 94-20 → 318337 (9004104-0120) O-ring 2
M96E 94-20 → 011296 (9004105-0120) O-ring 1
M97E 94-20 → 318345 (9004104-0240) O-ring 1
M98E 94-20 → 067678 (9007315-0504) Screw 4

KN E 94-20 → 8510185 EDC3 kit 1

M11 94-20 → 790345 (8800923) Control gasket 1
M1E 94-20 → 508289 (KVEAA1807) EDC 1
M9E 94-20 → MCV116A3501 PCP, type 3, MS conn. 1
M87E 94-20 → 592386 Seal Washer 1
M90E 94-20 → 692889 (9007314-0611) Screw 6
M95E 94-20 → 318337 (9004104-0120) O-ring 2
M96E 94-20 → 011296 (9004105-0120) O-ring 1
M97E 94-20 → 318345 (9004104-0240) O-ring 1
M98E 94-20 → 067678 (9007315-0504) Screw 4

KP E 94-20 → 8510156 EDC3 kit 1

M11 94-20 → 790345 (8800923) Control gasket 1
M1E 94-20 → 506937 (KVEAB1804) EDC 1
M9E 94-20 → MCV116F4204 PCP, type 4, Weather pack conn. 1
M87E 94-20 → 592386 Seal Washer 1
M90E 94-20 → 692889 (9007314-0611) Screw 6
M95E 94-20 → 318337 (9004104-0120) O-ring 2
M96E 94-20 → 011296 (9004105-0120) O-ring 1
M97E 94-20 → 318345 (9004104-0240) O-ring 1
M98E 94-20 → 067678 (9007315-0504) Screw 4

Bold Items indicate recommended parts to be stocked for servicing

27
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Control

S40
M72M
M90M M71M
M7M
M1M

M M11

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

28
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
MA M 94-20 → 8510158 MDC kit w/o neutral start 1
M11 94-20 → 790345 (8800923) Control gasket 1
M1M 94-20 → 787242 MDC w/o neutral start switch 1
M7M 94-20 → 006874 (9800916) Control handle 1
M71M 94-20 → 689018 (9009660-3100) Washer 1
M72M 94-20 → 040642 (9003513-0800) Nut 1
M87M 94-20 → 592386 Seal Washer 1
M90M 94-20 → 692889 (9007314-0611) Screw 6

MB M 94-20 → 8510186 MDC kit w/neutral start 1

M11 94-20 → 790345 (8800923) Control gasket 1
M1M 94-20 → 787267 MDC w/neutral start switch 1
M7M 94-20 → 006874 (9800916) Control handle 1
M71M 94-20 → 689018 (9009660-3100) Washer 1
M72M 94-20 → 040642 (9003513-0800) Nut 1
M87M 94-20 → 592386 Seal Washer 1
M90M 94-20 → 692889 (9007314-0611) Screw 6
S40 94-20 → 8510027 Neutral start switch kit 1

Bold Items indicate recommended parts to be stocked for servicing

29
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Filtration

N35S
N10S
N00R
N35A

N35R N10R N10A

N35A
N25R
N20R
N15

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

30
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

N: Filtration Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
D None

S N10S 94-20 → 757831 Reducer fitting 1

N10A 94-20 → 093823 (9004201-9000) O-ring 1
N35S 94-20 → 515965 (9005110-5600) Plug 1
N35A 94-20 → 085043 (9004201-3700) O-ring 1

T N00R 94-20 → 8510147 Filtration manifold kit 1

N10R 94-20 → 507014 Manifold 1
N15 94-20 → 093823 (9004201-9000) O-ring 1
N20R 94-20 → 367102 Nut 1
N25R 94-20 → 507016 Tube 1
N35R 94-20 → 046151 (9005100-5600) Plug 2
N35A 94-20 → 085043 (9004201-3700) O-ring 2

Bold Items indicate recommended parts to be stocked for servicing

31
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

High Pressure Regulation

View 'C' View 'C'

P80 P80
P802
P70 P70

P702

Left Hand Rotation Right Hand Rotation Left/Right Hand Rotation

With Pressure Limiters Without Pressure Limiters

P60
P60A
P65 Veiw 'C'

P06 P95 P06

P2 P13 P90 P2 P13

P06 P06
P1 P13 P1 P13

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

32
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

P: High Pressure Regulation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
C P1 94-20 → 8510187 Multi-function valve, w/o PL 1
(240-520 bar) P2 94-20 → 8510187 Multi-function valve, w/o PL 1
P6 94-20 → 360784 (9004105-0290) O-ring 2
P13 94-20 → 775155 (9004105-0250) O-ring 2
P60 94-20 → 046151 (9005100-5600) Plug 1
P60A 94-20 → 085043 (9004201-3700) O-ring 1
P65 94-20 → 677997 Screw 4
P90 94-20 → 916346 O-ring 2
P95 94-20 → 508659 O-ring 2

1 P1 89-41 → 8510023-1 Multi-function valve, w/PL 1

(0-450 bar) P2 89-41 → 8510023-1 Multi-function valve, w/PL 1
P6 94-20 → 360784 (9004105-0290) O-ring 2
P13 94-20 → 775155 (9004105-0250) O-ring 2
P70 89-41 → 681817 (8800188) Check valve 2
P80 89-41 → 508655 (9005475-0004) Special plug 2

2 P2A1 89-41 → 8510023-2 Multi-function valve, w/o PL 1

(0-450 bar) P2B1 89-41 → 8510023-2 Multi-function valve, w/o PL 1
P6 94-20 → 360784 (9004105-0290) O-ring 2
P13 94-20 → 775155 (9004105-0250) O-ring 2
P702 89-41 → 327007 (9005110-4400) Plug 1
P802 89-41 → 508655 (9005475-0004) Special plug 3

Bold Items indicate recommended parts to be stocked for servicing

33
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Orifice

Installed in
Control Housing

T001

T301
T401

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

34
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

T: Orifice Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
00 None

03 T001 87-02 → 8002T003-A Control orifice kit - .032 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

05 T001 87-02 → 8002T005-A Control orifice kit - .054 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

35
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Special Hardware

C20

C30
S07
C40

C05 C50
E30
E30
C70

C13 E22
C14 E82 E20

C15 E22
E80 E82
C16
E24
E80

E24 E50
C80

E90

E10
Enlarged Bold type item numbers
are recommended parts to be
stocked for servicing
E60
E70
E40

36
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S07 89-41 → 8510160 Cyl. block kit 1
C05 89-41 → 313767 Cylinder block assembly 1
C13 89-41 → 700922 Spring seat 1
C14 89-41 → 302828 Cylinder block spring 1
C15 89-41 → 700930 Spring retainer 1
C16 89-41 → 302836 Retaining ring 1
C20 89-41 → 755181 Welded piston 9
C30 89-41 → 313445 Slipper guide 1
C40 89-41 → 313452 Slipper guide bearing 2
C50 89-41 → 313460 Spacer 4
C70 89-41 → 308643 Screw 4

E10 94-20 → 501579 Side cover 1

E20 94-20 → 746420 Leveler 1
E22 94-20 → 746438 Spring Seat 2
E24 94-20 → 359067 Shim 2
E30 96-09 → 8300012 Guide post (SB-9711) 2
E40 94-20 → 042432 Nut 2
E50 94-20 → 746446 O-ring 1
E60 94-20 → 508441 Screw 6
E70 94-20 → 676734 (9005110-9500) Plug 1
E80 94-20 → 746453 Spring 2
E90 94-20 → 506914 Insert assembly (SB-9604) 1

W: Special Hardware Group

FAC C80 95-04 → 755983 Pump valve plate, 1.5 degree 1
E82 95-04 → 755553 Spring 2

EEB C80 94-20 → 755983 Pump valve plate, 1.5 degree 1

NNN C80 94-20 → 783050 Pump valve plate, 0.5 degree 1

Bold Items indicate recommended parts to be stocked for servicing

37
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

180 cc Variable Displacement Pump

Overhaul Seal Kit
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S30 94-20 → 8510062 Overhaul seal kit 1
C70 94-20 → 308643 Screw 4
E40 94-20 → 042432 Nut 2
E50 94-20 → 746446 O-ring 1
E60 94-20 → 508441 Screw 6
F11 94-20 → 755264 O-ring 2
F12 94-20 → 507801 Piston ring 2
F40 94-20 → 092742 (9004104-1520) O-ring 1
F50 94-20 → 755272 O-ring 2
G088 94-20 → 689117 Gasket 1
G308 94-20 → 504417 End cap gasket (SB-9713) 1
J40 94-20 → 916940 O-ring 1
J50 94-20 → 505068 O-ring 1
J90 94-20 → 726950 (9004104-0420) O-ring 1
J90 94-20 → 726935 (9004104-0450) O-ring 1
J90 94-20 → 726943 (9004104-0490) O-ring 1
J90 94-20 → 726927 O-ring 1
K50 94-20 → 001156 (9004201-7500) O-ring 1
L40 94-20 → 673525 (9008000-0114) Lip seal 1
L50 94-20 → 509353 O-ring 1
M11 94-20 → 790345 (8800923) Control gasket 1
M11 94-20 → 753806 (K11420) Control gasket 1
M87 94-20 → 592386 Seal washer 1
N15 94-20 → 093823 (9004201-9000) O-ring 1
P6 94-20 → 360784 (9004105-0290) O-ring 2
P13 94-20 → 775155 (9004105-0250) O-ring 2

Bold Items indicate recommended parts to be stocked for servicing

38
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

NOTES

39
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9507

PRODUCTS AFFECTED: Series 90 180 cc Variable Pumps

SUBJECT: Charge Pump Design Change

DESCRIPTION:
To improve efficiency and reliability, the number of charge pump parts in the Series 90
180 cc pump is being reduced. The charge pump design is being changed to make the
outer port plate an intergal part of the charge pump cover and to eliminate the distance
plates.
For auxiliary pad options, the new charge pump cover is rotation dependent. The cover
will be marked either left hand (L) or right hand (R). The non-auxiliary pad cover is not
rotation dependent.
The complete charge pump assembly can be interchanged with corresponding hardware.
However, piece parts are not interchangeable.

Gear Set
Gear Set

Old Charge
Pump Configuration

New Charge
Pump Configuration

New charge pump cover for

pumps without auxiliary pads
(same cover for left hand or
right hand rotation)
L
Both left hand and right hand charge pump covers for
pumps with auxiliary pads are included in auxiliary pad kits

The new charge pump covers have an 'L' or

'R' stamped on them for easy identification
40
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9507

MODELS AFFECTED: All 982xxxx variable pumps
SERIAL NUMBERS AFFECTED: Units built N-94-06-xxxxx and after
PART NUMBERS AFFECTED:
The following information must be known to determine
the correct charge pump replacement kit:
1. Charge pump displacement (34 or 47 cc)
2. Auxilary pad (Yes or No)
3. Rotation (LH or RH)
Obsoleted Charge Pump Parts Chg. pump
Auxilary Replacement
displace- Rotation
pad Kit
Gear Set Shaft Cover ment
347518 No LH or RH 8510091
503517 750141 347526 34 cc Yes LH 8510092
347526 Yes RH 8510093
347518 No LH or RH 8510094
750125 750141 347526 47 cc Yes LH 8510095
347526 Yes RH 8510096
The following information pertains to 'L' charge pump option only:
Auxilary Replacement Replacement
Old Shaft Old Cover Rotation
pad Cover Shaft
347518 No LH or RH 501400
750141 LH 501401 503519
347526 Yes
RH 501402
PARTS DISPOSITION:
Not Applicable
X Interchangeable ☛ Piece parts are not interchangeable.
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
41
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9625

PRODUCTS AFFECTED: Series 90: 42 - 250 cc Variable Pumps

SUBJECT: Swashplate Feedback Link

DESCRIPTION:
Series 90 pumps of frame sizes 42 thru 130 cc may be operated with the swashplate
feedback link installed and no control (cover plate only). This is only true for pumps built
89-47-xxxxx and beyond. Pumps built prior to this date must have the feedback link
removed if no control is used.

The swashplate feedback link must be removed if no control is used on frame sizes 180
and 250 cc.

42
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9625

MODELS AFFECTED:
All 932xxxx, 942xxxx, 952xxxx, 962xxxx, 972xxxx, 982xxxx, and 992xxxx variable pumps

SERIAL NUMBERS AFFECTED:

Units built N-89-47-xxxxx and beyond

PART NUMBERS AFFECTED:

N/A

PARTS DISPOSITION:
X Not Applicable
Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
43
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9711

PRODUCTS AFFECTED: Series 90: 130 - 250 cc Variable Pumps

SUBJECT: Guide Post Part Number Change

DESCRIPTION:
As a product improvement, Sauer-Danfos has changed the design of the guide post
that is used on Series 90 130-250 cc pumps.

The old guide post has a "W" dimension of 0.457 inches (11.61 mm) and the new guide
post has a "W" dimension of 0.449 inches (11.41 mm).

The old style guide post will become obsolete and no longer available as a service part.

Guide Posts

"W"

44
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9711

MODELS AFFECTED:
All 97-2xxxx, 972xxxx, 982xxxx and 992xxxx variable pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-97-08-xxxxx

PART NUMBERS AFFECTED:

Frame Old Guide Post New Guide Post

Size Part Number Part Number
130 thru 250 cc 506368 8300012

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
45
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9713

PRODUCTS AFFECTED: Series 90: 180 cc Variable Pumps

SUBJECT: End Cap Gasket Change

DESCRIPTION:
As a product improvement, Sauer-Danfoss has changed the design of the end cap
gasket used on the Series 90 - 180 cc variable pump. This allows the 180 and 250 cc
pumps to use a common gasket.

The old style gasket will become obsolete and no longer available as a service part.

Old Style New Style

46
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9713

MODELS AFFECTED:
All 982xxxx Variable Pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-97-08-xxxxx

PART NUMBERS AFFECTED:

Old Gasket New Gasket

Part Number Part Number
Gasket - Twin Ports 501472 504417

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
47
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9714

PRODUCTS AFFECTED: Series 90: 42, 130, 180 and 250 cc Variable Pumps

SUBJECT: Charge Pump Shaft Part Number Change

DESCRIPTION:
As a product improvement, Sauer-Danfoss has changed the design of the charge
pump shaft used in Series 90 - 42, 130, 180, and 250 cc variable pumps.

The new and old shafts are interchangeable.

The old style charge pump shaft will become obsolete and no longer available as a
service part.

Charge Pump Shaft

48
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Service Bulletin SB-9714

MODELS AFFECTED:
All 932xxxx, 972xxxx, 982xxxx and 992xxxx variable pumps

SERIAL NUMBERS AFFECTED:

See table below

PART NUMBERS AFFECTED:

Old Shaft New Shaft

Frame Part Part Effectivity
Size Number Number Date
42 505202 509485 97-06
130 501399 509483 97-06
180 503519 509484 97-12
250 504439 509482 97-12

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
49
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Notes

50
 Series 90
180 cc Pump
Genuine Parts BLN-2-41695
Original
Ersatzteile May, 1997

Notes

51
 Hydraulic Power Systems
SAUER-DANFOSS Hydraulic Power Systems - Market Leaders Worldwide
SAUER-DANFOSS is a world leader in the design and SAUER-DANFOSS specializes in integrating a full
manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers
development resources in both North America and Europe with the most advanced total-design system.
enable SAUER-DANFOSS to offer a wide range of
design solutions utilizing hydraulic power system SAUER-DANFOSS is Your World Source for
technology. Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives

Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

Pumps and Motors Electrohydraulic Controls Packages

Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts

Worldwide Service Support

SAUER-DANFOSS provides comprehensive worldwide service for its

products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.

Look to SAUER-DANFOSS for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

SAUER-DANFOSS COMPANY SAUER-DANFOSS GMBH & CO.

2800 East 13th Street Postfach 2460, D-24531 Neumünster
Ames, IA 50010, U.S.A. Krokamp 35, D-24539 Neumünster, Germany
Phone: +1 515 239-6000, FAX: +1 515 239-6618 Phone: +49 4321 871-0, Fax: +49 4321 871 122
BLN-2-41695 • May, 1997
 Genuine Parts
Original
Ersatzteile

Series 90

130 cc - Axial Piston

Pump
Service Parts Manual

BLN-2-41673 May, 1996

 Series 90
saueContents Genuine Parts
130 cc Pump
BLN-2-41673
Original
Ersatzteile May, 1996

Unit and Service Parts Identification ............................................................................................................... 3-4

Order Code ...................................................................................................................................................... 5
Common Parts ................................................................................................................................................ 6-9
Displacement Limitation ............................................................................................................................. 10-11
End Cap ...................................................................................................................................................... 12-13
Charging System ........................................................................................................................................ 12-13
Auxiliary Mounting Flange .......................................................................................................................... 14-17
Charge Pressure ........................................................................................................................................ 18-19
Shaft ........................................................................................................................................................... 18-19
Control ........................................................................................................................................................ 20-23
Filtration ...................................................................................................................................................... 24-25
High Pressure Regulation ........................................................................................................................... 26-27
Orifice ......................................................................................................................................................... 28-29
Special Hardware/Side Cover .................................................................................................................... 30-31
Overhaul Kit .................................................................................................................................................... 32
BLN-10107 ................................................................................................................................................. 34-35
SB-9102 ...................................................................................................................................................... 36-37
SB-9114 ...................................................................................................................................................... 38-39
SB-9203 ...................................................................................................................................................... 40-43
SB-9302 ...................................................................................................................................................... 44-45
SB-9312 ...................................................................................................................................................... 46-47
SB-9413 ...................................................................................................................................................... 48-49
SB-9425 ...................................................................................................................................................... 50-51
SB-9436 ...................................................................................................................................................... 52-53
SB-9503 ...................................................................................................................................................... 54-55
SB-9510 ...................................................................................................................................................... 56-57
SB-9514 ...................................................................................................................................................... 58-59
SB-9518 ...................................................................................................................................................... 60-61
SB-9601 ...................................................................................................................................................... 62-63
SB-9604 ...................................................................................................................................................... 64-65

Copyright 1993, 1994 Sauer-Danfoss. All rights reserved.

Contents subject to change. Information contained herein should be confirmed before placing orders.
Printed in U.S.A.
2
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Parts Identification

The following information and procedure is used to identify the module group, item number, manufactured date,
part number, and part name of the parts included in the Series 90 Pump.

The parts listed include all parts which may be used when performing either "Minor Repairs", "Major Repairs", or
"Conversions" on the Series 90 Pump.

- Nameplate -

Each pump will have a nameplate affixed to the housing. The

name plate will include the following information.

Model Code Ames, Iowa, U.S.A. NeumŸnster, Germany

The Sauer-Danfoss model code completely defines the Model Code Typ

specific unit and must be used when ordering the complete unit 90R130 MA 1 B
for the first time or for ordering parts to service the product. 6 S 3 C6 C 03
NNN 42 42 20
Model Number Model No. Ident Nr
The Sauer-Danfoss model number is used by the factory in 97 - 2062
manufacturing. On repeat orders, a complete unit can also be A - 92 - 26 - 12345
ordered by the model mumber. Serial No. Fabr Nr
MADE IN U.S.A.

Serial Number
The Sauer-Danfoss serial number is used to identify the
manufacturing location, manufacturing date and the unit se-
Ames, Iowa, U.S.A. NeumŸnster, Germany
quence in the build. The serial number is also used to identify Model Code Typ
the unit's warranty time period. 90R130 MA 1 B
Identification Number
6 S 3 C6 C 03
Pumps manufactured in Germany will have an identification NNN 42 42 20
Model No. Ident Nr
number instead of a model number.
123456
N - 92 - 26 - 12345
Serial No. Fabr Nr
The letter code indicates the location of original manufacture MADE IN GERMANY
(assembly). "A" indicates the unit was originally assembled
in Ames, Iowa, USA. "N" indicates the unit was originally
assembled in NeumŸnster, Germany.

The first number (2 digits) indicates the year of manufacture.

("92" would indicate the unit was manufactured in 1992)

The second number (2 digits) indicates the calender week of

manufacture.

The third number (5 digits) is a sequential number used to

identify a specific unit.

3
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Date Code

The date code is defined as the year and week of manufacture. The same reference number may list more than
one part number. This indicates that there is more than one configuration for that reference number. You will see
that there are different date codes for the different part numbers. Find the date code of your unit via the name-
plate to determine which service part number you need to order.

EXAMPLE: The service part desired is Item E10.

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model
E10 92-19 → 746107 Side cover (SB-9203) 1
" 89-41 → 92-18 340133 Side cover 1

All units using this module group with a date code of 89-41 and up to and including 92-18 must use part number
340133. All units with a date code of 92-19 and up must use part number 746107.

Service Bulletins

A Service Bulletin Number (SB- _ _ _ _) may follow the Description of the part you desire. You must read that
Service Bulletin prior to ordering that part. A copy of each of these Service Bulletins, as of the print date of this
bulletin, are included at the end of this manual. Service Bulletins contain more detailed information such as
interchangeability, what additional parts are involved, etc. It is suggested that you add additional Service Bulletins
to this manual as you receive them.

Procedure to Identify a Given Part/Part Number

General
The modular design of Series 90 units results in a simplified Service Parts List and Part Identification Procedure.

The same item numbers are used for same part description on all units within a product type. (Example: The shaft
seal - Item Number L40 has the same item number on all variable displacement pumps.)

All Item Numbers begin with a letter. The letter identifies a particular module. (Example: any items beginning with
K relate to the charge relief valve; items beginning with L relate to the drive shaft components, etc.)

Example of a Part Identification

The nameplate on a Series 90 pump has an Order Code of 90L130 EP 1 V 6 P 3 S4 E 05 NNN 38 38 20. Use
the following procedures to determine the part number of the filtration kit used on this pump.

1) Referring to the filtration module in the Model Code (see page 5), the filtration option for this unit is identified
by the code P (90L130 EP 1 V 6 P 3 S4 E 05 NNN 38 38 20)
2) Referring to the Service Parts List, find the filtration group. Next find the order code that relates to this unit,
which is P. The filtration kit is found to be item N00M and part number 8002N00M-A. Also note that the
saleable parts included in this kit are indented, which indicates the filter is not included in the kit.

4
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

90 R 1 3 0 MA 1 B 6 S 3 C6 C 03 NNN 42 42 20

Charge
Series Pressure Setting

Rotation High Pressure Setting

Port A

Pump Size (cc) High Pressure Setting

Port A

Control Type Special Hardware Features

Pressure Regulation Control Orifice

Auxilary Mounting Pad Charging System

End Cap Ports Input Shaft

Filtration Displacement Limitation

5
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Common Parts

L60 L70

L40
B70 L30
G538
B80 L20
L10
G548 B82
B90
B70 L50
B90

G908
G508

G94
G93
G518
G95

G528

G958
G508

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

6
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model/Kit
B70 89-41 → 9005110-5600 Plug 2
B80 89-41 → 9005110-9200 Plug 1
B82 92-19 → 9005110-5600 Plug (SB-9203) 1
B83 92-19 → 9005110-5600 Plug (SB-9203) 1
B90 89-41 → 9803390 Control filter screen 3
G93 89-41 → 8800564 Spacer 1
G94 89-41 → 8800565 Lifting bracket 1
G95 89-41 → 502195 Washer 1
G508 89-41 → 9005100-5600 Plug 2
G518 89-41 → 9005110-4400 Plug 1
G528 89-41 → 9005110-5600 Plug 1
G538 89-41 → 9005110-5600 Plug 1
G548 89-41 → 9005110-5600 Plug 1
G908 89-41 → 713719 Screw 1
G958 89-41 → 9007314-0811 Screw 1
L10 89-41 → 304857 Roller bearing 1
L15 89-41 → 376319 Shim 1
L20 89-41 → 392209 Retaining ring 1
L30 89-41 → 303503 Seal carrier 1
L40 89-41 → 9008000-0114 Lip seal 1
L50 89-41 → 353961 O-ring 1
L60 89-41 → 303529 Retainer plate 1
L70 89-41 → 9007315-0805 Screw, M8 x 20 3

Bold Items indicate recommended parts to be stocked for servicing

7
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Common Parts

B10

D14

D55
D65 B50
B20

F20 D10

D75 B50
D60 B20
D95 D70

D85 B30

D50 D80

D01

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

8
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model/Kit
B10 92-19 → 8510060 Variable housing assy. (SB-9203) 1
B20 89-41 → 9004800-1904 Pin 2
B30 89-41 → 324657 Bearing 1
B50 89-41 → 9004800-3708 Pin 2

D01 88-16 → 731026 Swashplate assy. 1

D10 88-16 → 303214 Servo arm assembly 1
D50 88-16 → 501188 Swashplate 1
D55 89-41 → 9007276-0111 Screw 1
D60 89-41 → 766022 Swashplate guide 1
D65 89-41 → 504493 Screw 1
D70 89-41 → 127464 Washer 1
D75 89-41 → 333369 Spiral head pin 1

D14 89-41 → 340091 Feedback link 1

D80 89-41 → 700948 Cage locator link 1
D85 89-41 → 754606 Pin 1
D95 89-41 → 303420 Spring 1
F20 89-41 → 765719 Slider block 1

Bold Items indicate recommended parts to be stocked for servicing

9
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Displacement Limitation

S01
F344
F354
F60
S03

F60
F40
F50

F40
F50

S10

F11
F12

F11
F12

F50
F40

Enlarged bold type item numbers F50 F60

are Recommended parts to be F40

stocked for servicing. F60 S02

F344
F354
S04

10
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Displacement Limitation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
3 S02 89-41 → 8302F003-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
S03 89-41 → 8302F003-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4

4 S01 89-41 → 8302F004-A Servo sleeve kit - No limitation 1

F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
F344 89-41 → 572180 Set screw 1
F354 89-41 → 42432 Seal nut, M10 1
S04 89-41 → 8302F004-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
F344 89-41 → 572180 Set screw 1
F354 89-41 → 42432 Seal nut, M10 1

S10 89-41 → 509286 Servo piston assembly 1

F11 89-41 → 9004100-2240 O-ring 2
F12 89-41 → 507800 Piston ring 2

Bold Items indicate recommended parts to be stocked for servicing

11
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

End Cap

G20

G308

H90L

G40
G048
H50
H05L

H60
H50
H40

H05

H70
Enlarged bold type item numbers
are Recommended parts to be
H80
stocked for servicing.

12
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

G: End Cap Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
8 G048 89-41 → 303511 End cap, twin ports 1
G20 89-41 → 303693 Journal bearing 1
G40 89-41 → 303651 Bushing 1
G308 89-41 → 730895 End cap gasket (SB-9203) 1

H: Charging System Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
E H05 93-34 → 501404 Charge pump, 20 cc (SB-9425*) 1
H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

F H05 93-34 → 501405 Charge pump, 26 cc (SB-9425*) 1

H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

H H05 93-34 → 501406 Charge pump, 34 cc (SB-9425*) 1

H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

L H05L 89-41 → 339762 Charge pump spacer 1

H50 93-34 → 501399 Charge pump shaft 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6
H90L 89-41 → 9005110-9500 Plug 1
*
* For additional information regarding replacement parts for units
built prior to 93-34, refer to BLN-10107 in the appendix

Bold Items indicate recommended parts to be stocked for servicing

13
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Auxiliary Mounting Pad

J15
J30
J10
J60
L

J70

J80

J50

J40
J90 J

J92

J95

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

14
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
A J 89-41 → 8302J00A-A Aux. mtg. A flange kit, 9 tooth 1
J10 89-41 → 310466 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 303339 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004100-0420 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 9802336 Cover plate 1
J95 89-41 → 9007200-3714 Screw 2
B J 89-41 → 8302J00B-A Aux. mtg. B flange kit, 13 tooth 1
J10 89-41 → 310474 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 365312 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004104-0440 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 4460370 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2
C J 89-41 → 8302J00C-A Aux. mtg. C flange kit, 14 tooth 1
J10 89-41 → 310508 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 726463 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004100-0480 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 8800406 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2
* The new style covers are interchangable with either charge pump design

Bold Items indicate recommended parts to be stocked for servicing

15
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Auxiliary Mounting Pad

J80N
J40N
J15N
J30

J15
J30
J10
J60
L

J70

J80

J50

J40
J90 J

J92

J95

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

16
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
D J 89-41 → 8302J00D-A Aux. mtg. D flange kit, 13 tooth 1
J10 89-41 → 310490 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
" 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 505118 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 916742 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 338400 Cover plate 1
J95 89-41 → 9007200-7524 Screw 4

N J15N 89-41 → 501400 Charge pump cover (SB-9425*) 1

J30 89-41 → 303651 Bushing 1
J40N 89-41 → 354324 O-ring 1
J80N 89-41 → 9007314-1622 Screw (SB-8923) 4

V J 89-41 → 8302J00V-A Aux. mtg. B-3 flange kit, 15 tooth 1

J10 89-41 → 310482 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
" 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 365312 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004104-0440 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 4460370 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2

Bold Items indicate recommended parts to be stocked for servicing

17
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Shaft

K90
K10 K000

K50
K70
K80

L1

L8

L9
L1

L6

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
18
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

K: Charge Pressure Setting

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
00-30 K10 89-41 → 343095 Plug assembly 1
K50 89-41 → 9004201-7500 O-ring 1
K70 89-41 → 709469 Spring 1
K80 89-41 → 343087 Poppet 1
K90 89-41 → 343848 Nut 1

L: Shaft Group
C8 L1 89-46 → 303495 Shaft, 27 t 16/32 1

F1 L1 89-46 → 335695 Shaft, 13 t 8/16 1

T4 L1 89-46 → 346601 Shaft, 1.75 tapered 1

L6 89-41 → 9004600-1230 Cotter pin 1
L8 89-41 → 94-11 9003326-0005 Key (SB-9407) 1
L9 89-41 → 9700189 Slotted nut 1
Bold Items indicate recommended parts to be stocked for servicing

19
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Control
M9E
M98E
M90E
M95E
M97E

E
M1E
M96E

M1C M90C
M11

M11
M90D D

M1D

C
M11

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
20
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
CA C 89-41 → 8102M0CA-A Control cover plate kit 1
M11 89-41 → 8800923 Control gasket 1
M1C 89-41 → 8800336 Cover plate 1
M90C 89-41 → 9007314-0606 Screw 6
(No feedback link on Swashplate)
CB C 89-41 → 8102M0CA-A Control cover plate kit 1
M11 89-41 → 8800923 Control gasket 1
M1C 89-41 → 8800336 Cover plate 1
M90C 89-41 → 9007314-0606 Screw 6
(Feedback link on Swashplate)
DC D 89-41 → 8302M0DC-A Control kit,3 position sol.,12v 1
M11 89-41 → 8800923 Control gasket 1
M1D 89-41 → 344010 Control,3 position sol.,12v 6
M90D 89-41 → 9007314-0606 Screw 6
EA E 92-19 → 8302M0EA-B EDC1 kit w/MS conn.(SB-9302) 1
M11 92-19 → 8800923 Control gasket 1
M1E 92-19 → MCV111B1402 EDC1 w/MS connector (SB-9302) 1
M9E 92-19 → MCV110A1017 PCP type 3 oil filled 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6
EM M1E 92-19 → MCV114E1303 EDC w/weather-pack conn. 1
M11 92-19 → 8800923 Control gasket 1
M9E 92-19 → MCV116A3102 PCP, weather-pack conn. 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6
EN M1E 92-19 → MCV114A1307 EDC2 w/MS conn. (SB-9302) 1
M11 92-19 → 8800923 Control gasket 1
M9E 92-19 → MCV116A3501 PCP, 643 ohm, MS conn. 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6

Bold Items indicate recommended parts to be stocked for servicing

21
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Control
S40
M72M
M9E
M90M M71M M98E
M7M M90E M95E
M1M M97E

M1E M96E
M M11
M11

E
M90H

M1H

H M11

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
22
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
EP E 92-19 → 8302M0EP-B EDC1, packard conn.(SB-9203) 1
M11 92-19 → 8800923 Control gasket 1
M1E 92-19 → MCV111B1404 EDC1 w/packard connector 1
M9E 92-19 → MCV110A1058 PCP, packard connector 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19 → 9004104-0140 O-ring 1
M97E 92-19 → 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6

HC M1H 92-19 → 94-16 MCV112A1403 HDC, 3-11 bar 1

M11 92-19 → 94-16 8800923 Control gasket 1
M90H 92-19 → 94-16 9007314-0611 Screw 6

HF M1H 92-19 → MCV115A1303 HDC2, 3-11 bar (SB-9203) 1

M11 92-19 → K11420 Control gasket (SB-9302) 1
M90H 92-19 → 9007314-0611 Screw 6

HM M1H 92-19 → MCV115A1301 HDC2, 1.1-6.7 bar (SB-9203) 1

M11 92-19 → K11420 Control gasket (SB-9302) 1
M90H 92-19 → 9007314-0611 Screw 6

MA M 92-19 → 8302M0MA-B MDC kit w/o neutral start (SB-9203) 1

M11 92-19 → 8800923 Control gasket 1
M1M 92-19 → 772749 MDCw/o neutral start switch 1
M7M 92-19 → 9800916 Control handle 1
M71M 92-19 → 9009660-3100 Washer 1
M72M 92-19 → 9003513-0800 Nut 1
M90M 92-19 → 9007314-0611 Screw 6

MB M 92-19 → 8302M0MB-B MDC kit w/neutral start (SB-9203) 1

M11 92-19 → 8800923 Control gasket 1
M1M 92-19 → 772756 MDCw/neutral start switch 1
M7M 92-19 → 9800916 Control handle 1
M71M 92-19 → 9009660-3100 Washer 1
M72M 92-19 → 9003513-0800 Nut 1
M90M 92-19 → 9007314-0611 Screw 6
S40 92-19 → 80020S40 Neutral start switch kit 1

Bold Items indicate recommended parts to be stocked for servicing

23
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Filtration

N40P
N35S
N10S

N00M

N35M N40L
N10M
N00R
N20M N25M
N35R
N10R
N15

N20R N25R

N15

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

24
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

N: Filtration Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
L N00M 89-41 → 8302N00M-A Filtration manifold kit 1
N10M 89-41 → 8800896 Manifold (SB-9436) 1
N15 89-41 → 9004201-9000 O-ring 1
N20M 89-41 → 5000222 Nut (SB-9436) 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35M 89-41 → 9005100-5600 Plug 2
N40L 89-41 → 8700068 Filter, long 1

P N00M 89-41 → 8302N00M-A Filtration manifold kit 1

N10M 89-41 → 8800896 Manifold (SB-9436) 1
N15 89-41 → 9004201-9000 O-ring 1
N20M 89-41 → 5000222 Nut (SB-9436) 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35M 89-41 → 9005100-5600 Plug 2
N40P 89-41 → 9700810 Filter, short 1

R N00R 89-41 → 8302N00R-A Filtration manifold kit 1

N10R 89-41 → 350777 Manifold 1
N15 89-41 → 9004201-9000 O-ring 1
N20R 89-41 → 9002863-1600 Nut 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35R 89-41 → 9005100-5600 Plug 1

S N10S 89-41 → 5000230 Reducer fitting 1

N35S 89-41 → 9005110-5600 Plug 1

Bold Items indicate recommended parts to be stocked for servicing

25
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

High Pressure Regulation

END CAP GASKET FACE END CAP GASKET FACE

P80 P80
P802
P70 P70

P702

Left Hand Rotation Right Hand Rotation Left/Right Hand Rotation

With Pressure Limiters Without Pressure Limiters

P2B1
P6
P13

P6
P13 P2B1
P2A1 P6
P13

Side Port End Cap P6

P2A1 P13

Enlarged bold type item numbers

are Recommended parts to be Twin Port End Cap
stocked for servicing.
26
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

P: High Pressure Regulation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
1 P2A1 89-41 → 8510023-1 Multi-function valve, w/PL (SB-9114) 1
(Range 1) P2B1 89-41 → 8510023-1 Multi-function valve, w/PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P70 89-41 → 8800188 Check valve 2
P80 89-41 → 9005475-0004 Special plug 2

2 P2A1 89-41 → 8510023-2 Multi-function val., w/o PL (SB-9114) 1

(Range 1) P2B1 89-41 → 8510023-2 Multi-function val, w/o PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P702 89-41 → 9005110-4400 Plug 1
P802 89-41 → 9005475-0004 Special plug 3

6 P2A1 89-41 → 8510023-6 Multi-function valve, w/PL (SB-9114) 1

(Range 2) P2B1 89-41 → 8510023-6 Multi-function valve, w/PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P70 89-41 → 8800188 Check valve 2
P80 89-41 → 9005475-0004 Special plug 2

7 P2A1 89-41 → 8510023-7 Multi-function val., w/o PL (SB-9114) 1

(Range 2) P2B1 89-41 → 8510023-7 Multi-function val., w/o PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P702 89-41 → 9005110-4400 Plug 1
P802 89-41 → 9005475-0004 Special plug 3

Bold Items indicate recommended parts to be stocked for servicing

27
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Orifice

Installed in
Control Housing

T001

T521

T721
T301
T821 T401
T621

28
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

T: Orifice Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
01 T001 87-02 → 8002T001-A Control orifice kit - .018 1
T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

02 T001 87-02 → 8002T002-A Control orifice kit - .026 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

03 T001 87-02 → 8002T003-A Control orifice kit - .032 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

04 T001 87-02 → 8002T004-A Control orifice kit - .040 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

05 T001 87-02 → 8002T005-A Control orifice kit - .054 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

06 T001 87-02 → 8002T006-A Control orifice kit - .062 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

09 T001 87-02 → 8002T009-A Control orifice kit - .092 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

22 T001 87-02 → 8002T022-A Control orifice kit - .022 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

29 T001 91-30 → 8002T003-A Control orifice kit - .032 1

T301 91-30 → 8700007 Spring 1
T401 91-30 → 8800340 Spring retainer 1
T521 91-30 → 639104 Orifice plug, .7mm, M5 x 6 1
T621 91-30 → 639104 Orifice plug, .7mm, M5 x 6 1

50 T001 87-02 → 8002T002-A Control orifice kit - .026 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1
T721 87-02 → 521054 Orifice plug, .9mm 1
T821 87-02 → 521054 Orifice plug, .9mm M8 x 8 1

29
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Special Hardware Feature

B83

B83
C20

C30
S07
C40

C05 C50
E30
E30
C70

C13 E22
C14 E80 E20

C15 E22
E24
E80
C16
E24

E50
C80

E90

E10

E60
E70
E40

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
30
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S07 89-41 → 83020S07 Cyl. block kit (SB-9312) 1
C05 89-41 → 302851 Cylinder block assembly 1
C13 89-41 → 700922 Spring seat 1
C14 89-41 → 302828 Cylinder block spring 1
C15 89-41 → 700930 Spring retainer 1
C16 89-41 → 302836 Retaining ring 1
C20 89-41 → 727750 Welded piston 9
C30 89-41 → 735506 Slipper guide 1
C40 89-41 → 700963 Slipper guide brg. 2
C50 89-41 → 700971 Spacer 4
C70 89-41 → 308643 Screw 4

E10 96-03 → 501576 Side cover (SB-9604) 1

" 92-19 → 96-02 746107 Side cover (SB-9203) 1
E20 92-19 → 730143 Leveler (SB-9203) 1
E22 89-41 → 367037 Spring Seat 2
E24 89-41 → 359067 Shim 2
E30 96-03 → 506368 Guide post (SB-9604) 2
" 92-19 → 96-02 503205 Guide post (SB-9203) 2
E40 92-19 → 42432 Nut (SB-9203) 2
E50 89-41 → 9004104-2590 O-ring 1
E60 89-41 → 308700 Screw 6
E70 89-41 → 9005110-9200 Plug 1
E80 89-41 → 503091 Spring 2
E90 96-03 → 8300004 Insert assembly (SB-9604) 1

W: Special Hardware Features Group

EDB B83 89-41 → KPPC154 Speed sensor 1
C05 89-41 → 503753 Cylinder block assy. w/speed ring 1
C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

EEB B83 89-41 → 9005110-5600 Plug 1

C05 89-41 → 503753 Cylinder block assy. w/speed ring 1
C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

GBA & NSN B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

GCA B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 739540 Pump valve plate, 1.5 degree 1

NDN & NNN B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 700203 Pump valve plate, -2 degree 1

Bold Items indicate recommended parts to be stocked for servicing

31
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Overhaul Seal Kit
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S30 92-19 → 83020S30 Overhaul seal kit (SB-9203) 1
C70 89-41 → 308643 Screw 4
E40 92-19 → 42432 Nut (SB-9203) 2
E50 89-41 → 9004104-2590 O-ring 1
E60 89-41 → 308700 Screw 6
F11 89-41 → 9004100-2240 O-ring 2
F12 89-41 → 507800 Piston ring 2
F40 89-41 → 9004100-0370 O-ring 2
F50 89-41 → 9004100-0360 O-ring 2
G308 89-41 → 730895 End cap gasket (SB-9203) 1
J40 89-41 → 92-29 354324 O-ring 1
J50 89-41 → 505068 O-ring 1
J90 89-41 → 9004100-0420 O-ring 1
J90 89-41 → 9004104-0440 O-ring 1
J90 89-41 → 9004100-0480 O-ring 1
K50 89-41 → 9004201-7500 O-ring 1
L40 89-41 → 9008000-0114 Lip seal 1
L50 89-41 → 353961 O-ring 1
M11 89-41 → 8800274 Control gasket 1
M11 89-41 → K11420 Control gasket (SB-9302) 1
N15 89-41 → 9004201-9000 O-ring 1
P6 89-41 → 9004100-0250 O-ring 2
P13 89-41 → 9004100-0290 O-ring 2

Bold Items indicate recommended parts to be stocked for servicing

32
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

NOTES

33
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

BLN-10107 Rev. B

Charge Pump Design Change

To improve efficiency and reliability, the number of parts in Series 90 pumps
is being reduced. The charge pump design on 55cc thru 130cc frame sizes
is being changed so that the outer port plate is an integral part of the charge
pump cover and distance plates are eliminated. The change is taking effect
at the following manufacturing dates:
55cc: 93-10 75cc: 93-10 100cc: 93-15 130cc: 93-34

For auxiliary pad options, the new charge pump cover is rotation dependent.
The cover will be marked as either left hand (L) or right hand (R). The non-
axiliary pad cover is not rotation dependent.

The charge pump shaft also changes and must be replaced when using the
new style hardware. The complete charge assembly can be interchanged
with corresponding hardware from 89-17 and beyond. However, piece
parts are not interchangeable. For units prior to 89-17, consult Sauer-
Sundstrand.

The old design charge pump hardware is obsolete and is no longer available.
Refer to the chart on the reverse side of this page to determine the
replacement kit.

34
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

BLN-10107 Rev. B
The following information must be known to determine the correct
charge pump replacement kit:
1. Unit size (055, 075, 100 or 130 cc)
2. Charge pump displacement (11, 14, 17, 20, 26 or 34 cc)
3. Auxilary pad (Yes or No)
4. Rotation (LH or RH)

Obsoleted Charge Pump Parts Chg. pump

Auxilary Replacement
Unit Size displace- Rotation
pad Kit
Gear Set Shaft Cover ment
8800513 No LH or RH 8510028
8000169 8000174 8800514 055 11 cc Yes LH 8510029
8800514 Yes RH 8510030
8800513 No LH or RH 8510031
8000170 8000174 8800514 055 14 cc Yes LH 8510032
8800514 Yes RH 8510033
8800513 No LH or RH 8510034
8000171 8000174 8800514 055 17 cc Yes LH 8510035
8800514 Yes RH 8510036

8800513 No LH or RH 8510037
8100313 337956 8800514 075 14 cc Yes LH 8510038
8800514 Yes RH 8510039
8800513 No LH or RH 8510040
8100314 337956 8800514 075 17 cc Yes LH 8510041
8800514 Yes RH 8510042
8800513 No LH or RH 8510043
8100315 337956 8800514 075 20 cc Yes LH 8510044
8800514 Yes RH 8510045

8800513 No LH or RH 8510046
8200158 337956 8800514 100 17 cc Yes LH 8510047
8800514 Yes RH 8510048
8800513 No LH or RH 8510049
8200159 337956 8800514 100 20 cc Yes LH 8510050
8800514 Yes RH 8510051
8800513 No LH or RH 8510052
8200160 337956 8800514 100 26 cc Yes LH 8510053
8800514 Yes RH 8510054

347518 No LH or RH 8510064
714444 303636 347526 130 20 cc Yes LH 8510065
347526 Yes RH 8510066
347518 No LH or RH 8510067
714451 303636 347526 130 26 cc Yes LH 8510068
347526 Yes RH 8510069
347518 No LH or RH 8510070
714469 303636 347526 130 34 cc Yes LH 8510071
347526 Yes RH 8510072
35
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9102

PRODUCTS AFFECTED: Series 90 Variable Pumps
SUBJECT: Side Cover Lock Tab Washer

DESCRIPTION:

The lock tab washers, located under the side cover screws, have been replaced with flat
washers on all Series 90 variable pumps.

As before, the side cover screws must be replaced if they are removed for any reason. The
special coating, which seals and retains the screws, wears off when the screws are removed.

Lock tab washer

Screw

36
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9102

MODELS AFFECTED:
All 93-2xxx(42cc), 94-2xxx(55cc), 95-2xxx(75cc). 96-2xxx(100cc), and
97-2xxx(130cc) variable pumps

SERIAL NUMBERS AFFECTED:

New washers can be used on any vintage pump. Change will take place immediately.

PART NUMBERS AFFECTED:

Pump Size Lock Tab Washer p/n Washer p/n

42 314203 723981

55, 75, and 100 8100307 502195

130 370767 502187

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
Non-Restricted Distribution
37
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9114

PRODUCTS AFFECTED: Series 90 130 cc Variable Pumps
SUBJECT: Multi-Function Valve Installation

DESCRIPTION:

To avoid damaging the multi function cartridge used on 130cc variable pumps, the
installation torque has been lowered from 206 ft. lbsf. (279 Nm) to 155 ft. lbsf. (210 Nm).

The Series 90 Service Manual will be changed to show the lower installation torque at
its next revision.

38
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9114

MODELS AFFECTED:
All 97-2xxx pumps

SERIAL NUMBERS AFFECTED:

All

PART NUMBERS AFFECTED:

N/A

PARTS DISPOSITION:
X Not Applicable
Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
39
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

PRODUCTS AFFECTED: Series 90: 55,75,100, 130 cc Pumps
SUBJECT: Block Point Change: Components Redesign

DESCRIPTION:
As part of our overall Series 90 product improvement program, numerous components are
being redesigned. This redesign is referred to as a blockpoint change. The objective of the
blockpoint change is to minimize the number of times we change the units while we convert to high
volume tooling at various plant sites. These design improvements will provide increased reliability
and more application flexibility. The nature of these changes makes customer requalification
unnecessary. Old style (pre-block point) variable housings and endcaps will no longer be available
as spare parts.

40
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

FRAME SIZE: 130
Parts Affected:
Pre "blockpoint" New Part Number
Item Description Part Number (92-19 & Later)
Common Parts Group, 130 cc
B10 Variable housing 700237✧ 8510060
E10 Side cover 340133 746107
E20 Leveler 701037 730143
E30 Guide post 340117 746255
E40 Screw 364489 (4) 042432 (2) Seal Nut ***
B82 Plug n/a 9005110-5600
End Cap Group, 130 cc
G308 End Cap gasket 709816*✧ 730895*
G908 Screw 376624 713719**
G958 Screw 527218 9007314-0811**
Special Hardware Features Group, 130 cc
B83 Plug-Speed Pick-up n/a 9005110-5600
Control Group, 130 cc
All Control Types-Delete The Following Parts:
M810 Plate 738203✧ N/A
M820 O-ring 9004104-0440 N/A
M830 O-ring 9004100-0220 N/A
M840 O-ring 9004101-0130 N/A
M860 Screw 345496 N/A
M870 Plug 9005100-4400 N/A
M880 Washer 723981 N/A

WARNING: On 130cc pumps, "Pre" and "Post" blockpoint controls

(MDC's, HDC's and EDC's) are not interchangeable due to different length
control pins. Ensure positive pin engagement. Failure to do so may result
in pump output, and the vehicle may move.

Pre-Block Point Post-Block Point

1.13 in 0.89 in
(28.7 mm) (22.7 mm)

41
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

FRAME SIZE: 130

Controls, 130 cc
Module Pre "blockpoint" New Part Number
Groups Description Part Number (92-19 & Later)
EA EDC kit MS connector MCV111B1302 See EC Group
EP EDC kit Packard MCV111B1304 See EE Group
EC EDC, MS,standard MCV114A1402 MCV114B1302
EE EDC, Packard, standard MCV114A1404 MCV114B1304
EG EDC, MS, annular MCV114C1402 MCV114D1302
EH EDC, Packard, annular MCV114C1404 MCV114D1304

HA HDC , 1-11 bar MCV112A1302 See HK Group

HB HDC, 1-6.7 bar MCV112A1301 See HM Group
HC HDC, 3-11 bar MCV112A1303 See HF Group
HF HDC, 3-11 bar, standard MCV115A1403 MCV115A1303
HG HDC, .8-4.6 bar, annular MCV115B1405 MCV115B1305
HH HDC, 1-11 bar, annular MCV115B1402 MCV115B1302
HJ HDC, 3-11 bar, annular MCV115B1403 MCV115B1303
HK HDC, 1-11 bar, standard MCV115A1402 MCV115A1302
HL HDC, .8-4.6 bar, standard MCV115A1405 MCV115A1305
HM HDC, 1.1-6.7 bar, standard MCV115A1401 MCV115A1301
HN HDC, 1.1-6.7 bar, annular MCV115B1401 MCV115B1301

MA MDC w/o nss 8302MOMA-A 8302MOMA-B

MB MDC w/ nss 8302MOMB-A 8302MOMB-B

* Interchangeable part.
** 8mm screws - torque to 24 ft. lbs.
*** 10mm nut - torque to 32 ft. lbs.
✧ Obsolete

42
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

MODELS AFFECTED:
All Series 90 94-2xxx, 95-2xxx, 96-2xxx, and 97-2xxx Variable Pumps.
SERIAL NUMBERS AFFECTED:
Changes will take place at the following Serial Numbers:
55 cc 92-06 & beyond
75 cc 92-19 & beyond
100 cc 92-12 & beyond
130 cc 92-19 & beyond
PART NUMBERS AFFECTED:
Refer to text of this bulletin for specific part numbers.
Housing: (all frame sizes)Thickness adjacent to the side cover has been in-
creased.
Side Cover: (100 cc & 130cc only) Thickness increased.
End Cap: (all frame sizes) Match housing change; small end cap screws (55 cc-
100 cc) will be larger; the orientation of the charge relief valve on side
port end caps has been changed from an oblique to a vertical orienta-
tion.
Controls: (130cc only) Eliminate mounting plate, three-pin link change.
Side Cover: (130cc only) Swashplate hold-down ("T-bar") mounting will be changed
to commonize the design with the smaller displacement units.
NOTE: Reference PIB-9102 for design changes and outline dimensions.
PARTS DISPOSITION:
Not Applicable
Interchangeable
X Non-Interchangeable except where noted
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
43
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9302

PRODUCTS AFFECTED: Series 90 Pumps: All Frame Sizes

SUBJECT: Control Gasket Changes for New

MCV115 Hydraulic Displacement Control
DESCRIPTION:
In October of 1992, Sauer-Danfoss began offering a new style hydraulic displacement
control (MCV115) that is a direct replacement for the MCV112.

The control gasket also changed, and the new style gasket must be used with the MCV115
control. The old style gasket is to be used with the MCV112 control, all manual displacement
controls, and MCV111 electric displacement controls.

WARNING
Failure to use the appropriate gasket may result in uncontrolled pump displacement.

30 cc/42 cc/55 cc 75 cc/100 cc/130 cc

8800520 8800521
Do NOT use Do NOT use
with MCV115 with MCV115

K11419 K11420
Use ONLY with Use ONLY with
MCV115 MCV115

44
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9302

MODELS AFFECTED:
All 92-2xxx, 93-2xxx, 94-2xxx, 95-2xxx, 96-2xx, and 97-2xxx pumps.

SERIAL NUMBERS AFFECTED:

October 1992 and beyond.

PART NUMBERS AFFECTED:

Control Gasket for Control Gasket for HDC Control Gasket for
Frame Size EDC (MCV111) (MCV112) (MCV115) MDC (8X02M0MX)

30/42/55cc 8800520 8800520 K11419 8800520

75/100/130cc 8800521 8800521 K11420 8800521

PARTS DISPOSITION:
Not Applicable
Interchangeable
X Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
45
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9312

PRODUCTS AFFECTED: All Series 90 Pumps

SUBJECT: Removal of Valve Plate from Cylinder Block Kit

DESCRIPTION:
Due to the increasing number of valve plate options, the valve plate (item C80) will be no
longer included in the cylinder block kit (item S07) on all Series 90 variable pumps. Valve
plates must be ordered separately for service parts. See special hardware features group
in your Service Parts Manual for appropriate valve plate number.

C20

C30
C50
C40
C65
C70

S07

C05

C13
C14
C80
C15
C16

46
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9312

MODELS AFFECTED:
All 93-2xxx, 94-2xxx, 95-2xxx, 96-2xx, and 97-2xxx pumps.

SERIAL NUMBERS AFFECTED:

Not Applicable

PART NUMBERS AFFECTED:

Frame Size Cylinder Block Kit

42 cc 80520S07
55 cc 80020S07
75 cc 81020S07
100 cc 82020S07
130 cc 83020S07

PARTS DISPOSITION:
X Not Applicable
Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
All Product Related Sauer-Danfoss Distributors
All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
47
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9413 Rev. A

PRODUCTS AFFECTED: Series 90 and Series 51 Units with
Pulse Pickup (Speed Sensing)
SUBJECT: Pulse Pick-up Change

DESCRIPTION:
A small number of pulse pick-ups used on pumps and motors between June 1992 and April
1994 have been found to be defective due to corrosion of internal circuitry.

The corrosion of the internal circuitry may cause intermittent operation or partial loss of
signal and eventual failure.

A typical installation of a pulse pick-up is pictured below. Note the "silver" color of the
potentially defective pulse pick-up body. This should be replaced with a pulse pick-up body
that is "black" in color.

NOTE: If your speed sensor is in an electrical closed loop feedback circuit, possibly used
with a microprocessor, the silver colored speed sensor must be changed regardless of the
special hardware features code.

Silver Pulse Pick-up Body

48
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9413 Rev. A

MODELS AFFECTED:
All pumps and motors that used the pulse pick-up option, 90L055 EA 1 N
which is indicated by the special hardware features order 6 S 3 C6 C 03
code. EAA 35 35 24
Options: 51 Series = ACA, NNT, AAA, NNU, ABA
90 Series = EAA, EAB, EAD, NNS, EBB, ECA 51V160 RFIN
SERIAL NUMBERS AFFECTED: F1A1 ANE1 ACA
A-92-22-xxxxx thru A-94-17-xxxxx 050AA21 0322

PART NUMBERS AFFECTED:

Sensor Connector Style Body Color

KPPA124 Weather Pack Silver

KPPB124 Weather Pack Silver

KPPA125 Metri Pac Silver

KPPB125 Metri Pac Silver

KPPC124 Weather Pac Black

KPPC125 Metri Pac Black

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
49
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9425

PRODUCTS AFFECTED: Series 90 130 cc Variable Pumps

SUBJECT: Charge Pump Design Change

DESCRIPTION:
To improve efficiency and reliability, the number of parts in the charge pump is being
reduced. The charge pump on the 130 cc frame size is changing such that the outer port
plate (H30) is an integral part of the charge pump cover (J15) and the distance plates are
eliminated.
For auxiliary pad options, the new charge pump cover is rotation dependent. The cover will
be marked either left hand (L) or right hand (R). The non-auxiliary pad cover is not rotation
dependent.
The charge pump shaft also changes and must be replaced when using the new style
hardware. The complete charge pump assembly can be interchanged with corresponding
hardware.
However, piece parts are not interchangeable.

H60
Old charge pump design H50
H40
H30
H05
H60
H50
(H30) H40
H05

New charge pump design

J15N J40N

J30

L
J15
New charge pump cover J10
for pumps without auxilary pads L J30
(same cover for left hand or
right hand rotation)

New charge pump covers for pumps with auxiliary pads.

The new charge pump covers have an "L" or "R" stamped
on them for easy identification
50
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9425

MODELS AFFECTED:
All 97-2xxx and 972xxxx Pumps

SERIAL NUMBERS AFFECTED:

N-93-34-xxxxx

PART NUMBERS AFFECTED:

Obsoleted Charge Pump Parts Chg. pump

Auxilary Replacement
displace- Rotation
pad Kit
Gear Set Shaft Cover ment
347518 No LH or RH 8510064
714444 303636 347526 20 cc Yes LH 8510065
347526 Yes RH 8510066
347518 No LH or RH 8510067
714451 303636 347526 26 cc Yes LH 8510068
347526 Yes RH 8510069
347518 No LH or RH 8510070
714469 303636 347526 34 cc Yes LH 8510071
347526 Yes RH 8510072

PARTS DISPOSITION:
Not Applicable
X Interchangeable Piece parts are not interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
51
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9436

PRODUCTS AFFECTED: Series 90 55 thru 130 cc Variable Pumps

SUBJECT: Integral Filtration Manifold

DESCRIPTION:

As a product improvement, Sauer-Danfoss is changing the integral filter manifold and

bulkhead nut to make it more easily indexed.

The old bulkhead nut may be used with either the old or new filter manifold. The new
bulkhead nut can only be used with the new filter manifold.

The old bulkhead nut will remain available as a service part. The old filter manifold will be
obsoleted and no longer available as a service part.

Old Design

Manifold

Nut

New Design

Manifold

Nut

52
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9436

MODELS AFFECTED:
All Series 90 55 thru 130 cc Variable Pumps with 'L', 'M', or 'P' filtration option code

SERIAL NUMBERS AFFECTED:

Change occurred at serial number 95-18-xxxxx

PART NUMBERS AFFECTED:

Part Number Part Number
Description (prior to 95-18) (95-18 & beyond)
Filter Manifold 8800200 8800896
Bulkhead Nut 9002863-1600 5000222

PARTS DISPOSITION:
Not Applicable
X Interchangeable - new bulkhead nut can only be used with new filter manifold
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
53
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9503

PRODUCTS AFFECTED: Series 90 Pumps - All Frame Sizes

SUBJECT: Manual Displacement Control (MDC)

with DC Electric Solenoid Override
DESCRIPTION:
In order to accomodate our European customers, the manifold which attaches to the front
of the manual displacement control (MDC) housing is being changed.
The European solenoid valve requires a thicker manifold to provide clearance between
the solenoid and the front of the MDC housing. The revised manifold will protrude closer
to the mounting flange of the pump, reducing dimension "A" shown in the accompanying
drawing by approximately 5 mm [0.2 in]. Please see chart below for specific clearances.
The thicker manifold requires longer screws and may be used with either the U.S. or
European sourced solenoid.
This change will become effective during March of 1995. The old manifold will be
obsoleted and no longer available as a service part.

SOLENOID VALVE

"A"

"X"

NEUTRAL START
SWITCH (NSS)
OPTION

TOP VIEW VIEW IN DIRECTION "X"

SERIES 90 FRONT VIEW
MANUAL DISPLACEMENT CONTROL
WITH DC SOLENOID OVERRIDE

Frame Size 042 055 075 100 130

Dimension Current 39.9 55.9 54.1 60.2 74.4
"A" [1.57] [2.20] [2.13] [2.37] [2.93]
mm Future 34.9 50.9 49.1 55.2 69.4
[in] [1.37] [2.0] [1.93] [2.17] [2.73]

54
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9503

MODELS AFFECTED:
All Series 90 Variable Pumps using manual displacement control (MDC) with
DC electric solenoid override.

SERIAL NUMBERS AFFECTED:

Change will take place in March '95

PART NUMBERS AFFECTED:

Current Part Number New Part Number Quantity

Manifold 8800365 505022 1

Screw 9007314-0605 9007314-0606 2

PARTS DISPOSITION:
Not Applicable
X Interchangeable (new manifold requires longer screws)
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
55
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9510

PRODUCTS AFFECTED: Series 90 Variable Pumps

SUBJECT: Solenoid Valve Change

DESCRIPTION:

Sauer-Danfoss has changed suppliers of the solenoid valve for the manual displacement
control with 12 volt two position solenoid valve (order codes ME and MJ).
The new solenoid valve requires shorter mounting screws.
The old solenoid valve is being obsoleted and no longer available as a service part. A kit
has been created that includes the new solenoid valve and the appropriate mounting
screws.

Solenoid
Mounting Screw

56
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9510

MODELS AFFECTED:
All Series 90 variable pumps using control order codes ME and MJ

SERIAL NUMBERS AFFECTED:

Units built N-95-24-xxxxx and after

PART NUMBERS AFFECTED:

Replacement
Old Solenoid Old Screws Kit
504381 9007315-0510 8510107

PARTS DISPOSITION:
Not Applicable
X Interchangeable ☛ Piece parts are not interchangeable.
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
57
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9514

PRODUCTS AFFECTED: Series 20 & 90 Pumps With
Optional Neutral Start Switch
SUBJECT: Neutral Start Switch Change

DESCRIPTION:

Sauer-Danfoss has changed suppliers of the neutral start switch on Series 20 and
some neutral start switch options (MR, MS and ML) on Series 90 pumps. Advanced
notification of this change was given with Product Information Bulletin number PIB-9403.

The new switch has Teflon tape on the threads instead of Vibra-Seal. New Teflon tape
should be applied to the threads if the switch is removed for any reason.

Due to interchangeability, the old switch has been obsoleted and no longer available as
a service part.

Teflon Tape Applied To Threads

58
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9514

MODELS AFFECTED:
All Series 20 variable pumps and Series 90 variable pumps using control order codes
ML, MR and MS

SERIAL NUMBERS AFFECTED:

Units built N-95-17-xxxxx and after

PART NUMBERS AFFECTED:

Old Switch New Switch NSS Kit

9700922 503545 8510027*

* The Neutral Start Switch Kit part number did not change

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
59
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9518

PRODUCTS AFFECTED: Series 90 - 130 cc Variable Pumps

SUBJECT: Filter Tube - Pressure and Remote Filtration

DESCRIPTION:
This bulletin was issued in Feb, 96. The purpose of revision 'A' is to add the tube
length for the remote filter adaptor that was omitted at first publication.

The filtration tube that is used in the manifold for remote or integral pressure filtration may
be too short in length. The filtration tube should be measured for proper length and replaced
if necessary at first repair for units built prior to N-95-41. The correct length of the integral
filtration tube is 143.76 ± .25mm [5.66 ±.01 inches] and 101.09 ± .25mm [3.98 ± .01 inches]
for the remote filtration tube.

The old filtration tubes are obsolete and no longer available as a service part.

Integral Filter Tube

Remote Filter Tube

60
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9518

MODELS AFFECTED:
All Series 90 -130cc Variable Pumps with integral pressure filtration or remote pressure
filtration.

SERIAL NUMBERS AFFECTED:

Units built prior to N 95-41-XXXXX

PART NUMBERS AFFECTED:

Old Part New Part

Filter Option Number Number
Remote 355206 8800938
Integral Pressure 355214 8800939

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
X Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
61
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9601

PRODUCTS AFFECTED: Series 90, 130 cc Variable Pumps

SUBJECT: Swashplate Leveler Spring

DESCRIPTION:
As a product improvement, Sauer-Danfoss has reduced the number of springs
used on the swashplate leveler from four springs to two springs. The older nested
springs will be obsoleted and no longer available as a service part.

Old Design New Design

62
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9601

MODELS AFFECTED:
All 972xxx and 97-2xxx variable pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-89-41-xxxxx

PART NUMBERS AFFECTED:

Item No. Desc Old P/N Qty New P/N Qty
E82 Spring 704494 2 - -
E80 Spring 704486 2 503091 2

PARTS DISPOSITION:
Not Applicable
X Interchangeable ➛ (if old springs are replaced with new springs)
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
63
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9604

PRODUCTS AFFECTED: Series 90, 42, 130,180, & 250 cc Variable Pumps

SUBJECT: Side Cover Design Change

DESCRIPTION:
As a product improvement, Sauer-Danfoss is changing the side cover and swashplate
leveler ("T-Bar") guide post design.
The new design side cover will have two hardened inserts in the machined slot which
serves as a guide for the swashplate leveler, and modified guide posts. The swashplate
leveler does not change.
Old guide posts will remain available for service requirements of pumps with the old
design side cover.
The old style side cover will be obsoleted and no longer available as a service part. A
service kit has been created for replacing the old design side cover. The kit includes the
new side cover, guide posts and inserts. Piece parts are not interchangeable.

Guide Post
Guide Post

Swashplate Leveler

Inserts

Side Cover

64
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9604

MODELS AFFECTED:
All 42, 130, 180, & 250 cc variable pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-96-08-xxxxx

PART NUMBERS AFFECTED:

Old Part Numbers New Part Numbers

Description Guide Post Side Cover Insert assy. Guide Post Side Cover Kit

42 cc 344465 751305 506916 506369 506380

130 cc 503205 746107 8300004 506368 506289

180 cc 503205 746404 506914 506368 506290

250 cc 503205 746404 506914 506368 506290

PARTS DISPOSITION:
Not Applicable
X Interchangeable as a kit Piece parts are not interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
65
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Notes

66
 Hydraulic Power Systems
SAUER-DANFOSS Hydraulic Power Systems - Market Leaders Worldwide
SAUER-DANFOSS is a world leader in the design and SAUER-DANFOSS specializes in integrating a full
manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers
development resources in both North America and Europe with the most advanced total-design system.
enable SAUER-DANFOSS to offer a wide range of
design solutions utilizing hydraulic power system SAUER-DANFOSS is Your World Source for
technology. Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives

Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

Pumps and Motors Electrohydraulic Controls Packages

Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts

Worldwide Service Support

SAUER-DANFOSS provides comprehensive worldwide service for its

products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.

Look to SAUER-DANFOSS for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

SAUER-DANFOSS COMPANY SAUER-DANFOSS GMBH & CO.

2800 East 13th Street Postfach 2460, D-24531 Neumünster
Ames, IA 50010, U.S.A. Krokamp 35, D-24539 Neumünster, Germany
Phone: +1 515 239-6000, FAX: +1 515 239-6618 Phone: +49 4321 871-0, Fax: +49 4321 871 122
BLN-2-41673 • May, 1996
67
 Genuine Parts
Original
Ersatzteile

Series 90

130 cc - Axial Piston

Pump
Service Parts Manual

BLN-2-41673 May, 1996

 Series 90
saueContents Genuine Parts
130 cc Pump
BLN-2-41673
Original
Ersatzteile May, 1996

Unit and Service Parts Identification ............................................................................................................... 3-4

Order Code ...................................................................................................................................................... 5
Common Parts ................................................................................................................................................ 6-9
Displacement Limitation ............................................................................................................................. 10-11
End Cap ...................................................................................................................................................... 12-13
Charging System ........................................................................................................................................ 12-13
Auxiliary Mounting Flange .......................................................................................................................... 14-17
Charge Pressure ........................................................................................................................................ 18-19
Shaft ........................................................................................................................................................... 18-19
Control ........................................................................................................................................................ 20-23
Filtration ...................................................................................................................................................... 24-25
High Pressure Regulation ........................................................................................................................... 26-27
Orifice ......................................................................................................................................................... 28-29
Special Hardware/Side Cover .................................................................................................................... 30-31
Overhaul Kit .................................................................................................................................................... 32
BLN-10107 ................................................................................................................................................. 34-35
SB-9102 ...................................................................................................................................................... 36-37
SB-9114 ...................................................................................................................................................... 38-39
SB-9203 ...................................................................................................................................................... 40-43
SB-9302 ...................................................................................................................................................... 44-45
SB-9312 ...................................................................................................................................................... 46-47
SB-9413 ...................................................................................................................................................... 48-49
SB-9425 ...................................................................................................................................................... 50-51
SB-9436 ...................................................................................................................................................... 52-53
SB-9503 ...................................................................................................................................................... 54-55
SB-9510 ...................................................................................................................................................... 56-57
SB-9514 ...................................................................................................................................................... 58-59
SB-9518 ...................................................................................................................................................... 60-61
SB-9601 ...................................................................................................................................................... 62-63
SB-9604 ...................................................................................................................................................... 64-65

Copyright 1993, 1994 Sauer-Danfoss. All rights reserved.

Contents subject to change. Information contained herein should be confirmed before placing orders.
Printed in U.S.A.
2
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Parts Identification

The following information and procedure is used to identify the module group, item number, manufactured date,
part number, and part name of the parts included in the Series 90 Pump.

The parts listed include all parts which may be used when performing either "Minor Repairs", "Major Repairs", or
"Conversions" on the Series 90 Pump.

- Nameplate -

Each pump will have a nameplate affixed to the housing. The

name plate will include the following information.

Model Code Ames, Iowa, U.S.A. NeumŸnster, Germany

The Sauer-Danfoss model code completely defines the Model Code Typ

specific unit and must be used when ordering the complete unit 90R130 MA 1 B
for the first time or for ordering parts to service the product. 6 S 3 C6 C 03
NNN 42 42 20
Model Number Model No. Ident Nr
The Sauer-Danfoss model number is used by the factory in 97 - 2062
manufacturing. On repeat orders, a complete unit can also be A - 92 - 26 - 12345
ordered by the model mumber. Serial No. Fabr Nr
MADE IN U.S.A.

Serial Number
The Sauer-Danfoss serial number is used to identify the
manufacturing location, manufacturing date and the unit se-
Ames, Iowa, U.S.A. NeumŸnster, Germany
quence in the build. The serial number is also used to identify Model Code Typ
the unit's warranty time period. 90R130 MA 1 B
Identification Number
6 S 3 C6 C 03
Pumps manufactured in Germany will have an identification NNN 42 42 20
Model No. Ident Nr
number instead of a model number.
123456
N - 92 - 26 - 12345
Serial No. Fabr Nr
The letter code indicates the location of original manufacture MADE IN GERMANY
(assembly). "A" indicates the unit was originally assembled
in Ames, Iowa, USA. "N" indicates the unit was originally
assembled in NeumŸnster, Germany.

The first number (2 digits) indicates the year of manufacture.

("92" would indicate the unit was manufactured in 1992)

The second number (2 digits) indicates the calender week of

manufacture.

The third number (5 digits) is a sequential number used to

identify a specific unit.

3
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Date Code

The date code is defined as the year and week of manufacture. The same reference number may list more than
one part number. This indicates that there is more than one configuration for that reference number. You will see
that there are different date codes for the different part numbers. Find the date code of your unit via the name-
plate to determine which service part number you need to order.

EXAMPLE: The service part desired is Item E10.

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model
E10 92-19 → 746107 Side cover (SB-9203) 1
" 89-41 → 92-18 340133 Side cover 1

All units using this module group with a date code of 89-41 and up to and including 92-18 must use part number
340133. All units with a date code of 92-19 and up must use part number 746107.

Service Bulletins

A Service Bulletin Number (SB- _ _ _ _) may follow the Description of the part you desire. You must read that
Service Bulletin prior to ordering that part. A copy of each of these Service Bulletins, as of the print date of this
bulletin, are included at the end of this manual. Service Bulletins contain more detailed information such as
interchangeability, what additional parts are involved, etc. It is suggested that you add additional Service Bulletins
to this manual as you receive them.

Procedure to Identify a Given Part/Part Number

General
The modular design of Series 90 units results in a simplified Service Parts List and Part Identification Procedure.

The same item numbers are used for same part description on all units within a product type. (Example: The shaft
seal - Item Number L40 has the same item number on all variable displacement pumps.)

All Item Numbers begin with a letter. The letter identifies a particular module. (Example: any items beginning with
K relate to the charge relief valve; items beginning with L relate to the drive shaft components, etc.)

Example of a Part Identification

The nameplate on a Series 90 pump has an Order Code of 90L130 EP 1 V 6 P 3 S4 E 05 NNN 38 38 20. Use
the following procedures to determine the part number of the filtration kit used on this pump.

1) Referring to the filtration module in the Model Code (see page 5), the filtration option for this unit is identified
by the code P (90L130 EP 1 V 6 P 3 S4 E 05 NNN 38 38 20)
2) Referring to the Service Parts List, find the filtration group. Next find the order code that relates to this unit,
which is P. The filtration kit is found to be item N00M and part number 8002N00M-A. Also note that the
saleable parts included in this kit are indented, which indicates the filter is not included in the kit.

4
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

90 R 1 3 0 MA 1 B 6 S 3 C6 C 03 NNN 42 42 20

Charge
Series Pressure Setting

Rotation High Pressure Setting

Port A

Pump Size (cc) High Pressure Setting

Port A

Control Type Special Hardware Features

Pressure Regulation Control Orifice

Auxilary Mounting Pad Charging System

End Cap Ports Input Shaft

Filtration Displacement Limitation

5
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Common Parts

L60 L70

L40
B70 L30
G538
B80 L20
L10
G548 B82
B90
B70 L50
B90

G908
G508

G94
G93
G518
G95

G528

G958
G508

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

6
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model/Kit
B70 89-41 → 9005110-5600 Plug 2
B80 89-41 → 9005110-9200 Plug 1
B82 92-19 → 9005110-5600 Plug (SB-9203) 1
B83 92-19 → 9005110-5600 Plug (SB-9203) 1
B90 89-41 → 9803390 Control filter screen 3
G93 89-41 → 8800564 Spacer 1
G94 89-41 → 8800565 Lifting bracket 1
G95 89-41 → 502195 Washer 1
G508 89-41 → 9005100-5600 Plug 2
G518 89-41 → 9005110-4400 Plug 1
G528 89-41 → 9005110-5600 Plug 1
G538 89-41 → 9005110-5600 Plug 1
G548 89-41 → 9005110-5600 Plug 1
G908 89-41 → 713719 Screw 1
G958 89-41 → 9007314-0811 Screw 1
L10 89-41 → 304857 Roller bearing 1
L15 89-41 → 376319 Shim 1
L20 89-41 → 392209 Retaining ring 1
L30 89-41 → 303503 Seal carrier 1
L40 89-41 → 9008000-0114 Lip seal 1
L50 89-41 → 353961 O-ring 1
L60 89-41 → 303529 Retainer plate 1
L70 89-41 → 9007315-0805 Screw, M8 x 20 3

Bold Items indicate recommended parts to be stocked for servicing

7
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Common Parts

B10

D14

D55
D65 B50
B20

F20 D10

D75 B50
D60 B20
D95 D70

D85 B30

D50 D80

D01

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

8
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per

Code Item Begin → End Part Number Description Model/Kit
B10 92-19 → 8510060 Variable housing assy. (SB-9203) 1
B20 89-41 → 9004800-1904 Pin 2
B30 89-41 → 324657 Bearing 1
B50 89-41 → 9004800-3708 Pin 2

D01 88-16 → 731026 Swashplate assy. 1

D10 88-16 → 303214 Servo arm assembly 1
D50 88-16 → 501188 Swashplate 1
D55 89-41 → 9007276-0111 Screw 1
D60 89-41 → 766022 Swashplate guide 1
D65 89-41 → 504493 Screw 1
D70 89-41 → 127464 Washer 1
D75 89-41 → 333369 Spiral head pin 1

D14 89-41 → 340091 Feedback link 1

D80 89-41 → 700948 Cage locator link 1
D85 89-41 → 754606 Pin 1
D95 89-41 → 303420 Spring 1
F20 89-41 → 765719 Slider block 1

Bold Items indicate recommended parts to be stocked for servicing

9
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Displacement Limitation

S01
F344
F354
F60
S03

F60
F40
F50

F40
F50

S10

F11
F12

F11
F12

F50
F40

Enlarged bold type item numbers F50 F60

are Recommended parts to be F40

stocked for servicing. F60 S02

F344
F354
S04

10
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Displacement Limitation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
3 S02 89-41 → 8302F003-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
S03 89-41 → 8302F003-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4

4 S01 89-41 → 8302F004-A Servo sleeve kit - No limitation 1

F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
F344 89-41 → 572180 Set screw 1
F354 89-41 → 42432 Seal nut, M10 1
S04 89-41 → 8302F004-A Servo sleeve kit - No limitation 1
F40 89-41 → 354316 O-ring 1
F50 89-41 → 9004104-0360 O-ring 1
F60 89-41 → 9007210-0804 Screw 4
F344 89-41 → 572180 Set screw 1
F354 89-41 → 42432 Seal nut, M10 1

S10 89-41 → 509286 Servo piston assembly 1

F11 89-41 → 9004100-2240 O-ring 2
F12 89-41 → 507800 Piston ring 2

Bold Items indicate recommended parts to be stocked for servicing

11
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

End Cap

G20

G308

H90L

G40
G048
H50
H05L

H60
H50
H40

H05

H70
Enlarged bold type item numbers
are Recommended parts to be
H80
stocked for servicing.

12
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

G: End Cap Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
8 G048 89-41 → 303511 End cap, twin ports 1
G20 89-41 → 303693 Journal bearing 1
G40 89-41 → 303651 Bushing 1
G308 89-41 → 730895 End cap gasket (SB-9203) 1

H: Charging System Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
E H05 93-34 → 501404 Charge pump, 20 cc (SB-9425*) 1
H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

F H05 93-34 → 501405 Charge pump, 26 cc (SB-9425*) 1

H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

H H05 93-34 → 501406 Charge pump, 34 cc (SB-9425*) 1

H40 89-41 → 308718 Pin 1
H50 93-34 → 501399 Charge pump shaft (SB-9425*) 1
H60 89-41 → 734608 Key 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6

L H05L 89-41 → 339762 Charge pump spacer 1

H50 93-34 → 501399 Charge pump shaft 1
H70 89-41 → 303644 Retaining plate 1
H80 89-41 → 9007210-0804 Screw 6
H90L 89-41 → 9005110-9500 Plug 1
*
* For additional information regarding replacement parts for units
built prior to 93-34, refer to BLN-10107 in the appendix

Bold Items indicate recommended parts to be stocked for servicing

13
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Auxiliary Mounting Pad

J15
J30
J10
J60
L

J70

J80

J50

J40
J90 J

J92

J95

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

14
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
A J 89-41 → 8302J00A-A Aux. mtg. A flange kit, 9 tooth 1
J10 89-41 → 310466 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 303339 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004100-0420 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 9802336 Cover plate 1
J95 89-41 → 9007200-3714 Screw 2
B J 89-41 → 8302J00B-A Aux. mtg. B flange kit, 13 tooth 1
J10 89-41 → 310474 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 365312 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004104-0440 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 4460370 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2
C J 89-41 → 8302J00C-A Aux. mtg. C flange kit, 14 tooth 1
J10 89-41 → 310508 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
Ò 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 726463 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004100-0480 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 8800406 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2
* The new style covers are interchangable with either charge pump design

Bold Items indicate recommended parts to be stocked for servicing

15
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Auxiliary Mounting Pad

J80N
J40N
J15N
J30

J15
J30
J10
J60
L

J70

J80

J50

J40
J90 J

J92

J95

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

16
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

J: Auxiliary Mounting Pad Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
D J 89-41 → 8302J00D-A Aux. mtg. D flange kit, 13 tooth 1
J10 89-41 → 310490 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
" 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 505118 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 916742 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 338400 Cover plate 1
J95 89-41 → 9007200-7524 Screw 4

N J15N 89-41 → 501400 Charge pump cover (SB-9425*) 1

J30 89-41 → 303651 Bushing 1
J40N 89-41 → 354324 O-ring 1
J80N 89-41 → 9007314-1622 Screw (SB-8923) 4

V J 89-41 → 8302J00V-A Aux. mtg. B-3 flange kit, 15 tooth 1

J10 89-41 → 310482 Coupling 1
J15 89-41 → 501402 Cover assy., CW (SB-9425*) 1
" 89-41 → 501401 Cover assy., CCW (SB-9425*) 1
J30 89-41 → 303651 Bushing 1
J50 89-41 → 505068 O-ring 1
J60 89-41 → 365312 Flange adaptor 1
J70 89-41 → 9009625-0132 Washer 4
J80 89-41 → 9007314-1625 Screw 4
J90 89-41 → 9004104-0440 O-ring 1
J40 89-41 → 92-29 354324 O-ring 1
J92 89-41 → 4460370 Cover plate 1
J95 89-41 → 9007200-5021 Screw 2

Bold Items indicate recommended parts to be stocked for servicing

17
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Shaft

K90
K10 K000

K50
K70
K80

L1

L8

L9
L1

L6

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
18
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

K: Charge Pressure Setting

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
00-30 K10 89-41 → 343095 Plug assembly 1
K50 89-41 → 9004201-7500 O-ring 1
K70 89-41 → 709469 Spring 1
K80 89-41 → 343087 Poppet 1
K90 89-41 → 343848 Nut 1

L: Shaft Group
C8 L1 89-46 → 303495 Shaft, 27 t 16/32 1

F1 L1 89-46 → 335695 Shaft, 13 t 8/16 1

T4 L1 89-46 → 346601 Shaft, 1.75 tapered 1

L6 89-41 → 9004600-1230 Cotter pin 1
L8 89-41 → 94-11 9003326-0005 Key (SB-9407) 1
L9 89-41 → 9700189 Slotted nut 1
Bold Items indicate recommended parts to be stocked for servicing

19
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Control
M9E
M98E
M90E
M95E
M97E

E
M1E
M96E

M1C M90C
M11

M11
M90D D

M1D

C
M11

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
20
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
CA C 89-41 → 8102M0CA-A Control cover plate kit 1
M11 89-41 → 8800923 Control gasket 1
M1C 89-41 → 8800336 Cover plate 1
M90C 89-41 → 9007314-0606 Screw 6
(No feedback link on Swashplate)
CB C 89-41 → 8102M0CA-A Control cover plate kit 1
M11 89-41 → 8800923 Control gasket 1
M1C 89-41 → 8800336 Cover plate 1
M90C 89-41 → 9007314-0606 Screw 6
(Feedback link on Swashplate)
DC D 89-41 → 8302M0DC-A Control kit,3 position sol.,12v 1
M11 89-41 → 8800923 Control gasket 1
M1D 89-41 → 344010 Control,3 position sol.,12v 6
M90D 89-41 → 9007314-0606 Screw 6
EA E 92-19 → 8302M0EA-B EDC1 kit w/MS conn.(SB-9302) 1
M11 92-19 → 8800923 Control gasket 1
M1E 92-19 → MCV111B1402 EDC1 w/MS connector (SB-9302) 1
M9E 92-19 → MCV110A1017 PCP type 3 oil filled 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6
EM M1E 92-19 → MCV114E1303 EDC w/weather-pack conn. 1
M11 92-19 → 8800923 Control gasket 1
M9E 92-19 → MCV116A3102 PCP, weather-pack conn. 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6
EN M1E 92-19 → MCV114A1307 EDC2 w/MS conn. (SB-9302) 1
M11 92-19 → 8800923 Control gasket 1
M9E 92-19 → MCV116A3501 PCP, 643 ohm, MS conn. 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19→ 9004104-0140 O-ring 1
M97E 92-19→ 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6

Bold Items indicate recommended parts to be stocked for servicing

21
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Control
S40
M72M
M9E
M90M M71M M98E
M7M M90E M95E
M1M M97E

M1E M96E
M M11
M11

E
M90H

M1H

H M11

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
22
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

M: Control Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
EP E 92-19 → 8302M0EP-B EDC1, packard conn.(SB-9203) 1
M11 92-19 → 8800923 Control gasket 1
M1E 92-19 → MCV111B1404 EDC1 w/packard connector 1
M9E 92-19 → MCV110A1058 PCP, packard connector 1
M95E 92-19 → 9004104-0120 O-ring 2
M96E 92-19 → 9004104-0140 O-ring 1
M97E 92-19 → 9004104-0240 O-ring 1
M98E 92-19 → 9007315-0504 Screw 4
M90E 92-19 → 9007314-0611 Screw 6

HC M1H 92-19 → 94-16 MCV112A1403 HDC, 3-11 bar 1

M11 92-19 → 94-16 8800923 Control gasket 1
M90H 92-19 → 94-16 9007314-0611 Screw 6

HF M1H 92-19 → MCV115A1303 HDC2, 3-11 bar (SB-9203) 1

M11 92-19 → K11420 Control gasket (SB-9302) 1
M90H 92-19 → 9007314-0611 Screw 6

HM M1H 92-19 → MCV115A1301 HDC2, 1.1-6.7 bar (SB-9203) 1

M11 92-19 → K11420 Control gasket (SB-9302) 1
M90H 92-19 → 9007314-0611 Screw 6

MA M 92-19 → 8302M0MA-B MDC kit w/o neutral start (SB-9203) 1

M11 92-19 → 8800923 Control gasket 1
M1M 92-19 → 772749 MDCw/o neutral start switch 1
M7M 92-19 → 9800916 Control handle 1
M71M 92-19 → 9009660-3100 Washer 1
M72M 92-19 → 9003513-0800 Nut 1
M90M 92-19 → 9007314-0611 Screw 6

MB M 92-19 → 8302M0MB-B MDC kit w/neutral start (SB-9203) 1

M11 92-19 → 8800923 Control gasket 1
M1M 92-19 → 772756 MDCw/neutral start switch 1
M7M 92-19 → 9800916 Control handle 1
M71M 92-19 → 9009660-3100 Washer 1
M72M 92-19 → 9003513-0800 Nut 1
M90M 92-19 → 9007314-0611 Screw 6
S40 92-19 → 80020S40 Neutral start switch kit 1

Bold Items indicate recommended parts to be stocked for servicing

23
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Filtration

N40P
N35S
N10S

N00M

N35M N40L
N10M
N00R
N20M N25M
N35R
N10R
N15

N20R N25R

N15

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.

24
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

N: Filtration Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
L N00M 89-41 → 8302N00M-A Filtration manifold kit 1
N10M 89-41 → 8800896 Manifold (SB-9436) 1
N15 89-41 → 9004201-9000 O-ring 1
N20M 89-41 → 5000222 Nut (SB-9436) 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35M 89-41 → 9005100-5600 Plug 2
N40L 89-41 → 8700068 Filter, long 1

P N00M 89-41 → 8302N00M-A Filtration manifold kit 1

N10M 89-41 → 8800896 Manifold (SB-9436) 1
N15 89-41 → 9004201-9000 O-ring 1
N20M 89-41 → 5000222 Nut (SB-9436) 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35M 89-41 → 9005100-5600 Plug 2
N40P 89-41 → 9700810 Filter, short 1

R N00R 89-41 → 8302N00R-A Filtration manifold kit 1

N10R 89-41 → 350777 Manifold 1
N15 89-41 → 9004201-9000 O-ring 1
N20R 89-41 → 9002863-1600 Nut 1
N25M 89-41 → 8800939 Tube (SB-9518) 1
N35R 89-41 → 9005100-5600 Plug 1

S N10S 89-41 → 5000230 Reducer fitting 1

N35S 89-41 → 9005110-5600 Plug 1

Bold Items indicate recommended parts to be stocked for servicing

25
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

High Pressure Regulation

END CAP GASKET FACE END CAP GASKET FACE

P80 P80
P802
P70 P70

P702

Left Hand Rotation Right Hand Rotation Left/Right Hand Rotation

With Pressure Limiters Without Pressure Limiters

P2B1
P6
P13

P6
P13 P2B1
P2A1 P6
P13

Side Port End Cap P6

P2A1 P13

Enlarged bold type item numbers

are Recommended parts to be Twin Port End Cap
stocked for servicing.
26
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

P: High Pressure Regulation Group

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
1 P2A1 89-41 → 8510023-1 Multi-function valve, w/PL (SB-9114) 1
(Range 1) P2B1 89-41 → 8510023-1 Multi-function valve, w/PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P70 89-41 → 8800188 Check valve 2
P80 89-41 → 9005475-0004 Special plug 2

2 P2A1 89-41 → 8510023-2 Multi-function val., w/o PL (SB-9114) 1

(Range 1) P2B1 89-41 → 8510023-2 Multi-function val, w/o PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P702 89-41 → 9005110-4400 Plug 1
P802 89-41 → 9005475-0004 Special plug 3

6 P2A1 89-41 → 8510023-6 Multi-function valve, w/PL (SB-9114) 1

(Range 2) P2B1 89-41 → 8510023-6 Multi-function valve, w/PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P70 89-41 → 8800188 Check valve 2
P80 89-41 → 9005475-0004 Special plug 2

7 P2A1 89-41 → 8510023-7 Multi-function val., w/o PL (SB-9114) 1

(Range 2) P2B1 89-41 → 8510023-7 Multi-function val., w/o PL (SB-9114) 1
P6 89-41 → 9004105-0290 O-ring 2
P13 89-41 → 9004105-0250 O-ring 2
P702 89-41 → 9005110-4400 Plug 1
P802 89-41 → 9005475-0004 Special plug 3

Bold Items indicate recommended parts to be stocked for servicing

27
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Orifice

Installed in
Control Housing

T001

T521

T721
T301
T821 T401
T621

28
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

T: Orifice Group
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
01 T001 87-02 → 8002T001-A Control orifice kit - .018 1
T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

02 T001 87-02 → 8002T002-A Control orifice kit - .026 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

03 T001 87-02 → 8002T003-A Control orifice kit - .032 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

04 T001 87-02 → 8002T004-A Control orifice kit - .040 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

05 T001 87-02 → 8002T005-A Control orifice kit - .054 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

06 T001 87-02 → 8002T006-A Control orifice kit - .062 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

09 T001 87-02 → 8002T009-A Control orifice kit - .092 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

22 T001 87-02 → 8002T022-A Control orifice kit - .022 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1

29 T001 91-30 → 8002T003-A Control orifice kit - .032 1

T301 91-30 → 8700007 Spring 1
T401 91-30 → 8800340 Spring retainer 1
T521 91-30 → 639104 Orifice plug, .7mm, M5 x 6 1
T621 91-30 → 639104 Orifice plug, .7mm, M5 x 6 1

50 T001 87-02 → 8002T002-A Control orifice kit - .026 1

T301 87-02 → 8700007 Spring 1
T401 87-02 → 8800340 Spring retainer 1
T721 87-02 → 521054 Orifice plug, .9mm 1
T821 87-02 → 521054 Orifice plug, .9mm M8 x 8 1

29
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Special Hardware Feature

B83

B83
C20

C30
S07
C40

C05 C50
E30
E30
C70

C13 E22
C14 E80 E20

C15 E22
E24
E80
C16
E24

E50
C80

E90

E10

E60
E70
E40

Enlarged bold type item numbers

are Recommended parts to be
stocked for servicing.
30
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S07 89-41 → 83020S07 Cyl. block kit (SB-9312) 1
C05 89-41 → 302851 Cylinder block assembly 1
C13 89-41 → 700922 Spring seat 1
C14 89-41 → 302828 Cylinder block spring 1
C15 89-41 → 700930 Spring retainer 1
C16 89-41 → 302836 Retaining ring 1
C20 89-41 → 727750 Welded piston 9
C30 89-41 → 735506 Slipper guide 1
C40 89-41 → 700963 Slipper guide brg. 2
C50 89-41 → 700971 Spacer 4
C70 89-41 → 308643 Screw 4

E10 96-03 → 501576 Side cover (SB-9604) 1

" 92-19 → 96-02 746107 Side cover (SB-9203) 1
E20 92-19 → 730143 Leveler (SB-9203) 1
E22 89-41 → 367037 Spring Seat 2
E24 89-41 → 359067 Shim 2
E30 96-03 → 506368 Guide post (SB-9604) 2
" 92-19 → 96-02 503205 Guide post (SB-9203) 2
E40 92-19 → 42432 Nut (SB-9203) 2
E50 89-41 → 9004104-2590 O-ring 1
E60 89-41 → 308700 Screw 6
E70 89-41 → 9005110-9200 Plug 1
E80 89-41 → 503091 Spring 2
E90 96-03 → 8300004 Insert assembly (SB-9604) 1

W: Special Hardware Features Group

EDB B83 89-41 → KPPC154 Speed sensor 1
C05 89-41 → 503753 Cylinder block assy. w/speed ring 1
C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

EEB B83 89-41 → 9005110-5600 Plug 1

C05 89-41 → 503753 Cylinder block assy. w/speed ring 1
C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

GBA & NSN B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 758425 Pump valve plate, 0.5 degree 1

GCA B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 739540 Pump valve plate, 1.5 degree 1

NDN & NNN B83 89-41 → 9005110-5600 Plug 1

C80 89-41 → 700203 Pump valve plate, -2 degree 1

Bold Items indicate recommended parts to be stocked for servicing

31
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

130 cc Variable Displacement Pump

Overhaul Seal Kit
Order Date Code Qty. per
Code Item Begin → End Part Number Description Model/Kit
S30 92-19 → 83020S30 Overhaul seal kit (SB-9203) 1
C70 89-41 → 308643 Screw 4
E40 92-19 → 42432 Nut (SB-9203) 2
E50 89-41 → 9004104-2590 O-ring 1
E60 89-41 → 308700 Screw 6
F11 89-41 → 9004100-2240 O-ring 2
F12 89-41 → 507800 Piston ring 2
F40 89-41 → 9004100-0370 O-ring 2
F50 89-41 → 9004100-0360 O-ring 2
G308 89-41 → 730895 End cap gasket (SB-9203) 1
J40 89-41 → 92-29 354324 O-ring 1
J50 89-41 → 505068 O-ring 1
J90 89-41 → 9004100-0420 O-ring 1
J90 89-41 → 9004104-0440 O-ring 1
J90 89-41 → 9004100-0480 O-ring 1
K50 89-41 → 9004201-7500 O-ring 1
L40 89-41 → 9008000-0114 Lip seal 1
L50 89-41 → 353961 O-ring 1
M11 89-41 → 8800274 Control gasket 1
M11 89-41 → K11420 Control gasket (SB-9302) 1
N15 89-41 → 9004201-9000 O-ring 1
P6 89-41 → 9004100-0250 O-ring 2
P13 89-41 → 9004100-0290 O-ring 2

Bold Items indicate recommended parts to be stocked for servicing

32
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

NOTES

33
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

BLN-10107 Rev. B

Charge Pump Design Change

To improve efficiency and reliability, the number of parts in Series 90 pumps
is being reduced. The charge pump design on 55cc thru 130cc frame sizes
is being changed so that the outer port plate is an integral part of the charge
pump cover and distance plates are eliminated. The change is taking effect
at the following manufacturing dates:
55cc: 93-10 75cc: 93-10 100cc: 93-15 130cc: 93-34

For auxiliary pad options, the new charge pump cover is rotation dependent.
The cover will be marked as either left hand (L) or right hand (R). The non-
axiliary pad cover is not rotation dependent.

The charge pump shaft also changes and must be replaced when using the
new style hardware. The complete charge assembly can be interchanged
with corresponding hardware from 89-17 and beyond. However, piece
parts are not interchangeable. For units prior to 89-17, consult Sauer-
Sundstrand.

The old design charge pump hardware is obsolete and is no longer available.
Refer to the chart on the reverse side of this page to determine the
replacement kit.

34
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

BLN-10107 Rev. B
The following information must be known to determine the correct
charge pump replacement kit:
1. Unit size (055, 075, 100 or 130 cc)
2. Charge pump displacement (11, 14, 17, 20, 26 or 34 cc)
3. Auxilary pad (Yes or No)
4. Rotation (LH or RH)

Obsoleted Charge Pump Parts Chg. pump

Auxilary Replacement
Unit Size displace- Rotation
pad Kit
Gear Set Shaft Cover ment
8800513 No LH or RH 8510028
8000169 8000174 8800514 055 11 cc Yes LH 8510029
8800514 Yes RH 8510030
8800513 No LH or RH 8510031
8000170 8000174 8800514 055 14 cc Yes LH 8510032
8800514 Yes RH 8510033
8800513 No LH or RH 8510034
8000171 8000174 8800514 055 17 cc Yes LH 8510035
8800514 Yes RH 8510036

8800513 No LH or RH 8510037
8100313 337956 8800514 075 14 cc Yes LH 8510038
8800514 Yes RH 8510039
8800513 No LH or RH 8510040
8100314 337956 8800514 075 17 cc Yes LH 8510041
8800514 Yes RH 8510042
8800513 No LH or RH 8510043
8100315 337956 8800514 075 20 cc Yes LH 8510044
8800514 Yes RH 8510045

8800513 No LH or RH 8510046
8200158 337956 8800514 100 17 cc Yes LH 8510047
8800514 Yes RH 8510048
8800513 No LH or RH 8510049
8200159 337956 8800514 100 20 cc Yes LH 8510050
8800514 Yes RH 8510051
8800513 No LH or RH 8510052
8200160 337956 8800514 100 26 cc Yes LH 8510053
8800514 Yes RH 8510054

347518 No LH or RH 8510064
714444 303636 347526 130 20 cc Yes LH 8510065
347526 Yes RH 8510066
347518 No LH or RH 8510067
714451 303636 347526 130 26 cc Yes LH 8510068
347526 Yes RH 8510069
347518 No LH or RH 8510070
714469 303636 347526 130 34 cc Yes LH 8510071
347526 Yes RH 8510072
35
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9102

PRODUCTS AFFECTED: Series 90 Variable Pumps
SUBJECT: Side Cover Lock Tab Washer

DESCRIPTION:

The lock tab washers, located under the side cover screws, have been replaced with flat
washers on all Series 90 variable pumps.

As before, the side cover screws must be replaced if they are removed for any reason. The
special coating, which seals and retains the screws, wears off when the screws are removed.

Lock tab washer

Screw

36
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9102

MODELS AFFECTED:
All 93-2xxx(42cc), 94-2xxx(55cc), 95-2xxx(75cc). 96-2xxx(100cc), and
97-2xxx(130cc) variable pumps

SERIAL NUMBERS AFFECTED:

New washers can be used on any vintage pump. Change will take place immediately.

PART NUMBERS AFFECTED:

Pump Size Lock Tab Washer p/n Washer p/n

42 314203 723981

55, 75, and 100 8100307 502195

130 370767 502187

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
Non-Restricted Distribution
37
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9114

PRODUCTS AFFECTED: Series 90 130 cc Variable Pumps
SUBJECT: Multi-Function Valve Installation

DESCRIPTION:

To avoid damaging the multi function cartridge used on 130cc variable pumps, the
installation torque has been lowered from 206 ft. lbsf. (279 Nm) to 155 ft. lbsf. (210 Nm).

The Series 90 Service Manual will be changed to show the lower installation torque at
its next revision.

38
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9114

MODELS AFFECTED:
All 97-2xxx pumps

SERIAL NUMBERS AFFECTED:

All

PART NUMBERS AFFECTED:

N/A

PARTS DISPOSITION:
X Not Applicable
Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
39
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

PRODUCTS AFFECTED: Series 90: 55,75,100, 130 cc Pumps
SUBJECT: Block Point Change: Components Redesign

DESCRIPTION:
As part of our overall Series 90 product improvement program, numerous components are
being redesigned. This redesign is referred to as a blockpoint change. The objective of the
blockpoint change is to minimize the number of times we change the units while we convert to high
volume tooling at various plant sites. These design improvements will provide increased reliability
and more application flexibility. The nature of these changes makes customer requalification
unnecessary. Old style (pre-block point) variable housings and endcaps will no longer be available
as spare parts.

40
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

FRAME SIZE: 130
Parts Affected:
Pre "blockpoint" New Part Number
Item Description Part Number (92-19 & Later)
Common Parts Group, 130 cc
B10 Variable housing 700237✧ 8510060
E10 Side cover 340133 746107
E20 Leveler 701037 730143
E30 Guide post 340117 746255
E40 Screw 364489 (4) 042432 (2) Seal Nut ***
B82 Plug n/a 9005110-5600
End Cap Group, 130 cc
G308 End Cap gasket 709816*✧ 730895*
G908 Screw 376624 713719**
G958 Screw 527218 9007314-0811**
Special Hardware Features Group, 130 cc
B83 Plug-Speed Pick-up n/a 9005110-5600
Control Group, 130 cc
All Control Types-Delete The Following Parts:
M810 Plate 738203✧ N/A
M820 O-ring 9004104-0440 N/A
M830 O-ring 9004100-0220 N/A
M840 O-ring 9004101-0130 N/A
M860 Screw 345496 N/A
M870 Plug 9005100-4400 N/A
M880 Washer 723981 N/A

WARNING: On 130cc pumps, "Pre" and "Post" blockpoint controls

(MDC's, HDC's and EDC's) are not interchangeable due to different length
control pins. Ensure positive pin engagement. Failure to do so may result
in pump output, and the vehicle may move.

Pre-Block Point Post-Block Point

1.13 in 0.89 in
(28.7 mm) (22.7 mm)

41
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

FRAME SIZE: 130

Controls, 130 cc
Module Pre "blockpoint" New Part Number
Groups Description Part Number (92-19 & Later)
EA EDC kit MS connector MCV111B1302 See EC Group
EP EDC kit Packard MCV111B1304 See EE Group
EC EDC, MS,standard MCV114A1402 MCV114B1302
EE EDC, Packard, standard MCV114A1404 MCV114B1304
EG EDC, MS, annular MCV114C1402 MCV114D1302
EH EDC, Packard, annular MCV114C1404 MCV114D1304

HA HDC , 1-11 bar MCV112A1302 See HK Group

HB HDC, 1-6.7 bar MCV112A1301 See HM Group
HC HDC, 3-11 bar MCV112A1303 See HF Group
HF HDC, 3-11 bar, standard MCV115A1403 MCV115A1303
HG HDC, .8-4.6 bar, annular MCV115B1405 MCV115B1305
HH HDC, 1-11 bar, annular MCV115B1402 MCV115B1302
HJ HDC, 3-11 bar, annular MCV115B1403 MCV115B1303
HK HDC, 1-11 bar, standard MCV115A1402 MCV115A1302
HL HDC, .8-4.6 bar, standard MCV115A1405 MCV115A1305
HM HDC, 1.1-6.7 bar, standard MCV115A1401 MCV115A1301
HN HDC, 1.1-6.7 bar, annular MCV115B1401 MCV115B1301

MA MDC w/o nss 8302MOMA-A 8302MOMA-B

MB MDC w/ nss 8302MOMB-A 8302MOMB-B

* Interchangeable part.
** 8mm screws - torque to 24 ft. lbs.
*** 10mm nut - torque to 32 ft. lbs.
✧ Obsolete

42
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9203 Rev. A

MODELS AFFECTED:
All Series 90 94-2xxx, 95-2xxx, 96-2xxx, and 97-2xxx Variable Pumps.
SERIAL NUMBERS AFFECTED:
Changes will take place at the following Serial Numbers:
55 cc 92-06 & beyond
75 cc 92-19 & beyond
100 cc 92-12 & beyond
130 cc 92-19 & beyond
PART NUMBERS AFFECTED:
Refer to text of this bulletin for specific part numbers.
Housing: (all frame sizes)Thickness adjacent to the side cover has been in-
creased.
Side Cover: (100 cc & 130cc only) Thickness increased.
End Cap: (all frame sizes) Match housing change; small end cap screws (55 cc-
100 cc) will be larger; the orientation of the charge relief valve on side
port end caps has been changed from an oblique to a vertical orienta-
tion.
Controls: (130cc only) Eliminate mounting plate, three-pin link change.
Side Cover: (130cc only) Swashplate hold-down ("T-bar") mounting will be changed
to commonize the design with the smaller displacement units.
NOTE: Reference PIB-9102 for design changes and outline dimensions.
PARTS DISPOSITION:
Not Applicable
Interchangeable
X Non-Interchangeable except where noted
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
43
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9302

PRODUCTS AFFECTED: Series 90 Pumps: All Frame Sizes

SUBJECT: Control Gasket Changes for New

MCV115 Hydraulic Displacement Control
DESCRIPTION:
In October of 1992, Sauer-Danfoss began offering a new style hydraulic displacement
control (MCV115) that is a direct replacement for the MCV112.

The control gasket also changed, and the new style gasket must be used with the MCV115
control. The old style gasket is to be used with the MCV112 control, all manual displacement
controls, and MCV111 electric displacement controls.

WARNING
Failure to use the appropriate gasket may result in uncontrolled pump displacement.

30 cc/42 cc/55 cc 75 cc/100 cc/130 cc

8800520 8800521
Do NOT use Do NOT use
with MCV115 with MCV115

K11419 K11420
Use ONLY with Use ONLY with
MCV115 MCV115

44
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9302

MODELS AFFECTED:
All 92-2xxx, 93-2xxx, 94-2xxx, 95-2xxx, 96-2xx, and 97-2xxx pumps.

SERIAL NUMBERS AFFECTED:

October 1992 and beyond.

PART NUMBERS AFFECTED:

Control Gasket for Control Gasket for HDC Control Gasket for
Frame Size EDC (MCV111) (MCV112) (MCV115) MDC (8X02M0MX)

30/42/55cc 8800520 8800520 K11419 8800520

75/100/130cc 8800521 8800521 K11420 8800521

PARTS DISPOSITION:
Not Applicable
Interchangeable
X Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
45
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9312

PRODUCTS AFFECTED: All Series 90 Pumps

SUBJECT: Removal of Valve Plate from Cylinder Block Kit

DESCRIPTION:
Due to the increasing number of valve plate options, the valve plate (item C80) will be no
longer included in the cylinder block kit (item S07) on all Series 90 variable pumps. Valve
plates must be ordered separately for service parts. See special hardware features group
in your Service Parts Manual for appropriate valve plate number.

C20

C30
C50
C40
C65
C70

S07

C05

C13
C14
C80
C15
C16

46
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9312

MODELS AFFECTED:
All 93-2xxx, 94-2xxx, 95-2xxx, 96-2xx, and 97-2xxx pumps.

SERIAL NUMBERS AFFECTED:

Not Applicable

PART NUMBERS AFFECTED:

Frame Size Cylinder Block Kit

42 cc 80520S07
55 cc 80020S07
75 cc 81020S07
100 cc 82020S07
130 cc 83020S07

PARTS DISPOSITION:
X Not Applicable
Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
All Product Related Sauer-Danfoss Distributors
All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
47
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9413 Rev. A

PRODUCTS AFFECTED: Series 90 and Series 51 Units with
Pulse Pickup (Speed Sensing)
SUBJECT: Pulse Pick-up Change

DESCRIPTION:
A small number of pulse pick-ups used on pumps and motors between June 1992 and April
1994 have been found to be defective due to corrosion of internal circuitry.

The corrosion of the internal circuitry may cause intermittent operation or partial loss of
signal and eventual failure.

A typical installation of a pulse pick-up is pictured below. Note the "silver" color of the
potentially defective pulse pick-up body. This should be replaced with a pulse pick-up body
that is "black" in color.

NOTE: If your speed sensor is in an electrical closed loop feedback circuit, possibly used
with a microprocessor, the silver colored speed sensor must be changed regardless of the
special hardware features code.

Silver Pulse Pick-up Body

48
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9413 Rev. A

MODELS AFFECTED:
All pumps and motors that used the pulse pick-up option, 90L055 EA 1 N
which is indicated by the special hardware features order 6 S 3 C6 C 03
code. EAA 35 35 24
Options: 51 Series = ACA, NNT, AAA, NNU, ABA
90 Series = EAA, EAB, EAD, NNS, EBB, ECA 51V160 RFIN
SERIAL NUMBERS AFFECTED: F1A1 ANE1 ACA
A-92-22-xxxxx thru A-94-17-xxxxx 050AA21 0322

PART NUMBERS AFFECTED:

Sensor Connector Style Body Color

KPPA124 Weather Pack Silver

KPPB124 Weather Pack Silver

KPPA125 Metri Pac Silver

KPPB125 Metri Pac Silver

KPPC124 Weather Pac Black

KPPC125 Metri Pac Black

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
49
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9425

PRODUCTS AFFECTED: Series 90 130 cc Variable Pumps

SUBJECT: Charge Pump Design Change

DESCRIPTION:
To improve efficiency and reliability, the number of parts in the charge pump is being
reduced. The charge pump on the 130 cc frame size is changing such that the outer port
plate (H30) is an integral part of the charge pump cover (J15) and the distance plates are
eliminated.
For auxiliary pad options, the new charge pump cover is rotation dependent. The cover will
be marked either left hand (L) or right hand (R). The non-auxiliary pad cover is not rotation
dependent.
The charge pump shaft also changes and must be replaced when using the new style
hardware. The complete charge pump assembly can be interchanged with corresponding
hardware.
However, piece parts are not interchangeable.

H60
Old charge pump design H50
H40
H30
H05
H60
H50
(H30) H40
H05

New charge pump design

J15N J40N

J30

L
J15
New charge pump cover J10
for pumps without auxilary pads L J30
(same cover for left hand or
right hand rotation)

New charge pump covers for pumps with auxiliary pads.

The new charge pump covers have an "L" or "R" stamped
on them for easy identification
50
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9425

MODELS AFFECTED:
All 97-2xxx and 972xxxx Pumps

SERIAL NUMBERS AFFECTED:

N-93-34-xxxxx

PART NUMBERS AFFECTED:

Obsoleted Charge Pump Parts Chg. pump

Auxilary Replacement
displace- Rotation
pad Kit
Gear Set Shaft Cover ment
347518 No LH or RH 8510064
714444 303636 347526 20 cc Yes LH 8510065
347526 Yes RH 8510066
347518 No LH or RH 8510067
714451 303636 347526 26 cc Yes LH 8510068
347526 Yes RH 8510069
347518 No LH or RH 8510070
714469 303636 347526 34 cc Yes LH 8510071
347526 Yes RH 8510072

PARTS DISPOSITION:
Not Applicable
X Interchangeable Piece parts are not interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
51
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9436

PRODUCTS AFFECTED: Series 90 55 thru 130 cc Variable Pumps

SUBJECT: Integral Filtration Manifold

DESCRIPTION:

As a product improvement, Sauer-Danfoss is changing the integral filter manifold and

bulkhead nut to make it more easily indexed.

The old bulkhead nut may be used with either the old or new filter manifold. The new
bulkhead nut can only be used with the new filter manifold.

The old bulkhead nut will remain available as a service part. The old filter manifold will be
obsoleted and no longer available as a service part.

Old Design

Manifold

Nut

New Design

Manifold

Nut

52
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9436

MODELS AFFECTED:
All Series 90 55 thru 130 cc Variable Pumps with 'L', 'M', or 'P' filtration option code

SERIAL NUMBERS AFFECTED:

Change occurred at serial number 95-18-xxxxx

PART NUMBERS AFFECTED:

Part Number Part Number
Description (prior to 95-18) (95-18 & beyond)
Filter Manifold 8800200 8800896
Bulkhead Nut 9002863-1600 5000222

PARTS DISPOSITION:
Not Applicable
X Interchangeable - new bulkhead nut can only be used with new filter manifold
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
53
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9503

PRODUCTS AFFECTED: Series 90 Pumps - All Frame Sizes

SUBJECT: Manual Displacement Control (MDC)

with DC Electric Solenoid Override
DESCRIPTION:
In order to accomodate our European customers, the manifold which attaches to the front
of the manual displacement control (MDC) housing is being changed.
The European solenoid valve requires a thicker manifold to provide clearance between
the solenoid and the front of the MDC housing. The revised manifold will protrude closer
to the mounting flange of the pump, reducing dimension "A" shown in the accompanying
drawing by approximately 5 mm [0.2 in]. Please see chart below for specific clearances.
The thicker manifold requires longer screws and may be used with either the U.S. or
European sourced solenoid.
This change will become effective during March of 1995. The old manifold will be
obsoleted and no longer available as a service part.

SOLENOID VALVE

"A"

"X"

NEUTRAL START
SWITCH (NSS)
OPTION

TOP VIEW VIEW IN DIRECTION "X"

SERIES 90 FRONT VIEW
MANUAL DISPLACEMENT CONTROL
WITH DC SOLENOID OVERRIDE

Frame Size 042 055 075 100 130

Dimension Current 39.9 55.9 54.1 60.2 74.4
"A" [1.57] [2.20] [2.13] [2.37] [2.93]
mm Future 34.9 50.9 49.1 55.2 69.4
[in] [1.37] [2.0] [1.93] [2.17] [2.73]

54
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9503

MODELS AFFECTED:
All Series 90 Variable Pumps using manual displacement control (MDC) with
DC electric solenoid override.

SERIAL NUMBERS AFFECTED:

Change will take place in March '95

PART NUMBERS AFFECTED:

Current Part Number New Part Number Quantity

Manifold 8800365 505022 1

Screw 9007314-0605 9007314-0606 2

PARTS DISPOSITION:
Not Applicable
X Interchangeable (new manifold requires longer screws)
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
55
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9510

PRODUCTS AFFECTED: Series 90 Variable Pumps

SUBJECT: Solenoid Valve Change

DESCRIPTION:

Sauer-Danfoss has changed suppliers of the solenoid valve for the manual displacement
control with 12 volt two position solenoid valve (order codes ME and MJ).
The new solenoid valve requires shorter mounting screws.
The old solenoid valve is being obsoleted and no longer available as a service part. A kit
has been created that includes the new solenoid valve and the appropriate mounting
screws.

Solenoid
Mounting Screw

56
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9510

MODELS AFFECTED:
All Series 90 variable pumps using control order codes ME and MJ

SERIAL NUMBERS AFFECTED:

Units built N-95-24-xxxxx and after

PART NUMBERS AFFECTED:

Replacement
Old Solenoid Old Screws Kit
504381 9007315-0510 8510107

PARTS DISPOSITION:
Not Applicable
X Interchangeable ☛ Piece parts are not interchangeable.
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit
DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
57
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9514

PRODUCTS AFFECTED: Series 20 & 90 Pumps With
Optional Neutral Start Switch
SUBJECT: Neutral Start Switch Change

DESCRIPTION:

Sauer-Danfoss has changed suppliers of the neutral start switch on Series 20 and
some neutral start switch options (MR, MS and ML) on Series 90 pumps. Advanced
notification of this change was given with Product Information Bulletin number PIB-9403.

The new switch has Teflon tape on the threads instead of Vibra-Seal. New Teflon tape
should be applied to the threads if the switch is removed for any reason.

Due to interchangeability, the old switch has been obsoleted and no longer available as
a service part.

Teflon Tape Applied To Threads

58
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9514

MODELS AFFECTED:
All Series 20 variable pumps and Series 90 variable pumps using control order codes
ML, MR and MS

SERIAL NUMBERS AFFECTED:

Units built N-95-17-xxxxx and after

PART NUMBERS AFFECTED:

Old Switch New Switch NSS Kit

9700922 503545 8510027*

* The Neutral Start Switch Kit part number did not change

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
59
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9518

PRODUCTS AFFECTED: Series 90 - 130 cc Variable Pumps

SUBJECT: Filter Tube - Pressure and Remote Filtration

DESCRIPTION:
This bulletin was issued in Feb, 96. The purpose of revision 'A' is to add the tube
length for the remote filter adaptor that was omitted at first publication.

The filtration tube that is used in the manifold for remote or integral pressure filtration may
be too short in length. The filtration tube should be measured for proper length and replaced
if necessary at first repair for units built prior to N-95-41. The correct length of the integral
filtration tube is 143.76 ± .25mm [5.66 ±.01 inches] and 101.09 ± .25mm [3.98 ± .01 inches]
for the remote filtration tube.

The old filtration tubes are obsolete and no longer available as a service part.

Integral Filter Tube

Remote Filter Tube

60
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9518

MODELS AFFECTED:
All Series 90 -130cc Variable Pumps with integral pressure filtration or remote pressure
filtration.

SERIAL NUMBERS AFFECTED:

Units built prior to N 95-41-XXXXX

PART NUMBERS AFFECTED:

Old Part New Part

Filter Option Number Number
Remote 355206 8800938
Integral Pressure 355214 8800939

PARTS DISPOSITION:
Not Applicable
X Interchangeable
Non-Interchangeable
Use Parts in Stock
X Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
61
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9601

PRODUCTS AFFECTED: Series 90, 130 cc Variable Pumps

SUBJECT: Swashplate Leveler Spring

DESCRIPTION:
As a product improvement, Sauer-Danfoss has reduced the number of springs
used on the swashplate leveler from four springs to two springs. The older nested
springs will be obsoleted and no longer available as a service part.

Old Design New Design

62
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9601

MODELS AFFECTED:
All 972xxx and 97-2xxx variable pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-89-41-xxxxx

PART NUMBERS AFFECTED:

Item No. Desc Old P/N Qty New P/N Qty
E82 Spring 704494 2 - -
E80 Spring 704486 2 503091 2

PARTS DISPOSITION:
Not Applicable
X Interchangeable ➛ (if old springs are replaced with new springs)
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
63
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9604

PRODUCTS AFFECTED: Series 90, 42, 130,180, & 250 cc Variable Pumps

SUBJECT: Side Cover Design Change

DESCRIPTION:
As a product improvement, Sauer-Danfoss is changing the side cover and swashplate
leveler ("T-Bar") guide post design.
The new design side cover will have two hardened inserts in the machined slot which
serves as a guide for the swashplate leveler, and modified guide posts. The swashplate
leveler does not change.
Old guide posts will remain available for service requirements of pumps with the old
design side cover.
The old style side cover will be obsoleted and no longer available as a service part. A
service kit has been created for replacing the old design side cover. The kit includes the
new side cover, guide posts and inserts. Piece parts are not interchangeable.

Guide Post
Guide Post

Swashplate Leveler

Inserts

Side Cover

64
 Series 90
130 cc Pump
Genuine Parts BLN-2-41673
Original
Ersatzteile May, 1996

Service Bulletin SB-9604

MODELS AFFECTED:
All 42, 130, 180, & 250 cc variable pumps

SERIAL NUMBERS AFFECTED:

This change became effective at serial number N-96-08-xxxxx

PART NUMBERS AFFECTED:

Old Part Numbers New Part Numbers

Description Guide Post Side Cover Insert assy. Guide Post Side Cover Kit

42 cc 344465 751305 506916 506369 506380

130 cc 503205 746107 8300004 506368 506289

180 cc 503205 746404 506914 506368 506290

250 cc 503205 746404 506914 506368 506290

PARTS DISPOSITION:
Not Applicable
X Interchangeable as a kit Piece parts are not interchangeable
Non-Interchangeable
Use Parts in Stock
Scrap Used Parts
Return New Parts for Credit
Order Replacement Parts
Rework Parts in Stock
Revise Existing Part Orders
Scrap New Parts and Supply for Credit

DISTRIBUTION:
X All Product Related Sauer-Danfoss Distributors
X All Product Related OEM's
X All ASCs
X Non-Restricted Distribution
65
 Hydraulic Power Systems
SAUER-DANFOSS Hydraulic Power Systems - Market Leaders Worldwide
SAUER-DANFOSS is a world leader in the design and SAUER-DANFOSS specializes in integrating a full
manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers
development resources in both North America and Europe with the most advanced total-design system.
enable SAUER-DANFOSS to offer a wide range of
design solutions utilizing hydraulic power system SAUER-DANFOSS is Your World Source for
technology. Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives

Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

Pumps and Motors Electrohydraulic Controls Packages

Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts

Worldwide Service Support

SAUER-DANFOSS provides comprehensive worldwide service for its

products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.

Look to SAUER-DANFOSS for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

SAUER-DANFOSS COMPANY SAUER-DANFOSS GMBH & CO.

2800 East 13th Street Postfach 2460, D-24531 Neumünster
Ames, IA 50010, U.S.A. Krokamp 35, D-24539 Neumünster, Germany
Phone: +1 515 239-6000, FAX: +1 515 239-6618 Phone: +49 4321 871-0, Fax: +49 4321 871 122
BLN-2-41673 • May, 1996
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R902411765

Designation: A A6V M 250 HD1D /63W2-VZB157 B-SO 68

Drawing no.: R910939288

Pos. Part No. Designation Quantity

1 R910935504 G A6V M 250 /63W2-VZB 1 ST L

2 R902411766 V A6V M 250 HD1D /63-V157 -SO 68 1 ST L
3 R910800755 SPUEL.-U.SPEISEDRUCKV. A6V-V 1 ST

Safety Notes:
Service – and repair works have to be carried out by the Bosch Rexroth AG or their repair stations only.
We do not grant any warranty for defects due to assembly, maintenance or repair not effected by the
Bosch Rexroth AG or their repair stations.

L = Assembly group D = Sealing element Page: 1 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R902411765

Designation: A A6V M 250 HD1D /63W2-VZB157 B-SO 68

Drawing no.: R910939288

L = Assembly group D = Sealing element Page: 2 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910935504

Designation: G A6V M 250 /63W2-VZB

Drawing no.: R910933674

Pos. Part No. Designation Quantity

1 R910906477 TW A6V M 250 /63W-VZ 1 ST L

2 R910933596 EINSTELLTEIL M16X130-V 1 ST L
3 R910933592 EINSTELLTEIL M16X 90-V 1 ST L
5 R902443566 PUMP HOUSING 1 ST
9 R910647187 V-SCHRAUBE N 02.009-M 22X1,5 V # 60NM 1 ST D
10 R910532347 V-SCHRAUBE N 02.009-M 14X1,5 V # 30NM 1 ST D

L = Assembly group D = Sealing element Page: 3 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910935504

Designation: G A6V M 250 /63W2-VZB

Drawing no.: R910933674

L = Assembly group D = Sealing element Page: 4 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910906477

Designation: TW A6V M 250 /63W-VZ

Drawing no.: R910905227

Pos. Part No. Designation Quantity

1 R902407113 DRIVE FLANGE 1 ST

3 R910798754 PISTON 7 ST
4 R910798789 PISTON RING 14 ST
6 R902432783 ZYLINDER BG32/BR6 1 ST
7 R910922503 STEUERLINSE A6VM 250/63W 1 ST
8 R910900130 PRESSURE PIN 1 ST
9 R910709042 RETAINING PLATE 1 ST
11 R902412282 SEAL FLANGE 1 ST
13 R910969915 ADJUSTMENT RING 1 ST
14 R910900002 SPRING 1 ST
15 R910900003 SHIM 1 ST
16 R910999169 ABSTIMMSATZ TW-LAG. BG32/BR6 1 ST
17 R910969893 SPACER BOLT 1 ST
21 R910904776 TAPERED-ROLLER BEARING 1 ST
22 R910693944 PLAIN ROLLER BEARING 1 ST
24 R910963544 WDR BAFSL1SF 60X 80X 7/5.5 -FPM 75 V 595 1 ST D
26 R910928968 O-RING 1 ST D
29 R910797448 SICHERUNGSR. 125X4,0 DIN 472 1 ST
30 R910188034 SICHERUNGSR. 85X3,0 DIN 471 1 ST
34 R910203297 SHIM 1 ST
39 R910584614 ZYL.SCHR.M 8X 16 -10.9 DIN 912 #37NM 14 ST

L = Assembly group D = Sealing element Page: 5 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910906477

Designation: TW A6V M 250 /63W-VZ

Drawing no.: R910905227

L = Assembly group D = Sealing element Page: 6 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910933596

Designation: EINSTELLTEIL M16X130-V

Drawing no.: R910933544

Pos. Part No. Designation Quantity

1 R910900271 THREADED PIN 1 ST

2 R910933539 CAP NUT 1 ST
3 R910912737 NUT 1 ST
4 R910903130 O-RING 2 ST D

L = Assembly group D = Sealing element Page: 7 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910933596

Designation: EINSTELLTEIL M16X130-V

Drawing no.: R910933544

L = Assembly group D = Sealing element Page: 8 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910933592

Designation: EINSTELLTEIL M16X 90-V

Drawing no.: R910933544

Pos. Part No. Designation Quantity

1 R910323497 THREADED PIN 1 ST

2 R910933540 CAP NUT 1 ST
3 R910912737 NUT 1 ST
4 R910903130 O-RING 2 ST D

L = Assembly group D = Sealing element Page: 9 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910933592

Designation: EINSTELLTEIL M16X 90-V

Drawing no.: R910933544

L = Assembly group D = Sealing element Page: 10 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R902411766

Designation: V A6V M 250 HD1D /63-V157 -SO 68

Drawing no.: R910946844

Pos. Part No. Designation Quantity

1 R910936728 VERSTELLTEIL A6VM 250/63-V157 1 ST L

2 R910946054 STEUERT. A6VM 250 HD1/63-V 1 ST L
3 R910935604 DECKEL A6VM 250 HDD/63-V -SO 68 1 ST L

L = Assembly group D = Sealing element Page: 11 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R902411766

Designation: V A6V M 250 HD1D /63-V157 -SO 68

Drawing no.: R910946844

L = Assembly group D = Sealing element Page: 12 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910936728

Designation: VERSTELLTEIL A6VM 250/63-V157

Drawing no.: R910929924

Pos. Part No. Designation Quantity

4 R910935855 PORT PLATE 1 ST

5 R910929870 STELLKOLBEN A6,A7 250/63 'KC' 1 ST
6 R902413010 POSITIONING TRUNNION 1 ST
7 R910819891 THREADED PIN 1 ST
14 R910802013 RECHTECKR. 50 X2,5 -S1 DIN 34110 2 ST D
15 R910917440 O-RING 1 ST D
16 R910907799 TURCON-STEPS. RS1300400-T46 B+S 1 ST D
17 R910973147 O-RING 1 ST D
18 R910910938 CYLINDER PIN 2 ST
19 R910126411 ZYL.SCHR.M 16X 50 -10.9 DIN 912 #310NM 8 ST
20 R910977645 PLUG 3 ST D
21 R910532347 V-SCHRAUBE N 02.009-M 14X1,5 V # 30NM 2 ST D

L = Assembly group D = Sealing element Page: 13 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910936728

Designation: VERSTELLTEIL A6VM 250/63-V157

Drawing no.: R910929924

L = Assembly group D = Sealing element Page: 14 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910946054

Designation: STEUERT. A6VM 250 HD1/63-V

Drawing no.: R910929926

Pos. Part No. Designation Quantity

1 R910926601 VALVE CARTRIDGE 1 ST

2 R910930574 CONTROL HOUSING 1 ST
3 R910929872 SPRING COLLAR 1 ST
5 R910930556 SPRING 1 ST
8 R910974659 EINST.RUECKSCHL.V. A6,A7 250,355/63 2 ST L
10 R910109991 ZYL.SCHR.M 16X 70 - 8.8 DIN 912 #215NM 4 ST
13 R910976410 O-RING 2 ST D
14 R910518336 O-RING 2 ST D
15 R910929855 O-RING 2 ST D
16 R910929791 STUETZR. SP/SS11109-132-P 2 ST D
19 R909831318 DOUBLE BREAK-OFF PIN 1 ST D
20 R910532347 V-SCHRAUBE N 02.009-M 14X1,5 V # 30NM 1 ST D

L = Assembly group D = Sealing element Page: 15 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910946054

Designation: STEUERT. A6VM 250 HD1/63-V

Drawing no.: R910929926

L = Assembly group D = Sealing element Page: 16 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910974659

Designation: EINST.RUECKSCHL.V. A6,A7 250,355/63

Drawing no.: R910974660

Pos. Part No. Designation Quantity

1 R910974661 POPPET SEAT 1 ST

2 R910974662 VALVE POPPET 1 ST
4 R910974636 SPRING 1 ST

L = Assembly group D = Sealing element Page: 17 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910974659

Designation: EINST.RUECKSCHL.V. A6,A7 250,355/63

Drawing no.: R910974660

L = Assembly group D = Sealing element Page: 18 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910935604

Designation: DECKEL A6VM 250 HDD/63-V -SO 68

Drawing no.: R910935602

Pos. Part No. Designation Quantity

1 R910935503 VALVE CARTRIDGE 1 ST

2 R910934358 STELLZEITBEGRENZUNGSVENTIL-V 1 ST L
3 R910930674 COVER 1 ST
4 R910960086 ANSCHLAGSCHEIBE 1 ST
6 R910109991 ZYL.SCHR.M 16X 70 - 8.8 DIN 912 #215NM 4 ST
7 R910788317 LOCKING SCREW 1 ST D
8 R910977645 PLUG 2 ST D
9 R909831318 DOUBLE BREAK-OFF PIN 1 ST D
10 R910529044 DP-ABREISSTOPFEN M 4 WN1067 1 ST
11 R910518336 O-RING 3 ST D
12 R910929855 O-RING 1 ST D
13 R910929791 STUETZR. SP/SS11109-132-P 1 ST D
14 R910921703 ORIFICE 1 ST
15 R910532347 V-SCHRAUBE N 02.009-M 14X1,5 V # 30NM 2 ST D

L = Assembly group D = Sealing element Page: 19 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910935604

Designation: DECKEL A6VM 250 HDD/63-V -SO 68

Drawing no.: R910935602

L = Assembly group D = Sealing element Page: 20 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910934358

Designation: STELLZEITBEGRENZUNGSVENTIL-V

Drawing no.: R910930691

Pos. Part No. Designation Quantity

1 R909077836 PISTON 1 ST
2 R910931238 LOCKING SCREW 2 ST
3 R909077334 SPRING COLLAR 2 ST
4 R909077478 SPRING COLLAR 2 ST
5 R910591955 SPRING 2 ST
6 R909077838 THROTTLE SCREW 1 ST
7 R910302139 O-RING 2 ST D
9 R910642827 BONDED SEAL RING 4 ST D
10 R910913806 NUT 2 ST
11 R910913805 CAP NUT 2 ST
12 R910914466 THREADED PIN 2 ST

L = Assembly group D = Sealing element Page: 21 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
 Rexroth
Bosch Group
Mobile Hydraulics

Spare parts list Product Unit

Axial Piston Units

Part No.: R910934358

Designation: STELLZEITBEGRENZUNGSVENTIL-V

Drawing no.: R910930691

L = Assembly group D = Sealing element Page: 22 Date: 06.12.2005

Status of version: 11/2005

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb
Spare parts list Brueninghaus Hydromatik
Order No.: 09409224 Elchingen Plant
Denomination: A2FM160/61W-VZB040
Type: 211.24.25.45

Drawing no.: 02030565

Info:

Item Order No. Denomination Quantity

1 02030551 ROTARY GROUP 1 ST L
3 02040419 HOUSING 1 ST
4 09422973 PORT PLATE 1 ST
5 09084174 CYLINDER PIN 1 ST
ISO 2338- 8H6X16-ST-S
6 09154656 O-RING 1 ST D
N 02.079-110,72 X 3,53-S-FKM70
7 09083129 SOCKET-HEAD SCREW 6 ST
DIN 912-M16X 40-8.8 #215NM
19 09156654 LOCKING SCREW 1 ST D
N 02.009-M22X1,5-FKM #60NM

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 1 Following page: 2 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02030551 Elchingen Plant
Denomination: ROTARY GROUP
Type: 201.24.33.11

Drawing no.: 02030666

Info:

Item Order No. Denomination Quantity

1 02028937 ROTARY GROUP, HYDR. SECTION 1 ST L
2 02030597 DRIVE SHAFT WITH BEARING ASSY 1 ST L
4 09404384 COVER 1 ST D
12 09083421 RETAINING RING 1 ST
DIN 472-140X4
14 09831662 SHAFT SEAL RING 1 ST D
BAFSL1SF 60X 80X 7/5,5-FKM
15 09086635 O-RING 1 ST D
N 02.079-132,94 X 3,53-S-FKM70
17 09154260 SHIM 2 ST
N 02.085-2-PS110 X140 X0,2
18 09087601 SHIM 1 ST
N 02.085-2-PS110 X140 X0,3

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 2 Following page: 3 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02028937 Elchingen Plant
Denomination: ROTARY GROUP, HYDR. SECTION
Type: 201.24.33.90

Drawing no.: 02028927

Info:

Item Order No. Denomination Quantity

1 09421312 CYLINDER 1 ST
2 09650838 CONTROL PLATE 1 ST
3 02028819 CENTER PIN 1 ST
4 02031680 PISTON WITH PISTON RINGS 7 ST L
5 09409186 WASHER 1 ST
20125.0710
6 09921535 ADJUSTMENT SHIM 1 ST
6 09921536 ADJUSTMENT SHIM 1 ST
6 09921537 ADJUSTMENT SHIM 1 ST
6 09921538 ADJUSTMENT SHIM 1 ST
6 09921539 ADJUSTMENT SHIM 1 ST
6 09921540 ADJUSTMENT SHIM 1 ST
7 02028820 PRESSURE SPRING 1 ST
' 4,00/ 13,80/ 58,50'
11 09444065 RETAINING PLATE 1 ST
12 09831109 PAN HEAD SCREW W. TORX 7 ST
N 02.119-M 8X20-10.9-MK #37,7NM

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 3 Following page: 4 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02028937 Elchingen Plant
Denomination: ROTARY GROUP, HYDR. SECTION
Type: 201.24.33.90

Drawing no.: 02028927

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 4 Following page: 5 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02031680 Elchingen Plant
Denomination: PISTON WITH PISTON RINGS
Type: 201.24.33.90

Drawing no.: 02021888

Info:

Item Order No. Denomination Quantity

1 02028627 PISTON 1 ST
2 09831894 STEEL SEALING RING 2 ST
21,1X23,6X3,2

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 5 Following page: 6 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02031680 Elchingen Plant
Denomination: PISTON WITH PISTON RINGS
Type: 201.24.33.90

Drawing no.: 02021888

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 6 Following page: 7 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02030597 Elchingen Plant
Denomination: DRIVE SHAFT WITH BEARING ASSY
Type: 201.24.33.10

Drawing no.: 02030521

Info:

Item Order No. Denomination Quantity

2 02028924 DRIVE SHAFT 1 ST
3 09430089 BEARING RING 1 ST
6 02030517 BACK-UP PLATE 1 ST L
7 09084419 RETAINING RING 1 ST
DIN 471- 65X2,5
10 09154344 TAPERED-ROLLER BEARING 1 ST
T 7FC 070.T51EF
11 09152775 TAPERED-ROLLER BEARING 1 ST
DIN 720-33113

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 7 Following page: 8 Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
Spare parts list Brueninghaus Hydromatik
Order No.: 02030517 Elchingen Plant
Denomination: BACK-UP PLATE
Type: 201.25.33.10

Drawing no.:
Info:

Item Order No. Denomination Quantity

1 09921453 BACK-UP PLATE 1 ST
2 09921454 BACK-UP PLATE 1 ST
3 09921455 BACK-UP PLATE 1 ST
4 09921456 BACK-UP PLATE 1 ST
5 09921457 BACK-UP PLATE 1 ST
6 09921458 BACK-UP PLATE 1 ST
7 09921459 BACK-UP PLATE 1 ST
8 09651281 BACK-UP PLATE 1 ST
9 02028812 BACK-UP PLATE 1 ST
10 02028813 BACK-UP PLATE 1 ST
11 02028814 BACK-UP PLATE 1 ST
12 09153341 BACK-UP PLATE 1 ST D
DIN 988-S 65X 85

L = Assembly group D = Sealing element

->In order to assure a correct processing of spare parts orders, Page: 8 Following page: - Date: 19.09.2000
the order must have the following information:
Type, fabrication no., denomination and order no.
If there is no purchase order no. the complete denomination is enough.

Status of version: 08/2000

Brueninghaus Hydromatik GmbH, Elchingen Plant, Glockeraustraße 2, D-89275 Elchingen, Phone (07308) 820, Fax (07308) 7273
SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE

Getriebe – Typ: ZHP 4.29

Gear Type:
Réducteur Type:

Geräte – Nr.: 60 0 4.29 10749

Aggregate No:
Appareil No:

Serien – Nr.: 101 - 102

Serial No:
Série No:

Auftrags – Nr.: 6797040 vom 30.08.2004

Order No:
Commande No:

Firma : Neuenfelder Maschinenfabrik GmbH

Company:
Société:
Anschrift : Neuenfelder Faehrdeich 120
Address:
Adresse: D - 21129 Hamburg
Abteilung : zu Hd. Hr. B. Holler
Department:
Service:

Bestell – Nr.: 402276 vom 19.02.2004 Sach – Nr.: 1391GT8621

Order No: Ident. No:
Commande No Produit No:
Geräte – Typ: --- Pos – Nr.: ---
Aggregate Type: Pos. No:
Appareil Type: Pos. No:
Bau / Komm – Nr. --- Projekt – Nr.: 80110 + 80111
Constr. No: Project No:
Constr. Spéc. No: Projet No:

Lieferumfang: 1-fach deutsch/englisch per e-mail 01.09.2004 MA/KD

ZOLLERN Vertriebs-GmbH & Co.KG Telefon: 07586 / 959 - 0
Heustrasse 1 Telefax: 07586 / 959 - 710
E-Mail: service@zollern.de
D-88518 Herbertingen Homepage: www.zollern.de
1000000001271.doc Seite 1
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

1 1,0 ST 1005784 Getriebe

21 1,0 ST 60193006186 Seiltrommel
22 1,0 ST 1005786 Flanschlagerung
24 1,0 ST 60193008254 Antrieb
60 1,0 ST 60193006188 Ölleitung
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART NO. DESCRIPTION TECHNICAL DESCRIPTION.

1 1,0 PC 1005784 Gear

21 1,0 PC 60193006186 Rope drum
22 1,0 PC 1005786 Flange bearing
24 1,0 PC 60193008254 Drive
60 1,0 PC 60193006188 Oil line
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

1 1,0 ST 1005784 Getriebe

1/1 1,0 ST 1005785 Abtrieb
1/1/1 1,0 ST 60242901900 Planetenträger
1/1/3 1,0 ST 60242901834 Lagerring
1/1/6 1,0 ST 60242901790 Zwischengehäuse
1/1/14 1,0 ST 60242901835 Scheibe A114_I86_S6
1/1/21 18,0 ST 60411200023 Zylinderschraube DIN912_M24_L150_10.9
1/1/24 4,0 ST 60411230072 Zylinderschraube DIN912_M12_L20_8.8
1/1/25 4,0 ST 60403900049 Federring DIN7980_A18_I12,2
1/1/27 18,0 ST 60240700320 Scheibe A37_I25_S4
1/1/31 1,0 ST 60441100070 Wellendichtring DIN3760_B2_NM460_A500_B20_FPM
1/1/41 1,6 M 60442000005 Profilschnur DIN7715_10,0*36
1/1/42 1,7 M 60542000010 Befestigungsband
1/1/43 1,0 ST 60542100010 Bandschloss S0,4_L8_BEFESTIGUNGSBAND_V2A
1/1/51 1,0 ST 60453300171 Zylinderrollenlager NM375_A444,82_B48_RN
1/1/53 1,0 ST 60453000212 Rillenkugellager DIN625_NM220_A340_B56
1/1/60 1,0 ST 60403100082 Sicherungsring DIN471_NM260_S5_A
1/1/61 1,0 ST 60403100078 Sicherungsring DIN471_NM220_S5_A
1/1/62 1,0 ST 60403200212 Sicherungsring DIN472_NM340_S6_J
1/1/201 1,0 ST 60242901838 Zwischenflansch
1/1/202 24,0 ST 60421200110 Zylinderschraube DIN912_M24_L60_10.9
1/1/203 24,0 ST 60240700320 Scheibe A37_I25_S4
1/1/444 1,0 ST 60403200045 Sicherungsring DIN472_NM75_S2,5_J
1/1/473 14,0 ST 60404300241 Passscheibe DIN988_A75_I60_S1
1/1/491 1,0 ST 60230001543 Scheibe A75_I51_S2
1/1/951 2,0 ST 60414030001 Verschlußschraube DIN908_M10_P1_ZYL.+BUND
1/1/952 2,0 ST 60441000207 Flach-Dichtring DIN7603_A13,5_S1_A_ST
1/11 1,0 ST 60100100712 BG Planetenstufe
1/11/1 1,0 ST 60233900001 Innenrad
1/11/3 1,0 ST 60242901904 Sonnenrad
1/21 1,0 ST 60100100415 BG Planetenstufe
1/21/1 1,0 ST 60232700277 Innenrad
1/21/3 1,0 ST 60242701025 Sonnenrad
1/24 1,0 ST 60100010617 BG Planetenträger
1/24/1 1,0 ST 60232700585 Planetenträger
1/24/3 1,0 ST 60403100062 Sicherungsring DIN471_NM130_S4_A
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

1/24/4 1,0 ST 60503100059 Sprengring NM130

1/27 1,0 ST 60100020334 BG Zwischengehäuse
1/27/1 1,0 ST 60242701277 Zwischenflansch
1/27/3 1,0 ST 60242400992 Lagerflansch
1/27/4 1,0 ST 60243100326 Abtriebsflansch
1/27/6 1,0 ST 60243101185 Deckel
1/27/10 1,0 ST 60243101193 Ring A110_I80,2_L23_R7
1/27/20 18,0 ST 60411230106 Zylinderschraube DIN912_M20_L140_8.8
1/27/21 18,0 ST 60411230076 Zylinderschraube DIN912_M12_L40_8.8
1/27/22 18,0 ST 60411230094 Zylinderschraube DIN912_M16_L100_8.8
1/27/30 1,0 ST 60453000051 Rillenkugellager DIN625_NM130_A200_B22
1/27/31 1,0 ST 60453000115 Rillenkugellager DIN625_NM160_A240_B25
1/27/40 1,0 ST 60403200082 Sicherungsring DIN472_NM240_S5_J
1/27/50 1,0 ST 60441110386 Wellendichtring DIN3760_BA_NM125_A150_B12_FPM
1/31 1,0 ST 60100100906 BG Planetenstufe
1/31/1 1,0 ST 60232400477 Innenrad
1/31/3 1,0 ST 60242401199 Sonnenrad
1/34 1,0 ST 60100100907 BG Planetenträger
1/34/1 1,0 ST 60232400479 Planetenträger
1/34/3 1,0 ST 60403100050 Sicherungsring DIN471_NM80_S2,5_A
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

1 1,0 PC 1005784 Gear

1/1 1,0 PC 1005785 Output
1/1/1 1,0 PC 60242901900 Planet carrier
1/1/3 1,0 PC 60242901834 Bearing ring
1/1/6 1,0 PC 60242901790 Intermediate housing
1/1/14 1,0 PC 60242901835 Disc A114_I86_S6
1/1/21 18,0 PC 60411200023 Cylindrical bolt DIN912_M24_L150_10.9
1/1/24 4,0 PC 60411230072 Cylindrical bolt DIN912_M12_L20_8.8
1/1/25 4,0 PC 60403900049 Retaining ring DIN7980_A18_I12,2
1/1/27 18,0 PC 60240700320 Disc A37_I25_S4
1/1/31 1,0 PC 60441100070 Shaft sealing ring DIN3760_B2_NM460_A500_B20_FPM
1/1/41 1,6 M 60442000005 Profiled cord DIN7715_10,0*36
1/1/42 1,7 M 60542000010 Holding strap
1/1/43 1,0 PC 60542100010 Belt lock S0,4_L8_BEFESTIGUNGSBAND_V2A
1/1/51 1,0 PC 60453300171 Cylindrical roller bearing NM375_A444,82_B48_RN
1/1/53 1,0 PC 60453000212 Grooved ball bearing DIN625_NM220_A340_B56
1/1/60 1,0 PC 60403100082 Circlip / locking ring DIN471_NM260_S5_A
1/1/61 1,0 PC 60403100078 Circlip / locking ring DIN471_NM220_S5_A
1/1/62 1,0 PC 60403200212 Circlip / locking ring DIN472_NM340_S6_J
1/1/201 1,0 PC 60242901838 Intermediate flange
1/1/202 24,0 PC 60421200110 Cylindrical bolt DIN912_M24_L60_10.9
1/1/203 24,0 PC 60240700320 Disc A37_I25_S4
1/1/444 1,0 PC 60403200045 Circlip / locking ring DIN472_NM75_S2,5_J
1/1/473 14,0 PC 60404300241 Adjusting ring DIN988_A75_I60_S1
1/1/491 1,0 PC 60230001543 Disc A75_I51_S2
1/1/951 2,0 PC 60414030001 Screw plug DIN908_M10_P1_ZYL.+BUND
1/1/952 2,0 PC 60441000207 Flat sealing ring DIN7603_A13,5_S1_A_ST
1/11 1,0 PC 60100100712 BG planetary stage
1/11/1 1,0 PC 60233900001 Inner wheel
1/11/3 1,0 PC 60242901904 Planetary wheel / sun wheel
1/21 1,0 PC 60100100415 BG planetary stage
1/21/1 1,0 PC 60232700277 Inner wheel
1/21/3 1,0 PC 60242701025 Planetary wheel / sun wheel
1/24 1,0 PC 60100010617 BG planet carrier
1/24/1 1,0 PC 60232700585 Planet carrier
1/24/3 1,0 PC 60403100062 Circlip / locking ring DIN471_NM130_S4_A
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

1/24/4 1,0 PC 60503100059 Circlip / snap ring NM130

1/27 1,0 PC 60100020334 BG intermediate housing
1/27/1 1,0 PC 60242701277 Intermediate flange
1/27/3 1,0 PC 60242400992 Bearing flange
1/27/4 1,0 PC 60243100326 Output flange
1/27/6 1,0 PC 60243101185 Cover
1/27/10 1,0 PC 60243101193 Ring A110_I80,2_L23_R7
1/27/20 18,0 PC 60411230106 Cylindrical bolt DIN912_M20_L140_8.8
1/27/21 18,0 PC 60411230076 Cylindrical bolt DIN912_M12_L40_8.8
1/27/22 18,0 PC 60411230094 Cylindrical bolt DIN912_M16_L100_8.8
1/27/30 1,0 PC 60453000051 Grooved ball bearing DIN625_NM130_A200_B22
1/27/31 1,0 PC 60453000115 Grooved ball bearing DIN625_NM160_A240_B25
1/27/40 1,0 PC 60403200082 Circlip / locking ring DIN472_NM240_S5_J
1/27/50 1,0 PC 60441110386 Shaft sealing ring DIN3760_BA_NM125_A150_B12_FPM
1/31 1,0 PC 60100100906 BG planetary stage
1/31/1 1,0 PC 60232400477 Inner wheel
1/31/3 1,0 PC 60242401199 Planetary wheel / sun wheel
1/34 1,0 PC 60100100907 BG planet carrier
1/34/1 1,0 PC 60232400479 Planet carrier
1/34/3 1,0 PC 60403100050 Circlip / locking ring DIN471_NM80_S2,5_A
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

21 1,0 ST 60193006186 Seiltrommel

21/1 1,0 ST 60242901643 Seiltrommel
21/5 1,0 ST 60243100481 Seilblech
21/20 24,0 ST 60411130573 Sechskantschraube DIN933_M24_L55_8.8
21/21 24,0 ST 60411230424 Zylinderschraube DIN912_M24_L55_8.8
21/23 6,0 ST 60412300013 Gewindestift DIN915_M20_L45_Innensechskant_45H
21/30 24,0 ST 60411130523 Sechskantschraube DIN933_M16_L45_8.8
21/31 24,0 ST 60415130011 Sechskantmutter DIN934_M16_VERZINKT
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

21 1,0 PC 60193006186 Rope drum

21/1 1,0 PC 60242901643 Rope drum
21/5 1,0 PC 60243100481 Rope plate
21/20 24,0 PC 60411130573 Hexagon bolt DIN933_M24_L55_8.8
21/21 24,0 PC 60411230424 Cylindrical bolt DIN912_M24_L55_8.8
21/23 6,0 PC 60412300013 Threaded pin DIN915_M20_L45_Innensechskant_45H
21/30 24,0 PC 60411130523 Hexagon bolt DIN933_M16_L45_8.8
21/31 24,0 PC 60415130011 Hexagon nut DIN934_M16_VERZINKT
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

22 1,0 ST 1005786 Flanschlagerung

22/1 1,0 ST 1000410 Flansch
22/2 1,0 ST 60242902087 Flanschplatte
22/3 1,0 ST 60230002115 Ring A91_I73_L8
22/4 1,0 ST 60541000228 O-Ring I74_SD3_NBR-72_-35/120
22/5 1,0 ST 60541000444 O-Ring I86_SD2,5_NBR-70_-35/120
22/6 1,0 ST 60453400090 Pendelrollenlager DIN635_NM150_A225_B56_23030 S.MB
22/8 1,0 ST 60230002114 Deckel
22/50 1,0 ST 60453000250 Rillenkugellager DIN625_NM120_A150_B16
22/51 2,0 ST 60403100060 Sicherungsring DIN471_NM120_S4_A
22/52 2,0 ST 60503200096 Sprengring NM150
22/53 1,0 ST 60403200228 Sicherungsring DIN472_NM87_S3_J
22/54 1,0 ST 60403200227 Sicherungsring DIN472_NM92_S3_J
22/55 1,0 ST 60441100380 Wellendichtring DIN3760_BA_NM120_A150_B12_NBR
22/56 1,0 ST 60412700005 Gewindeeinsätze 302_M5_M8_P1_L10
22/57 1,0 ST 60412300521 Gewindestift DIN914_M5_L16_Innensechskant_45H
22/58 1,0 ST 60412300409 Gewindestift DIN913_M6_L6_Innensechskant_45H
22/59 1,0 ST 60417000094 Spannstift DIN1481_NM4_L16
22/65 1,0 ST 60541000227 O-Ring I24,99_SD3,53_NBR-70_-35/120
22/66 2,0 ST 60505100038 DU-Buchse I8_A10_EL4,5_STAHLRÜ.
22/67 6,0 ST 60411230063 Zylinderschraube DIN912_M10_L40_8.8
22/68 3,0 ST 60411530300 Senkschraube DIN7991_M6_L16_8.8
22/80 1,0 ST 1000977 Platte
22/81 2,0 ST 60411530300 Senkschraube DIN7991_M6_L16_8.8
22/85 1,0 ST 1000959 Deckel
22/86 1,0 ST 60541000506 O-Ring I35_SD1,5_NBR-72_-35/120
22/87 4,0 ST 60411230010 Zylinderschraube DIN912_M4_L12_8.8
22/401 1,0 ST 60449900003 Schmiernippel DIN71412_KEGEL_M10
22/421 1,0 ST 60230001181 Deckel
22/422 3,0 ST 60411230035 Zylinderschraube DIN912_M6_L12_8.8
22/451 1,0 ST 60242902085 Zahnwelle
22/500 1,0 ST 1000411 Lagerflansch
22/502 1,0 ST 60242902091 Sonnenrad
22/503 1,0 ST 60242902090 Zahnscheibe
22/504 1,0 ST 60242902092 Zahnrad
22/510 1,0 ST 1000572 Zahnwelle
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

22 1,0 PC 1005786 Flange bearing

22/1 1,0 PC 1000410 Flange
22/2 1,0 PC 60242902087 Flange plate
22/3 1,0 PC 60230002115 Ring A91_I73_L8
22/4 1,0 PC 60541000228 O-ring I74_SD3_NBR-72_-35/120
22/5 1,0 PC 60541000444 O-ring I86_SD2,5_NBR-70_-35/120
22/6 1,0 PC 60453400090 Self-aligning roller bearing DIN635_NM150_A225_B56_23030 S.MB
22/8 1,0 PC 60230002114 Cover
22/50 1,0 PC 60453000250 Grooved ball bearing DIN625_NM120_A150_B16
22/51 2,0 PC 60403100060 Circlip / locking ring DIN471_NM120_S4_A
22/52 2,0 PC 60503200096 Circlip / snap ring NM150
22/53 1,0 PC 60403200228 Circlip / locking ring DIN472_NM87_S3_J
22/54 1,0 PC 60403200227 Circlip / locking ring DIN472_NM92_S3_J
22/55 1,0 PC 60441100380 Shaft sealing ring DIN3760_BA_NM120_A150_B12_NBR
22/56 1,0 PC 60412700005 Threaded inserts 302_M5_M8_P1_L10
22/57 1,0 PC 60412300521 Threaded pin DIN914_M5_L16_Innensechskant_45H
22/58 1,0 PC 60412300409 Threaded pin DIN913_M6_L6_Innensechskant_45H
22/59 1,0 PC 60417000094 Slotted pin DIN1481_NM4_L16
22/65 1,0 PC 60541000227 O-ring I24,99_SD3,53_NBR-70_-35/120
22/66 2,0 PC 60505100038 DU-bushing I8_A10_EL4,5_STAHLRÜ.
22/67 6,0 PC 60411230063 Cylindrical bolt DIN912_M10_L40_8.8
22/68 3,0 PC 60411530300 Countersunk screw / countersunk bolt DIN7991_M6_L16_8.8
22/80 1,0 PC 1000977 Plate
22/81 2,0 PC 60411530300 Countersunk screw / countersunk bolt DIN7991_M6_L16_8.8
22/85 1,0 PC 1000959 Cover
22/86 1,0 PC 60541000506 O-ring I35_SD1,5_NBR-72_-35/120
22/87 4,0 PC 60411230010 Cylindrical bolt DIN912_M4_L12_8.8
22/401 1,0 PC 60449900003 Lubricating nipple DIN71412_KEGEL_M10
22/421 1,0 PC 60230001181 Cover
22/422 3,0 PC 60411230035 Cylindrical bolt DIN912_M6_L12_8.8
22/451 1,0 PC 60242902085 Toothed shaft
22/500 1,0 PC 1000411 Bearing flange
22/502 1,0 PC 60242902091 Planetary wheel / sun wheel
22/503 1,0 PC 60242902090 Toothed washer
22/504 1,0 PC 60242902092 Cog toothed wheel
22/510 1,0 PC 1000572 Toothed shaft
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

24 1,0 ST 60193008254 Antrieb

24/1 1,0 ST 60242901839 Bremsflansch
24/4 1,0 ST 60193004627 Antriebshülse
24/7 1,0 ST 60230000021 Motorflansch
24/18 1,0 ST 60242400086 Deckel
24/20 8,0 ST 60411230455 Zylinderschraube DIN912_M12_L190_8.8
24/22 4,0 ST 60411230341 Zylinderschraube DIN912_M12_L150_8.8
24/25 4,0 ST 60411130705 Sechskantschraube DIN933_M20_L30_8.8
24/30 1,0 ST 60453000039 Rillenkugellager DIN625_NM90_A140_B24
24/40 1,0 ST 60403200066 Sicherungsring DIN472_NM140_S4_J
24/41 1,0 ST 60403100054 Sicherungsring DIN471_NM90_S3_A
24/42 1,0 ST 60503200148 Sicherungsring DIN472_NM46_S1,75_J
24/43 1,0 ST 60503200148 Sicherungsring DIN472_NM46_S1,75_J
24/50 1,0 ST 60441100573 Wellendichtring DIN3760_BA_NM100_A100_A130_B12_FPM
24/53 1,0 ST 60441100666 Wellendichtring DIN3760_B1_NM130_A160_B8_FPM
24/59 1,0 ST 60541000070 O-Ring I200_SD3_NBR-70_-35/120
24/60 3,0 ST 60414030023 Verschlußschraube DIN910_M10_P1_ZYL.+BUND
24/61 3,0 ST 60441000207 Flach-Dichtring DIN7603_A13,5_S1_A_ST
24/64 1,0 ST 60414030005 Verschlußschraube DIN908_M18_P1,5_ZYL.+BUND
24/65 1,0 ST 60441000213 Flach-Dichtring DIN7603_A22_S1,5_A_ST
24/66 1,0 ST 60242400144 Deckel
24/67 4,0 ST 60541800007 Verschlussstopfen GPN300 F 5_14_D10,7_H5,5
24/69 1,0 ST 60543400075 Luftfilter
24/70 23,0 ST 60404300227 Passscheibe DIN988_A45_I35_S1
24/75 20,0 ST 60402100312 Druckfeder
24/76 20,0 ST 60402100313 Druckfeder
24/77 12,0 ST 60242901220 Scheibe A19_I13_S5
24/79 4,0 ST 60404130015 Scheibe DIN125_A37_I21_S3
24/95 1,0 ST 60506701104 Betätigungseinheit
24/96 1,0 ST 60506700230 Lamellengehäuse
24/97 9,0 ST 60506700192 Aussenlamelle
24/98 7,0 ST 60506700193 Innenlamelle
24/122 1,0 ST 60414030002 Verschlußschraube DIN908_M12_P1,5_ZYL.+BUND
24/123 1,0 ST 60441000208 Flach-Dichtring DIN7603_A16_S1,5_A_ST
24/611 1,0 ST 60540100869 Schwenkverschraubung WH_8_PLM_M12_P1,5
24/612 0,3 M 60620100005 VM Präzisionsstahlrohr
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

24/613 1,0 ST 60540100073 Gerade Verschraubung G_8_S

24/614 1,0 ST 60541800005 Verschlussstopfen GPN300 F 3_14_D8,4_H6
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

24 1,0 PC 60193008254 Drive

24/1 1,0 PC 60242901839 Brake flange
24/4 1,0 PC 60193004627 Drive sleeve
24/7 1,0 PC 60230000021 Motor flange
24/18 1,0 PC 60242400086 Cover
24/20 8,0 PC 60411230455 Cylindrical bolt DIN912_M12_L190_8.8
24/22 4,0 PC 60411230341 Cylindrical bolt DIN912_M12_L150_8.8
24/25 4,0 PC 60411130705 Hexagon bolt DIN933_M20_L30_8.8
24/30 1,0 PC 60453000039 Grooved ball bearing DIN625_NM90_A140_B24
24/40 1,0 PC 60403200066 Circlip / locking ring DIN472_NM140_S4_J
24/41 1,0 PC 60403100054 Circlip / locking ring DIN471_NM90_S3_A
24/42 1,0 PC 60503200148 Circlip / locking ring DIN472_NM46_S1,75_J
24/43 1,0 PC 60503200148 Circlip / locking ring DIN472_NM46_S1,75_J
24/50 1,0 PC 60441100573 Shaft sealing ring DIN3760_BA_NM100_A100_A130_B12_FPM
24/53 1,0 PC 60441100666 Shaft sealing ring DIN3760_B1_NM130_A160_B8_FPM
24/59 1,0 PC 60541000070 O-ring I200_SD3_NBR-70_-35/120
24/60 3,0 PC 60414030023 Screw plug DIN910_M10_P1_ZYL.+BUND
24/61 3,0 PC 60441000207 Flat sealing ring DIN7603_A13,5_S1_A_ST
24/64 1,0 PC 60414030005 Screw plug DIN908_M18_P1,5_ZYL.+BUND
24/65 1,0 PC 60441000213 Flat sealing ring DIN7603_A22_S1,5_A_ST
24/66 1,0 PC 60242400144 Cover
24/67 4,0 PC 60541800007 Stopper GPN300 F 5_14_D10,7_H5,5
24/69 1,0 PC 60543400075 Air filter
24/70 23,0 PC 60404300227 Adjusting ring DIN988_A45_I35_S1
24/75 20,0 PC 60402100312 Pressure spring
24/76 20,0 PC 60402100313 Pressure spring
24/77 12,0 PC 60242901220 Disc A19_I13_S5
24/79 4,0 PC 60404130015 Disc DIN125_A37_I21_S3
24/95 1,0 PC 60506701104 Actuation unit
24/96 1,0 PC 60506700230 Disc housing
24/97 9,0 PC 60506700192 Outer disc
24/98 7,0 PC 60506700193 Inner disc
24/122 1,0 PC 60414030002 Screw plug DIN908_M12_P1,5_ZYL.+BUND
24/123 1,0 PC 60441000208 Flat sealing ring DIN7603_A16_S1,5_A_ST
24/611 1,0 PC 60540100869 Swivel screw connection WH_8_PLM_M12_P1,5
24/612 0,3 M 60620100005 VM Precision steel pipe
 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

24/613 1,0 PC 60540100073 Straight screw connection G_8_S

24/614 1,0 PC 60541800005 Stopper GPN300 F 3_14_D8,4_H6
 ZOLLERN GmbH & Co. KG

ERSATZTEILLISTE Hausanschrift: Heustr. 1

D-88518 Herbertingen
Datum: 01.09.2004

Bei Ersatzteilbestellung Typ, Materialnummer, Serialnummer und Teilenummer angeben!

Typ: Seilwinde ZHP 4_29

Materialnr.: 60042900749
Serialnummer(n): 101 - 102
Stückliste: 1 / Z001
Kunde: 113264 Neuenfelder
Kunden-ID-Nr: 1391GT8621
Öleinfüllmenge: 17,000 L Gewicht: 2.100,000 KG
POS-NR. MENGE ME TEILE-NR. BEZEICHNUNG TECHN. BEZEICHNUNG.

60 1,0 ST 60193006188 Ölleitung

 ZOLLERN GmbH & Co. KG

SPARE PARTS LIST Hausanschrift: Heustr. 1

D-88518 Herbertingen
Date: 01.09.2004

When ordering spares parts, please indicated type, material number, serial number and part number !

Type: Rope winch ZHP 4_29

Materialno.: 60042900749
Serial number(s): 101 - 102
Parts list 1 / Z001
Customer: 113264 Neuenfelder
Cust.-ident-No.: 1391GT8621
Oil filling quantity: 17,000 L Weight: 2.100,000 KG
POS-NO. QUANTITY PART-NO. BEZEICHNUNG TECHNICAL DESCRIPTION.

60 1,0 PC 60193006188 Oil line

EINBAUANLEITUNG
Allgemein
Beachten Sie hierzu auch die Angaben auf unserer Einbauzeichnung!
Die ZOLLERN Seilwinde wird fertig montiert ausgeliefert.
Zum Einbau der Winde muss der Flansch und die Drehmomentmesswelle demontiert werden.
Prüfen Sie vor der Montage der Winde Ihren Stahlbau gemäß unserer Einbauzeichnung.
Die Anschraubflächen müssen in gleicher Ebene sauber bearbeitet sein.

Demontage
Flansch und Drehmomentmesswelle:

Bei Auslieferung werden die Teile Pos. 2 (Zahnscheibe), Pos. 5 (Messwelle), Pos. 10 (Dichtring) und Pos. 7
(Zahnrad) im Beipack mitgeliefert.

• Seilwinde Pos. 1 lastfrei schalten

• Deckel Pos. 9 demontieren
• Sicherungsring Pos. 4 entfernen
• Deckel Pos. 6 demontieren
• Flansch Pos. 8 abziehen

Montage
Einbaulage der Winde gemäß unserer Einbauzeichnung beachten!
Alle Anschraubflächen und Gewindebohrungen am Getriebe und am Flansch metallisch blank reinigen.
Alle Zollern Schraubverbindungen, die bei der Demontage gelöst wurden, mit Loctite Typ 242 sichern -
Loctite-Verarbeitungsvorschriften beachten!
Festigkeitsklassen und Anzugsmomente der Schrauben siehe Einbauzeichnung.
Markierung "O" (oben) am Getriebeflansch auf die in der Einbauzeichnung angegebene Stelle drehen.
Seilwinde in Stahlbau einfahren.
Getriebe im Stahlbau zentrieren.
Getriebe mit Schrauben befestigen.
Flansch und Drehmomentmesswelle montieren.
Achtung:
Zahnrad Pos. 7 horizontal montieren!
Kabelausgang unten mit Kranelektrik verbinden.
Einbaulage Flansch siehe Einbauzeichnung "Ansicht Z".

1000000000318.d.doc Seite 1
 • Flansch Pos. 8 gleichmäßig aufziehen
• Zahnrad Pos. 7 einsetzen
• Deckel Pos. 6 montieren
• Messwelle Pos. 5 mit Dichtring Pos. 10
vorsichtig in die Verzahnung schieben
• Sicherungsring Pos. 4 einsetzen
• Stecker Pos. 3 verschrauben
• Zahnscheibe Pos. 2 auf Nockenendschalter
montieren und befestigen
• Nockenendschalter im Flansch Pos. 8 befestigen

Öl- und Entlüftungsleitung montieren.

Ölstandsrohr mit Rohrschellen und Schrauben am Stahlbau befestigen.
Das Ölstandsrohr vertikal so platzieren, dass die "MAX" - Kerbe am Ölmessstab Mitte Getriebe ist.
Ölstand mit Ölmessstab überprüfen.
Gegebenenfalls Öl nachfüllen.
Ist die Winde ohne Öl ausgeliefert, so weist ein Aufkleber darauf hin.
Ölsorte siehe Typenschild bzw. Wartungsanleitung.
Ölmenge siehe Typenschild bzw. Ersatzteilliste.
Transportdeckel am Motorflansch demontieren.
Bremsleitung anschließen (siehe Einbauzeichnung).
Lamellenbremse hydraulisch lüften.
Die Antriebshülse in der Antriebseinheit muss sich leicht durchdrehen lassen.
Verschlussstopfen von der Antriebshülse der Antriebseinheit abziehen.
Die Antriebshülse wird zum Schutz vor Passungsrost vom Getriebe aus mit Getriebeöl versorgt. Der
Verschlussstopfen verhindert, dass sich der Motorflansch vor der Montage des Motors mit Öl füllt.
Achtung: Motorwelle fettfrei!
Motor im Motorflansch zentrieren.
Verbindungsflächen abdichten.
Motor mit Schrauben befestigen.
Vor dem Probelauf den Motorflansch mit Getriebeöl ganz füllen.
Seilwinde mit laufendem Motor auf Funktion überprüfen.
Insbesondere die Steuerung und Funktion der Haltebremse und des Antriebmotors überprüfen.
Ölstand nach Probelauf nochmals mit Ölmessstab überprüfen.
Während des Probelaufs gleicht sich der Ölstand im Getriebe und Motorflansch aus und füllt dadurch den
Raum zur Motorwelle langsam mit Getriebeöl. Deshalb kann sich der Ölstand vermindern.
Gegebenenfalls Öl nachfüllen.
Seil einfädeln.
Seil mit Druckschrauben befestigen.
Druckschrauben entsprechend sichern.

1000000000318.d.doc Seite 2
WARTUNGSANLEITUNG
Schmierung
Das Zollern-Seilwindengetriebe hat Tauchschmierung.
Ölfüllung ab Werk :MOBIL SHC 630
Bezeichnung nach DIN :synthetisches PAO-Schmieröl
Die Öleinfüllmenge ist auf dem Typenschild vermerkt. Wird das Getriebe ohne Öl ausgeliefert, ist mit einem
Aufkleber darauf hingewiesen.

Das Wälzlager am Gegenlagerflansch ist mit Schmierfett gefüllt.

Fettfüllung ab Werk :AVIA AVIALITH 2 EP
Auswahl nach DIN :DIN 51502
Bezeichnung nach DIN :Schmierfett, DIN 51825-KP2K
Vor Inbetriebnahme ist das Gegenlager nachzuschmieren, bis das Fett am Abdichtprofil bzw. an der
Spaltdichtung austritt.
Weitere verwendbare Öl- und Fettsorten von anderen Herstellern siehe Schmierstoffempfehlung.

Empfehlung für Wartungstermine

Öl-Kontrolle: Wöchentlich. Ölstand nur bei stillstehendem Getriebe prüfen.
Erster Ölwechsel nach 200, dann alle 3000 Betriebsstunden, mindestens jedoch alle 3 Jahre.
Intervalle beziehen sich auf die in der Einbauzeichnung angegebenen Betriebstemperaturen.
Ölwechsel möglichst in betriebswarmen Zustand vornehmen.
Bei niedriger Umgebungstemperatur sollte mit einer erwärmten Teilmenge Neuöl gespült werden, damit
möglicher Abrieb bzw. Verunreinigungen abfließen können.
Schmierintervalle: Wöchentlich oder vor Wiederinbetriebnahme der Seilwinde.

190000751.d.doc Seite 1
SCHMIERSTOFFEMPFEHLUNG
Auswahltabelle

Schmieröl Auswahl Schmierfett Auswahl

nach DIN 51502

SCHMIERÖL, DIN 51517 SCHMIERFETT
BEZEICHNUNG NACH DIN
CLP PAO 220 DIN 51825 KP2K

ARAL ARAL DEGOL PAS 220 ARAL FETT HLP 2

AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP

BP ENERSYN HTX 220 BP ENERGR. LS EP 2

CASTROL SPHEEROL
CASTROL ---
EPL 2 GREASE

DEA DEA UBTOR HCLP 220 ---

ELF --- ELF EPEXA 2

ESSO --- ESSO BEACON 2 EP

FUCHS --- FUCHS RENOLIT FEP 2

GULF --- GULF CROWN GREASE NO.2

MOBIL MOBIL SHC 630 MOBILUX 2 EP

SHELL OMALA HD 220 SHELL ALVANIA EP 2

Achtung: Synthetisches Getriebeöl auf PAO-Basis darf nicht mit

synthetischem Getriebeöl auf Polyglykolbasis gemischt werden.
Ölwechsel- und Fettschmierintervalle siehe Wartungsanleitung.

190000752.d.doc Seite 1
GETRIEBEINSPEKTION
Getriebeölanalyse - Vorbeugende Instandhaltung
Überwachungsmechanismen bei Maschinen und Getrieben gewinnen immer mehr an Bedeutung, denn die
Anforderungen und Betriebsbedingungen sind oft anders als der Konstrukteur sie vorsah.
Durch systematische Öluntersuchungen, in regelmäßigen Intervallen durchgeführt, wird eine trendmäßig
verlässliche Diagnose über die Verschleißentwicklung und beginnenden Schaden möglich. Entscheidend
wird sein ob das jeweilige, in der Schmierstoffempfehlung zugelassene, Öl tatsächlich immer verwendet
wird.

Wozu Ölanalysen?

Frühdiagnose von Schäden:

Verschleißpartikel „schweben“ im Öl. Sie können durch die Ölanalyse festgestellt werden und liefern einen
Hinweis auf den Verschleiß des Bauteils von dem sie abgetragen wurden.

Zustandsabhängige Instandhaltung:
Ein Schaden, welcher durch die Ölanalyse frühzeitig erkannt wird, bedeutet geringere Reparatur- und
Stillstandskosten.

Kostengünstige Schadensanalyse:
Eine Aussage über die mögliche Schadensursache wird durch die kostengünstige Öluntersuchung möglich.
Spuren von Verunreinigungen durch Staub und Wasser, Vermischung mit anderen Ölen, Anteil von
Verschleißmetallen sowie Veränderungen des Ölstandes lassen eine gezielte frühzeitige Erkennung von
Schäden zu.

Einfache Überwachung:
Um eine gezielte Aussage über den Zustand des Getriebes zu erhalten, wird durch regelmäßig
durchgeführte Ölanalysen eine Teildemontage oder Komplettdemontage überflüssig.

Beeinflussende Störfaktoren des Schmieröles:

Verschleißmetalle, Verunreinigungen, Veränderung des Ölstandes und der Additive können die Wirkung des
verwendeten Schmieröles ganz wesentlich negativ beeinflussen. In Ölanalysen, durchgeführt von einem
autorisierten Labor, werden die Werte über Verschleißmetalle, Verunreinigungen etc. erfasst.
Entsprechend den zur Verfügung gestellten Daten und Informationen wird die Analyse kommentiert.
Je genauer die Angaben über das verwendete Öl, die Einsatzdauer sowie die Einsatzbedingungen sind,
desto aussagefähiger und gezielter sind in der Konsequenz vorbeugende Maßnahmen möglich.
Es gibt keine verlässlichen Vergleichs- und Grenzwerte was Verschleißmetalle und Verunreinigungen
betrifft. Ein entscheidender Faktor ist immer die Ölmenge aus der die Ölprobe stammt.
Eine verlässliche Diagnose ist nur von einem kompetenten Labor möglich. Extrem hoch erscheinende
Ergebnisse in der Auswertung müssen nicht unbedingt mit einem beginnenden Schaden gleichgesetzt
werden.

190000781.d.doc Seite 1
In der Gesamtbeurteilung des prüfenden Laboranten sind alle festgestellten Werte durch dessen Erfahrung
in der richtigen Zuordnung berücksichtigt. Ölanalysen, in regelmäßigen Intervallen durchgeführt, lassen
trendmäßig einen sicheren Verschleißwert bzw. Rückschlüsse auf einen beginnenden Schaden eines
bestimmten Bauteiles zu.
Jedes Getriebe hat, entsprechend seiner Einsatzbedingungen, sein eigenes Verschleißverhalten.
Werden magnetisierbare Partikel größer 5 µm in einer Analyse festgestellt, so liegt mit sehr großer
Wahrscheinlichkeit eine beginnende Pittingbildung eines Bauteils vor.
Partikel in der Größenordnung von 40 µm sind im klaren Öl mit dem Auge erkennbar. Ist dies der Fall, so
kann mit Sicherheit davon ausgegangen werden, dass im Getriebe ein fortgeschrittener Schaden vorliegt.

Ziehen der Ölprobe:

Eine sichere, aussagefähige Diagnose einer Ölprobe hängt entscheidend von der Art der Entnahme der
Probe ab.
Das Ziehen der Ölprobe muss immer in der selben Art und Weise erfolgen. Prinzipiell soll das Öl zumindest
handwarm beim Ziehen sein. Ist die Möglichkeit gegeben, muss das zu analysierende Öl aus etwa der Mitte
des Ölspiegels gezogen werden.
Bei Windengetrieben, wo kein Zugriff auf den Ölspiegel möglich ist, wird das zu analysierende Öl aus der
Ölablassleitung aufgefangen. Es sind hier etwa 1-2 l Öl in einem Auffangbehälter abzulassen und aus dem
abfließenden Öl eine Probemenge aufzufangen.
Bei Drehwerksgetrieben gestaltet sich ein Zugriff auf den optimalen Ölspiegel ebenfalls schwierig. Auch hier
empfehlen wir, durch Entfernen einer zugänglichen Ölablass-Schraube eine Teilmenge Öl abzulassen und
eine Ölprobe aus dem abfließenden Öl aufzufangen.

190000781.d.doc Seite 2
ANZUGSMOMENTE
Anzugsmomente für Befestigungsschrauben von M 4 bis M 36 und für
Festigkeitsklassen 8.8, 10.9 und 12.9 bei Reibungszahl 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

• Die angegebenen Anzugsmomente sind Maximalwerte.

• Schrauben gesichert mit Loctite Typ 242.
• Verbindungsflächen an den Getriebeteilen mit Loctite Typ 640 abgedichtet.
• Planflächen an der Haltebremse mit Loctite Type 573 abgedichtet (siehe Bild).
• Verschraubungsgewinde der Rohrleitungen und die Verbindungsfläche des Antriebsmotors zum
Getriebe mit Loctite Typ 572 abgedichtet.

• Anwendervorschriften der Firma Loctite beachten!

Loctite Type 573

190000159.d.doc Seite 1
INSTALLATION INSTRUCTION
General
Please also note the indications in our installation drawing.
The ZOLLERN rope winch is supplied completely assembled.
For installation of the winch dismount the flange.
Before assembly, verify the steel construction of the winch according to our installation drawing.
The screw-on-surfaces have to be worked properly to the same level.

Disassembly
Flange and torque measuring shaft:

On delivery the parts Pos. 2 (toothed disc), Pos. 5 (measuring shaft), Pos. 10 (sealing ring) and Pos. 7
(gear wheel) are enclosed.

• Switch Rope Winch Pos. 1 without load

• Disassemble cover Pos. 9
• Remove circlip Pos. 4
• Disassemble Cover Pos. 6
• Remove flange Pos. 8

Assembly
Please note installation position of winch according to our installation drawing!
Clean all screw-on-surfaces and tape holes at the gear and the flange metallically clean.
Secure with Loctite Type 242 all ZOLLERN screw-on-connections which were loosened during disassembly.
Please note Loctite-processing- information.
Strength classes and torque moments for screws see installation drawing.
Turn the marking "O" (= top) at gear flange to the position indicated in the installation drawing.
Put rope winch into steel frame.
Centre gear in the steel frame.
Fix gear with screws.
Mount flange and torque measuring shaft
Attention:
Mount toothed disc Pos. 7 horizontally!
Connect cable outlet with crane electrics.
Installation position of flange see installation drawing “view Z”

1000000000318.gb.doc Seite 1
 • Fit equally flange Pos. 8
• Fit toothed disc Pos. 7
• Mount cover Pos. 6
• Push torque shaft Pos. 5 with sealing ring
Pos. 10 carefully into the toothing
• Fit circlip Pos. 4
• Screw plug Pos. 3
• Mount and fix toothed disc Pos. 2 onto the
end limit switch
• Fix end limit switch in flange Pos. 8

Mount oil and ventilation pipe.

Fix oil gauge pipe with clamp and screws at steel frame.
Place oil gauge vertically so that the "max."-groove at oil dipstick is mid gear.
Check oil level with oil dipstick.
Refill oil if necessary.
If the 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.
Remove transport cover off the motor flange.
Connect brake line (see installation drawing).
Release hydraulically multiple disc 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 surfaces.
Fix motor with screws.
Before test-running, fill motor flange completely with gear oil.
Control 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.
Fix rope with pressure screws.
Secure pressure screws accordingly.

1000000000318.gb.doc Seite 2
MAINTENANCE INSTRUCTION
Lubrication
The Zollern planetary gear of rope winch has splashed lubrication.
Oil filling ex factory :MOBIL SHC 630
Description :synthetically PAO-oil
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 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.

190000751.gb.doc Seite 1
RECOMMENDATION FOR LUBRICANTS
Choice list

CHOOSEN ACCORDING CHOOSEN ACCORDING

TO DIN 51502
OIL, DIN 51517 GREASE; DIN 51825
DESCRIPTION ACC. TO DIN
CLP PAO 220 KP2K

ARAL ARAL DEGOL PAS 220 ARAL GREASE HLP 2

AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP

BP ENERSYN HTX 220 BP ENERGR. LS EP 2

CASTROL SPHEEROL EPL 2

CASTROL ---
GREASE

DEA DEA UBTOR HCLP 220

ELF --- ELF EPEXA 2

ESSO --- ESSO BEACON 2 EP

FUCHS --- FUCHS RENOLIT FEP 2

GULF --- GULF CROWN GREASE NO.2

MOBIL MOBIL SHC 630 MOBILUX 2 EP

SHELL OMALA HD 220 SHELL ALVANIA EP 2

Attention: Synthetically gear oil on PAO-base may not be mixed with

synthetically gear oil on polyglycol base.
Oil change and greasing intervals see maintenance instruction.

190000752.gb.doc Seite 1
GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Surveying mechanisms for machines and gearboxes get more and more important, because the
requirements 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
recommendation, 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
construction 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
resulting 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
analysing 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.

190000781.gb.doc Seite 1
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.

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.

190000781.gb.doc Seite 2
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 (see picture).
• 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

Loctite Type 573

190000159.gb.doc Seite 1
SERVICE BLATT
SERVICE FORM
FEUILLE DE SERVICE

Getriebe – Typ: ZHP 4.29

Gear Type:
Réducteur Type:

Geräte – Nr.: 0 4.29 10740

Aggregate No:
Appareil No:

Serien – Nr.: 101 - 104

Serial No:
Série No:

Auftrags – Nr.: 6789250 vom 29.10.2003

Order No:
Commande No:

Firma : Neuenfelder Maschinenfabrik GmbH

Company:
Société:
Anschrift : Neuenfelder Fährdeich 120
Address: D-21129 Hamburg
Adresse:
Abteilung : zu Hd. Hr. Holler
Department:
Service:

Bestell – Nr.: 310210 vom 21.10.2003 Sach – Nr.: 1391GT857

Order No: Ident. No:
Commande No Produit No:
Geräte – Typ: --- Pos – Nr.: ---
Aggregate Type: Pos. No:
Appareil Type: Pos. No:
Bau / Komm – Nr. --- Projekt – Nr.: ---
Constr. No: Project No:
Constr. Spéc. No: Projet No:

Lieferumfang: 1-fach deutsch/englisch per E-Mail 29.01.2004 Eh/KD

Fürstlich Hohenzollernsche Werke Telefon: 07586 / 959 - 0
Laucherthal GmbH & Co.KG Telefax: 07586 / 959 - 710
Heustrasse 1 E-Mail: service@zollern.de
D-88518 Herbertingen Homepage: www.zollern.de
190014706.doc Seite 2
INHALT
CONTENS

Typ Geräte-Nr. Bezeichnung Description Serien-Nr.

Type Aggregate-No. Serial-No.

ZHP 4.29 0 4.29 10740 Seilwinde Rope winch 101 - 104

Dokument-Nr. Bezeichnung Description

Document-No.

190014706 Service-Blatt Service form

042910740 Einbauzeichnung Installation-drawing
Seilwinde Rope winch
Getriebe Gear
Seiltrommel Rope drum
Flansch Flange
Antrieb Drive
Hydrauliklamellenbremse Hyd. multiple disc brake
Ölleitung Oil pipe
193008877 Ersatzteilliste Spare part list
190000297 Einbauanleitung Installation instruction
190000751 Wartungsanleitung Maintenance instruction
190000752 Schmierstoffempfehlung Recommendation for lubricants
190000781 Getriebeinspektion Gearbox inspection
190000159 Anzugsmomente Tightening torques

Fürstlich Hohenzollernsche Werke Telefon: 07586 / 959 - 0

Laucherthal GmbH & Co.KG Telefax: 07586 / 959 - 710
Heustrasse 1 E-Mail: service@zollern.de
D-88518 Herbertingen Homepage: www.zollern.de
190014706.doc Seite 1
ERSATZTEILLISTE
SPARE PART LIST

193008877

Typ Geräte-Nr. Bezeichnung Description Serien-Nr.

Type Aggregate-No. Serial-No.

ZHP 4.29 0 4.29 10740 Seilwinde Rope winch 101 - 104

BEI ERSATZTEILBESTELLUNG TYP, GERÄTE-NR, SER.-NR UND TEILE-NR ANGEBEN!
IF YOU ORDER SPARE PARTS INDICATE TYPE, AGGREGATE-NO, SERIAL-NO AND PART-NO!

Pos-Nr. Stück Teile-Nr. Bezeichnung Description

Pos-No. Quantity Part-No.

1 1,0 193008878 Getriebe Gear

21 1,0 193000425 Seiltrommel Rope drum
22 1,0 193006169 Flansch Flange
24 1,0 193008880 Antrieb Drive
60 1,0 193006188 Ölleitung Oil pipe

Gewicht :1 684,0 kg Ölmenge :16,0 l

Weight : Oil quantity :
193008877.doc Seite 1
 DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIEBS-GMBH + CO
-------- ------------------------------- HEUSTRASSE 1
29.01.04 S P A R E - P A R T - L I S T D-88518 HERBERTINGEN/WÜRTT.

ZHP 4.29 - 042910740 193008877 GEWICHT ÖLEINFÜLLMENGE

WEIGHT OIL QTY
SERIEN - NR. 101 - 104 SERIAL - NO. 101 - 104 1.684,000 KG 16,0 LITER

************************************************************************************************* SEITE - 1
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************

Pos-Nr. Stück Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH Technische - Daten

POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
______________________________________________________________________________________________________________________
1 1,0 193008878 GETRIEBE GEAR

-----------------------------------------------------------------------------------------------------------
1 / 1 1,0 193008879 ABTRIEB OUTPUT DRIVE

1 / 1/ 1 1,0 242901900 PLANETENTRÄGER PLANETARY CARRIER

1 / 1/ 3 1,0 242901834 LAGERRING BEARING RING
1 / 1/ 6 1,0 242901790 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING
1 / 1/ 14 1,0 242901835 SCHEIBE WASHER
1 / 1/ 21 18,0 411200023 ZYLINDERSCHRAUBE BOLTS M 24x150 10.9 DIN 912
1 / 1/ 24 4,0 411230072 ZYLINDERSCHRAUBE BOLTS M 12x 20 8.8 DIN 912
1 / 1/ 25 4,0 403900049 FEDERRING LOCK WASHER 12,20x 18,00x 2,50-
1 / 1/ 27 18,0 240700320 SCHEIBE WASHER 25,00x 37,00x 4,00
1 / 1/ 31 1,0 441100070 WELLENDICHTRING SHAFT SEALING RING 460x500x20B2---/-35/ DIN3760
1 / 1/ 41 1,0 442000005 PROFILSCHNUR SEALING RING 10,0x36/------------
1 / 1/ 42 1,0 542000010 BEFESTIGUNGSBAND STEEL BAND PF 6180
1 / 1/ 43 1,0 542100010 SCHLOß NUT 8x0,4---------------
1 / 1/ 51 1,0 453300171 ZYLINDERROLLENLAGER CYLINDER ROLLER BEARING 375x444,820x48,00 55R24D36
1 / 1/ 53 1,0 453000212 RILLENKUGELLAGER BALL BEARING 220x340x56,00 DIN 625
1 / 1/ 60 1,0 403100082 SICHERUNGSRING CIR CLIP 260x---x5,00 WELLE-- DIN 471
1 / 1/ 61 1,0 403100078 SICHERUNGSRING CIR CLIP 220x---x5,00 WELLE-- DIN 471
1 / 1/ 62 1,0 403200212 SICHERUNGSRING CIR CLIP ---x340x6,00 BOHRUNG DIN 472
1 / 1/201 1,0 242901838 ZWISCHENFLANSCH INTERMEDIATE FLANGE
1 / 1/202 24,0 421200110 ZYLINDERSCHRAUBE BOLTS M 24x 60 10.9 DIN 912
1 / 1/203 24,0 240700320 SCHEIBE WASHER 25,00x 37,00x 4,00
1 / 1/444 1,0 403200045 SICHERUNGSRING CIR CLIP ---x75x2,50 BOHRUNG DIN 472
1 / 1/473 14,0 404300241 PAßSCHEIBE WASHER 60,00x 75,00x 1,00
1 / 1/491 1,0 230001543 SCHEIBE WASHER
1 / 1/951 2,0 414030001 VERSCHLUßSCHRAUBE BOLTS M 10x 1,0 ZN DIN 908
1 / 1/952 2,0 441000207 FLACHDICHTRING SEALING RING A 10,00x 13,50x 1,00

-----------------------------------------------------------------------------------------------------------
1 / 11 1,0 100100712 PLANETENSTUFE PLANETARY STAGE

1 / 11/ 1 1,0 233900001 INNENRAD INTERNAL WHEEL

1 / 11/ 3 1,0 242901904 SONNENRAD SUN WHEEL

-----------------------------------------------------------------------------------------------------------
1 / 21 1,0 100100678 PLANETENSTUFE PLANETARY STAGE

1 / 21/ 1 1,0 232700277 INNENRAD INTERNAL WHEEL

1 / 21/ 3 1,0 242701372 SONNENRAD SUN WHEEL

-----------------------------------------------------------------------------------------------------------
1 / 24 1,0 100100757 PLANETENTRÄGER PLANETARY CARRIER

1 / 24/ 1 1,0 232700803 PLANETENTRÄGER PLANETARY CARRIER

1 / 24/ 3 1,0 403100062 SICHERUNGSRING CIR CLIP 130x---x4,00 WELLE-- DIN 471
1 / 24/ 4 1,0 503100059 SPRENGRING CIR CLIP 130x---x2,50 WELLE-- DIN ----
 DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIEBS-GMBH + CO
-------- ------------------------------- HEUSTRASSE 1
29.01.04 S P A R E - P A R T - L I S T D-88518 HERBERTINGEN/WÜRTT.

ZHP 4.29 - 042910740 193008877 GEWICHT ÖLEINFÜLLMENGE

WEIGHT OIL QTY
SERIEN - NR. 101 - 104 SERIAL - NO. 101 - 104 1.684,000 KG 16,0 LITER

************************************************************************************************* SEITE - 2
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************

Pos-Nr. Stück Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH Technische - Daten

POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
______________________________________________________________________________________________________________________

-----------------------------------------------------------------------------------------------------------
1 / 27 1,0 100020509 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING

1 / 27/ 1 1,0 232700551 ZWISCHENGEHÄUSE INTERMEDIATE HOUSING

1 / 27/ 2 18,0 411230434 ZYLINDERSCHRAUBE BOLTS M 20x130 8.8 DIN 912

-----------------------------------------------------------------------------------------------------------
1 / 31 1,0 100100758 PLANETENSTUFE PLANETARY STAGE

1 / 31/ 1 1,0 232500555 INNENRAD INTERNAL WHEEL

1 / 31/ 3 1,0 242500960 SONNENRAD SUN WHEEL

-----------------------------------------------------------------------------------------------------------
1 / 34 1,0 100010519 PLANETENTRÄGER PLANETARY CARRIER

1 / 34/ 1 1,0 232500842 PLANETENTRÄGER PLANETARY CARRIER

1 / 34/ 3 1,0 403100050 SICHERUNGSRING CIR CLIP 80x---x2,50 WELLE-- DIN 471

-----------------------------------------------------------------------------------------------------------
1 / 39 1,0 100020506 DECKEL COVER

1 / 39/ 1 1,0 242700943 DECKEL COVER

1 / 39/ 11 18,0 411230340 ZYLINDERSCHRAUBE BOLTS M 16x110 8.8 DIN 912
1 / 39/ 21 1,0 453000265 RILLENKUGELLAGER BALL BEARING 25x62x17,00 DIN 625

-----------------------------------------------------------------------------------------------------------
21 1,0 193000425 SEILTROMMEL CABLE DRUM

21 / 1 1,0 242901319 SEILTROMMEL ROPE DRUM

21 / 5 1,0 234705567 SEILBLECH CABLE FIXING AND WEDGES
21 / 20 24,0 411130574 SECHSKANTSCHRAUBE BOLTS M 24x 60 8.8 DIN 933
21 / 21 24,0 411230110 ZYLINDERSCHRAUBE BOLTS M 24x 60 8.8 DIN 912
21 / 23 5,0 412300803 GEWINDESTIFT SEALING SCREW M 20x 50 FLECKBE.45H DIN 915

-----------------------------------------------------------------------------------------------------------
22 1,0 193006169 FLANSCH FLANGE

22 / 1 1,0 242900831 FLANSCH FLANGE

22 / 2 1,0 242901160 FLANSCHPLATTE FLANGE PLATE
22 / 3 1,0 234705440 SCHEIBE WASHER
22 / 4 1,0 403200078 SICHERUNGSRING CIR CLIP ---x200x4,00 BOHRUNG DIN 472
22 / 5 1,0 688100003 FILZDICHTSTREIFEN FELT STRIP 5,0x 4,0-----------
22 / 6 1,0 453400072 PENDELROLLENLAGER PENDULUM ROLLER BEARING 110x200x53,00 DIN 635
22 / 8 1,0 242900950 DECKEL COVER
22 / 9 1,0 242200389 MITNEHMER DRIVER
22 / 10 1,0 411230417 ZYLINDERSCHRAUBE BOLTS M 8x 85 8.8 DIN 912
22 / 12 1,0 417000094 STIFT PINS 4,0x 16,0 DIN1481
22 / 13 1,0 417000094 STIFT PINS 4,0x 16,0 DIN1481
22 / 14 1,0 412300409 GEWINDESTIFT SEALING SCREW M 6x 6 45H DIN 913
 DATUM E R S A T Z T E I L - L I S T E ZOLLERN VERTRIEBS-GMBH + CO
-------- ------------------------------- HEUSTRASSE 1
29.01.04 S P A R E - P A R T - L I S T D-88518 HERBERTINGEN/WÜRTT.

ZHP 4.29 - 042910740 193008877 GEWICHT ÖLEINFÜLLMENGE

WEIGHT OIL QTY
SERIEN - NR. 101 - 104 SERIAL - NO. 101 - 104 1.684,000 KG 16,0 LITER

************************************************************************************************* SEITE - 3
ACHTUNG : BEI ERSATZTEILBESTELLUNG TYP UND SERIEN - NUMMER ANGEBEN
ATTENTION : IF YOU ORDER SPARE PARTS PLEASE IINDICATE TYPE AND SERIAL NUMBER
**********************************************************************************************************************

Pos-Nr. Stück Teile-Nr Bezeichnung - Deutsch BEZEICHNUNG - ENGLISCH Technische - Daten

POS-NO. QTY PART - NR. DESCRIPTION - GERMAN DESCRIPTION - ENGLISH TECHNICAL - DATA
______________________________________________________________________________________________________________________
22 /401 1,0 449900003 KEGELSCHMIERNIPPEL GREASE NIPPLE M 10x1,00-KEGEL A- DIN71412
22 /421 1,0 230001181 DECKEL COVER
22 /422 3,0 411230035 ZYLINDERSCHRAUBE CHEESEHEAD SCREW M 6x 12 8.8 DIN 912

-----------------------------------------------------------------------------------------------------------
24 1,0 193008880 ANTRIEB DRIVE

24 / 1 1,0 242401088 BREMSFLANSCH BRAKE FLANGE

-----------------------------------------------------------------------------------------------------------
24 / 4 1,0 193002958 ANTRIEBSHÜLSE DRIVING SLEEVE

24 / 7 1,0 230000217 MOTORFLANSCH MOTOR FLANGE

24 / 18 1,0 242400085 DECKEL COVER
24 / 20 8,0 411230076 ZYLINDERSCHRAUBE BOLTS M 12x 40 8.8 DIN 912
24 / 22 12,0 411230341 ZYLINDERSCHRAUBE BOLTS M 12x150 8.8 DIN 912
24 / 25 4,0 411130519 SECHSKANTSCHRAUBE HEXAGON BOLT M 16x 25 8.8 DIN 933
24 / 30 1,0 453000039 RILLENKUGELLAGER BALL BEARING 90x140x24,00 DIN 625
24 / 40 1,0 403200066 SICHERUNGSRING CIR CLIP ---x140x4,00 BOHRUNG DIN 472
24 / 41 1,0 403100054 SICHERUNGSRING CIR CLIP 90x---x3,00 WELLE-- DIN 471
24 / 43 2,0 403200029 SICHERUNGSRING CIR CLIP ---x42x1,75 BOHRUNG DIN 472
24 / 50 1,0 441100573 WELLENDICHTRING SHAFT SEALING RING 100x130x12BA---/-35/ DIN3760
24 / 53 1,0 441100665 WELLENDICHTRING SHAFT SEALING RING 110x130x8 B1---/-35/ DIN3760
24 / 59 1,0 541000393 O-RING SEALING RING 180,00x3,00 /120/--
24 / 60 3,0 414030001 VERSCHLUßSCHRAUBE BOLTS M 10x 1,0 ZN DIN 908
24 / 61 3,0 441000207 FLACHDICHTRING SEALING RING A 10,00x 13,50x 1,00
24 / 64 1,0 414030005 VERSCHLUßSCHRAUBE BOLTS M 18x 1,5 ZN DIN 908
24 / 65 1,0 441000213 FLACHDICHTRING SEALING RING A 18,00x 22,00x 1,50
24 / 66 1,0 242400143 DECKEL COVER
24 / 69 1,0 543400040 ENTLÜFTUNGSVENTIL AIR FILTER M 10x1,0 0,02B
24 / 70 6,0 404300228 PAßSCHEIBE WASHER 36,00x 45,00x 1,00
24 / 75 16,0 402100310 DRUCKFEDER SPRINGS
24 / 76 16,0 402100311 DRUCKFEDER SPRINGS
24 / 79 4,0 404130013 SCHEIBE WASHER 17,00x 30,00x 3,00
24 / 95 1,0 506701093 ÖLDRUCKEINHEIT HYDR. PART FOR DISC BRAKE
24 / 96 1,0 506700224 LAMELLENGEHÄUSE CLUTCH PLATE CARRIER
24 / 97 8,0 506700162 AUßENLAMELLE MULTIPLE DISC DIN 867RAD-NUT-L2,30
24 / 98 7,0 506700163 INNENLAMELLE MULTIPLE DISC DIN 867--------L2,20
24 /611 1,0 540100869 SCHWENKVERSCHRAUBUNG THREADED JOINT CONNECTION M12x1,5--DKA 12-315B
24 /612 0,2 620100005 ROHRROHTEIL PIPING PIECE
24 /613 1,0 540100073 GERADE VERSCHRAUBUNG THREADED JOINT CONNECTION ----------------630B
24 /614 1,0 541800005 VERSCHLUßSTOPFEN SEALING PLUG ---,--x 8,40x 6,00

-----------------------------------------------------------------------------------------------------------
60 1,0 193006188 ÖLLEITUNG OIL PIPE

______________________________________________________________________________________________________________________

<-- Ende der Stückliste -->

EINBAUANLEITUNG
General
Beachten Sie hierzu auch die Angaben auf unserer Einbauzeichnung!
Die ZOLLERN Seilwinde wird fertig montiert ausgeliefert.
Zum Einbau der Winde muss der Flansch demontiert werden.
Prüfen Sie vor der Montage der Winde Ihren Stahlbau gemäß unserer Einbauzeichnung.
Die Anschraubflächen müssen in gleicher Ebene sauber bearbeitet sein.

Demontage
Flansch: Schraube am Mitnehmer demontieren.
Flansch mit Mitnehmer abziehen.

Montage
Einbaulage der Winde gemäß unserer Einbauzeichnung beachten!
Alle Anschraubflächen und Gewindebohrungen am Getriebe und am Flansch metallisch blank reinigen.
Alle Zollern Schraubverbindungen, die bei der Demontage gelöst wurden, mit Loctite Typ 242 sichern -
Loctite-Verarbeitungsvorschriften beachten!
Festigkeitsklassen und Anzugsmomente der Schrauben siehe Einbauzeichnung.
Markierung "O" (oben) am Getriebeflansch auf die in der Einbauzeichnung angegebene Stelle drehen.
Seilwinde in Stahlbau einfahren.
Getriebe im Stahlbau zentrieren.
Getriebe mit Schrauben befestigen.
Flansch gleichmäßig und gerade aufziehen und im Stahlbau zentrieren.
Keine Gewalt anwenden!
Flansch mit Schrauben befestigen.
Mitnehmer einsetzen.
Achtung: Mitnehmer und Gegenstück sind über einen Spannstift formschlüssig verbunden.
Mitnehmer drehen bis Spannstift einlocht.
Mitnehmer mit Schraube befestigen.
Öl- und Entlüftungsleitung montieren.
Ölstandsrohr mit Rohrschellen und Schrauben am Stahlbau befestigen.
Das Ölstandsrohr vertikal so platzieren, dass die "MAX" - Kerbe am Ölmessstab Mitte Getriebe ist.
Ölstand mit Ölmessstab überprüfen.
Gegebenenfalls Öl nachfüllen.
Ist die Winde ohne Öl ausgeliefert, so weist ein Aufkleber darauf hin.
Ölsorte siehe Typenschild bzw. Wartungsanleitung.
Ölmenge siehe Typenschild bzw. Ersatzteilliste.
Transportdeckel am Motorflansch demontieren.
Bremsleitung anschließen (siehe Einbauzeichnung).
Lamellenbremse hydraulisch lüften.
Die Antriebshülse in der Antriebseinheit muss sich leicht durchdrehen lassen.
Verschlussstopfen von der Antriebshülse der Antriebseinheit abziehen.
Die Antriebshülse wird zum Schutz vor Passungsrost vom Getriebe aus mit Getriebeöl versorgt. Der
Verschlussstopfen verhindert, dass sich der Motorflansch vor der Montage des Motors mit Öl füllt.

190000297.d.doc Seite 1
 Achtung: Motorwelle fettfrei!
Motor im Motorflansch zentrieren.
Verbindungsflächen abdichten.
Motor mit Schrauben befestigen.
Vor dem Probelauf den Motorflansch mit Getriebeöl ganz füllen.
Seilwinde mit laufendem Motor auf Funktion überprüfen.
Insbesondere die Steuerung und Funktion der Haltebremse und des Antriebmotors überprüfen.
Ölstand nach Probelauf nochmals mit Ölmessstab überprüfen.
Während des Probelaufs gleicht sich der Ölstand im Getriebe und Motorflansch aus und füllt dadurch den
Raum zur Motorwelle langsam mit Getriebeöl. Deshalb kann sich der Ölstand vermindern.
Gegebenenfalls Öl nachfüllen.
Seil einfädeln.
Seil mit Druckschrauben befestigen.
Druckschrauben entsprechend sichern.

190000297.d.doc Seite 2
WARTUNGSANLEITUNG
Schmierung
Das Zollern-Seilwindengetriebe hat Tauchschmierung.
Ölfüllung ab Werk :MOBIL SHC 630
Bezeichnung nach DIN :synthetisches PAO-Schmieröl
Die Öleinfüllmenge ist auf dem Typenschild vermerkt. Wird das Getriebe ohne Öl ausgeliefert, ist mit einem
Aufkleber darauf hingewiesen.

Das Wälzlager am Gegenlagerflansch ist mit Schmierfett gefüllt.

Fettfüllung ab Werk :AVIA AVIALITH 2 EP
Auswahl nach DIN :DIN 51502
Bezeichnung nach DIN :Schmierfett, DIN 51825-KP2K
Vor Inbetriebnahme ist das Gegenlager nachzuschmieren, bis das Fett am Abdichtprofil bzw. an der
Spaltdichtung austritt.
Weitere verwendbare Öl- und Fettsorten von anderen Herstellern siehe Schmierstoffempfehlung.

Empfehlung für Wartungstermine

Öl-Kontrolle: Wöchentlich. Ölstand nur bei stillstehendem Getriebe prüfen.
Erster Ölwechsel nach 200, dann alle 3000 Betriebsstunden, mindestens jedoch alle 3 Jahre.
Intervalle beziehen sich auf die in der Einbauzeichnung angegebenen Betriebstemperaturen.
Ölwechsel möglichst in betriebswarmen Zustand vornehmen.
Bei niedriger Umgebungstemperatur sollte mit einer erwärmten Teilmenge Neuöl gespült werden, damit
möglicher Abrieb bzw. Verunreinigungen abfließen können.
Schmierintervalle: Wöchentlich oder vor Wiederinbetriebnahme der Seilwinde.

190000751.d.doc Seite 1
SCHMIERSTOFFEMPFEHLUNG
Auswahltabelle

SCHMIERÖL AUSWAHL SCHMIERFETT AUSWAHL

NACH DIN 51502
SCHMIERÖL, DIN 51517 SCHMIERFETT, DIN 51825
BEZEICHNUNG NACH DIN
CLP PAO 220 KP2K

ARAL ARAL DEGOL PAS 220 ARAL FETT HLP 2

AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP

BP ENERSYN HTX 220 BP ENERGR. LS EP 2

CASTROL SPHEEROL
CASTROL ---
EPL 2 GREASE

DEA DEA UBTOR HCLP 220 ---

ELF --- ELF EPEXA 2

ESSO --- ESSO BEACON 2 EP

FUCHS --- FUCHS RENOLIT FEP 2

GULF --- GULF CROWN GREASE NO.2

MOBIL MOBIL SHC 630 MOBILUX 2 EP

SHELL OMALA HD 220 SHELL ALVANIA EP 2

Achtung: Synthetisches Getriebeöl auf PAO-Basis darf nicht mit

synthetischem Getriebeöl auf Polyglykolbasis gemischt werden.
Ölwechsel- und Fettschmierintervalle siehe Wartungsanleitung.

190000752.d.doc Seite 1
GETRIEBEINSPEKTION
Getriebeölanalyse - Vorbeugende Instandhaltung
Überwachungsmechanismen bei Maschinen und Getrieben gewinnen immer mehr an Bedeutung, denn die
Anforderungen und Betriebsbedingungen sind oft anders als der Konstrukteur sie vorsah.
Durch systematische Öluntersuchungen, in regelmäßigen Intervallen durchgeführt, wird eine trendmäßig
verlässliche Diagnose über die Verschleißentwicklung und beginnenden Schaden möglich. Entscheidend
wird sein ob das jeweilige, in der Schmierstoffempfehlung zugelassene, Öl tatsächlich immer verwendet
wird.

Wozu Ölanalysen?

Frühdiagnose von Schäden:

Verschleißpartikel „schweben“ im Öl. Sie können durch die Ölanalyse festgestellt werden und liefern einen
Hinweis auf den Verschleiß des Bauteils von dem sie abgetragen wurden.

Zustandsabhängige Instandhaltung:
Ein Schaden, welcher durch die Ölanalyse frühzeitig erkannt wird, bedeutet geringere Reparatur- und
Stillstandskosten.

Kostengünstige Schadensanalyse:
Eine Aussage über die mögliche Schadensursache wird durch die kostengünstige Öluntersuchung möglich.
Spuren von Verunreinigungen durch Staub und Wasser, Vermischung mit anderen Ölen, Anteil von
Verschleißmetallen sowie Veränderungen des Ölstandes lassen eine gezielte frühzeitige Erkennung von
Schäden zu.

Einfache Überwachung:
Um eine gezielte Aussage über den Zustand des Getriebes zu erhalten, wird durch regelmäßig
durchgeführte Ölanalysen eine Teildemontage oder Komplettdemontage überflüssig.

Beeinflussende Störfaktoren des Schmieröles:

Verschleißmetalle, Verunreinigungen, Veränderung des Ölstandes und der Additive können die Wirkung des
verwendeten Schmieröles ganz wesentlich negativ beeinflussen. In Ölanalysen, durchgeführt von einem
autorisierten Labor, werden die Werte über Verschleißmetalle, Verunreinigungen etc. erfasst.
Entsprechend den zur Verfügung gestellten Daten und Informationen wird die Analyse kommentiert.
Je genauer die Angaben über das verwendete Öl, die Einsatzdauer sowie die Einsatzbedingungen sind,
desto aussagefähiger und gezielter sind in der Konsequenz vorbeugende Maßnahmen möglich.
Es gibt keine verlässlichen Vergleichs- und Grenzwerte was Verschleißmetalle und Verunreinigungen
betrifft. Ein entscheidender Faktor ist immer die Ölmenge aus der die Ölprobe stammt.
Eine verlässliche Diagnose ist nur von einem kompetenten Labor möglich. Extrem hoch erscheinende
Ergebnisse in der Auswertung müssen nicht unbedingt mit einem beginnenden Schaden gleichgesetzt
werden.

190000781.d.doc Seite 1
In der Gesamtbeurteilung des prüfenden Laboranten sind alle festgestellten Werte durch dessen Erfahrung
in der richtigen Zuordnung berücksichtigt. Ölanalysen, in regelmäßigen Intervallen durchgeführt, lassen
trendmäßig einen sicheren Verschleißwert bzw. Rückschlüsse auf einen beginnenden Schaden eines
bestimmten Bauteiles zu.
Jedes Getriebe hat, entsprechend seiner Einsatzbedingungen, sein eigenes Verschleißverhalten.
Werden magnetisierbare Partikel größer 5 µm in einer Analyse festgestellt, so liegt mit sehr großer
Wahrscheinlichkeit eine beginnende Pittingbildung eines Bauteils vor.
Partikel in der Größenordnung von 40 µm sind im klaren Öl mit dem Auge erkennbar. Ist dies der Fall, so
kann mit Sicherheit davon ausgegangen werden, dass im Getriebe ein fortgeschrittener Schaden vorliegt.

Ziehen der Ölprobe:

Eine sichere, aussagefähige Diagnose einer Ölprobe hängt entscheidend von der Art der Entnahme der
Probe ab.
Das Ziehen der Ölprobe muss immer in der selben Art und Weise erfolgen. Prinzipiell soll das Öl zumindest
handwarm beim Ziehen sein. Ist die Möglichkeit gegeben, muss das zu analysierende Öl aus etwa der Mitte
des Ölspiegels gezogen werden.
Bei Windengetrieben, wo kein Zugriff auf den Ölspiegel möglich ist, wird das zu analysierende Öl aus der
Ölablassleitung aufgefangen. Es sind hier etwa 1-2 l Öl in einem Auffangbehälter abzulassen und aus dem
abfließenden Öl eine Probemenge aufzufangen.
Bei Drehwerksgetrieben gestaltet sich ein Zugriff auf den optimalen Ölspiegel ebenfalls schwierig. Auch hier
empfehlen wir, durch Entfernen einer zugänglichen Ölablass-Schraube eine Teilmenge Öl abzulassen und
eine Ölprobe aus dem abfließenden Öl aufzufangen.

190000781.d.doc Seite 2
ANZUGSMOMENTE
Anzugsmomente für Befestigungsschrauben von M 4 bis M 36 und für
Festigkeitsklassen 8.8, 10.9 und 12.9 bei Reibungszahl 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

• Die angegebenen Anzugsmomente sind Maximalwerte.

• Schrauben gesichert mit Loctite Typ 242.
• Verbindungsflächen an den Getriebeteilen mit Loctite Typ 640 abgedichtet.
• Planflächen an der Haltebremse mit Loctite Type 573 abgedichtet.
• Verschraubungsgewinde der Rohrleitungen und die Verbindungsfläche des Antriebsmotors zum
Getriebe mit Loctite Typ 572 abgedichtet.

• Anwendervorschriften der Firma Loctite beachten!

190000159.d.doc Seite 1
INSTALLATION INSTRUCTION
General
Please also note the indications in our installation drawing.
The ZOLLERN rope winch is supplied completely assembled.
For installation of the winch dismount the flange.
Before assembly, verify the steel construction of the winch according to our installation drawing.
The screw-on-surfaces have to be worked properly to the same level.

Disassembly
Flange: Dismount screw off driver.
Draw off flange with driver.

Assembly
Please note installation position of winch according to our installation drawing!
Clean all screw-on-surfaces and tape holes at the gear and the flange metallically clean.
Secure with Loctite Type 242 all ZOLLERN screw-on-connections which were loosened during disassembly.
Please note Loctite-processing- information.
Strength classes and torque moments for screws see installation drawing.
Turn the marking "O" (= top) at gear flange to the position indicated in the installation drawing.
Put rope winch into steel frame.
Centre gear in the steel frame.
Fix gear with screws.
Fit flange equally and straight and centre it in the steel frame.
Do not use force !
Fix flange with screws.
Insert driver.
Attention: Driver and counter piece are connected positive locked via a clamp pin.
Turn driver until clamp pin mortises.
Fix driver with screw.
Mount oil and ventilation pipe.
Fix oil gauge pipe with clamp and screws at steel frame.
Place oil gauge vertically so that the "max."-groove at oil dipstick is mid gear.
Check oil level with oil dipstick.
Refill oil if necessary.
If the 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.
Remove transport cover off the motor flange.
Connect brake line (see installation drawing).
Release hydraulically multiple disc 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.

190000297.gb.doc Seite 1
 Attention: Motor shaft grease-free!
Centre motor in the motor flange.
Seal connecting surfaces.
Fix motor with screws.
Before test-running, fill motor flange completely with gear oil.
Control 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.
Fix rope with pressure screws.
Secure pressure screws accordingly.

190000297.gb.doc Seite 2
MAINTENANCE INSTRUCTION
Lubrication
The Zollern planetary gear of rope winch has splashed lubrication.
Oil filling ex factory :MOBIL SHC 630
Description :synthetically PAO-oil
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 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.

190000751.gb.doc Seite 1
RECOMMENDATION FOR LUBRICANTS
Choice list

CHOOSEN ACCORDING CHOOSEN ACCORDING

TO DIN 51502
OIL, DIN 51517 GREASE; DIN 51825
DESCRIPTION ACC. TO DIN
CLP PAO 220 KP2K

ARAL ARAL DEGOL PAS 220 ARAL GREASE HLP 2

AVIA AVIA SYNTHOGEAR 220 EP AVIA AVIALITH 2 EP

BP ENERSYN HTX 220 BP ENERGR. LS EP 2

CASTROL SPHEEROL EPL 2

CASTROL ---
GREASE

DEA DEA UBTOR HCLP 220

ELF --- ELF EPEXA 2

ESSO --- ESSO BEACON 2 EP

FUCHS --- FUCHS RENOLIT FEP 2

GULF --- GULF CROWN GREASE NO.2

MOBIL MOBIL SHC 630 MOBILUX 2 EP

SHELL OMALA HD 220 SHELL ALVANIA EP 2

Attention: Synthetical gear oil on PAO-base may not be mixed with

synthetical gear oil on polyglycol base.
Oil change and greasing intervals see maintenance instruction.

190000752.gb.doc Seite 1
GEARBOX INSPECTION
Gear oil analyses - preventive maintenance
Surveying mechanisms for machines and gearboxes get more and more important, because the
requirements 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
recommendation, 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
construction 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
resulting 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
analysing 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.

190000781.gb.doc Seite 1
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.

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.

190000781.gb.doc Seite 2
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

190000159.gb.doc Seite 1
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39
GEARBOX DESCRIPTION RE 2523 Z2 P16Z10 141 F604L PAM REXROTH SPEC.NMF
GEARBOX CODE 91B8IP301410

Oil filling 17,5 l

Pagina 1
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR SUPPORT RE2520 Z2P GRU-2520-Z2P

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 PIGNONE INTEGR. M16 Z10 X0.5 PINION 1 02261236
2 ANELLO NILOS 22224 AV NILOS RING 1 415052100
3 CUSCINETTO RULLI BOTTE 23224 BEARING 1 401023800
4 SEEGER FORO Ø160 EXTERNAL RING 2 421102400
5 ANELLO DI TENUTA 120X160X12 BA RING SEAL 2 415018400
6 SUPPORTO RE2520 Z2P SPEC. NMF OUTPUT SUPPORT 1 02201275
7 RONDELLA UNI 6953 3/8" RAME RIC. WOSHER 4 423000600
8 TAPPO TCEI DIN 908 R 3/8" PLUG 4 419000700
9 DISTANZ.RIDUZ.RE2520 ZP SPACER 1 02731256
10 CUSCINETTO CRCI NJ220 EC BEARING 1 401007600
11 SEEGER ALBERO Ø100 UNI 7436 EXTERNAL RING 1 421007300
12 DIST. CUSC. SPACER 1 02731307
SPESSORE DI RASAM. 100X125X1 SHIM 1 427004500
13
SPESSORE DI RASAM. 100,5X119,5X0,5 SHIM 3 427019700
14 OR CORDA 3.53 D.INT.338 O-RING SEAL 1 100017700
15 INGRASS.DOPPIO ESAGONO 1/8"GAS GREASER 1 420010500

SUB ASSEMBLY CODE: 99210000

Pagina 2
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR GEAR SET RE2520 i=5,20 CRI-2520-M

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 PORTASATELLITE RE2520 i=5,2 PLANETARY CARRIER 1 02221250
2 PASTIGLIA PAD 1 02741027
3 FONDELLO END PLATE 1 02551073
4 SEEGER E. Ø42 DIN 471 SEEGER 3 421006300
5 RULLINO Ø7x18 NEEDLE 312 404007200
6 RALLA RE 2520 53x72x2 WHEEL 6 02741042
7 SATELLITE RE 2520 i=5,2 PLANETARY GEAR 3 02621034
8 CORONA RE2520 RING GEAR 1 02231015
9 OR CORDA 3.53 D.INT.338 O-RING SEAL 2 100017700
10 SOLARE RE2520 i=5,2 SUN GEAR 1 02611044
11 PERNO PORTASATELLITI SATELLITE SHAFT 3 02581020
12 ANELLO DI SPALLAMENTO SHOULDER RING 1 415022800

SUB ASSEMBLY CODE: K0500I1B01

Pagina 3
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR INTERM. FLANGE RE2520 GRFL-2520

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 FLANGIA INTERMEDIA RE 2520 INTERMEDIATE FLANGE 1 02731047
2 TAPPO TCEI DIN 908 R 3/8" PLUG 4 419000700
3 RONDELLA UNI 6953 3/8" RAME RICOT. WASHER 4 423000600
SPINA ELASTICA §16X60 PIN * 434011400
4
SPINA ELAST. SPIROL §16X70 PIN 6 434011500
5 OR CORDA 3.53 D.INT.338 O RING SEAL 1 100017700
6 OR 2-177 O-RING SEAL 1 406013200

Pagina 4
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR GEAR SET RE 810 i=5,10 GRI-810-N

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 CORONA RE810 RING GEAR 1 02231011
2 SOLARE 2ST i=5,10 RE810 SUN GEAR 1 02611032
3 PASTIGLIA 020,6X8 BRONZO PAD 1 02741008
4 RAGGR.INGRANAGGIERIA RE 810 i=5,10 GEAR SET 1 99109000
5 OR 2-177 O-RING SEAL 2 406013200

SUB ASSEMBLY CODE: K0500F1C01

Pagina 5
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR INTERMEDIATE FLANGE 810-1020 GRFL-810-1020

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 GUARNIZIONE OR 2-177 O RING SEAL 1 406013200
2 FLANGIA INTERMEDIA RE810-1020 INTERMEDIATE FLANGE 1 02731043
3 GUARNIZIONE OR 2-171 O RING SEAL 1 406015000

Pagina 6
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR GEAR SET RE 310 i=5,33 GRI-310-N

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 CORONA (RE 300) RING GEAR 1 20300213
2 SOLARE 2ST i=5,33 RE310 SUN GEAR 1 20300241
3 RAGG. INGRANAGGIERIA RE310 i=5,33 GEAR SET 1 99106200
4 OR 2-171 O-RING SEAL 2 406015000

SUB ASSEMBLY CODE: K0500D1C01

Pagina 7
LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

Pagina 8
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR F5-F6.. BRAKE GR-F5-F6

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 ALBERO IN ENTRATA FRENO F20 INPUT SHAFT 1 02241000
2 ANELLO DI TENUTA 60X75X8 BABSL RING SEAL 1 415001900
3 DISTANZIALE LAMELLE FRENO F20 SPACER 1 02731004
4 DISCO IN BRONZO SP.1 FRENO F5-F6 BRONZE DISC 7 02941000
5 LAMELLA ACCIAIO SP.1,3 FRENO F5-F6 STEEL DISC 8 02941001
6 OR 147X2,62 N70-N003 O-RING SEAL 1 406018200
7 CORPO FRENO F610/F612 HOUSING 1 02431014
8 RONDELLA RAME 1/4"RICOTTO 13X19X1.5 WASHER 5 423000300
9 TAPPO TCEI 1/4"GAS DIN 908 PLUG 5 419000600
10 SUPPORTO ENTR.FRENO F5-F6 (EX F20) INPUT FLANGE 1 02501000
11 OR 2-161 N 741-75 (PARKER) O-RING SEAL 1 406016100
12 OR 2-154 O-RING SEAL 1 406012100
13 SEEGER FORO Ø95 EXTERNAL SNAP RING 1 421102100
14 ANELLO DI TENUTA 60X80X7/7.5 BABSL RING SEAL * ****
15 SEEGER ALBERO Ø60 INTENAL SNAP RING 1 421001000
16 CUSCINETTO A SFERE 16012 TIPO A BEARING 1 400005200
17 MOLLA FRENO F5-F6 (EX F20) HELICAL SPRING 8 02701000
18 PISTONE FRENO F5-F6 (EX F20) BRAKE PISTON 1 02271000
19 VITE TCEI M10X30 12.9 SCREW 8 410401700
20 RONDELLA SCHNORR 10 WASHER 8 423202100
21 ANTIESTRUSIONE PARBAK 8-161 ANTIEXTRUSION RING 1 415067400
22 OR 2-161 N 741-75 (PARKER) O-RING SEAL 1 406016100
23 OR 2-158 N 741-75 (PARKER) O-RING SEAL 1 406016000
24 ANTIESTRUSIONE PARBAK 8-158 ANTIEXTRUSION RING 1 415067200

SUB ASSEMBLY CODE: 99195800

Pagina 9
 LISTA RICAMBI N°383-00 N°PAGINE 10
DATA DI COMPILAZIONE 18/12/2006
FIRMA : M.Corazzari N° RICHIESTA: CI_a39

SPARE PARTS LIST FOR MOTOR FIXING FLANGE GR-PAM-NMF

POS. DESCRIZIONE ITEM Q.TA' CODICE

1 TAPPO TCEI M10X1 DIN 908 PLUG 1 419001400
2 RONDELLA RAME CRUDO 10,5X16X1,5 WASHER 1 423000400
3 LANGIA ATTACCO 8 F.MOTORE SPEC.NMF MOTOR FIXING FLANGE 1 02971817
4 OR 2-159 O RING SEAL 1 406012600
5 OR 2-154 O RING SEAL 1 406012100
6 GIUNTO SCANALATO W35X2 Z16 COUPLING 1 4000067000

Pagina 10
 Spare Parts

QTY. Position DESCRIPTION SAP CODE

2 10 Feet 295x30x15 3087930

1 9 Pump FZP-1/1.1/P/71/10/RV4.5 721068
1 8 Motor M. 220/480-50/60HZ 0.37KW 1500G B14-B14 2507124
1 7 Indicator 303854
1 6 Filter MF-160 314858
1 5 Filter Support 3087899
1 4 Grid Ø294 strengthened 3087932
1 3 Fan Ø300/6-6/25LD/PPG/D/FM14 3087898
1 2 Casing 3087762
1 1 Radiator BSR-70 3078616

5 5 5 5

5
5
5
9
9

8 8
HYDAC Label
44

22 33

7
7

11

6
6

10
10

OKAF-EL2S/10/3.0/M/400-50/MF160/10/1/So61
 Type NG

Documentation

part-no..: 70853
cabin 1 to 5

Karl Miller GmbH

Industriestr. 19
D - 77933 Lahr / Schwarzwald
Tel.: (0049) (0) 7821 / 9476-0
Fax: (0049) (0) 7821 / 9476-10
e-mail: info@kml-miller.de
www.kml-miller.de
 Karl Miller GmbH
Systemlösungen im Kabinenbau

www.kml-miller.de

general drawing

4
 Karl Miller GmbH
Systemlösungen im Kabinenbau

www.kml-miller.de

drawings

35/36 39
5

12
14/32
33
1
27/29-31
11
26
34
28/29-31
28/29-31
2

19
3
38
37
26
20

15
9/10

27/29-31

14/32 42

5
 Karl Miller GmbH
Systemlösungen im Kabinenbau

www.kml-miller.de

43/44 25

11
16-18

40

4 21/23
22/24

7/8

41

13
6

6
spare part list

pos. name
1. ESG-glass________________________________________________
2. ESG-glass________________________________________________
3. ESG-glass________________________________________________
4. ESG-glass________________________________________________
5. VSG-glass________________________________________________
6. VSG-glass________________________________________________
7. clamping profile___________________________________________
8. filling profile _____________________________________________
9. clamping profile___________________________________________
10. filling profile _____________________________________________
11. edge protection with sealing _________________________________
12. transparent sealant ________________________________________
13. double sided scotch tape ____________________________________
14. bed _____________________________________________________
15. label „emergency exit only“ _________________________________
16. cover for windscreen wiper motor_____________________________
17. fixing for cover____________________________________________
18. windscreen wiper motor 60/70/80 degree, 24 V __________________
19. wiper arm 750 mm _________________________________________
20. wiper blade 800 mm ________________________________________
21. mortise lock, DIN right _____________________________________
22. profile cylinder____________________________________________
23. door handle ______________________________________________
24. escutcheon _______________________________________________
25. adjustable hinge___________________________________________
26. window stay ______________________________________________
 Karl Miller GmbH
Systemlösungen im Kabinenbau

www.kml-miller.de

27. handle right ______________________________________________

28. handle left _______________________________________________
29. hook ____________________________________________________
30. PVC – disc hard ___________________________________________
31. PVC – disc soft____________________________________________
32. hinge plastic ______________________________________________
33. star gripp, M12____________________________________________
34. duct for wiring ____________________________________________
35. blind plug M 25 x 1,5_______________________________________
36. locknut M 25 _____________________________________________
37. drivers seat _______________________________________________
38. ashtray __________________________________________________
39. hanger __________________________________________________
40. eye______________________________________________________
41. finned plug _______________________________________________
42. rubber mat isolated ________________________________________
43. insulation with textile cover, 20 mm ___________________________
44. insulation 20 mm __________________________________________

8
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

Descender device

AG 10 K
EN 341
CE 0158

Technical data:

Manufacturer: : RK Sicherheitstechnik
Type : AG 10
Device class : A
Serial no. / Yr. of manufacture : .........../...............
Permitted abseiling height : 200 m max.
Permitted abseiling height
for 2 persons : 100 m max.
Max. abseiling load : 150 kg
Max. abseiling load for
two persons : 220 kg
Abseiling speed : ...................... m/s
Device weight : 0.9 kg (without rope)
Rope length : .....................

RK Sicherheitstechnik
Faunaweg 7
42119 Wuppertal

Descender Device AG 10 K 1
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

1 issue Tel: +49 (0) 202 / 4303302

1/2001 +49 (0) 212 / 2542059
Fax: +49 (0) 212 / 530283

Table of contents

1. Description

2. Preparation

3. Abseiling

4. Storage and transportation

5. Cleaning

6. Maintenance

7. Inspection

8. Illustration of the AG

9. Inspection book

Descender Device AG 10 K 2
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

1. Description

The Abseiling Device AG 10 K Hoist A is used for the abseiling of persons

from high work locations.

The abseiling device AG 10 K is not a fall arresting system.

The temperature-dependent utilisation range of the abseiling equipment lies
between ambient temperatures of -25°C to 60°C.

2. Preparation
The pre-assembled abseiling equipment is ready for use after its removal from
the equipment bag or case.
The abseiling device must be visually examined by the user prior to each use in
order to confirm that the abseiling device and the rescue rope are in a fit-for-use
condition.
An anchor point as per EN 795, with a minimum loadability of 1000 kg and at
an adequate height (approx. 2.0 m measured from the floor), must be available
for the securing the anseiling device with the carabiner. The anchor point should
- when possible - be at a position on the structure which allows a free abseiling
without obstruction.
The carabiner located on the abseiling device is hooked into the eye of the
anchor point and secured with the swivel nut. The textile rope is lowered coil-
free to the ground.
Avoid abseiling over sharp edges whenever possible and maintain an adequate
distance from the wall (approx. 0.5 m) in order to make the abseiling process
easier. An edge protection device should be placed under the rope to protect the
rope when an adequate spacing distance cannot be maintained.

Note: It must be ensured that the persons involved in the rescue are always
secured during the entire rescue process; i.e. if a railing is not
available, the persons must be secured, for example, by way of a full-
body harness as per EN 361, connecting devices as per EN 354 and
energy absorbers as per EN 355.

Descender Device AG 10 K 3
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

It should be ensured that the rope entry and rope exit points of the
abseiling device permit a smooth running of the rope through the
device.

3. Abseiling

• Abseiling of individual persons in alternating travel

Secure the carabiner on the rope termination to the chest or back eye of
the full-body harness.

Put on the full-body harness as per EN 361 or the rescue harness as per EN 1497
(observe the respective instructions for use).
Hang the carabiner located on the rope termination into the chest or back eye
and secure it with the swivel nut.
The rope between the abseiling device and the person to be lowered must not be
a slack rope; the free rope on the other side must be pulled downwards and held
with force.
The person to be rescued can now be lowered from the rescue platform by
releasing the held rope.
The descending speed will be controlled automatically by a centrifugal force
brake (standard speed of approx. 0.7 m/s). It is also possible to interrupt the
descend by braking (holding) the upward travelling rope with the hand.
Further persons can be lowered as described above after the end of the first
abseiling process. This is first possible when:

- the person lowered to the ground has been released from the carabiner
of the rescue rope.
- the persons still to be lowered from the secured recovery location have
a sufficient number of full-body/rescue harnesses or the full-
body/rescue harness of the person already lowered is pulled up with the
rescue rope.

Descender Device AG 10 K 4
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

• Abseiling of one person

The carabiner on the rope termination is hooked into the anchor point
and the carabiner on the abseiling device is hooked into the chest eye of
the full-body harness.

Put on the full-body harness as per EN 361 or the rescue harness as per EN 1497
(observe the respective instructions for use).
Hang the carabiner located on the rope termination into the chest or back eye
and secure it with the swivel nut.
The rope between the abseiling device and the person to be lowered must not be
a slack rope; the free rope on the other side must be pulled downwards and held
with force.
The person to be rescued can now be lowered from the rescue platform by
releasing the held rope.
The descending speed will be controlled automatically by a centrifugal force
brake. It is also possible to interrupt the descend on the upward travelling rope
by braking with the hand.

• Simultaneous abseiling of two persons

Secure the carabiner on the rope termination to the chest eye located on
the full-body harness or to the extension of the back eye by way of a
connecting device.

Both persons must put on a full-body harness as per EN 361 or a rescue harness
as per EN 1497 (observe the respective instructions for use).
Hang the carabiner located on the rope termination into the chest eye or to the
connecting device located on the back eye and secure with the swivel nut.
The rope between the abseiling device and the person to be lowered must not be
a slack rope; the free rope on the other side must be pulled downwards and held
with force.
The persons can now abseil from the rescue platform by releasing the held rope.

Descender Device AG 10 K 5
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

The descending speed will be controlled automatically by a centrifugal force

brake. It is also possible to interrupt the descend on the upward travelling rope
by braking with the hand.
The simultaneous abseiling of two person allows a casualty to be lowered under
accompanying medical supervision.
The simultaneous abseiling of two persons is only permitted up to a maximum
abseiling height of 100 m.

Note: It must be ensured that the rope travelling upwards during the abseiling
process does not catch or hook on the structure and consequently
interrupt the abseiling process.

Attention should be given to the avoidance of obstacles during the

abseiling process.

4. Storage and transportation

The rescue equipment should be stored in a dry and cool room and protected
from UV light.
Avoid contact with acids, caustic liquids and oils.

Rope which has been unavoidably wetted should only be dried in a natural way.

A strong equipment bag or equipment case should always be used for the
transportation of the abseiling equipment in order to avoid a damage by external
influences.

5. Cleaning
A cleaning of the textile components of the abseiling equipment may only be
carried out by the manufacturer.

Descender Device AG 10 K 6
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

6. Maintenance
The abseiling equipment must be visually examined by the user prior to each use
in order to confirm that the equipment is in a fit-for-use condition.
The rescue equipment is to be withdrawn from use and subjected to an
inspection by the manufacturer when damage to rope, carabiner or the abseiling
device is ascertained.

A utilisation period of 4-6 years can be assumed for the textile ropes under
normal conditions of use.

Attention: A modification or add-on to the abseiling device is not permitted.

7. Inspection

The rescue equipment must be inspected by the manufacturer or a qualified

person at least 1 x year.
In the case of numerous use or greater stressing (e.g. environmental or industrial
factors affecting the materials), the complete abseiling equipment should be
subjected to inspection at an accordingly higher frequency.
The abseiling equipment must be inspected by the manufacturer after every use
for rescue (not training).

The rope must be examined after 2000 m descend/hoisting travel and the brake
must be examined after 5000 m descend/hoisting travel. These examinations
must comply with the manufacturer's inspection instructions.

Descender Device AG 10 K 7
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

8. Illustration of the AG 10 K

Safety hook for attechment

at the FSD

Descender device AG 10 K

Holding rope

Safety hook for

rescue harness RG 16

Descender Device AG 10 K 8
 RK
Sicherheitstechnik INSTRUCTIONS FOR USE

9. Inspection book Serial no.:

Date of Outstanding Inspection results, Stamp/

inspection part inspection details of identified defects signature of
qualified person

Descender Device AG 10 K 9
RK
Sicherheitstechnik INSTRUCTIONS FOR USE

Descender Device AG 10 K 10
product: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

Documentation
for

hoisting block SWL 80 t, single

welded pulley, swivel
and
ramshorn
product: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

1. assembled drawing
hoisting block SWL 80 t single welded pulley, swivel and ramshorn

II

III

Picture: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

Pos. quantity name norm weight remark

Kg/Stck

I 1 Hoisting block SWL 80 t single welded 1530

pulley
II 1 swivel SWL 80t 320
III 1 Double hook SWL 80 t 197
Σ 2047 kg
product: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

2. detail drawing
2.1 part I [hoisting block]

picture: hoisting block 80 t, single welded pulley

2.1.1 parts list I [hoisting block]

Pos. quantity name material norm weight remark

Kg/Stck
1 2 plate 1625 x 1400 x 35 S355JRG3 030900638-2 580
2 1 Wire rope sheave S355JRG3 030900638/11 300
R23/1120/1270 with bearing INA
SL 045030 PP 2 NR INA
3 1 bolt D=150 x 180 1.4057 030900638-2 25
4 1 bolt D=125 x 180 1.4057 030900638-2 17
5 6 bolt M24 x 160 with nut 8.8 DIN 931/ DIN 934 1 galvanized
6 6 Lock pin 190 x 50 x 12 S235JRG2 DIN 15058 2
7 6 bolt M20 x 50 8.8 DIN 931 0,5 galvanized
8 6 Tube D=40x25x110 S235JRG2 DIN 15058 1 galvanized
9 2 Lubrication nipple M10x1 Ms DIN 3404 0,5

Σ 1530kg
product: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

2.2 part II [Swivel SWL 80t]

Picture: Swivel SWL 80 t

2.2.1 parts list II [swivel SWL 80t]

Pos. quantity name material norm weight remark

Kg/Stck
1 1 Body with roundeye S355JRG3 030900638-4 150
2 1 Jaw M 120 x 6 S355JRG3 030900638-4 114
3 1 Roundnut M 120 x 6 S355JRG3 030900638-4 12
4 1 Spreader M190 x 6 S355JRG3 030900638-4 15
5 1 bearing 81224 INA INA 3
6 1 Pin lock 32 x 10 S235JRG2 similar DIN 15058 1
7 2 Bolt M12 x 20 8.8 DIN 933 1 galvanized
8 bolt D=100 x 233 with nut 030900638-4
1 S355JRG3 20
M 80 x 6 flat DIN 934
9 1 Lubrication nipple M10x 1 MS DIN 3404 -
10 1 Split 13 x 100 Stahl DIN 94 1 galvanized
11 Pin lock 220x30x10 with bolt S235 similar DIN 15058
2 2
M 20 x 40 8.8 DIN 933

Σ 320 kg
product: hoisting block SWL 80t, single welded pulley, swivel and ramshorn

2.3 part III [double hook SWL 80t]

Picture: double hook SWL 80 t

2.2.1 Stückliste Bauteil III

Pos. quantity name material norm weight remark

Kg/pcs
1 1 Double hook with round eye GS 42CRMO4 00400 b 185
2 1 Safety latch with bolt M20 S235JRG2 12 galvanized

Σ 197 kg
Rückenbreite bis 10 mm (1 Blatt = 0,106 mm)

Building Automation Industrial Automation Systems

Moeller GmbH Hardware and Engineering

Industrieautomation
Hein-Moeller-Straße 7–11
D-53115 Bonn
PS4-201-MM1
E-Mail: info@moeller.net
Internet: www.moeller.net

© 2001 by Moeller GmbH 03/02 AWB27-1184-GB

Subject to alteration
AWB27-1184-GB DMD/DMD/Ki 03/02
Printed in the Federal Republic of Germany (03/02)
Article No.: 48988

A
Think future. Switch to green.
A
Think future. Switch to green.
Rückenbreite festlegen! (1 Blatt = 0,106 mm)

All brand and product names are trademarks or registered

trademarks of the owner concerned.

1st published 1994, edition date 04/94

2nd edition 04/1994
3rd edition 06/1997
4th edition 04/1999
5th edition 03/2002
See revision protocol in the “About this manual“ chapter

© Moeller GmbH, 53105 Bonn

Author: Werner Albrecht

Editor: Thomas Kracht
Translator: Terence Osborn

All rights reserved, including those of the translation.

No part of this manual may be reproduced in any form

(printed, photocopy, microfilm or any other process) or
processed, duplicated or distributed by means of electronic
systems without written permission of Moeller GmbH, Bonn.

Subject to alteration without notice.

 Warning!
Dangerous electrical voltage!

Before commencing the installation

• Disconnect the power supply of the device. • Suitable safety hardware and software
• Ensure that devices cannot be accidentally measures should be implemented for the
restarted. I/O interface so that a line or wire breakage
on the signal side does not result in
• Verify isolation from the supply. undefined states in the automation
• Earth and short circuit. devices.
• Cover or enclose neighbouring units that • Ensure a reliable electrical isolation of the
are live. low voltage for the 24 volt supply. Only
• Follow the engineering instructions (AWA) use power supply units complying with
of the device concerned. IEC 60364-4-41 (VDE 0100 Part 410) or
HD 384.4.41 S2.
• Only suitably qualified personnel in
accordance with EN 50110-1/-2 • Deviations of the mains voltage from the
(VDE 0105 Part 100) may work on this rated value must not exceed the tolerance
device/system. limits given in the specifications, otherwise
this may cause malfunction and dangerous
• Before installation and before touching operation.
the device ensure that you are free of
electrostatic charge. • Emergency stop devices complying with
IEC/EN 60204-1 must be effective in all
• The functional earth (FE) must be operating modes of the automation
connected to the protective earth (PE) or devices. Unlatching the emergency-stop
to the potential equalisation. The system devices must not cause restart.
installer is responsible for implementing
this connection. • Devices that are designed for mounting in
housings or control cabinets must only be
• Connecting cables and signal lines should operated and controlled after they have
be installed so that inductive or capacitive been installed with the housing closed.
interference does not impair the Desktop or portable units must only be
automation functions. operated and controlled in enclosed
• Install automation devices and related housings.
operating elements in such a way that they
are well protected against unintentional
operation.
Safety instructions
Moeller GmbH

I
 • Measures should be taken to ensure the • Wherever faults in the automation system
proper restart of programs interrupted may cause damage to persons or property,
after a voltage dip or failure. This should external measures must be implemented to
not cause dangerous operating states even ensure a safe operating state in the event
for a short time. If necessary, emergency- of a fault or malfunction (for example, by
stop devices should be implemented. means of separate limit switches,
mechanical interlocks etc.).

List of revisions to AWB 27-1184 GB

Edition date Page Description New Modifica- Omitted
tion
04/99 gen. Sucosoft S 30-S4 ҂
Sucosoft S 4 → S 40 ҂
AWB 27-1185/1186 ҂
AWB 27-1280-D → AWB 2700-1305 D ҂
AWB 27-1281-D → AWB 2700-1306 D ҂
14 Legend
҂
41 Slave adress ҂
52 Note ҂
52/53 Grafic/Table ҂
83 EMV: RFI, Surge ҂
03/02 10 Function Suconet K interface ҂
24-27 Figure and Legend ҂
78 Send data PS3, last byte ҂

II
 Contents

About this Manual 3

Documentation for the PS4-200 3
Symbols 4
1 About the PS4-200 Compact PLC 5
Hardware and software requirements 5
Features 6
Setup 6
Elements 8
2 Engineering 15
Electromagnetic compatibility (EMC) 15
Connections 15
Programming device interface 18
Suconet K interface 20
Setting the bus terminating resistors 21
Local expansion 21
Arrangement of the control cabinet 22
Power supply 23
Avoiding interference 28
3 Mounting 33
Mounting on a top-hat rail 33
Mounting on feet 34
4 Software Configuration 35
General 35
Topology configuration procedure 36
Configuring and setting parameters 38
Configuration example with local expansions 43
Configuration example 44
5 Slave Addressing 49
03/02 AWB 27-1184-GB

Slaves for expanding remote inputs/outputs 49

Intelligent slaves 51

1
 6 Operation 55
Power-up behaviour 55
Shut-down behaviour 55
Operating states of the PLC 56
Start-up behaviour 59
Program transfer 61
Starting the PLC with a program stored in
the memory module 63
Programming via Suconet K 63
7 Testing/Commissioning/Diagnostics 65
Status LEDs 65
Diagnostics 66
Message byte 69
Appendix 71
Optimizing the exchange of send and
receive data 71
Accessories 75
Slave addressing 76
Technical Data 79
Index 85
03/02 AWB 27-1184-GB

2
 About this Manual

Documentation for The documentation for the PS4-201-MM1 compact

the PS4-200 PLC (referred to below as PS4-200) is subdivided
into four manuals with the following topics:
Hardware and engineering
User interface for the programming software
Programming
Training guide
Hardware and engineering manual
This manual, “Hardware and Engineering”, explains
how the PLCs are to be installed and engineered. It
describes the elements of the PS4-200 and tells you
how to alter the settings.
The configuration and setting of PLC parameters is
carried out in the topology configurator of the
programming software. This is described in the
chapter “Software configuration”.
The chapter “Slave addressing” defines the general
syntax rules for addressing the stations in a
Suconet K network.
The chapter “Test/commissioning/diagnostics”
provides an overview of the possible error and
diagnostic signals and their meanings.
Manual for user interface for the programming
software
To program the PS4-200 you need the Sucosoft S 40
programming software
(Windows, IEC 1131).
03/02 AWB 27-1184-GB

The user interface for the software is described in the

manual AWB2700-1305GB.

3
 About this Manual

Programming manual
Information on programming the PS4-200 is
contained in the “Language elements of the
PS4-150/-200/-300 and PS416” manual
(AWB2700-1306GB).
Training guide
The training guide AWB27-1307GB uses practical
examples to illustrate the key functions of the
Sucosoft S 40 software.

Symbols The symbols in this manual have the following

meaning:

! Draws your attention to interesting tips and

additional information

Warning!
Warns of the possibility of damage. The product,
anything in the immediate vicinity and data may
be damaged.

Caution!
Warns of the possibility of severe damage. The
product, anything in the immediate vicinity and
data may be severely damaged or totally
destroyed. There is also a risk of injury or even
death.

왘 Indicates handling instructions

03/02 AWB 27-1184-GB

4
 1 About the PS4-200 Compact PLC

Hardware and software Sucosoft S 40

requirements
To program the PS4-200 you need a PC (IBM or IBM-
compatible) with
at least a Pentium processor
a Windows 95, Windows 98 or Windows NT 4.01)
operating system
at least 16 Mbyte RAM
3.5″disk drive/1.44 MByte and CD-ROM drive
Hard disk with at least 40 MByte free capacity;
the temporary directory C:\ {_S40_}.TMP is
created during the installation and deleted again.
This requires at least 250 Kbytes free space on
drive C:
Serial ports (COM 1 to COM 4)
Parallel printer port (LPT1)
VGA graphics card
Programming cable ZB4-303-KB1 (connecting
cable between PC and PS4-200)
1) (Sucosoft 3.x is the last version supported by
Windows 3.1x)
03/02 AWB 27-1184-GB

5
 About the PS4-200
Compact PLC

Features The main features of the PS4-200 compact PLC are

as follows:
24 V DC power supply
8 digital inputs, 24 V DC
6 digital outputs, 24 V DC
2 analog inputs
1 analog output

Setup Figure 1 provides an overview of the operating and

display elements of the programmable controller as
well as the device connections.

Warning!
Make sure that you are free of electrostatic
charge before touching the PLCs, in order to
protect the components from static electrical
discharges.

03/02 AWB 27-1184-GB

6
 Setup

a bc d

24V 0V
Power Supply e

.0 .1 .2 .3 .4 .5 .6 .7 24VQ 0VQ Power

Output
Supply

n 1=Ready Digital
f
2=Run Input
3=Not Ready
1 2 3 4 4=Battery

m
PRG Suconet K
PS4-201-MM1
g
Digital Analog
Output Input/Output
1 2 .0 .1 .2 .3 .4 .5 U0 U1 U10 0VA
e
S1 P1 P2

l k j i h

Figure 1: Overview of the PS4-200

 24 V DC power supply
 High-speed counter input (alternative to I 0.0), 3 kHz

Alarm input (alternative to I 0.1)
 8 digital inputs 24 V DC and 24 V DC input for the
outputs
 Plug-in screw terminal
 Status LEDs for digital inputs
 Status LEDs for digital outputs
 6 digital outputs 24 V DC/0.5 A;
short-circuit and overload proof
2 analog inputs U0, U1 (0 to 10 V)
1 analog output U10 (0 to 10 V)
Suconet K interface
Setpoint potentiometers P1, P2
03/02 AWB 27-1184-GB

Switch S1 for bus terminating resistors

Programming device interface (PRG)
Memory module
 Status LEDs for the PLC

7
 About the PS4-200
Compact PLC

Elements  Power supply unit

The PS4-200 is operated with a rated voltage of
24 V DC. The power supply connection is protected
against polarity reversal. The 24 V connection
enables the PLC in the control cabinet to be supplied
with voltages to industrial standards (IEC).
 High-speed counter input
You can count pulses at up to 3 kHz via the digital
input I 0.0, irrespective of the cycle time. The up
counter is capable of processing square-wave
pulses with a pulse/pause ratio of 1. A function block
is provided in the programming software for the high-
speed counter.

Alarm input
The digital input I 0.1 enables you to respond to
events quickly, irrespective of the cycle time. You
can use either the rising or the falling edge to
evaluate these events. A function block is provided in
the programming software for the alarm input.
 Digital inputs
The PLC has 8 digital inputs. They are galvanically
isolated from the CPU. The inputs are designed for
24 V DC. The input delay of normally 55 ms ensures
short response times (e.g. for direct peripheral scans
and alarm evaluations). Inputs I 0.0 to I 0.7 can be
addressed in bit or byte format with peripheral I/O
commands.
03/02 AWB 27-1184-GB

8
 Elements

 Status LEDs for digital inputs

The physical states of the inputs and the diagnostics
status word are indicated by LEDs.
 Status LEDs for outputs
The logical states of the outputs are indicated with
light-emitting diodes (LEDs). Outputs Q 0.6 and Q 0.7
are only provided as LEDs.
 Digital/analog outputs, analog inputs
Digital outputs:
The PS4-200 has 6 24 V/0.5 A digital outputs. They
are galvanically isolated from the CPU and protected
against short-circuits and overloads. Up to four
outputs can be connected in parallel.

! Outputs Q 0.0 to Q 0.5 can be addressed either

in bit or byte format with peripheral commands
(see chapter 5 “Slave addressing”).

Analog inputs/outputs:
The controller has two analog inputs and one analog
output. The signal range is 0 to 10 V. The resolution
of the inputs is 10 bits (1024 increments), while that
of the output is 12 bits (4096 increments)..

! The section “Power supply” in the Engineering

chapter contains a connection diagram of the
analog inputs and outputs.

All the inputs and outputs are wired via plug-in screw
terminals.
03/02 AWB 27-1184-GB

9
 About the PS4-200
Compact PLC

햺 Suconet K interface
The RS 485 interface is galvanically isolated from the
CPU. It has the following functions:
Networking of Suconet K stations (e.g. EM4...
expansion modules)
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This
communication interface is used for process data
acquisition, visualization, etc. Data for process
control must not be exchanged here.
Programming networks for several PLCs via a PC
(see section “Programming with Suconet K” in
the “Operation” chapter).
Serial communication in transparent mode (see
the following paragraph):
With this function, the PLC exchanges data with a
partner device. The data can be sent or received
using the half-duplex method with the aid of the SCO
function block (see "Language Elements of the PS4/
PS416" manual, AWB2700-1306GB). The settings of
the interface can be taken from the configurator
under ‹ Parameterization ➝ General settings› with
transparent mode. The "Baud rate", "Parity" and
"Stop bit" count are adjustable and must correspond
with the settings on the partner device. The data bit
setting is a fixed value.

Table 1: Interface parameter settings for serial

communication via the RS 485 interface

Start bit Stop bit Data bit Parity

1 1 8 –
1 1 8 even
03/02 AWB 27-1184-GB

1 1 8 odd
1 2 8 –

10
 Elements

Setpoint potentiometers
You can set the two setpoint potentiometers P1 and
P2 externally, in other words direct adjustment
without the need for a programming device. The
resolution is 10 bits (1024 increments). They can be
accessed with the operands “IAW0” and “IAW2”.
Switch S1 for bus terminating resistors
You can set the bus terminating resistors for the first
and last physical stations with switch S1.
Programming device interface (PRG)
The RS 232 interface is galvanically isolated from the
CPU. It has the following functions:
Programming the PLC via the PC
Data exchange with partner devices that have a
serial port (printers, terminals, etc.). This type of
communication is used for process data
acquisition, visualization etc. but should not be
used to exchange data for process control (see
also “Function block SCO” in the manual
“Language Elements of the PS4-150/-200/-300
and PS416” in AWB2700-1306GB, chapter 6).
Memory modules
The PS4-200 has an internal, battery-backed,
32 kByte RAM. The memory is subdivided into a data
memory and a user program memory.
Up to 24 Kbyte are available for the user program.
This allocation is dynamic, i.e. if the data memory
requires more than 8 Kbyte, the size of the user
program memory is reduced accordingly.
The memory capacity of the internal RAM can be
expanded with plug-in memory modules. The
available modules are as follows:
03/02 AWB 27-1184-GB

11
 About the PS4-200
Compact PLC

The 32 Kbyte RAM module expands the user

program memory. Up to 56 Kbyte can then be
allocated to this memory.
The 128 Kbyte flash module is subdivided into a
64 Kbyte backup memory (retentive storage of
the user program in the event of a voltage failure)
and a 64 Kbyte memory for recipe data, for
example.
The 160 Kbyte combination module integrates all
the features of the other two memory modules.

8 Kbyte data memory

Data memory

RAM memory
PS 4
24 Kbyte program memory
Programm memory

Memory module
32 Kbyte program memory (external)

Figure 2: Dynamic memory allocation

 Status LEDs for the PLC

The PLC states are indicated by means of the
“Ready”, “Run”, “Not Ready” and “Battery” LEDs
(see chapter entitled “Test/Commissioning/
Diagnostics”).
03/02 AWB 27-1184-GB

12
 Elements

Diag.
b

Battery
+ Reset
c
1
1 Halt/Diag. 2
2 Run 3
3 Run M-Reset S2

Figure 3: Controls and display elements of the PS4-200

(with housing flap open)

 Back-up battery
 Reset button

Plug connector for local expansion modules
 Operating mode selector switch

 Back-up battery
The battery backs up the internal RAM and the real-
time clock.

Warning!
The back-up battery must only be replaced with
the power supply switched on, or data will be
lost.
03/02 AWB 27-1184-GB

13
 About the PS4-200
Compact PLC

,  Operating mode selector switch/

reset button
You can select the “Halt” (stop), “Run” and
“Run M-Reset” modes with the operating mode
selector switch. The selected mode is activated
when you press the Reset button. The operating
states are described in detail in the chapter
“Operation”.

Plug connector for local expansion module
The plug connector provides the interface for
connecting the LE4-... local expansion modules
Real-time clock
The PLC is equipped with a battery-backed, real-
time clock. It facilitates the time-controlled switching
of machines and equipment. You can change
between summer and winter time in the user
program. A function block in the user program can be
used to address and scan the real-time clock.

03/02 AWB 27-1184-GB

14
 2 Engineering

Electromagnetic Observe the engineering instructions in the manual

compatibility (EMC) “EMC Engineering Guidelines for Automation
Systems” (AWB27-1287GB).

Connections Screened data and signal cables

왘 Route screened data and signal cables on the left
and the right of the device along the shortest
possible distance and connect the screen braid
to the ground terminal using a low-impedance
connection and large contact areas (See Fig. 4,
item ).
왘 Connect the screen braid with the metal sleeve of
the plug connector (DIN plugs)
.
왘 Insulate the end of the screen braid as close as
possible to the signal cable entry .
03/02 AWB 27-1184-GB

15
 Engineering

M4 햲
24 V
0V

PS 4/EM 4

Figure 4: Screen connection to reference potential surface

03/02 AWB 27-1184-GB

16
 Connections

Overview

c
b

a
24V 0V
Power Supply

.0 .1 .2 .3 .4 .5 .6 .7 24VQ 0VQ Output

Power Supply

+
d
PRG Suconet K

1 2 .0 .1 .2 .3 .4 .5 U0 U1 U10 0VA

S1 P1 P2

f e

b
c
Figure 5: Overview of connections

 Screw terminals: 24 V DC power supply

Terminal cross-sections:
Flexible with ferrule 0.22 - 2.5 mm2
Solid 0.22 - 2.5 mm2
 Plug-in screw terminal

Terminal cross-sections:
Flexible with ferrule 0.22 to 1.5 mm2
Solid 0.22 to 2.5 mm2
 Plug connector for local expansion modules (LE4)
 Suconet K interface (RS 485)
03/02 AWB 27-1184-GB

 Interface for programming device (RS 232)

17
 Engineering

Programming device Connector pin assignments

interface
2 햲
4 5
6
1 3

7 8

Figure 6: Pin assignment of the programming device

connector (PRG) (left-hand socket, top view)

 The housing of the socket is connected to the ground

terminal of the power supply for the PS4-200 via a
capacitor (only applies to version 03 and earlier).

PIN 1 Not assigned

PIN 2 RxD
PIN 3 0 V of interface
PIN 4 Not assigned
PIN 5 TxD
PIN 6 – 8 Not assigned

03/02 AWB 27-1184-GB

18
 Programming device
interface

Connecting the programming device (PC)

왘 Connect the PC to the PRG interface of the
PS4-200 (left-hand socket) using the
programming cable ZB4-303-KB1.
PS4-201-MM1: PC:
PRG interface COM interface
(8-pole. DIN pin (9-pole. socket)
connector)

1
5 2
2 3
4
3 5
6 햲

7
8
9

Figure 7: Pin assignment of the ZB4-303-KB1

programming cable

 Jumpers

Warning!
In order to avoid potential equalization currents
between the PLC and the PC, devices attached
to the PRG and Suconet K interfaces must have
the same ground potential. If the ground
potentials differ, the interfaces can be destroyed.

If identical ground potentials cannot be achieved,

either connect the PC to the mains supply via an
03/02 AWB 27-1184-GB

isolating transformer or use a laptop powered by an

internal battery.

19
 Engineering

Suconet K interface Connector pin assignments

2 햲
4 5

1 3

Figure 8: Pin assignment of the Suconet K interface (PRG)

(right-hand socket, top view)

 The housing of the socket is connected to the ground

terminal of the PS4-200 power supply via a capacitor
(only applies to version 03 and earlier).

PIN 1 RS 485 data cable, Suconet K (TB/RB)

PIN 2 Assigned internally
PIN 3 Assigned internally
PIN 4 RS 485 data cable, Suconet K (TA/RA)
PIN 5 Assigned internally

Connecting to the Suconet K field bus

왘 Use the bus cable KPG 1-PS3 to connect
additional Suconet K stations (PS4, EM4) to the
compact PLC.
5-pole DIN plug 5-pole DIN plug
(pins) (pins)
1--------------------------------1
4--------------------------------4

왘 Connect the screen of the Suconet K data cable

both to the potential reference surface and to the
housing of the plug connector (see Fig. 4 “Screen
03/02 AWB 27-1184-GB

connection to reference potential surface”).

20
 Setting the bus terminating
resistors

Setting the bus 왘 Set the bus terminating resistors on the module
terminating resistors for the first and last physical stations on a line. To
do this, both S1 switches should be set to the
“ON” position. Both switches must be set to the
“OFF” position for all other stations.

1 2

OFF

Figure 9: Bus terminating resistors active

! In order for the PLC to function correctly the two

S1 switches must be set to the same position
(“ON” or “OFF”).

Local expansion The PS4-200 can be expanded locally. The local

expansion modules (LE4 modules) are connected to
the local bus connector of the PS4-200 using a local
bus ribbon cable. Up to six LEs can be connected
locally. All available LE types can be used. Up to two
of the LE4 shown in the legend under  can be
connected to a local line. They must only be
connected directly adjacent to the master (from
version 05).

PS4-201- a a LE4-... LE4-... LE4-... LE4-...

MM1

 LE4-206-AA1, LE4-622-CX1, LE4-501-BS1,

LE4-503-BS1, LE4-505-BS1
03/02 AWB 27-1184-GB

21
 Engineering

Arrangement of the The arrangement of the components in the control

control cabinet cabinet has a significant influence on the correct
operation of the machine or plant. When planning,
designing and installing the equipment, ensure that
the power section and the control section are
separated from one another. The power section
includes:
Contactors
Coupling modules
Transformers
Frequency converters
Power converters
DC power supply units
In order to effectively eliminate electromagnetic
interference, we recommend subdividing the control
cabinet into sections according to the different
power and interference levels. Simple partitions are
often sufficient to reduce interference in small control
cabinets.

Ventilation
In order to ensure that the PS4-200 is adequately
cooled, a minimum clearance of 5 cm (2″) must be
allowed between other components and the
ventilation slots in the housing. The values specified
in the technical data must be observed
(see Appendix).

Device arrangement
The PS4-200 should be installed horizontally in the
03/02 AWB 27-1184-GB

control cabinet as shown in the following figure.

22
 Power supply

햳
햲

햲
PS 4-
201-MM1

Figure 10: Horizontal installation

 At least 5 cm (2″) clearance

 Power section

Cable duct

! When you use the PS4-200 together with local

expansion modules, you must install the
controller horizontally.

Power supply The next few pages show circuit diagrams for the
following power supply arrangements:
Figure 11:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for grounded operation
Figure 12:
Common power supply for the PS4-200 and the
digital inputs/outputs wired for non-grounded
(floating ground) operation

! An insulation monitoring device must be installed

if the supply voltage is not grounded (EN 60204,
03/02 AWB 27-1184-GB

Part 1 and VDE 0100, Part 725). For floating

operation, the 24 V DC power supply must be a
safety extra-low voltage version to IEC 364-4-41.

23
 Engineering

Legend for Figure 11:

 Main switch
 Protective device for power supply units

Miniature circuit-breakers
 Power supply for the digital inputs
 Power supply for the PS4-200
 Power supply for the digital outputs
 Reference potential for the digital inputs/outputs
 Connect top-hat rail to mounting plate (galvanized
sheet steel) with a low impedance connection over a
large surface and with protection against corrosion.

! Maintain a clearance of at least 30 cm (12″)

between the analog cable and the power supply
cables.
Do not lay the 0 V of the analog signals together
with the 0 V of the PS4-200 and the 0 V of the
digital inputs/outputs.
Ensure that the analog actuators and
transmitters are galvanically isolated. If potential
isolation is not sufficient, the manufacturers of
the analog transmitters and actuators can
03/02 AWB 27-1184-GB

provide suitable filters.

24
 Power supply


L1
L2
L3
N
PE

 
I> I> I>

+24 V 0V +24 V 0V

+24 V 0V







.0
.1
.2
.3
.4
.5
.6
.7
24 VQ
0 VQ
24 V
0V

PS 4-201-MM1
0 VA
U10
U0
U1
.0
.1
.2
.3
.4
.5
03/02 AWB 27-1184-GB

Figure 11: Common power supply wired for grounded operation

25
 Engineering

Legend for Figure 12:

 Main switch
 Protective device for power supply units

Capacitive ground
 Potential equalization rail
 Earth fault monitoring device
 Miniature circuit-breaker
 Power supply for the digital inputs
 Power supply for the PS4-200
Power supply for the digital outputs
Reference potential for the digital inputs/outputs
Connect top-hat rail to mounting plate (galvanized
sheet steel) with a low impedance connection over a
large surface and with protection against corrosion.

! Maintain a clearance of at least 30 cm (12″)

between the analog cable and the power supply
cables.
Do not lay the 0 V of the analog signals together
with the 0 V of the PS4-200 and the 0 V of the
digital inputs/outputs.
Ensure that the analog actuators and
transmitters are galvanically isolated. If potential
isolation is not sufficient, the manufacturers of
the analog transmitters and actuators can
03/02 AWB 27-1184-GB

provide suitable filters.

26
 Power supply


L1
L2
L3
N
PE

 
I> I> I>

C1 C1
K1 P1



P1
K1 

+24 V +24 V 0V

0V
+24 V 0V



24 VQ
0 VQ
.0
.1
.2
.3
.4
.5
.6
.7
24 V
0V

PS 4-201-MM1
0 VA
U10
U0
U1
.0
.1
.2
.3
.4
.5
03/02 AWB 27-1184-GB

Figure 12: Common power supply wired for non-grounded operation

27
 Engineering

Avoiding interference Cabling and wiring

Cables come under the following categories:
Power cables (e.g. cables carrying heavy current
or cables to power converters, contactors or
solenoid valves)
Control and signal cables
(e.g. digital input cables)
Measuring and signal cables (e.g. field bus
cables)

! Power, control and signal cables must always be

laid as far apart from one another as possible, in
order to prevent capacitive and inductive
interference. If separate cabling is not possible,
the cables that represent the potential source of
interference must be screened above all.

In order to keep interference to a minimum ensure

that the cabling both inside and outside the control
cabinet is laid correctly as follows:
왘 Avoid long, parallel cable runs with adjacent
cables of different power ratings.
왘 Always lay AC cables separately from DC cables.
Observe the following minimum clearances:
At least 10 cm (4″) between power cables and
signal cables.
At least 30 cm (12″) between power cables and
data/analog cables.
왘 Make sure that the supply and return cables
belonging to each circuit are laid together. The
opposing direction of current flow means that the
sum of all the currents is zero so that any fields
03/02 AWB 27-1184-GB

which are produced are compensated.

28
 Avoiding interference

 Cover
 Communication cables 

Cable duct
 Measuring cables, analog 
cables


 Control cables
 Power cables

 Continuous partition

 
Figure 13: Using separate ducts for power and signal
cables
03/02 AWB 27-1184-GB

29
 Engineering

Suppressor circuits for interference sources

왘 All suppressor circuits must be installed as close
as possible to the interference sources
(contactors, relays, valves).

! Suppressor circuits should be provided for all

switched inductances.

Screening
왘 Only use screened cables for the programming
device interface (PRG) and the Suconet K
interface of the PS4-200.
General rule: the lower the coupling impedance, the
better the screening effect. The screen is then able to
carry high interference currents.

! If you use the Suconet K or PRG interface,

connect the screen of the cable to the housing of
the plug connector. The housing of the socket is
connected via a capacitor to the earth terminal of
the power supply.

03/02 AWB 27-1184-GB

30
 Avoiding interference

Lightning protection
External lightning protection
All cables which are laid between two different
buildings must be screened. Metal conduits are
recommended for this purpose. Protective elements
against overvoltage, such as varistors or other types
of lightning arrester, should be used for signal
cables. The cables must be protected at the point at
which they enter the building, or at the latest at the
control cabinet.
Internal lightning protection
Internal lightning protection includes all measures
that reduce the effects of the lightning current and its
electrical and magnetic fields on the metal
installations and electrical systems inside a building.
These measures comprise:
Lightning-protection potential equalization
Screening
Overvoltage protection devices
Further information on this subject is provided in the
TB27-001GB manual from Moeller entitled
“Electromagnetic Compatibility (EMC) of Automation
Systems”.
03/02 AWB 27-1184-GB

31
32
03/02 AWB 27-1184-GB
 3 Mounting

Mounting on a top-hat Proceed as follows to mount the PLC on a top-hat

rail rail:
왘 Place the module on the top-hat rail so that the
top edge of the rail latches into the groove.
왘 Insert a screwdriver  into the slot of the sliding
clip and lever the clip down .
왘 Press the module onto the top-hat rail
.
왘 Release the sliding clip. It will then snap into
position behind the top-hat rail.
왘 Check that the module is seated firmly.

3 2

Figure 14: Mounting on a top-hat rail

03/02 AWB 27-1184-GB

33
 Mounting

Mounting on feet Proceed as follows to mount the PLC on feet:

왘 Press in the feet so that they snap into position .
왘 Check that they are correctly in position. The lug
must latch in the hole .
왘 Fasten the feet to the mounting plate
with M4
screws.

Figure 15: Mounting on feet

03/02 AWB 27-1184-GB

34
 4 Software Configuration

General You can configure the PLCs and all the other
components you need for your application with the
Sucosoft S 40 Topology Configurator. These
components are as follows:
Master PLC (with local expansion modules for the
inputs/outputs)
Network stations (slaves for expanding the
remote I/O or intelligent slaves)
Local expansion modules (LE4-...)

e.g. PS 4-201-MM1 LE 4-... LE 4-... LE 4-... LE 4-... LE 4-... LE 4-...

e.g. PS 4-201-MM1 LE 4-...

Intelligent slave

e.g. EM 4-201-DX2 LE 4-...

Slave for I/O expansion

Figure 16: Components of a topology configuration

! The following example describes the procedure

03/02 AWB 27-1184-GB

for configuring a topology.

35
 Software Configuration

Topology configuration Each Suconet K line in an automation system is

procedure assigned to a single master. All the other stations on
the master’s line are slaves. A separate configuration
must be defined for every station with its own CPU,
i.e. for the master itself and for all intelligent slaves.

Configuration of the master with local expansion

modules
The master’s configuration also specifies the local
expansion modules. Local expansion modules are
assigned the same line number and station number
as the master (“0” for both line and station number).
The modules are numbered consecutively. The
master is module number “0” and the local
expansion modules are numbered “1” to “6”.

Configuration of the master with remote

expansion modules
The master’s configuration also specifies the slaves
that are connected to the master’s line. The slaves
are classified according to whether they have their
own CPU (intelligent slaves) or not (slaves for
expanding the remote inputs/outputs):
In the case of intelligent slaves (e.g. PS4-200)
the master configuration only specifies the device
itself, and not any local expansion modules
(LE4...) that are connected to it.
In the case of slaves for expanding the remote
inputs/outputs the connected local expansion
modules (modules 1 to 6) are specified in the
master’s configuration file as “network stations”
03/02 AWB 27-1184-GB

in addition to the base module (module 0).

36
 Topology configuration
procedure

e.g. PS 4-201-MM1
Line 0
Station 0

e.g. PS 4-201-MM1
Station 1

Line 1

Module 0

e.g. EM 4-201-DX2 LE 4-...

Station 2

Module 0 Module 1
Figure 17: Master configuration

! If intelligent Suconet K stations have local

expansion modules, you only specify the base
module (module 0) as a “network station” in the
master’s configuration. The local expansion
modules are specified in the intelligent slave’s
configuration but not in the master’s
configuration.

Configuration of intelligent slaves

All the local components of intelligent slaves are
configured in the slave’s configuration file. Their line
and station numbers are always 0. The modules are
03/02 AWB 27-1184-GB

numbered consecutively.

37
 Software Configuration

e.g. PS 4-201-MM1 LE 4-...

Line 0
Station 0

Module 0 Module 1
Figure 18: Slave configuration

Configuration of slaves for expanding the remote

inputs/outputs
Slaves for expanding the remote inputs/outputs are
configured in the master’s configuration file.

Configuring and setting The configuration steps for the PS4-200 PLCs
parameters described here differ according to the functions the
stations must perform:
Suconet K master
Suconet K slave
SCO (from PLC firmware version 05)

! “SCO” stands for serial communication. This

function allows the PS4-200 to exchange serial
data with a partner device via its Suconet K
interface (see also “Function block SCO” in the
manual “Language Elements of the
PS4-150/-200/-300 and PS416” in
AWB2700-1306GB, chapter 6).

The table below shows how the various types of

station can be configured depending on their
functions. The fields which are not self-explanatory
are subsequently described in more detail.
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38
 Configuring and setting
parameters

Table 2: Station configurations

Master Intelligent slave

(m) (s)
Line 0 1 0
Station 0 1 to 8 0
Module 0 0 0

(m) = Master's configuration

(s) = Slave's configuration

Table 3: Station parameters

Master Intelligent slave

(m) (s)
Bus status Master – Slave
Baud rate (kBaud) 187./375 – –
(Suconet K1:
187.5 kBaud only)
Slave address – – 2 to 9
CRC Optional for slaves Optional –
via
master
Input data – a c
(Receive data)
Output data – b d
(Send data)
Remote control – – Optional

a-d = See description of input/output data in the

table below
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39
 Software Configuration

Line: Number of the network line to which a station is

connected. The master is always connected to line 0
and the slaves to line 1.
Station: Number of the station connected to a line
Module: Number of the module belonging to a station
Baud rate: Select 375 kBaud as the data transfer rate if only
Suconet K stations are connected to the Suconet K
line. The internal plausibility checks of Sucosoft S 40
will automatically set the baud rate of the line to
187.5 kBaud if the line includes Suconet K1 stations.

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40
 Configuring and setting
parameters

Slave address: The station number must be entered here in order to

configure an intelligent slave. The station address is
always 1 higher than the station number (e.g. slave 1
has address 2).
CRC: Method of enhancing data transmission integrity.
You should activate CRC (ON) if you attach greater
importance to data integrity than to short response
times.
Remote Control: If this parameter is active (ON), the intelligent slave
always has the same status as the master. If the
master changes from the “Halt” (stop) state to the
“Run” state, for example, or vice versa, the intelligent
slave changes its state accordingly. However, the
operating mode selector switch of the intelligent
slave must not be set to “Halt” (stop).
Input data, Number of bytes which the master must receive from
master (a): the intelligent slave. This number must be identical to
the number of output bytes (d) defined in the
configuration of the intelligent slave.
Output data, Number of bytes which the master must send to the
master (b): intelligent slave. This number must be identical to the
number of input bytes (c) defined in the configuration
of the intelligent slave.
Input data, Number of bytes which the intelligent slave must
slave (c): receive from the master. This number must be
identical to the number of output bytes (b) defined in
the configuration of the master.
Output data, Number of bytes which the intelligent slave must
slave (d): send to the master. This number must be identical to
the number of input bytes (a) defined in the
configuration of the master.
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41
 Software Configuration

Maximum values for send and receive bytes

The Suconet K protocol allows data with a variable
length to be transferred cyclically, whereby the
number of bytes is dependent on the settings for the
master and the slave (see below). The data length for
communication with slaves for expanding the remote
inputs/outputs is dependent on the slave type. With
intelligent slaves you can specify the number of send
and receive bytes yourself. However, the following
maximum values must not be exceeded:

Table 4: Maximum values for send and receive bytes for the
PS4-200

Send/receive bytes Master Slave

Max. no. of send bytes (output) 128 78
Max. no. of receive bytes (input) 128 78
Max. no. of send and receive bytes 128* 78
(output/input)

* For certain configurations, the number of

send and receive bytes can be increased to
256 (see Appendix).

! The maximum number of receive bytes (input

bytes) also includes the diagnostics bytes of the
stations and of any local expansion modules
which are connected to the same line. 03/02 AWB 27-1184-GB

42
 Configuration example with
local expansions

Defining input and output data

왘 First of all you must decide how many bytes an
intelligent slave should send to the master and
specify this number with the “Input data”
parameter in the master’s configuration. When
you later specify the slave’s own configuration,
you must specify the same number with the
“Output data” parameter.
왘 Now decide how many bytes the master is to
send to the intelligent slave and specify this
number as the “Output data” parameter in the
master's configuration. When you later define the
slave’s own configuration, you must specify the
same number with the “Input data” parameter.

Configuration example Table 5: Configuration with local expansion modules

with local expansions
Type Line Station Module Parameter
PS4-200 0 0 0 Bus status:
master
1st LE4 0 0 1 –
2nd LE4 0 0 2 –
3rd LE4 0 0 3 –
4th LE4 0 0 4 –
5th LE4 0 0 5 –
6th LE4 0 0 6 –

1st LE 2nd LE 6th LE

PS 4-201-
MM1
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43
 Software Configuration

Configuration example This example requires topology configurations for

the master (device A) and the intelligent slaves
(devices B and C).

! Note that intelligent slaves are configured twice -

once in the master’s configuration and once in
the slave’s own configuration.

PS 4-201-MM1
Device A

PS 4-201-MM1 LE 4-... LE 4-... LE 4-...

Device B
Station 1

PS 4-151-MM1
Device C
Line 1

Station 2

EM 4-201-DX2 LE 4-... LE 4-... LE 4-...

Device D
Station 3

Figure 19: Configuration example

Master: Device A
Intelligent slaves: Devices B and C
03/02 AWB 27-1184-GB

Slave for expanding the remote I/O: D

44
 Configuration example

The stations shown in the configuration example are

configured as follows:

Configuration of device A

PS 4-201-MM1
Device A

PS 4-201-MM1 LE 4-... LE 4-... LE 4-...

Device B
Station 1

PS 4-151-MM1
Device C
Line 1

Station 2

EM 4-201-DX2 LE 4-... LE 4-... LE 4-...

Device D
Station 3

Module 0 Module 1 Module 2 Module 3

Figure 20: Configuration of device A

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45
 Software Configuration

Table 6: Configuration of device A

Device Type Line Station Module Parameter

A PS4-201-MM1 0 0 0 Bus status: master
Baud rate: 375 kBaud
CRC status for slaves
1 to 3: OFF
B PS4-201-MM1 1 1 0 Input data: 20
Output data: 10
C PS4-151-MM1 1 2 0 Input data: 40
Output data: 38
D EM4-201-DX2 1 3 0 –
1st LE4 1 3 1
2nd LE4 1 3 2
3rd LE4 1 3 3

Configuration of device B

PS 4-201-MM1 LE 4-... LE 4-... LE 4-...

Figure 21: Configuration of device B

Table 7: Configuration of device B

Device Type Line Station Module Parameter

B PS4-201-MM1 0 0 0 Bus status: slave
Slave address: 2
Input data: 10
Output data: 20
Remote control: OFF
1st LE4 0 0 1 –
2nd LE4 0 0 2
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3rd LE4 0 0 3

46
 Configuration example

Configuration of device C

PS 4-151-MM1

Figure 22: Configuration of device C

Table 8: Configuration of device C

Device Type Line Station Module Parameter

C PS4-151-MM1 0 0 0 Bus status: slave
Slave address: 3
Input data: 38
Output data: 40
Remote control: OFF
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47
48
03/02 AWB 27-1184-GB
 5 Slave Addressing

Slaves for expanding The PS4-200 master PLC and the slaves for
remote inputs/outputs expanding the remote inputs/outputs can
communicate with one another using the Suconet K
or K1 protocols. The protocol is selected by the
master automatically according to the capabilities of
the slaves. It is not necessary to parameterize the
send or receive data length in the Topology
Configurator. Suconet K/K1 selects the appropriate
telegram length and automatically addresses the
relevant data ranges in your application.
You can thus access remote input/output operands
just as easily as local operands.

Table 9: Operand addressing of slaves for expanding

remote inputs/outputs

Communication data
Operands Line Station Module Word/byte Bit
I/Q 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master) 0, 2, 4, ... (word)
IB/QB IAB/ –
QAB ICB
IW/QW IAW/
QAW/ ICW
Status/diagnostics
IS 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master)
ISB

! The RD/SD syntax must be used for certain types

of slave for expanding the inputs/outputs instead
of the I/Q syntax described here. Please refer to
the table in the Appendix for the correct
03/02 AWB 27-1184-GB

addressing for each station type.

49
 Slave Addressing

The general syntax rule is as follows:

Operand-data type-line-station-module-byte-bit

Example
You wish to scan the inputs of slaves 1 and 2 marked
in the diagram below.

PS 4-201-MM1
Master

EM 4-201-DX2 LE 4-116-DX1
.7 Slave 1
Line 1

EM 4-201-DX2
.0 ... .7 Slave 2
Line 1

Figure 23: Configuration example for scanning the inputs

of remote slaves

You can derive the syntax for scanning the inputs

from the configuration:
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50
 Intelligent slaves

Table 10: Syntax for addressing slaves for expanding

remote inputs/outputs

IL program Data Ope- Data Line Station Module Byte/ Bits S 40 syntax
in ... flow rand type word
Master Master I Bit 1 1 1 0 7 LD % I1.1.1.0.7
↑
Slave 1
Master IB Byte 1 2 0 0 – LD% IB1.2.0.0
↑
Slave 2

Intelligent slaves When the master and an intelligent slave

communicate with one another, the application
determines which data is exchanged. You cannot
access the input/output operands directly. You must
therefore address the communication data using the
RD/SD syntax.
The table below shows the operands which are
available when the PS4-200 master PLC is operated
with intelligent slaves.

Table 11: Operand addressing of intelligent slaves

Communication data
Operands Line Station Module Word/byte Bit
RD/SD 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master) 0, 2, 4, ... (word)
RDB/SDB –
RDW/SDW
Status/diagnostic
IS 0, 1 1 to 8 0 to 6 0, 1, 2, ... (byte) 0 to 7
(0 = master) (0 = master)
ISB

RD = Receive Data; defined receive data

03/02 AWB 27-1184-GB

SD = Send Data; defined send data

51
 Slave Addressing

The general syntax rule is as follows:

Operand-data type-line-station-module-byte-bit

! If the PS4-200 is run as slave, it provides status

bytes %ISB0.0.0.0 for device status information
and %ISB0.0.0.1 for slave status information.
These status bytes cannot be scanned together
in one word but must be addressed separately.

Example
The PS4-200 (master) exchanges word data with an
intelligent slave. You can define the number of send
and receive bytes when you set the station
parameters in the Sucosoft S 40 Topology
Configurator (see chapter 4, “Software
Configuration”).

Master PS 4-201-MM1 Slave

RD 햲 RD
SD SD
햳 PS 4-151-MM1

Station 1
Line 1
Figure 24: Configuration example for sending and receiving
communication data to/from an intelligent slave 03/02 AWB 27-1184-GB

52
 Intelligent slaves

You can derive the syntax for sending and receiving

the data from the configuration.

Table 12: Syntax for addressing intelligent slaves (data

type: word)

IL program Data flow Ope- Data Line Sta- Module Byte/ Bit Syntax
in ... rand type tion word
Master Master ← Slave RDW/ Word 1 1 0 0 – RDW1.1.0.0/
Master → Slave SDW SDW1.1.0.0
Slave Slave ← Master RDW/ Word 0 0 0 0 – RDW0.0.0.0/
Slave → Master SDW SDW0.0.0.0
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53
54
03/02 AWB 27-1184-GB
 6 Operation

Power-up behaviour After the power supply is switched on, the PS4-200
carries out its own system test. The PLC then
switches to the “Ready” or “Run” status if no
hardware errors have been found.
The system test consists of the following routines:
Memory test
User program test
The results of the test are indicated by the “Ready”,
“Run” and “Not Ready” LEDs. If the test is
successful, these LEDs light up briefly when the
power supply is switched on; if not, they blink.
The PLC's status depends on how the operating
mode selector switch is set (see Table 13).

Shut-down behaviour The power supply unit of the PLC detects when the
power supply is switched off. Voltage dips of ≤ 10 ms
can be bridged by the power supply unit. If a longer
voltage dip occurs, the internal 5 V supply remains
stable for at least a further 5 ms. This time is used by
the microcontroller to save all the data required for a
restart in the memory ranges provided for this
purpose.
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55
 Operation

Operating states of the The PLC can have the following operating states:
PLC “Run”, “Ready”, “Not Ready”.

! Communication with the PC is possible in all

three operating states. Accordingly, the current
status of the PLC and the real-time clock can
always be read, for example.

Ready
The “Ready” status means the following:
There is a user program loaded in the PLC;
The user program is not running;
The outputs are reset and disabled.
The PLC is switched to the “Ready” status:
If the “Reset” button is pressed when the
operating mode selector switch is set to “Halt”;
After the power supply is switched on if the
operating mode selector switch is set to “Halt”;
By means of the programming software on the
PC;
In slave mode, if the master switches to the “Halt”
(stop) status and you have set in the slave
parameters the “remote control” function to ON in
the Sucosoft Topology Configurator (see
AWB2700-1305GB, chapter 5);
If the tab of the memory module is pulled out.
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56
 Operating states of the
PLC

Run
“Run” status means that the user program is running
cyclically.
The PLC is switched to the “Run” status:
If the “Reset” button is pressed when the
operating mode selector switch is set to “Run” or
“Run M-Reset”;
After the power supply is switched on if the
operating mode selector switch is set to “Run” or
“Run M-Reset”;
By means of the programming software on the
PC.

Not Ready
The user program does not run in “Not Ready”
status.
The PLC is switched to the “Not Ready” status:
If there is no program loaded in the PLC;
As a result of a hardware error;
As a result of a serious error in the user program
(e.g. cycle time violation)
Once the error has been rectified, you can cancel the
“Not Ready” status as follows:
By pressing the “Reset” button; if the operating
mode selector switch is set to “Run M-Reset”, the
PLC will be switched to the “Run” status;
By switching the power supply off and then on
again; if the operating mode selector switch is set
to “Run M-Reset” the PLC will be switched to the
03/02 AWB 27-1184-GB

“Run” status;
By means of the programming software on the
PC.

57
 Operation

Overview

Table 13: Overview of the operating states

Position of PLC status Action PLC status after action

operating before
Press Power
mode action (DSW = diagnostic status word)
Reset supply off/
selector
button on
switch
1 (Halt) Run ⫻ – Ready
Ready ⫻ – Ready; DSW acknowledged1)
Not Ready ⫻ – Ready; DSW acknowledged1)
Run – ⫻ Ready after remaining cycle processed1)
Ready – ⫻ Ready1)
Not Ready – ⫻ Not Ready
– – DSW (diagnostic)
– – DSW (error)
2 (Run) Run ⫻ – DSW acknowledged
Ready ⫻ – Run (depends on system parameter setup)1) 2)
Not Ready ⫻ – Via “Ready” to “Run” (depends on setup)1)
Run – ⫻ Run (with start condition)1), after remaining
cycle processed
Ready – ⫻ Run (depends on system parameter setup)1) 2)
Not Ready – ⫻ Via “Ready” to “Run”
(acc. to system parameter setup)1)
3 (Run Run ⫻ – DSW acknowledged
M-Reset) ⫻
Ready – Run (cold start)1)
Not Ready ⫻ – Run (cold start)1)
Run – ⫻ Run (cold start)1)
Ready – ⫻ Run (cold start)1)
Not Ready – ⫻ Run (cold start)1)
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58
 Start-up behaviour

Legend for Table 13:

1) If the programs in the memory module and the RAM of
the PLC are not the same, the program in the memory
module (backup program) will be copied to the RAM.
2 ) After the user program has been transferred to the PLC
or after the memory module has been booted, the PLC
is switched to “Not Ready” if the start condition in the
system parameter setup has been set to “Halt” (stop),
i.e. a cold start is required.

Whenever the PLC is started by switching on the

power supply, by pressing the “Reset” button or by
means of the PC, the backup program is compared
with the program in the RAM. If the programs are not
the same, the program in the memory module
(backup program) is copied to the RAM.
If the user program in the memory module is
defective, it is updated, providing the user program
in the RAM is valid. An update is also carried out
every time the user program is transferred from the
PC to the PLC.

Start-up behaviour The PLC can be either cold-started or warm-started.

Cold start
A cold start causes all the data fields (marker ranges,
inputs/outputs, module parameters) to be reset. The
user program is executed from the beginning.
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59
 Operation

A cold start can be initiated as follows:

By pressing the “Reset” button if the operating
mode selector switch is set to “Run M-Reset”,
providing the PLC is currently in the “Ready” or
“Not Ready” status;
By switching on the power supply if the operating
mode selector switch is set to “Run M-Reset”;
By means of the programming software on the
PC provided that the PLC is currently in the
“Ready” or “Not Ready” status.

! A cold start can also be initiated via the system

parameters if the operating mode selector switch
is set to “Run”. For this activate the Cold Start
option in Behaviour after Not Ready in the
Parameters dialog.

A cold start is always necessary after a new user

program has been transferred to the PLC.

Warm start
A warm start causes the user program to be
continued from the point at which it was interrupted
to the end of the cycle. The outputs and the
communication data are set to “0” for the remainder
of this cycle. The PLC is then initialized and the
program is executed cyclically. Retentive data fields
remain stored.
The setting of retentive marker ranges is described in
the manual “Sucosoft S 40 User Interface”
(AWB2700-1305GB, chapter 7).
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60
 Program transfer

A warm start can be initiated as follows:

By pressing the “Reset” button if the operating
mode selector switch is set to “Run”, providing
the PLC is currently in the “Ready” status;
By switching on the power supply if the operating
mode selector switch is set to “Run”, providing
the PLC contains a battery in working condition;
By means of the programming software on the
PC, providing the PLC is currently in the “Ready”
status.

! A warm start can also be initiated via the system

parameters if the operating mode selector switch
is set to “Run”. For this activate the Warm Start
option in Behaviour after Not Ready in the
Parameters dialog.

Warning!
If you initiate a warm start via the system
parameters, your data may lose its consistency.

Program transfer If the user program does not contain any syntax
errors, the compiler in the programming device (PC)
translates it into a code that can be understood and
executed by the CPU. You must then load the user
program into the RAM of the CPU using the
“Transfer” menu. The microprocessor executes the
program there in the “Run” status.
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61
 Operation

PC → PLC
When a program is transferred from the PC to the
PLC, the PS4-200 must be in the “Ready” or “Not
Ready” status. The setting of the operation mode
selector switch on the operator console is not
important.
왘 Transfer the program to the PLC; refer to the
manual “Sucosoft S 40 User Interface”
(AWB2700-1305GB, chapter 8).

! Please refer to the section “Programming

through Suconet K” for details of how to transfer
the user program to the PLC through Suconet K.

If the operating mode selector switch is set to “Halt”

(stop), the LEDs for “Ready” and “Not Ready” will
light up while the program is being transferred
together with the LED for input I 0.0. They confirm
that the data transfer between the PS4-200 and the
PC is progressing successfully.

PC → PLC and memory module

왘 Plug the memory module into the PLC (the PLC
must be switched off).
왘 Switch on the PLC. The PLC must be switched to
the “Ready” or “Not Ready” status.
왘 Transfer the program from the PC to the PLC. The
program is now loaded into both the PLC and the
memory module.
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62
 Starting the PLC with a
program stored in
the memory module

Starting the PLC with a The procedure for starting a user program in the
program stored in memory module is as follows:
the memory module
왘 Plug the memory module into the PLC (the PLC
must be switched off). The setting of the operate
mode selector switch is not important.
왘 Switch on the PLC. The program in the memory
module is then copied to the PS4-200 and the
PLC is started up according to the configured
startup conditions.

Programming via It is possible to program several networked stations

Suconet K and to run test and startup functions from a single
programming device attached to Suconet K without
having to connect a programming cable to each of
the stations in turn. This method can be used for all
stations which are connected to the line served
directly by the master PLC. If one of these stations
(e.g. LE4-501-BS1) opens another line, you will not
be able to access the stations connected to it (see
broken line in figure below). For further information
on this topic refer to the manual “Sucosoft S 40 User
Interface” (AWB2700-1305GB, chapter 8).
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63
 Operation

PC

PLC program

PS 4-141-MM1

PS 4-201-MM1*) LE 4-501-BS1

PS 4-151-MM1

PS 4-151-MM1

Figure 25: Programming via Suconet K

*) Programming on the PS4-201-MM1 is possible with

03/02 AWB 27-1184-GB

Version 05 or higher.

64
 7 Testing/Commissioning/Diagnostics

Status LEDs The coloured light-emitting diodes (LEDs) allow fast

and simple diagnostics of the PLC functions. The
states of the inputs/outputs are easy to monitor.

Table 14: Significance of the LEDs

LED Status Significance

Ready Off –
On (yellow) Self-test successfully
completed and CPU ready to
start
Blinking Suconet K error
(3 seconds)
Run Off Program in “Halt” (stop)
status
On (yellow) User program is running
Not Ready Off No errors in CPU and user
program
On (red) No user program or user
program incorrect
CPU error
Serious error in
user program
Battery Off Battery in good condition
On (red) Battery fault1)
Status of Off Input not activated
Inputs
On (green) Input activated
Status of outputs Off Output not activated
On (green) Output activated

1)Caution!
Data may be lost if the battery does not supply
03/02 AWB 27-1184-GB

sufficient power. Always replace the battery with

the power supply switched on!

65
 Testing/Commissioning/
Diagnostics

Diagnostics Status information is scanned hierarchically using

the diagnostics status word and the station’s
diagnostics byte as well as the diagnostics bytes of
any local expansion modules which are connected to
it.

Diagnostics status word

The diagnostics status word provides an overview of
the various error messages. It consists of 16 bits. The
diagnostics bits are subdivided into two categories:
Category D (diagnostics): bits 0 - 7
Category E (error): bits 8 - 15
The diagnostics bits in category D have an indication
function. They can become set while the PLC is still
in the “Run” or “Ready” status.
The diagnostics bits in category E cause the PLC to
be switched to the “Not Ready” status.
The diagnostics bits are displayed in the System
Diagnostics window of Sucosoft S 40 (see manual
“Sucosoft S 40” User Interface AWB2700-1305GB,
chapter 8).
The diagnostics bits can also be displayed on the
controller’s input LEDs. For this proceed as follows:
왘 Set the operating mode selector switch to “Halt”
and refer to the following tables to interpret the
controller’s operating state. Press the “Reset”
button if you want to acknowledge the error
signals.
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66
 Diagnostics

Table 15: Diagnostics bit display

LED PLC status PLC status

Run/ Ready Not Ready
.0 – –
.1 DDS ENR
.2 DDK ERT
.3 DLS EDR
.4 DLK EPM
.5 DMC EWD
.6 DBM EDC
.7 DAC ECT

Table 16: Description of diagnostic (indication) bits (Run/

Ready status)

Code Message name Diagnostics message description

DDS Diagnostic Remote Error in the status of a remote expansion device. The basic unit’s Suconet K
Status interface has encountered a network error with one of the stations. The error
can be localized by inspecting the diagnostics byte for each of the stations.
DDK Diagnostics Error in the configuration of the remote expansion devices. Possible causes:
Remote – Less Suconet stations than the number defined in the
Configuration Topology Configurator
– Suconet station not responding
– Data transfer error
DLS Diagnostics Error in status of local expansion device.
Local Status
DLK Diagnostics Local Error in the configuration of the local expansion devices.
Configuration
DMC Diagnostics Backup not present; the memory module is not present or faulty. “DMC” also
Memory Card appears if the ZB4-032-SR1 memory module is used.
DBM Diagnostics Battery Battery monitoring: the battery voltage is too low. Change the battery.
Module
DAC Diagnostics Power Power supply failure.
Failure
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67
 Testing/Commissioning/
Diagnostics

Table 17: Description of diagnostic (error) bits (Not Ready

status)

Code Message name Diagnostics message description

ENR Restart only with M- This error appears if you have selected the option “Halt” under “Start after
Reset (retentive Not Ready” in the PS4-200 configuration and have tried to carry out a warm
marker reset). start after a category E error has occurred. You need to carry out a cold start
(M-Reset).
ERT Error Run Time The PLC has encountered a runtime error.
EDR Error Data Retention The data retention is corrupted in the operating system.
EPM Error Program Error in program memory; error found via checksum for user program.
Module
EWD Error Watch Dog CPU failure; the CPU hardware watchdog has indicated a failure.
EDC Error DC DC supply failure in base module (module 0)
ECT Error Cycle Time Cycle time exceeded; the max. cycle time set in the program was exceeded.

Diagnostics byte for Suconet K stations

In order to get more details about the information
contained in the diagnostics status word, you can
scan the diagnostics byte of each of the stations and
of any local expansion modules that are connected
to them. You only have read access to this
information.
Each station and each local expansion module on
the Suconet K line has its own status information.
The diagnostics information available is dependent
on the respective type of Suconet station or local
expansion module.

! There is a group message containing status

information for every station on the Suconet K
line. This information applies to the respective
CPU and to any local expansion modules (LE)
03/02 AWB 27-1184-GB

which are connected to it.

68
 Message byte

The status information indicates, for example,

whether:
The device ID is incorrect
The device has been disconnected from the
Suconet bus or does not respond
There is a short-circuit at the digital output of the
station, etc.
The status information and its meaning are described
in the manuals for the respective Suconet stations
and local expansion modules.

Message byte The message byte contains information about the

status of the PLC, image data relating to the network
stations, the PLC’s startup behaviour, etc. You only
have read access to this information.
For further information on message byte, refer to the
“PLC_Message” function block description in the
manual “Language elements for the PS4-150/
-200/-300 and PS416” (AWB2700-1306GB).
03/02 AWB 27-1184-GB

69
70
03/02 AWB 27-1184-GB
 Appendix

Optimizing the The 128 byte communication buffer (COB) of the

exchange of send and PS4-200 master is used to alternately send and
receive data receive data to and from each of the stations in turn.
After the master has sent the data (send data) to a
station, this now free area of the COB memory plus
any unused COB memory is available to receive data
(receive data) from the slave. As long as there is
sufficient free memory available in the COB each
time the master receives data from a slave in this
way, the 128 byte COB can be used alternately for
128 bytes of send data and 128 bytes of receive
data.
If there is not sufficient free memory when the master
receives data from a slave, valid data in the COB may
be overwritten and the PS4-201-MM1 may switch to
the “Not Ready” status (error messages “ERT” and
“EPM”) after transferring the program.
The reason for this behaviour and its remedy is
illustrated in the following examples.
Example
A PS4-201-MM1 (master) needs to exchange data
with three slaves A, B, C (also PS4-201-MM1) as
shown in the following figure. The number of bytes
received from each slave also includes the
diagnostics bytes from the slave and from any local
expansion modules which are connected to it.
03/02 AWB 27-1184-GB

71
 Appendix

40 Byte
Master Slave A
50 Byte

30 Byte
Slave B
40 Byte

48 Byte
Slave C
38 Byte

Figure 26: Data exchange between master and slaves

Incorrect station address assignment

Slave A: station 1
Slave B: station 2
Slave C: station 3
The subdivision of the communication buffer (COB)
in the master is then as follows:

03/02 AWB 27-1184-GB

72
 Optimizing the exchange of
send and receive data

Send Receive

free 10

A 40 A 50

B 30 B 40

C 48 C 38

욾 128 Byte 욾 128 Byte

Figure 27: Subdivision of the COB with incorrect station
address assignment

Sequence of communication:
1. Master sends 40 bytes to slave A:
Free COB memory at this stage = 50 bytes
2. Master receives 50 bytes from slave A:
Free COB memory at this stage = 0 bytes
3. Master sends 30 bytes to slave B:
Free COB memory at this stage = 30 bytes
4. Master receives 40 bytes from slave B:
Overlapping of 10 bytes between send and
receive data. The controller goes to the “Not
Ready” state.

!
03/02 AWB 27-1184-GB

The Sucosoft S 40 software automatically

checks the configuration and warns about
possible overlapping.

73
 Appendix

Correct station address assignment:

The required amount of data can be sent and
received successfully by assigning different slave
addresses with the topology configurator as follows:
Slave A: station 3
Slave B: station 2
Slave C: station 1
Send Receive

free 10

C 38
C 48

B 40
B 30

A 50
A 40

욾 128 Byte 욾 128 Byte

Figure 28: Subdivision of the COB with functionally correct

station address assignment

No overlapping takes place in this case. After polling

the first station, the master has sent 48 bytes but only
received 38 bytes. Including the unused 10 bytes, a
total of 20 bytes of memory are now available. This is
used by the second and third polling process, where
the master receives 10 bytes more from both stations
03/02 AWB 27-1184-GB

2 and 3 (40/50 bytes) than it sends (30/40 bytes).

74
 Accessories

Accessories
Designation Type Description/application
Programming cable ZB4-303-KB1 Adapter for programming the PS4-200 with a PC
Memory module ZB4-160-SM1 32 Kbyte RAM module for expanding the user program
memory and 128 Kbyte flash EPROM
Memory module ZB4-032-SR1 32 Kbyte RAM module for expanding the user program
memory
Memory module ZB4-128-SF1 128 Kbyte flash EPROM
Plug-in screw terminal ZB4-110-KL1 Plug-in screw terminal for the input/output level
Twin-level terminal ZB4-122-ML1 Twin-level terminal block for distributing potential, e.g. for
block connecting 3-pole proximity switches to a PLC or a local
expansion module
Hinged cover ZB4-101-GZ1 Hinged cover with space for labelling inputs/outputs (PS4,
EM4, LE4)
Feet ZB4-101-GF1 Feet for screwing the PS4 onto a mounting plate
Backup battery ZB4-600-BT1 Battery for backing up the RAM of the PS4-200
Simulator ZB4-108-ES1 Simulator for digital inputs
Data cable KPG 1-PS3 Cable between the PS4-200 and a slave; length: 0.5 m
T connector TBA 3.1 For connecting a station to the Suconet K/K1 line
Data plug connector S1-PS3 5-pole DIN plug connector for the RS 485 interface of the
PS4-200-MM1
Cable LT 309.096 Cable, 2 ⫻ 0.5 mm2, screened and twisted for making your
own Suconet K cable
Screen grounding kit ZB4-102-KS1 Screen grounding kit for Suconet incl. screen grounding clips
Snap fastener for the FM4/TS35 Weidmüller, Order no. 068790
top-hat rail
Terminal clip for snap KLBü3-8SC Weidmüller, Order no. 169226
fastening
03/02 AWB 27-1184-GB

75
 Appendix

Slave addressing Receive data

Slave Byte 1 Byte 2 Byte 3 ... Last byte Data type

EM4-111-DR1 IBx.y.0.0 Bit, byte
EM4-101-DD1/88 IBx.y.0.0 Bit, byte
EM4-101-DD1/106 IBx.y.0.0 IBx.y.0.1 Bit, byte
EM4-101-AA1 V 01 IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.5 Byte
EM4-101-AA1 V 02
AA1B64 ( IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.5 Byte
8 Bit/SBI)
AA1W33 ( IAWx.y.0.0 IAWx.y.0.2 IAWx.y.0.4 Word
12 Bit/SBI)
EM4-101-AA2
AA2B84 IABx.y.0.0 IABx.y.0.1 IABx.y.0.2 ... IABx.y.0.7 Byte
AA2W84 IAWx.y.0.0 IAWx.y.0.2 ... IAWx.y.0.14 Word
EM4-201-DX1 IBx.y.0.0 IBx.y.0.1 Bit, byte
EM4-201-DX2 IBx.y.0.0 IBx.y.0.1 Bit, byte, word
PS4-1x1, passive IBx.y.0.0 – IABx.y.0.0 IABx.y.0.1 (Bit), Byte
PS4-1x1, active RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte
PS4-141-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.77 Bit, byte, word
PS4-151-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.77 Bit, byte, word
PS4-201-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.77 Bit, byte, word
PS4-401-MM1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
PS4-401-MM2 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.83 Bit, byte, word
PS316 (SBI)/306 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte, word
EPC335 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte, word
PS3-DC IBx.y.0.0 IBx.y.0.1 IABx.y.0.0 ... IABx.y.0.3 (Bit), Byte
PS3-AC IBx.y.0.0 IBx.y.0.1 IABx.y.0.0 ... IABx.y.0.3 (Bit), Byte
PS3-8 IBx.y.0.0 IBx.y.0.1 Bit, byte
LE4-501-BS1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.77 Bit, byte, word
CM-501-FS1 IBx.y.0.0 RDBx.y.0.1 RDBx.y.0.1 ... RDBx.y.0.5 Bit, byte
03/02 AWB 27-1184-GB

76
 Slave addressing

Slave Byte 1 Byte 2 Byte 3 ... Last byte Data type

SBI-AMD3 RDBx.y.0.0 RDBxBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
SBI-AMX RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
SIS Type 80D0 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte, word
to
SIS Type 80EF RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Bit, byte, word
A4-220.1 RDBx.y.0.0 RDBx.y.0.1 Byte, word
A5-220.1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
VTP0-H-Tx RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.6 Byte, word
VTP1/2-H-T6 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.17 Byte, word
ZB4-501-UM2 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 ... RDBx.y.0.23 Bit, byte, word
RMQ16I IBx.y.0.0 IBx.y.0.1 Bit, byte
RBI1.1 RDBx.y.0.0 RDBx.y.0.1 RDBx.y.0.2 .... RDBx.y.0.6 Bit, byte

x = line, y = station

Send data

Slave Byte 1 Byte 2 Byte 3 ... Last byte Data type

EM4-111-DR1 QBx.y.0.0 Bit, byte
EM4-101-DD1/88 QBx.y.0.0 Bit, byte
EM101-DD1/106 QBx.y.0.0 QBx.y.0.1 Bit, byte
EM4-101-AA1 V 01 QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 – QABx.y.0.4 Byte
EM4-101-AA1 V 02
AA1B64 QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 – QABx.y.0.4 Byte
( Bit/SBI)
AA1W33 QAWx.y.0.0 QAWx.y.0.2 QAWx.y.0.4 Word
(2 Bit/SBI)
EM4-101-AA2
AA2B84 QABx.y.0.0 QABx.y.0.1 QABx.y.0.2 – QABx.y.0.3 Byte
AA2W84 QAWx.y.0.0 QAWx.y.0.2 ... QAWx.y.0.6 Word
03/02 AWB 27-1184-GB

77
 Appendix

Slave Byte 1 Byte 2 Byte 3 ... Last byte Data type

EM4-201-DX1 QBx.y.0.0 QBx.y.0.1 Bit, byte
EM4-201-DX2 QBx.y.0.0 QBx.y.0.1 Bit, byte, word
PS4-1x1, passive QBx.y.0.0 – – – (Bit,) Byte
PS4-1x1, active SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte
PS4-141-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.77 Bit, byte, word
PS4-151-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.77 Bit, byte, word
PS4-201-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.77 Bit, byte, word
PS4-401-MM1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
PS4-401-MM2 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.83 Bit, byte, word
PS316 (SBI)/306 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
EPC335 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
PS3-DC QBx.y.0.0 QBx.y.0.1 QABx.y.0.0 (Bit), Byte
PS3-AC QBx.y.0.0 QBx.y.0.1 QABx.y.0.0 (Bit), Byte
PS3-8 QBx.y.0.0 QBx.y.0.1 Bit, byte
LE4-501-BS1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 .... SDBx.y.0.77 Bit, byte, word
CM-501-FS1 QBx.y.0.0 SDBx.y.0.1 SDBx.y.0.1 ... SDBx.y.0.5 Bit, byte
SBI-AMD3 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
SBI-AMX SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
SIS Type 80D0 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
to
SIS Type 80EF SDBx.y.0.0 RDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Bit, byte, word
A4-220.1 SDBx.y.0.0 SDBx.y.0.1 Byte, word
A5-220.1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
VTP0-H-Tx SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.5 Byte, word
VTP1/2-H-T6 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.17 Byte, word
ZB4-501-UM2 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDBx.y.0.23 Bit, byte, word
RMQ16I QBx.y.0.0 QBx.y.0.1 Bit, byte
RBI1.1 SDBx.y.0.0 SDBx.y.0.1 SDBx.y.0.2 ... SDB x.y.0.5 Bit, byte
03/02 AWB 27-1184-GB

x = line, y = station

78
 Technical Data

Technical Data General

Standards EN 61 131-2, EN 50 178
Ambient temperature 0 to 55 °C
Storage temperature –20 to 70 °C
Vibration resistance 1 g/0 to 150 Hz
Shock resistance 15 g/11 ms
Vibration Constant 1 g, f = 0 up to
150 Hz
EMC see page 83
Programming interface RS 232, length of
programming cable < 3 m
Network interface RS 485
Bus Suconet K
Data cable length 600 m/300 m
Transfer rate 187.5 kBit/s to 375 kBit/s
Operating mode Master/slave
Degree of protection IP 20
Rated insulation voltage Ui 600 V AC
Real-time clock Yes
Accuracy of real-time clock 6.1 min./year (battery-backed)
Battery (life) Normally 5 years
Expandable (locally) Max. 6 LEs
Expandable (remotely) Max. 8 stations
User and data memory (internal) 32 Kbyte
Memory modules (external) 32 Kbyte RAM or 128 Kbyte
flash memory
or 32 Kbyte RAM and 128
Kbyte flash memory
Normally Cycle time for 1 K 5 ms
instructions (bits, bytes)
No. of inputs (local) 8
No. of outputs (local) 6
03/02 AWB 27-1184-GB

Max. no. of inputs/outputs (local) 104/102

Weight Approx. 540 g

79
 Appendix

Power supply for CPU

Rated voltage Ue 24 V DC
Permissible range 20.4 to 28.8 V DC
Residual ripple of input voltage < 5%
Polarity reversal protection Yes
Rated current Ie Normally 250 mA + 300 mA
per LE
Inrush current and duration 4 A < 5 ms
Power consumption Approx. 6 W
Power dissipation (complete device) Approx. 6 W
Bridging of voltage dips
Duration of dip 10 ms
Repetition rate 1s
Error indication Yes (LEDs)
Protection class 1
Galvanic isolation Yes
Terminals Plug-in screw terminals
Conductor cross-section
Flexible with ferrule 0.22 to 2.5 mm2
Solid 0.22 to 2.5 mm2
Rated insulation voltage 600 V AC
Inputs
No. of inputs 8
Rated voltage Ue 24 V DC
For “0” signal ≤ 5 V DC (limit value type 1)
For “1” signal ≥ 15 V DC (limit value type 1)
Max. ripple <5%
Rated current Ie
For “1” signal Normally 6 mA for 24 V DC
Max. delay time
03/02 AWB 27-1184-GB

From “0” to “1” max. 100 µs

From “1” to “0” max. 100 µs

80
 Technical Data

Galvanic isolation Yes

Galvanic isolation between inputs No
Input status indication Yes (LEDs)
Terminals Plug-in screw terminals
Conductor cross-section
Flexible with ferrules 0.22 to 1.5 mm2
Solid 0.22 to 2.5 mm2
High-speed counter input I0.0
Clock frequency 3 kHz
Pulse shape Square
Pulse duration 50 %
Edge duration ≤3 %
Alarm input I0.1
Analog inputs
No. 2
Signal range 0 V to 10 V
Total error Normally 0.8% of full scale
No. of conversions 1 ⫻ per cycle
Input resistance 20 kΩ
Connection type of signal transmitter Two-wire connection to
transmitter
Digital representation of input signal 10 bits (1024 increments)
Setpoint potentiometers
No. 2
Value range 10 bits (1024 increments)
Adjustment With screwdriver
03/02 AWB 27-1184-GB

81
 Appendix

Outputs
No. of outputs 6
Rated voltage Ue 24 V DC
Permissible range 20.4 to 28.8 V DC
Polarity reversal protection Yes
Max. ripple ≤5%
Galvanic isolation
in groups No
Rated current Ie
For “1” signal 0.5 A DC for 24 V DC
Lamp load 4 W without series resistor
Utilization factor 1
Relative duty factor 100 %
Parallel connection of outputs
No. of outputs max. 4
Total maximum current 2A
Total minimum current 250 mA
Residual current with “0” signal Approx. 140 µA
Short-circuit protection Yes, without set
Max. short-circuit release current 1.2 A over 3 ms per output
Off delay Normally 100 µs
Limiting of breaking voltage
With inductive loads Yes, –21 V (with UN = 24 V DC)
Operations per hour
With time constant 4800 (G = 1)
t ≤ 72 ms 7500 (G = 0.5)
With time constant 18000 (G = 1)
t≤ 15 ms
Power supply
Polarity reversal protection Yes
03/02 AWB 27-1184-GB

Permissible range 20.4 to 28.8 V DC

Max. ripple ≤5%

82
 Technical Data

Output status indication Yes (LEDs)

Terminals Plug-in screw terminals
Conductor cross-section
Flexible with ferrules 0.22 to 1.5 mm2
Solid 0.22 to 2.5 mm2
Analog output
No. 1
Bit resolution 12 (4096 increments)
Total error Normally 0.4% of full scale
Output variables 0 to 10 V DC/2 mA
Connection type Two-wire connection

General specifications on electromagnetic compatibility (EMC) of automation equipment

Emission EN 55 011/22 Class A
Immunity to interference
ESD EN 61 000-4-2 Contact discharge 4 kV
air discharge 8 kV
RFI EN 61 000-4-3 AM/PM 10 V/m
Burst EN 61 000-4-4 Supply/digital I/O 2 kV
Analog I/O, fieldbus 1 kV
Surge EN 61 000-4-5 Digital I/O, asymmetrical 0.5 kV
DC supply, asymmetrical 1 kV
DC supply, symmetrical 0.5 kV
AC supply, asymmetrical 2 kV
AC supply, symmetrical 1 kV
Line-conducted ENV 50 141 AM 10 V
interference
03/02 AWB 27-1184-GB

83
84
03/02 AWB 27-1184-GB
 Index

A
Addressing
Slaves ................................................................... 49, 76
Alarm input ....................................................................... 8
Analog inputs/outputs ...................................................... 9
Arrangement of the control cabinet ............................... 22

B
Backup battery ......................................................... 13, 75
Backup memory ............................................................. 12
Base module (i.e. module 0) .......................................... 36
Battery
Backup ....................................................................... 13
Baud rate ....................................................................... 40
Bus cable ....................................................................... 20

C
Cable .............................................................................. 75
Cabling ........................................................................... 28
Clock (real-time) ............................................................. 14
Cold start ....................................................................... 59
Combination memory module (160 Kbyte) .................... 12
Commissioning .............................................................. 65
Communication with PC ................................................ 56
Configuration ................................................................. 38
Intelligent slaves ......................................................... 37
Local expansion ......................................................... 36
Master with remote expansions ................................. 36
Slaves for expanding remote inputs/outputs ............. 38
Configuration example ................................................... 44
Connection
Overview ..................................................................... 15
Connections
Programming device .................................................. 19
Suconet K field bus .................................................... 20
03/02 AWB 27-1184-GB

Connector pin assignments

Suconet K interface .................................................... 20

85
 Index

Controls .......................................................................... 13
Counter, high-speed ........................................................ 8
CRC ................................................................................ 41

D
Data cable ...................................................................... 75
Data exchange ......................................................... 10, 11
Data integrity .................................................................. 41
Data plug connector ....................................................... 75
Data transfer
LEDs ........................................................................... 62
Daylight savings time ..................................................... 14
Device arrangement ....................................................... 22
Diagnostics ............................................................... 65, 66
Diagnostics byte for Suconet K stations ........................ 68
Diagnostics status word ................................................. 66
Digital inputs ..................................................................... 8
Status LEDs .................................................................. 9
Digital outputs .................................................................. 9
DST ................................................................................. 14
Dynamic memory allocation ........................................... 12

E
Elements, PS 4-200 .......................................................... 8
EMC regulations ............................................................. 15
Engineering instructions ................................................. 15

F
Fastening ........................................................................ 22
Features ............................................................................ 6
Feet ................................................................................ 75
Flash module .................................................................. 12

H
Hardware requirements for programming ........................ 5
High-speed counter ......................................................... 8
Hinged cover .................................................................. 75

I
03/02 AWB 27-1184-GB

Input data ....................................................................... 41

Input delay ........................................................................ 8
Insulation monitoring ...................................................... 23
Intelligent slaves ............................................................. 35

86
 Index

Interface
Programming device .................................................. 11
Suconet K ................................................................... 10
Interference .................................................................... 22

L
LED ................................................................................ 65
LED display ...................................................................... 9
LEDs ........................................................................... 9, 13
Status ......................................................................... 12
Light-emitting diodes ..................................................... 65
Lightning protection ....................................................... 31
Limit values, send and receive bytes ............................. 42
Line ................................................................................ 40
Local expansion modules .............................................. 35

M
Master PLC .................................................................... 35
Memory
128 Kbyte flash module .............................................. 12
160 Kbyte combination module ................................. 12
32 Kbyte RAM module ............................................... 12
Backup ....................................................................... 12
Recipe data ................................................................ 12
Memory allocation, dynamic .......................................... 12
Memory capacity ........................................................... 11
Memory module ....................................................... 11, 75
Memory test ................................................................... 55
Message byte for Suconet K stations ............................ 69
Module ........................................................................... 40
Module 0 (“base module”) ............................................. 36
Mounting
On feet ........................................................................ 34
On top-hat rail ............................................................ 33

N
Network programming ............................................. 62, 63
Networking ..................................................................... 10
Not Ready (operating state) ........................................... 57
03/02 AWB 27-1184-GB

87
 Index

O
Operand addresses
Intelligent slaves ......................................................... 51
Slaves for expanding remote inputs/outputs ............. 49
Operating mode selector switch .................................... 14
Operating states (PLC), overview ................................... 58
Output data .................................................................... 41

P
Parameters, setting ........................................................ 38
PC, connections ............................................................. 19
Peripheral command ........................................................ 9
Pin assignments
Programming device interface (PRG) ......................... 18
Suconet K interface .................................................... 20
Plug-in screw terminal .................................................... 75
Potential equalization ..................................................... 19
Power supply
grounding arrangements ............................................ 23
Power supply unit ............................................................. 8
Power-up behaviour ....................................................... 55
Program transfer
LEDs ........................................................................... 62
Program transfer to PLC ................................................ 61
Programming cable .............................................. 5, 19, 75
Programming device interface (PRG) ............................. 11
Pin assignments ......................................................... 18
Programming device, connections ................................. 19
Programming networks .................................................. 10
Programming via
Suconet K ................................................................... 63
Programming with
PC ............................................................................... 11

R
RAM memory ................................................................. 11
RAM module ................................................................... 12
Rated voltage ................................................................... 8
Ready ............................................................................. 56
03/02 AWB 27-1184-GB

Real-time clock .............................................................. 14

Receive bytes ................................................................. 41
Recipe data
Memory ....................................................................... 12

88
 Index

Remote control .............................................................. 41

Reset button .................................................................. 14
Resolution ........................................................................ 9
Retention of data ........................................................... 60
RS 232 ........................................................................... 11
RS 485 ........................................................................... 10
Run ................................................................................. 57

S
Screen connection to reference potential surface ......... 16
Screen grounding kit ...................................................... 75
Screening ....................................................................... 30
Send bytes ..................................................................... 41
Setpoint potentiometers ................................................ 11
Setting parameters ........................................................ 38
Setting the bus terminating resistors ............................. 21
Setup, PS 4-200 ............................................................... 6
Shutdown behaviour ...................................................... 55
Signal range ..................................................................... 9
Simulator ........................................................................ 75
Slave address ................................................................ 41
Slave addressing ...................................................... 49, 76
Slaves for expanding the remote I/O ............................. 35
Software requirements for programming ......................... 5
Start-up behaviour ......................................................... 59
Station ............................................................................ 40
Status LEDs ................................................................... 65
Digital inputs ................................................................. 9
Outputs ......................................................................... 9
PLC ............................................................................. 12
Suconet K
Programming via ........................................................ 63
Suconet K connection ................................................... 20
Suconet K interface ....................................................... 10
pin assignments ......................................................... 20
Summer time, winter time .............................................. 14
Suppressor circuits ........................................................ 30
Switch S1 ....................................................................... 11
Symbols ........................................................................... 4
03/02 AWB 27-1184-GB

Syntax rules for addressing slaves ................................ 50

System test .................................................................... 55

89
 Index

T
T connector .................................................................... 75
Test of memory .............................................................. 55
Test of user program ...................................................... 55
Testing ............................................................................ 65
Time
Summer/winter ........................................................... 14
Topology configuration, procedure ................................ 36
Transfer .......................................................................... 61
Transfer of program to PLC ........................................... 61
Twin-level terminal block ................................................ 75

U
Up counter ........................................................................ 8
User program test .......................................................... 55

V
Ventilation ....................................................................... 22

W
Warm start ...................................................................... 60
Wiring ............................................................................. 28

03/02 AWB 27-1184-GB

90
 Betriebsanleitung
Bordkran Typ: DK II NMF
9 Drawings + parts lists
December, 2007

Item. Denotation Drawing no.

no.

1 Maintenance chart 860 -0500- 00(0)

2 Electric Wiring Diagram 824 -0700- 151(4)
3 Crane housing complete 860 -0800- 00(0)
4 General Arrangement 860 -0900- 00(0)
5 Jib complete 860 -1500- 00(0)
6 Jib Foot complete 822 -2100 07(1)
7 Jib Foot complete 822 -2100 12(2)
8 Rope Sheave 800 -2400- 20(3)
9 Hydraulic Circuit 840 -4900- 28(1)
10 Pump Unit 820 -5000- 14(1)
11 Hydraulic Oil Tank 845 -6100 00(1)
12 Fan Flap 800 -7300- 03(2)
13 Slack Rope Connection 897 -8800- 07(2)
14 Energy Supply 860 -9000- 00(1)
15 Crane Rig

Table 7: List of the drawings

Neuenfelder Maschinenfabrik GmbH

Copyright © 2005 Drawings + parts lists 1

 Betriebsanleitung
NMF Bordkran Typ: DK II

2 Drawings + parts lists Copyright © 2005