AD - 001 - EN Spreader BROMA

ADDITIONAL DEVICES EN
Type:
LHM 550
Serial number:
141082
002 - 04.06.2012 / lwnkia0

Table of Content
AIR CONDITION TOWER CABIN

CABLE REEL BOOM
SMOKE HOOD
RADIO REMOTE CONTROL
ROTATOR
SPREADER
141082 / 001
1
141082 / 001
Owner¶s Guide
Read instructions completely before installing.
COOLING, HEAT/COOL AND HEAT PUMP SERIES
Have a question? Need Help?

Call 1-800-CARRIER
For future reference, fill in details of your purchase below, and keep this Owner¶s Guide in a safe place.
DEALER NAME ___________________________________________________________
ADDRESS _______________________________________________________________
TELEPHONE __________________________________ PURCHASE DATE _____________
MODEL/CATALOG NO.* ______ SERVICE/DISCRETE NO.* _______ SERIAL NO.* _______
* Printed on nameplate. See Fig 7.

TABLE OF CONTENTS
Page No.
A Few Words About Your New Air Conditioner........................................... 2
Some Suggestions ..................................................................................... 2
Electrical Data ........................................................................................... 3
Control Panel and Operating Instructions ................................................. 4
Energy-Saving Tips .................................................................................... 7
Tools You Will Need for Window Installation............................................. 7
Window Installation .................................................................................. 8
Through-the-Wall Installation ................................................................. 13
Troubleshooting Guide ............................................................................ 15
Warrantly ................................................................................................ 16
A FEW WORDS ABOUT YOUR NEW

AIR CONDITIONER
Thank you for choosing Carrier! You can feel Carrier room air conditioners quietly give you
confident in your selection because the same maximum comfort!
pride in craftsmanship and engineering
knowledge that went into Carrier equipment This Owner¶s Guide will supply you with all the
installed in the Astrodome in Texas, the Sistine information you need for installing, operating and
Chapel in Rome, the United States Capitol¶s halls maintaining your new unit. Take a few moments
of Congress and thousands of other installations to discover how to get the most in comfort and
worldwide has gone into the construction of your economic operating from your new Carrier room
unit. air conditioner.
In addition to cooling or heating the room, this

Carrier unit will also filter and dehumidify the air.
SOME SUGGESTIONS
1. To avoid installation difficulties, read 3. When possible, install unit on a shaded side of
instructions completely before starting. This the house or building.
publication contains information pertinent to the
installation and operation of your new room air 4. Make sure that wall mounting area (or
conditioner. window, if window installation is chosen) is
structurally sound enough to support the unit.
2. This unit can be installed in a double-hung
window or through a wall. For both installations, 5. Room air conditioners are designed to fit
you must first remove the chassis from the easily into standard double-hung windows.
casing, install the casing first and then reinsert However, some window frame design variations
the chassis. require modification to the window for safe,
proper installation. If assistance is needed,
please call your local Carrier Distributor. If there
is no distributor in your area, call
1-800-CARRIER (227-7437).
CONTROL PANEL AND OPERATING INSTRUCTIONS
See Fig. 1 for reference throughout this section
Your Carrier unit is equipped with an electronic 3. Timer operation active display
panel that controls the functions of the unit. This
section explains how to best use these functions
to suit your specific needs. The panel is located
behind the control door. To open, use the Finger
Tab to swing door downward.
To indicate the operating status of your unit the
following displays are used:
1. Initial power or power failure display
REMEMBER:
In timer active mode, the unit will start-up

automatically according to the timer setting. If
automatic start-up is not desired while you are
away from home, check to be sure the timer is
deactivated.
2. Normal unit operating display
ON/OFF
The power to your unit is controlled by the

ON/OFF button. If the ON/OFF button is
pressed, the unit will turn on and the display will
show a temperature setpoint, fan speed, and
operating mode.
If the ON/OFF button is pressed again, the unit

will turn off. The display and all the indicators
(except the clock time display) will go blank.
ELECTRICAL DATA
1. All wiring must comply with local and national
electrical codes. All wiring must be installed by
qualified and skilled electricians. If you have any
questions regarding the following instructions,
contact a qualified electrician.
2. Check available power supply and resolve any

household wiring problems BEFORE installing and AWG-Amencan Wire Gage
operating this unit. * Based on copper wire at 60 C temperature rating
3. An individual branch circuit and single

receptacle used only for this air conditioner must
be available. See Table 1 for suggested wire
sizes for individual branch circuit.
4. For your safety and protection, this unit is

grounded through the power cord plug when
plugged into a matching wall outlet. If you are
not sure whether your wall outlet is
properly grounded, please consult a
qualified electrician.
5. The wall outlet you select must match the

plug on the unit power cord, and must be within * May be used for 15-amp applications-if fused for 15 amp.
reach of the installed unit.
NOTE: Power cord is 55 in. long and extends

from bottom of control panel. Do NOT use a plug
adapter or extension cord. See Table 2 for
receptacle and fuse information.
6. Follow fuse specifications indicated on unit

nameplate. See Table 2. Nameplate is located
above unit control panel inside the air discharge
section. For clear access to nameplate, front
grille must be removed as described on page 8.
NOTE: Unit model/catalog number,

service/discrete number, and serial number can
be found on the nameplate. When calling for
information and service, be sure to provide the
service/discrete number.
SET TIMER
To change the on or off time, push the SET TIMER
button. The word TIME ON will flash in the display.
The ³time on´ clock can then be set by pushing the Up
or Down arrow buttons. When the desired ³time on´ is
reached, push the SET TIMER button;
Important: Be sure to turn off the AIR CIRC function
before manually adjusting the louvers. Failure to do so TIME OFF will flash, allowing you to set the ³time off´
may cause damage to internal operating parts. by pushing the Up or Down arrow buttons. When the
desired ³time off´ is reached, push the SET TIMER
TURBO button. The unit is now programmed to turn on and
off at the times you have selected.
The TURBO function allows your Carrier unit to reach
the temperature setting at the fastest rate. When the IMPORTANT: Press the ACTIVATE TIMER button to
TURBO button is pressed, TURBO lights on the start the timer function. The unit will turn on and off at
display and the unit automatically switches to your set times using the current modes and
maximum cooling and remains in this mode until the temperature setpoints you have selected. To
temperature demand is satisfied. After the setpoint is deactivate, simply push the activate timer button.
reached, the unit will automatically return to COOL and
AUTO fan speed. If TURBO is operating and the IMPORTANT: If you are leaving your home for an
TURBO button is pressed again, the indicators turns extended period of time, be sure the timer program IS
off and the unit returns to COOL and AUTO. NOT ACTIVATED!!! This ensures that the unit will
not turn on and off while your home is unoccupied.
NOTE: The ENERGY SAVER will not operate with
TURBO. If the ENERGY SAVER button is pressed, ROOM TEMPERATURE
TURBO is cancelled.
To display the current room temperature push the Up
SET CLOCK and Down Arrow Buttons simultaneously. The
Display will go blank, show the room temperature for 3
To set the clock, push the SET CLOCK button. The seconds, then return to the setpoint.
word TIME will flash on the display, allowing the clock If in the dry mode and the Up and Down arrow
to be set by using the UP AND DOWN ARROW buttons are pushed simultaneously, a ³d´ will appear
BUTTONS. in the display, indicating ³dehumidify´.
(A) Up arrow will move time forward NOTE: The value displayed reflects the temperature
in (1) minute increments. closest to the unit. The value may not reflect the
(B) Down arrow will move time backward average temperature of the entire room.
in (1) minute increments.
(C) Holding button down will allow the time FILTER
to change at a faster pace
When the unit has operated for 200 hours, the clean
When the clock indicates the correct time, push the filter indicator will light. This indicates that the filter
SET CLOCK button again and the clock will start. needs to be checked and cleaned if necessary. After
cleaning, push the SLEEP and the TURBO buttons
NOTE: The SET CLOCK will not work while simultaneously to reset the operating hours. The
programming the automatic timer, or when the timer indicator will turn off.
mode is activated.
NOTE: More frequent cleaning may be necessary
ACTIVATE TIMER depending on indoor-air quality. See Energy-Saving
(AUTOMATIC TIMER) Tips section for filter removal and cleaning procedures.
Your Carrier unit comes equipped with a timer program ENGLISH/METRIC DISPLAY
that allows you to select times the unit will turn on and
off. The unit has been pre-programmed at the factory Your Carrier unit can display temperatures and
with an On and Off time. To activate the timer function, setpoints in Fahrenheit or Celsius. To change, press
push the ACTIVATE TIMER button. The display will the MODE and FAN buttons at the same time. To
show the current on and off time. The arrow indicates change back, press MODE and FAN buttons again.
³IN TIMER OPERATION´. To deactivate the timer
option push the ACTIVATE TIMER button. To change
on or off times see Set Timer.
FAN SELECTION SET TEMP/TIME (INCREASE AND
DECREASE SETPOINT)
The FAN SELECT BUTTON allows you to choose the
speed of the fan. When the button is pressed, an Setpoint is the room temperature you want the unit to
arrow on the display alternates between AUTO, HIGH, maintain. To change the setpoint one degree, push the
MED and LOW. The arrow indicates the selected fan UP OR DOWN ARROW buttons. The setpoint cannot
speed. The Auto Fan setting will automatically select be increase above 80 F (26.5 C) or decrease below 65
the speed that will best maintain the room at the F (18.5 C). (To change display form Deg F to Deg C
desired temperature. see English/Metric display, Page 6).
MODE SELECTION ENERGY SAVER

When the MODE SELECT button is pressed, the The ENERY SAVER feature allows the fan to cycle off
arrow on the display alternates between COOL, FAN with the compressor during cooling.
and DRY. The arrow next to the function will light to
indicate the mode. With a heat/cool or heat pump When the thermostat is satisfied, the fan as well as the
unit, HEAT and SMART modes are also available. compressor will cycle off, saving energy.
COOL ± The COOL mode provides air conditioning To activate the energy saver mode push the ENERGY
comfort for the selected area. SAVER button. The indicator will light showing energy
saver in use. To deactivate, simply push the Energy
FAN ± When the FAN mode is selected, the unit will Saver button again.
provide air circulation without cooling the room.
To further increase savings while in the Auto Fan Mode
DRY ± The dry mode is used for maximum moisture the control will not allow the use of High Fan or Turbo.
removal. When DRY mode is activated, the unit will
adjust the fan speed to either MED or LOW to provide Occasionally, use of the energy saver mode may result
the most efficient dehumidification. You cannot in wider variations of room temperature and humidity.
adjust this fan speed.
NOTE: Turbo Will Not Operate With Energy
HEAT ± The heat mode provides warm air for the Saver.
selected area. If the Turbo Button Is Pressed Energy
Saver Is Cancelled
SMART ± The smart mode is an automatic mode
selection feature. Depending on the temperature of
the room the unit thermostat will automatically select SLEEP
and provide cooling or heating as required.
The SLEEP function is an energy saving and comfort
NOTE: To avoid damage to the unit, your Carrier air device which gradually increase the room temperature
conditioner is equipped with a built-in safety feature. over a period of time while you sleep. The SLEEP
This feature will not allow the compressor to be button activates this function. The arrow on the
activated unless two minutes have passed after the display next to the word ³SLEEP´ will light when the
compressor has cycled off. If you try activate the SLEEP button degree every hour for four hours. The
compressor before the two minute time period has unit remains at that new setpoint for another three
expired, the clock time will disappear from the display hours, or until the SLEEP button is pushed again. At
and the time remaining in the two minute countdown the end of 7 hours the unit will return to your original
will appear. The display will show CP (compressor setpoint.
protection) in place of the TIME OFF clock until the
countdown is finished. AIR CIRCULATION (AUTO-AIR
CIRCULATOR)
Your Carrier unit is equipped with an automatic air
circulator which automatically moves the vertical
louvers back and forth for better air distribution
around the room. To activate this function, push the
AIR CIRC button. The arrow next to Air Circ on the
display will light, indicating the circulator is on. To
deactivate, push the Air Circ button again.
If you want the louvers to remain in a fixed position,

use the AIRFLOW lever to manually adjust the
louvers.
TROUBLESHOOTING GUIDE
If you have problems with your room air conditioner unit, check this convenient guide before contacting your service representative.
POSSIBLE CAUSES SOLUTIONS
UNIT DOES NOT START

· Unit may have become unplugged. · Check that plug is securely in wall receptacle.
· Fuse may have blown. · Replace the fuse. See Note 1.
· Circuit breaker may have been tripped. · Reset circuit breaker. See Note 1.
· Unit may be set at OFF. · Switch to an operating position
UNIT NOT COOLING ROOM
· Unit air discharge section is blocked. · Make sure that curtains, blinds or furniture are not
restricting or blocking unit air flow.
· Thermostat setting not low enough. · Reset to a lower temperature.
· Unit air filter is dirty. · Remove and clean filter.
· Room excessively hot when unit is started. · Allow sufficient amount of time for unit to cool
room. Start cooling early before outdoor
temperature, cooking heat or gatherings of people
make room hot and uncomfortable.
· Exhaust left open · Close exhaust door.
· Clicking, gurgling and whooshing noises are
UNIT MAKING NOISES normal during operation of unit.
· Condensation run-off during very hot and humid
WATER DRIPPING OUTSIDE weather is normal. See Note 2.
WATER DRIPPING INSIDE

· Unit not installed with proper trip to outside. · Unit must be installed with slight tip to outside to
prevent water from dripping inside. See Step 19
under Window Installation, or Fig. 25 under
Through-The-Wall Installation.
ICE OR FROST FORMS ON COIL
· Low outdoor temperature. · When outdoor temperature is approximately 55 F
or below, frost may form when unit is in cooling
mode. Switch unit to FAN operation unit ice or
frost melts.
· Dirty filter. · Remove and clean filter.
UNABLE TO ACCESS FILTER

· Extra-wide sill prevents filter removal. · Remove front grille, then remove filter.
MESSAGE DISPLAY CODES MEANING

· Unit is in dehumidification mode
· Unit is in 2 minute compressor protection mode.
Count down clock showing time remaining.
· Power failure
· Room air thermistor failure. Contact your dealer

the Carrier Authorized Service Center
· Out door thermistor failure. Contact your dealer
the Carrier Authorized Service Center
Notes: 1. If circuit breaker is tripped or fuse is blown will drip onto pedestrians or neighboring property,
more than once, contact a qualified electrician. install the enclosed external drain. See instruction on
2. If unit is installed where condensation drainage page 12.
Carrier
Room Air Conditioner
Full Warranty
ONE-YEAR WARRANTY ± CARRIER warrants to the user that this product will CARRIER WILL NOT BE RESPONSIBLE FOR:
be free from defects of workmanship under normal use and maintenance for a
period of one year from the date of original purchase. CARRIER, through an 1. Damage due to failure to perform normal maintenance as outlined in the Owner¶s
independent servicing dealer or service station, will either repair or replace a Guide.
defective product (as decided solely by CARRIER) free of charge to the user.
CARRIER may replace any defective part with either a new or remanufactured part 2. Instruction on methods of control and use of air conditioning unit after initial
at CARRIER¶s sole option. installation.
EXTENDED FOUR-YEAR WARRANTY ON SEALED REFIGERATION SYSTEM 3. Damage or repairs needed as a consequence of faulty installation or application.
ONLY ± During the second through fifth years after date of original purchase, This is the responsibility of the installer.
CARRIER further warrants to the user that the compressor, condenser,
evaporator, and connecting tubing will be free from defects in material or 4. Failure to start due to voltage conditions, blown fuses, open circuit breakers, or
workmanship under normal use and maintenance. CARRIER will either repair or any other damages due to the inadequacy or interruption of electrical service.
replace (as decided solely by CARRIER) any defective compressor, condenser,
evaporator, or connecting tubing free of charge to the user, including a recharge 5. Damage or repairs needed as a consequence of any misapplications, abuse,
of refrigerant for the system if necessary. However. THIS LIMITED WARRANTY unauthorized alternation, improper servicing or operation.
DOES NOT INCLUDE costs incurred for diagnosing, removing, installing, shipping,
or transporting the product or any parts. User is responsible for these costs; 6. Damage as a result of floods, winds, fires, lightning, accident, corrosive
however, SUCH COSTS MAY BE COVERED by a separate warranty or service environments, or other conditions beyond the control of CARRIER.
agreement provided by the seller or another third party, such agreement being
separate and distinct from this factory warranty. 7. Any parts not supplied or designated by CARRIER.
LIMITATION OF WARRANTIES ± ALL IMPLIED WARRANTIES (INCLUDING 8. CARRIER products installed outside the continental U.S.A., Alaska, Hawaii, and
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR Canada.
PURPOSE) ARE HEREBY LIMITED IN DURATION TO THE PERIOD FOR WHICH
THE APPLICABLE PRODUCT COMPONENT IS EXPRESSLY WARRANTED HEREIN. 9. Shipping damage or damage as a result of storing or transporting the unit.
Some states do not allow Limitations on how long an implied warranty lasts, so
the above limitations may not apply to you. THE EXPRESS WARRANTIES MADE IN
THIS WARRANTY ARE EXCLUSIVE AND MAY NOT BE ALTERED; ENLARGED, or
CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON WATSOEVER.
CARRIER WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL OR
NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or
consequential damages, so the above limitation may not apply to you. All work
provided for by this warranty shall be performed during normal working hours. All
replacement parts, whether new or remanufactured, assume as their warranty
period only the remaining time period for which the applicable component is
expressly warranted herein.
CARRIER CORPORATION
IF YOUR UNIT DOES NOT WORK, FOLLOW THESE STEPS IN ORDER:
1. CHECK THE THINGS YOU CAN DO YOURSELF. These 3. CONTACT THE NEAREST CARRIER DISTRIBUTOR
include being sure the air conditioner is plugged in SERVING YOUR AREA. (See Telephone Yellow
firmly in an appropriate receptacle, checking the Pages.)
fuse or circuit breaker and ensuring its replacement
or resetting, if necessary, and rereading the 4. CONTACT CARRIER IF A SATISFACTORY SOLUTION
instruction book to ensure all controls are set IS NOT REACHED IN STEPS 2 AND 3.d
properly. By doing this you can save money. Many
unnecessary calls result in the serviceman doing Carrier Air Conditioning
what the owner can do for himself. Consumer Relations Department
P.O. Box 4808
Carrier Parkway
2. CONTACT YOUR DEALER OR THE CARRIER Syracuse, New York 13221
AUTHORIZED SERVICE CENTER. You may find this Telephone: 1-800-CARRIER (227-7437)
name on the product, on your invoice or in your From Canada: (315) 432-7885
Homeowner¶s Packet.
Model/Catalog No. _________________________
Service/Discrete No.________________________ Unit Serial No. __________________________
Date of Installation ________________________ Installed By: ___________________________
Name of Owner ___________________________ Address of Installation ____________________

Remove the
safetydevice
Remove the screws

of the top.
Remove the AC-cap.
Change the filter.
For installation reverse the order.

2
141082 / 001
No.:
B-E 07 467
Page 1 from 9
Maintenance Instruction and Spare Parts List
Type: G5F15/26-HVDR-37-36-3-R36D
Special: --
Drawing No.: G-3839-00
Ident No.: 10019878
*CTVOCPP-ÑPKI
S t ro m zuf üh ru n gs A G
Leitungstrommeln - Schlauch - Seil - Sondertrommeln - Schleifringkörper
Postfach 1260 76677 Graben-Neudorf Telefon: 07255 / 7120-0
Siemensstraße 6 76676 Graben-Neudorf Telefax: 07255 / 5038
www.hukag.com
E - Mail: info@ hukag.com
No.:
Maintenance Instruction and Spare Parts List
Type: G5F15/26-HVDR-37-36-3-R36D B-E 07 467
Page 2 from 9
List of Contents
1.0 Assembly of the Drum.......................................................................................................3

2.0 Drum Body Dimensions ....................................................................................................3
3.0 Observance at Spiral Type Drum Body ............................................................................3
4.0 Connection of the Main Power Cable ...............................................................................4
5.0 Connection of the Payout Cable.......................................................................................4
6.0 Checks before Commissioning ........................................................................................4
7.0 Maintenance.......................................................................................................................5
a.) Wear Part............................................................................................................................5
b.) Hydraulic Motor .................................................................................................................5
c.) Bevel Gearbox....................................................................................................................5
8.0 Liability for Faults..............................................................................................................6
9.0 Enclosure ...........................................................................................................................6
10.0 Spare Parts List .................................................................................................................6
11.0 Spare Parts Drawing..........................................................................................................9
*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 25.02.2004 Drawn by.: Chr. Fricke

No:
Maintenance Instruction and Spare Parts List B-E 07 467
Type: G5F15/26-HVDR-37-36-3-R36D
Page 3 from 9
ATTENTION: Technical operations should only be carried out by quali-

fied technical personnel!
1.0 Assembly of the Drum

The cable reeling drum is constructed for heavy duty. Its construction consists of the fol-
lowing main parts which is apparent from the attached spare parts drawing SK-5237-00-2.
The drum body (1) is fixed to the gearbox (16) on the hallow shaft (15) with the drum
flange (2). Safety device for the drum flange to the hallow shaft (3) and (4). On the oppo-
site side of the drum body (1) the slip ring body (30) and brush holder unit (33) is installed.
The driving of the drum body (1) is a hydraulic motor (19) with a hydraulic air multiple disc
brake spring brake (17) which is controlled through a motor controller. The function of the
control device is to adjust the tension of the cable reeling drum. Through that control de-
vice, it is guaranteed that the cable is treated gentle. The heating (28) prevent the accumu-
lation of the condensation water inside the slip ring housing (heating must run in continu-
ous operation). The installed limit switch (58) is for stop positions.
2.0 Drum Body Dimensions

Diameter: Ø 1470 x 2600 x 33 mm width.
3.0 Observance at Spiral Type Drum Body

Before presenting the cable the drum body on accuracy to size is related to drum body
width (pipe diameter + approx. 5%) and plan parallelism to examine possibly align.
Note that there is enough seal between the round plate and
the bottom of the terminal box. Optionally this must be ac-
complished by the customer side locally. Control the sealing
in regular intervals and renew it every 3-5 years.
You receive this necessary sealant H&K-Sikaflex 221 over
our spare part sales.

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 4 from 9
Note! Please considered the operating manual and handling instruc-

tions of the cable manufacture!!!
4.0 Connection of the Main Power Cable

Remove the slip ring cover (63), (62) and (61) connect your fixed cable to the terminal
block (42) through the gland (29) at the slip ring housing (25). The terminal block (42) is al-
ready connected to the brushes. Then the cores of the cable goes through the hallow shaft
(13) of the gear box (16) and have to be connected at both sides.
Note: The 1st, slip ring () nearest the axle is always earth Ũ.
5.0 Connection of the Payout Cable

Go with the cable through the gland (7) at the housing (6) to the terminal strip (10) and
connect it to the terminal strip. Fix the cable with the strain relief clamps at the drum body
(1). Coil on the payout cable adding 2 safety windings for strain-relief on the drum body.
6.0 Checks before Commissioning

We recommend the following check.
a.) check cable glands for proper sealing

b.) check slip ring unit for dampness, no moisture must be present
c.) check brush holders for proper contacts to the slip rings a rotation must be smooth
d.) grease slip rings lightly with contact grease.

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 5 from 9
7.0 Maintenance
a.) Wear Part
The brush holders/collector and slip rings/plane slip rings are subject to a natural wear and
are depending upon need to be replaced. The brush bearing surfaces are to be cleaned
and the mobility of the pendulum brush holders are to examine (with wire brush holding the
pressure * is to the slip rings to examine), if necessarily should take place a cleaning or an
exchange (during 2/3 wear of the brush coals). After cleaning of the slip rings these should
be injected with contact spray. You receive the for this necessary special spray over our
spare part sales. It is to be made certain that the slip rings are always clean and no brush
coal dust at the slip rings set (flash over). After running in (after commissioning for the first
time after 3 months) of the brush coals the brush coal dust in the slip ring area is to be re-
moved. You have to made weekly maintenance in the running-in period (approx. 4-8
weeks) after commissioning. That’s important to ensure correct function further on. After-
wards in regular intervals (every 6 months and / or depending upon turnings of the slip
rings) repeat this procedure. If you fall into no pattern, please you request a maintenance
plan from us (with description of your data e.g. turnings, layer duration, travel speed). The
inserted grooved ball bearings are by the factory plentifully provided with camp fat, so that
a greasing is necessary only in larger time intervals. It is to be made certain by the cus-
tomer that the steel flange is closely screwed on and the cable entry is well after IP54
(IP65) sealed.
Pressure* = when easy one-sided taking from 3-4 mm off should set itself the hook again
well on the slip ring course. If this effected can take place re-bent and/or must an ex-
change.
The electrical connection must be done according to VDE 0100 - 0113 resp. IEC-Nr.: 204-
1:1992 or CENELEC.
According the EC recommendation 89/382/EEC, we point out that rotating parts have to be
secured against danger of accident.
b.) Hydraulic Motor

Sizes: 12
Series: 6
Nominal Pressure: 400 bar
Peak Pressure: 450 bar
See maintenance instruction B+E 00 051.
c.) Bevel Gearbox

Type: size 5
Ratio: i= 85.98
Model: H-032-A
Type of oil: PAO 220
Oil quantity: 124.4 liter
See maintenance instruction B+E 00 060.

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 6 from 9
8.0 Liability for Faults

If any alterations or repairs to the cable reeling drum are done by anyone else within the
time of warranty, we do not take any further liability for faults.
Notice
According the EC recommendation 89/392/EEC, we point out that rotating parts have to be
secured against danger of accident.
9.0 Enclosure
General security advices for motor driven cable reeling drums B+E 00 049
Screws / tightening torque B+E 00 069
Maintenances instruction for hydraulic motor B+E 00 060
Maintenances instruction for hydraulic air multiple disc brake B+E 00 06
10.0 Spare Parts List

Item Drawing-/Article no. Description Piece
1 G-3232-20a-00-1-4 drum body Ø 1470 x Ø 2600 x 33 1

2 G-3232-21a-00-3-2 drum flange 1
3 X5053-0003 shaft nut KM 20 – M100 x 2 2
4 X5115-0002 safety plate 1
5 X5200-0043 feather key 1
6 G-3839-30-00-3-5 housing for terminal strip 1
7 X6027-1004 gland M50 x 1.5 1
8 X06-05-015-0-00-4-3 cover 1
9 X06-07-024-0-00-3-5 clamp ring 1
10 X6501-0015 terminal block EK 4 mm² 1
X6501-0016 terminal block SAK 4 mm² 36
X6503-0002 endplate AP 4-10 1
X6502-0001 endplate EWK 1 2
11 X6505-0001 mounting rail 1
12 SK-4789-02-00-4 owner terminal block 1
X6505-0001 mounting rail 1
13 X6501-0002 terminal block SAK 2.5 mm² – CAN BUS 3
X6502-0001 endplatte EWK 1 2
14 X5009-0147 hexagon nut M20 x 80 6
15 X5750-5006-A gearbox size 5; i=85.98 1
16 G-3839-32-00-3-1 gearbox foot 1
17 X5498-0002 hydraulic air multiple disc brake 1
18 G-3839-02-00-4-1 motor flange 1

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 7 from 9
Item Drawing-/Article-no. Description Piece
19 X5490-0008 hydraulic motor 1

23 G-3232-22a-00-3-2 intermediate flange 1
24 X5210-0055 shaft sealing 1
25 G-3839-31-00-3-5 slip ring housing 1
26 G-3232-23-00-3-1 slip ring carrier 1
27 X06-03-063-0-00-4-1 angle for heating 1
28 X6000-0001 heating 33 W, 230 V 1
29 gland at the slip ring housing
X6027-1003 gland M40 x 1.5 1
X6027-1010 gland M25 x 1.5 2
X6027-1001 gland M20 x 1.5 1
X5441-0001 vent connection 1
30 slip ring body 36 poles + earth 36 A 1
31 G-1662-16-00-4-0 slip ring earth 36 A 1
32 G-1662-15-00-4-0 slip ring phase 36 A 36
33 brush holder unit 36 poles + earth 36 A 1
34 X41-12-106-0-00-3-0 brush holder earth 36 A 1
35 X41-12-107-0-00-3-0 brush holder phase 36 A 36
36 G-3697-04-00-4-0 supporting ring 1
37 Y-2028-01-00-4-7 intermediate ring 1
38 G-3232-11-00-4-0 slip ring 1
39 G-3232-24a-00-3-1 supporting plate 1
40 G-3232-09-00-4-1 fixing device for terminal strip 4
G-3232-10-00-4-1 fixing for terminal strip 4
42 X6501-0015 terminal block EK 4 mm² 1
X6501-0016 terminal block SAK 4 mm² 36
X6503-0002 end plate AP 4-10 1
X6502-0001 end plate EWK 1 4
43 X41-13-026-1-00-4-0 insulation disc 41
44 SK-4789-10-00-3-1 bearing flange 2
45 X5270-0016 ball-bearing 2
46 SK-4789-11-00-3-0 follower slip ring 1
47 X01-10-008-0-00-4-1 slip ring boss 1
48 X41-12-045-0-00-4-10 slip ring phase R32 A – CAN BUS 3
49 SK-4789-12a00-3-0 follower for limit switch 1
50 SK-4789-03-00-4-1 follower 1
51 M-504-16-00-4-0 bush 1
52 X41-12-107-1-00-3-0 brush holder phase S 32 A – CAN BUS 6
53 G-3697-07-00-4-0 Spacer rod 1
54 G-3232-09-00-4-1 fixing device for terminal strip 2
G-3232-10-00-4-1 fixing for terminal strip 2

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 8 from 9
Item Drawing-/article-no. Description Piece

56 X6501-0002 terminal block SAK 2.5 mm² – CAN BUS 3
X6502-0001 endplate EWK 1 2
57 G-3232-15-00-4-6 plate for limit switch 1
58 X5400-0034 limit switch 1
59 G-3232-31a-00-3-1 takener 1
60 G-3697-06-00-4-0 spacer rod 2
61 G-3697-20-00-3-5 between cover 1
62 G-3697-20-00-3-5 between cover 1
63 G-3697-23-00-3-5 cover 1
64 G-3839-33-00-3-1 fixing device for vent 1
65 X7100-0027 oil level glass 2
66 fitting glands
X6874-0021 vent threaded pipe – 100 mm length 1
G-3232-34-00-4-0 vent threaded pipe – 280 mm length 1
X6874-0020 vent threaded pipe - 60 mm length 1
X6451-0002 1/3” gland 2
X6874-0009 strew plug 1
X6874-0022 angle 1
X6874-0011 curve piece 90° with inner and outer thread – 1/2” 1
X6874-0012 T-piece 1/2” with inner thread 4
X6874-0008 muff 1/2” 1
X5440-0037 vent 1/2” 2
X6874-0023 reduction piece 2
When ordering spare parts, please state our order- and our serial number, to avoid wrong
deliveries. The order- and our serial number are on the type plate on the drum.

No:
Type: G5F15/26-HVDR-37-36-3-R36D
Page 9 from 9
11.0 Spare Parts Drawing

Drawing-no.: SK-5237-00-2

Nr.:
General Security Advices B 00 049
for Motor Driven Cable Reeling Drums
Seite 1 von 1
Safety References
– The cable reeling drum is built and is reliable in service delivered after the newest
state design. Arbitrary changes, which impair the working reliability, are not permissi-
ble. That concerns also protection device, which is appropriate as contact protection.
– The cable reeling drum may be used and operated only in the context of the condi-
tions specified in the achievement and supply contract.
– The operator has to ensure that with the assembly, the commissioning , servicing and
maintenance as well as the repair assigned persons consider the manual. Make sure
that they read and understood it in all points to prevent:
• dangers for life and health of the user and other persons.
• To guarantee the working reliability of the device.
• loss of use and environmental pollutions by wrong handling.
- for transport, assembling and disassembly, the operation as well as servicing and
maintenance, the relevant regulations are to be considered to the industrial safety
and to environmental protection.
- the cable reeling drum may only maintained or repaired by authorized, trained and in-
structed personnel.
- all work is to be accomplished carefully and under the aspect of "security".
- work on the cable reeling drum may be accomplished only in the switched off condi-
tion.
- The changed oil has to be filled into suitable container. Possibly developed oil on the
floor are to be eliminated immediately with an oil bonding agent. Strongly oil-soaked
cloths has to be kept in suitable containers. The waste oil is just like the oil bonding
agent and the cleaning cloths to be thrown according to the relevant environmental-
protection regulations.
- rotary drive components, like clutches, gear wheels or belt drives must be secured
against danger of accidents.
- at the cable reeling drum appropriate references, e.g. identification plate, rotation ar-
row etc. are to be considered. They must be free by colour and dirt. Missing ones de-
scribe have to be replaced.
No.:
B 00 069
page 1 from 2
Maintenance instruction
Screws/tightening torque
*CTVOCPP-ÑPKI
Stromzuführungs AG
Cable reeling drum – Hose – Special drums – Slip ring bodies
p.o.box 0100 76674 Graben-Neudorf phone: +0049-7255 / 7120-0
Siemensstraße 6 76676 Graben-Neudorf fax: +0049-7255 / 5038
www.hukag.com
E - Mail: info@hukag.com
No.:
Maintenance instruction B 00 069
Screws/tightening torque
page 2 from 2
1.0 Screws/tightening torque

Caution:
To avoid overloading the individual screws, the maximum tightening torque (see
table 6.1) must not be exceeded, what is more important is that the faces are flush. If
this flushness cannot be reached during clamping, consolations of us is necessary
maximum tightening torque per screw (with ȝ=0.1)

Clamping screw
thread Property class Property class Property class
8.8 Nm 10.9 Nm 12.9 Nm
M6 10 12 14.5
M8 25 29 35
M 10 50 58 70
M 12 90 100 121
M 14 -- 160 193
M 16 210 240 295
M 20 450 470 570
M 24 750 820 980
M 27 -- 1210 1450
M 30 1500 1640 1970
M 33 -- 2210 2650
M 36 2500 2850 3420
Table 6.1: Maximum tightening torque of the clamping screws
Note: Unserviceable screws should be replaced by new ones of the same property class
and type.

No.:
B 00 090
page 1 from 8
Maintenance Instruction
and Spare Parts List
for
Replacement of the Springs Type LT
*CTVOCPP-ÑPKI
Stromzuführungs AG
Cable Reeling Drum – Hose – Special Drums – Slip Ring Bodies
Siemensstraße 6 76676 Graben-Neudorf fax: +0049-7255 / 5038
www.hukag.com
EMail: info@hukag.com
No.:
Maintenance Instruction and Spare Parts List B-00 090
Type: LT parallel or in serial
page 2 from 8
List of Contents
1.0 Cable Reeling Drum parallel ............................................................................................. 3

1.1 Replacement of the broken Springs ................................................................................ 3
1.2 Installation of the new Springs......................................................................................... 4
1.3 Spare Parts List ................................................................................................................. 4
1.4 Spare Part Drawing ........................................................................................................... 5
2.0 Cable Reeling Drum in serial ............................................................................................ 6
2.1 Replacement of the broken Springs ................................................................................ 6
2.2 Installation of the new Springs......................................................................................... 7
2.3 Spare Parts List ................................................................................................................. 7
2.4 Spare Part Drawing ........................................................................................................... 8
*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

No.:
page 3 from 8
1.0 Cable Reeling Drum parallel

1.1 Replacement of the broken Springs
The Replacement of the springs are only accomplish by qualified technical per-
sonnel.
Attention: The springs are made of rolled flat steel. The consequences of this
properties are, that they want to go back to its primitive state. So you have to look
and be carefully about the danger of accidents by using this kind of springs.
Disconnect the main power cable from the slip rings and pull the cable out of the hollow
shaft. The winding cable can remains on the drum body if it is secured against automatic
unwinding. Otherwise it must be uncoil completely from the drum body.
Remove the reeling drum from the fixing flange by loosen the screws (customer side).
Now remove the cable gland (1), the circlip ring (2) and the fixing flange from the hollow
shaft and the feather key. Remove the shield (7) with the spring housing (10), the ball
bearing (8) and the bearing cover (9) by unscrewing of the fixing nuts (5 and 6). The ball
bearing (8) should not be removed from the shield (7).
Attention! If the shield (7) is lifting up itself from the spring housing (16) by loosen-
ing one of the last nut you have to tighten it immediately. After that please contact
us for specify the next procedure.
The springs (12) were now visible and can be replaced out of the spring housing (10),
with the spacer plate and with their bandage.
Handle with care!
If you have a cable reeling drum with more springs you have to repeat the procedure until
all springs are took out of the spring housing.

No.:
page 4 from 8
1.2 Installation of the new Springs

Before you attach the new spring make sure that the hollow shaft with the takener (14) is
clean and all broken spring parts are removed from the compartment (16).
Attention! The new springs should be handle with care. Never remove the spring
bandage because this could cause very serious accidents.
The new springs must be placed into position with the bandage on. It is also important to
ensure that the inner eyelet of the spring engages properly in the groove of the takener
(14) which is fixed on the hollow shaft. After that you have to grease the new spring well.
Further take into consideration that all springs have the same direction of rotating. Con-
sider the type designation for example LT300/… on the type plate. After that you have to
grease the springs well. Now you can assemble the cable reeling drum in reverse order.
Attention! The hollow shaft (15) has to be proper cleaned and the shield (7) with the ball
bearing (8) must be slide easier on it.
Item Description Piece
01 cable gland 1
02 circlip ring 1
03 fixing flange 1
04 nut M6 4
05 nut M6 8
06 nut M8 3
07 shield 1
08 ball bearing 1
09 bearing cover 1
10 spring housing 1
11 spacer plate
12 spring 1
13 spacer plate 1
14 takener (hollow shaft) 1
15 spring bolt 1
16 spring housing 1

No.:
page 5 from 8
1.4 Spare Part Drawing

Drawing no.: SK-5579-00

No.:
page 6 from 8
2.0 Cable Reeling Drum in serial

2.1 Replacement of the broken Springs
The Replacement of the springs are only accomplish by qualified technical per-
sonnel.
Attention: The springs are made of rolled flat steel. The consequences of this
properties are, that they want to go back to its primitive state. So you have to look
and be carefully about the danger of accidents by using this kind of springs.
Disconnect the main power cable from the slip rings and pull out the cable of the hollow
shaft. The winding cable can remains on the drum body if it is secured against automatic
unwinding. Otherwise it must be uncoil completely from the drum body.
Remove the reeling drum from the fixing flange by loosen the screws (customer side).
Now remove the cable gland (1), the circlip ring (2) and the fixing flange from the hollow
shaft and the feather key. Remove the shield (7) the spring housing (10), the ball bearing
(8) and the bearing cover (9) by unscrewing of the fixing nuts (5 and 6). The ball bearing
(8) should not be removed from the shield (7).
Attention! If the shield (7) is lifting up itself from the spring housing (16) by loosen-
ing one of the last nut you have to tighten it immediately. After that please contact
us for specify the next procedure.
The springs were now visible and can be replaced out of the spring housing (16) with the
spring housing (10), the spacer plate and with their bandage.
Handle with care!
Attention! This applies only for cable reeling drum types LT220 and LT530.
During the replacement of the spring you have to press down the takener (14) by
using an screwdriver for example. Otherwise the inner eyelet of the lower spring
can jump out of the spring housing (10).
A circlip ring is constructional handled that by the other cable reeling drum types.

No.:
page 7 from 8
2.2 Installation of the new Springs

Before you attach the new spring make sure that the axle is clean and all broken spring
parts are removed from the compartment (11).
Attention! The new springs should be handle with care. Never remove the spring
bandage because this could cause very serious accidents.
The new springs must be placed into position with the bandage on. It is also important to
ensure that the inner eyelet of the spring engages properly in the groove of the Takener
(14) which is fixed on the hollow shaft. Pay
attention by the last spring, because you
don’t see it correctly, that the spring bolt
engages properly in the outer eyelet of the
spring. Otherwise you have a malfunction
of the spring (see pic.).
Further take into consideration that one
spring should be placed with inverted
direction to the other to cause a serial
effect. Consider the type designation on the
type plate LT300 …/H (H = in serial) for
example. After that you have to grease the
spring well. Now you can assemble the cable
reeling drum in reverse order. Attention!
The shield (7) with the ball bearing (8) must
be slide easier on it.
Item Description Piece
01 cable gland 1
02 circlip ring 1
03 fixing flange 1
04 nut M6 4
05 nut M6 8
06 nut M8 3
07 shield 1
08 ball bearing 1
09 bearing cover 1
10 spring housing 1
11 spacer plate
12 spring 1
13 spacer plate 1
14 takener 1
15 spring bolt 1
16 spring housing 1
17 hollow shaft

No.:
page 8 from 8
2.4 Spare Part Drawing

Drawing no.: SK-5578-00

no.:
B-E 00 061
page 1 from 7


for
Hydraulically Released
Spring-applied Multi-plate Brakes
*CTVOCPP-ÑPKI
S t ro m zuf üh ru n gs A G
Cable Reeling Drum - Hose - Rope - Special Drums - Slip Ring Bodies
Siemens Street 6 76676 Graben-Neudorf fax: +49-7255 / 5038
www.hukag.com
E - Mail: info@hukag
Nr.:
Maintenance Instruction B-E 00 061
Hydraulically Released Spring-applied
Multi-plate Brakes series 0-022-..0/..9 Seite 2 von 7
*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 25.03.2008 Drawn by Lippmann

No.:
Hydraulically Released Spring-applied B-E 00 061
Multi-plate Brakes series 0-022-..0/..9 Page 3 from 7
*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann

No.:

No.:

No.:

No.:

3
141082 / 001
A
1
6
2
5
3
B C
D E
2
1
00520266.eps
Strictly follow the Instructions for Use
Any use of the apparatus requires full understanding and strict observation of these
instructions.
The apparatus is only to be used for purposes specified here.
Maintenance
The apparatus must be inspected and serviced regularly by trained service personnel.
Repair of the apparatus may only be carried out by trained service personnel.
We recommend that a service contract be obtained with Dräger Safety and that all repairs
also be carried out by them.
Only authentic Dräger spare parts may be used for maintenance.
Safety Symbols Used in these Instructions for Use

These Instructions for Use use a number of warnings for risks and hazards, which might
occur when using the apparatus. These warnings contain signal words, which will alert
you to the degree of hazard you may encounter. These signal words and corresponding
hazards are as follows:
DANGER
Indicates an immediate hazardous situation which, if not avoided, could result in death
or serious injury.
WARNING
Indicates a potential hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a potential hazardous situation which, if not avoided, could result in physical
injury or damage to property.
It may also be used to alert against unsafe practices.
NOTICE
Indicates additional information on how to use the apparatus.
Intended Use
PARAT C is a smoke hood designed for single use, which provides respiratory protection
against smoke and most hazardous combustible gases. It is designed for an escape
period of at least 15 minutes.
WARNING
Do not use the smoke hood at temperatures below -10 oC. The filter does not work
properly at low temperatures!
PARAT C with CO-P2 filter complies with EN 403:2004 (M) for mobile hoods or
EN 403:2004 (S) for stationary hoods. Only use the smoke hood for the purpose of
escaping in an emergency. Do not use during regular operations!
DANGER
The smoke hood is suitable for single use only. Dispose after use.
The smoke hood does not provide protection against oxygen deficiency!
Failure to observe this can lead to death or severe bodily injuries.
The nose cup fits all adults and children from the age of four.
What is What?
(Figure A)
1 hood 4 pull cord
2 nose cup 5 filter
3 adjustable strap 6 exhalation valve
Explanation of Symbols
Important! Strictly follow the Instructions for Use.
Suitable for storage until ...
70% Maximum humidity of storage conditions

20%
Temperature range of storage conditions
03
Date of manufacture (see explanations under
http://www.draeger.com/ST/internet/pdf/ 9021650_01_2005_MUL036.pdf)
Keep Smoke Hood Ready

Keep smoke hood ready within reach and protected against damage, e.g. at the
workplace, in your hand luggage or on the bedside table. Avoid high temperatures (e.g. do
not store on window sill).
Check the expiry date on the packaging. Do not manipulate the hood! If a filter sealing
plug on the smoke hood is incorrectly sealed or open (indicated by broken seal), the hood
can no longer be used!
CAUTION
The pull cords must be attached to the packaging. If this is not the case, the sealing
plugs are not automatically released when the escape hood is unpacked before use!
Memorise the Instructions for Use.
Use
WARNING
Only use hood if it is undamaged and the seal on the filter is still intact!
z Open packaging and remove smoke hood.
PARAT C twin pack:
Grip lid of the twin box at the top, pull forwards and remove smoke hood.
PARAT C single pack:
Open packaging and remove smoke hood.
PARAT C soft pack:
Open zipper and remove smoke hood.
PARAT C traveller pack:
Remove retaining clip, open box and remove smoke hood.
PARAT C box:
Lift lever with the index finger, then the rubber band will open.Open packaging and
remove smoke hood.
z Opening the filter (Figure B):
Hold smoke hood with one hand. Grip the two red pull cords with the other hand and
pull the sealing plugs completely out of their holes.
DANGER
Before using the smoke hood, ensure that the filter opening is free, since breathing will
otherwise be impaired!
z Put aside the packaging, pull cords and seal plugs.
z Using both thumbs, push the filter out of the hood from inside (Figure C).
z Grip the collar with both hands and open it wide.
z Put the chin into the smoke hood first (Figure D1).
z Pull the hood over the head (Figure D2).
Ensure that nose and chin are positioned inside the nose cup. If required, take hold
of the filter and move the nose cup so that it is positioned snugly around the mouth
and nose.
Ensure that the hair is covered completely by the smoke hood.
NOTICE
There is no need to remove spectacles.
z Tighten the adjustable strap until the nose cup is positioned snugly around the mouth
and nose, holding the filter with the other hand (Figure E).
z If it is not possible to tighten the adjustable strap, hold mask firmly in position using
the hand.
WARNING
Full beards can cause leaks and put the wearer of the hood at risk!
If the smoke hood is used by children, an adult should make sure that the nose cup is
positioned correctly around the chin and nose.
z Breathe calmly!
Breathing is slightly more difficult. The breathing air becomes noticeably warmer: this
is an indication of correct operation of the filter.
z Find an escape route to an emergency exit. If this is not possible, wait for the arrival
of the fire brigade! Knock on walls or stand at a window so that the rescuers can find
you.
Maintenance
The maximum lifetime of the smoke hood is 12 years from the date of manufacture.
The smoke hood must be maintained by qualified trained personnel only.
Replace filter and valve disc of an unused smoke hood if
– the sealing plugs of the filter for the smoke hood have been removed.
– the sealing is damaged.
– the expiry date shown on the box has been exceeded.
For this purpose, use spare-part kit R 57302.
Storage
Store the hood in the box in a cool and dry place. Do not expose to direct sunlight and
temperatures above 50 oC.
Disposal
Dispose of filter and hood in accordance with the applicable local waste disposal
regulations.
Order List
Name and Description Part No.
PARAT C single pack: R 52 817
PARAT C traveller pack: R 52 818
PARAT C twin pack: R 52 845
Seal D 12 378
Seal wire T 13 028
PARAT C soft pack: R 53 555
PARAT C box: R 54 461
Spare-part kit R 57 302
99
4
141082 / 001
OPERATING
INSTRUCTIONS
RADIO REMOTE CONTROL
VERSION
001 − 15.11.2006
LIEBHERR
RADIOREMOTECONTROL
INDEX
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
1.1. BASIC SAFETY PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
1.2. BATTERY AND BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 6

1.2.1. TRANSMITTER BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 6
1.2.2. BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 6
1.3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7
2. OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 8
2.1. OVERVIEW OF OPERATING CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . 1. 8
2.2. OVERVIEW OF DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 15

2.2.1. DISPLAYS WHILE CONNECTION IS BEING MADE . . . . . . . . . . . . . . . . . . . . . . . . 1. 15
2.2.2. ERROR DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 16
2.2.3. CHASSIS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 17
2.2.4. CRANE AND SERVICE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 20
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 23
3.1. OPERATIONAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
3.2. PUTTING INTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 24

3.2.1. SWITCHING ON THE REMOTE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 24
3.2.2. PREPARING THE CRANE FOR RADIO OPERATION . . . . . . . . . . . . . . . . . . . . . . . 1. 25
3.2.3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 26
3.3. SELECTING THE OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 27

3.3.1. FOLD DOWN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 27
3.3.2. SERVICE MODE WINCH 1 OR WINCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 28
3.3.3. SPREADER MODE BYPASS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 28
3.3.4. GRAB AND MOTOR GRAB OPERATOIN BYPASS KEY . . . . . . . . . . . . . . . . . . . . . 1. 28
3.4. STARTING AND STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 29

3.4.1. START DIESEL ENGINE IN ECO−MODE OR ELECTRO DRIVE . . . . . . . . . . . . . . 1. 29
3.4.2. START DIESEL ENGINE WITHOUT ECO−MODE . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 29
3.4.3. STOP DIESEL ENGINE OR ELECTRO−DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 29
3.5. EMERGENCY STOP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 30
3.6. INTERRUPTION TO RADIO CONNECTION . . . . . . . . . . . . . . . . . . . . . . . 1. 30

3.6.1 INTERRUPTION FOR LONGER THAN 0.5 s AND LESS THAN APPROX. 8 s. . 1. 30
3.6.2. INTERRUPTION FOR LONGER THAN APPROX 8 seconds . . . . . . . . . . . . . . . . . 1. 30
LIEBHERR
RADIOREMOTECONTROL
LIEBHERR
RADIOREMOTECONTROL
1. GENERAL
1.1. BASIC SAFETY PRINCIPLES

In many situations work is made easier if a crane or machine can be radio controlled.
However users must first get used to remote control operation!
− Please read through all of the operating instructions very carefully before you
work with the radio transmitter for the first time!
− It is essential that you observe all the safety instructions and safety information contained in the
operating instructions, as well as the points regarding general safety and accident prevention.
A fatal accident can be the result if these instructions are not strictly followed.
− The operating instructions must be kept accessible at the place of use!
− Only authorised and properly instructed staff are allowed to work with the radio transmitter.
− No person under the influence of drugs, alcohol or medication that can affect a person’s capacity
to react, must be allowed to start, operate, service or repair the radio transmitter.
− Before switching on the radio transmitter, make sure that no−one can be at risk by its operation.
− Use only original rechargeable batteries. The use of non−original rechargeable batteries can cause
performance and safety problems when they are recharged (the battery could over−heat or even
explode!).
− When a fault relating to operational safety and operational reliability is detected, the radio
transmitter must be
stopped immediately, or not put into
operation, i.e. the transmitter must be switched off.
− the transmitter must be protected from unauthorised access.
− switch off the supply voltage from the receiver.
− Pull out the connection cable on the receiver!
− Any faults must be fixed immediately!
− Only an expert is authorised to repair a faulty radio transmitter.
Use only original spare parts. If non−original spare parts are used, the safety of the appliance is
not longer guaranteed, and our extended warranty lapses. Only the statutory warranty regulations
shall apply in that case.
− It is essential that the appliance is checked or inspected at the prescribed intervals or at the
intervals stated in the operating instructions!
− Please observe without fail all work safety and accident prevention regulations applicable and in
force at the place of use!
The radio transmitter has been checked to EMC guidelines and meets all the relevant standards
with regard to interference emissions and interference resistance for use in industry.
− Always take care when working with the radio transmitter. This applies particularly when you
control a crane or a machine by radio for the first time.
−1.5− LIEBHERR
RADIOREMOTECONTROL
1.2. BATTERY AND BATTERY CHARGER
1.2.1. TRANSMITTER BATTERY
. IMPORTANT NOTE!
You need to fully charge the battery before using it for the first time!
A battery’s operating time depends on its age and the ambient temperature. Over time older batteries lose
their capacity. At temperatures below 0°C the battery does not achieve its full capacity.
If properly treated, a battery can be recharged over 500 times:
− Only recharge the battery when it is completely discharged, i.e. when the red
display is flashing on the transmitter and/or the audible signal is emitted.
− Do not keep the battery in your tool box or in your trouser pocket.
− Store batteries at room temperature (approximately 20°C).
− Always use the protective caps supplied when keeping the batteries.
Batteries stored for a long period of time should be charged before they are used.
1.2.2. BATTERY CHARGER
− Only type FuB10AA and FuB 10XL batteries should be charged on the FLG 11 0B charger.
− Do not operate the charger in potentially explosive areas.
− The charger must be operated only at the mains voltage stated on its base.
− The charger should be operated only in closed indoor rooms.
− Operate the charger at room temperature and protect it from
overheating, dust and humidity.
− The mains plug must be removed without fail before the device is opened.
− Do not cover the charger while it is in operation.
− Unplug the charger from the mains supply when it is not in use.
− The appliance must be taken out of operation if a fault occurs on the appliance or on the power cable.
− Do not make any technical changes to the charger or the power cable.
− Any repairs must be effected only by a specialist technician.
Charging the battery
1. Connect the charger to the power supply by plugging

in the connection plug.
2. Place the battery with the lettered panel facing outwards
into the charging shaft. Make sure that the battery
poles are in the correct positions.
The charging process now takes place automatically.
The current operational status is indicated on 3 LEDs
red LED The battery is faulty
yellow LED The battery is charging
green LED The battery is charged
Charging time is approximately 3 hours
−1.6− LIEBHERR
RADIOREMOTECONTROL
1.3. MAINTENANCE
The radio equipment requires almost no maintenance. Nevertheless you should take note of the following:
− Make sure that the switches operate smoothly.
Dirt of all kinds can hinder and even prevent switches from actuating.
− Regularly check the corrugated bellows on the operating controls for seal.
Any faulty corrugated bellows must be replaced immediately because penetrating
dirt and dampness can affect the operation of the controls.
− The transmitter batteries must be charged and discharged regularly.
− Never clean the transmitter with a high pressure cleaner.
− If necessary, clean the transmitter with a brush or a soft cloth.
− Make sure that no metal components are located above the antenna.
− Make a daily visual check of the antenna.
− If the antenna is damaged, immediately cease radio controlled operation.
. IMPORTANT NOTE!
In the event that problems occur with your radio equipment, please contact your
LIEBHERR Customer Services point
−1.7− LIEBHERR
RADIOREMOTECONTROL
2. OPERATING CONTROLS
2.1. VIEW OF THE OPERATING CONSOLE
"Crane operation" selector switch
Selections
Strut
Folding spars
Lateral drive mode (crab steering)
Drive mode
Crane operation normal hook lift
Crane operation heavy hook lift
Four−rope grab operation
Service mode winch 1
Cable drum manual
−1.8− LIEBHERR
RADIOREMOTECONTROL
Configuration of left−hand operating joystick
D E C
A Selections Function
Drive mode reverse movement
Crane operation Raise boom
Automatic strut Extend strut
B Selections Function
Drive mode move forwards
Crane operation Lower boom
Automatic strut Retract strut
C Selections Function
Crane operation Turn rotary platform clockwise
D Selections Function
Turn rotary platform counter−
Crane operation
clockwise
E Selections Function
Turn motor swing gear
Motor swing gear
counter−clockwise
Turn motor swing gear clock

Motor swing gear
wise
−1.9− LIEBHERR
RADIOREMOTECONTROL
Configuration of right−hand operating joystick
D C
E
A Selections Function
Crane operation Lift load
Operate cable drum manually Raise cable
B Selections Function
Crane operation Lower load
Operate cable drum manually Lower cable
C Selections Function
Four−rope grab / motor grab Open grab
Drive mode Steer to right
Spreader Open twistlocks
D Selections Function
Four−rope grab / motor grab Close grab
Drive mode Steer to left
Spreader Close twistlocks
E Function
Horn
−1.10− LIEBHERR
RADIOREMOTECONTROL
Toggle switch
Selections Function
Strut arm 1 extend
Strut 1 retract
Grab Grab blocked goods
Strut arm 1 retract
Strut 1 extend
Flipper switch, red down
Toggle switch
Selections Function
Strut arm 2 extend
Strut 2 retract
Grab descend
Strut arm 2 retract
Strut 2 extend
Flipper switch, white down
Toggle switch
Selections Function
Spreader telescope out
Grab raise
Spreader telescope in
Magnet switch off
−1.11− LIEBHERR
RADIOREMOTECONTROL
Toggle switch
Selections Function
counterbalance spreader
Spreader
to black flipper switches
Strut automatic strut
Magnet switch off
Counterbalance spreader
Spreader
to white flipper switches
Toggle switch
Selections Function
Strut arm 3 extend
Strut 3 retract
Magnet Fade out
Strut arm 3 retract
Strut 3 extend
Black flipper down
Toggle switch
Selections Function
Strut arm 4 extend
Strut 4 retract
Magnet switch on
Strut arm 4 retract
Strut 4 extend
Green flipper down
−1.12− LIEBHERR
RADIOREMOTECONTROL
"Display illumination" button
"Start/stop engine" and "idle/full power" button
"Free−wheel rotator"
"All flippers up" button
"Bypass" button
−1.13− LIEBHERR
RADIOREMOTECONTROL
"Lighting" button
"Twin Spreader" button
"Battery charge status" LED
Master key−operated switch (on the left−hand side)
Emergency stop button (on the right hand side)
−1.14− LIEBHERR
RADIOREMOTECONTROL
2.2. OVERVIEW OF DISPLAYS
2.2.1. DISPLAYS WHILE CONNECTION IS MADE
Interruption to connection between transmitter and receiver
Connection between transmitter (console) and receiver in crane is faulty.
Interruption to connection between receiver and crane control system
Connection between transmitter (console) and receiver in crane is OK.

Connection between receiver and crane control system is faulty.
Interruption to connection between

transmitter and receiver
Interruption to connection between

receiver and crane control system
−1.15− LIEBHERR
RADIOREMOTECONTROL
2.2.2. ERROR DISPLAY
In the event that there is a fault on the crane which would normally appear on the crane’s screen in the
form of a text message, this is now simply indicated by a flashing stop light on the control console screen.
No text messages are displayed on the control console screen.
The page displays in flashing and beep mode if a fault occurs on the crane (text
message on the crane screen).
Interruption to connection between receiver and crane control system
If the connection between the transmitter and the receiver is lost for a short period (less than 8 seconds),
all the master switches and toggle switches must be put back to their home positions, so that further
movement can take place. This requirement to set all switches to home is displayed to the operator in the
form of a STOP symbol which remains on the screen until all the master switches and toggle switches
have been set to home position.
. IMPORTANT NOTE!
As soon as a STOP symbol appears on the control console screen, radio operation must cease
immediately! The error message on the crane screen must be read out!
−1.16− LIEBHERR
RADIOREMOTECONTROL
2.2.3. CHASSIS PAGE
Current load Pos1 Pos2 Pos3 Pos4 Pos5
Pos6 Pos7 Pos8
Maximum load
Pos9 Pos10 Pos11
Progress
Position 1: Operating mode is active when the symbol is active;
Crab steering
Normal steering
Operation to move the folding spars
Operation to move the strut

Flashes when drive operation is not possible, strut can only be moved out;
Position 2:
Overload exceeded; symbol flashes;

Beeper active;
Load warning threshold exceeded (97.5%); symbol flashes;

Beeper active;
Turret not bolted; Symbol active;

Turret not bolted and turret bolted signals are the same; symbol flashes;
automatic strut ready but still activated; symbol active;

automatic strut not ready but activated; symbol active;
Wheel sets at zero position; symbol active;

Wheels not synchronous with selected drive mode; symbol flashes;
−1.17− LIEBHERR
RADIOREMOTECONTROL
Position 3:
Folding spar not in position; symbol flashes;
Wheel set − no pressure or support plate on floor; symbol flashes;

Beeper active;
Land feed plugged; symbol flashes;
Key to climb into undercarriage pressed; symbol flashes for 10 seconds;

Beeper is active during that period;
Level of diesel in main diesel tank is below 5%; symbol flashes;

Beeper active for 10 seconds;
Position 4:
Folding spar in position, strut on floor and no pressure at wheel sets; symbol active;
Folding spar in position and folding spar or strut are moving; symbol flashes;
Folding spar not in position, strut on floor and no pressure at wheel sets;
symbol active;
Folding spar not in position and strut or folding spar are moving;
symbol flashes;
Position 5:
Diesel engine preheating; symbol active;
symbol active;
symbol flashes;
Position 6:
Drive mode has been selected; load, slewing gear position or unload position not in drive range
(Selection not possible); symbol flashes;
Drive mode active; load, slewing gear or unload position is now out of drive range;
Symbol flashes;
−1.18− LIEBHERR
RADIOREMOTECONTROL
Position 7:
symbol active;
symbol flashes;
Position 8:
symbol active;
symbol flashes;
Position 9:
Slewing gear in drive position; symbol active;

Slewing gear not in drive position; symbol flashes;
Position 10:
Wind speed exceeded; symbol flashes; beeper active;
Position 11:
Engine symbol (for function see 3.4 "Starting and stopping the unit")
−1.19− LIEBHERR
RADIOREMOTECONTROL
2.2.4. CRANE AND SERVICE PAGE
Pos1 Pos2 Pos3 Pos4 Pos5 Current load
Pos6
Pos7 Wind speed
Pos8
Wind symbol
Pos9 Pos10 Pos11
Unload Maximum load

Current load
Position 1: Operating mode is active when the symbol is active;
Hook operation, normal lift
Rotator operation, normal lift
Spreader operation, Twistlock open
Spreader operation, Twistlock closed
Motor grab operation
Hook operation, heavy lift
Rotator operation, heavy lift
Grab operation, grab open
Grab operation, grab closed
Grab operation, blocked goods key activated
Magnet operation
Magnet switched on
Cable drum, manual operation
Additional function, fold down mode
−1.20− LIEBHERR
RADIOREMOTECONTROL
Position 2:
Overload exceeded; symbol flashes;

Beeper active;
Load warning threshold exceeded (97.5%); symbol flashes;

Beeper active;
Turret not bolted; Symbol active;

Turret not bolted and turret bolted signals are the same; symbol flashes;
Service operation winch 1 or winch 2 and bypass key pressed;

Symbol active;
Load threshold in magnet operation; symbol active;
Spreader landed; symbol active;
Position 3:
Folding spar not in position; symbol flashes;
Slack rope winch 1 and 2 or slack rope due to load threshold; symbol flashes;
Beep signal on slack rope winch 1 and winch 2 active;
Slack rope winch 1; symbol flashes; beeper active;
Slack rope winch 2; symbol flashes; beeper active;
Difference in rope length too great or bypass key is pressed in service mode winch 1 or winch 2;
Symbol flashes;
Slewing gear stop left and right;
Slewing gear stop right;
Slewing gear stop left;
Wheel set − no pressure or support plate not on floor; symbol flashes;
Key to climb into undercarriage pressed; symbol flashes for 10 seconds;

Level of diesel in main diesel tank is below 5%; symbol flashes;

−1.21− LIEBHERR
RADIOREMOTECONTROL
Position 4:
Stop raising/lowering lifting gear
Stop raising lifting gear
Stop lowering lifting gear
Position 5:
Stop raising/lowering bascule gear
Stop raising bascule gear
Stop lowering bascule gear
Position 6:
Crane and service operation; symbol active;

Wind speed exceeded; symbol flashes; beeper active;
Position 7:
Lifting gear raise/drive, symbol flashes;
Position 8:
Lifting gear lower/drive, symbol flashes;
Position 9:
Bascule gear raise/drive, symbol flashes;
Position 10:
Bascule gear lower/drive, symbol flashes;
Position 11:
Engine symbol (for function see 3.4 "Starting and stopping the unit")
−1.22− LIEBHERR
RADIOREMOTECONTROL
3. OPERATION
3.1. OPERATIONAL SAFETY INFORMATION

− When using the radio control unit choose a safe place in which to stand, where
you can see the entire working range. You must be able to ensure visual
contact with the crane and the load.
− Depending on the angle of vision between the radio control unit and the crane or
the machine, commands such as "turn left" or
"turn right"; can obviously change! Think about your position in relation to the crane or the machine,
before you start a procedure.
− In an emergency or if any interference is caused to the working area of the crane
or the machine, you must, without fail, switch off the radio controller!
In the event of a technical fault on the radio controller, the radio system must
be put out of operation!
− It is essential that you switch off the radio controller when taking a break from work, or at the end of a
shift!
This will prevent the crane or machine from movements caused by inadvertent
operation of the controls.
This is particularly important in situations where you have moved away from your safe
position, and, for example, if you need to climb over an obstacle.
− It is absolutely prohibited to place a transmitter that is switched on in an
unsupervised position! It is essential that you observe the applicable regulations
relating to work safety and accident prevention.
− No person may stand underneath a load or in the hazardous area!
. IMPORTANT NOTE!
If during a procedure the radio connection is interrupted briefly, the transmitter and receiver react
by indicating what is known as the "home position requirement".
This means that you must release all operating controls such as the small master switches or
push−buttons, so that they all return to the home position. Only once this has been done will the crane
or machine react again to radio commands! This prevents uncontrolled movement of the crane or
machine once the radio connection is restored.
If you are working with a radio control unit for the first time, at first you will probably miss the physical
contact with the crane to which you are accustomed at the control stand inside the crane. If at first
the reaction of the crane appears different, it is because you do not feel the crane movements quite
so perceptibly as when you are actually on the crane.
−1.23− LIEBHERR
RADIOREMOTECONTROL
3.2. PUTTING INTO OPERATION

3.2.1. SWITCHING ON THE REMOTE CONTROL UNIT
− Insert a fully charged battery with the
lettering facing outwards into the battery compartment.
. IMPORTANT!
Make sure that the battery poles are in the correct positions.
− The remote controls are selected at the 4T−S01 switch (side panel of switch cabinet).
− Use the master key at the side of the operating console to switch on the transmitter.
− Once the connection between the transmitter and receiver has been made, the horn image is displayed.
. IMPORTANT NOTE!
The horn symbol also appears when the radio connection is switched back on
after an interruption longer than 4 seconds, or after an emergency stop.
− Press the horn key to switch on the crane control system.

While the system is starting up a plug connector displays on the screen; this means that the receiver with
the control system is trying to make a connection.
− If this is successful, depending on the position of the selector knob, either the crane image or the drive
image appears.
. IMPORTANT NOTE!
If there is a fault at the crane (text message), the screen shows a flashing stop symbol and it also
beeps. Error messages cannot be output on the screen. For this reason any faults must be rectified
immediately!
The screen in the rotary platform cabin or turret cabin is active while the radio remote control
is switched on and the crane control system is operational.
−1.24− LIEBHERR
RADIOREMOTECONTROL
3.2.2. PREPARING THE CRANE FOR RADIO OPERATION
− Make sure that no load is suspended from the hook!

− Switch the key−operated switch on the control cabinet from 0 to 1!
− The lamp immediately lights up to signify active status!
. IMPORTANT NOTE!
When the switch is operated, the crane’s ignition is automatically switched on!
you should note the following:

− The joysticks and the control consoles in the rotary platform cabin and the turret cabinet are deactivated!
− Both monitors (the one in the rotary platform cabin and the turret cabin) are activated so that any error
messages can be read out.
− In both cabins, the operation release levers are bypassed.
Warning! A danger exists when the radio remote control is switched on!
The radio remote control system is active as soon as radio operation is
enabled by actuating the switch on the control cabinet!
If any of the controls are inadvertently activated when the radio remote
control is switched on, a function will be triggered.
− Make sure that all the control and operation elements are at
resting position when you switch on!
− Make sure that you have read and understood all the safety
regulations in 1.1 and 3.1!
−1.25− LIEBHERR
RADIOREMOTECONTROL
3.2.3. TROUBLESHOOTING
Fault Possible cause Remedy

No reaction when No operating voltage − Fully charge the battery.
the transmitter is is present. − Insert a charged battery into
switched on. the battery compartment.
− Check the battery contacts for
any damage or contamination.
Low voltage warning − The battery is not charged. − Fully charge the battery.
even after a short − The battery contacts are − Check that the charging process
period of operation, i.e. dirty or damaged. is running correctly.
the status indicator on − The battery is faulty. − Check the transmission function with
the transmitter is flash a fully charged battery or with
ing red. a replacement battery.
− Check the battery contacts for
any damage or contamination.
ATTENTION!
Do not continue working with a faulty radio control system!
Do not attempt to reach into the electronics on the radio transmitter.

Send the defective appliance immediately to your LIEBHERR Customer Services point. They are familiar
with the system, and have the necessary original spare parts.
In principle always send the transmitter and the receiver, and enclose a detailed fault report.
−1.26− LIEBHERR
RADIOREMOTECONTROL
3.3. SELECTING THE OPERATING MODE
Once the crane control system has been switched on, unlike in the crane cabin, the most recently used
operating mode is not automatically reselected.
When the crane control system is switched on no operating mode is selected.
To select the operating mode, once the crane control system is operational, you need to set the rotary
switch to the required position. If it is already at the required position, you need to
leave that position, and reselect it.
. IMPORTANT NOTE!
Make sure that the motor is running, and all master switches and toggle switches are at home
setting (home position requirement).
If the required operating mode is available in the crane’s current position, it is activated. In normal lift and
heavy lift operation, a difference is made between the two options by means of the signal placed.
The operating mode depends on the signal placed (e.g. slewing gear, spreader,
etc.) and the position of the crane.
(e.g. supported, rotary gear position, etc.)
3.3.1. FOLD DOWN OPERATION
Fold down operation is possible only with the hook or rotator.
In order to fold down the boom, on the selector knob, select crane operation, hook. Then hold down the
bypass key to activate fold down operation. This remains active all the while the bypass key is kept
depressed. If it is released for longer than 1 second, the fold down operation is deselected. This means
that it is necessary to start again at the selector switch and bypass key if you wish to continue the fold
down operation.
The bypass key must be kept held down. If the bypass key is released for more
than 1 second −> operating mode is deselected− > start again.
−1.27− LIEBHERR
RADIOREMOTECONTROL
3.3.2. SERVICE MODE WINCH 1 OR WINCH 2
By turning the selector knob to the Winch 1 or Winch 2 position,

the operating mode is selected. However in order to drive with the winch, the bypass switch must also be
depressed.
The bypass key must be kept held down so that the required winch.
can be driven.
3.3.3. SPREADER OPERATION BYPASS KEY
In spreader mode it is possible to bypass the load threshold and the signal it has triggered by holding
down the bypass key. This makes it possible to lower further if this is needed. It can be very helpful to
bypass the load threshold when constructing or dismantling the spreader from the crane. In spreader
mode it is possible to lower only up to this load threshold.
The bypass key must be kept held down in order to bypass the load threshold or
the signal it has triggered.
3.3.4. GRAB AND MOTOR GRAB MODE BYPASS KEY
In grab and motor grab mode a ’stop lowering’ command is triggered via a load threshold, and this is
displayed by means of the slack rope symbol. In order to be able to bypass this stop command, the
bypass key has to be held down. This can be very helpful when re−suspending loads.
The bypass key must be kept held down in order to bypass the load threshold.
−1.28− LIEBHERR
RADIOREMOTECONTROL
3.4. STARTING AND STOPPING THE UNIT
Once the console has been switched on, the top right−hand corner of the screen displays a symbol
indicating that the engine is heating up. Once this symbol has disappeared, the engine can be started.
The diesel engine is started at the engine key.
When the diesel engine is running, an engine symbol appears at the bottom right−hand corner of the
screen, either flashing or constant. This depends on whether you are starting the electro−drive or the
diesel engine in Eco mode or not.
3.4.1. START DIESEL ENGINE IN ECO MODE OR ELECTRO DRIVE
Start the unit by briefly pressing the engine key. While the engine is starting, the engine symbol at the
bottom right−hand of the screen is flashing. When everything is ready for operation, the engine symbol
stops flashing and becomes solid.
Unit switched off: no engine symbol

Unit starting up: engine symbol flashing
Unit ready for operation: engine symbol active
3.4.2. STARTING THE DIESEL ENGINE WITHOUT ECO MODE
Start the diesel engine by briefly pressing the engine key. If the diesel engine is at idle power, this is
indicated on the screen by a flashing engine symbol at the bottom right edge of the screen. If you briefly
press the engine key again, the diesel engine switches to full power. When everything is ready for
operation, the engine symbol on the screen stops flashing and becomes solid. If you press the key again,
the diesel engine returns to idle power.
Diesel engine switched off: no engine symbol

Diesel engine at idle power: engine symbol flashes
Diesel engine at full power (ready for operation): engine symbol active
If you briefly press the engine key, the engine goes to full or idle power.
3.4.3. STOP DIESEL ENGINE OR ELECTRO−DRIVE
To switch off the diesel engine, you have to hold down the engine key for more than 2 seconds.
Press engine key for more than 2 seconds − > engine stops.
−1.29− LIEBHERR
RADIOREMOTECONTROL
3.5. EMERGENCY OFF BUTTON
If the emergency switch is pressed on the control console, it has the same effect as the emergency switch
on the crane, i.e. it switches off the crane completely, including the control system.
However,to switch the control unit back on, you need to release not only the emergency off switch as in
the crane, but you also need to switch the control console back on using the key−operated switch.
Once the emergency off button has been pressed and then released again, the
control consol must be switched back on with the key.
The crane control system must then be switched back on at the horn key. This is displayed on the screen
by means of the horn symbol.
3.6. INTERRUPTION TO RADIO CONNECTION
3.6.1. INTERRUPTION FOR LONGER THAN 0.5 s AND LESS THAN APPROX. 8 s
If an interruption to the radio connection occurs for more than 1 second but less than 8 seconds, the
interrupted connection symbol displays on the screen.
The mechanisms are blocked and movements are braked down for an integration period.
When the radio connection is restored, the movements are not automatically restored. This can only
happen once all the master switches and toggle switches have been returned to their home positions.
After an interruption to the radio connection, home position requirement for

master switches and toggle switches.
Until the master switches and toggle switches have been reset to their home positions, the stop symbol is
constantly displayed on the screen.
Once the home position requirement is met, you can restart movements.
3.6.2. INTERRUPTION FOR MORE THAN APROX. 8 SECONDS
If the interruption to the radio connection was for more than 8 seconds, the radio control system receiver
automatically triggers a passive emergency off signal. Like a normal emergency stop, this switches off the
entire crane, including the control system.
The interrupted connection symbol is displayed on the screen all the while the connection is interrupted.
Once the connection has been restored the horn symbol is displayed on the screen and the crane control
system can be switched on again by pressing the horn key.
−1.30− LIEBHERR
5
141082 / 001
DOCUMENTATION
Schwenkwerk-Typ / Slewing Unit Type:
SW 144 DISK
Bestell-Nr. / Order-no.:
2308.0453
Version / Version:
EC00407
Ident-Nummer / Identification-no.:
10514223
gültig für SW 144 DISK ab Seriennummer:

valid for SW 144 DISK from serial number:
0279 (bis zur Festlegung des Gültigkeitsbereichs)
(until the application range is specified)
6DO]JLWWHU0DVFKLQHQEDX$* 7HOHIRQ (PDLO 9RUVWDQG 6LW]GHU*HVHOOVFKDIW6DO]JLWWHU%DG

:LQGPKOHQEHUJVWUDH SHLQHU#VPDJGH 6HEDVWLDQ+%UDQGHV9RUVLW]HQGHU 5HJLVWHUJHULFKW
6DO]JLWWHU*HUPDQ\ 7HOHID[ ,QWHUQHW -UJHQ%LDOHN $PWVJHULFKW%UDXQVFKZHLJ
ZZZVPDJGH 9RUVLW]HQGHUGHV$XIVLFKWVUDWHV 5HJLVWHUQXPPHU
ZZZSHLQHUGH 8OULFK'HFNHU +5%
30.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
Sortier-Nr. Blatt-Nr.
A 16.0138-1 D 1-1
I n h a l t s v e r z e i c h n i s
Blatt-Nr. Sortier-Nr.
Maschinenkarte / Technische Daten
1.0 Sicherheit
1.1 Zu diesem Dokument 2-1 A 16.0200-1 D
1.2 Zielgruppe 2-1 A 16.0200-1 D
1.3 Bestimmungsgemäße Verwendung 2-1 A 16.0200-1 D
1.4 Grundlegende Sicherheitshinweise 2-2 A 16.0200/2-7 D
1.4.1 Warnhinweise 2-2 A 16.0200-2 D
1.4.2 Sicherheitszeichen 2-2 A 16.0200-2 D
1.4.3 Organisatorische Maßnahmen 2-3 A 16.0200-3 D
1.4.4 Personalauswahl und -qualifikation 2-4 A 16.0200-4 D
1.4.5 Maßnahmen durch den Betreiber 2-4 A 16.0200-4 D
1.4.6 Maßnahmen durch den Bediener 2-5 A 16.0200-5 D
1.4.7 Maßnahmen zu Wartung, Instandhaltung und 2/5-6 A 16.0200/5-6 D
Instandsetzung
1.4.8 Sicherheitshinweise zu Elektrik 2/6-7 A 16.0200/6-7 D
1.4.9 Sicherheitshinweise zu Hydraulik 2-7 A 16.0200-7 D
1.4.10 Umgang mit Ölen, Fetten und anderen 2-7 A 16.0200-7 D
chemischen Substanzen
2.0 Beschreibung und Übersichten

2.1 Grundgerät: Bau- und Funktionsbeschreibung
2.1.1 Baubeschreibung 3-1 A 16.0322 D
2.4 Teilebenennungsplan 7-1 A 16.1036 D
3.0 Betriebsanleitung
3.1 Hinweise für den sicheren Betrieb 8/1-2 A 16.0619/1-2 D
3.2 Inbetriebnahme
3.2.1 Montageanleitung - Erst-Inbetriebnahme 8/3-4 A 16.0619/3-4 D
3.2.2 Tägliche Inbetriebnahme 8-5 A 16.0619-5 D
3.3 Betrieb
3.3.1 Hinweise für den Betrieb 9-1 A 16.1218 D
3.4 Außerbetriebnahme 9-1 A 16.1218 D
3.5 Wieder-Inbetriebnahme 9-1 A 16.1218 D
3.6 Transport 9-1 A 16.1218 D
Originalbetriebsanleitung
30.09.2010
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A 16.0138-2 D 1-2
I n h a l t s v e r z e i c h n i s
Blatt-Nr. Sortier-Nr.
4.0 Instandhaltung 10-1 A 16.1222-1 D
4.1 Pflege und Wartung 10-2 A 16.1222-2 D
4.1.1 Wartungsübersicht 10-2 A 16.1222-3 D
4.1.2 Wartungsintervall nach den ersten 10-2 A 16.1222-4 D
50 Betriebsstunden
4.1.3 Wartungsintervall nach den ersten 10-2 A 16.1222-4 D
500 Betriebsstunden
4.1.4 Wartungsintervall wöchentlich 10-2 A 16.1222-5 D
4.1.5 Wartungsintervall alle 1000 Betriebsstunden 10-2 A 16.1222-6 D
4.1.6 Wartungsintervall alle 2000 Betriebsstunden 10-2 A 16.1222-7 D
4.1.7 Ölwechsel 10-2 A 16.1222-8 D
4.1.8 Ölfilter 10-2 A 16.1222-9 D
4.1.9 Schmieranweisung 10-2 A 16.1222-9 D
4.1.10 Schmierstellen 10-2 A 16.1222-10 D
4.1.11 Motor 10-2 A 16.1222-11 D
4.1.12 Schleifringübertrager 10-2 A 16.1222-12 D
4.2 Durchzuführende Prüfungen
4.2.1 Ölstand prüfen 10-2 A 16.1222-13 D
4.2.3 Abnutzung 10-2 A 16.1222-13 D

4.2.4 Sonstige Prüfungen 10-2 A 16.1222/13-18 D
4.3 Instandsetzung
4.3.1 Allgemeines 10-3 A 16.0722/1-2 D
4.3.2 Austausch des Hydraulikmotors 10-3 A 16.0722-3 D
4.3.3 Austausch der Hydraulikpumpe 10-3 A 16.0722-4 D
4.3.4 Austausch der Achslagerung 10-3 A 16.0722-5 D
4.3.5 Austausch des Ritzels 10-3 A 16.0722/6-7 D
4.4 Ölempfehlung 11/1-2 A 16.0721/1-2 D
4.5 Schmierstoffempfehlung 11/3-5 A 16.0721/3-5 D
5.0 Störung - Kennzeichen - Fehlerquellen

5.1 Schwenkwerk arbeitet nicht 12-1 A 16.0757 D
5.2 Schwenkwerk bringt keine Leistung 12-1 A 16.0757 D
6.0 Ersatzteilliste und Greiferzubehör Elektrik
Originalbetriebsanleitung
Erzeugnis: SW 144 DISK

Material-Nr.: 0023080453 Betriebsanleitung: A 16.0138
gültig für SW 144 DISK ab Werks-Nr.: 0279 (bis zur Festlegung des Gültigkeitsbereichs)
Eigengewicht: 3.600 kg
Tragfähigkeit SWL: 144.000 kg
erf. Krantragfähigkeit: 147.600 kg
Mechanische Daten
-1
Drehzahl / Achse: 5,4 / 6,8 min
Drehmoment / Achse: 4850 Nm
Elektrische Daten
Betriebsart: S3 Schutzart: IP 56 1)
Motor-Typ: 112M-4 Isolierklasse: F
Aussetzbetrieb: 40% ED max. Schalthäufigkeit: 120 /h
Motorleistung: 3,5 / 4,2 kW Schaltplan-Nr.: 2307.9132
Spannung: 400 V Steckvorrichtung: ODU-37 pol.
Frequenz: 50 / 60 Hz Steuerspannung: 230 V AC
Stromart: Drehstrom Anzahl d. Schleifringe: 31pol.x36A+PE+2 CAN
Nennstrom (Vollast): 7,9 A ± 10 % BUS
Stromaufnahme (Leerlauf):
Hydraulische Daten
max. Betriebsdruck Drehrichtung rechts [± 10 bar] 2) Drehrichtung links [± 10 bar]
2)
Messstelle MA 200
Messstelle MB 200
Pumpentyp / Fördermenge: P3DB2006L10 / 8,5 Liter/min

Steuerblock:
Hydromotor: M 300
eingefüllte Ölsorte: HLP 46
Ölmenge: 31 l
Filtertyp: Argo
Filterfeinheit: ȕ16(c) = 200 Exapor
zul. Betriebstemperatur: - 15 °C bis + 85 °C
verwendete Schmierfettsorte: Renolit GR 2 FUCHS EUROPE SCHMIERSTOFFE GMBH
verwendete Schmierfettsorte Elektromotor: PETAMO GY 193 KLÜBER LUBRICATION
verwendeter Zahnradschmierstoff: Zählit VZ Möllenberg & Sonntag OHG
Zubehör
– Kreuzstück mit Doppelhaken Nr. 32
1)
Schutzart nur mit montierter und geschlossener Haube
2)
mit Blickrichtung von oben auf Haube / Schleifringübertrager
Erstellt: 15.10.2011 / VG-K - Skiba

Abmessungen
Erstellt: 15.10.2011 / VG-K - Skiba

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1.0 Sicherheit
1.1 Zu diesem Dokument

Diese Betriebsanleitung ist Bestandteil dieser Maschine und beschreibt die sichere und
sachgemäße Anwendung in allen Betriebsphasen.
Änderungen im Interesse der Weiterentwicklung unserer Produkte vorbehalten.
X Diese Maschine nur unter Beachtung der Betriebsanleitung verwenden.
X Betriebsanleitung ständig in der Nähe der Maschine aufbewahren.
X Diese Betriebsanleitung zum späteren Gebrauch aufbewahren.
X Betriebsanleitung an jeden nachfolgenden Benutzer oder Besitzer der Maschine
weitergeben.
1.2 Zielgruppe
Zielgruppe dieser Betriebsanleitung ist technisches Fachpersonal.
Die Maschine darf nur von technischem Fachpersonal bedient, gewartet und / oder
instandgesetzt werden die in das sachgemäße Arbeiten eingewiesen sind.
1.3 Bestimmungsgemäße Verwendung

Das Schwenkwerk ist für den Einsatz im gewerblichen Bereich vorgesehen.
Das Schwenkwerk ist ausschließlich zum Heben von frei stehenden Lasten sowie zum
Drehen und Transport von frei hängenden Lasten zu verwenden.
Die Beachtung der Bedienungsanweisung dieses Schwenkwerks sowie die Einhaltung
den Inspektions- – und Wartungsbedingungen sind Bestandteil der bestimmungs-
gemäßen Verwendung.
Der Hersteller haftet nicht für resultierende Schäden aus darüber hinausgehender, nicht
bestimmungsgemäßer Verwendung. Das Risiko hierfür trägt allein der Betreiber.
Eine nicht bestimmungsgemäße Verwendung ist zum Beispiel:
- Losreißen nicht frei stehender Lasten
- Horizontales Bewegen nicht frei hängender Lasten
- Vergrößern der Last, nachdem diese bereits angehoben wurde
- Pendeln oder Schwingen der Last
- Jede Belastung über die zulässige Tragfähigkeit hinaus (siehe SWL Angabe auf
dem Schwenkwerk)
- Heben oder Ziehen von Lasten schräg vom Standort
- Mitfahren von Personen auf der Last oder dem Schwenkwerk
- Das Betrieben des Schwenkwerks mit höherem Betriebsdruck als vorgegeben.
- Der Einsatz in explosionsfähiger Atmosphäre
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1.4 Grundlegende Sicherheitshinweise
1.4.1 Warnhinweise
Warnhinweise in dieser Betriebsanleitung weisen auf besondere Gefahren hin und
nennen Maßnahmen zum Vermeiden der Gefahr.
Warnhinweise gibt es in vier Stufen:
Signalwort Bedeutung
GEFAHR Unmittelbar bevorstehende Gefahr
Tod oder schwere Verletzung tritt ein
WARNUNG Möglicherweise bevorstehende Gefahr
Tod oder schwere Verletzung kann eintreten
VORSICHT Möglicherweise bevorstehende Gefahr
(Personenschaden) Leichte Verletzung kann eintreten
VORSICHT Möglicherweise bevorstehende Gefahr
(Sachschaden) Sachschaden kann eintreten
Warnhinweise sind folgendermaßen aufgebaut:
Art und Quelle der Gefahr!

Mögliche Folgen, Erläuterung der Gefahr.
: Tun Sie ... nicht.
GEFAHR
X Führen Sie diese Maßnahmen durch.
1.4.2 Sicherheitszeichen
Warnung vor elektrischen Gefahren

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1.4.3 Organisatorische Maßnahmen

Die Betriebsanleitung ständig am Einsatzort des Schwenkwerks griffbereit aufbewahren!
Ergänzend zur Betriebsanleitung allgemein gültige gesetzliche und sonstige verbindliche
Regelungen zur Unfallverhütung und zum Umweltschutz beachten und anweisen!
Derartige Pflichten können z. B. auch den Umgang mit Gefahrstoffen oder die
Bereitstellung / das Tragen persönlicher Schutzausrüstungen oder straßenverkehrs-
rechtliche Regelungen betreffen.
Das Schwenkwerk ist nach dem Stand der Technik gebaut und bei bestimmungs-
gemäßer Verwendung betriebssicher. Von dieser Maschine können aber Gefahren
ausgehen, wenn sie von uneingewiesenem oder unachtsamem Personal unsachgemäß
oder zu nicht bestimmungsgemäßem Gebrauch eingesetzt wird (siehe
1.3 Bestimmungsgemäße Verwendung, Blatt-Nr. 1-1). Für darüber hinausgehende
Verwendung und daraus resultierende Schäden haftet der Hersteller nicht. Das Risiko
hierfür trägt allein der Anwender.
Das Schwenkwerk darf nur in technisch einwandfreiem Zustand betrieben werden.
Während des Einsatzes des Schwenkwerks ausreichenden Sicherheitsabstand zur Last
und dem Schwenkwerk einhalten! Der Aufenthalt unterhalb des Schwenkwerks ist
verboten!
Das mit Tätigkeiten am Schwenkwerk beauftragte Personal muss vor Arbeitsbeginn die
Betriebsanleitung, und hier besonders das Kapitel "Sicherheit", gelesen haben. Dies gilt
besonders für Personal, das nur gelegentlich am Schwenkwerk arbeitet, z. B. beim
Rüsten und Warten.
Alle Sicherheits- und Gefahrenhinweise am Schwenkwerk beachten und vollzählig in
lesbarem Zustand halten!
Bei sicherheitsrelevanten Störungen oder Änderungen des Betriebsverhaltens das
Schwenkwerk sofort stillsetzen und Störung der zuständigen Stelle/Person melden!
Betriebsanleitung um Anweisungen einschließlich Aufsichts- und Meldepflichten zur
Berücksichtigung betrieblicher Besonderheiten ergänzen, z. B. hinsichtlich Arbeits-
organisation, Arbeitsabläufen und eingesetztem Personal.
Das Anschlagen von Anschlagmitteln (Anschlagseile oder -ketten) nur an den dafür
angebrachten Einrichtungen vornehmen (z. B. am Doppelhaken).
Ausreichende Tragfähigkeit der Anschlagmittel vor dem Heben prüfen!
Keine Veränderungen, An- und Umbauten an der Maschine, die die Sicherheit
beeinträchtigen könnten, ohne Genehmigung des Lieferanten vornehmen! Dies gilt auch
für den Einbau und die Einstellung von Sicherheitseinrichtungen und –ventilen. Schweiß-
arbeiten an der Maschine dürfen nur nach Zustimmung und Vorgaben des Herstellers
erfolgen.
Ersatzteile müssen den vom Hersteller festgelegten technischen Anforderungen
entsprechen. Dies ist bei Originalersatzteilen immer gewährleistet.
Originalteile sind speziell für diese Maschine konzipiert. Nicht vom Hersteller gelieferte
Teile und Sonderausstattungen sind nicht freigegeben. Der Einbau und / oder die
Verwendung solcher Produkte kann die Sicherheit beeinträchtigen. Für Schäden, die
durch die Verwendung von nicht originalen Teilen oder Sonderausstattungen entstehen,
ist jegliche Haftung des Herstellers ausgeschlossen.
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1.4.4 Personalauswahl und –qualifikation

Jede Person, die mit der Montage/Demontage, Inbetriebnahme, Bedienung, Wartung
und Instandhaltung sowie Instandsetzung des Schwenkwerks beauftragt ist, muss die
komplette Betriebsanleitung und besonders das Kapitel "Sicherheit" gelesen haben,
verstehen und beachten.
Das Schwenkwerk darf nur von autorisiertem, ausgebildetem und eingewiesenem
Personal bedient, gewartet und instand gesetzt werden. Dieses Personal muss eine
spezielle Unterweisung über auftretende Gefahren erhalten haben. Dem Personal muss
das Ablehnen sicherheitswidriger Anweisungen Dritter ermöglicht werden.
Zuständigkeiten des Personals für Montage/Demontage, Inbetriebnahme, Bedienung,
Wartung und Instandhaltung sowie Instandsetzung klar festlegen und einhalten!
Sicherstellen, dass nur dazu beauftragtes Personal am Schwenkwerk tätig wird!
Arbeiten an den elektrischen Einrichtungen des Schwenkwerks dürfen nur von einer
Elektrofachkraft oder von unterwiesenem Personal unter Leitung und Aufsicht einer
Elektrofachkraft gemäß den elektrotechnischen Regeln vorgenommen werden.
An hydraulischen Einrichtungen darf nur Personal mit speziellen Kenntnissen und
Erfahrungen in der Hydraulik arbeiten!
Zu schulendes, anzulernendes, einzuweisendes oder im Rahmen einer allgemeinen
Ausbildung befindliches Personal nur unter ständiger Aufsicht einer erfahrenen Person
am Schwenkwerk tätig werden lassen!
1.4.5 Maßnahmen durch den Betreiber

Durch entsprechende Wartung und Kontrolle muss der Betreiber dafür Sorge tragen,
dass das Schwenkwerk immer in einem technisch einwandfreien Zustand betrieben wird.
Der Betreiber muss die Zuständigkeiten für Montage / Installation, Bedienung, Wartung
und Instandsetzung eindeutig regeln und festlegen.
Der Betreiber ist verpflichtet, nur geschultes und eingewiesenes Personal an dem Gerät
arbeiten zu lassen, die
- mit den grundlegenden Vorschriften über Arbeitssicherheit und Unfallverhütung
vertraut und in die Handhabung des Geräts eingewiesen sind.
- das Sicherheitskapitel und die Warnhinweise in dieser Betriebsanleitung gelesen
und verstanden haben.
Der Betreiber ist verpflichtet, das sicherheitsbewusste Arbeiten des Personals in
regelmäßigen Abständen zu überprüfen.
Der Betreiber hat dafür zu sorgen, dass diese Betriebsanleitung am Einsatzort an leicht
erreichbarer Stelle jederzeit eingesehen werden kann.
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1.4.6 Maßnahmen durch den Bediener

Die für den Einsatzort geltenden Vorschriften beachten. Für den Betrieb des
Schwenkwerks gelten in jedem Fall die örtlichen Sicherheits- und Unfallverhütungs-
vorschriften.
Vor Inbetriebnahme des Schwenkwerks sicherstellen, dass niemand durch den Betrieb
gefährdet werden kann! Beim Wiedereinschalten des Schwenkwerks können sich
Bauteile des Schwenkwerks automatisch wieder in Gang setzen!
Der Kranführer muss jederzeit den Arbeitsbereich und die Last einsehen können! Bei
schlechter Sicht und Dunkelheit für ausreichende Beleuchtung sorgen.
Nicht unter schwebenden Lasten aufhalten oder arbeiten!
Jede sicherheitsbedenkliche Arbeitsweise unterlassen!
Mindestens einmal pro Schicht das Schwenkwerk auf Schäden und Mängel prüfen!
Eingetretene Veränderungen (einschließlich der des Betriebsverhaltens) sofort der
zuständigen Stelle/Person melden! Schwenkwerk ggf. sofort stilllegen und sichern!
Störungen umgehend beseitigen!
1.4.7 Maßnahmen zu Wartung, Instandhaltung und Instandsetzung

In der Betriebsanleitung vorgeschriebene Einstell-, Wartungs- und Inspektionstätigkeiten
und -termine einschließlich Angaben zum Austausch von Teilen/Teilausrüstungen
einhalten! Diese Tätigkeiten darf nur Fachpersonal durchführen.
Bedienungspersonal vor Beginn von Wartungs- und Instandhaltungsarbeiten
informieren! Aufsichtsführenden benennen.
Bei allen Arbeiten, die Montage/Demontage, Inbetriebnahme, Bedienung, Wartung und
Instandhaltung sowie Instandsetzung betreffen, Ausschaltvorschriften gemäß Betriebs-
anleitung beachten.
Instandsetzungsarbeiten an der Hydraulik und der Elektrik sind in einer sauberen und
staubgeschützten Umgebung vorzunehmen.
Soweit erforderlich, Arbeitsbereich absichern!
Schwenkwerk vor Beginn von Wartungs- oder Instandhaltungsarbeiten komplett
ausschalten und gegen unbefugtes Wiedereinschalten sichern:
- Elektro-Steckvorrichtung abziehen.
Schutzvorrichtungen nur bei Stillstand der Maschine abnehmen!
Einzelteile und Baugruppen beim Austausch sorgfältig an Hebezeugen befestigen und
sichern, so dass von ihnen keine Gefahr ausgehen kann. Nur geeignete und technisch
einwandfreie Hebezeuge und Lastaufnahmemittel mit ausreichender Tragfähigkeit
verwenden!
Nicht unter schwebenden Lasten aufhalten oder arbeiten!
Soweit erforderlich, bei Montage- und Instandhaltungsarbeiten sicherheitsgerechte
Aufstiegshilfen und Arbeitsbühnen verwenden! Maschinenteile nicht als Aufstiegshilfen
benutzen! Bei Arbeiten in größerer Höhe Absturzsicherungen tragen.
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Grundsätzlich Schutzbrille und Schutzhandschuhe tragen, da die Berührung mit heißen

Teilen sowie der Austritt von Öl während der Wartungs- und Instandhaltungsarbeiten
nicht ausgeschlossen werden kann.
Elektrische Bauteile nur in spannungsfreiem Zustand reinigen. Dazu die Elektro-
Steckvorrichtung abziehen. Diese Vorschrift gilt auch für berührungslose Reinigung
(abblasen).
Druckschalter, Druckventile, Sicherheitsventile und sonstige Sensoren nicht
überbrücken.
Das Verstellen der Druckschalter, Druckventile, Sicherheitsventile und sonstigen
Sensoren bedarf einer schriftlichen Genehmigung des Herstellers.
Sicherheitsventile dürfen nur durch gleiche Ventile ersetzt werden.
Beschädigte Hydraulikschläuche, Rohrleitungen, Kabel und Ventile sofort wechseln.
Hydraulikschläuche in den angegebenen bzw. in angemessenen Zeitabständen
wechseln, auch wenn keine sicherheitsrelevanten Mängel erkennbar sind (siehe
Überprüfung der Hydraulik-Schlauchleitungen, Blatt 10-2).
Vorgeschriebene Anziehdrehmomente einhalten und regelmäßig prüfen.
Bei Wartungs- und Instandsetzungsarbeiten gelöste Schraubenverbindungen stets
vorschriftsmäßig festziehen.
Vor dem Reinigen des Schwenkwerks mit Wasser oder Dampfstrahl (Hochdruckreiniger)
oder anderen Reinigungsmitteln alle Öffnungen abdecken oder verschließen, in die aus
Sicherheits- bzw. Funktionsgründen kein Wasser/Dampf/Reinigungsmittel eindringen
darf. Besonders gefährdet sind Elektromotoren, Schaltschränke, Endschalter,
Kugellager, Getriebe und Ketten.
Regelmäßig alle Elektro- und Hydraulikölleitungen auf Beschädigungen und
Scheuerstellen untersuchen. Hydraulikölleitungen zusätzlich auf Dichtheit prüfen.
Vor Wiederinbetriebnahme, nach Abschluss der Wartungs- oder Instandsetzungs-
arbeiten prüfen, ob alle Sicherheitseinrichtungen an der Maschine wieder angebracht
und funktionsfähig sind! Alle Funktionen des Schwenkwerks sowie den Betriebsdruck
prüfen!
1.4.8 Sicherheitshinweise zu Elektrik

Arbeiten an elektrischen Anlagen oder Betriebsmitteln dürfen nur von einer
Elektrofachkraft oder von unterwiesenen Personen unter Leitung und Aufsicht einer
Elektrofachkraft, den elektrotechnischen Regeln entsprechend, vorgenommen werden.
Nur Originalsicherungen mit vorgeschriebener Stromstärke verwenden (siehe
Ersatzteilliste)! Bei Störungen in der elektrischen Stromversorgung Schwenkwerk sofort
abschalten!
Maschinen- und Anlagenteile, an denen Inspektions-, Wartungs- oder Reparaturarbeiten
durchgeführt werden, müssen – falls vorgeschrieben – spannungsfrei geschaltet werden.
Die freigeschalteten Teile zuerst auf Spannungsfreiheit prüfen, dann erden und
kurzschließen sowie benachbarte, unter Spannung stehende Teile isolieren!
Die elektrische Ausrüstung des Schwenkwerks ist regelmäßig zu prüfen. Mängel, wie
lose Verbindungen oder beschädigte Kabel, sofort beseitigen.
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Sind Arbeiten an Spannung führenden Teilen notwendig, eine zweite Person

hinzuziehen – wobei ein ständiger Sicht- oder Sprechfunkkontakt gewährleistet sein
muss –, die im Notfall den Not-Aus- bzw. den Hauptschalter mit Spannungsfreischaltung
betätigt. Arbeitsbereich mit einer rot-weißen Sicherungskette und einem Warnschild
absperren. Nur spannungsisoliertes Werkzeug benutzen!
Nach entsprechender Elektromontage oder -instandsetzung sind die installierten Schutz-
maßnahmen zu testen (z. B. Erdungswiderstand).
1.4.9 Sicherheitshinweise zu Hydraulik

Arbeiten an der Hydraulikanlage dürfen nur Personen mit speziellen Kenntnissen und
Erfahrungen in der Hydraulik durchführen. Das Personal muss, in der Lage sein, die
Hydraulikpläne zu lesen und vollständig zu verstehen, insbesondere die Zusammen-
hänge bezüglich der eingebauten Sicherheitseinrichtungen.
Bei arbeiten an der Hydraulik ist die persönlichen Schutzausrüstung zu tragen z.B.
Handschuhe, Schutzkleidung, Schutzbrille oder Helm mit Visier.
Bei allen Arbeiten an Hydraulikaggregaten ist das Auslaufen von Öl zu vermeiden.
Auslaufendes Öl ist in geeigneten Behältern aufzufangen und vorschriftsmäßig zu
Entsorgungen.
Die Hydraulikanlage steht unter hohem Druck! Keine Hydraulikverschraubungen lösen
oder anziehen, solange die Anlage unter Druck steht! Eventuelle Leckagen sofort
beheben.
Bauteile (z. B. Doppelhaken) gegen unbeabsichtigte Bewegungen sichern!
Bei allen Arbeiten an der Hydraulik ist auf größte Sauberkeit zu achten! Vor dem Lösen
von Verschraubungen ist die äußere Umgebung zu reinigen. Alle Öffnungen mit
Schutzkappen verschließen, damit kein Schmutz eindringen kann.
Alle Leitungen, Schläuche und Verschraubungen regelmäßig auf Undichtheiten und
äußerlich erkennbare Beschädigungen prüfen! Beschädigungen umgehend beseitigen!
Undichte Verschraubungen nur im drucklosen Zustand nachziehen. Herausspritzendes
Öl kann zu Verletzungen, Bränden und Umweltverschmutzung führen.
Zu öffnende Systemabschnitte und Druckleitungen der Hydraulik vor Beginn der
Instandsetzungsarbeiten drucklos machen! Wenn vorhanden: Systemabschnitte über die
Manometeranschlüsse drucklos machen (siehe MA1 etc. im Hydraulikplan).
Die Hydraulikleitungen fachgerecht verlegen und montieren! Anschlüsse nicht
verwechseln! Armaturen, Länge und Qualität der Schlauchleitungen müssen den
Anforderungen entsprechen.
Eigenmächtige Umbauten und Veränderungen an der Hydraulikanlage sind verboten.
1.4.10 Umgang mit Ölen, Fetten und anderen chemischen Substanzen

Beim Umgang mit Ölen, Fetten und anderen chemischen Substanzen die für das
Produkt geltenden Sicherheits- und Umweltvorschriften beachten!
Vorsicht beim Umgang mit heißen Betriebs- und Hilfsstoffen (z. B. Hydrauliköl), es
besteht Verbrennungs- bzw. Verbrühungsgefahr!
20.10.2008
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Das PEINER Motor-Schwenkwerk hat folgenden Aufbau:
Das Schwenkwerk besteht aus einer Traverse (1), in der das Hydraulikaggregat (22),
der Hydraulikmotor (3) und die Nabe (4) angeordnet sind. Die Nabe dient zur Aufnahme
der Achse (5). Die Lastkräfte werden über eine auf der Achse aufgeschraubten Mutter
(6) von einem in der Nabe eingebauten Axial-Rillenkugellager (7) aufgenommen. Auf der
Achse kann je nach Bedarf ein mehrpoliger Schleifringkörper (8) befestigt werden. Durch
die Achse wird vom Schleifringkörper eine Leitung (9) mit entsprechender Aderzahl dem
angehängten Lastaufnahmemittel zugeführt.
Das Hydraulikaggregat (22) ist als kpl. Einheit senkrecht in der Traverse eingebaut. Das
Hydraulikaggregat besteht aus Motor (2) und Pumpe (20).
Durch Lösen der Befestigungsschrauben kann das kpl. Hydraulikaggregat aus dem
Schwenkwerk herausgenommen werden. Der Hydrauliksteuerblock (17) ist an der
Traversenseitenwand befestigt. Das Magnetventil (18) sitzt auf einem Klotz und ist direkt
am Hydraulikmotor (3) angeschlossen.
Durch die Montageöffnung in der Haube können alle wichtigen Wartungsarbeiten an

dem Hydraulikaggregat durchgeführt werden (z. B. Hydrauliköl nachfüllen).
Die Bauteile Hydraulikaggregat, Hydraulikmotor und Schleifringkörper sind durch eine

Haube gegen mechanische Beschädigungen geschützt.
Das an der Achse befestigte Kreuzstück mit dem Doppelhaken gewährleistet eine
weitestgehend zentrische Krafteinleitung in die Hohlachse und schützt sie somit vor zu
großer Biegebelastung. Eine Leitungszugentlastung verhindert eine mechanische
Belastung der Elektro-Steckvorrichtung.
12.07.2010
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1 Traverse 18 Magnetventil
2 Motor 20 Pumpe
3 Hydraulikmotor 21 Ritzel
5 Achse 22 Hydraulikaggregat
6 Mutter 23 Filter
7 Axial-Zylinderrollenlager 27 Doppelhaken
8 Schleifringübertrager 29 Verschlußschraube
9 Leitung (Belüftungsschraube)
12 Kreuzstück 32 Steckvorrichtung
17 Hydrauliksteuerblock 33 Stromversorgungskabel
27.01.2010
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3.0 Betriebsanleitung
3.1 Hinweise für den sicheren Betrieb
X Die Bestimmungen der einschlägigen Unfallverhütungsvorschriften für "Lastaufnahme-

mittel" beachten!
X Immer in Übereinstimmung mit dieser Bedienungsanleitung arbeiten.
X Das Schwenkwerk darf nur von darin unterwiesenen Personen betrieben werden.
X Die Last darf nicht über Personen hinweggeführt werden.

Der Kranführer hat bei Bedarf Warnzeichen zu geben. Bemerkt der Kranführer die
Anwesenheit von Personen, die durch den Kran gefährdet werden können, so hat er
den Kran sofort still zu setzen und nicht eher wieder anzufahren, bis sich die Personen
außerhalb des Gefahrenbereiches befinden.
X Die Beförderung von Personen auf der Last oder dem Schwenkwerk ist verboten!
X Das Schwenkwerk ausschließlich im Originalzustand oder in einem vom Hersteller

freigegebenen Zustand betreiben.
X Sicherstellen, dass beim Betrieb alle Schläuche, Leitungen, Rohre und Verschraubun-
gen intakt und dicht sind.
X Tragfähigkeit des Krans nicht überschreiten!
X Das Losreißen festsitzender Lasten ist verboten.
X Das Schwenkwerk, der Doppelhaken und die Anschlagmittel dürfen niemals über ihre
Tragfähigkeit hinaus belastet werden!
X Der Doppelhaken darf nicht an der Hakenspitze belastet werden.
X Kauschen, Seilösen, Aufhängeringe und andere Aufhängeglieder müssen im Haken-

grund liegen und auf dem Doppelhaken frei beweglich sein.
X Die Sicherungsklappen des Doppelhakens müssen funktionsfähig sein, damit ein

unbeabsichtigtes Aushängen verhindert wird.
X Das Anschlagen des Schwenkwerkes gegen Gegenstände vermeiden, um

Beschädigungen zu verhindern.
X Der Doppelhaken darf nicht unmittelbar in die Last eingehängt werden. Ausgenommen
ist das Einhängen in besonders hierfür eingerichtete Einhängevorrichtungen.
X Den Doppelhaken so einzusetzen, dass ein unbeabsichtigtes Aushängen des Last-

aufnahmemittels, des Anschlagmittels oder der Last verhindert ist.
X Verwenden Sie niemals eine Anschlagmittel, die schadhaft oder deren Kennzeichnung
nicht mehr vorhanden ist!
X Kettenstränge dürfen nicht verdreht oder verknotet sein.

27.01.2010
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X Bei allen Kranbewegungen hat der Kranführer vor allem die Last oder bei Leerfahrt das
Lastaufnahmemittel zu beobachten. Ist das nicht möglich, darf er den Kran nur auf
Zeichen eines Einweisers führen.
X Ruckweises Anfahren, Anheben, Anhalten oder Senken des Schwenkwerks ist zu

vermeiden.
X Jede Störung am Schwenkwerk oder den Anschlagmittel sowie jede Beobachtung, die
das Entstehen einer Störung erwarten lässt (z.B. Geräusche, erhöhte Temperaturen,
ungewöhnliches Verhalten des Schwenkwerks usw.) sind dem zuständigen Aufsichts-
führenden unverzüglich zu melden.
X Das Schwenkwerk, das Hydrauliköl und die Schmierstoffe nur im zulässigen

Temperaturbereich betreiben (siehe Technische Daten bzw. Ölempfehlung).
X Bei Funktionsstörungen ist das Schwenkwerk sofort still zusetzen und gegen wieder-
einschalten zu sichern. Störungen umgehend beseitigen lassen!
X Schutzvorrichtungen ausschließlich bei Stillstand des Schwenkwerks demontieren.

27.01.2010
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3.2 Inbetriebnahme
3.2.1 Montageanleitung - Erst-Inbetriebnahme

Die Montage und die Erst-Inbetriebnahme darf nur von Fachpersonal vorgenommen
werden.
Bei allen Arbeiten ist persönliche Schutzausrüstung zu tragen. Dazu gehören:
• Schutzkleidung
• Schutzhelm
• Sicherheitsschuhe
• Schutzbrille
• Schutzhandschuhe
Verletzungsgefahr durch unsachgemäßes Arbeiten und unsachgemäße

Inbetriebnahme!
f Nur unter Beachtung aller Sichheitshinweise, Sicherheitsvorschriften und
WARNUNG Unfallverhütungsvorschriften am Schwenkwerk arbeiten.
f Werkzeuge und andere Teile nur so ablegen, dass sie nicht herunterfallen
können.
f Die beweglichen Schwenkwerksteile wie zum Beispiel den Doppelhaken
gegen unbeabsichtigte Bewegung sichern.
Lebensgefahr durch Stromschlag!

f Sicherstellen, dass die Stromversorgung ausgeschaltet und gegen Wieder-
einschalten gesichert ist.
GEFAHR f Sicherstellen, dass Spannung und Frequenz der Stromversorgung mit den
auf dem Typenschild angegebenen Werten übereinstimmen.
f Sicherstellen, dass das Stromversorgungs-Kabel unbeschädigt ist.
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Voraussetzungen für die Montage:

• Spannung und Frequenz der Stromversorgung stimmen mit den auf dem Typen-
schild angegebenen Werten überein.
• Am Stromversorgungs-Kabel ist eine Zugentlastung angebracht.
• Die Teile mit denen das Schwenkwerk am Tragmittel zum Beispiel Kranseil
befestigt wird passen in Größe und Tragfähigkeit zum Schwenkwerk und zum Kran.
• Die problemlose Verständigung mit dem Kranführer ist gewährleistet.
Montage:
1. Schläuche, Verbindungselemente und Dichtungen der Hydraulik auf Dichtheit
prüfen.
2. Aufhängung des Schwenkwerks mit dem Tragmittel verbinden; Tragfähigkeit des
Hebezeuges beachten.
3. Schwenkwerk mit der Steckvorrichtung des Stromversorgungs-Kabels verbinden.
4. Zugentlastung anbringen; das Stromversorgungs-Kabel darf keinerlei Zug auf die
Steckvorrichtung ausüben. (Befestigungspunkte siehe Bild 4.1.5 Schmierstellen)
Die Zugentlastung so anbringen, dass das Stromversorgungs-Kabel nirgends
scheuert.
5. Sicherstellen, dass sich niemand im Gefahrenbereich des Schwenkwerks aufhält.
Das Schwenkwerk soweit anheben, dass der Doppelhaken frei hängt.
6. Ölstand prüfen und bei Bedarf nachfüllen (siehe 4.2.1)
Ölempfehlung siehe Bl.-Nr. 11-1
7. Drehrichtung des Schwenkwerks überprüfen. Bei falscher Drehrichtung zwei
Außenleiter vertauschen. Bei nicht montierter Steckvorrichtung diese nach Schalt-
plan anklemmen.
8. Prüfen ob die Sicherungen an allen Bolzen und Schäkel vorhanden und fest sind.
9. Vor der Erst-Inbetriebnahme ist die ordnungsgemäße Montage und die sichere
Funktion des Schwenkwerkes von einer hierzu befähigten Personen zu prüfen
f Wenn die Temperatur der Hydraulikflüssigkeit unter der Anlauftemperatur liegt (siehe
Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) dann muss die Hydraulikflüssigkeit mit
einer Heizung bis zur Inbetriebnahmetemperatur vorwärmt werden (ob eine Heizung
im Schwenkwerk vorhanden ist siehe 2.4 Teilebenennungsplan und Ersatzteilliste:
Schaltplan). Wenn keine Heizung vorhanden ist: die Hydraulikflüssigkeit wechseln;
falls erforderlich vorgewärmte Hydraulikflüssigkeit verwenden.
Bei Temperaturen zwischen der Anlauftemperatur und der Inbetriebnahmetemperatur
(siehe Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) die Hydraulikflüssigkeit mit einer
Heizung bis zur Inbetriebnahmetemperatur vorwärmen oder
• wenn vorhanden, Kugelhähne KH2 und KH3 schließen (siehe Blatt-Nr. 10-1)
oder wenn vorhanden das Schwenkwerk gegen den Anschlag fahren (siehe
Nummer 36 Kapitel 2.4 Teilebenennungsplan)
• Das Schwenkwerk für eine Minute einschalten damit die Pumpe das Öl über das
Druckbegrenzungsventil in den Tank pumpt.
• Danach zwei Minuten pausieren.
27.01.2010
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• Den Vorgang so lange wiederholen bis sich das Öl auf die Inbetriebnahme-
temperatur erwärmt hat.
• wenn vorhanden, Kugelhähne KH2 und KH3 wieder öffnen (siehe Blatt-Nr. 10-1)
Tabelle 3.2.1 Öltemperaturen
Hydraulikflüssigkeit Anlauftemperatur Inbetriebnahme- maximale obere
temperatur Einsatztemperatur
Shell Tellus Arctic 32 -30 °C -20 °C +70 °C
NATO-Kode: H 540 -25 °C -15 °C +85 °C
HVLP 32 -15 °C -5 °C +70 °C
nach DIN 51524/3 HV
HLP 46 -5 °C +5 °C +80 °C
nach DIN51524/2
HLP 68 +5 °C +12 °C +85 °C
nach DIN51524/2
f Nach ca. 50 Betriebsstunden Ölfiltereinsatz wechseln (siehe Bl.-Nr. 10-1) und

Schrauben und Muttern auf festen Sitz prüfen; Anziehmomente siehe Ersatzteilliste.
3.2.2 Tägliche Inbetriebnahme

f Ölstand prüfen (siehe 4.2.1).
f Wenn die Temperatur der Hydraulikflüssigkeit unter der Anlauftemperatur liegt (siehe
Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) dann muss die Hydraulikflüssigkeit mit
einer Heizung bis zur Inbetriebnahmetemperatur vorwärmt werden (ob eine Heizung
im Schwenkwerk vorhanden ist siehe 2.4 Teilebenennungsplan und Ersatzteilliste:
Schaltplan). Wenn keine Heizung vorhanden ist: die Hydraulikflüssigkeit wechseln;
falls erforderlich vorgewärmte Hydraulikflüssigkeit verwenden.
Bei Temperaturen zwischen der Anlauftemperatur und der Inbetriebnahmetemperatur
(siehe Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) die Hydraulikflüssigkeit mit einer
Heizung bis zur Inbetriebnahmetemperatur vorwärmen oder
• wenn vorhanden, Kugelhähne KH2 und KH3 schließen (siehe Blatt-Nr. 10-1)
oder wenn vorhanden das Schwenkwerk gegen den Anschlag fahren (siehe
Nummer 36 Kapitel 2.4 Teilebenennungsplan)
• Das Schwenkwerk für eine Minute einschalten damit die Pumpe das Öl über das
Druckbegrenzungsventil in den Tank pumpt.
• Danach zwei Minuten pausieren.
• Den Vorgang so lange wiederholen bis sich das Öl auf die Inbetriebnahme-
temperatur erwärmt hat.
• wenn vorhanden, Kugelhähne KH2 und KH3 wieder öffnen (siehe Blatt-Nr. 10-1)
f Schläuche, Verbindungselemente und Dichtungen der Hydraulik auf Dichtheit prüfen.
f Steckvorrichtung auf einwandfreien Sitz prüfen. Die Zugentlastung muss so
angebracht sein, dass das Stromversorgungs-Kabel keinerlei Zug auf die Steck-
vorrichtung ausübt.
f Schmierstellen mit Fett versorgen gemäß 4.1.9 Schmieranweisung (Schmierstellen
siehe 4.1.10 vom Hersteller verwendete Fettsorte siehe Maschinenkarte).
18.6.2010
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$&+781* Anschlagen des Schwenkwerkes gegen Gegenstände vermeiden, um
Beschädigungen zu verhindern.
Hinweise für den sicheren Betrieb siehe 3.1 Blatt-Nr. 8-1
Funktionsbeschreibung siehe Blatt-Nr. 4-1 bis 4-3
f Es ist zu beachten, dass sich das mögliche Lastgewicht des Krans um das Gewicht
des Schwenkwerks reduziert.
f Den Doppelhaken immer über dem Schwerpunkt positionieren.
f Immer die besonderen Gebrauchshinweise für jedes Anschlagmittel beachten.
f Die Aufhängeglieder von Anschlagmitteln sind so groß zu wählen, dass sie sich frei
im Doppelhaken bewegen können.
f Hebebänder oder Rundschlingen niemals lose über den Doppelhaken laufen
lassen. Die Last könnte kippen!
f Schief hängende Lasten wieder ablassen und neu befestigen.
f Die Funktion der Hakensicherung des Doppelhakens regelmäßig überprüfen.
$XHUEHWULHEQDKPH
f Das Absetzen des Schwenkwerkes sollte auf einer geeigneten Unterlage
(Holzbalken) erfolgen, da sonst das Schwenkwerk beschädigt werden kann.
f Beim Absetzen ist darauf zu achten, daß die nach unten hängende Leitung nicht
abgeknickt oder gequetscht wird.
f Die Steckvorrichtung ist mit Schutzkappen zu versehen.
f Bei längerer Außerbetriebnahme ist darauf zu achten, daß das Schwenkwerk in
Abständen von ca. 3 Monaten mehrere Male betätigt wird, um eine Korrosions-
bildung bzw. ein Verharzen des Hydrauliköles in den Steuerelementen zu
verhindern.
f Wird das Schwenkwerk langfristig außer Betrieb genommen, sind grundsätzlich alle
Schmierstellen mit Fett zu versorgen.
:LHGHULQEHWULHEQDKPH
f alle Punkte von 3.2 und 3.3 beachten
f auf eventuelle Beschädigungen prüfen
f Schmierstellen mit Fett gemäß 4.4 Ölempfehlung versorgen (Schmieranweisung
siehe 4.1.4; Schmierstellen siehe 4.1.5; vom Hersteller verwendete Fettsorte siehe
Maschinenkarte ).
7UDQVSRUW
f Das Transportieren des Schwenkwerkes muß auf einer geeigneten Unterlage
erfolgen, da es sonst beschädigt werden kann.
f Das Schwenkwerk ist gegen Kippen zu sichern.
24.09.2010
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4.0 Instandhaltung
Bild 4.01
Bild 4.02
Beschreibung:
8 Belüftungsschraube
9 Ölstandsauge
10 Schmierstelle Achse
11 Ölfilter
12 Ölablaßschraube
14 Hydraulikschlauch
15 Tankdeckelbefestigung
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4.1 Pflege und Wartung

Unzureichende und unsachgemäße Wartung kann zu Betriebsstörungen und damit zu
hohen Reparaturkosten und Stillstandszeiten führen. Eine regelmäßige Wartung ist
deshalb unerlässlich.
Verletzungsgefahr durch unsachgemäß ausgeführte Wartungsarbeiten!

Unsachgemäßes Arbeiten kann zu erheblichen Personen- und Sachschäden
führen.
WARNUNG f Das Schwenkwerk darf nur von autorisiertem, ausgebildetem und
eingewiesenem Fachpersonal gewartet und instandgesetzt werden. Dieses
Personal muss eine spezielle Unterweisung über auftretende Gefahren
erhalten haben. Dem Personal muss das Ablehnen sicherheitswidriger
Anweisungen Dritter ermöglicht werden.
f Vor Beginn der Wartungsarbeiten ist das Bedienpersonal diesbezüglich zu
informieren.
f Zuständigkeiten des Personals für Montage / Demontage, Inbetrieb-nahme,
Bedienung, Wartung und Instandhaltung sowie Instandsetzung sind klar
festzulegen und einzuhalten!
f Es ist Sicherzustellen, dass nur dazu beauftragtes Personal am Schwenkwerk
tätig wird!
f Vor Beginn der Wartungsarbeiten die elektrische Versorgung des
Schwenkwerks abschalten und und gegen Wiedereinschalten sichern. Dies
kann auch durch abziehen der Elektro-Steckvorrichtung geschehen.
f Beim Umgang mit Ölen und Fetten sind die, für das Produkt geltenden
Sicherheitsvorschriften zu beachten.
Arbeiten an der Hydraulikanlage und an der Elektrik dürfen nur von hierfür
qualifiziertem Fachpersonal nach den gültigen Schaltplänen durchgeführt werden.
Das Personal muss über die auftretenden Gefährdungen und die sich hieraus
ergebenden Schutzmaßnahmen unterwiesen sein.
GEFAHR
Lebensgefahr durch unter hohem Druck austretendes Hydrauliköl

f Sicherstellen, dass die Teile der Hydraulik, an denen gearbeitet wird, drucklos
sind. Undichte Verschraubungen nur im drucklosen Zustand nachziehen.
f Eventuelle Leckagen umgehend beheben.
GEFAHR
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4.1.1 Wartungsübersicht Tabelle 4.1.1 Wartungsübersicht

Pos. Wartungsarbeit Wartungsintervall
*)
wöchentlich b)
c)
nach 500 h
alle 1000 h
alle 2000 h
nach 50 h
täglich
a)
1 Schmierstellen G (Bolzen) schmieren (und M) X X X X X X
2 Schmierstellen H (Verzahnung) schmieren X X
3 Schmierstellen K (Achse) schmieren X X
4 Schmierstellen L (Lager) und S (Schäkel und X X X
Ketten) schmieren
5 Schläuche, Verbindungselemente und Dichtungen X X X X X
der Hydraulik auf Dichtheit prüfen
6 Steckvorrichtung und Zugentlastung auf X X X X X
einwandfreien Sitz prüfen (siehe Kapitel 3.2.2)
7 Hydraulikölstand prüfen X X X X X X
d)
8 Hydrauliköl wechseln X X
9 Verschmutzung des Filterelements prüfen; X X
10 Filterelement vom Rücklauffilter wechseln X Xd)
11 Hydraulik-Schlauchleitungen auf ordnungsgemäße X X
Montage und auf arbeitssicheren Zustand zu prüfen
12 Alle Schraubverbindungen auf festen Sitz prüfen X X X
13 Doppelhaken auf Abnutzung und Risse prüfen X X
14 Schwenkwerk auf Risse und Bruchanzeigen im X X
Werkstoff und an Schweißfugen prüfen
15 Bauteilen und Einrichtungen auf Beschädigung, X X
Verschleiß oder sonstige Veränderungen prüfen
16 Vollständigkeit und Funktion von Sicherheitsein- X X X
richtungen (z.B. Bolzensicherungen) prüfen
17 Wartungsarbeiten am Schleifringübertrager Xc)
a)
bei Containerhandling wöchentlich, spätestens nach 100 Betriebsstunden, bei
anderen Lasten monatlich, spätestens nach 300 Betriebsstunden, abschmieren
b)
spätestens nach jeweils 100 Betriebsstunden
c)
spätestens nach einem Jahr; siehe Wartungsanweisung in der Ersatzteilliste
d)
Eine Verlängerung der Nutzungszeit des Hydrauliköls ist möglich, wenn die
Überprüfung des Hydrauliköls durch ein Labor, dies zulässt.
*) Die Zahlen in dieser Spalte entsprechen den Positionen in den Kapiteln mit den
einzelnen Wartungsintervallen.
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4.1.2 Wartungsintervall nach den ersten 50 Betriebsstunden

f Nach den ersten 50 Betriebsstunden folgende Wartungsarbeiten durchführen:
Tabelle: 4.1.2 Wartungsarbeiten nach den ersten 50 Betriebsstunden
Pos. Wartungsarbeit Wartungsarbeit
*) durchgeführt
Datum Unterschrift
1 Schmierstellen G (und M) abschmieren
6 Schläuche, Verbindungselemente und
Dichtungen der Hydraulik auf Dichtheit prüfen
7 Steckvorrichtung und Zugentlastung auf
8 Hydraulikölstand prüfen
11 Filterelement vom Rücklauffilter wechseln
13 Alle Schraubverbindungen auf festen Sitz prüfen
*) Die Zahlen in dieser Spalte entsprechen den Positionen in der Wartungsübersicht

(siehe 4.1.1 Wartungsübersicht).
4.1.3 Wartungsintervall nach den ersten 500 Betriebsstunden

f Nach den ersten 500 Betriebsstunden folgende Wartungsarbeiten durchführen:
Tabelle: 4.1.3 Wartungsarbeiten nach den ersten 500 Betriebsstunden
*) durchgeführt
Datum Unterschrift
1 Schmierstellen G (und M) abschmieren
6 Schläuche, Verbindungselemente und
Dichtungen der Hydraulik auf Dichtheit prüfen
9 Hydrauliköl wechseln

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4.1.4 Wartungsintervall wöchentlich

f Wartungsintervall wöchentlich; spätestens nach jeweils 100 Betriebsstunden:
Tabelle: 4.1.4 Wartungsarbeiten wöchentlich
*) durchgeführt
Datum Unterschrift
a)
1 Schmierstellen G (Bolzen) (und M) schmieren

a)
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4.1.5 Wartungsintervall alle 1000 Betriebsstunden

f Wartungsintervall alle 1000 Betriebsstunden; spätestens nach jeweils einem Jahr:
Tabelle: 4.1.5 Wartungsarbeiten alle 1000 Betriebsstunden
*) durchgeführt
Datum Unterschrift
a)
2 Schmierstellen H (Verzahnung) schmieren
3 Schmierstellen K (Achse) schmieren
4 Schmierstellen L (Antriebslager) und S (Schäkel
und Ketten) schmieren
5 Schläuche, Verbindungselemente und Dichtungen
8 Verschmutzung des Filterelements prüfen;
10 Hydraulik-Schlauchleitungen auf ordnungs-
gemäße Montage und auf arbeitssicheren Zustand
zu prüfen
13 Doppelhaken aut Abnutzung und Risse prüfen
14 Schwenkwerk auf Risse und Bruchanzeigen im
15 Bauteilen und Einrichtungen auf Beschädigung,
16 Vollständigkeit und Funktion von Sicherheitsein-

a)
1x jährlich den Schleifringübertrager warten.

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4.1.6 Wartungsintervall alle 2000 Betriebsstunden

f Wartungsintervall alle 2000 Betriebsstunden:
Tabelle: 4.1.6 Wartungsarbeiten alle 2000 Betriebsstunden
*) durchgeführt
Datum Unterschrift
a)
2 Schmierstellen H (Verzahnung) schmieren
3 Schmierstellen K (Achse) schmieren
4 Schmierstellen L (Antriebslager) und S (Schäkel
und Ketten) schmieren
5 Schläuche, Verbindungselemente und Dichtungen
8 d)
Hydrauliköl wechseln
9 Verschmutzung des Filterelements prüfen;
d)
10 Filterelement vom Rücklauffilter wechseln
11 Hydraulik-Schlauchleitungen auf ordnungs-
gemäße Montage und auf arbeitssicheren Zustand
zu prüfen
13 Doppelhaken auf Abnutzung und Risse prüfen
14 Schwenkwerk auf Risse und Bruchanzeigen im
15 Bauteilen und Einrichtungen auf Beschädigung,
16 Vollständigkeit und Funktion von Sicherheitsein-
c)
17 Wartungsarbeiten am Schleifringübertrager

a)
d)
Eine Verlängerung der Nutzungszeit des Hydrauliköls ist möglich, wenn die
Überprüfung des Hydrauliköls durch ein Labor, dies zulässt.
c)
spätestens nach einem Jahr; siehe Wartungsanweisung in der Ersatzteilliste
Alle 15000 Betriebsstunden Lager des Elektromotors reinigen und fetten. (siehe 4.1.11)
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4.1.7 Ölwechsel
Der erste Ölwechsel ist nach ca. 500 Betriebsstunden vorzunehmen. Weitere Ölwechsel
nach jeweils 1000 Betriebsstunden - spätestens nach 1 Jahr.
Außergewöhnliche Betriebszustände können eine unzulässig hohe Verschmutzung oder
eine Alterung des Öles verursachen. In solchen Fällen wird empfohlen, bereits vor dem
fälligen Ölwechsel eine Ölanalyse im Labor des Ölherstellers durchführen zu lassen.
− Ölarten, siehe Tabelle Ölempfehlung Blatt-Nr. 11-1. Eingefüllte Ölsorte siehe
Maschinenkarte.
Zum Schutz der Hydraulikkomponenten muss das Öl mindestens die Reinheitsklasse
20/18/15 nach ISO 4406 haben (entspricht in etwa der Klasse 9 nach NAS 1638).
Neues Öl hat in der Regel eine schlechtere Reinheitsklasse, es ist deshalb erforderlich
das neue Öl zu filtern. Dies kann erfolgen in dem das Öl durch den Filter nachgefüllt
wird oder durch die Verwendung von speziellen Befüllaggregaten, die das Öl so filtern
dass die geforderte Reinheitsklasse erreicht wird.
Hinweis: Beim Ölwechsel auf größte Sauberkeit achten. Verschmutzungen können
zu Fehlfunktionen und zu Schäden an der Hydraulik führen. Die Teile der
Hydraulik (Tank, Pumpe, Schläuche usw.) nie länger als nötig offen lassen.
X Durchführung: (Bauteile siehe Bild 4.01 und Bild 4.02)

1. Geöffnetes Schwenkwerk absetzen
2. Geeigneten Auffangbehälter unter der Ölablaßschraube positionieren
3. Ölablaßschraube entfernen und reinigen
4. Ölmessstab (Belüftungsschraube) zur Tankbelüftung herausschrauben
5. Tankfüllung ablassen (bei betriebswarmer Anlage)
6. Tank reinigen
y Den Bereich des Tankdeckels reinigen.
y Den Druck in den Schläuchen (14) (Bild 4.0) ablassen.
y Schläuche (14) (Bild 4.0) am Tankdeckel abschrauben.
y Den Tankdeckel von der Traverse abschrauben (15) und das Hydraulik-
aggregat einschließlich Tankdeckel aus der Traverse herausheben.
y Tank mit einem flachen Schaber aus Kunststoff reinigen. Keine Putzwolle,
Tücher oder Reinigungspapier verwenden, weil Fasern zurück bleiben
können. Mit geeignetem Reinigungsmittel z.B. Waschbenzin den Tank sauber
spülen.
Hinweis: Metallpartikel im Tank können auf Verschleiß an der Pumpe
hindeuten.
y Gewindebohrungen der Tankdeckelbefestigung prüfen. Bei Bedarf Gewinde
reinigen bzw. nachschneiden.
y Bei der Montage des Hydraulikaggregats und der Schläuche auf größte
Sauberkeit achten.
7. Ölfiltereinsatz wechseln
8. Ölablaßschraube einschrauben
9. Tank füllen (über Filter)
10. Ölstand prüfen (siehe 4.2.1)
11. Schwenkwerk Probe fahren
12. Dichtheit der Hydraulik prüfen
13. Das Altöl entsprechend der örtlichen Vorschriften entsorgen
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4.1.8 Ölfilter
Bei Neuanlagen ist der Filtereinsatz nach etwa 50 Betriebsstunden auszuwechseln -
ansonsten nach jedem Ölwechsel. Ferner ist der Ölfilter nach Reparaturarbeiten an der
Hydraulik zu kontrollieren und ggf. der Filtereinsatz zu wechseln.
4.1.9 Schmieranweisung
Um einen einwandfreien Betrieb des Schwenkwerkes zu gewährleisten Schmierstellen,
regelmäßig abschmieren (siehe 4.1.10).
f Schmierstellen G bei Containerhandling wöchentlich, spätestens nach 100 Betriebs-
stunden, abschmieren
f Schmierstellen G bei anderen Lasten monatlich, spätestens nach 300 Betriebs-
stunden, abschmieren.
f Schmierstelle H, K und L vierteljährlich, spätestens nach 1000 Betriebsstunden,
abschmieren.
Fettempfehlung für Schmierstelle G und K: Lithiumverseiftes Fett, KP 2 K DIN 51502

Fettempfehlung für Schmierstelle H: M2E-20; DIN 51502, z. B. Zählit VZ
(Zählit VZ ist ein calciumverseiftes Fett auf Mineralölbasis der Firma MÖLLENBERG &
SONNTAG mit einer Penetration von 265-295 mm²/s )
Bei tiefen Temperaturen ab -20°C:

Fettempfehlung für Schmierstelle G, K und L:
KE1N-50; DIN 51502, z. B. URETHYN LT 60
Fettempfehlung für Schmierstelle H: KE1N-50; DIN 51502, z. B. URETHYN LT 60
(URETHYN LT 60 ist ein synthetisches Tieftemperaturfett der Firma FUCHS LUBRITECH
GMBH)
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4.1.10 Schmierstellen
Beschreibung:
Schmierstelle H (Verzahnung)
Schmierstelle K (Achse)
Schmierstelle L (Antriebslager)
Schmierstelle G (Bolzen)
Schmierstelle S (Kettenglied,
Schäkel)
Ausstattungsvariante:
„Aufhängung mit Bolzen“
Schmierstelle M (Bolzen)
1 Befestigungspunkte für
Zugentlastung
Hinweis: Durch regelmäßige Schmierung der Kette beziehungsweise Aufhängeglieder

und Schäkel kann eine wesentlich längere zulässige Nutzungsdauer als bei
ungeschmierten Teilen erreicht werden. Es wird empfohlen alle Kettenglieder
und Schäkel vor der Inbetriebnahme zu schmieren. Beim Schmieren ist darauf
zu achten, dass die Berührungsflächen geschmiert werden um einen
vorzeitigen Verschleiß zu verhindern. Als Schmiermittel eignet sich
Schmierstoff zum Schmieren von Drahtseilen oder Verzahnungen (siehe
Kapitel 4.4)
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4.1.11 Elektromotor
Vorsicht Verbrennungsgefahr!
An der Oberfläche des Elektromotors können hohe Temperaturen von über 80°C
auftreren.
WARNUNG f Vor Beginn der Wartungsarbeiten den Motor abkühlen lassen.
Wartungsintervalle: alle 15.000 Betriebsstunden längstens nach 3 Jahren

f Vor Beginn der Wartungsarbeiten die elektrische Versorgung des Schwenkwerks
abschalten und und gegen Wiedereinschalten sichern.
f Lager reinigen und zur Hälfte mit Fett, gemäß Kapitel 4.5 Schmierstoffempfehlung
füllen.
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4.1.12 Schleifringübertrager
Installation, Wartung und Reparatur darf nur durch elektrotechnisch

qualifiziertes und autorisiertes Personal durchgeführt werden.
GEFAHR
Wartungsintervalle: 1x jährlich
f Vor Beginn der Wartungsarbeiten die elektrische Versorgung des Schwenkwerks
abschalten und und gegen Wiedereinschalten sichern.
A c h t u n g ! Alle Arbeiten am Schleifringübertrager nur im elektrisch spannungs-
losen Zustand durchführen!
f Haube des Schwenkwerks öffnen beziehungsweise entfernen.
f Abgefallenen Abrieb durch Absaugen entfernen.
V o r s i c h t ! Die Schleifbügel können dabei leicht verbogen werden.
Wenn das Absaugen nicht möglich ist: Entfernen des Staubes durch Ausblasen mit
trockener, ölfreier, sauberer Luft.
f Die Kontaktstellen von Schleifring und Drahtschleifbügel hauchdünn Einsprühen mit
dem vorgeschriebenen Kontaktöl: CRAMOLIN Schutz (ITW Chemische Produkte
GmbH)
V o r s i c h t ! Den Kohlebürstenhalter und seinen Schleifring n i c h t einsprühen!
f Verschleiß der Schleifbügel prüfen
f Verschleiß der Kohlenbürsten prüfen. Teile vom Kohlebürstenhalter dürfen keine
Isolierringe oder Schleifringe berühren.
f Nach dem Reinigen die Haube wieder montieren.
Darauf achten, dass keine Leitung gequetscht, die Isolierung abgeschabt oder sonst
wie beschädigt wird.
Beschreibung:
1 Drahtschleifbügel
2 Kohlebürste
3 Kohlebürstenhalter
4 Schleifring
5 Isolierring
Bild 4.1.12
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4.2 Durchzuführende Prüfungen
4.2.1 Ölstand prüfen

− Das Schwenkwerk muß gerade stehen.
− Maximaler oder minimaler Ölstand wird am Ölstandsauge abgelesen.
− Zuviel Öl erzeugt Überdruck im Tank.
− Zu wenig Öl führt zur Überhitzung der Hydraulikanlage und kann Pumpenschäden
zur Folge haben.
− Bei erforderlicher Ölnachfüllung, siehe Ölempfehlung Blatt-Nr. 11-1.
4.2.3 Abnutzung
Der Doppelhaken ist entsprechend den Einsatzbedingungen und den betrieblichen

Verhältnissen nach Bedarf, jedoch mindestens jährlich, durch einen Sachkundigen zu
prüften. Sachkundiger ist, wer auf Grund seiner fachlichen Ausbildung und Erfahrung
ausreichende Kenntnisse auf dem Gebiet der Lastaufnahmemittel hat und mit den
einschlägigen staatlichen Arbeitsschutzvorschriften, Unfallverhütungsvorschriften und
allgemein anerkannten Regeln der Technik soweit vertraut ist, dass er den arbeits-
sicheren Zustand von Schwenkwerken und Kranhaken beurteilen kann.
Die zulässige Abnutzung ist in Tabelle 4-1 angegeben. Beim Messen genügt
Meßschieber- (Schieblehren-) Genauigkeit.
Verschleißkerben dürfen im Bereich der zulässigen Abnutzung kerbfrei nachgeschliffen
werden. Teile mit unzulässiger Abnutzung oder Beschädigung sind zu ersetzen.
Schweißungen an Doppelhaken und Bolzen, z. B. zum Ausbessern von Abnutzungen,
sind nicht zulässig.
4.2.4 Sonstige Prüfungen

Überprüfung des Doppelhakens
Die Prüfung auf Verformung, z. B. am Hakenmaul und Hakenschaft, ist nach Bedarf,
jedoch mindestens einmal im Jahr durchzuführen. Bei einer größeren Aufweitung der
Maulweite a2 max nach Tabelle 4-1 ist der Doppelhaken zu ersetzen.
Der Doppelhaken ist ebenfalls zu ersetzen, wenn die Verformung 10 %, bezogen auf
das Ausgangsmaß Y1 oder Y2, überschreitet (die Ausgangsmaße sind auf dem
Doppelhaken angegeben siehe auch Bild Doppelhaken Blatt-Nr. 10-2).
Wurden Verformungen festgestellt, so muss eine Prüfung auf Oberflächenrisse nach
einem hierfür geeigneten Verfahren durchgeführt werden oder das entsprechende Teil
ist zu ersetzen. Wenn diese Prüfung im Abnutzungs- und Verformungsbereich am
eingebauten Doppelhaken nicht durchgeführt werden kann, muss er ausgebaut werden.
Dies betrifft auch den Hals und die Augen des Doppelhakens.
Vor dem Prüfen sind die Oberflächen in einen Zustand zu versetzen, der das
einwandfreie Erkennen von Oberflächenrissen ermöglicht. Beschädigungen und
Oberflächenrisse dürfen kerbfrei beseitigt werden, soweit Funktion, zulässige
Maßabweichungen und zulässige Abnutzung es erlauben. Teile mit unzulässigen
Oberflächenrissen sind zu ersetzen.
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Tabelle 4-1 zulässige Abnutzung / Verformung des Doppelhakens

Bestell-Nr. Haken Größe a2 max b1 min b2 min d1 min d2 max d3 max S2 min S3 min h min
00022454 22-8411 NG 16 99 91 91 91 96 90 52 36 113
00022400 22-8412 NG 25 123 113 113 113 107 97 57 70 143
00022287 22-8413 NG 25 123 113 113 113 117 97 52 70 143
00022279 22-9864 NG 32 137 113 126 126 138 97 61 70 162
00027971 22-8412 NG 25 123 113 113 113 107 97 57 70 143
00040483 22-7370 NG 25 123 113 86 113 100 - 45 - 143
23084393 NG 50 176 162 152 162 159 97 87 *) 70 202
Alle Angaben in Millimeter *) einschließlich Buchse
Bestell-Nr. siehe Ersatzteilliste
Ausgangsmaße von
Y1 und Y2 siehe
Angaben auf dem
Doppelhaken
Doppelhaken
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Überprüfung der Hydraulik-Schlauchleitungen
Die Überprüfung der Hydraulik-Schlauchleitungen ist nach Bedarf, jedoch mindestens

einmal im Jahr durchzuführen, bei Mehrschichtbetrieb alle 6 Monate. Die Hydraulik-
Schlauchleitungen sind nach Wartungs- und Intstandsetzungsarbeiten auf ordnungs-
gemäße Montage und auf arbeitssicheren Zustand zu prüfen.
Schlauchleitungen müssen ersetzt werden wenn eins der folgenden Kriterien fest-
gestellt wurde:
- Beschädigungen der Außenschicht bis zur Drahtgeflechteinlage (z. B. Scheuer-
stellen, Schnitte, Risse)
- Versprödung der Außenschicht (Rissbildung des Schlauchmaterials)
- Verformungen, die der natürlichen Form des Schlauches oder der Schlauchleitung
nicht entsprechen,sowohl im drucklosen als auch im druckbeaufschlagten Zustand
oder bei Biegung, z. B. Schichtentrennung, Blasenbildung
- undichte Stellen
- Beschädigung oder Deformation der Schlaucharmatur (Dichtfunktion beeinträchtigt)
- Herauswandern des Schlauches aus der Armatur
- Funktion und Festigkeit mindernde Korrosion der Schlaucharmatur
- Lager- und / oder Verwendungsdauer des Schlauches oder der Schlauchleitung
überschritten.
f Hydraulikschläuche maximal 2 Jahre lagern.
f Hydraulikschläuche max. 6 Jahre verwenden (einschließlich max.
2-jähriger Lagerzeit).
f Mängel sofort beseitigen.

f Nur Austauschleitungen gemäß Ersatzteilliste verwenden.
f Sicherstellen, dass die Austauschleitungen sauber sind; bis zum Einbau mit
Staubschutzkappen verschließen.
f Sicherstellen, dass die Hydraulikschläuche für die erforderlichen Drücke zugelassen
sind.
Hydraulikschläuche sind mit dem Herstelldatum (Quartal und Jahr) gekennzeichnet.
Zum Beispiel kennzeichnet die Angabe 2 Q 09 die Herstellung im 2. Quartal 2009.
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Prüfung von Ketten und einzelnen Kettengliedern
Ketten und einzelne Kettenglieder beziehungsweise Aufhängeglieder (siehe Bild

Maschinenkarte - Abmessungen) müssen in Abständen von nicht mehr als 12 Monaten
von einem Sachkundigen c geprüft werden. Bei ungünstigen Einsatzbedingungen zum
Beispiel erhöhtem Verschleiß oder verstärkter Korrosion sind kürzere Abstände
erforderlich. Zusätzlich zu den Sichtprüfungen muss in Abständen von längstens drei
Jahren eine magnetische Prüfung auf Rißfreiheit durchgeführt werden. Die Prüfungen
sind gemäß den Vorschriften des Landes in dem die Kette eingesetzt wird zu
dokumentieren.
Vor der Überprüfung müssen die Kettenglieder gründlich gereinigt werden, sodass sie
frei von Öl, Schmutz und Rost sind. Die Reinigungsmethode darf den Grundwerkstoff
nicht angreifen und darf keine Risse oder Oberflächenschäden verdecken.
Die Ketten oder Aufhängeglieder müssen ausgewechselt werden:

a) Bei Verformung oder Bruch eines Kettengliedes und wenn ein Kettenglied
Ablagerungen aufweist, die nicht entfernt werden können.
b) Wenn Kettenglieder gerichtet, geschweißten, gebogen gebrannten oder auf
andere Weise verändert wurden.
c) Wenn ein Kettenglied Kerben, Anrisse, Rillen, Schnitte, Korrosionsnarben, oder
Quetschungen aufweist. Kleinere Kerben können von einem Sachkundigen c
angeglichen werden, wenn die verbleibende Materialdicke an dieser Stelle
größer als 90% des Ursprungsdurchmessers ist und keine plötzliche Quer-
schnittsänderung erkennbar ist.
d) Wenn durch plastische Verformung die äußere Länge eines Kettengliedes um
mehr als 3% des äußeren Nennmaßes länger geworden ist,
e) bei Verschleiß oder übermäßiger Korrosion an irgendeiner Stelle eines
Kettengliedes. Bis zu 90 % des Ursprungsdurchmessers (dn) ist der Verschleiß
zulässig, als Mittelwert aus zwei unter 90° zueinander durchgeführten
Messungen der Durchmesser d1 und d2 (siehe Bild 4.2.4).
f) Wenn sich durch Verschleiß eine Vergrößerung der Innenlänge ergeben hat, die
bei Aufhängeglieder größer gleich ΔL=8% beträgt ( ΔL = L1 – Lo )
bei einem Kettenglied größer gleich ΔL=5% beträgt
bei einer Kette für 11 Teilungen (Glieder) größer gleich ΔL=2% beträgt
g) bei Verfärbungen durch Wärme oder Schädigungen durch chemische Einflüsse
Ketten ausgewechselt wenn:

d1+d2
> 0,9 dn
2
Bild 4.2.4
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Reparaturen dürfen nur vom Hersteller oder bei kleineren Kerben ( siehe Punkt c) )
von einem Sachkundigenc c durchgeführt werden.
c Sachkundige sind Personen, die auf Grund ihrer fachlichen Ausbildung und
Erfahrung ausreichende Kenntnisse auf dem Gebiet der Lastaufnahme-
einrichtungen beim Verladen von Schüttgütern haben und mit den einschlägigen
staatlichen Arbeitsschutzvorschriften, Unfallverhütungsvorschriften, Regeln für
Sicherheit und Gesundheit bei der Arbeit, Richtlinien und allgemein anerkannten
Regeln der Technik (z.B. VDE-Bestimmungen, DIN-Blättern) sowie dieser
Betriebsanleitung soweit vertraut sind, dass sie den arbeitssicheren Zustand von
Lastaufnahmeeinrichtungen, Schäkeln und Ketten beurteilen können.
Hinweis: Durch regelmäßige Schmierung der Kette beziehungsweise Aufhängeglieder

und Schäkel kann eine wesentlich längere zulässige Nutzungsdauer als bei
ungeschmierten Teilen erreicht werden. Es wird empfohlen alle Kettenglieder
und Schäkel vor der Inbetriebnahme zu schmieren. Beim Schmieren ist darauf
zu achten, dass die Berührungsflächen geschmiert werden um einen
vorzeitigen Verschleiß zu verhindern. Als Schmiermittel eignet sich
Schmierstoff zum Schmieren von Drahtseilen oder Verzahnungen (siehe
Kapitel 4.4)
Prüfung von Schäkel

f Die Abstände in der die Schäkel genauer untersucht werden müssen, sind von einer
sachkundigen Person festzulegen. Die Prüfabstände sind so zu wählen, dass
Schäden rechtzeitig erkannt werden können und sollten 6 Monate nicht
überschreiten.
f Die Schäkelprüfungen sind von einer sachkundigen Person durchzuführen:
Der Schäkel muss ausgewechselt werden:
a) Bei Abnutzung von mehr als 5% des Nennmaßes an beliebiger Stelle.
b) Bei dauerhafter Verformung von Bolzen oder Bügel
c) Bei erfolgter Wärmebehandlung oder vorhandenen Schweißmarken
d) Wenn statt des Original-Bolzens ein anderer Bolzen im Schäkel montiert ist
e) Wenn nicht mehr alle Markierungen sichtbar sind
f) Wenn Kerben, Anrisse, Rillen, Schnitte, Korrosionsnarben, oder Quetschungen
im Bolzen oder Bügel vorhanden sind; (Kleinere Kerben können von einem
Sachkundigen angeglichen werden, wenn die verbleibende Materialdicke an
dieser Stelle größer als 95% des Ursprungsdurchmessers ist und keine
plötzliche Querschnittsänderung erkennbar ist)
g) Wenn der Bolzen nicht korrekt eingeschraubt ist (Bolzenbund und Mutter liegen
bei korrekter Montage plan auf den Schäkelaugen auf, die Mutter ist durch einen
Splint gesichert) muss die Montage geändert oder der Schäkel ersetzt werden.
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Prüfung des Schleifringübertragers
f 1x jährlich oder alle 100000 Umdrehungen den Schleifringübertrager prüfen:

a) Verschleiß der Schleifbügel prüfen
b) Verschleiß der Kohlebürsten prüfen Teile vom Kohlebürstenhalter dürfen keine
Isolierringe oder Schleifringe berühren.
c) Alle Befestigungsschrauben für mechanische und elektrische Verbindungen
prüfen ob sie fest angezogen sind
d) Das Vorhandensein der Beschriftungen überprüfen
Weitere Prüfungen:
f Verschraubungen auf Dichtheit prüfen

f Schraubverbindungen prüfen
f Lagerverschleiß kontrollieren
f Steckvorrichtung und Zugentlastung prüfen
f Öltemperatur überwachen
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A 16.0722-1 D 10-3
4.3 Instandsetzung
4.3.1 Allgemeines
Bei größeren Instandsetzungen den Kundendienst der Salzgitter Maschinenbau AG

einschalten.
Verletzungsgefahr bei unzureichender Qualifikation!

Unsachgemäßes Arbeiten kann zu erheblichen Personen- und Sachschäden
führen.
WARNUNG f Das Schwenkwerk darf nur von autorisiertem, ausgebildetem und
eingewiesenem Personal gewartet und instandgesetzt werden. Dieses
Personal muss eine spezielle Unterweisung über auftretende Gefahren
erhalten haben. Dem Personal muss das Ablehnen sicherheitswidriger
Anweisungen Dritter ermöglicht werden.
f Arbeiten an den elektrischen Einrichtungen des Schwenkwerks dürfen nur von
einer Elektrofachkraft oder von unterwiesenem Personal unter Leitung und
Aufsicht einer Elektrofachkraft gemäß den elektrotechnischen Regeln
vorgenommen werden.
f An hydraulischen Einrichtungen darf nur Personal mit speziellen Kenntnissen
und Erfahrungen in der Hydraulik arbeiten!
f Zuständigkeiten des Personals für Montage/Demontage, Inbetriebnahme,
Bedienung, Wartung und Instandhaltung sowie Instandsetzung sind klar
festzulegen und einzuhalten!
f Es ist Sicherzustellen, dass nur dazu beauftragtes Personal am Schwenkwerk
tätig wird!
f Bauteile gegen unbeabsichtigte Bewegungen sichern
f Vor allen Instandsetzungsarbeiten ist die Stromzufuhr zum Schwenkwerk zu
unterbrechen und gegen Wiederinbetriebnahme zu sichern. Wenn vorhanden
die Elektro-Steckvorrichtung (32) (siehe 2.4 Teilebenennungsplan) abziehen.
Bei allen Wartungs- und Instandsetzungsarbeiten ist folgende persönliche Schutz-

ausrüstung zu tragen:
- Schutzhelm
- Schutzbrille
- Schutzkleidung
- Schutzhandschuhe
- Sicherheitsschuhe mit Zehenschutzkappe und durchtrittsicherem Unterbau
Bei der Instandsetzung muß grundsätzlich folgendes beachtet werden:

24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-2 D 10-3
Das Schwenkwerk so absetzen, dass sich der Doppelhaken und die beweglichen Teile
der Schwenkwerksaufhängung nicht unbeabsichtigt bewegen.
Nach jeder Demontage bzw. Reparatur ist eine Überprüfung des auf dem Typenschild
bzw. der Maschinenkarte angegebenen max. Druckes erforderlich. Geeignete
Prüfmanometer sind zu verwenden.
Grundsätzlich sollten vor jeder Wiederinbetriebnahme alle Schmierstellen mit Fett

gemäß 4.4 Ölempfehlung versorgt werden (Schmieranweisung siehe 4.1.9, Schmier-
stellen siehe 4.1.10).
Das Schwenkwerk darf nach Instandsetzungs- und Änderungsarbeiten nur in Betrieb

genommen werden, wenn
- sich das Schwenkwerk wieder in sicherem Zustand befindet,

- autorisiertes Fachpersonal die Arbeiten für endgültig abgeschlossen erklärt und
- sich niemand im Gefahrenbereich befindet.
Vor der Wiederinbetriebnahme sind die im Abschnitt „3.2 Inbetriebnahme“ aufgeführten

Punkte zu beachten.
24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-3 D 10-3
4.3.2 Austausch des Hydraulikmotors

Beschreibung:
5 Schlauchleitung
6 Deckel
7 Hydraulikmotor
8 Schraube am Ritzel
(70 Nm Anziehmoment)
9 Ventilblock
10 Schraube (47 Nm
Anziehmoment)
11 Ritzel
13 Halterung
Bild 4.3.2

sind.
GEFAHR f Eventuelle Leckagen umgehend beheben.
1. Das Schwenkwerk stromlos machen und gegen wiedereinschalten sichern. Wenn

ein oder mehrere Steckvorrichtung vorhanden sind, das Schwenkwerk durch
abziehen dieser Steckvorrichtung stromlos machen.
2. Haube demontieren
3. Die Hydraulik drucklos machen.
4. Halterung (13) abschrauben und vorsichtig auf dem Schwenkwerk ablegen.
5. Die Hydraulik soweit wie es nötig ist demontieren und vor Verschmutzung schützen
6. Die offenen Hydraulikleitungen am Schwenkwerk vor Verschmutzung schützen.
7. Schrauben (8) und (10) abschrauben und den Hydraulikmotor (7) aus dem
Schwenkwerk heben.
8. Den neuen Hydraulikmotor in umgekehrter Reihenfolge montieren.
9. Den Hydraulikmotor über den Anschluss (5) mit Hydrauliköl füllen !
24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-4 D 10-3
4.3.3 Austausch der Hydraulikpumpe

Beschreibung:
1, 2 Schlauchleitungen
3 Schraube (47 Nm)
4 Hydraulikaggregat
5 Deckel
6 Zwischenflansch
7 Verteilerstück
8 Pumpe
9 Kunststoffstopfen
10 Schraube (25 Nm)
Bild 4.3.3

sind.

3. Die Hydraulik drucklos machen.
4. Die Hydraulik soweit wie es nötig ist demontieren und vor Verschmutzung
schützen.
5. Schrauben (3) abschrauben und das Hydraulikaggregat (4) aus dem Schwenk-
werk heben
6. Verteilerstücke (7) abschrauben
7. Pumpe (8) abschrauben
8. An der Unterseite der neuen Pumpe den Kunststoffstopfen (9)
entfernen !
9. Die neue Pumpe in umgekehrter Reihenfolge montieren.
24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-5 D 10-3
4.3.4 Austausch der Achslagerung
Bild 4.3.4
Beschreibung
1 Traverse 9 Schleifringkörper
3 Schleifringübertrager 10 Bürstenhalter
6 Zylinderschraube 11 Axial-Zylinderrollenlager
7 Achse
Vor Instandsetzungsarbeiten und vor dem Auswechseln der Achslagerung den

Kundendienst der Salzgitter Maschinenbau AG einschalten. Diese Arbeiten nur
von Fachwerkstätten, die Erfahrungen in der Handhabung von Axial-Zylinder-
rollenlagern hat, durchführen lassen.
Service Manager:
Hr. Kevin Wenke +49 -5341 / 302 - 493 kevin.wenke@smag.de
Service Administration:
Fr. Schwarz +49 -5341 / 302 - 673 elke.schwarz@smag.de
Service Techniker:
Hr. Müller +49 -5341 / 302 - 672 marcus.müller@smag.de
Hr. Olbrich +49 -5341 / 302 - 491 olaf.olbrich@smag.de
Hr. Schmerschneider +49 -5341 / 302 - 492 bernd.schmerschneider@smag.de
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-6 D 10-3
4.3.5 Austausch des Ritzels
Bild 4.3.5
Beschreibung
8 Hydraulikmotor 12 Flansch
9 Sechskantschraube (70 Nm Anziehmoment) 13 Schmierstoffleitung
10 Zylinderschrauben (47 Nm Anziehmoment) 14 Ritzel
11 Zylinderschrauben (250 Nm Anziehmoment) 16 Ritzelhalter
17 Schutzblech

sind.

3. Die Hydraulik drucklos machen
4. Deckel (17) abschrauben
5. Schrauben (9) abschrauben
6. Schrauben (10) abschrauben
7. Schrauben (11) abschrauben, Schmierstoffleitung (13) abschrauben und den
Flansch (12) herausheben.
8. Ritzel (14) herausziehen und Ritzelhalter (16) demontieren. Wenn sich das Ritzel
nicht ohne weiteres herausziehen lässt, so verfahren wie es unten beschrieben ist.
Zum Demontieren des Ritzels eine Abziehvorrichtung verwenden.
24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
SCHWENKWERK
A 16.0722-7 D 10-3
Wenn sich das Ritzel nicht ohne weiteres herausziehen lässt:

8.a Den Hydraulikmotor (8) wie unter 4.3.2 beschrieben ausbauen.
9. Schrauben (11) abschrauben, Schmierstoffleitung (13) abschrauben und den
Flansch (12) herausheben.
10. Ritzel (14) herausziehen und Ritzelhalter (16) demontieren
11. Das neue Ritzel in umgekehrter Reihenfolge montieren. Die Anziehmomente der
Schrauben sind in der Ersatzteilliste zu finden.
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-1 D 11-1
4.4 Tabelle: Ölempfehlung - Hydrauliköle
Für den normalen Betrieb ist ein Hydrauliköl der ISO-Viskositätsklasse VG 46 zu

verwenden. Für Sommerbetrieb bzw. Winterbetrieb ist entsprechend der Umgebungs-
temperatur ein Hydrauliköl der ISO-Viskositätsklasse VG 68 bzw. VG 32 zu verwenden.
Zum Schutz der Hydraulikkomponenten muss das Öl mindestens die Reinheitsklasse
20/18/15 nach ISO 4406 haben (entspricht in etwa der Klasse 9 nach NAS 1638).
Neues Öl hat in der Regel eine schlechtere Reinheitsklasse, es ist deshalb erforderlich
das neue Öl zu filtern. Dies kann erfolgen in dem das Öl durch den Filter nachgefüllt
wird oder durch die Verwendung von speziellen Befüllaggregaten, die das Öl so filtern
dass die geforderte Reinheitsklasse erreicht wird.
Nachfolgend sind die geeigneten und von der SMAG freigegebenen Ölsorten
aufgeführt.
Winter Sommer
ISO-Viskositätsklasse VG 32 VG 46 VG 68
Norm HVLP 32 HLP 46 HLP 68
nach DIN 51524/3 HV nach DIN51524/2 nach DIN51524/2
Anlauftemperatur *) -15°C -5°C +5°C
Inbetriebnahme- -5°C +5°C +12°C
temperatur
maximale obere +70°C +80°C +85°C
Einsatztemperatur
Umgebungstemperatur < -5°C bis -20°C -5°C bis +30°C > +30°C
ARAL Vitam HF 32 Vitam GF 46 Vitam GF 68
AVIA AVIA FLUID HVI 32 AVIA FLUID RSL46 AVIA FLUID RSL68
BP ENERGOL ENERGOL ENERGOL
SHF-HV 32 HLP-HM 46 HLP-HM 68
CASTROL HYSPIN AWH-M 32 HYSPIN AWS 46 HYSPIN AWS 68
ESSO UNIVIS J 32 NUTO H 46 NUTO H 68
FUCHS RENOLIN MR 32 MC RENOLIN MR 15 RENOLIN MR 20
FUCHS LUBRITECH RENOLIN B 32 HVI RENOLIN RENOLIN
B15VG46 B20VG68
MOBIL Univis N 32 DTE 25 DTE 26
SHELL Tellus T 32 Tellus 46 Tellus 68
Tellus S2 V 32 Tellus S2 M 46 Tellus S2 M 68
TOTAL Equivis ZS 32 Azolla ZS 46 Azolla ZS 68
*) Temperatur ab der die Hydraulikpumpe eingeschaltet werden darf, um das Öl mit dem
Druckbegrenzungsventil auf die Inbetriebnahmetemperatur vorzuwärmen.
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-2 D 11-2
Der Einsatz anderer Hydrauliköle darf nur nach Freigabe durch die SMAG erfolgen.
Es sind zinkhaltige Hydraulikflüssigkeiten zu verwenden, um die Verträglichkeit mit den

bronzegefüllten PTFE-Abdichtungen sicherzustellen
Das Mischen von verschiedenen Hydraulikflüssigkeiten ist nur nach Rücksprache mit
dem jeweiligen Hersteller und nach entsprechender Freigabe erlaubt.
Der Einsatz von biologisch abbaubarem Hydrauliköl darf nur nach Freigabe durch die
SMAG erfolgen. Das Mischen von Mineral- und biologisch abbaubarem Hydrauliköl ist
grundsätzlich nicht zulässig!
Für den Betrieb bei -50°C bis +40°C ist ein Hydrauliköl vom Typ HVLP nach
DIN 51524-3 NATO-Kode: H 540 zu verwenden. Bei Temperaturen unter -25°C muss
das Hydrauliköl vorgewärmt werden.
Winter Winter
Norm HVLP
nach DIN 51524/3 HV
NATO-Kode: H 540
Anlauftemperatur *) -25°C -30°C
Inbetriebnahme- -15°C -20°C
temperatur
maximale obere +85°C +70°C
Einsatztemperatur
Umgebungstemperatur < - 50°C bis +40°C < - 50°C bis +40°C
ARAL Vitam H 540
AVIA AVILUB HYDRAULIKFL H 540
SHELL Hydraulikflüssigkeit H-540 Shell Tellus Arctic
H&R ChemPharm GmbH SRS Wiolan H-540
*) Temperatur ab der die Hydraulikpumpe eingeschaltet werden darf, um das Öl mit dem
Druckbegrenzungsventil auf die Inbetriebnahmetemperatur vorzuwärmen.
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-3 D 11-3
4.5 Schmierstoffempfehlung
Vom Hersteller verwendete Fettsorten: siehe Maschinenkarte!
Isolierklasse und Baugröße des Elektromotors: siehe Maschinenkarte
Hinweis: Synthetische Schmierstoffe nicht mit mineralischen Schmierstoffen

mischen!
Synthetische Schmierstoffe nur nach Absprache mit dem Schmierstoff-
hersteller mit einem anderen synthetischen Schmierstoff mischen.
Schmierstoff für die Lager Schmierstoff für die Lager

in einem Elektromotor mit im Elektromotor
Isolierklasse: H und Tieftemperaturbereich
Baugröße:
56 bis 400
synthetischer Schmierstoff synthetischer Schmierstoff
BREMER & Rivolta S.K.D. 4002

LEGUIL GMBH -50°C bis +210°C *)
Castrol Firetemp XT 2
- 25°C bis + 180°C
Fuchs RENOLIT PU 8-061/2 RENOLIT HLT 1

-20°C bis +180°C -50°C bis +140°C
FUCHS URETHYN E/M 2 URETHYN LT 60
LUBRITECH - 20°C bis + 180°C - 50°C bis + 140°C
KLÜBER PETAMO GY 193 ISOFLEX TOPAS NB 52

LUBRICATION ca. - 20°C bis + 180°C - 50°C bis + 120°C
Shell Gadus S3 T100/2 Gadus S2 V100/2

- 20°C bis + 160°C - 30°C bis + 130°C
*) Temperatureinsatzbereich
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-4 D 11-4
Schmierstoff für die Lager Schmierstoff für die Lager

in einem Elektromotor mit in einem Elektromotor mit
Isolierklasse: F und Isolierklasse: F und
Baugröße: Baugröße:
56 bis 112 132 bis 400
mineralischer Schmierstoff mineralischer Schmierstoff
Lithium-12-Hydroxystearat- Barium-Komplex- Verdicker
Verdicker
AVIA LITHOPLEX 3 EP
- 20°C bis + 150°C
BREMER & Rivolta S.K.D. 4002 Rivolta S.K.D. 4002
LEGUIL GMBH -50°C bis +210°C *) -50°C bis +210°C *)
BP Energrease LS 3
- 25°C bis + 130°C
Fuchs RENOLIT GP3 RENOLIT DURAPLEX EP 2
-30°C bis +120°C -30°C bis +160°C
FUCHS STABYL L 120 STABYL L 120

KLÜBER Staburags
LUBRICATION NBU 8 EP
- 20°C bis + 140°C
Shell Alvania RL3

- 25°C bis + 130°C
Bei der Umstellung auf ein Schmierfett mit anderer Seifenbasis oder anderem Verdicker
ist das zuvor verwendete Schmierfett möglichst weitgehend zu entfernen. Nach der
Umstellung sind die Nachschmierfristen zu verkürzen, um eine möglichst schnelle
Entfernung des alten Schmierfettes zu erreichen. Eine Vermischung von Schmierfetten
führt zu einer Verschlechterung der Schmiereigenschaften und somit zu einer
Verringerung der Lebensdauer der Bauteile.
24.09.2010
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PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-5 D 11-5
Schmierfett für Schmierfett für

Verzahnungen Verzahnungen
Tieftemperaturbereich
DIN 51502 KP2 K (KPF2 N) DIN 51502 KE 1 N -50
mineralischer Schmierstoff synthetischer Schmierstoff
Calzium Eindicker organischer Eindicker
AGIP AUTOL TOP 2000
-30 bis +120°C *)
AVIA AVIACAL 2 LD
-30 bis +120°C
BREMER & CERITOL PK 1

LEGUIL GMBH -60°C bis +140°C
BP Energrease Mp-MG 2
-30°C bis +175°C
Fuchs RENOLIT CA-LZ

-30°C bis +120°C
FUCHS LAGERMEISTER 3000 URETHYN LT 60

LUBRITECH PLUS - 50°C bis + 140°C
-30 bis +120°C
KLÜBER Klüberplex AG 11-462 ISOFLEX TOPAS NB 52
LUBRICATION - 40°C bis + 180°C - 50°C bis + 120°C
ISOFLEX TOPAS NCA 51
- 60°C bis + 140°C
Möllenberg & Zählit VZ

Sonntag - 20°C bis + 90°C
Shell Retinax HD2 AeroShell Grease 7

-20°C bis +130°C - 73°C bis + 135°C
Vom Hersteller verwendete Fettsorte siehe Maschinenkarte!

24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-6 D 11-6
Schmierfett für Gleit- und Schmierfett für Gleit- und

Wälzlager Wälzlager
Tieftemperaturbereich
DIN 51502 KP 2 K DIN 51502 KPHC2N-50
mineralischer Schmierstoff synthetischer Schmierstoff
Lithium Eindicker organischer Eindicker
AGIP Agip GR MU EP 2 Agip Longtime Grease 2
-20°C bis +120°C *) - 35°C bis + 135°C
ARAL Aralub HLP 2 Aralub SKL 2

-20°C bis +120°C - 50°C bis + 130°C
AVIA AVIALITH 2 EP AVIA SYNTOGREASE PE-T
-30°C bis +120°C -60 bis +140°C
BP Energrease LS-EP 2 Energrease SY 2202
-25°C bis +130°C - 40°C bis + 170°C
LEGUIL GMBH -20°C bis +140°C
Castrol Spheerol EPL 2 Optitemp LG 2
-20°C bis +140°C -50°C bis +120°C
Longtime PD 2
-35°C bis +140°C
FUCHS RENOLIT LZR 2 H RENOLIT HLT 2

EUROPE -30°C bis +140°C - 40°C bis + 140°C
SCHMIER- RENOLIT MP
STOFFE GMBH -40°C bis +120°C
FUCHS Lagermeister EP 2 URETHYN LT 60

LUBRITECH -20°C bis +130°C - 50°C bis + 140°C
KLÜBER Klüberplex BEM 41-132 ISOFLEX TOPAS NB 52

LUBRICATION -40°C bis +150°C - 50°C bis + 120°C
Mobil Oil Mobilux EP 2 Mobilith SHC 100

-20°C bis +120°C (KPHC2N-40)
- 40°C bis + 150°C
Shell Retinax HD2 (Li/Ca) AeroShell Grease 33
-25°C bis +120°C -70°C bis + 120°C
Total Multis EP 2 Multis XLT 2
-25°C bis +120°C -60°C bis +130°C
Vom Hersteller verwendete Fettsorte siehe Maschinenkarte!
24.09.2010
P
PEINER Greifer
BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
A 16.0721-7 D 11-7
Schleifringübertrager: Kontaktöl ausschließlich zum hauchdünnen Einsprühen von

Drahtschleifbügel und deren Schleifring.
CRAMOLIN Schutz
Hersteller: ITW CHEMISCHE PRODUKTE GMBH & Co KG
Mühlacker Strasse 149 D-75417 Mühlacker
Telefon: +49 (0) 7041-9634-0 Telefax: +49 (0) 7041-9634-29
Internet: www.itwcp.de E-Mail: info@itwcp.de
ACHTUNG: Zuviel Kontaktöl kann Kurzschlüsse verursachen.

Bürstenhalter und seinen Schleifring nicht einsprühen! Nach
dem Einsprühen mit Kontaktöl, Schleifringübertrager 5x um
360° drehen.
13.09.1999
3
3(,1(5*UHLIHU
%(75,(%6$1/(,781*
6&+:(1.:(5.
$'
6W|UXQJ.HQQ]HLFKHQ±)HKOHUTXHOOHQ
6W|UXQJ .HQQ]HLFKHQ )HKOHUTXHOOHQ

6FKZHQNZHUN - Elektromotor läuft nicht, - Sicherungen
DUEHLWHWQLFKW Elektromotor erhält - Schütze
$FKVHGUHKWVLFK keine Spannung - Schlauchleitung
QLFKW - Anschlußklemmen
- Schleifring und Bürsten der Kabel-
trommel
- Steckvorrichtung

- Spannung vorhanden - Motor defekt

- Elektromotor läuft - Rückschlagventil an den Pumpen-
ansaugöffnungen verklemmt
(infolge Ölverschmutzung)
- Druckleitungen von der Pumpe
zum Steuerblock defekt
- Feder im Druckbegrenzungsventil
gebrochen
- Verrohrung undicht
- Absperrhahn noch geöffnet
- Magnetventil defekt (verklemmt)
- Hydromotor defekt
- Ritzel defekt
- Stromregelventil zu weit geöffnet
- Wechselventil defekt
- Rückschlagventile defekt

6FKZHQNZHUNEULQJW - Drehzeit und Drehzahl - Druckbegrenzungsventil verstellt
NHLQH/HLVWXQJ merklich verlangsamt (siehe 4.2.2)
$FKVHGUHKWVLFK - Drehmoment zu gering - Verschleiß in der Pumpe
- Druckbegrenzungsventil ver-
schmutzt oder Feder ermüdet.
Drucknachstellung erforderlich..
- Ölstand im Tank zu niedrig. Wenn
die Pumpe hierbei Luft ansaugt,
führt es meistens zur Zerstörung
der Pumpe.
- Zuleitung von der Pumpe zum
Steuerblock hat sich gelöst oder ist
beschädigt.
- Schieberkolben im Steuerblock
verklemmt; kann durch Fremd-
körper im Öl oder durch Feder-
bruch verursacht werden.
- Verrohrung undicht
- Magnetventil defekt (verklemmt)
- Stromregelventil
21.09.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0138-1 E 1-1
C o n t e n t s
Page-no. Class-no.
Data Sheet / Technical Data
1.0 Safety
1.1 About this Document 2-1 A 16.0200-1 E
1.2 Audience 2-1 A 16.0200-1 E
1.3 Intended Use 2-1 A 16.0200-1 E
1.4 Fundamental Safety Notes 2-2 A 16.0200-2 E
1.4.1 Warning Notes 2-2 A 16.0200-2 E
1.4.2 Safety Symbols 2-2 A 16.0200-2 E
1.4.3 Organizational Measures 2-3 A 16.0200-3 E
1.4.4 Personnel Selection and Qualification 2-4 A 16.0200-4 E
1.4.5 Measures to be Performed by the Operating 2-4 A 16.0200-4 E
Company
1.4.6 Measures to be Performed by the Operator 2-5 A 16.0200-5 E
1.4.7 Measures for the Maintenance, Servicing and Repair 2/5-6 A 16.0200/5-6 E
1.4.8 Safety Notes for the Electrical System 2/6-7 A 16.0200/6-7 E
1.4.9 Safety Notes for the Hydraulic System 2-7 A 16.0200-7 E
1.4.10 Handling of Oil, Grease and Other Chemical 2-7 A 16.0200-7 E
Substances
2.0 Description and Survey of Features

2.1 Base unit: Constructional and Functional Description
2.1.1 Constructional Description 3-1 A 16.0322 E
2.4 Parts list 7-1 A 16.1036 E
3.0 Operating instructions

3.1 Details for safe use 8/1-2 A 16.0619/1-2 E
3.2 Putting into operation
3.2.1 Initial start-up 8/3-4 A 16.0619/3-4E
3.2.2 Daily start-up 8-5 A 16.0619-5 E
3.3 Operation
3.3.1 Information for operation 9-1 A 16.1218 E
3.4 Shut-down 9-1 A 16.1218 E
3.5 Reoperation 9-1 A 16.1218 E
3.6 Transportation 9-1 A 16.1218 E
Original operating instructions

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21.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0138-2 E 1-2
C o n t e n t s
Page-no. Class-no.
4.0 Maintenance and repair 10-1 A 16.1222-1 E
4.1 Maintenance 10-2 A 16.1222-2 E
4.1.1 Maintenance Overview 10-2 A 16.1222-3 E
4.1.2 Maintenance interval after the first 50 operating hours 10-2 A 16.1222-4 E
4.1.3 Maintenance interval after the first 500 operating 10-2 A 16.1222-4 E
hours
4.1.4 Maintenance interval weekly 10-2 A 16.1222-5 E
4.1.5 Maintenance interval every 1000 operating hours 10-2 A 16.1222-6 E
4.1.6 Maintenance interval every 2000 operating hours 10-2 A 16.1222-7 E
4.1.7 Oil change 10-2 A 16.1222/8-9 E
4.1.8 Oil filter 10-2 A 16.1222-9 E
4.1.9 Lubricating instructions 10-2 A 16.1222-9 E
4.1.10 Lubrication points 10-2 A 16.1222-10 E
4.1.11 Motor 10-2 A 16.1222-11 E
4.1.12 Slip-ring transmitter 10-2 A 16.1222-12 E
4.2 Required checks
4.2.1 Check oil level 10-2 A 16.1222-13 E
4.2.3 Wear 10-2 A 16.1222-13 E

4.2.4 Miscellaneous checks 10-2 A 16.1222/13-17 E
4.3 Repair
4.3.1 General 10-3 A 16.0722/1-2 E
4.3.2 Replacement of hydraulic motor 10-3 A 16.0722/3-4 E
4.3.3 Replacement of hydraulic pump 10-3 A 16.0722-5 E
4.3.4 Replacement of axle bearing 10-3 A 16.0722-6 E
4.3.5 Replacement of pinion 10-3 A 16.0722/7-8 E
4.4 Table: Oil recommendation - Hydraulic fluids 11/1-3 A 16.0721/1-2 E
4.5 Lubricant recommendation 11/3-5 A 16.0721/3-5 E
5.0 Failure - Symptoms - Sources of failures

5.1 Slewing unit not functioning 12-1 A 16.0757 E
5.2 Slewing unit malfunctioning 12-1 A 16.0757 E
6.0 Spare parts list and electric equipment
Original operating instructions

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Product: SW 144 DISK

Material-Nr.: 0023080453 Operating instructions: A 16.0138
valid for SW 144 DISK from Serial no.: 0279 (until the application range is specified)
Deadweight: 3.600 kg
Crane lifting capacity SWL: 144.000 kg
Required crane lifting capacity: 147.600 kg
Mechanical Data
-1
Rotational speed / axle: 5,4 / 6,8 min
Torque / axle: 4850 Nm
Electric Data
Mode of operation: S3 System of protection: IP 56 1)
Motor type: 112M-4 Insulation class: F
Intermittent service: 40% duty cycle max. duty classification: 120 /h
Motor power: 3,5 / 4,2 kW Circuit diagram no.: 2307.9132
Voltage: 400 V Plug-in connector: ODU-37 pol.
Frequency: 50 / 60 Hz Control voltage: 230 V AC
Current: threephase No. of slip rings: 31pol.x36A+PE+2 CAN
Rated current (full load): 7,9 A ± 10 % BUS
Current consumption:
Hydraulic Data
max. service pressure Rotational sense right [± 10 bar] 2) Rotational sense left [± 10 bar] 2)
Measuring point MA 200
Measuring point MB 200
Pump type / output: P3DB2006L10 / 8,5 litre/min

Control block:
Hydromotor: M 300
Filled oil quality: HLP 46
Oil quantity: 31 l
Filter Type: Argo
Filter mesh: ȕ16(c) = 200 Exapor
Admissible service temperature: - 15 °C up to + 85 °C
used grease: Renolit GR 2 FUCHS EUROPE SCHMIERSTOFFE GMBH
used grease for electric motor: PETAMO GY 193 KLÜBER LUBRICATION
used grease for toothed wheel works: Zählit VZ Möllenberg & Sonntag OHG
Zubehör
– Crosspiece with double hook no. 32
1)
System of protection ensured only with mounted and closed hood
2)
top view onto hood / slip ring transmitter
Author : 15.10.2011 / VG-K - Skiba

Dimensions
Author : 15.10.2011 / VG-K - Skiba

27.05.2009
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0200-1 E 2-1
1.0 Safety
1.1 About this Document

This operating manual is part of the machine and describes the safe and correct use in
all operational phases.
We reserve the right to make changes to our products in the interest of further
development.
X Adhere to the operating instructions when using this machine.
X Always keep the service manual close to the machine.
X Retain this service manual for further use.
X Hand over the service manual to any further proprietor or user of the machine.
1.2 Audience
The audience of this operating manual is the technical personnel.
The machine must only be used, maintained and/or repaired by technically skilled
personnel that is used to carry out such work.
1.3 Intended use

The slewing unit has been designed for industrial applications.
It must only be used to lift free-standing loads and to turn and handle freely suspended
charges.
Intended use includes adherence to the operating instructions of this slewing unit and to
the inspection and maintenance instructions.
The manufacturer does not accept any responsibility for any resulting damage caused
by improper use. The operating company alone carries the risk here.
An improper use is, for example:
- Breaking loose of non-freestanding loads
- Horizontal movement of non-freely hanging loads
- Adding to the load once it has already been raised
- Causing the load to oscillate
- Any loading that exceeds the permitted capacity (see SWL indicated on the slewing
unit)
- Lifting or dragging loads diagonally from the location
- Riding on the load or on the slewing unit
- Operation of the slewing unit at a higher working pressure than allowed..
- Use of the slewing unit in explosive atmosphere
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SLEWING UNIT
Class-no. Page-no.
A 16.0200-2 E 2-2
1.4 Fundamental Safety Notes
1.4.1 Warning Notes
Warning notes in this operating manual indicate particular dangers and mention
measures for the avoidance of the danger.
There are four levels of warning notes:
Signal word Meaning
DANGER Immediate potential danger
Death or severe injury occurs
WARNING Possible potential danger
Death or severe injury can occur
CAUTION Possible potential danger
(personal injury) Minor injury can occur
CAUTION Possible potential danger
(damage to property) Damage to property can occur
Warning notes have the following form:
Type and source of the danger

Possible consequences, explanation of the danger.
: Do not do ...
DANGER
X Perform these measures.
1.4.2 Safety Symbols
Warning of electrical dangers

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1.4.3 Organizational Measures

Always keep the service manual at the place of operation of the slewing unit!
In addition to the operating manual, observe generally valid legal and other binding
regulations for accident prevention and for environmental protection! Such obligations
can also concern, for example, the handling of dangerous materials or the
provision/wearing of personal protective equipment or traffic safety regulations.
The slewing unit has been built in accordance with the state of the art and is reliable if
used as specified. However, dangers might emanate from this machine if it is operated
improperly by uninstructed or disregardful personal or used for any other purpose than it
is intended for. (see 1.3 Intended use, page no. 1-1). The manufacturer will not be liable
for any other use in excess of the intended use nor for any damages resulting
therefrom. The user alone will bear such risk.
The slewing unit must only be operated in perfect technical condition.
During operation of the slewing unit keep sufficient safe distance to the load and to the
slewing unit! Don´t stay under the slewing unit!
The personnel who is assigned to work on the slewing unit must have read the operating
instructions, in particular the chapter „Safety“ before starting to work. This applies
particularly to personnel who only works on the slewing unit occasionally, e. g. for setup
or maintenance.
Adhere to all warnings and safety instructions applied to the slewing unit and make sure
they are always completely legible!
For safety-relevant malfunctions or changes to the operational state, stop the slewing
unit immediately and report the fault to the responsible office/person!
Augment the operating manual with instructions, including supervisory and reporting
obligations, to cater for special operational situations, for example, with regard to the
work organization, work procedures and the delegated personnel.
Only sling any slinging gear (slinging ropes or chains) to the devices provided fort his
purpose (e. g. at the double hook).
Check that the carrying capacity of the lifting tackle is adequate for the task before
starting hoisting!
Do not make any changes, additions or modifications to the machine that could impair
the safety without approval of the vendor! This is also the case for the installation and
the calibration of safety equipment and valves. The machine must not be subjected to
welding work without prior consent and specifications of the manufacturer.
Spare parts must conform to the technical specifications stipulated by the manufacturer.
This always the case when genuine spare parts are used.
Genuine spare parts are specially designed for the particular machine. Parts and special
equipment not supplied by the manufacturer have not been approved. The installation
and/or the use of such products can impair the safety. The manufacturer does not
accept any liability for damage caused by the use of non-genuine parts or any special
equipment.
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1.4.4 Personnel Selection and Qualification

Any person who is responsible for assembly/disassembly, putting into operation,
operation, maintenance and repair of the slewing unit must have read, understood and
adhere to the complete service manual, in particular the chapter „Safety“.
Only authorised, trained and instructed personnel is allowed to run, to maintain and to
repair the slewing unit. Such personnel must have been given special instruction in the
possible dangers. The personnel must be allowed to reject any safety-endangering
instructions from third-parties.
The responsibilities of the personnel for the installation/dismantling, commissioning,
operation, maintenance, servicing and repair must be clearly defined and observed!
Make sure that only personnel assigned to run the slewing unit will do so!
Only specialist electricians or instructed personnel under direction and supervision of a
specialist electrician are allowed to work on the electric systems of the slewing unit and
they must do this in compliance with the electrotechnical regulations.
Work on the hydraulic equipment may be performed only by personnel with special
hydraulics knowledge and experience!
The personnel being trained, instructed or participating in a general training may work
on the slewing unit only under the continuous supervision of an experienced person!
1.4.5 Measures to be Performed by the Operating Company

The owner must take appropriate maintenance and inspection measures to make sure
the slewing unit is always run in a perfect technical condition.
The owner must evidently manage and define the responsibilities for assembly /
installation, operation, maintenance and repair.
The owner shall be obliged to make sure that any work on the slewing unit is carried out
by well-trained and instructed personnel only who
- is aware of the basic instructions about working safety and prevention of accidents
and has been instructed to run the slewing unit;
- has read and understood the safety instructions and warnings in this service
manual.
The owner shall be obliged to verify regularly if the personnel works safety-consciously.
The owner shall be obliged to make sure that this service manual is always easily
accessible.
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1.4.6 Measures to be Performed by the Operator
The regulations applicable to the place of operation must be adhered to. The operation
of the slewing unit is in any case subject to the local safety regulations and instructions
for the prevention of accidents.
Before putting the slewing unit into operation make sure that nobody might be
endangered by operation of the slewing unit! Slewing unit components might
automatically restart when the slewing unit is restarted!
The crane operator must at all times be able to see the working area and the load!
Ensure adequate lighting in conditions of poor sight and darkness.
Do nor stand or work under suspended loads!
Avoid any safety-compromising working!
Examine the slewing unit at least once per shift to make sure it is exempt from damages
or defects! Notify the responsible post/person of any occurred abnormality (including
abnormal operating behaviour)! Immediately shut down and secure the slewing unit if
necessary! Remedy any failure immediately!
1.4.7 Measures for the Maintenance, Servicing and Repair
Observe the adjustment, maintenance and inspection tasks and schedules, including
details concerning the replacement of parts and equipment prescribed in the operating
manual! These tasks may only be performed by specialized personnel.
Inform the operations personnel before commencing maintenance and servicing work!
Designate a supervisory person.
The shutdown instructions according to the operating instructions must be adhered to
during any work referring to assembly/disassembly, putting into operation, operation,
maintenance and repair.
Carry out repair work on the hydraulic and electric system in a clean and dust-free
environment.
If necessary, secure the work area!
Before carrying out any maintenance or repair work completely shut down the slewing
unit and protect it against any unauthorized restart:
- Unplug electric plug-in connector.
Remove protective equipment only after the machine has been shut down!
Carefully fasten and secure spare parts and modules being replaced to the lifting gear
so that they do not endanger anyone. Use only suitable and technically perfect lifting
gear and load carrying equipment with adequate carrying capacity!
Do not stand or work under suspended loads!
If necessary, use security-conform ladders and work platforms for installation and
servicing work! Do not use machine parts as steps! Wear fall-prevention gear for work
performed at height.
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SLEWING UNIT
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A 16.0200-6 E 2-6
Because contact with hot parts and the discharge of oil during maintenance and
servicing work cannot be excluded, always wear protective glasses and protective
gloves.
Clean electric components in voltage-free state only. Unplug electric plug-in connector
for this purpose. This regulation also applies to non-touch cleaning (air-blasting).
Do not bypass pressure-operated switches, pressure-operated valves, safety valves and
other sensors.
The pressure-operated switches, pressure-operated valves, safety valves and other
sensors may only be adjusted with the written approval of the manufacturer.
Safety valves may only be replaced with the same valves.
Replace immediately any damaged hydraulic hoses, pipes, cables and valves.
Replace hydraulic hoses at indicated or reasonable intervals, even if no safety-relevant
defects can be detected (see check of hydraulic hose lines, page 10-2).
Observe the prescribed tightening torques and check regularly.
For maintenance and repair work, always tighten loosened screwed joints as specified in
the guidelines.
Before cleaning the slewing unit with water or by means of a vapour stream (high-
pressure cleaner) or with other detergents cover or obturate all openings in which no
water/vapour/detergent may penetrate for safety or functional reasons. Electromotors,
switch cabinets, stop switches, ball bearings, gears and chains are especially
vulnerable.
Regularly check all electrical cables and hydraulic oil lines for damage and abrasion.
Also inspect hydraulic oil lines for leaks.
Before resuming operation after completing maintenance or repair work, check whether
all safety equipment has been reattached to the machine and is operational! Check all
functions of the slewing unit and the working pressure!
1.4.8 Safety Notes for the Electrical System

In accordance with the electro-technical regulations, work on electrical systems may
only be performed by an electrician or by instructed persons under the guidance and
supervision of an electrician.
Only use original fuses with specified amperage (see spare parts list)! Shutdown the
slewing unit immediately should any malfunctions occur in the electrical power supply!
When prescribed, machine and system components for which inspection, maintenance
or repair work is to be performed, must be disconnected from the power supply. First
check that the disconnected parts are in fact free of power, then ground and short-
circuit, and insulate any neighboring parts still under power!
Check the electric equipment of the slewing unit regularly. Any defect, such as loose
connections or damaged cables, must be eliminated immediately.
If work needs to be performed on live parts, a second person must be present who must
always has visual or wireless contact and, in the case of an emergency, can active the
emergency-off switch or disconnect the master switch from the power supply. Secure
27.05.2009
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SLEWING UNIT
Class-no. Page-no.
A 16.0200-7 E 2-7
the work area with a red-white safety chain and a warning notice. Use only insulated
tools!
After the associated electrical installation or repair, test the installed protective measures
(e.g., earthing resistance).
1.4.9 Safety Notes for the Hydraulic System

Work on the hydraulic system may be performed only by persons with special
knowledge and experience in hydraulics. The personnel must be able to read and
completely understand the hydraulic diagram, in particular the correlations of the
integrated safety systems.
Wear your personal protective equipment, e. g. gloves, protective clothes, protective
goggles or helmet with visor when working on the hydraulic system.
Avoid any oil leakages when working on the hydraulic units. Leaking oil must be
collected in appropriate receptacles and disposed of in compliance with the
corresponding regulations.
The hydraulic system is under high pressure! Do not detach or tighten any screw fittings
of the hydraulic lines (hydraulic couplings) as long as the system is under pressure!
Immediately eliminate any leakages.
Prevent the components (such as the double hook) from moving accidentally!
Utmost cleanliness must be observed for all work performed on the hydraulics! The
external vicinity must be cleaned before removing the connections. Close all openings
with protective caps so that no dirt can enter.
Regularly inspect all lines, hoses and connections for leaks and externally visible
damage! Repair any damage without delay! Tighten untight screw fittings in pressure-
free state only. Escaping oil can cause injuries, fire and environmental contamination.
Before starting the repair work on system sections and pressure lines of the hydraulics
system to be opened, remove pressure in accordance with the construction and function
description! When present: remove pressure from system sections using the manometer
connections (MA1, etc., in the hydraulics diagram).
Route and install the hydraulic lines correctly! Do not interchange the connections! The
fittings, length and quality of the hose lines must be appropriate for the requirements.
Unapproved modifications and changes to the hydraulic system are prohibited.
1.4.10 Handling of Oil, Grease and Other Chemical Substances

Observe the appropriate product safety and environmental regulations for the handling
of oil, grease and other chemical substances!
Take care with the handling of hot fuels and agents (such as hydraulic oil), there is
danger of burning and scalding!
15.10.2008
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The PEINER Motor Slewing Unit is designed as follows:
The slewing unit consists of a traverse (1), which incorporates the hydraulic unit (22), the
hydraulic motor (3) and the hub (4). The hub holds the axle (5). Via a nut (6) that is
mounted on the axle, the loads are absorbed by an axial deep groove thrust ball bearing
(7) that is screwed into the hub. Depending on the requirement, a multi-pole slipring body
(8) may be fixed on the hollow axle. Through this axle, a cable (9) with a corresponding
number of leads, is led from the slipring body to the suspended load-lifting member.
The hydraulic unit (22) has been mounted vertically into the traverse, as a complete unit.
It consists of motor (2) and pump (20).
By loosening the fastening screws, the complete hydraulic unit can be taken out of the
slewing unit. The hydraulic control block (17) is mounted on the side wall of the traverse.
The solenoid valve (18) sits on a block and is connected directly to the hydraulic motor
(3).
By means of the assembly opening in the hood, all important maintenance jobs can be
carried out on the hydraulic unit (e. g. re-fill the hydraulic oil).
The components hydraulic unit, hydraulic motor and slipring body are protected against
mechanical damages by means of a hood.
The cross piece with the double hook that is fixed to the hollow axle guarantees that most
of the forces are led centrically into the hollow axle and thus protects it against excessive
bending stress. A cable tension relief prevents mechanical stressing of the electric plug-
in connector.
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1036 E 7-1
2.4 Parts list
Legend:
1 traverse 18 solenoid valve
2 motor 20 pump
3 hydraulic motor 21 pinion
5 axle 22 hydraulic unit
7 ball bearing slewing gear 23 oil filter
8 slipring transmitter 27 double hook
9 cable 29 screw plug (ventilation screw)
12 gimbal suspension 32 plug-in connector
17 control block 33 power supply cable
27.01.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0619-1 E 8-1
3.0 Operating instructions
3.1 Details for safe use
X Follow the regulations in the relevant accident prevention specifications for "Load
suspension devices".
X Always adhere to the service manual.
X Only instructed personnel is authorized to operate the slewing unit.
X It is not permitted to move the load over people.

When necessary, the crane operator must give warning signs. If the crane operator
becomes aware of the presence of people who could be endangered by the crane, the
operator must immediately shut down the crane and not start moving the crane again
until the people are no longer found in the area of danger.
X It is forbidden to transport people on the load or the slewing unit!
X Only operate the slewing unit in its original condition or in a condition released by the
manufacturer.
X Make sure that during operation of the grab all hoses, lines, pipes and fittings are in
good order and tight.
X Don’t exceed the lifting capacity of the crane!
X It is forbidden to tear off stuck loads.
X It is not permitted to ever load the slewing unit, the double hook, and the sling gear
more than their load-bearing capacity!
X It is not permitted to load the tip of the double hook.
X Grommets, becket, gimbals, and other suspended elements must be positioned in the
base of the hook and be able to move freely on the double hook.
X The double hook’s safety hood must be fully functioning to prevent accidental
unhinging.
X Avoid hitting the slewing unit against objects to prevent damage.
X It is not permitted to hang the double hook directly in the load. The exception here is
hanging the double hook in suspension equipment especially designed for this
purpose.
X The double hook is to be used so that accidental unhinging of the load-carrying

equipment, the sling gear, or the load is prevented.
X Never use a damaged sling gear or a sling gear where the identification mark is no
longer present!
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X Chains are not allowed to be twisted or knotted.
X The crane operator must particularly observe the load or the empty run of the load-
carrying equipment during all crane movements. If this is not possible, the crane
operator is only allowed to operate the crane when following a signalperson’s signals.
X Avoid any jerky starting, lifting, stopping or lowering of the slewing unit.
X Immediately inform the responsible supervising person of any slewing unit failure or
any lifting accessory failure as well as of any watched circumstance that might give rise
to expectations of a failure (e. g. noises, elevated temperatures, unusual behaviour of
the slewing unit, etc.).
X Only operate the slewing unit, the hydraulic fluid and the lubricants within the
admissible temperature range (see Technical Data or Recommended Oil).
X In case of any failures stop the slewing unit operation immediately and prevent it from
being restarted. Failures must immediately be remedied!
X Dismantle protective equipment when and only when the slewing unit is at standstill.
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SLEWING UNIT
Class-no. Page-no.
A 16.0619-3 E 8-3
3.2 Putting into operation
3.2.1 Assembly instructions - Initial start-up
The assembly and initial start-up may only be carried out by qualified personnel.
Personal protective equipment must be worn during all work. It includes:
• Protective clothes
• Protective helmet
• Safety shoes with toe caps and puncture-resistant base
• Protective goggles
• Protective gloves
Risk of injury due to improper work and improper start-up!

f Work at the slewing unit may be carried out only in accordance with all safety
instructions, safety regulations and accident prevention regulations.
WARNUNG f Tools and other parts must be stored in such a way as to prevent them from
falling down.
f The movable parts of the slewing unit, such as the double hook, must be
secured against unintentional displacement.
Danger of life due to electric shock!

f Make sure that the power is switched off and secured against switching on
again.
DANGER f Make sure that voltage and frequency correspond to the data indicated on the
nameplate.
f Make sure that the power supply cable is not damaged.
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Requirements for the assembly:

• Voltage and frequency of the power supply must correspond to the data indicated
on the nameplate.
• The power supply cable must be equipped with a tension relief.
• The parts with which the slewing unit is fastened to the carrying device, such as the
crane rope, must fit in size and lifting capacity to the slewing unit and the crane.
• Smooth communication with the crane operator must be ensured.
Assembly:
1. Check hosepipes, connecting elements and gaskets of the hydraulic system for
leaks.
2. Connect the suspension of the slewing unit with the carrying device and observe the
SWL of the lifting appliance.
3. Connect the slewing unit with the plug-in connector of the power supply cable.
4. Fit the cable tension relief. Take care that the rubber-sheathed power supply cable
does not stress the plug-in connector (for fastening points, see Fig. 4.1.5
Schmierstellen). Attach the tension relief in such a way as to avoid any chafing of
the power supply cable.
5. Make sure that nobody remains in the danger area of the slewing unit. Lift the
slewing unit until the double hook hangs freely.
6. Check the oil level and refill as needed (see chapter 4.2.1)
For oil recommendations, see sheet no. 11-1
7. Check the sense of rotation of the slewing unit. If the sense of rotation is wrong,
swap the two external cables. If the plug-in connector is not assembled, connect
them according to the wiring diagram.
8. Check that the locking devices on all pins and shackles are present and secured.
9. Before the initial commissioning, the proper assembly and the correct working of the
slewing unit must be inspected by a person qualified to do so.
f If the temperature of the hydraulic fluid is below the start-up temperature (see page
no. 8-5 Table: 3.2.1 Oil temperature), then the hydraulic fluid must be preheated by
means of a heating up to the temperature that is necessary to put the system into
operation (Please refer to chapter 2.4 Nomenclature and Hydraulic Diagram in the
Spare parts list to see if the slewing unit is equipped with a heating). If no heating is
available, change hydraulic fluid and use preheated hydraulic fluid if necessary.
If the temperature is between the start up temperature and the temperature that is
necessary to put the system into operation, (see page no. 8-5 Table: 3.2.1 Oil
temperature), use a heating to preheat the hydraulic fluid up to the temperature that
is necessary to put the system into operation or
• Close the ball cocks KH2 and KH3 (see page no. 10-1), if any,
or move the slewing unit until the stop, if any, is reached (see number 36 chapter
2.4 Legend)
• Turn on the slewing unit and keep it turned on for one minute to ensure the pump
pumps oil via the pressure relief valve into the tank.
• Then pause for two minutes.
• Repeat this procedure until the oil is warmed-up to the temperature that is
necessary to put the system into operation.
• Open ball cocks KH2 and KH3, if any (see page no. 10-1).
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0619-5 E 8-5
Table: 3.2.1 Oil temperature

Hydraulic fluid Start up Temperature that is Max. upper
temperature necessary to put the working
system into operation temperature
Shell Tellus Arctic 32 -30 °C -20 °C +70 °C
NATO-code: H 540 -25 °C -15 °C +85 °C
HVLP 32 -15 °C -5 °C +70 °C
acc. to DIN 51524/3 HV
HLP 46 -5 °C +5 °C +80 °C
acc. to DIN51524/2
HLP 68 +5 °C +12 °C +85 °C
acc. to DIN51524/2
f After about 50 operating hours, change the oil filter set (see sheet no. 10-1) and
check that screws and nuts are tightly secured; for tightening torques, see the spare
parts list..
3.2.2 Daily start-up

f Check the oil level (see point 4.2.1)
f If the temperature of the hydraulic fluid is below the start-up temperature (see page
no. 8-5 Table: 3.2.1 Oil temperature), then the hydraulic fluid must be preheated by
means of a heating up to the temperature that is necessary to put the system into
operation (Please refer to chapter 2.4 Nomenclature and Hydraulic Diagram in the
Spare parts list to see if the slewing unit is equipped with a heating). If no heating is
available, change hydraulic fluid and use preheated hydraulic fluid if necessary.
If the temperature is between the start up temperature and the temperature that is
necessary to put the system into operation, (see page no. 8-5 Table: 3.2.1 Oil
temperature), use a heating to preheat the hydraulic fluid up to the temperature that
is necessary to put the system into operation or
• Close the ball cocks KH2 and KH3 (see page no. 10-1), if any,
or move the slewing unit until the stop, if any, is reached (see number 36 chapter
2.4 Legend)
• Turn on the rotator and keep it turned on for one minute to ensure the pump
pumps oil via the pressure relief valve into the tank.
• Then pause for two minutes.
• Repeat this procedure until the oil is warmed-up to the temperature that is
necessary to put the system into operation.
• Open ball cocks KH2 and KH3, if any (see page no. 10-1).
f Check hosepipes, connecting elements and gaskets of the hydraulic system for leaks
f Check the coupler for firmness. The strain relief must be located in such a manner
that the power supply cable does not exert any kind of traction on the coupler.
f Supply the lubricating points with grease in accordance with 4.1.9 Lubricating
instructions (for lubricating points, see 4.1.10, For greases used by the manufacturer
please refer to data sheet).
21.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1218 E 9-1
3.3 Operation
3.3.1 Information for operation

ATTENTION! Collisions of the slewing unit with other objects are to be avoided in
order to prevent damages.
Instructions for safe operation, see 3.1 page no.. 8-1

Function description, see page no. 4-1 to 4-3
f Please note that the possible load weight of the crane is reduced by the weight of the
slewing unit.
f The double hook must always be positioned above the centre of gravity.
f The specific operating instructions for each sling gear must be followed.
f The suspension links of the sling gear must be of such size that they can move freely
in the double hook.
f Lifting straps or round slings must never be allowed to run loosely over the double
hook. The load could topple!
f Lopsided loads must be lowered and fastened again.
f The function of the hook safety catch of the double hook must be checked regularly.
3.4 Shut-down
f The slewing unit must be put down on a suitable support (wooden beam) since
otherwise the turner can be damaged.
f During putting down it is to be seen to it that the hanging cable is neither broken nor
pinched.
f The plug-in connector is to be provided with protective caps.
f In addition, for longer periods out of service, the slewing unit should be exercised
every 3 month to prevent corrosion and gumming of the hydraulic oil in the control
elements.
f In case the slewing unit is intended to be put out of operation for a longer period of
time, grease must be applied to all lubricating points.
3.5 Reoperation
f Observe all the specifications of point 3.2 and 3.3
f Check the device for possible damages
f Supply the lubricating points with grease in accordance with 4.4 Oil
Recommendation (for lubricating instructions, see 4.1.4, for lubricating points, see
4.1.5; for the greases used by the manufacturer please refer to data sheet).
3.6 Transportation
f The slewing unit must be transported on a suitable support since otherwise
damages can occur.
f The slewing unit is to be secured against overturning.
29.09.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-1 E 10-1
4.0 Maintenance and repair
Figure 4.01
Figure 4.02
Legend:
8 ventilation screw
9 oil level glass
10 lubricating point K: axle
11 oil filter
12 oil drain plug
14 hosepipes
15 tank cap mounting
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-2 E 10-2
4.1 Maintenance
Insufficient and improper maintenance might result in operating troubles and thus high
repair costs and downtimes. This is why regular maintenance is imperative.
Risk of injury due to maintenance work that has been carried out
improperly!
Improper working might cause considerable personal and material damages.
WARNING f Maintenance and repair of the slewing unit must only be carried out by
authorized, well-trained and instructed specialized personnel. This personnel
must be specifically instructed in the imminent dangers. the personnel must be
allowed to reject any instructions of third parties that might breach the safety
instructions.
f The operating staff must be informed about any maintenance work carried out
before starting the maintenance work.
f Responsibilities of the staff for assembly/disassembly, putting into operation,
operation, maintenance and repair must be clearly defined and adhered to!
f Make sure that only such personnel works on the slewing unit who is assigned
to do so!
f Before starting the maintenance work disconnect the power supply of the
slewing unit and protect it against accidental restart. To do this, it is also
possible to unplug the electric plug-in connector.
f The product-specific safety instructions must be complied with when handling
oils and greases.
Only qualified technical personnel may carry out any work on the hydraulic system
and the electrical system in accordance with the valid circuit diagrams.
Personnel must be instructed regarding the possible hazards and the protective
measures that need to be taken.
DANGER
Danger to life from hydraulic oil discharge at high pressure

f Ensure that parts of the hydraulic system on which you are working have been
relieved of pressure. Tighten untight hydraulic couplings in unpressurized
condition only.
DANGER
f Rectify any leakage immediately.
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-3 E 10-2
4.1.1 Maintenance Overview Table: 4.1.1 Maintenance Overview

Item. Maintenance work Maintenance interval
*)
c)
every 1000 h
every 2000 h
after 500 h
after 50 h
weekly b)
daily
a)
1 Grease lubricating points G (pin) (and M) X X X X X X
2 Grease lubricating points H (toothing) X X
3 Grease lubricating points K (axle) X X
4 Grease lubricating points L (bearing) and S X X X
(shackles and chains)
5 Check hoses, connecting elements and gaskets of X X X X X
the hydraulics for tightness
6 Check the plug-in connector and the tension relief X X X X X
for firm seating (see chapter 3.2.2)
7 Check the hydraulic oil level X X X X X X
d)
8 Change the hydraulic oil X X
9 Check the filter element for clogging X X
10 Change the filter element of the return filter X Xd)
11 Check the hydraulic hoses for proper assembly and X X
operational safety
12 Check all screw connections for firm seating X X X
13 Check the double hook for wear and cracks X X
14 Check the slewing unit for cracks and signs of X X
breakage in the material and at welding joints
15 Check the parts and fittings for damage, wear or X X
other changes
16 Check the integrity and function of safety devices X X X
(e.g. pin locking devices)
17 Maintenance work on the slip-ring transmitter Xc)
a)
for container handling: grease weekly, after 100 operating hours at the latest; for
other loads: grease monthly, after 300 operating hours at the latest
b)
after every 100 operating hours at the latest
c)
after one year at the latest; see maintenance instructions in the spare parts list
d)
An extension of the useful life of the hydraulic oil is possible if a laboratory testing of
the hydraulic oil will allow it.
*) The values in the column correspond to the items in the sections with the individual
maintenance intervals.
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-4 E 10-2
4.1.2 Maintenance interval after the first 50 operating hours

f Carry out the following maintenance work after the first 50 operating hours:
Table: 4.1.2 Maintenance work after the first 50 operating hours
Item Maintenance work Maintenance work
*) performed
Date Signature
1 Grease lubricating points G (and M)
6 Check hoses, connecting elements and gaskets
of the hydraulics for tightness
7 Check the plug-in connector and the tension
relief for firm seating (see chapter 3.2.2)
8 Check the hydraulic oil level
11 Change the filter element of the return filter
13 Check all screw connections for firm seating
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
4.1.3 Maintenance interval after the first 500 operating hours

f Carry out the following maintenance work after the first 500 operating hours:
Table: 4.1.3 Maintenance work after the first 500 operating hours
*) performed
Date Signature
1 Grease lubricating points G (and M)
9 Change the hydraulic oil
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-5 E 10-2
4.1.4 Maintenance interval weekly

f Maintenance interval weekly; after each 100 operating hours at the latest:
Table: 4.1.4 Maintenance work weekly
*) performed
Date Signature
a)
1 Grease lubricating points G (pin) (and M)
5 Grease lubricating points K (axle) and S (rope
pulley)
a)
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-6 E 10-2
4.1.5 Maintenance interval every 1000 operating hours

f Maintenance interval every 1000 operating hours; after one year at the latest:
Table: 4.1.5 Maintenance work every 1000 operating hours
*) performed
Date Signature
a)
2 Grease lubricating points H (toothing)
3 Grease lubricating points K (axle)
4 Grease lubricating points L (bearing) and S
8 Check the filter element for clogging
10 Check the hydraulic hoses for proper assembly
and operational safety
13 Check the double hook for wear and cracks
14 Check the slewing unit for cracks and signs of
15 Check the parts and fittings for damage, wear or
other changes
16 Check the integrity and function of safety
devices (e.g. pin locking devices)
a)
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-7 E 10-2
4.1.6 Maintenance interval every 2000 operating hours

f Maintenance interval every 2000 operating hours:
Table: 4.1.6 Maintenance work every 2000 operating hours
*) performed
Date Signature
a)
2 Grease lubricating points H (toothing)
3 Grease lubricating points K (axle)
4 Grease lubricating points L (drive end bearing) and S
5 Check hoses, connecting elements and gaskets of the
hydraulics for tightness
6 Check the plug-in connector and the tension relief for
firm seating (see chapter 3.2.2)
8 d)
Change the hydraulic oil
9 Check the filter element for clogging
d)
10 Change the filter element of the return filter
11 Check the hydraulic hoses for proper assembly and
operational safety
13 Check the double hook for wear and cracks
14 Check the slewing unit for cracks and signs of
15 Check the parts and fittings for damage, wear or other
changes
16 Check the integrity and function of safety devices (e.g.
pin locking devices)
c)
17 Maintenance work on the slip-ring transmitter
a)
d)
An extension of the useful life of the hydraulic oil is possible if a laboratory testing of
the hydraulic oil will allow it.
c)
after one year at the latest; see maintenance instructions in the spare parts list
Clean and grease the bearings of the electric motor every 15000 operating hours (see
4.1.11 )
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-8 E 10-2
4.1.7 Oil change

The first oil change is to be carried out after about 500 service hours. Further oil
changes every 2000 service hours - after one year at the latest. An extension of the
useful life of the hydraulic oil is possible if a laboratory testing of the hydraulic oil will
allow it.
Extraordinary service conditions may cause excessive pollution or an ageing of the oil.
In such cases, we recommend to have an oil analysis carried out in the laboratories of
the oil supplier.
− Oil brands, see table oil recommendation, page no. 11-1 Filled oil grade see data
sheet.
In order to protect the hydraulic components, the oil must be in accordance with purity
level 20/18/15 according to ISO 4406 at least (approximately corresponding to class 9
according to NAS 1638).
Since the purity level of new oil is generally lower, the new oil must be filtered. To do this
either refill oil via the filter or use special filling devices that filter the oil to reach the
required purity class.
N O T I C E ! Pay attention to utmost cleanliness during the oil change. Any pollution
might cause malfunctions and damages of the hydraulic system. Make
sure that parts of the hydraulic system such as tank, pump, hoses, etc.
never are open longer than necessary.
X Proceeding: (Components see figure 4.0 and figure 4.1.10)
1. Set down the slewing unit
2. Put a suitable collection basin under the oil drain plug (5)
3. Unscrew and clean drain plug (5) (figure 4.1.10)
4. Unscrew ventilation screw (8) (figure 4.0) to ventilate the tank
5. Drain oil out of tank (the unit should have its operational temperature)
6. Clean tank:
• Clean the area around the tank cap.
• Depressurize the hoses (10) (see figure 4.0). For this purpose connect a
MINIMESS hose to the test point (MA) in such a way to ensure the oil flows
into a basin at the other end of the MINIMESS hose. Repeat this procedure at
test point (MB) and (MT).
• Unscrew hoses (10) (see figure 4.0) from the tank cap.
• Unscrew the tank cap from the traverse (15) and take the hydraulic unit
including tank cap out of the traverse.
• Clean the tank by means of a plain plastic scraper. Don´t use cleaning wool,
cloths or cleaning paper since they might leave fibers. Clean the tank by
rinsing it by means of a suitable detergent, e. g. benzene.
Note: If metal particles are found in the tank, this might be a sign of pump
wear.
• Check the threaded holes of the tank cap mounting (15). Clean and/or recut
thread if necessary.
• Pay attention to utmost cleanliness during assembly of the hydraulic unit and
hoses.
19.07.2010
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SLEWING UNIT
Class-no. Page-no.
A 16.1220-9 E 10-2
7. Replace oil filter insert (11)

8. Rescrew oil drain plug
9. Fill tank (via filter (11))
10. Check oil level (see chapter 4.2.1)
11. Make a test run of the slewing unit.
12. Check tightness of hydraulic system.
13. Dispose of the waste oil in accordance with local regulations.
4.1.8 Oil filter

In case of new units, the filter insert is to be replaced after about 50 service hours, in
any other case after every oil change. Furthermore, the oil filter must be checked after
repairs of the hydraulic system and, if necessary, the filter insert must be replaced.
4.1.9 Lubricating instructions

Regular lubrication is required in order to ensure trouble free operation of the slewing
unit (see lubrication points figure 4.1.10).
f Grease lubricating points G weekly, after 100 service hours at the latest, if
containers are handled.
f Grease lubricating points G monthly, after 300 service hours at the latest, if other
loads are handled.
f Grease lubricating point H, K and S every three months, after 1000 service hours at
the latest.
f Grease lubricating point M weekly, after 100 service hours at the latest.
For greases used by the manufacturer please refer to data sheet!
(Grease recommendation see chapter 4.4)
If you mix different greases, please ensure compatibility of grease grades. If you have
any questions regarding grease compatibility, please ask the corresponding grease
manufacturer.
In general, we recommend the following:
At temperatures up to -20°C:
Recommended grease for lubrication of lubrication point G and K:
lithium-saponified grease, DIN 51825- KP 2 K
Recommended grease for lubrication of lubrication point H:
M2E-20; DIN 51502, e. g. Zählit VZ
(Zählit VZ is a calcium-saponified grease on a mineral oil base from the MÖLLENBERG &
SONNTAG company, with a penetration of 265-295 mm²/s )
At temperatures up to -50°C:
Recommended grease for lubrication of lubrication point G and K:
Recommended grease for lubrication of lubrication point H:
(URETHYN LT 60 is a synthetic low-temperature grease from the company FUCHS
LUBRITECH GMBH)
Note: Do not mix synthetic lubricants with each other, neither with mineral lubricants!
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-10 E 10-2
4.1.10 Lubrication points
Legend:
lubrication point H (toothing)
lubrication point K (axle)
lubrication point L (drive end
bearing)
lubrication point G (pin)
lubrication point S (shackles and
chains)
Design version:
„suspension with pin“
lubrication point M (pin)
1 fastening point for tension relief
Figure 4.1.10
Note: Regular lubrication of the chain, suspension links and shackles can ensure a
significantly longer permissible service life compared to unlubricated parts. It
is recommended to lubricate all chain links and shackles before the initial
start-up. During lubrication, make sure that you lubricate the contact surfaces
to prevent premature wear. Suitable lubricants are those used for lubrication
of wire ropes or toothing (see Chapter 4.4)
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-11 E 10-2
4.1.11 Electric motor
Beware! Danger of burning!

High temperatures of over 80°C can occur on the surface of the electric motor.
f The motor must be allowed to cool before the start of the maintenance work.
WARNING
Maintenance intervals: every 15,000 operating hours, after 3 years at the latest
f Before the start of the maintenance work, the power supply of the slewing unit must
be disconnected and secured against restart.
f Clean the bearings and fill them to the half with grease, according to Chapter 4.5
“Lubricant recommendation“.
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-12 E 10-2
4.1.12 Slip-ring transmitter
Installation, maintenance or repair may only be carried out by qualified and

authorized electrician!
DANGER
Maintenance rate: 1x yearly

f Before the start of the maintenance work, disconnect the power supply of the slewing
unit and secure it against restart.
C a u t i o n ! All work on the slip-ring transmitter may only be carried out after
disconnecting the power supply!
f Open and remove the hood of the slewing unit.
f Remove the accumulated dust by vacuum cleaning.
B e w a r e ! The bow contacts can be slightly bent during this process.
If vacuum cleaning is not possible: Remove the dust by dry, clean and oil-free
compressed air.
f Protect the carbon brush holder and its slip ring against moisture with contact oil.
f The contact points of the slip ring and wire bow contact must be sprayed very lightly
with the prescribed contact oil: CRAMOLIN Protection (ITW Chemische Produkte
GmbH)
B e w a r e ! Do n o t spray the carbon brush holder and its slip ring!
f Check the wear of the bow contacts.
f Check the wear of the carbon brushes. The parts of the carbon brush holder must not
touch any insulating rings or slip rings.
f Mount the hood again after the cleaning.
Do not damage or squeeze any cable insulations!
Legend:
1 carbon-brush
2 carbon-brush holder
3 slip-ring way
4 insulating ring
Figure 4.1.12
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-13 E 10-2
4.2 Required checks
4.2.1 Check oil level

− The slewing unit must be levelled horizontally.
− The maximum or minimum oil level can be read on the oil dipstick or on the oil level
glass.
− Too much oil causes inadmissible overpessure in the tank.
− Too little oil causes an overheating of the hydraulic system and might lead to pump
damages.
− To replenish oil, please see table of recommended fluids, page no. 11-1.
4.2.3 Wear
Depending on the conditions of use and the circumstances of operation, the double
hook must be assessed by a competent person as required. This must occur at least
once a year. A competent person is someone who has sufficient knowledge of load-
carrying equipment due to their specialist training and experience. They must be familiar
with the corresponding state work safety rules, accident prevention rules, and general
recognised rules of engineering to an extent that they can evaluate the work safety
conditions for slewing units and crane hooks.
The permissible wearing is listed in Table 4-1. Calliper gauge (sliding calliper) precision
is sufficient when measuring.
Grooves of wear may be reground to remove grooves within the amount of wearing
permissible. Parts that are impermissibly worn or damaged must be replaced.
Welding on double hooks and bolts, e.g., to repair signs of wear, is not permitted.
4.2.4 Miscellaneous checks

Check of the double hook
The presence of deformations, e.g., on the jaw and shaft of the hook, must be assessed
at least once per year. The double hook must be replaced when the jaw width is
considerably widened based on the a2 max according to Table 4-1.
The double hook must also be replaced if the deformation exceeds 10 % of the initial
dimensions Y1 or Y2 (the initial dimensions are specified on the double hook. Also see
the diagram of the double hook on Page no. 10-2).
If deformations have been identified, the surface must be examined for cracks using an
appropriate method or the corresponding part must be replaced. If an inbuilt double
hook cannot be examined for wear or deformation, the double hook must be dismantled.
This also applies to the shank and eye of the double hook.
Surfaces must be prepared before examination to ensure that surface cracks can be
recognised without question. Damage and surface cracks may be repaired by removing
grooves providing the function, permissible dimensional deviations, and the permissible
amount of wearing permit this. Parts with impermissible surface cracks are to be
replaced.
19.07.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.1220-14 E 10-2
Table 4-1 Permissible wear / deformation of the double hook

Ref. no. Hook Size a2 max b1 min b2 min d1 min d2 max d3 max S2 min S3 min h min
00022454 22-8411 NG 16 99 91 91 91 96 90 52 36 113
00022400 22-8412 NG 25 123 113 113 113 107 97 57 70 143
00022287 22-8413 NG 25 123 113 113 113 117 97 52 70 143
00022279 22-9864 NG 32 137 113 126 126 138 97 61 70 162
00027971 22-8412 NG 25 123 113 113 113 107 97 57 70 143
00040483 22-7370 NG 25 123 113 86 113 100 - 45 - 143
23084393 NG 50 176 162 152 162 159 97 87 *) 70 202
All specifications are in millimetres *) including bushing
For the Ref. no. refer to spare parts list
See specifications on
the double hook for
initial dimensions from
Y1 and Y2
Figure 4.2.4 Double hook

19.07.2010
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SLEWING UNIT
Class-no. Page-no.
A 16.1220-15 E 10-2
Check of hydraulic hose lines
The hydraulic hose lines must be checked as required, but at least once a year, in case
of multishift operation every six months. After any maintenance and repair work the
hydraulic hose lines must be checked to make sure they are assembled properly and in
an operational safety state.
The hose lines must be replaced if one of the following criteria has been detected:
- Damages of the external layer event to the wire braid reenforcement (e. g. chafe
marks, cuts, cracks)
- Brittleness of the external layer (formation of cracks in the hose material)
- Deformations that do not correspond to the natural form of the hose or of the hose
line, in unpressurized as well as in pressurized condition or when bended, e. g.
separation of layers, bubbling
- Leakages
- Damage or deformation of the hose fitting (prejudiced sealing function)
- Detaching of the hose out of the fitting
- Corrosion of hose fitting impairing the function and rigidity
- Specified period of storage and/or use of the hose or of the hose line is exceeded.
f Hydraulic hoses must not be stored longer than 2 years.
f Hydraulic hoses must not be used longer than 6 years (including
maximum storage period of 2 years).
f Any defect must be eliminated immediately.

f Only use hose lines according to the spare parts list to replace defective hose lines.
f Make sure that the replacement lines are clean; close them with dust covers until
they are fitted.
f Make sure thate the hydraulic hoses are admitted for the required pressures.
A marking on the hydraulic hoses indicates the date of their manufacture (quarter
and year). For example, the mark 2 Q 09 means that the hose was manufactured in
the second quarter of 2009.
Inspection of chains and individual chain links

The chains and individual chain links or suspension links (see Fig. Data Sheet -
Dimensions) must be inspected by a specialist c at intervals of not more than 12
months. Shorter intervals are required under unfavourable conditions of use such as
increased wear or intensified corrosion. In addition to visual inspections, a magnetic
testing for absence of cracks must be performed at intervals of maximum three years.
The inspections have to be documented in accordance with the regulations of the
country where the chain is used.
Prior to the inspection, the chain links must be thoroughly cleaned to ensure that they
are free from oil, dirt and rust. The cleaning method may not corrode the base material
and may not cover cracks or surface defects.
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Class-no. Page-no.
A 16.1220-16 E 10-2
The chains or suspension links must be replaced:

a) If a chain link is deformed or broken and if it has deposits that cannot be removed.
b) If chain links were straightened, welded, bent, burned or otherwise changed.
c) If a chain link has dents, cracks, grooves, cuts, corrosion pits or deformations.
Minor dents can be repaired by a specialist c, provided that the remaining material
thickness in that place is more than 90% of the original diameter and no abrupt
change in cross section is noticeable.
d) If, as a result of plastic deformation, the outside length of a chain link has increased
by more than 3% of the outside nominal dimension.
e) If wear or excessive corrosion is present anywhere on a chain link. The wear of up
to 90 % of the original diameter (dn) is permissible, calculated as the average value
of two measurements of the diameters d1 und d2 performed at 90° to each other
(see Fig. 4.2.4).
f) If, as a result of wear, the inside length has increased by at least ΔL=8%
( ΔL = L1 – Lo ) for suspension links
by at least ΔL=5% for a chain link
by at least ΔL=2% for a chain with 11 pitches (links)
g) In the event of discolouration caused by heat or damage due to chemical influences
Chains to be replaced if:

d1+d2
> 0,9 dn
2
Figure 4.2.4
The repairs may only be carried out by the manufacturer or, for minor dents (see Point
c) ), by a specialist c.
c Specialists are persons who, by virtue of their professional training and

experience, have sufficient knowledge in the field of lifting equipment for loading
of bulk materials and who are acquainted with relevant national work safety
regulations, accident prevention regulations, rules for safety and health at work,
guidelines and generally recognised technical standards (e.g. ISO sheets) as
well as the present operating instructions to the extent that they are able to judge
the safe working condition of lifting equipment, shackles and chains.
Note: Regular lubrication of the chain, suspension links and shackles can ensure a
significantly longer permissible service life compared to unlubricated parts. It is
recommended to lubricate all chain links and shackles before the initial start-up.
During lubrication, make sure that you lubricate the contact surfaces to prevent
premature wear. Suitable lubricants are those used for lubrication of wire ropes
or toothing (see Chapter 4.4)
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A 16.1220-17 E 10-2
Miscellaneous checks
f Check the hydraulic couplings to tightness.

f Check the screw connections.
f Check the bearing wear.
f Check the plug-in connector and tension relief.
f Monitor the oil temperature.
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-1 E 10-3
4.3 Repairs
4.3.1 General
For major repairs please consult the after-sales service of Salzgitter Maschinenbau AG.
Risk of injury in case of insufficient qualification!

Improper working might cause considerable personal and material damages.
f Maintenance and repair of the slewing unit must only be carried out by
WARNING authorized, well-trained and instructed specialized personnel. This personnel
must be specifically instructed in the imminent dangers. the personnel must be
allowed to reject any instructions of third parties that might breach the safety
instructions.
f Only specialist electricians or instructed personnel under direction and
supervision of a specialist electrician are allowed to work on the electric systems
of the slewing unit in compliance with the electrotechnical regulations.
f Only personnel who has special knowledge of and experience in hydraulic
systems is allowed to work on hydraulic systems!
f Responsibilities of the staff for assembly/disassembly, putting into operation,
operation, maintenance and repair must be clearly defined and adhered to!
f Make sure that only such personnel works on the slewing unit who is assigned to
do so!
f Secure the parts against unintentional movement.
f Disconnect power supply to the slewing unit and protect it against accidental
restart before starting repair work. If available, remove the electric plug-in
connector (32) (see 2.4 Parts list).
Wear the following personal when carrying out any maintenance or repair work:
- Protective helmet
- Protective goggles
- Protective clothes
- Protective gloves
- Safety shoes with toe caps and puncture-resistant base
The following must be observed for any repair:
Shift the slewing unit in such a way that the double hook and the movable parts do not
move accidentally.
After each disassembly or repair the maximum pressure indicated on the nameplate
must be checked. Use appropriate test manometers for this purpose.
27.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-2 E 10-3
As a basic principle, supply all the lubricating points with grease in accordance with 4.4
Oil Recommendation before any restart (for lubricating instructions see 4.1.9, for
lubricating points see 4.1.10).
Only start the slewing unit after repairs or modifications if

- the reliable operating state is restored,
- the work is definitely declared completed by authorized qualified personnel
- nobody is within the area of danger.
Before restarting the slewing unit adhere to the instructions specified in chapter
„3.2 Putting into operation“.
27.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-3 E 10-3
4.3.2 Replacement of hydraulic motor

Legend:
5 hosepipe (drain
connection)
6 cover
7 hydraulic motor
8 pinion screw (tightening
torque 70 Nm)
9 valve block
10 screw (tightening torque
47 Nm)
11 pinion
13 mounting
Figure 4.3.2

relieved of pressure.
DANGER f Rectify any leakage immediately.
1. Disconnect power supply to the slewing unit and secure it against restart. If one or
more plug-in connectors are available, remove them.
2. Dismantle the hood.
3. Depressurise the hydraulics.
4. Unscrew the mounting (13) and put it down carefully on the slewing unit.
5. Dismantle the hydraulics, where required, and protect it from dirt.
6. Protect the open hydraulic pipes on the slewing unit from dirt.
7. Unscrew the screws (8) and (10) and lift the hydraulic motor (7) from the slewing
unit.
8. Assemble the new hydraulic motor in reverse order.
9. Fill the hydraulic motor with hydraulic oil through the drain connection (5) !
27.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-4 E 10-3
4.3.3 Replacement of hydraulic pump

Legend:
1, 2 hosepipes
3 screw (47 Nm)
4 hydraulic unit
5 cover
6 intermediate flange
7 distributor part
8 pump
9 plastic plug
10 screw (25 Nm)
Figure 4.3.3

3. Depressurise the hydraulics
4. Dismantle the hydraulics, where required, and protect it from dirt.
5. Unscrew the screws (3) and lift the hydraulic unit (4) from the slewing unit.
6. Unscrew the distributor parts (7) and protect them from dirt.
7. Unscrew the pump (8).
8. Remove the plastic plug (9) on the underside of the new pump !
9. Assemble the new pump in reverse order.
27.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-5 E 10-3
4.3.4 Replacement of axle bearing
Figure 4.3.4
Legend:
1 traverse 9 slip-ring body
3 slip-ring transmitter 10 brush holder
6 socket head cap screw 11 axial cylindrical roller bearing
7 axle
Before repair work and before replacement of the axle bearing, please consult
the after-sales service of Salzgitter Maschinenbau AG. Only specialist service
centres who have experience of handling with axial cylindrical roller bearings are
allowed to carry out this work.
Manager Service:
Mr. Kevin Wenke +49 -5341 / 302 - 493 kevin.wenke@smag.de
Service Administration:
Mrs. Schwarz +49 -5341 / 302 - 673 elke.schwarz@smag.de
Service Technicians:
Mr. Müller +49 -5341 / 302 - 672 marcus.müller@smag.de
Mr. Olbrich +49 -5341 / 302 - 491 olaf.olbrich@smag.de
Mr. Schmerschneider +49 -5341 / 302 - 492 bernd.schmerschneider@smag.de
27.09.2010
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-6 E 10-3
4.3.5 Replacement of pinion
Figure 4.3.5
Legend:
8 hydraulic motor 12 flange
9 hexagon screw (tightening 13 lubricant duct
torque 70 Nm) 14 pinion
10 socket head cap screws 16 pinion holder
(tightening torque 47 Nm) 17 cover
11 socket head cap screws
(tightening torque 250 Nm)

3. Depressurise the hydraulics.
4. Unscrew the cover (17).
5. Unscrew the screw (9)
6. Unscrew the screw (11)
7. Pull out the pinion (14) and dismantle the pinion holder (16). If the pinion cannot
be pulled out easily, proceed as described below. Use an extractor tool to
dismantle the pinion.
8. Assemble the new pinion in reverse order. For tightening torque of the screws,
see the spare parts list.
27.09.2010
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PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0722-7 E 10-3
If the pinion cannot be pulled out easily:

8.a Dismantle the hydraulic motor (8) as described under 4.3.2.
9. Unscrew the screws (11), unscrew the lubricant duct (13) and lift the flange (12).
10. Pull out the pinion (14) and dismantle the pinion holder (16).
11. Assemble the new pinion in reverse order. For tightening torque of the screws,
see the spare parts list.
28.09.2010
P
PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-1 E 11-1
4.4 Table: Oil recommendation - Hydraulic fluids
For normal operation, a hydraulic fluid of ISO-viscosity VG 46 shall be used. For

summer or winter operation, a hydraulic fluid of ISO-viscosity VG 68 or FB 32 is to be
used according to the ambient temperature.
In order to protect the hydraulic components, the oil must be in accordance with purity
level 20/18/15 according to ISO 4406 at least (approximately corresponding to class 9
according to NAS 1638).
Since the purity level of new oil is generally lower, the new oil must be filtered. To do this
either refill oil via the filter or use special filling devices that filter the oil to reach the
required purity class.
The following oil grades are appropriate and released by SMAG:
Winter Summer
ISO viscosity VG 32 VG 46 VG 68
Standard HVLP 32 HLP 46 HLP 68

acc. to DIN 51524/3 HV acc. to DIN51524/2 acc. to DIN51524/2
Start up temperature *) -15°C -5°C +5°C
Temperature that is -5°C +5°C +12°C
necessary to put the
system into operation
Max. upper working +70°C +80°C +85°C
temperature
Ambient temperature < -5°C to -20°C -5°C to +30°C > +30°C
ARAL Vitam HF 32 Vitam GF 46 Vitam GF 68

AVIA AVIA FLUID HVI 32 AVIA FLUID RSL46 AVIA FLUID RSL68
BP ENERGOL ENERGOL ENERGOL
SHF-HV 32 HLP-S 46 HLP-HM 46
CASTROL HYSPIN AWH-M 32 HYSPIN AWS 46 HYSPIN AWS 68
ESSO UNIVIS J 32 NUTO H 46 NUTO H 68
FUCHS RENOLIN MR 32 MC RENOLIN MR 15 RENOLIN MR 20
FUCHS LUBRITECH RENOLIN B 32 HVI RENOLIN B 15 RENOLIN B 20
MOBIL Univis N 32 DTE 25 DTE 26
SHELL Tellus T 32 Tellus 46 Tellus 68
Tellus S2 V 32 Tellus S2 M 46 Tellus S2 M 68
TOTAL Equivis ZS 32 Azolla ZS 46 Azolla ZS 68
*) Temperature from which the hydraulic pump may be started in order to preheat the
oil by means of the pressure relief valve up to the temperature that is necessary to
put the system into operation.
28.09.2010
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PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-2 E 11-2
Do not use other hydraulic fluids without SMAG´s prior release.

Use zinc-containing hydraulic fluids to ensure the compatibility with the bronze-filled
PTFE seals.
Mixing of different hydraulic fluids is not allowed without prior consultation of the
corresponding manufacturer and without prior release.
Do not use biodegradable hydraulic oil without SMAG´s prior release. It is generally not
allowed to mix mineral and biodegradable hydraulic oil!
A hydraulic oil of type HVLP according to DIN 51524-3 NATO code: H 540 should be
used for operation at -50°C to +40°C. In case of temperatures below -25°C, the
hydraulic oil must be pre-heated.
Winter Winter
Standard HVLP
acc. to DIN 51524/3 HV
NATO-code: H 540
Start up temperature *) -25°C -30°C
Temperature that is -15°C -20°C
necessary to put the
system into operation
Max. upper working +85°C +70°C
temperature
Ambient temperature < - 50°C bis +40°C < - 50°C bis +40°C
ARAL Vitam H 540
AVIA AVILUB HYDRAULIKFL H 540
SHELL Hydraulikflüssigkeit H-540 Shell Tellus Arctic
H&R ChemPharm GmbH SRS Wiolan H-540
*) Temperature from which the hydraulic pump may be started in order to preheat the
oil by means of the pressure relief valve up to the temperature that is necessary to
put the system into operation.
28.09.2010
P
PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-3 E 11-3
4.5 Lubricant recommendation

Insulation class und size of the electric motor: see machine data sheet
Note: Do not mix synthetic lubricants with mineral lubricants!

Mix synthetic lubricants with another synthetic lubricant only after
consultation with the lubricant manufacturer.
Lubricant for the bearings Lubricant for the bearings

in the electric motor in the electric motor
with insulation class: H Low-temperature range
and size:
56 to 400
synthetic lubricant synthetic lubricant

LEGUIL GMBH -50°C to +210°C *)
Castrol Firetemp XT 2
- 25°C to + 180°C
Fuchs RENOLIT PU 8-061/2 RENOLIT HLT 1

-20°C to +180°C
FUCHS URETHYN E/M 2 URETHYN LT 60

LUBRITECH - 20°C to + 180°C - 50°C to + 140°C
KLÜBER PETAMO GY 193 ISOFLEX TOPAS NB 52

LUBRICATION approx. - 20°C to + 180°C - 50°C to + 120°C
Shell Gadus S3 T100/2 Gadus S2 V100/2

- 20°C to + 160°C - 30°C to + 130°C
*) operating temperature range

28.09.2010
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PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-4 E 11-4
Lubricant for the bearings Lubricant for the bearings

in the electric motor in the electric motor
with with
insulation class: F and insulation class: F and
size: size:
56 to 112 132 to 400
mineral lubricant lithium 12- mineral lubricant
hydroxystearate grease barium complex grease
AVIA LITHOPLEX 3 EP
- 20°C bis + 150°C
BREMER & Rivolta S.K.D. 4002 Rivolta S.K.D. 4002
LEGUIL GMBH -50°C bis +210°C *) -50°C bis +210°C *)
BP Energrease LS 3
- 25°C bis + 130°C
Fuchs RENOLIT GP3 RENOLIT DURAPLEX EP 2
-30°C bis +120°C -30°C bis +160°C
FUCHS STABYL L 120 STABYL L 120

KLÜBER Staburags
LUBRICATION NBU 8 EP
- 20°C bis + 140°C
Shell Alvania RL3

- 25°C bis + 130°C
If you change over to a grease based on another soap type or another thickening agent,
the grease that had been used so far should be completely removed if possible. After
changeover the regreasing periods should be reduced in order to ensure the old grease
is removed as quickly as possible. If greases are mixed, this will impair the lubricating
properties and thus reduce the service life of the parts.
28.09.2010
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PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-5 E 11-5
Grease for toothing Grease for toothing

Low-temperature range
DIN 51502 KP2 K (KPF2 N) DIN 51502 KE 1 N -50
mineral lubricant synthetic lubricant
calcium thickener organic thickener
AGIP AUTOL TOP 2000
-30 to +120°C *)
AVIA AVIACAL 2 LD
-30 to +120°C
BREMER & CERITOL PK 1

LEGUIL GMBH -60°C to +140°C
BP Energrease Mp-MG 2
-30°C to +175°C
Fuchs RENOLIT CA-LZ

-30°C to +120°C
FUCHS LAGERMEISTER 3000 URETHYN LT 60

LUBRITECH PLUS - 50°C to + 140°C
-30 to +120°C
KLÜBER Klüberplex AG 11-462 ISOFLEX TOPAS NB 52
LUBRICATION - 40°C to + 180°C - 50°C to + 120°C
ISOFLEX TOPAS NCA 51
- 60°C bis + 140°C
Möllenberg & Zählit VZ

Sonntag - 20°C to + 90°C
Shell Retinax HD2 AeroShell Grease 7

-20°C to +130°C - 73°C to + 135°C

28.09.2010
P
PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-6 E 11-6
Grease for sliding and Grease for sliding and

rolling bearings rolling bearings
Low-temperature range
DIN 51502 KP 2 K DIN 51502 KPHC2N-50
mineral lubricant synthetic lubricant
lithium thickener organic thickener
AGIP Agip GR MU EP 2 Agip Longtime Grease 2
-20°C to +120°C *) - 35°C to + 135°C
ARAL Aralub HLP 2 Aralub SKL 2

-20°C to +120°C - 50°C to + 130°C
AVIA AVIALITH 2 EP AVIA SYNTOGREASE PE-T
-30°C to +120°C -60 to +140°C
BP Energrease LS-EP 2 Energrease SY 2202
-25°C to +130°C - 40°C to + 170°C
LEGUIL GMBH -20°C to +140°C
Castrol Spheerol E PL 2 Optitemp LG 2
-20°C to +140°C -50°C to +120°C
FUCHS RENOLIT LZR 2 H RENOLIT HLT 2
EUROPE -30°C to +140°C - 40°C to + 140°C
SCHMIER- RENOLIT MP
STOFFE GMBH -40°C to +120°C
FUCHS Lagermeister EP 2 URETHYN LT 60

LUBRITECH -20°C to +130°C - 50°C to + 140°C
KLÜBER Klüberplex BEM 41-132 ISOFLEX TOPAS NB 52

LUBRICATION -40°C to +150°C - 50°C to + 120°C
Mobil Oil Mobilux EP 2 Mobilith SHC 100

-20°C to +120°C (KPHC2N-40)
- 40°C to + 150°C
Shell Retinax HD2 (Li/Ca) AeroShell Grease 33
-25°C to +120°C -70 to + 120°C
Total Multis EP 2 Multis XLT 2
-25°C to +120°C -60°C to +130°C

28.09.2010
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PEINER Greifer
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-7 E 11-7
Slip-ring transmitter: the contact oil is solely intended for very light spraying of
wire contact bows and their slip ring.
CRAMOLIN Protection
Manufacturer: ITW CHEMISCHE PRODUKTE GMBH & Co KG
Mühlacker Strasse 149 D-75417 Mühlacker
Phone: +49 (0) 7041-9634-0 Fax: +49 (0) 7041-9634-29
Website: www.itwcp.de E-mail: info@itwcp.de
CAUTION: Too much contact oil may cause short circuits.

Do not spray the brush holder and its slip ring!
After spraying with contact oil, turn the slip-ring
transmitter 5 times by 360°.
13.09.1999
P
PEINER Greifer
SLEWING UNIT
Class-no. Page-no.
A 16.0757 E 12-1
5.0 Failure - Symptoms - Sources of failures
- Failure - Symptoms - Sources of failures
5.1 Slewing unit does - motor is not running, - fuses

not work (axle does motor does not receive - contactors
not turn) current - hoses
- connecting terminal
- sliprings and brushes in cable
drum
- plug-in connector
- current o.k. - motor defect
- motor running - nonreturn valve on the pump's

suction hole is jammed (due to
dirty oil)
- pressure line pump / control block
is defect
- spring inside the pressure relief
valve is broken
- tubes are not tight
- shut-off valve is still open
- solenoid valve is defect (jammed)
- motor is defect
- pinion is defect
- flow regulator is opened too wide
- shuttle valve is defect
- nonreturn valves are defect
5.2 Slewing unit does - turning time and number - pressure relief valve is
not render enough of rotations are maladjusted (see 4.2.2)
out-put (axle turns) considerably slower - pump is worn
- torque is too low - either dirt in the pressure relief
valve or the spring is too old -
pressure adjustment is required
- oil level in the tank is too low
In case the pump sucks air, this
mostly leads to a destruction of the
pump.
- connection between pump and
control block is loose or damaged
- slide piston in the control block is
jammed; this might be caused by
foreign matter in the oil or a
broken spring
- tubes are not tight
- solenoid valve is defect (jammed)
- flow regulator
28.04.2011 -1/2-
P
PEINER Greifer
Inhaltsverzeichnis
Contents
Sach-Nr. / Subject no.:

Erzeugnis / Product: SW 144 DISK
S 23080453
Benennung Description Bestell-Nr. / Gruppe-Nr. /

Order-no. Group-no.
Zusammenstellung compilation 23080453 1.0

Grundgerät basic unit 23080455 3.0
Haube hood 23082943 5.0
Schelle für Elektro-Leitung clamp for cable 23084214 5.6
Bügel, kpl. frame, cpl. 23082017 8.0
Hydraulikaggregat hydraulic unit 23084830 10.0
Rückschlagventil, kpl. nonreturn valve, cpl. 23084713 10.1
Rücklauffilter return filter 00020900 11.0
Doppelhaken mit Aufhängung double hook with suspension 23082811 25.4
Hydraulikmotor mit Anbaublock hydraulic motor with valve plate 23084827 37.0
Hydraulikmotor hydraulic motor 00041083 37.4
Antriebslager drive end bearing 23084564 37.5
Schleifringübertrager slip-ring transmitter 00040328 38.0
Bei Ersatzteilbestellung ist außer der Bestellnummer das Erzeugnis, die Werks-Nr. und Kommissions-Nr.
anzugeben.
For spare part orders, the product, serial-no. and commission-no. must be given in addition to the
requisition-no.
Salzgitter Maschinenbau AG Phone: E-mail: Board of management: Domicile of company: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Chairman), Registration court:
38259 Salzgitter / Germany Fax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 53 41 / 302 424 www.smag.de Chairman of the Supervisory Board: Registration number:
www.peiner.de Ulrich Decker HRB 201 389
08.10.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Motor-Schwenkwerk SW 144 DISK B 23080453
Motor Slewing Unit SW 144 DISK Gruppe-Nr.
Group-no. 1.0
1/1
10.12.2010 (12023)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Motor-Schwenkwerk SW 144 DISK Order-no. 23080453
Group-no. 1.0
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
01 23080455 1 Grundgerät (s. Gruppe-Nr. 3.0)

basic unit (see group-no. 3.0)
02 23084814 1 Traverse
traverse
03 23082943 1 Haube, kpl. (s. Gruppe-Nr. 5.0)

hood, cpl. (see group-no. 5.0)
04 23083822 1 Achse
axle
05 23082811 1 Doppelhaken mit Aufhängung (s. Gruppe-Nr. 25.4)

double hook with suspension (see group-no. 25.4)
06 00024265 1 4/2-Wegeventil NG6 24 V DC

4/2-way valve
07 65165309 4 6kt.-Shr. M 20x40 / 8.8A3P / DIN EN ISO 4017

hexagon screw

hexagon screw
09 23082111 2 Blinddeckel
blind cover
15 74731980 4 O-Ring 80x3

o-ring

hexagon screw
17 63871908 16 Scheibe 8,0 / 200HV-A3P / DIN EN ISO 7090

disc
18 66828403 8 6kt.-Mu M 8 / 8A2P / DIN EN ISO 4032

hexagon nut
1/2
B 23080453
10.12.2010 (12023)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Motor-Schwenkwerk SW 144 DISK Order-no. 23080453
Group-no. 1.0

hexagon screw
20 00027131 4 Zyl.-Shr. M 5x45 / 10.9 / DIN EN ISO 4762

cap screw, socket head
21 23082496 1 Stopfen
plug
22 23004907 1 Dichtung
gasket
26 23082553 1 Bolzen 130x315

pin
27 69520310 1 Schmiernippel AM 10x1 / 5.8Zn / DIN 71412

lubricating nipple
28 23082703 2 Achshalter 190x60x12

axle holder
29 23079132 1 Installation Elektrik (s. Geräteausrüstung Elektrik)

electric installation (see electric equipment)
34 23083438 2 Dichtung
gasket
35 23084510 1 Anschlussplatte
connecting plate

hexagon screw
37 23083469 1 Deckel
cover
2/2
B 23080453
08.10.2010 (12023)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Grundgerät B 23080455
basic unit Gruppe-Nr.
Group-no. 3.0
1/1
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.

3RV %HVWHOO1U 0HQJH %HQHQQXQJ
,WHP 2UGHUQR 4XDQWLW\ 'HVFULSWLRQ
01 23084830 1 Hydraulikaggregat (s. Gruppe-Nr. 10.0)

hydraulic unit (see group-no. 10.0)
02 23084827 1 Hydraulikmotor mit Anbaublock (s. Gruppe-Nr. 37.0)

hydraulic motor with valve plate (see group-no. 37.0)
03 65985503 5 Zyl.-Shr. M 10x35 / 8.8A3P / DIN EN ISO 4762

04 00040328 1 Schleifringübertrager (s. Gruppe-Nr. 38.0)

slip ring transmitter (see group-no. 38.0)
05 23084565 1 Stirnrad
spur gear
06 23082059 1 Flansch
flange
07 23082586 1 Halterung
mounting
08 00028878 13 Nord-Lock Sicherungsscheibe NL 10

locking washer Nord-Lock

10 23082027 1 Keil
fitting key
11 23083067 1 Mutter
nut
12 02955564 1 Axial-Zylinderrollenlager 812 38 / DIN 722

axial-cylindrical roller bearing
13 23083070 1 Buchse 215/195x120

bush


B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
Group-no.


16 00023191 1 Verschluß-Shr. VSTI R½-ED/A3C

screw plug
17

19 65547211 14 Senk-Shr. M 8x20 / 8.8A2P / DIN EN ISO 10642

countersunk screw
20 23083069 1 Ring
ring
21 02416228 2 Kerbstift M 12x50 / 6.8 / DIN EN ISO 8745

grooved dowel pin
22 65150002 1 6kt.-Shr. M 8x20 / Ms / DIN EN ISO 4017

23 63871925 2 Scheibe 8 / Ms / DIN EN ISO 7090

disc
24 00020722 1 Fächerscheibe A 8,4 / F-StZn / DIN 6798

serrated lock washer

hexagon screw
26 23082600 1 Ring
ring
27 31 l Hydrauliköl HLP 46 (s. Ölempfehlung)

hydraulic oil (look to oil recommendation)

hexagon screw

B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
Group-no.

29 23084564 1 Antriebslager (.s Gruppe-Nr. 37.5)

drive end bearing (see group-no. 37.5)
30 63873003 3 Scheibe 16 / 200HV-A3P / DIN EN ISO 7090

disc
31 00022499 1 O-Ring 65x2,5 / 70NBR/769

o-ring
32 23082601 1 Schauglas
side class
33 08022741 2 Verschluß-Shr. R¾
screw plug

35 00022845 2 Dichtring C 27x32x2,5 / CuFa / DIN 7603

sealing ring
36 00022463 1 V-Ring V-250A

V-ring
37 63872402 6 Scheibe 10 / 200HV-A3P / DIN EN ISO 7090

disc

41 60000118 1 Ro. 10x1,5 – 170 mm / 1,0255-NBK/C /

DIN EN 10305-4
pipe
42 69359309 1 Verschraubung GE 10-PLR

bolted joint
43 00022404 1 Verschraubung EVW 10-PLR/A3C

bolted joint

B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
Group-no.

44 00022403 4 Verschraubung RED 14/12-PS/A3C

bolted joint
45 00022411 2 Verschraubung EVL 14-PS/A3C

bolted joint
46
47 00022413 2 Verschlußbutzen VKA 14/A3C

locking slug
48 00022412 6 Verschlußbutzen VKA 12/A3C

locking slug
49 00022409 1 Verschraubung EL 12-PS/A3C

bolted joint
50 00022405 1 Verschraubung GE 12-PS/ R½/A3C

bolted joint
51 00022795 2 Verschraubung SNV 14-S

bolted joint
52 00041314 2 Steckverschraubung GEK6 M 10x1

bush-in fitting
53 23084826 1 Deckel, kpl.

cover, cpl.
54 00020900 1 Rücklauffilter D 043-88 (s. Gruppe-Nr. 11.0)

return filter (see group-no. 11.0)
55 00025799 5 Nord-Lock Sicherungsscheibe NL 16

locking washer Nord-Lock
56 08031074 2 Blockkugelhahn
ball cock
57 27993613 1 Schlauchltg. DN 8x590

hose

B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
Group-no.

58 23084832 1 Schmierverlängerung
lubricating extension
59 23084833 1 Schmierverlängerung
lubricating extension
60 69520310 2 Schmiernippel AM 10x1 / 5.8Zn / DIN 71412

lubricating nipple

62 00030881 1 Druckkunststoffrohr 6x1,5

plastic pipe

B 23080455
10.11.2006
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
+DXEH %
KRRG Gruppe-Nr.
Group-no.

23.01.2009 (10686)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Haube 31pol. Order-no. 23082943
hood Gruppe-Nr.
Group-no. 5.0
01
07 23082017 2 Bügel, kpl. (s. Gruppe-Nr. 8.0)

frame, cpl. (see group-no. 8.0)
10 23083391 2 Deckel, kpl.

cover, cpl.

hexagon screw
12 63872804 4 Scheibe 12,0 / 200HV-A2 / DIN EN ISO 7090

disc
13 63959512 4 Fächerscheibe A 13 / F-StZn / DIN 6798

serrated lock washer
14 66908300 4 Hut-Mu M 12 / 6A3P / DIN 1587

cap nut
15
16 23084214 1 Schelle, kpl. für E-Leitung (s. Gruppe-Nr. 5.6)

clamp, cpl. for cable (see group-no. 5.6)
1/1
B 23082943
05.11.2007
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
6FKHOOHIU(OHNWUR/HLWXQJ %
FODPSIRUFDEOH Gruppe-Nr.
Group-no.

23.01.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Schelle für Elektro-Leitung Order-no. 23084214
clamp for cable Gruppe-Nr.
Group-no. 5.6
01 00030146 1 Anschweißplatte SPAL 6 S

welding plate
02 23084231 1 Schellenkörper, kpl.

clamp body, cpl.
03
04 23084229 1 Deckplatte
cover plate
05 23084227 2 Spezialschraube M 12x100

special screw
06 23084228 2 Scheibe
disc
07 68531840 2 Sprengring A 12 / DIN 7993

snap ring
08 P0000335 1 Knotenkette 2 – 500 mm / St / DIN 5686

knotted-link chain
09 65169538 2 6kt.-Shr. M 6x12 / A2-70 / DIN EN ISO 4017

hexagon screw
1/1
B 23084214
09.02.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
%JHONSO %
IUDPHFSO Gruppe-Nr.
Group-no.

3
3(,1(5*UHLIHU

(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
%HVWHOO1U
%JHONSO 2UGHUQR
IUDPHFSO *UXSSH1U
*URXSQR

%JHO

IUDPH

NW6KU0[$3',1(1,62

KH[DJRQVFUHZ
6FKHLEH+9$3',1(1,62

GLVF
NW0X0$3',1(1,62

KH[DJRQQXW

%
16.07.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
+\GUDXOLNDJJUHJDW %
K\GUDXOLFXQLW Gruppe-Nr.
Group-no.

08.10.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
+\GUDXOLNDJJUHJDW Order-no.
Group-no.

01 23081600 1 Zwischenflansch für Pumpe

intermediate flange for pump
02 23005109 2 Verteilerstück
distributor part
03
04 23081601 1 Kupplung
coupling
05 00022394 1 E-Motor 112M-4 (s. Maschinenkarte)

electric motor (see machine card)
06 00019447 1 Zahnradpumpe P3 DB2006 L10, kpl.

gear pump, cpl.
07 65157203 4 6kt.-Shr. M 12x30 / 8.8A3P / EN 24017

hexagon screw
08 65984702 4 Zyl.-Shr. M 8x25 / 8.8A2P / EN ISO 4762

09 00018778 8 Zyl.-Shr. M 6x50 / 8.8A2P / EN ISO 4762

10
11 00022426 2 Verschraubung WSV 14-PS

bolted joint
12 05585996 2 Verschraubung EVW 14-PSR

bolted joint
13 23084713 2 Rückschlagventil, kpl. (s. Gruppe - Nr. 10.1)

nonreturn valve, cpl. (see group - no. 10.1)
14 08014374 2 O-Ring 22x3

o-ring
15

B 23081599
08.10.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
+\GUDXOLNDJJUHJDW Order-no.
Group-no.

16 23004916 1 Dichtung
gasket
17 1 Ro. 14x2 – 290 mm / 1,0255-NBK/C / DIN EN 10305-4

tube
18
19 74577027 2 Dichtring A 22x27x1,5 / Cu / DIN 7603

sealing ring

B 23081599
04.06.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
/LVWHGHVSLqFHVGHUHFKDQJH
5FNVFKODJYHQWLONSO %
FODSHWDQWLUHWRXUFRPSO Gruppe-Nr.
o
N de groupe

3
3(,1(5*UHLIHU

(UVDW]WHLOOLVWH
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%HVWHOO1U
5FNVFKODJYHQWLONSO 2UGHUQR
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*URXSQR

5FNVFKODJYHQWLO

QRQUHWXUQYDOYH
.XJHO

EDOO

%
11.11.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Rücklauffilter D 043-88 25 μm B 00020900
return filter Gruppe-Nr.
Group-no. 11.0
1/1
29.04.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
5FNODXIILOWHU'P Order-no.
UHWXUQILOWHU Gruppe-Nr.
Group-no.

01 D 043.2202 1 Deckel, kpl.

cover, cpl.
02 N 031.0562 1 Flachdichtung
gasket
03 D 023.0704 1 Flachdichtung
gasket
04 D 043-1104 1 Gehäuse mit Rohr, kpl.

housing with pipe, cpl.
05 00021735 1 Exapor-Filterelement
filter element Exapor

B 00020900
11.11.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Doppelhaken mit Aufhängung B 23082811
double hook with suspension Gruppe-Nr.
Group-no. 25.4
1/1

3
3(,1(5*UHLIHU

(UVDW]WHLOOLVWH
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*URXSQR

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'RSSHOKDNHQ*U

GRXEOHKRRN
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SLQ
$FKVKDOWHU[[

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NW6KU0[$3',1(1,62

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6FKPLHUQLSSHO$0[=Q',1

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%
05.08.2009 (10735)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Hydraulikmotor mit Anbaublock B 23084827
hydraulic motor with valve plate Gruppe-Nr.
Group-no. 37.0
1/1
29.07.2009 (11237)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Hydraulikmotor mit Anbaublock Order-no. 23084827
hydraulic motor with valve plate Gruppe-Nr.
Group-no. 37.0
01 00041083 1 Hydraulikmotor HCC-M300 (s. Gruppe-Nr. 37.4)

hydraulic motor (see group-no. 37.4)
02 23005095 1 Ventilblock NG 6
valve block

04 08014374 2 O-Ring 22x3

o-ring
05 00016261 2 Verschluß-Shr. G¼A / 5.8A3P / DIN 908

screw plug

sealing ring
07 00022428 2 Verschraubung EVW 14-PSR/A3C

bolted joint
08 00022427 1 Verschraubung GE 10-PL/R3/8/A3C

bolted joint
09 00016264 1 Verschluß-Shr. GǪA / 5.8A3P / DIN 908

screw plug

sealing ring
1/1
B 23084827
11.06.2010

P
PEINER Greifer
Ersatzteilliste
Spare parts list
Hydraulikmotor HCC - M300 B 00041083
hydraulic motor HCC - M300 Gruppe-Nr.
Group-no. 37.4
1/1
11.06.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Hydraulikmotor HCC - M300 Order-no. 00041083
hydraulic motor HCC - M300 Gruppe-Nr.
Group-no. 37.4
1.2 74429104 5 O-Ring 15,54x2,62 2-114

o-ring
2.2 00041834 1 Wellendichtring Ø55xØ72x8

shaft seal
2.4 00040897 1 O-Ring 129,77x3,53

o-ring
3.7 00041835 5 O-Ring 82,27x1,78 2-042

o-ring
5.6 00041836 5 Zylinderdichtung für HCC-M300 50x5,5

cylinder sealing
9.1 74429107 5 O-Ring 21,89x2,62 2-118

o-ring
9.2 00030441 1 O-Ring 82,14x3,53 2-236

o-ring
10.5 00030441 5 O-Ring 82,14x3,53 2-236

o-ring
12.1 74429152 1 O-Ring 39,34x2,62 2-129

o-ring
12.2 00041837 1 Dichtring für HCC-M300 47,2x3

sealing ring
00041838 1 Dichtungssatz, kpl. für HCC-M300

seal kit, cpl.
Zur fehlerfreien und schnellen Ersatz-
teillieferung sind folgende Daten anzugeben:
To ensure the correct and fast delivery of spare
parts, the following data must be specified:
Hydraulikmotor:
hydraulic motor:
Typ
Fabr.
Nr.
Sach
Nr.
1/1
B 00041083
25.08.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Antriebslager B 23084564
drive end bearing Gruppe-Nr.
Group-no. 37.5
1/1
29.07.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Antriebslager Order-no. 23084564
drive end bearing Gruppe-Nr.
Group-no. 37.5
01 23084566 1 Ritzel
pinion
02 23084567 1 Ritzelhalter
pinion holder
03 23084568 1 Flansch
flange
04 23084569 1 Distanzring
spacer ring
10 00041172 2 Rillenkugellager
deep groove ball bearing
11 63912500 1 Sicherungsring 125x4 / F-St / DIN 472

circlip

hexagon screw
13 67842912 1 Kerbstift 6x12 / St / DIN EN ISO 8745

grooved pin
14 63965502 1 Scheibe 13 / StTZn / DIN 432

disc
1/1
B 23084564
01.04.2009 1/1
3
3(,1(5*UHLIHU
%HVFKUHLEXQJ
'HVFULSWLRQ
:DUWXQJVDQZHLVXQJIU6FKOHLIULQJEHUWUDJHU
$&+781*
Installation, Wartung und Reparatur darf nur durch HOHNWURWHFKQLVFKTXDOLIL]LHUWHVund DXWRULVLHUWHV
Personal durchgeführt werden. 'HU6FKOHLIULQJEHUWUDJHUPXVVYRU%HJLQQGHU:DUWXQJ
spannungsfrei JHVFKDOWHWZHUGHQ
:DUWXQJ
Wartungsintervall: 1 x jährlich oder nach 100000 Umdrehungen
Vorgehensweise:
1. Der Schleifringübertrager muss YRU%HJLQQGHU:DUWXQJspannungsfreiJHVFKDOWHWZHUGHQ
2. +DXFKGQQHV(LQVSUKHQGHU.RQWDNWVWHOOHYRQ6FKOHLIULQJXQG6FKOHLIEJHOPLW
.RQWDNW|O Es darf nur das Kontaktöl ³&5$02/,16FKXW]´ verwendet warden.
Achtung! Zuviel Kontaktöl kann Kurzschlüsse verursachen.
3. Nach dem Einsprühen mit Kontaktöl Schleifringübertrager 5x um 360° drehen.
Kontaktöl ³&5$02/,16FKXW]´ ist unter der Artikelnummer 920809000011 zu beziehen.
0DLQWHQDQFHLQVWUXFWLRQIRUVOLSULQJWUDQVPLWWHU
:$51,1*
Installation, maintenance and repair may only carried out by DXWKRULVHGHOHFWULFDOO\TXDOLILHG
personal. %HIRUHWKHVWDUWRIDQ\ZRUNRQWKHVOLSULQJDVVHPEO\LWEHVHSDUDWHGIURPWKH
electrical supply.
0DLQWHQDQFH
Maintenance interval: Once per year or after every 100000 revolutions.
Procedure:
1. The slip ring assembly PXVWEHseparatedIURPWKHHOHFWULFDOVRXUFHEHIRUHDQ\ZRUNWDNHV

SODFH
2. 6SUD\DYHU\ILQHILOPRIFRQWDFWRLORQWKHVOLSULQJZD\VDQGZLUHEUXVKHV Only the

contact oil ³&5$02/,16FKXW]´ may be used.
WARNING: Too much contact oil can cause short-circuiting.
3. After spraying the slip ring assembly with contact oil turn it 5 times 360 degrees.
Contact oil ³&5$02/,16FKXW]´ can be ordered under article no. 920809000011.

03.12.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Schleifringübertrager 31x36A + PE, 150 A B 00040328
slip-ring transmitter Gruppe-Nr.
Group-no. 38.0
18.06.2008
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
6FKOHLIULQJEHUWUDJHU[$3($ Order-no.
VOLSULQJWUDQVPLWWHU Gruppe-Nr.
Group-no.

01 920401600080 33 Schleifbügel 3xD1,2

slip bracket
02 920415000005 1 PE-Bürstenhalter 150 A

brush holders
03 921100001319 1 Klemmscheibe oben, kpl.

terminal plate above, cpl.
04 921100001421 1 Klemmleiste
terminal strip

B 00040328
28.04.2011 -2/2-
P
PEINER Greifer
Inhaltsverzeichnis
Contents
Sach-Nr. / Subject no.:

Erzeugnis / Product: SW 144 DISK
S 23080453
Geräteausrüstung Elektrik Schaltplan 2307.9132 D / E

electric equipment wiring diagram
Benennung Description Bestell-Nr. / Gruppe-Nr. /

Order-no. Group-no.
Geräteteil, Stifte male part with pins 23079903 16.1

Geräteteil, Buchsen female part with bushes 23079904 16.1
Kabelbaum Bron wiring harness 23079272 16.11
Kabelbaum UW wiring harness 23079273 16.11
Installation Elektrik installation electric 23079132 40.0
Bei Ersatzteilbestellung ist außer der Bestellnummer das Erzeugnis, die Werks-Nr. und Kommissions-Nr.
anzugeben.
For spare part orders, the product, serial-no. and commission-no. must be given in addition to the
requisition-no.
Salzgitter Maschinenbau AG Phone: E-mail: Board of management: Domicile of company: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Chairman), Registration court:
38259 Salzgitter / Germany Fax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 53 41 / 302 424 www.smag.de Chairman of the Supervisory Board: Registration number:
www.peiner.de Ulrich Decker HRB 201 389
24.11.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Geräteteil UW-SEE B 23079944
plug connection, mounted part Gruppe-Nr.
Group-no. 16.1
1/1
09.06.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Geräteteil UW-SEE, 37pol., 27A, Stifte Order-no. 23079903
male part, pins Gruppe-Nr.
Group-no. 16.1
01
02
03 00023644 37 Schrumpfschlauch CPX 50 5x25

shrink hose
12 06165984 1 Schlüssel 309 098 000 719

mounting key
16 06172240 1 Geräteteilgehäuse 309 013 000 554

male part
17 00022868 1 Stifteinsatz 309 803 160 037 151, 37polig

male insert
18
19 06171808 1 Schutzring 309 001 151 721

protective ring
20 06171801 1 Zwischenring 802-0105

intermediate ring
21 74731980 1 O-Ring 80x3 / 70 NBR/769

o-ring
22 06172265 1 Deckel 309 097 005 926

cover
23 06172248 1 Schraubensatz 100 000 000 12

set of screw
1/2
B 23079944
09.06.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Geräteteil UW-SEE, 37pol., 27A, Stifte Order-no. 23079903
male part, pins Gruppe-Nr.
Group-no. 16.1
24
25 06172273 1 Kette 021 338 020 902

chain
26
27 08014726 1 O-Ring 80x6 / 70 NBR/769

o-ring
28 06171802 2 Gewindering 802-0107

threaded ring
2/2
B 23079944
30.05.2006
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
*HUlWHWHLO %
SOXJFRQQHFWLRQPRXQWHGSDUW Gruppe-Nr.
Group-no.

28.08.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Geräteteil 3.09, Bron., 37pol., 27A, Buchsen Order-no. 23079904
female part with bushes Gruppe-Nr.
Group-no. 16.1
01
02
03 00023644 37 Schrumpfschlauch CPX 50 5x25

shrink hose
08 06171802 2 Gewindering 802-0107

threaded pin
09 06171809 1 Zwischenscheibe 802-0106

intermediate washer
10 06172306 1 Geräteteilgehäuse 309 010 554 00

female part housing
11 00022867 1 Buchseneinsatz 309 703 160 037, 37polig

female insert
12 06171801 1 Zwischenring 802-0105

intermediate ring
13 08013040 1 Dichtung 309 010 113 945 00

gasket
14 06165984 1 Schlüssel 309 098 000 719

mouting key
1/1
B 23079997
25.09.2008
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
.DEHOEDXP6:/:1%URQ %
ZLULQJKDUQHVV Gruppe-Nr.
Group-no.

15.05.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
.DEHOEDXP6:/:1%URQ Order-no.
Group-no.

01 90017100 33 Leitung H07V-K 1x2,5 – 1,8 m

electric cable
02 90017108 2 Leitung H07V-K 1G2,5 – 1,8 m

electric cable
03 00024490 1 PVC-Isolierschlauch Ø 35 mm – 1,5 m

PVC insolating hose
07 23079904 1 Geräteteil 3.09, Bron, 37pol. (s. Gruppe-Nr. 16.1)

female part (see group-no. 16.1)
08
09 98900046 31 Adernendhülse 2,5 mm² / 51342

cable end pieces
10 00027205 2 Quetschkabelschuh 1,5-2,5 mm² / 42028

crimp type socket

B 23079272
25.09.2008
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
.DEHOEDXP6:/:18: %
Group-no.

15.05.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
.DEHOEDXP6:/:18: Order-no.
Group-no.

01 90017100 35 Leitung H07V-K 1x2,5 – 1,9 m

electric cable
02 90017108 2 Leitung H07V-K 1G2,5 – 1,9 m

electric cable
03 00024490 1 PVC-Isolierschlauch Ø 35 mm – 1,6 m

PVC insolating hose
07 23079903 1 Geräteteil UW-SEE, 37pol. (s. Gruppe-Nr. 16.1)

male part (see group-no. 16.1)
08
09 93140000 31 Stecker
plug
10 74731980 1 O-Ring 80x3

o-ring
11 98900046 6 Adernendhülse
cable end pieces

B 23079273
08.10.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
,QVWDOODWLRQ(OHNWULN Order-no.
LQVWDOODWLRQHOHFWULF Gruppe-Nr.
Group-no.

01 23079272 1 Kabelbaum SW LWN Bron 31pol. (s. Gruppe-Nr. 16.11)

wiring harness (see group-no. 16.11)
02 23079273 1 Kabelbaum SW LWN UW 31pol. (s. Gruppe-Nr. 16.11)

wiring harness (see group-no. 16.11)
03 00029350 1 Ventilstecker 3+PE mit 2 m Leitung

plug with 2 m electric cable
08 90106900 1 Leitung H07RN-F 4G2,5 – 1,5 m

electric cable
09 00023342 1 Kabelverschraubung M 25x1,5

cable gland
10
11 00040329 1 Einbaustecker 10pol. Stifte mit Datenleitung

male plug with cable
12 00023355 1 Blindstopfen-Rund M 25x1,5

blind plug
13 08014259 1 Vergussmasse
sealing compound
14 91440002 1 Spiralwickelband – 1 m
wrapping tape
15 90017508 1 Leitung H07V-K 1G16 – 2,5 m

electric cable
16 00024426 4 Quetschkabelschuh
crimp type socket
17 00019680 1 Entstörmodul
suppressor

B ----------
6
141082 / 001
Operations manual
for
BROMMA TELESCOPIC SPREADER
TYPE: EH170U
General assembly drawing No: 1012972
Serial number:
SWL: 41 tonne
Twinlift capacity: 2 x 25 tonne
Customer: Liebherr
End User:
Date of shipping:11
_____________________________________________________________________________________
BROMMA CONQUIP AB 00 01 ENG
rev.
Warning!
This Operations manual is intended as a guide to the use and maintenance of
Bromma spreaders.
 READ AND UNDERSTAND THE MANUAL BEFORE THE SPREADER IS

PLACED INTO OPERATION!
 Bromma Conquip AB or it’s affiliated - companies (to the extent permitted

by law) accept no liability for loss or damage suffered as a result of the use
of this manual.
 If in doubt always refer to the original equipment manufacturer.
 Refer at all time to the ”Safety precautions” under section 5!
 DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The
Safe Working Load is found on the nameplate that is permanently affixed
to the side frame of the spreader.
__________________________________________________________________________________
rev.
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1 x INTRODUCTION

2 x SPREADER DATA SHEET
3 x TECHNICAL DESCRIPTION SPREADER

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4 x TESTING RECORDS AND CERTIFICATE
5 x SAFETY PRECAUTIONS
6 x START-UP PROCEDURES
7 x MAINTENANCE PROCEDURES
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8 x SPARE PARTS AND SERVICE
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9 x HYDRAULIC CIRCUIT DIAGRAMS
10 x ELECTRICAL WIRING DIAGRAMS
11 x FAULT FINDING DIAGNOSTICS

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12 x APPENDICES
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_________________________________________________________________________________
BROMMA CONQUIP 00 03 ENG
rev.01
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
1  Introduction
BROMMA Conquip has since 1967 been the leading manufacturer of

telescopic container handling spreaders. A great number of BROMMA
spreaders are in service today in ports and terminals around the world.
A complete range of fixed length and telescopic spreaders are available,
and each one provides high handling efficiency, excellent reliability,
ease of maintenance and repair.
This Operation Manual describes the many features of the

BROMMA spreader. It will guide you in:
 Maintenance.
 Repairs.
 Trouble-shooting.
 Service.
 Spare parts.
In the event You should need additional information or support, our

sales and/or technical staff will be pleased to assist you.

rev.
BrommaGroupManual
2 x Spreader - Datasheet
Type EH170U
Art.No 1012972
Container Range 20’- 40’
Capacity
Lifting capacity (evenly loaded) 41 tonne
Lifting capacity (10% gravity point off set) 41 tonne
Twinlift capacity 2 x 25 tonne
Twinlift capacity (10% gravity point off set) 2 x 20,5 tonne
Lifting lug capacity (gable end) 4 x 10 tonne
Lifting lug capacity (main beam) 4 x 10 tonne
Operating Movements
Telescoping 20’ to 40’ or 40’ to 20’ 30 s
Twistlock rotation locking or unlocking 90o 1,5 s
Electrical Equipment
Power voltage 400 V AC
Frequency 50 Hz
Control voltage 230 V AC
Control valve 24 V DC
Total power consumption 2x2,2 k + 1x3kW + 3+5,5 =15,9kW
Electrical protection IP 5
Hydraulic Equipment
Pump running Pressure 100 bar
Pump flow 3 x 15 l/min
Tank capacity 3 x 50 l
Normal running temperature (above ambient) 50˚C
Filter type 10 μm
Filter
Pressure line 10 μm
Corrosion protection
All surfaces are grit blasted SA 2.5
Interzinc 72 EPA 069/073 (Interzink 72 EPA 069/073) 0 μm
Intervinux Serie VL (Intervinux Serie VL) [50 μm
Intervinux Serie VS (Intervinux Serie VS) 0 μm
Min. coating thickness, total 200 μm
______________________________________________________________________________________________________
BROMMA CONQUIP AB 02 01ENG
rev..1
BrommaGroupManual
3  Technical description
Functional description
Bromma telescopic spreader EH5 (EH12 & EH170) are fabricated as all
welded, high quality steel, construction. Two pairs of telescopic beams slide in
the centre main frame construction. The telescopic beams are joined together
at the ends by end beams, which house the twistlocks, flipper arms and
hydraulic valves.
The spreader has an inbuilt under clearance of 185 mm. This enables
hatchcovers and containers with protrusions up to 185 mm to be handled. If
larger clearances are required then overweight extension legs need to be fitted.
The spreader is optionally fitted with one set of lifting lugs. Mostly, they are
placed at each corner of the gable end. In case the spreader is provided with
this device, it can be used for handling of badly damaged containers or non-
containerised cargo.
Use only approved slings and shackles.

Where the telescopic arms slide in the mainframe they are supported by a
number of low friction slides plates, one at each corner of the mainframe (total
4) and on the top and bottom at the end on each telescopic arm (total 8).
Sufficient clearance is provided between the slide plates and the structure to
allow the beams to flex, enabling distorted containers to be handled.
The spreader function (i.e. twistlocks, flippers, telescoping) is operated from the
driver’s controls in the crane cab.
TELESCOPIC SYSTEM
The telescoping system is driven by means of an electric motor and reduction
gearbox connected to an endless chain. This chain is titted with stacks of spring
washers that work as chock absorbers where the chain attaches to the tension
rods.. These tension rods are connected to the end beam. The springs allow for
changes in the length of the spreader up to plus or minus 7 mm . The springs
do not only act as shock absorbers; they also provide a floating possibility for
the twistlocks to handle distorted containers. This "floating" action also
eliminates the need for corner guide rollers.
In the event of a power failure the telescoping motion can be handcranked.

The positioning system works with proximity switches for positioning the
spreader in the 20', 30' and 40' positions. This system enables the positioning
of the twistlocks with an accuracy of plus or minus
3 mm (less than 1/8"). The drive motor incorporates an electric brake that is
spring applied and takes electrical power to release.
________________________________________________________________________________________________________
1 of 3 BROMMA CONQUIP AB 03 09 ENG.
rev. x
This brake not only controls the accuracy in stopping the expansion and
retraction but also prevents changes from occurring in the spreader length
during use.
TOWER
The main frame of the spreader is connected to the crane through a sliding
tower assembly. This enables the centre of gravity lifting point to be moved a
maximum of 1,2 meters toward each end of the spreader. This means that
unevenly loaded containers can be picked up horizontally, which is specially
important when loading or unloading in the guides in the ship´s cells. After
unlocking an unevenly loaded container, the sliding tower assembly
automatically returns to the central position
FLIPPERS
Flat gather guides, commonly called flippers, are fitted to each end beam of the
spreader. They are of strong construction and are driven by a powerful
hydraulic motor, which enables easy and fast location of the spreader onto the
containers. The flipper gather is 155 mm and has a gathering torque of
1200 Nm. The flipper arms are always under pressure and each arm has a
shock relief valve, which opens at a pre-set pressure of 45 bar above the
normal working pressure. As soon as the shock load ends the flipper returns to
the vertical position.
Each flipper is controlled by its own solenoid valve and shock relief valve. The
flippers work in pairs along the length of the spreader, individually at the gable
ends, or all together.
The speed of the flipper is approximately 180 in 6 seconds and is
controlled by an orifice plug in the pipe connection to the motor.
TWISTLOCK
Four twistlocks for single container spreader are located in the corners of the
spreader to engage and lift the container. A hydraulic cylinder rotates the
twistlock and two sensors indicate the position of the twistlock, Locked or
Unlocked.
A landing pin safety system is provided to assure that the spreader is properly
landed on the container before rotating the twistlocks.
A spring loaded landing pin near each twistlock is pushed up into the twistlock
housing when the spreader is landed on the container. When the spreader is
properly landed on a container, the landing pin will activate a proximity switch.
Only when all the corners of the spreader are landed, can the twistlocks be
turned. At the same time, the blockading key is moved high enough so the
blockading stop on the twistlock lever arm passes underneath it. If the
spreader is not properly landed the proximity switch will not be activated and
________________________________________________________________________________________________________
rev. x
the blockading key will get in the way of the blocking stop. This will stop the
twistlocks from turning.
CENTER TWISTLOCKS (EH 170U)

The EH 170 is equipped with center twistlocks to be able to handle two 20 foot
containers at the same time. These center twistlocks are placed in housings on
the main frame. The twistlock boxes can be tilted to “down” position by four
hydraulic cylinders. (one per twistlock box). The center twistlocks operate the
same way as the end beam twistlocks.
SIGNAL LIGHT
Near each end of the spreader mainframe there is a set of three signals light,
one green, one red, one white, which can be clearly seen from the crane cabin.
The green and red lights indicate if corresponding twistlocks are unlocked or
locked respectively. The white light indicates when the spreader is properly
"landed", and the twistlocks are correctly engaged in the container corner
castings.
In twinlift spreaders (EH170U), when using the twinlift function, the left side
signal lamps are valid for the left side container and the right side lamps are for
the right side container.
HYDRAULIC UNITS
The hydraulic units are protected inside each end beam. The unit consists of a
built-in tank, variable displacement piston pump, motor valves and filter. The
filter cap is fitted with a pressure relief valve plus or minus 0,14 bar to allow
expansion and contraction of air inside the tank.
The hydraulic components used are designed to work at over 200 bar but
normal working pressure is 100 bar. The hydraulic valves are solenoid
operated and can be tested by hand operating.
The EH170U has a third hydraulic unit placed in the main beam. This unit
provides the four cylinders for center twistlock housings up-down and the four
cylinders for lock-unlock in the central twistlocks with power.
MAIN ELECTRICAL CABINET

The main electrical cabinet is mounted on heavy-duty rubber shock absorbers
and is well protected being placed on the tower. Relays, transformers, circuit
breakers, timers, hour counters and sockets are mounted in this cabinet. The
PLC is also placed on the tower. A junction box including motor protectors is
placed inside the main frame.
________________________________________________________________________________________________________
rev. x
 Design calculations
The spreader structure is designed according to DIN15018 and to the
following loading group which represents a container handling crane.
 HOISTING GROUP H2
 LOADING GROUP B4
LIFTING CASES
The following lifting cases are considered:
1. Most frequent load case

A symmetrically loaded container of 41 tonne. The permissible stress is
determined by analysis of direct loading and fatigue conditions. Depending
on intensity of use the structure is suitable for:
2 X 106 lifting cycles

"H” load case is determining.
2. Exceptional load cases

Permissible stresses are determined by analysis of direct loading only.
a) A container of 41 tonne weight but loaded unsymmetrically by 10% in

the longitudinal direction.
"H.Z" load case is determining.
b) A container of 41 tonne weight but loaded unsymmetrically by 10% in

the longitudinal and lateral direction.
"H.S" load case is determining

rev. x
Safety features
The following safety features are normally included in the crane:
1. The spreader should only be hoisted/lowered when all four twistlocks are
fully locked/unlocked.
2. The spreader twistlocks should be locked/unlocked when the spreader is

Properly "landed" on a container. This being when all four landing switches
are actuated.
3. A delay feature on the twistlocks locked/unlocked circuit is installed to

ensure the spreader is properly "landed" and not bouncing. This is in the
form of a timer whom is adjustable, but normally set to between 1 and 2
seconds.
4. During hoisting the four blockading pins move to the "down" position.
This prevents electrically the twistlocks from moving.
NOTE ! When carrying out maintenance on the twistlocks, the blockading pin clamps can
be fitted to each corner, to by pass the electric and mechanical blockading when running
the twistlock.
5. Telescoping of the spreader is prevented unless all four blockading pins

are in the "down" position and the twistlocks are unlocked.
Individual switches indicate twistlocks locked, twistlocks unlocked and
blockading pins "up".
The following safety features are fitted on the spreader:
6. A mechanical blockading device prevents each twistlock from locking/

unlocking unless the blockading pin is "up" position.
__________________________________________________________________________________
rev.
In-plant testing
STRUCTURAL
Each spreader is fully proof tested in the factory to a minimum of 50%
overload prior to delivery. The proof test loading report enclosed illustrates the
loads applied to the spreader.
All lifting lugs are also proof tested in the factory.
The testing is witnessed and certified by a third part inspection official.
All spreader twistlocks are individually proof tested, stamped and certified to a
loading of 37 tonne.
FUNCTIONAL
Each spreader is run in the factory prior to delivery being controlled by a
specially designed simulator.
__________________________________________________________________________________
rev. x
4  Testing records and certificates
______________________________________________________________________________________________________
rev.
BrommaGroupManual
5  Safety precautions
Warnings
READ AND UNDERSTAND THE MANUAL BEFORE THE SPREADER IS PUT

INTO OPERATION.
The manual contains vital information for the safety of personnel and the
correct use of the spreader.
Bromma Group will not accept any liability for the use of the spreader for
any purposes outside what is described in the manual.
DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The Safe
Working Load is shown on the nameplate that is permanently affixed to the
side frame of the spreader.
Safety precautions
1. The spreader shall be operated and serviced only by authorized

personnel.
2. The spreader must only be used for the purpose for which it is
designed.
3. DO NOT change system settings and functions.
4. Perform a functional test after any maintenance or repair work.
5. Stay clear of the spreader when in operation.
6. Stay clear of all moving parts, such as guide arms (flippers), moving
beams, telescopic chains, etc. A safe distance is 5 meters.
7. DO NOT connect or disconnect electrical connectors while the power is

on.
8. DO NOT tamper with hydraulic pressure settings once adjusted by

qualified personnel. See chapter 9. Hydraulic system for proper
pressure adjustment.
9. DO NOT unlock the spreader while a container is suspended in the air. It

could cause personnel injury or property damage.
1 of 2 BROMMA CONQUIP AB 05 01 ENG

rev.. x
10. Maintain adjustment of all electrical and hydraulic components
11. Inspect the spreader for damage daily.
12. Care must be taken when performing any maintenance inside the
spreader frame. It must be carried out under extreme caution and by
personnel familiar with risks related to spreader function and
movements. Serious injury by crushing can occur
13. Contact Bromma Conquip AB before doing any repair work on the
spreader apart from replacing normal wear parts.
14. DO NOT walk or stand beneath the spreader bar during operation.
15. DO NOT attempt to lift a container that is not level (+/- 5°).
16. DO NOT crawl beneath a spreader bar for maintenance, repair or

adjustment. Never put any body extremity beneath the spreader bar.
17. NEVER STAND BENEATH A SUSPENDED LOAD.
18. DO NOT attempt to restrain the movement of a container, whether laden

or empty, by hand or by tagline.
19. DO NOT stand between a container and any construction that many
prevent your movement to safety. A definite hazard exists that could
cause serious injury or death by being crushed between the container
and an obstruction (such as a building or another container).
20. Mobile work platforms which are used in repair and service work on the
spreader must be equipped with safety rails and kick plates.
21. It is incumbent on the operator in charge of the crane to restrict the

movements of the crane when repair or service work is being performed
on crane-mounted spreader.
22. The tower must be moved back to the centre of the spreader before it
leaves the container. There must be a good clearance between the
Spreader and the container before slewing the crane boom.
23. When welding might be needed on the spreader with SCS2 assembled,
make sure that it is properly grounded or dismantle the plug connection
and earth cable.

rev.. x
WARNING!
Because this spreader is equipped with double-coil flipper

arm valves but connected as a single coil valve function,
the following may occur:
If the operating voltage to the flipper arm valves

disappears (intentionally or accidentally), the FLIPPER
ARMS move upwards to their starting position.
If EMERGENCY STOP is used or if the power supply to
the electric motor of the hydraulic power unit is cut of in
some other way, the flipper arms stop immediately. The
flipper arms start moving again when the power supply to
the electric motor of the hydraulic power unit is restored.
It is essential to inform the personnel who work close to
the spreader about this.
_____________________________________________________________
BROMMA CONQUIP AB 05 02d ENG.
rev.
BrommaGroupManual
6  Start - Up procedure
ASSEMBLY OF TOWER (drg no 34476)
1 Check spreader and tower for damage.
2 Suspend the tower from a suitable forklift or crane (tower weight 1,4 t)
using
the main lifting pin (pos 1).
3 Remove the protective material from the robalon pads on tower (pos 2).
Remove the drive sprocket cover (pos 6).
Remove the (2) lifting lugs from main frame of the spreader at the
assembly end
(pos 3).
5 Lower the flipper arm, at assembly end of the spreader, by slackening

hydraulic hoses on the motor.
NOTE: Take care that flipper does not fall down and cause injury!
6 Remove top fixings for rubber covers (pos 4).
7 Remove lamp assembly by taking out the quick release fastening from
the four pins and lay the lamp assembly in the main frame.
8 Release the gravity point chain, by removing the two screws and the
locking device from adjuster.
9 You are now able to slide the tower into the main frame close to the
centre.
Note the direction of assembly. Arrows are painted on the tower and
frame.
10 Now replace the lamp assembly, rubber covers and lifting lugs. If the
flipper is rise at this time, care should be taken as it is liable to fall, now
that the motor is empty.
______________________________________________________________________________________________________
1 BROMMA CONQUIP AB 06 02 ENG
rev.
11 Remove the drive sprocket cover (pos 6).
It is now possible to install the chain, complete with the anchor block
fitted.
The chain goes, under the first sprocket, over the centre one and under
the third.
To assist with the chain installation, pull the brake release lever, towards
the back of the motor. It is then possible to turn the motor, using the
handle supplied.
12 Replace the chain back into it's fixing point and tighten the adjusting
screws, until the chain is tight (allow a sag of about 30 mm and place the
tower in middle position) and replace the locking device. Grease the chain.
13 Replace sprocket cover.
14 Pass the main plug up through the tower and fix conduit pipes with screws
supplied.
15 Place the cable into the top support clamp.
16 Connect the tower motor. The connections are marked u1 and w1 to give
correct position.
NOTE: Take care, incorrect rotation may result in serious damage!
17 Secure the cable to bracket with suitable cable ties.
18 Fix limit switch detection bar into place (pos 7).
19 Check all bolts are tight and the spreader is clear of all discarded material
and tools. Take care that nothing had fallen into the chain.
______________________________________________________________________________________________________
rev.
TOWER FUNCTIONS AND TESTING
The tower function is to level/unlevel loaded containers. Any other use of the
tower is an abuse of the equipment and could result in serious damage.
When the spreader is locked onto a container, it is possible to move the tower
in any direction. The tower will stay where it is placed. The return to the middle
position is done by the crane driver. When he has driven the tower to yellow or
blue, it goes always to the middle position.
To test the newly assembled unit, place the blockading pin clamps onto the
spreader and lock the twistlocks. With the spreader on the ground, commence
to travel the tower towards one end of the spreader. Now hold a piece of
metal, i.e. spanner or screwdriver, in front of the stop switch, for the end that
the tower is travelling. The tower should now stop.
Try the other direction. If both of the limits work, travel the tower to both ends
of the spreader, to confirm the limits work on the detection bar. When at each
end, unlock the twistlocks and release a clamp, to confirm the tower returns to
it's centre position. If any of these functions fail, please seek advice.
WARNING!
Use the tower only to level loads, or serious damage may occur!
Never use the hand crank on the motor with power connected, or serious
injury may occur!
______________________________________________________________________________________________________
rev.
Start - Up the spreader
1. Before any connection to container crane, place the main frame of the
spreader on trestles or similar about 0,7 m height and in such a way that the
flipper arms can be lowered.
2 Inspect the spreader for visible damage.
3. Connect the main current and control supply to the spreader. Connect the 24
pin plug to the service panel.
4. Start the electric motor of the hydraulic units by turning the ”pump on” switch on
service panel.
5. For testing of the twistlocks all 4 blockading pins should be in ”up” position. This
is achieved by using a blockading pin clamp. In the ”down” position the
blockading pins electrically and mechanically block all twistlock rotation.
6. Test all functions of the spreader using the push buttons and switches on the
service panel.
a) When ”pump on” switch is on, both electric motors should be running in
gable ends.
b) Operate the push buttons to put the spreader in the different length positions.
As an additional length, check that the twistlock centre length is marked on
the plate positioned on side of the main beam.
c) Check that the flippers works in pairs along the length of the spreader,
individually at the gable ends, or all together by pressing the appropriate
buttons.
d) Check that when clamps are fitted to the blockading pins and all pins are up,
this will be indicated by the white lights on the spreader.
e) Check that the twistlocks lock/unlock and that the light indicators on the top
of the spreader main frame indicate red when locked and green when
unlocked.
7. Check that the pump operating pressure is 100 bar.
______________________________________________________________________________________________________
rev.
8. Check each end hydraulic assembly to ensure there are no oil leaks.
9. Note that the solenoid valves operating flippers and twistlocks can be
manually operated if required.This is achieved by pushing the end of the
solenoid with a small screwdriver. As power is generally always on the
solenoid, the plug connection has to be disconnected first.
10. Service and lubrication should be carried out in accordance with the
lubrication manual.
______________________________________________________________________________________________________
rev.
7  Maintenance procedures
Maintenance Instructions
IMPORTANT!
When the spreader is disconnected from the crane the heating function
(if fitted) must always be connected and energised.
Pos. 1
TWISTLOCK (drg no 22808)
All twistlock are to be greased through the greasecups 4 per spreader.
Pos. 2
TWISTLOCK CYLINDER & BEARING HOUSING IN TOWER (drg no 22808)
Piston rod ends are to be greased. 8 per spreader. Bearing housing in tower.
2 per spreader.
Pos. 3
HYDRAULIC UNIT (drg no 22809)
Oil is to be changed after first 50 hours, then after every 1000 hours.
Pos. 4
OIL FILTER (drg no 22809)
Filter is to be changed after first 50 hours, then after every 1000 hours of
operation or when the indicator is red.
Pos. 5
LIFTING SHAFTS (drg no 22808)
(If the spreader/headblock is equipped with lifting shafts).
ACTION! To be greased.
Pos. 6
GLIDE PLATE (drg no 22810)
The robalon glide plates are to be replaced when the thickness is down to
17 mm.
ACTION! To be checked.

rev.3
Pos. 7
GUIDE ARMS (drg no 22808)
Shafts are to greased.
Pos. 8
TELESCOPIC GEARBOX (drg no 22808 & 22809)
Oil level is to be checked through dismantled oil level plug. Bearings at the
gearbox and the pedestal are to be greased through greasecups.
Pos. 9
ALL ROLLER CHAINS AND TENSION WHEEL (drg no 22808)
Roller chains and tension wheel are to be checked from abrasion and
greased.
Pos. 10
SIGNAL LAMPS (drg no 22810)
Vibration proof glow lamp.
ACTION! To be checked.
Pos. 11
TELESCOPIC BEAMS (drg no 22808)
To be greased as follows:
1. In 20'- position, through greasenipple underneath the mainframe ca

50g/week.
2. In fully expanded position, with a brush on the sliding area under the
telescopic beams ca 100g/ at interval min.1000 hour. The amount of
grease and service interval depends on spreader use and environmental
circumstances which vary from place to place.
Pos. 12
ELECTRICAL MOTORS (Only for EH5)
Adjust brakes as per attached instructions.

rev.3
Page 1 of 1
Article No: 1002945 TWISTLOCK ASSEMBLY date
Drawing No: 1002945 ISO, STD, LEFT sign: PWH 2005-02-18
Serial No: - BGS rev: b / SC 2007-01-23
Customer: -
Standard: -
Item Quant Title Material / Article No. Dwg No. Art. No. Remarks
1 1 TWISTLOCK PIN 1000431 1000431
2 1 GUIDE BLOCK 1000430 1000430
3 1 SPHERICAL WASHER 41683 53968
4 1 TWISTLOCK ARM, ASSY. 43653 43653 TYPE 1
5 1 TWISTLOCK KEY 1000434 1000434
6 1 NUT 1000432 1000432 (M39x4-6H)
7 1 SCREW A4 1000600 M6S 8x75, Art. No. was 70165
8 2 SPACER RING 41731 54049
9 1 HYDRAULIC CYLINDER 74147 (CA 32/20-100/65)
10 1 BLOCKADING PIN 37704 37704 FZB
11 1 SPRING 70429 SF-TF 4.5x22x90 SS 1774-04
12 1 NUT LOCK-KING A4 77891 M12, Art. No was 75055
13 2 WASHER NORD-LOCK A4 701440 M12, Art. No. was 75295
14 2 LOCK PIN 74044 R.R 3.0
15 2 GREASE FITTING 71328 R 1/8"
16 6 SWITCH ATTACH. STD. 74970 (SENSOR D=30)
18 1 SWITCH PAD h=10 1001482 1001482
21 1 BLOCKADING PIECE 43654 43654 FZB
22 4 NUT A4 76460 LOC-KING M8, Art. No. was 75090
23 6 WASHER A4 77798 BRB 8.4x16x1.6, Art. No. was 75328
24 3 BOLTING PLATE 48916 48916 FZB
26 3 COVER PLATE DEP4 79850 FZB
27 1 SENSOR PLATE ASSY. LEFT 1002453 1002453 FZB
Page 1 of 1
Article No: 1002946 TWISTLOCK ASSEMBLY date
Drawing No: 1002946 ISO, STD, RIGHT sign: PWH 2005-02-18
Serial No: - BGS rev: b / SC 2007-01-23
Customer: -
Standard: -
1 1 TWISTLOCK PIN 1000431 1000431
2 1 GUIDE BLOCK 1000430 1000430
3 1 SPHERICAL WASHER 41683 53968
4 1 TWISTLOCK ARM, ASSY. 43653 57059 TYPE 2
5 1 TWISTLOCK KEY 1000434 1000434
6 1 NUT 1000432 1000432 (M39x4-6H)
8 2 SPACER RING 41731 54049
10 1 BLOCKADING PIN 37704 37704 FZB
11 1 SPRING 70429 SF-TF 4.5x22x90 SS 1774-04
12 1 NUT LOCK-KING A4 77891 M12, Art. No was 75055
14 2 LOCK PIN 74044 R.R 3.0
18 1 SWITCH PAD h=10 1001482 1001482
21 1 BLOCKADING PIECE 43654 43654 FZB
22 4 NUT A4 76460 LOC-KING M8, Art. No. was 75090
23 6 WASHER A4 77798 BRB 8.4x16x1.6, Art. No. was 75328
24 3 BOLTING PLATE 48916 48916 FZB
27 1 SENSOR PLATE ASSY. RIGHT 1002454 1002454 FZB
A A
A-A
1:5
H:\DWG\A3\A38\38073A.dwg
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PERIODIC MAINTENANCE PROCEDURE
RUNNING-IN OF A NEW SPREADER
After 50 and 250 hours

1. Lubricate and check the various points as per the lubrication instructions.
2. Check the telescopic chain. Tighten if it can be moved more than r 25 mm

in vertical direction.
EVERY 100 WORKING HOURS Nut
1. Twistlock: Check the nut and the floating

mechanism and ensure that all parts are
properly tightened down. Check that the
locking pin can be moved easily and that it
indicates the correct position
(see 'Adjusting the locking pin').
2. Check that all hydraulic tank mountings are tight. Twistlock pin
3. Check that the hydraulic pump pressure is correct.
4. Carefully inspect all hoses, hose clips and hose connections. Defective
hydraulic hoses and connections may cause personal injury when jets of
liquid escape under high pressure.
5. Leaking hose connections and defective hoses should be rectified

immediately.
EVERY 1000 WORKING HOURS

Lubricate and check the various points as per the lubrication instructions.
CAUTION! When working on or in the vicinity of the spreader the electrical

supply to the spreader should be disconnected, if possible, to prevent
personal injury and material damage. This can be done using the main switch
or by disconnecting the power cable.
If the work requires that the electrical supply remains connected then staff on
or in the vicinity of the spreader must be informed that it could move.

rev. x
TWISTLOCK MAINTENANCE
Every 3000 working hours (100,000 containers handled2 or once annually3)
1. Dismantle all four twistlocks (eight on twin-lift- Nut

spreaders).
2. Inspect all parts. Look for any damage which

Spherical
necessitate their replacement. washer
3. Check that there are no cracks (or other faults)

in the threads of the twistlock pins or 'heads'.
Use penetrating fluid to detect fissures.
Twistlock
4. Replace the twistlock pin if cracks are detected. pin
5. Clean all parts.
6. Lubricate the parts.
7. Reassemble the twistlocks.
Every 6000 working hours (200,000 containers handled4 or every other

year5)
The twistlock pins and the spherical washers6 shall be replaced.
NOTE. See the twistlock drawing and/or the separate adjustment instructions
for the adjustment of the twistlock end stop switches after reassembly.
--------------------------
2
If the spreader is equipped with twistlock counter
3
If there is no hour counter or twistlockcounter
4
If the spreader is equipped with twistlock counter
5
If there is no hour counter or twistlock counter
6
Only for floating twistlocks

rev. x
PROCEDURE FOR ADJUSTMENT AND REPAIR
OF MAJOR ITEMS OF THE SPREADER
REPLACING THE HYDRAULIC PUMP
When ordering a new hydraulic pump always state the direction of rotation as
marked on the old pump housing.
To replace the hydraulic pump (free-standing pump unit):

1.Turn off the electrical supply using the main switch.
2. Disconnect the inlet , outlet hoses and drainhoses from the pump.
3. Reconnect the inlet and outlet hoses once the pump has been fitted.
4. Reconnect the drain hose to the pump.
5. See drawing no.45316 for setting the pump flow and pressure.
NOTE. Every time the pump is emptied, new oil must be added until it starts
to run out of the drain hose.
SHOCK RELIEF VALVES, general
These are cross over relief valves which relieves excess hydraulic pressure
caused by external forces on the flipper arms or the telescopic system. The
rising hydraulic pressure acts against the spring to open the flow path to the
other port.
All leakage’s through these valves at the normal operating pressure of the
pump (lower setting than the pump's operating pressure) cause a substantial
increase in the temperature of the hydraulic oil. Leaks of this type are often
indicated by a hissing sound coming from the relief valve.
Possible causes are:

* Slides jamming due to poor hydraulic oil
* Defective seals
* Incorrect pressure setting

rev. x
Locking
ADJUSTING THE TELESCOPIC CHAIN screws
(Drawing no. 38073)
1. Run the spreader to the maximum
position (40 foot).
Adjusting
2. Disconnect the power. nut
3. Remove the locking screws from
the adjuster nut.
4. Tighten the adjuster nuts on both sides
with a torque wrench to 50 Nm (37 ft-lbs.)
alternately one turn at a time . It is important Cotter pin
to adjust both sides equally. If not done
properly this could cause future problems
in operation and reduce the life of the chain. Chain lock
5. Reinstall the locking screws in the adjusting nut .
REPLACING A BROKEN CHAIN

If the chain should break and jump over the chain wheel, repair as follows:
1. Disconnect the electrical supply in the spreader control cabinet by turning

off the main switch.
2. Place the telescopic beams in the approximate position for a 30 foot

container using a fork lift truck or similar.
3. Turn the adjusting nut counterclockwise a quarter of a turn.
4. Remove the chain pin connected to the shock absorber by pulling out the
cotter pin.
5. Remove the chain.
6. Install a new chain or insert a joining link and reinstall the chain and the
adjusting nut.
7. Perform the steps described above (Adjusting the telescopic chain).
8. Connect the power supply and make a fine adjustment as per the
instructions in 'Setting the spreader length'.
9. Check the distance between the twistlocks as per the instructions in

Spreader lengths with different twistlocks'.
10. Lubricate the chain according to drawing 22808, Lubrication points.

rev. x
REPLACING ROBALON PLATES
Robalon plate in main frame
1. Extend the spreader to at least the 30 foot position.
2. Remove the locking plate and replace the Robalon plate.
Telescopic beam lower plates

1. Set the spreader to at least the 20 foot position.
2. Remove the electrical connectors from the electromagnetic telescopic

valves.
3. Operate the telescopic drive by manually pressing the valves until the
Robalon plate mounting bolts are accessible through the aperture in the
lower flange of the main beam. Replace the plates.
Telescopic beam upper plates

1. Set the spreader to at least the 20 foot position.
2. Remove the electrical connectors from the electromagnetic telescopic

valves.
3. Operate the telescopic drive by manually pressing the valves until the
Robalon plate mounting bolts are accessible.
4. Replace the plates.
DISMANTLING THE TELESCOPIC BEAMS AND END BEAM UNIT

If the telescopic beams require checking.
1. Start by removing all the Robalon plates from the ends of telescopic
beams. Leave the plates on the main frame in place.
2. Disconnect the power cables and the hydraulic hoses from the end units.
Seal all hydraulic hoses correctly.
3. Remove the stud from the drawbar connection in the end beam.
4. Take the weight off the end unit using a fork lift truck and extend the unit to
the 40 foot position.

rev. x
5. Secure a spacer between the telescopic beams to prevent lateral
movement.
6. Extract the beams from the main frame and inspect them as required.
6. Reassemble the beams and the end units in the reverse order to that in
the instructions above.
FLIPPER ARM UNIT (AUTOMATIC FLIPPER ARMS)
1. Remove the outlet plug to alter flipper arm speed.
NOTE. When replacing the flipper arm motor ensure that the outlet plug is
correctly positioned.
2. Removing and installing bearings
a) Remove the flipper arms
b) Remove the key
c) Drift out the shaft. Once the shaft has been removed the bearing will be
pushed out by the middle key.
d) Drift out the second bearing.
e) Install the parts in the reverse order to dismantle except for that both
bearings have to be drifted into position using a pipe of a suitable bore.

rev. x
ADJUSTING SPREADER LENGTH
Sensors:
a) Adjust the centre to centre distance Sensor
between twistlocks for each position
by moving the sensors.
b) For 30' check the centre to centre

distance between twistlock both when
extending and retracing the spreader.
The accurate distances between the
twistlocks are shown in ”Spreader
length with different twistlocks”. Sensor
plate
SPREADER LENGTH WITH TWISTLOCKS

BROMMA ISO Twistlock
20' 30' 40'
Floating: 5852 8918 11984
ADJUSTING THE LANDING PIN
a) Attach blockading pin clamps

at three of the corners.
b) At the fourth corner, press the

pin upwards.
c) When the lower part of the pin Landing

switch
is 6 - 7 mm from the bottom plate
of the corner, the lamp indicating
"spreader landed", shall go on.
d) If the distance is not correct, Landing pin

adjust the landing switch and
do the test again.

rev. x
e) Proceed in the same way for all four corners.
Twistlock
DISMOUNTING THE TWISTLOCK PIN nut
M6 nut
1. Dismout the twistlock cylinder as
M6 screw
described on the next page.
2. Remove the M6 screw and nut
from the top of the twistlock.
3. Grab hold of twistlock head.
4. Slack off the twistlock nut.
5. Lower the twistlock pin and guide Guide
block. neck
6. Do not lose the twistlock pin key.
Twistlock
MOUNTING housing
1. Perform the steps above in the Twistlock
reverse order. head
2. Carry out the adjustment below
3. before mounting the M6 screw and nut.
4. Lubricate according to instructions on drawing 22808, Lubrication points.
Distance between top of twistlock head

and bottom of guide block 1-2 mm
Checking the Float

1. Grab hold of the twistlock head.
2. Push or pull the twistlock to one of the corners.
3. Ensure the guide block is touching the twistlock
housing bottom plate. If not, the twistlock needs to be
adjusted /lowered.
4. If the twistlock is touching the bottom plate, press the
twistlock upwards while holding it in the corner. Twistlock nut
5. The twistlock should be moving up slightly. If it
moves a lot, adjust it higher. Spherical
6. If the twistlock does not move at all, it needs to be washer
adjusted down.
Adjusting Key
1. Remove the M6 screw from the top of the twistlock.
2. To lower the twistlock, loosen the twistlock nut
slightly. To raise the twistlock, tighten the nut.
The distance between the top of twistlock head and the Twistlock pin
bottom of guide block 1 -2 mm
3. Recheck the float of the twistlock.
4. Reinstall the M6 screw.
Twistlock
8 of 10 BROMMA CONQUIP AB
head
07 02 ENG
rev. x
Removing the Twistlock Cylinder
1. Make sure the power supply is disconnected
and the oil pressure is relieved from the
system. Split pin
2. Remove the hoses from the cylinder.
3. To avoid oil leakage, thread a plastic bag Spacer
over the end of the hoses and secure
ring
them with straps.
4. Pull out the split pins. Remove the spacer
rings and the cylinder.
Installing the Twistlock Cylinder

1. Perform the steps above in the reverse Cylinder
order.
2. The hoses must be tightened to 95 Nm
(70 ft-lbs) torque.
3. De-aerate the system by running the
cylinder several times.
Removing Sensors
1. Unscrew the cable connection from
the sensor.
2. Loosen the two screws on the switch
attachment. Signal
3. Remove the sensor. cable
Sensor connection
Installing Sensors
1. Perform the steps above in the reverse
order, using blue Loctite to the cable
connection.
2. The distance between sensor face and
flag is approximately 5-6 mm. Check
the sensor by grabbing the twistlock
head and moving it around in different
positions. If the signal is lost, adjust the
sensor closer to its flag. Make sure the
flag does not come in contact with
the sensor.

rev. x
Checking the tower motor brake
1. Disconnect the power.
2. Remove the crank from its stowed position in the tower.
3. Install the crank at the rear end of the
tower motor.
4. Place a torque wrench in the ½” socket on the crank
5. Adjust the torque to 65 Nm.
6. If the torque wrench releases as the 65 Nm torque is
reached, the brake adjustment is OK. If it does not release and
the motorshaft rotates, the brake must be adjusted.
See Inspection and maintenance of BGM8 Tower motor
at the end of this section.
Tower Crank
motor
75 Nm
Torque
wrench

rev. x
Inspection and maintenance periods 8
8 Inspection and Maintenance
•
•
•
•
8.1 Inspection and maintenance periods

Equ ipm ent/com po nen ts Frequency What to do ?
Inspecting the brake:
• Mea sure and set working air gap
BMG4 =Telescopic Motor Every Year • brake disc, lining
• P ressure plate
BMG8 = Tower Motor Every third month • C arrier / gearing
• P ressure rings
• E xtract the ab raded ma tter

• Inspect the switch elemen ts and
repla ce if necessary (e.g . in case o f
burn-out)
1
Bromma Manual
Important tightening torques EH5/EH170

Tower and
main frame
331Nm
165Nm
331Nm
331Nm
331Nm
End beam
68Nm 6.5 Nm
40Nm
Telescopic motor Telescopic motor

EH5 / EH170 EH5U / EH170U
331Nm
40Nm
331Nm
7-1- Sept. 10 rev.02 Bromma Conquip

Bromma Manual
Limit switch box

EH5 / EH170
91Nm
Twistlock Twistlock
EH5 / EH170 EH5U / EH170U
100 Nm
95 Nm
91Nm
Flipper motor and gearbox

250 Nm
after 200
test
cycles 331Nm
91 Nm
after 200
test cycles
Bromma Conquip 7-2- Sept. 10 rev.02

8 Inspection and maintenance of brake BMG 4 and 8
8.6 Inspection and maintenance of brake

BMG4 = Telescopic Motor
BMG8 = Tower Motor 9
8
7
6
5
4
3
2
22
21
e
10 20
c 19
b
a 18
17
16
15
14
11 12 13
2
Inspecting brake BMG 4 and 8 , setting the working air gap
1. Isolate the moto r and brake from the supply, safeguarding them against
un inten tional power -up.
2. Remove the following:
– If fitted, forced- cooling fan for
motor and brake maintenance.
– F lange co ver or fa n guard (21 ).
3. Pu sh the rubber sealing co llar (5) aside.
– R elease the clip to do this, if necessary .
– E xtract the abr aded ma tter.
4. Measure the brake disc (7 ):
If the brak e d isc is:
– ≤ 9 mm on b rake motors up to size 100 .(BMG4)
– ≤ 10 mm on bra ke motor s up to size 1 12.(BMG8)
Fit a new brake disc (→ Section "Ch anging brake disc on BMG 4 and 8
3
Inspection and maintenance of brake BMG 4 and 8 8
Changing thebrake disk BMG 4 and 8

When fitting a ne w brake disc, in spect the other removed pa rts as well and fit new one s
if nece ss ary
1. Iso late the moto r and brake from the supply,, safeguarding them against
un inten tional power -up.
– If fitted, forced coolin g fan
– F lange co ver or fa n guard (21 ), ci rclip (2 0) and fan (19).

3. Rem ove the ru bber sea ling colla r (5 ) an d the ma nual brake release:
– S etting nuts ( 18), con ica l coil sp rings (1 7), studs (16), rele ase lever (1 5), dowel
pin (1 4).
4. Unscr ew hex nuts (1 0e ), ca refully pull off the brake co il body (1 2) (brake ca ble!) an d
take out the brak e spr ings (11).
5. Rem ove the dam ping plate (9 ), pres sur e pla te (8) and brake disc (7, 7b) an d cle an
the br ak e com ponents .
6. Fit a ne w brake d isc.
7. Re- install th e br ake comp onents.
– E xcept fo r the r ubber sea ling colla r, fan and fan guard, se t the working air gap
(→ ”Inspe cting brake BMG 4 and 8, settin g the wor king air gap” , points 5
through 8)
8. With m anual brake r elease: Use se tting n uts to set the flo ating clear ance "s"
between the conical co il springs (pressed flat) an d the settin g nuts ( → following
illustration).
Brak e Floa ting clear ance s [mm]
BMG 4 and 8 2
Importan t: This flo ating clerance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not
gu ara nteed.
9. Fit the r ubber sea ling colla r ba ck in place and re-install th e dismantled pa rts.
Note: • T he locka ble man ual brake r elea s e ( type HF) is a lready r elea s ed if a re sistan ce is
encountered whe n ope rating the gr ub scre w.
• T he se lf-reengaging manual b rake re lea s e (type HR) ca n be operated with normal
hand pressu re.
Imp ortant: In brake motors with self-reengaging manual brake release, the
manual brake release lever must be removed after startup/maintenance. A bracket
is provided for storing it on the outside of the motor.
4
Changing Springs
1. Isolate the moto r and brake from the supply, safeguarding them against
un inten tional po wer -up.
– If fitted, fo rced -cooling fan ,
For motor and brake ma intenance .
– F lange cover or fa n guard (21 ), ci rclip (2 0) and fan (19).
3. Remove the ru bber sea ling colla r (5) an d the ma nual brake release:
– s etting nuts (18 ), conical coil sp rings (1 7), studs ( 16) , release le ver ( 15) , dowel
pin (1 4).
4. Unscrew he x nuts ( 10e ), pull o ff the co il body ( 12) .
– B y app rox. 50 mm (watch the bra ke ca ble!) .
5. Cha nge brake springs (11).
– P os ition the bra ke sp rings symme trically.
6. Re- install th e br ake components..
– E xcept fo r the r ubber sea ling colla r, fan an d fan gu ard,
set the wor king air ga p (→ ”Ins pecting brake BMG 4 and 8 setting the
working air gap ” , points 5 th rough 8)
7. With manual brake release: Use setting nuts to s et floating c learance "s" between
the co nical coil springs (pressed fla t) an d the setting nuts ( → following illustration.)
Brak e Floa ting clear ance s [mm]
BMG 4 and 8 2
Importan t: This floating clearance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not
gu aranteed.
8. Fit the rubber sealing colla r ba ck in place and re-install th e dismantled pa rts.
Note Fit new settingnuts (18) an d hexag on nuts ( 10e ) if the re moval pr oced ure is r epeated!
5
kVA n
9 f Work done, working air gap, braking torques of brake BMG 4 - 8
i
P Hz
9.3 Work done, working air gap, braking torques of brake BMG 4-8
Workin g air gap
Work do ne Br aking torque se ttings
[mm]
Brak e Fo r until
Br aking Type an d n o. of Order n umber o f
type motor size main tenance
[10 6 J] min. 1) ma x. torque springs spr ings
[N m] Nor mal Red Norma l Red
0.25 0.6
135 150 8 135 151 6

40 6 -
BMG 4 100 260
75 6 -
112M
BMG 8 600 0.3 1.2 184 845 3 135 570 8
132S
1)
Please note when checking the air gap:
Parallelism tolerances on the brake disk may give rice to deviation of ±0.1 after
a test run.
6
A ddres s lis t
C o n t a c t y o u r B R O M M A l o c a l r e p r e s e n t a t i v e o r S E W A ddres s es below.
G ermany
Headquarters B ruc hs al S E W-E UR ODR IV E G mbH & C o Tel. (0 72 51) 75-0
P roduc tion E rnst-B lickle-S traß e 42 F ax (0 72 51) 75-19 70
S ales D-76646 B ruchs al http://www.S E W-E UR ODR IV E .de
S ervic e P.O. B ox s ew@ s ew-eurodrive.de
P os tfach 3023 · D-76642 B ruchsal
P roduc tion G raben S E W-E UR ODR IV E G mbH & C o Tel. (0 72 51) 75-0
E rnst-B lickle-S traß e 1 F ax (0 72 51) 75-29 70
D-76676 G raben-Neudorf Telex 7 822 276
P.O. B ox
P os tfach 1220 · D-76671 G raben-Neudorf
A s s embly G arbs en S E W-E UR ODR IV E G mbH & C o Tel. (0 51 37) 87 98-30
S ervic e (near Hannover) Alte R icklinger S traß e 40-42 F ax (0 51 37) 87 98-55
D-30823 G arbs en s cm-garbs en@ s ew-eurodrive.de
P.O. B ox
P os tfach 110453 · D-30804 G arbs en
K irc hheim S E W-E UR ODR IV E G mbH & C o Tel. (0 89) 90 95 52-10
(near München) Domagks traß e 5 F ax (0 89) 90 95 52-50
D-85551 K irchheim s cm-kirchheim@ s ew-eurodrive.de
L angenfeld S E W-E UR ODR IV E G mbH & C o Tel. (0 21 73) 85 07-30
(near Düs s eldorf) S iemens s traß e 1 F ax (0 21 73) 85 07-55
D-40764 Langenfeld s cm-langenfeld@ s ew-eurodrive.de
Meerane S E W-E UR ODR IV E G mbH & C o Tel. (0 37 64) 76 06-0
(near Zwickau) Dänkritzer Weg 1 F ax (0 37 64) 76 06-30
D-08393 Meerane s cm-meerane@ s ew-eurodrive.de
Additional address es for s ervice in G ermany provided on reques t!
F ranc e
P roduc tion Haguenau S E W-US OC OME S AS Tel. 03 88 73 67 00
S ales 48-54, route de S oufflenheim F ax 03 88 73 66 00
S ervic e B . P. 185 http://www.us ocome.com
F -67506 Haguenau C edex s ew@ us ocome.com
A s s embly B ordeaux S E W-US OC OME S AS Tel. 05 57 26 39 00
S ales P arc d’a ctivité s de Magellan F ax 05 57 26 39 09
S ervic e 62, avenue de Magellan - B . P. 182
F -33607 P es s ac C edex
Lyon S E W-US OC OME S AS Tel. 04 72 15 37 00
P arc d’A f faires R oos evelt F ax 04 72 15 37 15
R ue J acques Tati
F -69120 Vaulx en Velin
P aris S E W-US OC OME S AS Tel. 01 64 42 40 80
Zone indus trielle F ax 01 64 42 40 88
2, rue Denis P apin
F -77390 Verneuil I’E t ang
Additional address es for s ervice in F rance provided on reques t!
A rgentina
A s s embly B uenos A ires S E W E UR ODR IV E AR G E NT INA S .A. Tel. (3327) 45 72 84
S ales C entro Indus trial G arin, Lote 35 F ax (3327) 45 72 21
S ervic e R uta P anamericana K m 37,5 s ewar@ s ew-eurodrive.com.ar
1619 G arin
A us tralia
A s s embly Melbourne S E W-E UR ODR IV E P T Y. LT D. Tel. (03) 99 33 10 00
S ales 27 B everage Drive F ax (03) 99 33 10 03
S ervic e Tullamarine, Victoria 3043
S ydney S E W-E UR ODR IV E P T Y. LT D. Tel. (02) 97 25 99 00
9, S leigh P lace, Wetherill P ark F ax (02) 97 25 99 05
New S outh Wales , 2164
A us tria
A s s embly Wien S E W-E UR ODR IV E G es .m.b.H. Tel. (01) 6 17 55 00-0
S ales R ichard-S traus s -S tras s e 24 F ax (01) 6 17 55 00-30
S ervic e A-1230 Wien s ew@ s ew-eurodrive.at
7
Address list
Belgium
Assembly Brüssel CARON-VECTOR S.A. Tel. (010) 23 13 11
Sales Avenue Eiffel 5 Fax (010) 2313 36
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Brazil
Production Sao Paulo SEW DO BRASIL Tel. (011) 64 60-64 33
Sales Motores-Redutores Ltda. Fax (011) 64 80 33 28
Service Rodovia Presidente Dutra, km 208 sew@sew.com.br
CEP 07210-000 - Guarulhos - SP
Additional addresses for service in Brazil provided on request!
Bulgaria
Sales Sofia BEVER-DRIVE GMBH Tel. (92) 9 53 25 65
Bogdanovetz Str.1 Fax (92) 9 54 93 45
BG-1606 Sofia bever@mbox.infotel.bg
Canada
Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. (905) 7 91-15 53
Sales 210 Walker Drive Fax (905) 7 91-29 99
Service Bramalea, Ontario L6T3W1 www.sew-eurodrive.ca
Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel. (604) 9 46-55 35
7188 Honeyman Street Fax (604) 946-2513
Delta. B.C. V4G 1 E2
Montreal SEW-EURODRIVE CO. OF CANADA LTD. Tel. (514) 3 67-11 24
2555 Rue Leger Street Fax (514) 3 67-36 77
LaSalle, Quebec H8N 2V9
Additional addresses for service in Canada provided on request!
Chile
Assembly Santiago de SEW-EURODRIVE CHILE Tel. (02) 6 23 82 03+6 23 81 63
Sales Chile Motores-Reductores LTDA. Fax (02) 6 23 81 79
Service Panamericana Norte No 9261
Casilla 23 - Correo Quilicura
RCH-Santiago de Chile
China
Production Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd. Tel. (022) 25 32 26 12
Assembly No. 46, 7th Avenue, TEDA Fax (022) 25 32 26 11
Sales Tianjin 300457
Service
Colombia
Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Tel. (0571) 5 47 50 50
Sales Calle 22 No. 132-60 Fax (0571) 5 47 50 44
Service Bodega 6, Manzana B sewcol@andinet.com
Santafé de Bogotá
Croatia
Sales Zagreb KOMPEKS d. o. o. Tel. +385 14 61 31 58
Service PIT Erdödy 4 II Fax +385 14 61 31 58
HR 10 000 Zagreb
Czech Republic
Sales Praha SEW-EURODRIVE S.R.O. Tel. 02/20 12 12 34 + 20 12 12 36
Business Centrum Praha Fax 02/20 12 12 37
Luná 591 sew@sew-eurodrive.cz
16000 Praha 6
Denmark
Assembly Kopenhagen SEW-EURODRIVEA/S Tel. 4395 8500
Sales Geminivej 28-30, P.O. Box 100 Fax 4395 8509
Service DK-2670 Greve http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Estonia
Sales Tallin ALAS-KUUL AS Tel. 6 59 32 30
Paldiski mnt.125 Fax 6 59 32 31
EE 0006 Tallin
8
Address list
inland
Assembly ahti SEW-EURODRIVE O Tel. (3) 589 300
Sales Vesim entie 4 Fax (3) 780 6211
Service FIN-15860 Hollola 2
reat Britain
Assembly ormanton SEW-EURODRIVE Ltd. Tel. 19 24 89 38 55
Sales Beckbridge Industrial Estate Fax 19 24 89 37 02
Service P.O. Box No.1
GB-Normanton, West- orkshire WF6 1QR
reece
Sales Athen Christ. Boznos Son S.A. Tel. 14 22 51 34
Service 12, Mavromichali Street Fax 14 22 51 59
P.O. Box 80136, GR-18545 Piraeus Boznos@otenet.gr
ong Kong
Assembly ong Kong SEW-EURODRIVE LTD. Tel. 2-7 96 04 77 + 79 60 46 54
Sales Unit No. 801-806, 8th Floor Fax 2-7 95-91 29
Service Hong Leong Industrial Complex sew@sewhk.com
No. 4, Wang Kwong Road
Kowloon, Hong Kong
ungary
Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06 58
Service H-1037 Budapest Fax +36 1 437 06 50
Kunigunda u. 18
ndia
Assembly Baroda SEW-EURODRIVE India Pvt. Ltd. Tel. 0 265-83 10 86
Sales Plot No. 4, Gidc Fax 0 265-83 10 87
Service Por Ramangamdi Baroda - 391 243 sew.baroda@gecsl.com
Gujarat
reland
Sales Dublin Alperton Engineering Ltd. Tel. (01) 8 30 62 77
Service 48 Moyle Road Fax (01) 8 30 64 58
Dublin Industrial Estate
Glasnevin, Dublin 11
taly
Assembly Milano SEW-EURODRIVE di R. Blickle Co.s.a.s. Tel. (02) 96 98 01
Sales Via Bernini,14 Fax (02) 96 79 97 81
Service I-20020 Solaro (Milano)
apan
Assembly Toyoda cho SEW-EURODRIVE APAN CO., LTD Tel. (0 53 83) 7 3811-13
Sales 250-1, Shimoman-no, Fax (0 53 83) 7 3814
Service Toyoda-cho, Iwata gun
Shizuoka prefecture, P.O. Box 438-0818
Korea
Assembly Ansan City SEW-EURODRIVE KOREA CO., LTD. Tel. (031) 4 92-80 51
Sales B 601-4, Banweol Industrial Estate Fax (031) 4 92-80 56
Service Unit 1048-4, Shingil-Dong master@sew-korea.co.kr
Ansan 425-120
u embourg
Assembly Brüssel CARON-VECTOR S.A. Tel. (010) 23 13 11
Sales Avenue Eiffel 5 Fax (010) 2313 36
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Macedonia
Sales Skopje SGS-Skopje / Macedonia Tel. (0991) 38 43 90
Teodosij Sinactaski Fax (0991) 38 43 90
6691000 Skopje / Macedonia
Malaysia
Assembly ohore SEW-EURODRIVE SDN BHD Tel. (07) 3 54 57 07 + 3 54 94 09
Sales No. 95, alan Seroja 39, Taman ohor aya Fax (07) 3 5414 04
Service 81000 ohor Bahru, ohor
West Malaysia
9
Address list
etherlands
Assembly Rotterdam VECTOR Aandrijftechniek B.V. Tel. +31 10 44 63 700
Sales Industrieweg 175 Fax +31 10 41 55 552
Service NL-3044 AS Rotterdam http://www.vector.nu
Postbus 10085 info@vector.nu
NL-3004 AB Rotterdam
e Zealand
Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. 0064-9-2 74 56 27
Sales P.O. Box 58-428 Fax 0064-9-2 74 01 65
Service 82 Greenmount drive sales@sew-eurodrive.co.za
East Tamaki Auckland
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. Tel. 0064-3-3 84 62 51
10 Settlers Crescent, Ferrymead Fax 0064-3-3 85 64 55
Christchurch sales@sew-eurodrive.co.nz
or ay
Assembly Moss SEW-EURODRIVE A/S Tel. (69) 2410 20
Sales Solgaard skog 71 Fax (69) 2410 40
Service N-1599 Moss sew@sew-eurodrive.no
Peru
Assembly ima SEW DEL PERU MOTORES REDUCTORES Tel. (511) 349-52 80
Sales S.A.C. Fax (511) 349-30 02
Service Los Calderos 120-124 sewperu@terra.com.pe
Urbanizacion Industrial Vulcano, ATE, Lima
Poland
Sales odz SEW-EURODRIVE Polska Sp.z.o.o. Tel. (042) 6 16 22 00
ul. Pojezierska 63 Fax (042) 6 16 22 10
91-338 Lodz sew@sew-eurodrive.pl
Portugal
Assembly Coimbra SEW-EURODRIVE, LDA. Tel. (0231) 20 96 70
Sales Apartado 15 Fax (0231) 20 36 85
Service P-3050-901 Mealhada infosew@sew-eurodrive.pt
Romania
Sales Bucuresti Sialco Trading SRL Tel. (01) 2 30 13 28
Service str. Madrid nr.4 Fax (01) 2 30 71 70
71222 Bucuresti sialco@mediasat.ro
Russia
Sales St Petersburg ZAO SEW-EURODRIVE Tel. (812) 3 26 09 41 + 5 35 04 30
P.O. Box 193 Fax (812) 5 35 22 87
193015 St. Petersburg sew@sew-eurodrive.ru
Singapore
Assembly SEW-EURODRIVE PTE. LTD. Tel. 8 62 17 01-705
Sales No 9, Tuas Drive 2 Fax 8 61 28 27
Service urong Industrial Estate Telex 38 659
Singapore 638644
Slovenia
Sales Celje Pakman - Pogonska Tehnika d.o.o. Tel. 00386 3 490 83 20
Service UI. IV. divizije 14 Fax 00386 3 490 83 21
SLO 3000 Celje pakman@siol.net
10
Address list
South Africa
Assembly ohannesburg SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. + 27 11 248 70 00
Sales Eurodrive House Fax +27 11 494 23 11
Service Cnr. Adcock Ingram and Aerodrome Roads ljansen@sew.co.za
Aeroton Ext. 2
ohannesburg 2013
P.O.Box 90004
Bertsham 2013
Capeto n SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. +27 21 552 98 20
Rainbow Park Fax +27 21 552 98 30
Cnr. Racecourse Omuramba Road Telex 576 062
Montague Gardens
Cape Town
P.O.Box 36556
Chempet 7442
Cape Town
Durban SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. +27 31 700 34 51
2 Monaceo Place Fax +27 31 700 38 47
Pinetown
Durban
P.O. Box 10433, Ashwood 3605
Spain
Assembly Bilbao SEW-EURODRIVE ESPA A, S.L. Tel. 9 44 31 84 70
Sales Parque Tecnol gico, Edificio, 302 Fax 9 44 31 84 71
Service E-48170 Zamudio (Vizcaya) sew.spain@sew-eurodrive.es
S eden
Assembly nk ping SEW-EURODRIVE AB Tel. (036) 34 42 00
Sales Gnejsv gen 6-8 Fax (036) 34 42 80
Service S-55303 önköping www.sew-eurodrive.se
Box 3100 S-55003 önköping
S itzerland
Assembly Basel Alfred lmhof A.G. Tel. (061) 4 17 17 17
Sales urastrasse 10 Fax (061) 4 17 17 00
Service CH-4142 M nchenstein bei Basel http://www.imhof-sew.ch
info@imhof-sew.ch
Thailand
Assembly Chon Buri SEW-EURODRIVE (Thailand) Ltd. Tel. 0066-38 21 40 22
Sales Bangpakong Industrial Park 2 Fax 0066-38 21 45 31
Service 700/456, Moo.7, Tambol Donhuaroh sewthailand@sew-eurodrive.co.th
Muang District
Chon Buri 20000
Turkey
Assembly stanbul SEW-EURODRIVE Tel. (0216) 4 41 91 63 + 4 41 91 64 + 3
Sales Hareket Sistemleri San. ve Tic. Ltd. Sti 83 80 14 + 3 83 80 15
Service Bagdat Cad. Koruma Cikmazi No. 3 Fax (0216) 3 05 58 67
TR-81540 Maltepe ISTANBUL seweurodrive@superonline.com.tr
SA
Production reenville SEW-EURODRIVE INC. Tel. (864) 4 39 75 37
Assembly 1295 Old Spartanburg Highway Fax Sales (864) 439-78 30
Sales P.O. Box 518 Fax Manuf. (864) 4 39-99 48
Service Lyman, S.C. 29365 Fax Ass. (864) 4 39-05 66
Telex 805 550
Assembly San rancisco SEW-EURODRIVE INC. Tel. (510) 4 87-35 60
Sales 30599 San Antonio St. Fax (510) 4 87-63 81
Service Hayward, California 94544-7101
Philadelphia PA SEW-EURODRIVE INC. Tel. (856) 4 67-22 77
Pureland Ind. Complex Fax (856) 8 45-31 79
200 High Hill Road, P.O. Box 481
Bridgeport, New ersey 08014
Dayton SEW-EURODRIVE INC. Tel. (9 37) 3 35-00 36
2001 West Main Street Fax (9 37) 4 40-37 99
Troy, Ohio 45373
Dallas SEW-EURODRIVE INC. Tel. (214) 3 30-48 24
3950 Platinum Way Fax (214) 3 30-47 24
Dallas, Texas 75237
11
Address list
SA
Additional addresses for service in the USA provided on request!
Venezuela
Assembly Valencia SEW-EURODRIVE Venezuela S.A. Tel. +58 (241) 8 32 98 04
Sales Av. Norte Sur No. 3, Galpon 84-319 Fax +58 (241) 8 38 62 75
Service Zona Industrial Municipal Norte sewventas@cantr.net
Valencia sewfinanzas@cantr.net
12
BrommaGroupManual
8  Spare parts and service
Spare parts list by major groups

rev.
KSI
eneral Assembly rev b 3/9/11
F/N Qty Name Title Title2 Specification

1012972 GENERAL ASSEMBL CAN-OPEN 1012972 b
1 1.0 1002141 FRAME EH170U CAN 0PEN 1002141 b
2 2.0 24142 TELESCOPIC BEAM UNIT - 24142 -
3 1.0 24161 TOWER - 24161 c
4 1.0 23854 TENSION ROD - 23854 a
5 1.0 23855 TENSION ROD - 23855 a
6 1.0 24143 FRAME - 24143 b
7 1.0 17023 TOWER STD. - 17023 b
8 2.0 1002945 TWISTLOCK ASS EMBL ISO, STD, LEFT 1002945 c
9 2.0 1002946 TWISTLOCK ASS EMBL ISO, STD, RIGHT 1002946 c
10 2.0 37409 CABLE CHAIN ASS . S 40/45E 37409 b
11 1.0 39047 TOWER CABLE CHAIN - 39047 a
12 2.0 17652 TWIN TWENT HOUSING MOUNT. ASSEMBL 17652 b
13 1.0 39311 H DRAULIC ASS EH 170 - 39311 -
14 2.0 34375 PUMP UNIT ASS . - 34375 f
15 1.0 39217 TWIN PUMP - 39217 b
16 2.0 24169 FLIPPER ARM ASS. - 24169 d
17 1.0 39055 GEARBO ASS - 39055 b
18 1.0 44768 GEARBO ASS . - 44768 e
19 1.0 17452 DECORATION EH5U / EH170U 17452 g
20 1.0 1002495 Electrical drawing SCS CANopen parallel interface 1002495 j
21 2.0 1001444 LED-PANEL MOUNT. DET. - 1001444 - 1001444 -
22 2.0 60633 IDENTIT SIGN729041214 44522 m
23 1.0 1002656 INPUT MODULE KIT 230VAC EH5-EH170 1002656 a
24 2.0 1002189 LED COVER ASS 1002189 - 1002189 -
Page - 1
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY
CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE

COPIED OR REPRODUCED WITHOUT THE WRITTEN
OF BROMMA CONQUIP AB. THE DESIGN AND OR
12 13 1 2 6 10
CONSENT OF THE OWNER.
5 9 4 3 14 7
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
DESIGNED TREATMENT SS-ISO 2768
Illtek 021029 EH5
PLOT DATE
SCALE REVISION
Spreader EH5 01
ARTICLE No
E DRAWING NUMBER
General assy
A Partek Company
SP-52000

48
3 33 47 4 32
1 49
35
36
37 50
16 20
26 34 17 10 21 14
7
39
43
38
8
39
9
2
24
15
29
11 23
5 43
6 44
38
22 43 44 20 38
28 43
41
18
38
12 43
31 46
25 39
40 38 36 43 42
30 19
38
43
39
45 27
TREATMENT SS-ISO 2768
DESIGNED Illtek 021029 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Tower DRAWING NUMBER
A Partek Company
SP-52001
EH5 Tower New standard
DRAWING SP-52001
PART NO DESCRIPTION QTY POS REMARKS
401517 GLIDE PLATE ASSY 1 0 Include pos.6,7,14,20
38863 TOWER CHAIN ASSY 1 0 Include pos. 5,9,11,12,15,23,24
24161 TOWER 1 1
1 SEE OTHER DRAWING 0 2 See SP-52002
51624 LIFTING SHAFT 90x334 1 3 Included in Pos 48
54662 LOCKING SHAFT ASSY 1 4 Included in Pos 48
71529 TUBE 1 1/2"CHAIN 4 5
39026 ROBALON PLATE LOWER 4 6
53137 GLIDE PLATE UPPER TOWER EH5 8 7
45476 CRANK ASSY EH5 1 8
401372 CHAIN ATTACHMENT 1 9
56242 CABLE CLAMP D=34 2 10
700737 CHAIN DUPLEX 1 1/2" 1 11
71520 CHAIN LOCK DUPLEX 1 1/2" 2 12
den 10 oktober 2002 Sida 1 av 4

401518 STEERING PIN 16 14
43075 LOCKING PLATE 12X12X40 1 15
401534 CABLE ATTACHMENT 4 16 Include pos. 10,17,21,26,34
401074 COVER PLATE 1 17
39171 BRACKET UPPER RIGHT 1 18
39174 BRACKET LOWER RIGHT 1 19
75497 SCREW MF6S 8X 35 FZB 10.9 32 20
78218 SCREW M6S 12X120 FZB 8.8 2 21
75051 SCREW M6S 20X 90 FZB 8.8 4 22
75713 SCREW MC6S 6X 30 FZB 8.8 1 23
700736 SCREW M6S 24x160 FZB 8.8 2 24
75052 NUT M20 LOC-KING FZB 4 25
75055 NUT M12 LOC-KING FZB DIN 985 2 26
39173 BRACKET LOWER LEFT 1 27
75292 WASHER BRB 21X36X3 FZB HB200 4 28
75268 WASHER NORD-LOCK M 6 FZB 1 29
39170 BRACKET UPPER LEFT 1 30

74339 WASHER TBRSB 21X52X8 FZB 4 31
72191 SCHACKLE "RAK GALV" 4 32 Included in Pos 48
85482 CHAIN HLZ 4.5-2 L=250 3 33 Included in Pos 48
75291 WASHER BRB 13X24X2.5 FZB HB200 4 34
54528 ATTACHMENT CABLE WAGON 1 35
75328 WASHER BRB 8.4X16X1.5 FZB HB2 10 36
75225 SCREW M6S 8X 22 FZB 8.8 2 37
75090 NUT M 8 LOC-KING FZB 16 38
70006 SCREW M6S 8X 35 FZB 8.8 16 39
401471 ANGEL BAR 1 40
401547 ANGLE BAR 1 42
70006 SCREW M6S 8X 35 FZB 8.8 5 44
401546 ANGLE BAR 1 45
24199 FRAME SCS2 1 46
700457 SNAP HOOK 1 47 Included in Pos 48
45596 LIFTING SHAFT ASSY 1 48 Include Pos. 3,4,32,33,47

46679 MOUNTING EL.CAB. 4 49 See also drawing SP-52013
24263 SPREADER CABINET TOWER 1 50


14 11 35 10 33 34 39 36 43 4
20
12
19 25
18
29 8
45 24
23
22
40 9
32 13
21
1 12 6
26
13
7 12
44 15
5
2 41
3
31 42
38
48 27
47
17 37 28 30 46 16
DESIGNED Illtek 021002 EH5 ll
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Tower gear box assy DRAWING NUMBER
A Partek Company
SP-52002
EH5 Tower Gearbox Assy
DRAWING SP-52002
58549 GEARBOX R97 ELM.BRAKE 360-404V 1 1 Part no for gearbox is 72157 and for only El motor is 58538
54659 MOTOR SHELF EH5 TOWER 1 2
52196 CHAIN COVER TOWER EH5 1 3
51233 COVERPLATE CHAIN WHEEL EH5 1 4
53129 CHAIN WHEEL TOWER EH5 25 1 5
36609 CHAIN WHEEL 2 6
34379 CHAIN WHEEL TOWER EH5 1 7
52150 TRANSMISSION SHAFT DIA 80 1 8
44756 SHAFT ASSY EH5 2 9
71328 GREASEFITTING NO.208 R1/8" 2 10
71546 BEARINGHOUSE SNL 518-615 2 11
71548 SEALING TSNA 518A TOWER 3 12 SEAL KIT
48188 DISTANS 4 13
71547 BEARING BUSH 2 14

71519 CHAIN 1 1/2" DUPLEX TOWER 1 15
71520 CHAIN LOCK DUPLEX 1 1/2" 1 16
70622 SCREW SK6SS 12X 12 14.9 1 17
71539 BEARING 22218 CCK W33 TOWER 2 18
71549 DISTANCE 4 19
74119 COVER BEARINGHOUSE ASNH518-615 1 20
51517 CHAIN WHEEL TOWER EH5 13 1 21
44196 LOCKING PLATE 1X20X46 2 22
75092 SCREW M6S 6X 20 FZB 8.8 4 23
76847 KEY 22X14X100 SMS2307 1 24
73965 KEY 22X14X100 SMS 2306 1 25
79513 KEY 18X11X100 RK 1 26
75225 SCREW M6S 8X 22 FZB 8.8 4 27
75286 SPRING PIN 5X30 FRP 1 28
70474 SCREW M6S 20X 80 FZB 8.8 4 29
75008 SCREW M6S 20X 70 FZB 8.8 1 30

76848 SCREW M6S 20X 90 FZB 8.8 FULLT 2 31
1 SEE REMARKS 1 33 CAP (SEW)
75051 SCREW M6S 20X 90 FZB 8.8 4 34
70477 SCREW M6S 16X 80 FZB 8.8 4 35
75225 SCREW M6S 8X 22 FZB 8.8 3 36
75285 LOCKING WASHER M20 1 37
70479 NUT M20 M6M FZB KLASS 8 2 38
70622 SCREW SK6SS 12X 12 14.9 1 41
44769 WASHER 1 44
70919 WASHER NORD-LOCK M20 4 45
71521 CHAIN LOCK1/2 LINK DUPL.1 1/2" 1 46



13
7
15 14
16
32
25
8 26
36
37
22
24
18 33
5 21
23 35
31
20 10 2
4 19 34
12 11
3
29
17
6 28
30
27
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Frame DRAWING NUMBER
A Partek Company
SP-52003
EH5 Frame
DRAWING SP-52003
16997 FRAME 1 1
43072 LIFTING LUG ASSY 4 2 Include pos.10,11,21,23,31,34,
401278 GLIDE PLATE FRAME 2 3 Included in Glide plate assy See drawing SP-52004
401401 FRAME COVER ASSY 4 4 Include pos.12,19,20
43036 GLIDE PLATE 80X40X20 1 5
401279 20´STOP ASSY 4 6 Include pos.17,27,28,29,30
1 SEE REMARKS 0 7 See lamp assy SP- 52010
401277 LANDING BUFFER ASSY 4 8 Include pos.25,26,32,36,37
1 SEE REMARKS 0 9 See Drawing SP 52006
47805 PLATE 1 10
38865 COVER 1 12
1 SEE REMARKS 0 15 See Electric drawing part list
48392 CLIP 3 16 Complete clip with screw,washer and nut

401281 SHIM 2 17
75497 SCREW MF6S 8X 35 FZB 10.9 2 18
75092 SCREW M6S 6X 20 FZB 8.8 2 19
54855 FLAT BAR 1 20
75051 SCREW M6S 20X 90 FZB 8.8 6 21
79830 WASHER SRB 14X28X2 FZB 2 25
49853 SLEEV 2 26
75607 SCREW M6S 12X 40 FZB 8.8 2 27
401280 20´BUFFER 1 28
401282 HOLDER FOR GLIDE PLATE 1 29
75295 WASHER NORD-LOCK M12 FZB 2 30
51110 LIFTING LUG WELD 1 31
76332 GREASE FITTING KR1/8 STRAIGHT 4 33

401276 BUFFER 1 36
79141 SCREW M6S 12X 35 FZB 8.8 2 37


17
19 25 16
15
18
2
10
11 9
13
20
12 3
24
15
14
10
22
21
23 1
6
5
7
8
4
6
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Beam DRAWING NUMBER
A Partek Company
SP-52004
EH5 Telescopic Beam
DRAWING SP-52004
38861 GLIDE PLATE ASSY 2 0 Include pos. 4,5,6,7,8 and pos 3 on drawing SP-52003
24142 TELESCOPIC BEAM ASSY 1 1 Assy with 2 Beams and 1 Gable end
62595 FLIPPER ARM 1 2 Please note! Rubber buffer not included, see item 11
44615 GLIDE PLATE LOWER 20X100X200 2 4
44614 GLIDE PLATE UPPER 25X100X250 2 5
75756 SCREW MF6S 12X 70 FZB 10.9 4 6
1 SEE REMARKS 3 10 See Drawing SP-52009
401528 BUFFER ASSY 1 11 Include pos.12,13,14,15,16
401529 BUFFER 1 12 Included in pos.11
401530 SHIM PLATE 2 13 Included in pos.11

75783 SCREW M6S 12X 50 FZB 8.8 2 14 Included in pos.11
75291 WASHER BRB 13X24X2.5 FZB HB200 4 15 Included in pos.11
75055 NUT M12 LOC-KING FZB DIN 985 2 16 Included in pos.11
51593 ATTACHMENT FLIPPER ARM B=45 1 17 Included in pos. 19
75330 SCREW MC6S 16X 50 FZB 8.8 2 18 Included in pos. 19
51593 ATTACHMENT FLIPPER ARM B=45 1 19 Include Pos.17, 18, 25.
76842 SCREW M6S 20X110 FZB 8.8 4 20
47678 SPACER (M20) 4 22
70918 WASHER NORD-LOCK M16 FZB 2 25 Included in pos. 19


15
2 3 38 53 54 55 231
47 10 13 12 16 17 59 19 58 40 41 23 65 37
4
34
57 49
35
33 32
56 42
43 7
24
45 61 18 14 51 14 25 28 22
11 39
44
31
62 60 20 28 29 30
46
8 9 74 63
27
26
36
71
68
72
67 73
52
64
69
69 70 66 65 70
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E DRAWING NUMBER
Hydraulic Assy End beam
A Partek Company
SP-52005
EH5 Hydraulic Assy
DRAWING SP-52005
76526 HYDRAULIC OIL ISO VG 32 50 50L OIL
56350 HOSE 821-04/KL 480/P86/P87 2 1
74564 COUPLING GE10-SR 3/8" 13 2
44447 COUPLING RESTRICT.GE10SR 1.2MM 3 3
71864 COUPLING SV10-S 6 4
71877 COUPLING GE12-SR 1/2" 2 5
79801 PRESSURE FILTER (50L) PI3605- 1 6
71297 FILTER INSERT 1 7
78371 SHOCK RELIF VALVE 140 BAR 3 8
76196 HYDRAULIC MOTOR INCL.CHOCKVALV 300CC 3 9 SEE DRAWING SP-52009 FOR MORE DETAILS
56360 HOSE 821-06/KL 580/P86/P86 1 10
24 June 2003 Sida 1 av 6

71872 COUPLING GE20-S 1 1/16"-12 UNF 2 11
71874 COUPLING GE12-S 9/16"-18 UNF 1 12
44553 DRAIN PIPE EH5 1 13
71764 COUPLING 3.5/28 1 14
78960 AIR BREATHER 3"MY" 1 15
71290 VALVE RHD12-S NON RETURN 2 16
73380 COUPLING EDKO 12-S 2 17
71320 HYDRAULIC PUMP PVQ10 1 18 WHEN YOU ORDER SEAL KIT FOR THIS PUMP PLEASE STATE K4264
72005 ELMOTOR 2.2kW 380/415/440/480 1 19
58016 HOSE 821-06/KL 460/P86/P86 1 20
56334 HOSE 821-06/KL 560/P86/P87 1 22
73096 VALVE DG4V-3-2C-MU-H7-60 4 23 WHEN YOU ORDER SEAL KIT PLEASE STATE PART NO K4222 AND SOLENOID 70422
700735 VALV BLOCK 1 24

75195 SCREW MC6S 8X100 12.9 DIN912 2 25
71871 COUPLING GE12-SR 3/8" 2 28
70157 COUPLING VSTI 3/8"-JE 4 29
56350 HOSE 821-04/KL 480/P86/P87 1 30
71866 COUPLING GE10-SR 1/4" 4 31
57419 HOSE 821-04/KL 630/P86/P86 2 32
56349 HOSE 821-04/KL 580/P86/P87 2 33
56348 HOSE 821-04/KL1720/P86/P87 2 34
56348 HOSE 821-04/KL1720/P86/P87 2 35
71343 SIGHT GLASS AS240 R 3/4" 2 36
56349 HOSE 821-04/KL 580/P86/P87 2 37

56350 HOSE 821-04/KL 480/P86/P87 2 38
56349 HOSE 821-04/KL 580/P86/P87 1 39
57425 HOSE 821-06/KL 770/P86/P86 1 40
75375 SCREW MC6S 5X 30 12.9 OBEH 16 41
44552 SUCTION PIPE EH5 1 43
45965 PLUG VSTIR 1/2" KOMPL. 1 44
71896 COUPLING KOR20-12-S 1 45
70084 COUPLING MÄTNIP.ST-04-R FORM A 1 46
79019 PLASTIC RING FOR COUPLI. 71764 1 51
46799 FLAP GB. EH130/600 2 52
34224 GASKET HYD.TANK EH5 1 53
39221 HYDR.TANK LID EH5 1 54

75212 SCREW M6S 6X 25 FZB 8.8 10 55
K3726 O-RING (HYDRV./BLOCK) 4 56
75294 WASHER BRB 10.5X22X2 FZB HB200 4 57
1 SEE REMARKS 1 58 KEY FOR MOTOR SHAFT ON EL.MOTOR PART NO 72005
1 SEE REMARKS 1 59 KEY FOR PUMP PART NO 71320
70040 SCREW SK6SS 6X 10 8.8 1 60
75290 SCREW M6S 10X 30 FZB 8.8 2 61
70403 CUP SPRING 23X10.2X1.25 D-2093 2 62
79281 PLUG IN BOX 8' OFF 1 63
75552 WASHER SRKB 7X25X1.5 FZB 6 64
401400 FLATBAR 1 65
401399 FLAP 1 66

44762 FLAT BAR 1 67
44760 FLAP EH5 1 68
75669 SCREW M6S 6X 30 FZB 8.8 14 70
75329 WASHER BRB 4.3X 9X0.8 FZB HB2 4 72
79265 SCREW MC6S 4X 25 FZB 8.8 4 73


8 6 5 2 7 18
26
25
1 7 4 5 7 3 9 10 13 15 16
12
11
23
22
19 20 14
24 17
21
28
27
30 29
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Gearbox Assy DRAWING NUMBER
A Partek Company
SP-52006
EH5 Telescopic Gearbox Assy
DRAWING SP-52006
53596 SHAFT 1 1
53603 DISTANCE 1 2
53604 DISTANCE 1 3
53605 DISTANCE 1 4
73562 BEARING 22212 CC W33 2 5
74243 LOCKING RING SGA 60 1 6
73573 RUBBER SEALING V-70A 3 7
53595 COVER 1 8
53594 COVER 1 9
75212 SCREW M6S 6X 25 FZB 8.8 12 10
700730 KEY 18X11X80 1 11
73564 KEY 18X11X 40 1 12
51515 CHAIN WHEEL E112-1-11 1 13
51664 WASHER 6X21X80 1 14

75285 LOCKING WASHER M20 1 15
75286 SPRING PIN 5X30 FRP 1 16
75289 SCREW M6S 20X 35 FZB 8.8 1 17
39055 GEARBOX ASSY TELESCOPIC 1 19 Include Pos.27-30
401287 PLATE 1 20
75008 SCREW M6S 20X 70 FZB 8.8 2 21
79785 SCREW M6S 10X 50 FZB 8.8 4 24
75294 WASHER BRB 10.5X22X2 FZB HB200 8 25
62345 EL MOTOR 3 KW BRAKE 230V 1 27
39059 GEARBOX KA87 1 28
79680 COUPLING GEARBOX+ELMOTOR KA87 1 29
77779 BRAKE ASSY 230V BM4 INCL.HR 1 30

Bromma roup Manual
Spare parts list for T istlock loating S

eft
Right
Aug 06 rev.02 Bromma Conquip 7.3.2.2 Twistlock Floating ISO Page 1

Bromma roup Manual
Page 2 7.3.2.2 Twistlock Floating ISO Bromma Conquip Aug 06 rev.02

Bromma roup Manual
SP P S PART DESCR PT T REMARKS TE

0 1002945 TWISTLOCK ASSY LEFT Items 4 and 27 excluded
0 1002946 TWISTLOCK ASSY RIGHT Items 28 and 29 excluded
1 1000431 TWISTLOCK PIN 1 *
2 0 GUIDE BLOCK 1
3 53968 SPHERICAL WASHER 1
4 57059 TWISTLOCK ARM, ASSY. 1 TYPE 2 Right
5 1000434 TWISTLOCK KEY 1 *
6 1000432 NUT 1 (M39x4-6H) *
7 1000600 SCREW 1 M6S 8x75 A4 *
8 54049 SPACER RING 2
10 37704 BLOCKADING PIN 1 FZB **
11 70429 SPRING 1 SF-TF 4.5x22x90 SS 1774-04 **
12 77891 NUT LOCK-KING 1 M12 A4 **
13 701440 WASHER NORD-LOCK 2 M12 A4 **
14 74044 LOCK PIN 2 R.R 3.0
17 1000596 SCREW 3 M6S 8x50 A4
18 1001482 SWITCH PAD h=10 1
19 1000585 SCREW 4 M6S 6x55 A4
20 1000587 SCREW 2 M6S 6x65 A4
21 43654 BLOCKADING PIECE 1 FZB
22 76460 NUT LOCK-KING 4 M8 A4 *
23 77798 WASHER 8 BRB 8.4x16x1.5 A4 *
24 48916 BOLTING PLATE 3 FZB
25 701081 WASHER NORD-LOCK 6 M6 A4
27 1002454 SENSOR PLATE ASSY. RIGHT 1 FZB
28 43653 TWISTLOCK ARM, ASSY. LEFT 1 TYPE 1 Included in 1002945 Tw istlock assy left
29 1002453 SENSOR PLATE ASSY. LEFT 1 included in 1002945 Tw istlock assy left
* 1001341 TWISTLOCK PI N KIT 1 Items 1, 5, 6, 7, 22, 23 included
* 1000987 BLOCKADING PIN KIT 1 Items 10, 11, 12, 13 included
Aug 06 rev.02 Bromma Conquip 7.3.2.2 Twistlock Floating ISO Page 3


6
7
9
13
10
3 4
S*
5
2
1
8
10
10
11 12
Single Sensor assembly SP10
6
9
7
10 13
15
4
S*
5
2
1
8
10
10 12
11
Dual Sensor assembly SP11
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Sensor Assy DRAWING NUMBER
A Partek Company
SP-52008
Single Sensor Assy Part no 38084 SP-52008
Pos Part no Description Qty Remarks
0 38084 SENSOR SINGEL ASSY 0 Include pos.2,3,4,5,6,7,8,9,10,11,12,13
1 38082 SINGLE SENSOR ATTACHMENT 1 Welded parts on frame
2 400267 PLATE 1
3 38087 PROTECTION PLATE 1
4 74970 CLAMP 04-430 PP 1
5 53951 PAD FOR SWITCH H=22 1
6 700647 SCREW M6S 6X 75 FZB 8.8 2
7 75268 WASHER NORD-LOCK M 6 FZB 2
8 75102 SCREW M6S 8X 30 FZB 8.8 2
9 75422 SCREW M6S 8X 25 FZB 8.8 2
10 75328 WASHER BRB 8.4X16X1.5 FZB HB2 6
11 75090 NUT M 8 LOC-KING FZB 4
12 76728 WASHER SRKB 9X28X2 FZB 2
13 79850 COVER PLATE DEP 4 1

Dual Sensor Assy Part no 38085 SP-52008
Pos Part no Description Qty Remarks
0 38085 DUAL SENSOR ASSY 1 Include pos.2,3,4,5,6,7,8,9,10,11,12,13
1 38083 DOUBLE SENSOR ATTACHMENT 0 Welded part on Frame
2 400267 PLATE 2
3 38086 PROTECTION PLATE 1
4 74970 CLAMP 04-430 PP 2
5 53951 PAD FOR SWITCH H=22 2
6 700647 SCREW M6S 6X 75 FZB 8.8 4
8 75102 SCREW M6S 8X 30 FZB 8.8 4
9 75422 SCREW M6S 8X 25 FZB 8.8 2
12 76728 WASHER SRKB 9X28X2 FZB 4
13 79850 COVER PLATE DEP 4 2


9
19
16
3
17
1
13
15
20 12
21 7
5
10 6
22
8
2
19
18 11 6 4
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Gearbox DRAWING NUMBER
A Partek Company
SP-52009
EH5 Flipper Gearbox Assy Part no 53275
DRAWING SP-52009
53275 GEAR BOX ASSY TYPE 1 1 0 Include pos.1-8,11-12,15-18 ( Pos.3 Drawn)
51176 GEAR HOUSING FLIPPER SMALL 1 1
55503 SHAFT FOR FLIPPER HOUSING SMALL 1 2
51177 COVER FOR FLIPPER HOUSING SMALL 1 3
54465 GEAR WHEEL 4-50-2541-03 1 4
54463 GEAR WHEEL 4-16-2541-03 1 5
54590 BUSHING FOR FLIPPERHOUSING 2 6
51284 BEARING FOR FLIPPERHOUSING 1 7
72010 KEY 20X12X 30 TK 3 8
76196 HYDRAULIC MOTOR INCL.CHOCKVALV 300CC 1 10
75049 SCREW MC6S 12X 40 FZB 8.8 1 11
70548 SCREW M6S 16X 55 FZB 8.8 1 12
79683 KEY 32X8X7 1 13

78493 SCREW MC6S 12X150 FZB 8.8 3 17
76922 VALVE BLOCK CHARLYNN 1 21
76915 SEAL KIT CHAR-LYN HYD.MOTOR 1 22

DRAWING SP-52009
60629 GEAR BOX ASSY TYPE 2 1 0 Include pos.1-8,11-12,15,17-20 ( Pos.3 Mirrow inverted)
54465 GEAR WHEEL 4-50-2541-03 1 4
54463 GEAR WHEEL 4-16-2541-03 1 5
72010 KEY 20X12X 30 TK 3 8
76900 GREASE FITTING R 1/8" 90GR 1 9
75049 SCREW MC6S 12X 40 FZB 8.8 1 11
70548 SCREW M6S 16X 55 FZB 8.8 1 12
79683 KEY 32X8X7 1 13

78493 SCREW MC6S 12X150 FZB 8.8 3 17

DRAWING SP-52009
60628 GEAR BOX ASSY TYPE 1 1 0 Include pos.1-8,11-12,15,17-20 ( Pos.3 Drawn)
54465 GEAR WHEEL 4-50-2541-03 1 4
54463 GEAR WHEEL 4-16-2541-03 1 5
72010 KEY 20X12X 30 TK 3 8
76900 GREASE FITTING R 1/8" 90GR 1 9
75049 SCREW MC6S 12X 40 FZB 8.8 1 11
70548 SCREW M6S 16X 55 FZB 8.8 1 12
79683 KEY 32X8X7 1 13

78493 SCREW MC6S 12X150 FZB 8.8 3 17

DRAWING SP-52009
56230 GEAR BOX ASSY TYPE 2 1 0 Include pos.1-8,11-12,15-18 ( Pos.3 Mirrow inverted)
54465 GEAR WHEEL 4-50-2541-03 1 4
54463 GEAR WHEEL 4-16-2541-03 1 5
72010 KEY 20X12X 30 TK 3 8
75049 SCREW MC6S 12X 40 FZB 8.8 1 11
70548 SCREW M6S 16X 55 FZB 8.8 1 12
79683 KEY 32X8X7 1 13

78493 SCREW MC6S 12X150 FZB 8.8 3 17


2
35
9 36 52
33 53
34 47
39
46
42
43
45 14
44
48
41
7 54
40
3 28
37 29
38 27
25 8
30
31
32
26
13
1 48
49
50 5
51
10 11 15 16
4
23 18 22 17 20 21 24 19
12
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Drive DRAWING NUMBER
A Partek Company
SP-52012
EH5 Telescopic Drive
DRAWING SP-52012
23855 TENSION ROD 1 1
16441 TELESCOPIC DRIVE ATT. ASSY 1 2 See Telescopic assy Drawing SP-52006
38073 CHAIN ASSY 2 3 Include pos.7,37,38
400242 TENSION ROD PIN ASSY 1 4 Include pos. 10,11,15,16
400244 END STOP ASSY 1 5 Include pos. 49,50,51,55
23854 TENSION ROD 1 6
61698 SHOCK ABSORBER 2 7 Includ pos.39,40,41,42,43,44,45,46,47,48,54
37409 CABLE CHAIN ASSY 1 8 Include pos.25,26,27,28,29,30,31,32
39047 CABLE CHAIN TOWER ASSY 1 9 Include pos.33,34,35,36
46744 SHAFT (TENSION ROD PIN ASSY) 1 10 Included in pos.4
400241 WASHER 1 11 Included in pos.4
38862 PEDESTAL BEARING 1 12 Include pos. 17,18,19,20,21,22,23,24
38084 SENSOR SINGEL ASSY 2 13 See Drawing SP-52008
38085 DUAL SENSOR ASSY 1 14 See Drawing SP-52008

75267 WASHER NORD-LOCK M 8 FZB 2 15 Included in pos.4
46773 SHAFT 1 17 Included in pos.12
46765 CHAIN WHEEL 1 18 Included in pos.12
73562 BEARING 22212 CC W33 2 21 Included in pos.12
73950 KEY 12X 8X 30 DIN 6885 B TK 1 22 Included in pos.12
74243 LOCKING RING SGA 60 2 23 Included in pos.12
71328 GREASEFITTING NO.208 R1/8" 1 24 Included in pos.12
37408 CABLE CHAIN 1 25 Included in pos.8
46771 GLIDE BLOCK 1 26 Included in pos.8
75499 SCREW MC6S 5X 16 FZB 8.8 2 27 Included in pos.8
75150 NUT M 5 LOC-KING FZB 3 28 Included in pos.8
75323 WASHER BRB 5.3X10X1 FZB HB200 3 29 Included in pos.8
79834 SCREW MC6S 5X 20 FZB 1 30 Included in pos.8
79835 SCREW MC6S 5X 12 FZB 1 31 Included in pos.8

75445 WASHER NORD-LOCK M 5 FZB 1 32 Included in pos.8
38996 CABLE CHAIN TOWER 1 33 Included in pos.9
75497 SCREW MF6S 8X 35 FZB 10.9 4 34 Included in pos.9
75328 WASHER BRB 8.4X16X1.5 FZB HB2 4 36 Included in pos.9
71512 CHAIN LOCK SIMPLEX 1 1/2" 177H 4 37 included in pos.3
47468 CHAIN SIMPLEX 1 1/2"177H 119 2 38 included in pos.3
53434 LINK SHOCK ABSORBER 1 39 Included in pos.7
59899 LINK L1=341 L2=381 1 40 Included in pos.7
59897 TUBE 35X2 L=196 1 41 Included in pos.7
53435 NUT SHOCK ABSORBER 1 42 Included in pos.7
74686 NUT M30 LOC-KING FZB KLASS 8 1 43 Included in pos.7
75293 WASHER BRB 6.4X12X1.5 FZB HB2 4 45 Included in pos.7
71529 TUBE 1 1/2"CHAIN 2 47 Included in pos.7
71686 CUP SPRING 71X36X4 No18 36 48 Included in pos.7

46757 SHIM 4 49 Include in pos.5
75267 WASHER NORD-LOCK M 8 FZB 2 50 Include in pos.5
78498 SCREW M6S 8X 40 FZB 8.8 2 51 Include in pos.5
70142 CLAMP 01-110 PP 2 52
75099 SCREW M6S 6X 40 FZB 8.8 2 53
71633 NUT M30 ML6M FZB 2 54 Included in pos.7
46743 END STOP 1 55 Include in pos.5

REV DESCRIPTION ECO-No. DATE BY
a One item 701016 and
Value 2008-10-14 PON
1001909 added
b No manufacturing change Value 2009-02-16 PON
1
A
A-A ( 1 : 2 )
9 6 2 4 3
7 10 5 8
A
SIGNED BY DATE MATERIAL SHEET WEIGHT TOLERANCE GENERAL
PON 2008-04-07 ALT. 1/1 11,3 kg SS-ISO 2768-c

FORMAT STANDARD REV.
CABINET X100 MOBILE SPREADER A1 b

DRAWING NUMBER
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY OF BROMMA CONQUIP AB. THE DESIGN AN OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE
COPIED OR REPRODUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.
C/C 430x150
1018972
ty ame Rev Type Title Title
E &DELQHW &$%,1(7;02%,/(635($'(5 &&[
F &DELQHW &$%,1(7; &&[
&RQQHFWRUVDQG7HUPLQDOV 02817,1*3/$7($66< -,%635($'(5
)DVWHQLQJ&RPSRQHQWV 6&5(:0&60[ $./$66
)DVWHQLQJ&RPSRQHQWV :$6+(5125'/2&.0 $
(QFORVXUHVDQG$FFHVVRULHV */$1'060PP 0[
&RQQHFWRUVDQG7HUPLQDOV (OHFWULFDOFRPSRQHQW *ODQGQXW06NLQGLFKW
REV DESCRIPTION ECO-No. DATE BY
RUBBER COVER ADDED
a Value 2008-09-30 PON
AND MOUNTING PARTS
b matrix update Value 2008-10-13 PON
MOUNTING PARTS FOR
c Value 2009-02-04 PON
RUBBER COVER CHANGED
A
1
A-A
6
B
2
A
a c 3
B (2:1)
7 8 9 2
SIGNED BY DATE MATERIAL SHEET WEIGHT TOLERANCE GENERAL
PON 2008-04-07 ALT. 1/1 7,35 kg SS-ISO 2768-c

FORMAT STANDARD REV.
CABINET X100 A2 c
DRAWING NUMBER
COPIED OR REPRODUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.

THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY OF BROMMA CONQUIP AB. THE DESIGN AN OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE
C/C 430x150
1018967
F/N Qty Name Title Title2
&$%,1(7; &&[
'225$66(0%/< ;
187/2&.,1*0 $',1./$66
(/(&75,&$/%2; :(/'$66(0%/<
9$/9(
/2&.,1*'(9,&( %HGQRU]9+1$15
/2&.,1*'(9,&( %HGQRU]&15
58%%(5&29(5 ;
6&5(:06[ $&/$66
:$6+(5$5%6 ./$66
0 1 2 3 4 5 6 7 8 9
A A
Cabinet X100
B B
Terminals for -M,-HL.

Marking 1,2,3......19.
Terminal fuses
C C
Marking 1,2,......7.
Shield plate CAN side / -M,-HL side
Sheild CANopen cable

D Terminal CANopen High D
Marking 1,2,......7
Terminal CANopen Low

Terminal 24V GND
Marking 1,2,......7
Marking 1,2,......7
E When stripping the CANopen cable, E
sheild should be max. 20mm

due to minimize electrical interference to CANopen
MACHINE TYPE: SHEET

- EH170 42
This drawing is copyright, and is SERIAL NO.
SCS² CANopen CONT.
- the property of BROMMA CONQUIP AB. - 43
F The design an or constructions CHECKED BY: Cable/ Sensor Layout TOTAL SH.
F
- 53
contained therein, may not be copied
or reproduced, whitout the written DRAWN BY: PLANT (=) : PLOTTED: DRAWING NO. REV.
- krpulha A1 2009-02-09 15:13
consent of the owner.
DRAWING DATE: UNIT (+) : FILENAME: 1002493 d
ITEM SUBJECT OF CHANGE SIGN. DATE 2009-02-09 X0
0 1 2 3 4 5 6 7 8 9

21 23 22 6 7 9
13
30
12
27
8 26
17 11
19
18 28
20
3
14
16
4
15
24
10 5
2 25
32 31 35 34 33 1 29
DESIGNED Illtek 031013 EH170 U
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Twinlift boxes DRAWING NUMBER
A Partek Company
SP-52014
17652 Twin Housing Assy
SP-DRAWING NO: 52014
SP-POS PART NO DESCRIPTION QTY REMARKS NOTE
1 17646 RETRACTABLE TWISTLOCK ASSY LEFT 1 See Drawing SP -52015
2 17607 RETRACTABLE TWISTLOCK HOUSE LEFT 1
3 17643 RETRACTABLE TWISTLOCK HOUSE RIGHT 1
4 39076 PIVOT PIN RETRACTABLE HOUSING 2
5 400887 PIN RETRACTABLE CYLINDER 2
6 23805 CYLINDER CONNECTION OFFSET LINK 2
7 400888 CYLINDER PIN 4
8 39909 TRIP/SLIDE WELDMENT LEFT HAND 1
9 39908 TRIP/SLIDE WELDMENT RIGHT HAND 1
10 39916 SENSOR MOUNTING BRACKET LEFT 1
11 39915 SENSOR MOUNTING BRACKET RIGHT 1
12 402534 SPACER 2
13 39891 CYLINDER 65/40-250 TWINL.EH170 2
14 78489 SCREW MC6S 12X180 FZB 8.8 2
15 75055 NUT M12 LOC-KING FZB DIN 985 8
16 75291 WASHER BRB 13X24X2.5 FZB HB200 4
den 19 november 2003 Page 1 of 2

17 74970 CLAMP 04-430 PP 8
18 75100 SCREW M6S 6X 45 FZB 8.8 8
20 79850 COVER PLATE DEP4 4
21 75052 NUT M20 LOC-KING FZB 2
22 700348 SHLD BOLT.D=24/M20X70 LG.12.9 2
23 70009 SPLIT PIN 3,2X25 8
24 74270 SPLIT PIN 3.2X63 FZB 4
25 75335 WASHER BRFB 26X45X4 FZB HB200 4
27 75294 WASHER BRB 10.5X22X2 FZB HB200 2
28 75783 SCREW M6S 12X 50 FZB 8.8 6
29 62907 RETRACTABLE TWISTLOCK ASSY RIGHT 1 See Drawing SP -52015
30 701244 WASHER TBRSUB 26X65X10 STEEL F 4
31 70145 CLAMP 02-218 PP (SIZE 2) 8
32 76914 CLAMP 02-214-PP 8
33 700646 SCREW M6S 6X 70 FZB 8.8 8


19 4
14 29 28 23 24 26 2
1
12
17 27 25
21 29
11
S*
13
20
15
30
6
19
25
26 18 8
24
23 10 16
22
5
31
S*
9 7
DESIGNED Illtek 031027 EH170 U
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Retractable Twistlock Assembly DRAWING NUMBER
A Partek Company
SP-52015
62907 Twin Twistlock Assy Right
SP-DRAWING NO: 52015
2 61751 SENSOR MOUNTING WELDMENT 1
4 62906 TRIP/SLIDE WELDMENT 1
5 402514 PLUNGER SENSOR TRIP 1
6 402515 BLOCKADING KEY 1
7 39879 BLOCKADING PIN 1
8 701243 SPRING 2X25X58 DIN2098 1
9 16060 TWISTLOCK PIN ISO 1
10 22238 GUIDE BLOCK ISO FLOATING 1
12 61687 CYLINDER ARM ASSY RIGHT 1
13 53968 WASHER SPHERICAL 20X69.5/42.5 1
14 44524 NUT M39 TWISTLOCK FLOAT. 1
16 75631 WASHER 22X34X4 FZB DIN 1440 1
17 74147 HYDRAULIC CYL. 32/20-100/85 1
18 71328 GREASEFITTING NO.208 R1/8" 2
19 74044 LOCK PIN R.R 3,0 2

20 402258 CYLINDER BOLT 1
21 402257 SPACER RING 1
22 700322 SPRING PIN 6X36 FRP 2
23 74970 CLAMP 04-430 PP 6
25 75100 SCREW M6S 6X 45 FZB 8.8 6
27 700647 SCREW M6S 6X 75 FZB 8.8 1
30 70918 WASHER NORD-LOCK M16 FZB 1
31 79098 KEY 12X 8X 20 TK DIN6885B 1

Bromma Group Manual
BGS Accessories
8.15 LED signal lamps
Application
Bromma telescopic spreaders can be equipped with LED
signal lamps to inform the crane driver and other personnel if
the sprader has landed, (white or yellow), is unlocked (green)
or has locked (red) on a container. For twinlift spreaders a
fourth lamp is used to indicate twinboxes down (blue). For
mobile harbour crane spreaders the fourth lamp indicates
- Low power consumption tower in mid position (yellow).
- No Phantom color effect Description

The Bromma LED lamp assy consists of an aluminum bottom
- Low maintenance plate and 1-4 LED lights. They are available in 24VDC or
110/230VDC versions. The 24VDC models are equipped
- Excellent durability with a M12 connector. The 110/230 models come with 10 m
connection cable with an open end. The LED Lamp assy also
includes attachment screws, washers and nuts (M8 FZB).
Available models
LED Colors voltage Art. No. Rec. cable
Green, red, yellow 24 VDC 1001399
70396 (M12 open end 10 m)

Green, red, white 24 VDC 1001400
Green, red, yellow, blue 24 VDC 1001401
Green, red, white, blue 24 VDC 1001402
✔ Blue 24 VDC 1001403
Green, red 24 VDC 1001404
Red, green, yellow 24 VDC 1001479

✔ Green, red, white, yellow 24 VDC 1001883
Green, red, yellow 110/230VAC 1001405

Green, red, white 110/230VAC 1001406
10m open end included
Green, red, yellow, blue 110/230VAC 1001407
Green, red, white, blue 110/230VAC 1001408

Blue 110/230VAC 1001409
Green, red 110/230VAC 1001410
Red, green, yellow 110/230VAC 700919
Green, red, white, yellow 110/230VAC 1001884
0-1- June. 06 rev.00 Bromma Conquip

Bromma Group Manual
Technical specifications
Model 24VDC 110/230VAC
Voltage range 21--30 VDC 100-240 VAC 50/60 Hz

Power consumption per light aspect 3.2 W 2.5 W
Light intesity per light aspect (clear cupola) 40 cd 30 cd
Ambient air temperature from -40OC to +55OC

Relative humidity up to 98% at temperature up to +35OC
Salt mist conditions IEC 60068-2-11
Mechanical wibration 10-50 Hz with acceleration up to 10 g
Ingress protection IP68 (IEC 60529)
Material Cupola Hi tech polycarbonate Makrolon ®
Material Bottm plate 10 mm aluminum alloy powder coated (RAL9005)
Dimensions
Light
aspects A (mm) B (mm)
1 160 130
2 305 275
3 450 420
4 595 565
Spare parts
SP-POS PART NO. DESCRIPTION QTY REMARKS
1 75102 Screw M6S 8x30 4 FZB 8.8
2 75328 Washer BRB 8,4x16x1,5 8 FZB HB2
3 75090 Nut M8 LOC-KING 4 FZB
4 see page 1
5 1001415 Attachment stright 2 per LED
6 1002903 Attachment tilted 300 2 per LED
70396 Cable 10m for 24VDC
Warnings
CAUTION: LED light units are sources of bright light. Do
not stare directly into the beam from close distances and
observe all the warnings and guidelines in the instruction
manual. Bromma LED indicator panels are classified as
Class 2M LED devices according to the standard
IEC60825-1:1993+A1:1997+A2:2001.
Bromma Conquip 8.15-2- Sept. 06 rev.01

Page 1 of 1
Article No: 1001444 LED-PANEL MOUNT. DET. date
Drawing No: 1001444 - sign: BNM 2004-04-19
Serial No: 7004-18 STS 45 rev: -
Customer: HNN / Antwerpen
Standard:
1 4 SCREW M6S 8x30 FZB 8.8 75102
2 8 WASHER BRB 8,4x16x1,5 FZB HB2 75328
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
x +RZWRRUGHUVSDUHSDUWVDQGRUVHUYLFH
All ordering of Bromma spare parts must be done by the Bromma e-commerce
website. To order the requested spare parts some important information must be
available.
The serial no. of the spreader. See Data Sheet chapt. 3or the dataplate mounted on
main frame of the current spreader.
The requested Art no. and the quantity needed. See Spare part list.
Registered User
To be able to log in at the Bromma e-commerce site you must be a registered user.
To become a registered user you have to fill in the Application Form on the Bromma
website. After a few days you will receive an User ID and a password by e-mail.
When you are a regitered user fill in your User ID and password at the fields on the
Bromma e-commerce website (www.bromma.com) to log in. Then follow the
instructions on the screen.
Search Function
If you do not find the parts requested on the e-commerce site or if you have any other
problems finding valid part numbers you can use the search function on the website
or call your local Bromma dealer. The phone number is published on the website
at www.bromma.com

FOR SERVICE AND SPARE PARTS PLEASE CONTACT YOUR LOCAL
DEALER

7RDYRLGGDPDJHWRSURSHUW\RUSHUVRQDOLQMXU\ZKHQUHSODFLQJSDUWVDOZD\V
XVH BROMMA CONQUIP RULJLQDOSDUWV
BROMMA CONQUIP 08 02 ENG

rev.3
9  Hydraulic circuit diagrams

rev.
BrommaGroupManual
10  Electrical wiring diagrams

rev

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9 91 891 9 9 $"#-& Y NNò/&0'-&9 "9
9 91 891 9 9 $"#-& Y NNò/&0'-&9 "9
9 91 891 1& 9 9 1& $"#-& Y NNò/&0'-&9 "9
9 91 891 #308/ 9 9 $"#-& Y NNò163 "9
9 91 891 #-6& 9 9 $"#-& Y NNò163 "9
9 91 1& 891 1& 9 9 1& $"#-& Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-$0/5"$501&/&/% Y NNò163 "9
9 91 891 8IJUF 9 9 $"#-&10-$0/5"$501&/&/% 99 9 HOZO "9
9 91 891 #SPXO 9 9 $"#-&10-$0/5"$501&/&/% 99 9 HOZO "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
."$)*/&5:1& 4)&&5
&)6
4$4ò$"/PQFO $0/5

1-055&% %3"8 */(/0 3&7
$3&"5&% 450$,)0-.48&%&/
NVIBNB[
DPOTFOUPGUIFPXOFS
%3"8 */(%"5& 6/*5
'*-&/".& K

'30. 1*//P $"#-& $03& 50 5&3.*/"-/P 5:1& "35/3 25: 4)&&5
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 1& $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 1& $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 891 9 9 1& $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 91 1& 891 1& 9 9 1& $"#-&10-)54$0/5"$501&/&/% Y NNò163 "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: # 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: " 9 91 $"#-&$0//&$503 . ."OH5XJOTVQQSFTT7%$ "9
9 : 8:: 9 91 $"#-&$0//&$503 . ."/(-&58*/46113&440347%$ "9
9 : 8:: 9 91 $"#-&$0//&$503 . ."/(-&58*/46113&440347%$ "9
9 : 8:: 9 91 $"#-&$0//&$503 . ."/(-&58*/46113&440347%$ "9
9 : 8:: 9 91 $"#-&$0//&$503 . ."/(-&58*/46113&440347%$ "9
# 919 ,&: 8) # 919 *%&/5*'*$"5*0/,&:'034$4ò "9
."$)*/&5:1& 4)&&5
&)6
4$4ò$"/PQFO $0/5

1-055&% %3"8 */(/0 3&7
$3&"5&% 450$,)0-.48&%&/
NVIBNB[
DPOTFOUPGUIFPXOFS
%3"8 */(%"5& 6/*5
'*-&/".& K

'30. 1*//P $"#-& $03& 50 5&3.*/"-/P 5:1& "35/3 25: 4)&&5
# 919 ,&: #/ # 919 *%&/5*'*$"5*0/,&:'034$4ò "9
# 919 ,&: (/ # 919 *%&/5*'*$"5*0/,&:'034$4ò "9
# 919 891 XIJUF 9 91 $"#-& $BO0QFOYY Y "9
# 919 891 CSPXO 9 91 $"#-& $BO0QFOYY Y "9
9 & 891 4IFJME 9 891 $"#-& $BO0QFOYY Y "9
."$)*/&5:1& 4)&&5
&)6
4$4ò$"/PQFO $0/5

1-055&% %3"8 */(/0 3&7
$3&"5&% 450$,)0-.48&%&/
NVIBNB[
DPOTFOUPGUIFPXOFS
%3"8 */(%"5& 6/*5
'*-&/".& K

Page 1 of 1
Article No: 1002656 Customised no. date

PDF No: . 230VAC SCS² sign: BLN 7/2/2004
Serial No: . with CANopen rev: a
SW .
Customer: .
Item Quant Title Specification Dwg/PDF No. Art. No. Remarks

1 13 Input module 1001747
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
BrommaGroupManual
0 1 2 3 4 5 6 7 8 9
A A
BROMMA
MALAXGATAN 7
SE-164 2 KISTA
SWEDEN
Email: SALES@BROMMA.COM
Tel: +46 (0)8 620 09 00
B B
Customer : CABINET X1
Plant designation : A1
C C
Drawing Number : 1002177
Revision : l
Manufacturer (Company) : BROMMA
Project name : 1002177 CANopen L

D D
Serial Number : -
Type : EH170U
Responsible for project :
E E
Created on the : 08/07/2010
The latest revition : 08/07/2010 By : chanka Number of pages : 24
Manufacturing site :
MACHINE TYPE: SHEET

- EH170U 1
Electrical cabinet X1 CANopen CONT.
F The design and/or constructions CHECKED BY: Flyleaf TOTAL SH.
F
- 24
- STOCKHOLM SWEDEN aveklle 08/07/2010 14:33
DRAWING DATE: UNIT (+) : FILENAME: 1002177 l
ITEM SUBJECT OF CHANGE SIGN. DATE 09/19/2001
0 1 2 3 4 5 6 7 8 9
Table of content
Plant des. Location Page Page description Rev Revision note Date Editor
1 Flyleaf 2007-06-15 aveklle
2 Table of contents 2009-04-01 krpulha
A1 X1 3 Circuit diagram 2005-06-11 BLN
A1 X1 4 Circuit diagram 2007-06-15 aveklle
A1 X1 5 Circuit diagram 2008-09-03 filipiv
A1 X1 6 Circuit diagram 2005-03-22 LAT
A1 X1 7 Circuit diagram 2005-03-22 LAT
A1 X1 8 Circuit diagram 2009-04-01 krpulha
A1 X1 11 Circuit diagram 2008-05-20 filipiv
A1 X1 13 Cabinet layout 2009-04-01 krpulha
A1 X1 14 Cabinet layout 2008-09-22 filipiv
A1 X1 15 Cabinet layout 2007-06-15 aveklle
A1 X1 18 Cabinet layout 2009-04-01 krpulha
A1 X1 19 Cabinet layout 2005-01-03 LAT
A1 X1 20 Sign Plate 2005-01-03 LAT
A1 X1 21 PLC diagram 2009-04-01 krpulha
A1 X1 22 I/O card overview 2009-04-01 krpulha
23 Parts list: (38906 - 79043) 2008-09-01 filipiv
24 Parts list: (79043 - 79371) 2008-09-01 filipiv
MACHINE TYPE: SHEET

EH170U 2
the property of BROMMA CONQUIP AB. - 3
The design and/or constructions CHECKED BY: Table of contents TOTAL SH.
24
STOCKHOLM SWEDEN
krpulha 08/07/2010 14:33
11/02/2001
0 1 2 3 4 5 6 7 8 9
A NOTE: A
Wire for 380-400VAC
shall bee 2,5mm²
with black colour.
-X2 :L1 :L1 :L2 :L2 :L3 :L3 :PE :PE
1 1
B 1 3 5 1 3 5 -F1 -P1 h B
2A 2 2
-QM8 I> I> I> -QM1 I> I> I>
2 4 6 2 4 6
1 3 5
-Q1
2 4 6
1 3 5
-K1
/5.01 1 3 5 1 3 5 1 3 5 1 3 5
2 4 6 -K8 -K9 -K2 -K3
/7.04 2 4 6 /7.05 2 4 6 /7.01 2 4 6 /7.02 2 4 6
C C
-XP23 PE 20 21 22 7 8 9 -X2 :1 :2 :3
D D
/4.00 / -Phase L1
/4.00 / -Phase L2
/4.00 / -Phase L3
E E
-M4 -M1 Time

. 3 Phase . . . . .
Telescopic motor Gravity point motor counter
MACHINE TYPE: SHEET

- EH170U 3
F The design and/or constructions CHECKED BY: Circuit diagram TOTAL SH.
F
- 24
- STOCKHOLM SWEDEN BLN A1 08/07/2010 14:33
ITEM SUBJECT OF CHANGE SIGN. DATE 03/22/2002 X1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
NOTE:
A Wire for 380-400VAC A
shall bee 2,5mm²
with black colour.
-X2 :101 :103 :102 :104

/3.01 / -Phase L3
/3.01 / -Phase L2
/3.01 / -Phase L1
B 14 12 24 22 B
-KA1 -KA1
/5.07 /5.07
11 21
1 3 5
1 3 5
-K6
/7.03 2 4 6
-QM10 I> I> I>
2 4 6
L
C -EH1 C
1 3 5 1 3 5
N
-QM6 -QM7 1 3 5
I> I> I> I> I> I> -K10
/7.06 2 4 6
2 4 6 2 4 6
-XP23 1 2 3 4 5 6 10 11 12
D D
E E
-M2 -M3 -M5 -EH1

Hydralic pump Hydralic pump Hydraulic pump Cabinet heater
left right twin .
MACHINE TYPE: SHEET
- EH170U 4
F
- 24
- STOCKHOLM SWEDEN chanka A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
NOTE:
All 24vdc supply should be ring Connected
-X2 :107 :105 :108 :106
13
-Q1
/3.01 14
B B
1 3
-F2 -X2 :N
10A 2 4
:N -N.VAC / /10.00
.01
21 :L
-SS1 -L.VAC / /8.00
22
-X2 :L
GND
L N
C C
BN YL/GL BU
90-255VAC -G1 A1
---- -KA1
A2 A2
24VDC
-K1
A1
RD RD BK BK
-24VDC SCS² / /12.00
+ + - -
-24VDC / /6.00
D -0VDC / /7.00 D
11
-SS1
.01 12
NOTE:
-X1 Wire for 24VDC
:2 7 8
.01
shall bee 2,5mm²
:1 with blue colour.
-X1 :3 -K1 :+ :+ :+ :+ :+ :+ :+ :- :- :- :- :- :- :-
-XP21 1 2 3 4 5 6 7 8 9 10
14
11/4.07
E 1 2 /3.01 12 E
24
3 4 /3.01 21/4.07
22
5 6 /3.01
7 8
/11.00 / -Spreader stop

.04
Spreader -KA1
. 24VDC . + 24VDC 0 VDC . .
stop Cabinet heater
MACHINE TYPE: SHEET

- EH170U 5
F
- 24
- STOCKHOLM SWEDEN filipiv A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
-B1 COMMON GROUP 1 COMMON GROUP 2
O O O O O O O O
A I 1 I 2 I 3 I 4 I 5 I 6 I 7 I 8 A
PIN NO: 21
PIN NO: 44
+B1-XPX1 :44 :31 :41 :43 :42 :21 :3 :2 :11 :1
/5.08 / -24VDC -24VDC / /7.00

B B
C C
-XP23 13 14 15 16 17 18 19
D D
E E
HL1 HL2 HL3 HL4,8 HL5 HL6 HL7 Not

Unlocked left Locked left Landed left Tower in centre left/right Unlocked right Locked right Landed right connected
MACHINE TYPE: SHEET

- EH170U 6
F
- 24
- STOCKHOLM SWEDEN LAT A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
O O O O O O O O
A I 9 I 10 I 11 I 12 I 13 I 14 I 15 I 16 A
PIN NO: 21
PIN NO: 44
+B1-XPX1 :8 :26 :16 :6 :7 :35 :4 :5 :25 :15
/6.09 / -24VDC -24VDC / /8.00

B B
C C
A1 A1 A1 A1 A1 A1
-K2 -K3 -K6 -K8 -K9 -K10
A2 A2 A2 A2 A2 A2
D D
/5.08 / -0VDC
-0VDC / /8.00
1 2 /3.07 1 2 /3.08 1 2 /4.01 1 2/3.04 1 2 /3.05 1 2 /4.05

E 3 4 /3.07 3 4 /3.08 3 4 /4.01 3 4/3.04 3 4 /3.05 3 4 /4.05
E
5 6 /3.07 5 6 /3.08 5 6 /4.01 5 6/3.04 5 6 /3.05 5 6 /4.05
K2 K3 K6 K8 K9 K10
Not Not
Gravity point Gravity point Hydralic pump Retract Extend Hydraulic pump
connected connected
to left to right left/right gable telescope telescope twin
MACHINE TYPE: SHEET
- EH170U 7
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
O O O O O O O O
A I 17 I 18 I 19 I 20 I 21 I 22 I 23 I 24 A
PIN NO: 9
PIN NO: 50
+B1-XPX1 :9 :10 :20 :30 :40 :50 :46 :47 :49 :48
/5.08 / -L.VAC -L.VAC / /9.00
B B
/7.09 / -24VDC -24VDC / /11.00
C C
-X2 :133
D D
1
-P2
2
/7.09 / -0VDC -0VDC / /11.00
E E
Twin legs down Not Not Not Container Not Not Not
signal connected connected connected counter connected connected connected
MACHINE TYPE: SHEET

- EH170U 8
F
- 24
- STOCKHOLM SWEDEN krpulha A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
O O O O O O O O
A I 25 I 26 I 27 I 28 I 29 I 30 I 31 I 32 A
PIN NO: 43
PIN NO: 11
+B1-XPX3 :11 :21 :31 :41 :42 :43 :24 :35 :44 :45
/8.09 / -L.VAC
B B
C C
-X2 :109 :110 :111 :112 :113 :114 :115 :116
D D
E E
Locked Unlocked Spreader landed G.p. in centre G.p. at left G.p. at right H.I.S TTDS ok
signal signal signal signal signal signal signal (option) signal (option)
MACHINE TYPE: SHEET

- EH170U 9
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B B
C C
-X2 :117 :118 :119 :120 :121 :122 :123 :124
D D
/5.08 / -N.VAC -N.VAC / /11.00
+B1-XPX3 :1 :5 :4 :3 :2 :15 :6 :16 :25 :26
-B1
E I I I I I I I I
E
O 33 O 34 O 35 O 36 O 37 O 38 O 39 O 40
PIN NO: 1
PIN NO: 15
COMMON GROUP 9 COMMON GROUP 10
Telescope Telescope Flippers Flipper Flipper Flipper Flipper

Not
retract expand all up waterside down right down left down landside down
connected
CMD CMD CMD CMD CMD CMD CMD
MACHINE TYPE: SHEET
- EH170U 10
F
- 24
- STOCKHOLM SWEDEN aveklle A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B B
C C
-X2 :125 :126 :127 :128 :131 :132
/8.09 / -24VDC
/5.00 / -Spreader stop GRAV.POINT

13
-SB1 AUT. RETURN
OFF ON
14
D D
/8.09 / -0VDC -0VDC / /12.00
/10.08 / -N.VAC
+B1-XPX3 :36 :49 :48 :47 :46 :8 :7 :10 :9 :40 :50 :30 :20
-B1
E I I I I I I I I
E
O 41 O 42 O 43 O 44 O 45 O 46 O 47 O 48
PIN NO: 8
PIN NO: 36
PIN NO: 10
PIN NO: 40
PIN NO: 20
COMMON GROUP 11
Twl Twl G.p. G.p. Twin legs Twin legs

Spreader G.p.
lock unlock move to left move to right up down
stop auto return
CMD CMD CMD CMD CMD CMD
MACHINE TYPE: SHEET
- EH170U 11
F
- 24
- STOCKHOLM SWEDEN filipiv A1 08/07/2010 14:33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B B
-X2 :129 :130
C C
-XP22 2 3
-WXP22 white brown

EEPROM
-E2
/11.09 / -0VDC
D D
/5.08 / -24VDC SCS²
WH
WH;BN
BN;GN
GN
RED
-KEY1
BLUE
BLACK
GREEN
6 16 26 36
+B1-XPX2 :42 :43 :44 :45 :10 :9 :19 :29 :39 :49 :30 :40 :50 :20 :48 :6 :16 :26 :36
-B1
E E
SD
SC
ID0
ID1
ID3
ID4
ID5
VCC
GND
GND
GND
GND
+24V
+24V
B-Can L
B-Can H
Can-GND
Can-open L
Can-open H
Main supply Node

. . B-Can Can-open EEPROM .
node B1 Address
MACHINE TYPE: SHEET

- EH170U 12
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A
Internal layout X1 cabinet EH170U A
B
B1 B
290mm
XP1 XP2 XP3 Rubber boot
Distance between cable

trunk and edge 45mm
C 30x90x640mm C
X1
/4.01 /4.03 /3.04 /3.07
/7.04 /7.01 /8.05
/7.03
740mm
30x90x115mm
-K6 -K8 -K2
-QM6 -QM7 -QM8 -P2
-QM1
D D
30x90x490mm
G1
-F1 2A /3.09 -EH1
/5.01 /4.05
/5.02 /5.07 /7.06
30x90x380mm
10A
Power supply -F2
/3.09
-KA1 -K10
-K1 -QM10
-P1 X2
E E
15mm 60x90x520mm
40mm
733mm
MACHINE TYPE: SHEET
- EH170U 13
F The design and/or constructions CHECKED BY: Cabinet layout TOTAL SH.
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B 1 B
101-134
106 105 108
L1-L3
Even number on top
L
N
1-3
2-3
+ -
C C
D D
Blue
X1 X2 Link by Jumper.
Based on main elec. drawing
E (106-105) for Liebherr E
and (108-105) for Gottwald.
MACHINE TYPE: SHEET

- EH170U 14
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A External layout X1 cabinet (glands,plugs) EH170 A
EEPROM-gland assembly
XP22 XP21 XP23
from the inside and out
(Female) (Female) (Female)
B B
Contact No.1
Contact No.1
Guide Pin
Guide Pin
C C
M25 Plug
D D
M25 Gland PG36 Gland

E E
Use Locktite 243 when assamble the chassi plug in to the cabinet
MACHINE TYPE: SHEET

- EH170U 15
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B B
C C
D D
PE-rail 12/3
Assembly the earth braid
between this two pin bults
200 mm
E E
MACHINE TYPE: SHEET

- EH170U 16
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B B
CE-label
BROMMA
P.O Box 1133
SE- 164 22 KISTA
SWEDEN
Control Cabinet
Circuit
diagram no. 10XXXXX
Rated voltage A Hz IP
400-460 XX 50/60 55
Spreader no.
C Year of manufacturing
C
89/336/EEC
73/23/EEC
Art.No. 1002455
Bromma art. no 78127
D D
E E
MACHINE TYPE: SHEET

- EH170U 17
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
CE-label
B B
BROMMA
P.O Box 1133
SE- 164 22 KISTA
SWEDEN
Control Cabinet
C C
Circuit
diagram no. 1002177
Rated voltage A Hz IP
400-460 30 50/60 55
Spreader no.
D D
Year of manufacturing
89/336/EEC
73/23/EEC
Art.No. 1002455
E E
MACHINE TYPE: SHEET

- EH170U 18
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
GORETEX VENT PLUG GORETEX VENT PLUG

700984, 700985 700984, 700985
Assembly from the outside Assembly from the outside
B B
C C
Q1
D D
SB1
SS1
E E
MACHINE TYPE: SHEET

- EH170U 19
F
- 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
SPREADER AUT.RETURN TEXT TEXT
STOP OFF ON
B B
TEXT TEXT TEXT TEXT
C C
TEXT TEXT TEXT TEXT
D D
TEXT TEXT TEXT TEXT
E E
MACHINE TYPE: SHEET

- EH170U 20
F The design and/or constructions CHECKED BY: Sign Plate TOTAL SH.
F
- 24
0 1 2 3 4 5 6 7 8 9
NODE I/O TYPE PIN NR. DESCRIPTION NODE I/O TYPE PIN NR. DESCRIPTION
-B1 1 Digital output -XPX1:31 HL1 Unlocked left -B1 25 Digital output -XPX3:21 Locked signal
-B1 2 Digital output -XPX1:41 HL2 Locked left -B1 26 Digital output -XPX3:31 Unlocked signal
-B1 3 Digital output -XPX1:43 HL3 Landed left -B1 27 Digital output -XPX3:41 Spreader landed signal
-B1 4 Digital output -XPX1:42 HL4,8 Tower in centre left/right -B1 28 Digital output -XPX3:42 G.p. in centre signal
-B1 5 Digital output -XPX1:3 HL5 Unlocked right -B1 29 Digital output -XPX3:24 G.p. at left signal
-B1 6 Digital output -XPX1:2 HL6 Locked right -B1 30 Digital output -XPX3:35 G.p. at right signal
-B1 7 Digital output -XPX1:11 HL7 Landed right -B1 31 Digital output -XPX3:44 H.I.S signal
-B1 8 Digital output -XPX1:1 Not connected -B1 32 Digital output -XPX3:45 TTDS ok signal
-B1 9 Digital output -XPX1:26 K2 Gravity point to left -B1 33 Digital input -XPX3:5 Telescope retract CMD
-B1 10 Digital output -XPX1:16 K3 Gravity point to right -B1 34 Digital input -XPX3:4 Not connected
-B1 11 Digital output -XPX1:6 K6 Hydralic pump left/right gable -B1 35 Digital input -XPX3:3 Telescope expand CMD
-B1 12 Digital output -XPX1:7 K8 Retract telescope -B1 36 Digital input -XPX3:2 Flippers all up CMD
-B1 13 Digital output -XPX1:4 K9 Extend telescope -B1 37 Digital input -XPX3:6 Flipper waterside down CMD
-B1 14 Digital output -XPX1:5 K10 Hydraulic pump twin -B1 38 Digital input -XPX3:16 Flipper right down CMD
-B1 15 Digital output -XPX1:25 Not connected -B1 39 Digital input -XPX3:25 Flipper left down CMD
-B1 16 Digital output -XPX1:15 Not connected -B1 40 Digital input -XPX3:26 Flipper landside down CMD
-B1 17 Digital output -XPX1:10 Twin legs down signal -B1 41 Digital input -XPX3:49 Twl lock CMD
-B1 18 Digital output -XPX1:20 Not connected -B1 42 Digital input -XPX3:48 Twl unlock CMD
-B1 19 Digital output -XPX1:30 Not connected -B1 43 Digital input -XPX3:47 G.p. move to left CMD
-B1 20 Digital output -XPX1:40 Not connected -B1 44 Digital input -XPX3:46 G.p. move to right CMD
-B1 21 Digital output -XPX1:46 Container counter -B1 45 Digital input -XPX3:7 Twin legs up CMD
-B1 22 Digital output -XPX1:47 Not connected -B1 46 Digital input -XPX3:9 Twin legs down CMD
-B1 23 Digital output -XPX1:49 Not connected -B1 47 Digital input -XPX3:50 Spreader stop
-B1 24 Digital output -XPX1:48 Not connected -B1 48 Digital input -XPX3:20 G.p. auto return
MACHINE TYPE: SHEET

EH170U 21
CHECKED BY: TOTAL SH.
I/0 OVERVIEW The design and/or constructions
PLC diagram 24
CREATED: 04/30/2010 08:58 STOCKHOLM SWEDEN
chanka A1 08/07/2010 14:33
11/23/2004 X1
K2 Telescope Twl
HL1 Twin legs down Locked
Gravity point retract lock
Unlocked left signal signal
to left CMD CMD
K3 Twl
HL2 Not Unlocked Not
Gravity point unlock
Locked left connected signal connected
to right CMD
K6 Telescope G.p.
HL3 Not Spreader landed
Hydralic pump expand move to left
Landed left connected signal
left/right gable CMD CMD
K8 Flippers G.p.
HL4,8 Not G.p. in centre
Retract all up move to right
Tower in centre left/right connected signal
telescope CMD CMD
K9 Flipper Twin legs
HL5 Container G.p. at left
Extend waterside down up
Unlocked right counter signal
telescope CMD CMD
K10 Flipper Twin legs
HL6 Not G.p. at right
Hydraulic pump right down down
Locked right connected signal
twin CMD CMD
Flipper
HL7 Not Not H.I.S Spreader
left down
Landed right connected connected signal stop
CMD
Flipper
Not Not Not TTDS ok G.p.
landside down
connected connected connected signal auto return
CMD
230VAC / Output 230VAC / Output 230VAC / Input 230VAC / Input

24VDC / Output red 24VDC / Output red
black black yellow yellow
230VAC / Output 230VAC / Input
black yellow
230VAC / Output 230VAC / Input 230VAC / Input
black yellow yellow
black yellow yellow
24VDC / Output red 24VDC / Output red 24VDC / Output red
black yellow yellow
black yellow yellow
24VDC / Output red 24VDC / Input white
black yellow
24VDC / Input white
black yellow
XP1 XP2 XP3
-B1
MACHINE TYPE: SHEET

EH170U 22
I/0 OVERVIEW The design and/or constructions
I/O card overview 24
chanka A1 08/07/2010 14:33
11/23/2004 X1
UNIT ITEM QTY DIAGRAM REF BROMMA No. DENOMINATION MANUFACTURE SUPPLIER TYPE / ARTICLE NUMBER / TECHNICAL DATA
X1 -1 1 =A1+X1/12.07 38906 EEPROM CC-SYSTEM CC-SYSTEM LENGTH 850MM
X1 -B1 1 =A1+X1/9.00 700498 SCS I/O MARKING BROMMA BROMMA 700498 See document
X1 -B1 1 =A1+X1/9.00 39952 Attachment for SCS² in cabinet NPP/ Bromma 39952 39952 EH5-170-U
X1 -B1 1 =A1+X1/9.00 700020 SCS² SOFTWARE LICENS ENEA ENEA OSE SYSTEMS AB
X1 -B1 9 =A1+X1/9.00 1001750 OUTPUT MODULE 0-240VAC DELCON/AXIOM OEM-AUTOMATIC GLO5TR GLO5TR Sek:0-240VAC 3A
X1 -B1 80 =A1+X1/9.00 700080 SCS² DUMMY PIN AD-CONTACT AD-CONTAKT AB 0413-204-2005 0413-204-2005
X1 -B1 14 =A1+X1/9.00 78603 OUTPUT MODULE DC OPTO22 ELECTRONA-SIEVERT AB G40DC5 G4 ODC 5 24VDC 4A
X1 -B1 1 =A1+X1/9.00 700086 SCS² PLUG K2 AD-CONTACT AD-CONTAKT AB DRC 26-50-S08 DRC 26-50-S08
X1 -B1 1 =A1+X1/9.00 38905 IDENTIFICATION KEY FOR SCS² CC-SYSTEM CC-SYSTEM SEE DRAWING 38905
X1 -B1 3 =A1+X1/9.00 1002003 SCS² CONNECTOR COVER BMAL BMAL 1002003 Rubber boot for deutsch connectors
X1 -B1 80 =A1+X1/9.00 700079 SCS² SOCKET PIN AD-CONTACT AD-CONTAKT AB 0462-201-2031 AU 0462-201-2031 AU
X1 -B1 1 =A1+X1/9.00 37524 SCS² PLC Bromma CC-System
X1 -B1 3 =A1+X1/9.00 78601 INPUT MODULE DC OPTO22 ELECTRONA-SIEVERT AB G4IDC5 G4 IDC 5 24 VDC
X1 -EH1 1 =A1+X1/4.07 1001690 HEATER CABINET STEGO OEM AUTOMATIC HG140 14001.0-01 30W 110-250V AC/DC
X1 -F1 1 =A1+X1/3.09 1001828 MCB 1-POL 2A SIEMENS SIEMENS 5SY6 102-7 C-CHARACTER
X1 -F2 1 =A1+X1/5.02 1001829 MCB 2-POL 10A SIEMENS SIEMENS 5SY6 210-7 C-CHARACTER
X1 -G1 1 =A1+X1/5.02 1001859 POWER SUPPLY 90-255VAC/ 24VDC PrimePower OEM-Automatic 0036515 0036515 30A / 0-400HZ
X1 -K1 1 =A1+X1/5.01 1001826 CONTACTOR SIEMENS SIEMENS 3RT13 25-1BB40 3RT13 25-1BB40 24VDC 22kW 4-pol SIZE 0
X1 -K2 1 =A1+X1/7.01 1001827 PHASEREVERSER SIEMENS SIEMENS 3RA13 25-8XB30-1BB4 3RA13 25-8XB30-1BB4 24VDC 7,5kW 17A
X1 -K6 1 =A1+X1/7.03 1000763 CONTACTOR SIEMENS SIEMENS 3RT1025-1BB40 32 667 91 24VDC 7.5KW 17A SIZE 0
X1 -K8 1 =A1+X1/7.04 1001827 PHASEREVERSER SIEMENS SIEMENS 3RA13 25-8XB30-1BB4 3RA13 25-8XB30-1BB4 24VDC 7,5kW 17A
X1 -K10 1 =A1+X1/7.06 1000763 CONTACTOR SIEMENS SIEMENS 3RT1025-1BB40 32 667 91 24VDC 7.5KW 17A SIZE 0
X1 -KA1 1 =A1+X1/5.07 78980 RELAY SOCKET 2-SWITCHING RELECO OEM-AUTOMATIC AB 40 165 54 S7M
X1 -KA1 1 =A1+X1/5.07 78986 AUXILIARY CONTACTOR RELECO OEM C7 A20 D24D C7 A20 D24D 24VDC 2-SWITCHING
X1 -KEY1 1 =A1+X1/12.03 38905 IDENTIFICATION KEY FOR SCS² CC-SYSTEM CC-SYSTEM SEE DRAWING 38905
X1 -P1 1 =A1+X1/3.09 70873 TIMECOUNTER 380 VAC BAUSER METRIC AB 632A.2 380VAC 24-0015-78
X1 -P2 1 =A1+X1/8.05 76140 PULSECOUNTER 190.07 24V DC BAUSER METRIC AB 632 A.2 24VDC 24-2032-25DC
X1 -Q1 1 =A1+X1/3.01 700869 LOCK HANDLE GREY 66X66mm BACO OEM 0174601 0174601
X1 -Q1 1 =A1+X1/3.01 700870 SEALING IP65 BACO OEM 0172267 0172267
X1 -Q1 1 =A1+X1/3.01 700871 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 0172179 172179 NO+NC 400V 10A SIGNALCONTACT
X1 -Q1 1 =A1+X1/3.01 700868 MAIN CIRCUIT BREAKER BACO OEM 0172200 0172200 50A
X1 -QM1 1 =A1+X1/3.07 78993 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 21 - 4BA10 3RV1021-4BA10 7.5KW 14-20A
X1 -QM6 1 =A1+X1/4.01 79042 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1GA10 3RV1011-1GA10 2.2kW 4.5-6.3 A
X1 -QM7 1 =A1+X1/4.03 79042 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1GA10 3RV1011-1GA10 2.2kW 4.5-6.3 A
X1 -QM8 1 =A1+X1/3.04 79043 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1HA10 3RV1011-1HA10 3,0kW 5,5-8A
MACHINE TYPE: SHEET

EH170U 23
Part List The design and/or constructions
Parts list: (38906 - 79043) 24
chanka 08/07/2010 14:33
10/03/2001
UNIT ITEM QTY DIAGRAM REF BROMMA No. DENOMINATION MANUFACTURE SUPPLIER TYPE / ARTICLE NUMBER / TECHNICAL DATA
X1 -QM10 1 =A1+X1/4.05 79043 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1HA10 3RV1011-1HA10 3,0kW 5,5-8A
X1 -SB1 1 =A1+X1/11.08 1019818 FRAME BACO OEM LWG3 (Suitable with LIB5 - 1019819)
X1 -SB1 1 =A1+X1/11.08 1019811 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 230 E10 230E 10 switch body with 1NO block
X1 -SB1 1 =A1+X1/11.08 1019832 SWITCH HEAD BACO OEM L21KA03 L21KA03 Only operating head 2 pos, 45º
X1 -SB1 1 =A1+X1/11.08 1019819 WHITE SIGNPLATE (+GRAVERING) BACO OEM-IDEALGRAVYR AB LIB5 GRAVERING ENL BILAGA (Suitable with LWG3 - 1019818)
X1 -SS1 1 =A1+X1/5.01 1019819 WHITE SIGNPLATE (+GRAVERING) BACO OEM-IDEALGRAVYR AB LIB5 GRAVERING ENL BILAGA (Suitable with LWG3 - 1019818)
X1 -SS1 1 =A1+X1/5.01 1019818 FRAME BACO OEM LWG3 (Suitable with LIB5 - 1019819)
X1 -SS1 1 =A1+X1/5.01 1019809 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 333E 02 333E 02 switch boddy with 2NC block
X1 -SS1 1 =A1+X1/5.01 1019810 PUSH BUTTON BLACK BACO OEM-AUTOMATIC AB L22 EC03 L22 EC03 FOR SPREADER STOP Ø29mm
X1 -XP21 1 700854 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP-K.10/24.AG 2-1102647-5 SCREW LOCK
X1 -XP21 10 700862 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 4-1105101-1 2,5mm2 AWG14
X1 -XP21 1 1002018 PROTECTION COVER HTS ABB ABB 5DLN296350-A 5DLN296350-A SIZE4
X1 -XP21 1 700858 INSERT FEMALE 10POLE HTS TYCO ELECTRONICS HE.10.BU.C 2-1103637-3 CRIMP
X1 -XP21 2 700863 GUIDE PIN HTS TYCO ELECTRONICS F-Sti-M3 1-1106102-1
X1 -XP22 1 1001921 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP.3/4.AG 1-1102603-5 SCREW LOCK
X1 -XP22 2 1001926 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 1-1105051-1 0,14-0,37mm²
X1 -XP22 1 1001923 INSERT FEMALE 7+POLE HTS TYCO ELECTRONICS HN.D.7.Bu.C 2-1103103-3 CRIMP
X1 -XP22 1 1002520 PROTECTION COVER HTS ABB ABB 5DLN296350-C 5DLN296350-C SIZE1
X1 -XP23 1 700854 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP-K.10/24.AG 2-1102647-5 SCREW LOCK
X1 -XP23 2 700863 GUIDE PIN HTS TYCO ELECTRONICS F-Sti-M3 1-1106102-1
X1 -XP23 1 1002018 PROTECTION COVER HTS ABB ABB 5DLN296350-A 5DLN296350-A SIZE4
X1 -XP23 1 700856 INSERT FEMALE 42POLE HTS TYCO ELECTRONICS HN.2D.42.BU.C 2-1103206-3 CRIMP
X1 -XP23 24 1001927 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 4-1105051-1 1,5mm²
X1 :1 1 =A1+X1/5.02 79367 FUSE ATTACHMENT WAGO HELLERMANN TYTON AB 282-696 282-696 Blade fuse terminal
X1 :1 1 =A1+X1/5.02 79371 FUSE 30A LITTELFUSE ELFA AB 33-051-82 Blade fuse 30A
MACHINE TYPE: SHEET

EH170U 24
the property of BROMMA CONQUIP AB. -
Part List The design and/or constructions
Parts list: (79043 - 79371) 24
chanka 08/07/2010 14:33
05/31/2002
GETTING STARTED
WITH
SCS²
1 REV 3
Index
Node Hardware ............................................................................................................... 4
DIGITAL I/O ................................................................................................................................................ 4
General............................................................................................................................ 4
The X2 connector............................................................................................................ 5
Node ID....................................................................................................................... 5
Main Supply................................................................................................................ 6
CAN ............................................................................................................................ 6
The X1 and X3 connectors (I/O-connectors).................................................................. 7
I/O Groups .................................................................................................................. 7
Common junction........................................................................................................ 8
Internal jumper bars .................................................................................................... 8
Connecting a switch.................................................................................................... 9
Connecting a valve...................................................................................................... 9
I/O Modules .............................................................................................................. 10
APPLICATION .......................................................................................................................................... 10
ABE (Application Builder Environment) ................................................................................... 10
System view .............................................................................................................. 10
Pin configuration....................................................................................................... 11
Component view ....................................................................................................... 11
Load view.................................................................................................................. 14
ANYBUS ..................................................................................................................................................... 15
General.......................................................................................................................... 15
Connecting the B1 node............................................................................................ 15
Connecting the A1 node............................................................................................ 16
The Anybus card (in this case for Profibus) ............................................................. 16
APPLICATION WITH A ANYBUS INTERFACE ................................................................................ 18
ABE............................................................................................................................... 18
ANYBUS GATEWAY................................................................................................................................ 20
General.......................................................................................................................... 20
BCAN - Status LEDs ................................................................................................ 21
Power connector........................................................................................................ 21
BCAN connector....................................................................................................... 21
Node address key switches ....................................................................................... 21
Serial port connector ................................................................................................. 21
APS .............................................................................................................................................................. 22
Absolute encoder on the telescope................................................................................ 22
General...................................................................................................................... 22
The RS485 component.............................................................................................. 22
From bits to millimetres (scale) ................................................................................ 23
2 REV 3
Teach......................................................................................................................... 23
EXTERNAL EE-PROM ............................................................................................................................ 24
General...................................................................................................................... 24
Hardware................................................................................................................... 24
Software .................................................................................................................... 25
Activate the EE-prom ............................................................................................... 26
3 REV 3
Node Hardware
Below is a picture of a SCS2 node.
I/O LED Field RS232 Display &

X2- I/O, bus bus
X1- I/O 1-48 (X5) Power
& supply X3- I/O
Connector LEDS
Connector Connector
Digital I/O
General
Here follows an example of how to build up a Can bus system with two nodes one with
one input and the other with one output.
Switch
Input
Slave (A1)
CAN network (BCAN) SCS 2
B1 Master
Output
Valve
4 REV 3
The X2 connector
The three connectors X1,X2&X3 have different connection keys to avoid the possibility
of connecting them in the wrong place. It is important to choose the correct one.This is
easy to check, on the connecting side of the connector just below the mounting screw
there is a number 7, 8 or 9.
connection
The X2 key
should be
marked “8”
Front view of X2 connector
Node ID
All nodes in a system must have a unique identity. This is read from the Id pins
9,19,29,39,49 on the X2 connector, where pins being connected to the ground pin (10)
correspond to ”zeroes” and pins left unconnected are correspond to ”ones”. A master
node (B1) has pins 10,9,19,29,49 connected together. (Commonly used as a spreader
Node)
A slave node on the crane A1 has pins 10,19,29,39,49 connected together.
Start with making “ID” jumpers.
And connect to the X2 connectors, one as B1 and one as A1.
5 REV 3
Main Supply
24Volt AC or DC powers the node internally. The signals are doubled in the connector
due to the current limit of single pins. DC voltage can be applied in either direction. The
potential is measured between the A section and the B section.
Name Pin number in
connector
24INA X2/42 Potential 1
24INA X2/43
24INB X2/45 Potential 2
24INB X2/44
CAN
The CAN net connection is placed in the X2 connector.
All nodes in the system have to be connected equal (bus topology) to CAN High and
CAN Low to be able to establish communication.
Name Pin number in
connector
CAN High X2/30
CAN Low X2/40
Here is a schematic with the X2 connectors of two nodes, one A1 and one B1 with node id,
CAN bus and power supply connected.
ID SUPPLY CAN BUS
+
24V Supply
-
Low
CAN Bus High
ID
9 10 19 29 30 40 42 43 44 45 49 10 19 29 30 39 40 42 43 44 45 49
B1 X2 A1 X2
Pin no.
CAN-bus
24V SUPPLY
6 REV 3
The X1 and X3 connectors (I/O-connectors)
Just like the X2 connector the X1 and X3 connectors are keyed to avoid connecting them
in the wrong place. The X1 can be identified by the number “7” on the front of the
connector, and the X3 connector by the number “9”.
connection
key

I/O Groups
There are 48 digital I/O on a node. Each I/O can be configured as either an input or an
output via the software. The I/O 1 to 44 are joined in groups of 4 resulting in 11 groups.
I/O 45 to 48 are single I/O’s. Each group has a “Common” junction. This makes it
possible to have different voltages in each group.
Name Description X1 pin

number
I/O-9 General purpose input or output 26
Common/Supply 3 Common junction for I/O-9 to I/O-12 8
Name Description X3 pin
number
Common/Supply 15 Common junction for I/O-48 20
7 REV 3
Common junction
This point is to be connected to live or neutral depending on if the group is used for
inputs or outputs, Inputs need neutral and outputs need live as showed below. Inputs can
be viewed upon as relay coils and outputs as switching contacts.
G roup used as Input G roup used as O utput

L/24V D C
N / 0V D C
SC S SC S
9 10 11 12 9 10
SC S 11 12
8 26 16 6 7 8 26 16 6 7
I/O M oduls
In the picture is one I/O group used as inputs on the left, and on the right the same group
is used as outputs.
Internal jumper bars

To make linking of common supplies easier the X1 and the X3 connector also has groups
of pins linked together to be used basically as jumper bars with the same potential. The
following pins are linked together internally for the purpose of feeding switches/valves
with common potential.
Pin number Link Pin number Link

configuration configuration
12 17
13 18
14 19
22 27
23 28
(Only in X1) 24 29
32 37
33 39
34 38
(Only in X1) 45 (Only in X1) 36
8 REV 3
Connecting a switch
Here is one example of how to use the internal jumpers while connecting the switch into A1.
One of the jumper groups is fed with live and supplies the switch, the other jumper group is
connected to neutral and supplies the I/O group.
L/24V Supply
Internal jumper groups
N/0V Supply
Switch
Cablage
6 7 8 12 13 1 4 16 17 18 19 22 23 24 26 27 X1 Connector
11 12
One Input group
10 9
SCS Internal
Connecting a valve
Here is one example of how to use the internal jumpers while connecting the valve into B1.
One of the jumper groups is connected to Neutral and supplies the valves secondary side, the
other jumper group is connected to live and supplies the I/O group.
L/24V Supply
Internal jumper groups
N/0V Supply
Valve
Cablage
6 7 8 12 13 1 4 16 17 18 19 22 23 24 26 27 X1 Connector
One output group SCS² Internal

11 12 10 9
9 REV 3
I/O Modules
To be able to adapt the I/Os to the system voltage each I/O channel have a solid-state
interface relay (OPTO 22). This makes it possible to choose input or output and a voltage
range of 12-230 VAC/DC. Each module has a led indicating active state. On the output
modules there is a 3 Amp fuse. These modules are located inside the SCS² cover. The
cover has a lens for each channel, so the I/O status can be seen from the outside.
LED
FUSE
Application
ABE (Application Builder Environment)
System view
When ABE is started a new application is automatically started, and the default view is
the system view. The system view enables the user to select a node configuration in the
software, the application compares the hardware with the software configurations and
these have to be equal to work. You may also set system properties in this view. Some
properties will be updated automatically when a project is saved.
In the system view we have to activate

the A1 node in the soft ware. The B1 is
the master and is active per default.
System properties
Menu tabs
10 REV 3
Pin configuration
Next menu tab is “pin configuration”, all present nodes are visible as tabs in this view. (1)
Make sure tab A1 is activated in the view. Give Port id# 9 the following name ”switch”.
(2) Comment field is optional. (3)
Activate tab B1 in the view (1) and do the same for Port id# 9 with following name
”VALVE”. (2)
Note: The red color of the fields indicates that the ports are not yet connected or that any
of the letters are unaccepted. Space between words is not accepted instead use “_”.
A red field makes it impossible to compile the application.
Component view
Next menu tab is the “component view”
The component view is where components are deployed and connected. A palette
displaying all components is available in the view.
The palette can be made visible
by pressing “components” if it is
not already visible.
Available
component
pallet
11 REV 3
Select the OD timer (On Delay timer) component from the available component pallet
(1). It’s located in the Digital tab (2).
Place the component on Page 1 in the view with the left mouse button. Then press the
right button to get the arrow back.
Right click the mouse on

the left red dot and work
your way to the input
”SWITCH” and left click.
Do the same thing on the right red dot and choose the output in this case “VALVE”
12 REV 3
Put the arrow on the component and right click, and select “properties”.
Put the delay time to two seconds (in mille seconds). The instance name is an internal
component address and should not be changed. When ready press “OK”.
Instance name
Delay time
If the application needs to be When the application is ready

saved before it is ready choose choose “Compile”. The file will
“Save”. The file will be stored as then be saved as a loadable file
a “spi” file. “spr” and is of curse editable.
13 REV 3
Load view
The last view is the “Load view”. From this view it is possible to download and up load
applications to and from a connected SCS² system. Press the “Download” button and a
dialogue box will appear, choose the desired “spr” file and press the “Open” button.
Download
Choose file
and press
open
Then ABE verifies the action in the progress bar.

First ABE sends the file to the connected node. The progress is displayed in the
connected node bar as percent.
Current transfer
completed (%)
Then the system distributes the file over the CAN-bus to the rest of the nodes (if
necessary).
When the download is ready
this dialogue box appears.
Current transfer
completed (%)
Total transfer
completed (%)
14 REV 3
Anybus
General
Here follows an example of how to build up the same system as before with two nodes,
but the B1 node has one output and one input and on the A1 node is the input replaced
with an Anybus
interface
Outside net
Slave (A1)
with anybus
SCS2
CAN network (BCAN)
B1 Master
Input Output
Switch Valve
Connecting the B1 node

Connect the B1 node as in the Digital I/O chapter, and add a switch to Port id# 1 as in the
picture below
G roup used as Input G roup used as O utput
L /24V D C
N / 0V D C
SC S² SC S²
1 2 3 4 9 10
SC S 11 12
44 31 41 43 42 8 26 16 6 7
I/O M oduls
15 REV 3
Connecting the A1 node
Connect power supply, can bus and an ID jumper as A1 in the X2 connector.
An “Anybus card” is also to be mounted and connected inside the hood where the digital
I/Os are located.
The Anybus card (in this case for Profibus)

This card is used for translation
between different field buses and
a standardized format read by the
SCS² system.
There is a D-sub connector on the card for connecting to outside net (1), and a selector
for termination resistance (2) and two selectors used for setting hard ware identification
of the unit in the outside net (3).
Item 3. HW address
1 2 3
1 2 *10 *1
4 3
The four LEDs are used for showing the state of the communication from the
Anybus-card and the outside net.
1:not used
2:(green) on-line on the Fieldbus
3:(red) off-line on the Fieldbus
4:(red) indicate faults on the Fieldbus side as follows:
Flashing 1hz-Error in configuration: IN and/or OUT length set during initialization
of the module is not equal to the length set during configuration of the network.
Flashing 2hz-Error in user parameter data: the length/contents of the user parameter
data set during initialization of the module is not equal to the length/contents set
during configuration of the network.
Flashing 4hz-Error in initialisation of the Profibus communication ASIC.
16 REV 3
The Anybus card
is to be mounted
inside the hood on
the right upper
corner of the node
Connect an Anybus jumper

to the D-sub connector on
the Anybus card.
And connect to the outside
connector on the connection
rail beside the card.
On the connection rail the

wires from the D-sub should
be connected in the
following order from the
right 8 3 5 (for Profibus)
Fieldbus connector used for

connecting to the outside
interface.
17 REV 3
Application with a Anybus interface
ABE
Open the application used in the digital chapter. Get in to the ”pin configuration” view
and remove the switch from A1, add a new “switch” to B1 in Port id# 1
Then get in to the “component view” and set the cursor on the OD timers input connector
(on the left) and press Disconnect, the connection point turns red if a connection is
acquired for the component to function.
Get an “Input bit”(1) from the “available component”

menu under the “Anybus” tab (2) and place it out in front
of the “OD timer” and also take an “or” gate from “gates” 1 2
and a “split” from “digital”.
Connect the switch to the “split”, the “input bit” and the “split” to the “or” and the “or” to
the “OD timer”. Yore connection should now be as below.
Choose an “Output bit” and connect it to the “split”
Note: A red dot on any of the components

makes it impossible to compile the application.
18 REV 3
Right click on in/output bits and choose properties. In the properties menu it is possible to
configure following.
“Note” is a free text field. Use this field for notes about the Anybus port.
“Bit number” is the bit number of the chosen byte in Anybus interface. (0-7)
“Byte number” is the start byte in the Anybus interface. (0-63)
“Node” is where the any bus card is located (in this case A1)
Note: The size of the data areas is decided of the highest byte in the application, in both
directions separately. The two sizes have to be equal on both sides of the Anybus card
(outside master/any bus) to be able to establish contact. If the outside areas is bigger than
in the application is it possible to put an empty byte to make the areas match.
19 REV 3
Anybus gateway
General
Compared to a conventional SCS² node the Anybus gateway does not have any digital or
analogue I/O’s, no internal battery backing up the event log (locally
The anybus gateway is used in cases where a physical I/O is not needed; one example is
when the SCS² system is connected as a slave unit (via a anybus card in the crane node)
on the crane PLC.
Status LEDs
Anybus card Power connector

(in this case
Profibus) BCAN connector
Node address key

switches
Serial port
connector
20 REV 3
BCAN - Status LEDs
There are three green LEDs for Power, BCAN and Anybus indicating operating status
and one red LED indicating error status.
Power LED is lit when power is applied and system starts to execute.
BCAN LED is lit when the BCAN communication interface is operating normally and
flashing when the communication interface is not working as intended.
Anybus LED is flashing when the Anybus interface is not configured and lit when
configured and operating normally. (Between the node and the anybus card)
Error LED is unlit when system is running normally and lit when an error has occurred.
Power connector
The power connector is a Phoenix Contact 2- NAME DESCRIPTION PIN NUMBER
pin header (MC1,5/2-G-3,81).
VCC 10 to 28 V DC 1
24Volt DC powers the node internally.
GND Ground 2
BCAN connector
The BCAN connector is a Phoenix Contact 3-
NAME DESCRIPTION PIN NUMBER
pin header (MC1,5/3-G-3,81). All nodes in
the system have to be connected equal (bus CAN H CAN high 1
topology) to CAN High and CAN Low to be CAN L CAN low 2
able to establish communication.
Node address key switches

There are five switches selecting node address. The node
identity is defined by using the same bit pattern as the A1
conventional nodes.
For example to configure a gateway node as an A1 (crane)

node: set DIPswitch 1 to ON and DIP switch 2-5 to OFF.
Or to configure a gateway node as an A2 (crane) node: set
DIPswitch 2 to ON and DIP switch 1,3,4 and 5 to OFF.
A2
Serial port connector

The serial port connector is used when connecting the SCS2 Anybus Gateway to a
computer serial port. (Corresponds to X5 on the conventional SCS² nodes)
Use a 9-pol D-sub extension lead to connect.
21 REV 3
APS
Absolute encoder on the telescope
General
The absolute encoder should be connected to the RS485 port. (Channel A at X2/38 and
channel B at X2/37) In the ABE component pallet under the “analogue” tab, the RS485
port component is located. It is also possible to rescale the information from the sensor to
be able to work or monitor the actual measurements (in for instance mm), the tool for this
is the “scale” component. The “scale” component is also located under the “analogue”
tab.
Teach is used Add the RS485 port component
for storing from the analogue tab
positions
The scale component
makes it possible to
translate the sensor
value to the
mechanical distance
The RS485 component

This component is used to access the RS485 interface. The component is made to handle
some different types of protocol in this case “slin”.
The parameters:
Node: each node has one RS485 input. To direct the

component in the software to the correct hardware input,
choose node corresponding to what node the sensor is
wired to.
Protocol: it is possible to choose

between some different standardised
protocols to suit the sensor used.
When using the SSI protocol some more information is needed. (See sensor/manufacture
for data)
Code type: determines how the sensor value (bit pattern) shall be read when converting
to a decimal value (made internally in the component). Gray or Binary.
Input resolution: how many steps (bits) per revolution.
Max revolutions: how many revolutions that are supported by the sensor.
22 REV 3
From bits to millimetres (scale)
Retract the spreader to the mechanical end stop, measure the distance between the single
twistlocks, note the value down, read the sensor value with the ABE online and make a
note of this. Expand the spreader to the mechanical end stop and repeat the same
procedure.
Note: It is very important that the sensor doesn’t wraparound (when counting up, after
the highest value it starts at zero again), the retracted value should be low and the
expanded value should be larger.
Right click on the scale component and choose “properties”

And fill in the noted values as following.
The measured max
value in millimeters
The measured min
value in millimeters
The up loaded max value
from the ABE online
The up loaded min value
from the ABE online
Then verify the scale, put the spreader in some different positions measure and compare
with the scaled value.
Teach
To be able to store positions the APS component is equipped with a storing function
called “TEACH”. By giving the teach command and expand or retract command it is
possible to move the spreader in a lesser speed (defied by the parameter “PWM value for
teach” in APS properties) to the required length, for position “20ft”, hold the teach
command and give the go to position “20ft” command. The value is now stored in the
spreader memory (NV RAM). Repeat this procedure on all the required positions.
The connection point for teach
The connection points for position

direct commands
The connection points for expand/
retract commands
Note: If the scale is made correctly it is possible to verify the spreader length by
activating the teach command, when the teach function is active the sensor value input on
the APS is displayed on the B1 display. Beware of if a "position direct command" is
given at the same time that position is destroyed.
23 REV 3
External EE-prom
General
In the external EE-prom it is possible to store information as spreader ID, twistlock
counters, running time etc. this makes it possible to replace the node(s) in the system
without loosing this information.
Hardware
The EE-prom is to be connected in to the node as following.
Name Pin number in Cable
connector
10V supply X2/36 Red
Serial data X2/16 Blue
Serial clock X2/26 Green
Signal ground X2/6 Black
The EE-prom is located in a gland. The gland should be mounted solid near by the SCS²
node within the cable range.
24 REV 3
Software
A “spreader properties” component needs to be added in the application, that make the
system try to find the “EE-prom” at boot.
The “spreader properties” component (1) is located in the “misc…” tab (2) in the
“available component” menu.
4
3
2 1
The “spreader properties” contains twistlock counters and a time counter etc. To make
the counters work some info is needed, connect the available signals corresponding to the
connection points on the left of the component (3).
The information is possible to send out as analogue words true the bus to the outside net
(if present), the connection points for these values is located on the right of the
component (4).
25 REV 3
Activate the EE-prom
The EE-prom is activated after the “Serial number” value is set.
The BMS have to be connected to the node that the EE-prom is connected to.
Left click on the “Serial number” key in the BMS “spreader info” tab.
In the “current key” dialogue box down in the left corner there should now be seen “serial
number”.
Put the spreader serial number in the value bar and press the “set” button to store and
activate the EE-prom. It now displays the different values.
The “Spreader info” tag
The “get all” button
The information from the EE-prom is possible to upload with the BMS from the
“spreader info” tag. Connect the BMS to the system and press the “get all” button.
26 REV 3
User Manual
Version 1.0
Revision Issued by Date Measures

PA1 Gunnar Ohlsson, CC Systems 2000-05-26 First draft.
PA2 Andy Lewis, Bromma Conquip 2000-08-09 Corrections
PA3 Gunnar Ohlsson, CC Systems 2000-10-10 More corrections
A GO, AL 2000-10-10 Version 1.0
PB1 Gunnar Ohlsson, CC Systems 2001-01-22 PID component, Online monitoring (manual and tutorial), *.apd
changed to *.spr, Figure numbering corrected, Allowed character set.
PB2 Hans Svanfeldt, CC Systems 2002-06-04 Revision after system release 1.04
Printed: 05-2-23 13.40

Document: Project: Project No
ABE_UserManual_1.0
Prepared by: Date: Version: Page:
Research & Development

Gunnar Ohlsson 2005-02-23 13:40 PB4 2(92)
Table of contents
1 INTRODUCTION .............................................................................................................5
2 INSTALLING ABE...........................................................................................................5
2.1 HW requirements .................................................................................................................................................... 5
2.2 Installation ............................................................................................................................................................... 5
2.3 Disclaimer................................................................................................................................................................. 5
3 USER INTERFACE .........................................................................................................6

3.1 Main window............................................................................................................................................................ 6
3.2 Error control............................................................................................................................................................ 6
3.3 Multiple language support ...................................................................................................................................... 6
3.4 General functions..................................................................................................................................................... 6

3.4.1 File..................................................................................................................................................................... 6
3.4.2 Edit .................................................................................................................................................................... 7
3.4.3 Settings .............................................................................................................................................................. 7
3.4.4 Tools .................................................................................................................................................................. 7
3.4.5 Help ................................................................................................................................................................... 8
4 SYSTEM VIEW ................................................................................................................9

4.1 General ..................................................................................................................................................................... 9
4.2 Functionality ............................................................................................................................................................ 9

4.2.1 Author................................................................................................................................................................ 9
4.2.2 Last date saved .................................................................................................................................................. 9
4.2.3 Creation date.................................................................................................................................................... 10
4.2.4 Version number ............................................................................................................................................... 10
4.2.5 Revision number.............................................................................................................................................. 10
4.2.6 Spreader type ................................................................................................................................................... 10
4.2.7 Drawing number .............................................................................................................................................. 10
4.2.8 Customer.......................................................................................................................................................... 10
4.2.9 Comments........................................................................................................................................................ 10
5 PIN CONFIGURATION VIEW........................................................................................11

5.1 General ................................................................................................................................................................... 11
5.2 Functionality .......................................................................................................................................................... 11

5.2.1 Address key ..................................................................................................................................................... 11
5.2.2 Exists port........................................................................................................................................................ 11
5.2.3 Anybus I/O ...................................................................................................................................................... 12
5.2.4 CANopen I/O................................................................................................................................................... 12
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6 COMPONENT VIEW .....................................................................................................13

6.1 General ................................................................................................................................................................... 13
6.2 Page functionality .................................................................................................................................................. 14

6.2.1 Adding pages ................................................................................................................................................... 14
6.3 Component functionality ...................................................................................................................................... 14

6.3.1 Adding a component........................................................................................................................................ 14
6.3.2 Moving a component ....................................................................................................................................... 15
6.3.3 Selecting multiple components........................................................................................................................ 15
6.3.4 Cutting / coping / pasting components ............................................................................................................ 15
6.3.5 Delete a component ......................................................................................................................................... 15
6.3.6 Connecting / disconnecting components ......................................................................................................... 15
6.3.7 Online monitoring............................................................................................................................................ 15
7 LOAD VIEW...................................................................................................................16
7.1 General ................................................................................................................................................................... 16
7.2 Functionality .......................................................................................................................................................... 16
8 COMPONENTS .............................................................................................................17
8.1 Controllers.............................................................................................................................................................. 17
8.1.1 TLC4 – Twistlock Controller 4 ....................................................................................................................... 17
8.1.2 TLC8 – Twistlock Controller 8 ....................................................................................................................... 20
8.1.3 FAC – Flipper Arm Controller ........................................................................................................................ 24
8.1.4 DPS – Discrete Positioning System................................................................................................................. 26
8.1.5 Tower – Head block ........................................................................................................................................ 29
8.1.6 APS – Automatic Positioning System ............................................................................................................. 32
8.1.7 MPS – Memory position system...................................................................................................................... 36
8.1.8 Twin Telescope................................................................................................................................................ 40
8.1.9 TwinUpDown .................................................................................................................................................. 42
8.1.10 PID................................................................................................................................................................... 46
8.1.11 AutoTuner........................................................................................................................................................ 50
8.2 AnyBus ................................................................................................................................................................... 53

8.2.1 Introduction ..................................................................................................................................................... 53
8.2.2 Anybus System ................................................................................................................................................ 54
8.2.3 Output Word .................................................................................................................................................... 55
8.2.4 Output Byte ..................................................................................................................................................... 55
8.2.5 Output Bit ........................................................................................................................................................ 56
8.2.6 Input Word....................................................................................................................................................... 56
8.2.7 Input Byte ........................................................................................................................................................ 57
8.2.8 Input Bit........................................................................................................................................................... 57
8.3 CANopen ................................................................................................................................................................ 58

8.3.1 Introduction ..................................................................................................................................................... 58
8.3.2 PDO Read Bit .................................................................................................................................................. 58
8.3.3 PDO Read........................................................................................................................................................ 58
8.3.4 PDO Write Bit ................................................................................................................................................. 59
8.3.5 PDO Write ....................................................................................................................................................... 59
8.3.6 SDO Write ....................................................................................................................................................... 59
8.4 Guards .................................................................................................................................................................... 61
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8.4.1 Spreader stop ................................................................................................................................................... 61

8.4.2 TTDS -Twin Twenty Detection System .......................................................................................................... 61
8.4.3 Analogue guard ............................................................................................................................................... 62
8.4.4 Digital guard .................................................................................................................................................... 63
8.5 Gates ....................................................................................................................................................................... 64

8.5.1 AND ................................................................................................................................................................ 64
8.5.2 NAND.............................................................................................................................................................. 65
8.5.3 NOR................................................................................................................................................................. 65
8.5.4 OR ................................................................................................................................................................... 66
8.5.5 NOT................................................................................................................................................................. 67
8.5.6 XOR................................................................................................................................................................. 67
8.5.7 SR Latch .......................................................................................................................................................... 68
8.5.8 RS Latch .......................................................................................................................................................... 68
8.5.9 Logical gate ..................................................................................................................................................... 69
8.6 Digital ..................................................................................................................................................................... 69

8.6.1 OD Timer – On Delay Timer........................................................................................................................... 69
8.6.2 UpDn Counter – Up Down Counter ................................................................................................................ 70
8.6.3 OSC - Oscillator .............................................................................................................................................. 70
8.6.4 Split ................................................................................................................................................................. 71
8.6.5 Pulse ................................................................................................................................................................ 71
8.7 Miscellaneous ......................................................................................................................................................... 72

8.7.1 Constant........................................................................................................................................................... 72
8.7.2 Dead end.......................................................................................................................................................... 73
8.7.3 Spreader properties .......................................................................................................................................... 73
8.7.4 Memory ........................................................................................................................................................... 75
8.7.5 Digital buffer ................................................................................................................................................... 76
8.7.6 Analogue buffer............................................................................................................................................... 76
8.8 Analogue................................................................................................................................................................. 78
8.8.1 RS485 port....................................................................................................................................................... 78
8.8.2 IN0 > IN1 ........................................................................................................................................................ 78
8.8.3 IN0 * IN1......................................................................................................................................................... 79
8.8.4 IN0 / IN1.......................................................................................................................................................... 79
8.8.5 IN0 – IN1......................................................................................................................................................... 79
8.8.6 IN0 + IN1 ........................................................................................................................................................ 80
8.8.7 Scale ................................................................................................................................................................ 80
8.8.8 AnalogueLatch ................................................................................................................................................ 81
8.8.9 Filter ................................................................................................................................................................ 81
8.8.10 AuxAnalogue................................................................................................................................................... 82
9 TUTORIAL.....................................................................................................................83
10 CANOPEN TUTORIAL ...............................................................................................90
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1 Introduction
ABE – Application Builder Environment has been developed to create and manage spreader programs specifically for the
Bromma Conquip SCS2 system used on Spreaders. This tool gives the programmer/user the possibility of configuring and
programming the logic of the SCS2 via a graphical interface.
In principal ABE generates a binary file describing the interconnection between the graphical objects the user has tied
together. This file, when downloaded onto the target system, connects the precompiled objects within the target system
together according to the functionality described by the user. Hence all logical objects, components, reside within the
target system and the program file generated by ABE determines their interconnection.
The objects, from no on referred to as components, within ABE contain a varying amount of logic ranging from basic
Boolean instruction sets to Spreader specific blocks of functionality which can be altered in behaviour via parameter
settings. The components containing specified Spreader functions are developed to ensure that years of Spreader
experience is re-used and also contain the interlocking for generating fault and event messages to the onboard NVRAM
(log).
This programming tool is intended for use by staff with adequate knowledge of both the system and the functionality of
the Spreader/Crane in which it shall be used only. Any alterations or new programs causing failure in functionality due to
logical faults in the program are the responsibility of the person/company carrying out this work.
2 Installing ABE
2.1 HW requirements
The minimum requirements to run this application on your PC are:
x an Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000.
x at least one serial communication port available (COM1 or COM2).
x at least 2Mb of free disk space.
2.2 Installation
x Close any other applications running under windows.
x Insert the CD into your station.
x Run the file Setup.exe.
x Follow the instructions on the screen.
2.3 Disclaimer
Copyright Bromma Conquip AB. All rights reserved.
Products and company names mentioned herein may be trademarks or trade names of their respective owners.
Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes
and improvements to any of the products described in this manual without prior notice.
Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.
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3 User interface
ABE-application is divided into four main functions.
This chapter describes the four main functions of the program.
Remark:
Allowed characters when giving names to Item identifiers, Comments, Components and Tags are:
[a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.
3.1 Main window

The main window of the application consists of one large frame. The four tabs at the bottom of this window represent the
four main functions of the program. The toolbar at the top of the window is used for common operations.
The application supports tool tips.
The application is designed to work on a laptop computer with a display size of 800 * 600 pixels or more.
3.2 Error control

Error control of the program file is performed after every operation. The errors found are marked red. The error control
can be turned off/on from the Settings menu.
3.3 Multiple language support

The default language is English. Additional languages can be requested from Bromma Conquip AB.
3.4 General functions

The toolbar functions are File, Edit, Settings, Tools and Help. Each function is described below.
3.4.1 File
Two types of files are available.
Type *.spr is a compiled file ready to download onto the SCS2.
Type *.spi is an intermediate file. Use Save or Save As... if you are not able to generate downloadable program file but
want to continue your work later on. The file extension will then be *.spi.
3.4.1.1 New
Creates a new program file for editing.
3.4.1.2 Open
Opens a program file for editing/viewing.
3.4.1.3 Save As...

Prompts the user to supply a new filename to which the project will be saved. The file extension will be *.spi.
3.4.1.4 Save
Saves the current project. The file extension will be *.spi.
3.4.1.5 Compile
Generates and prompts you to save a downloadable program file used in the SCS2. The file extension will be *.spr.
3.4.1.6 Print
Prints the Component view.
3.4.1.7 Exit
Exits the application.
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3.4.2 Edit
3.4.2.1 Cut
Selected components will be cut and saved to the clipboard.
3.4.2.2 Copy
Selected components will be copied to the clipboard.
3.4.2.3 Paste
Content of clipboard will be pasted into selected page in the Component view. If connections match existing ports theses
will also be pasted into the page.
3.4.2.4 Find
Finds a text string in component comments, component identifiers or an actual component.
3.4.3 Settings
3.4.3.1 Error Control

Turns the error control on/off.
3.4.3.2 Show hints

Turns the tool tips on/off.
3.4.3.3 Show component connection info

Turns information at component connection points on/off.
3.4.4 Tools
3.4.4.1 Export Pin configuration view

Exports a list of current Pin configuration as an html page for viewing in a web browser.
3.4.4.2 Export Component documentation

Exports a list of available components an their properties as a html page for viewing in a web browser.
3.4.4.3 Export parameters

Exports the selected components parameters to a file.
3.4.4.4 Import parameters

Imports parameters from a file to current project.
3.4.4.5 Show Ladder, Show function blocks

Shows the current project in Ladder format. Note that one cannot add, delete or online monitor components when ladder
look activated.
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3.4.5 Help
3.4.5.1 About
Short information about ABE such as version, current number of components etc.
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4 System view
4.1 General
The system view provides a way of enabling and disabling (connecting/disconnecting) nodes and setting system
properties such as version number, author, comments and date of modification. The nodes are named A1-A4 for the nodes
intended to be fitted to the crane and B1-B8 for the nodes intended to be fitted to the Spreader. Each node name
corresponds to a unique address key setting.
The system view allows the user to set up the node configuration by checking the desired nodes. A fixed set of
checkboxes are available that represent the used nodes in the system. The enabled nodes then have to be present in that
system. An exception is if the “EXISTS” function is used. This function can then replace a node on the bus with an input
on the master node.
The B1-node is selected by default, since every system has to contain exactly one Master node, B1. Four crane nodes and
seven spreader nodes are available for selection.
Checkboxes for enabling Twistlock redundancy as well as “Spreader stop” have to be checked here as well if these
functions are used.
Figure 4:1 System view
4.2 Functionality
The system view enables the user to select a node configuration. By filling in the checkboxes you determine the lay-out
(topology) of the system. You also determine on which nodes (B1 & B2) you are to have the twistlock redundancy and
Spreader stop enabled. Each node configuration gives the respective node a unique ID represented by the address key.
You may also set system properties in this view. Some properties will be updated automatically when a project is saved.
The properties are:
4.2.1 Author
This is the author of the spreader program. Contains text of max 80 characters.
4.2.2 Last date saved

Displays the date when the current project was last saved. Displayed in the format 1999-06-28 14:45.
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4.2.3 Creation date

Displays the date of the current project’s creation. The creation date is only changed upon creating a new project.
Displayed in the format 1999-06-28 14:45.
4.2.4 Version number

A user selectable version number. Maximum version number is 99.99.
4.2.5 Revision number

The revision number is incremented each time the specific project is compiled.
4.2.6 Spreader type

A text field representing the type of spreader that the current program is intended for. Contains text of max 80 characters.
4.2.7 Drawing number

A number corresponding to the electrical drawing belonging to the current project. Contains text of max 80 characters.
4.2.8 Customer
This property is to contain the name of the customer who will use the Spreader program. Contains text of max 80
characters.
4.2.9 Comments
This is a text field intended for general comments regarding the Spreader program. Contains text of max 80 characters.
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5 Pin configuration view
5.1 General
The pin configuration view is presented as a tabular view of the system, where each tab represents a node. An I/O list
corresponding tags will be available for all enabled nodes in the system. The top tabs indicate which node is displayed.
A tag is composed of its Item identifier and its Comment. The used I/O not yet connected is marked red.
The Port id# field contains a port id, the numerical ID of the I/O number of the SCS2. The Connection field is either IN,
OUT or NC (Not connected) and if it’s a digital, analogue, PWM or Encoder signals. These fields cannot be edited.
Remark:
Figure 5:1 Pin configuration view
5.2 Functionality
This view allows you to change the tag for all port numbers on all nodes in the system. Within this view you give each
individual I/O its’ nick name, Item Identifier, to make the program more comprehensible, you also assign any comments
to the I/O. The connection type (IN/OUT) will be updated automatically as the Spreader program is altered in the
component view; i.e. the direction of the I/O point is decided when the I/O is connected. Note that ABE will only permit
I/O configuration that is supported by the current SCS2 HW, hence the digital I/O direction can only differ outside of
groups of four apart from the last four I/O points in the list (45-48) which can configured individually.
5.2.1 Address key

The “address key” field illustrates how the address key should be linked for the viewed node. This pattern corresponds to
the required connection on the X2 connector on the SCS2 HW.
5.2.2 Exists port

The “exists port” is used in case versatility on the number of used nodes is required. By letting an Input “replace” a node
within a system one can then have for instance three nodes active in one case and two node plus the selected input active
in another case, and still run the system without having to re-configure it. This can be useful when different models of
Spreaders are to be used within the same system.
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5.2.3 Anybus I/O

With this button you can view all Anybus inputs and outputs in current spreader program.
5.2.4 CANopen I/O

With this button the CANopen configuration form appears, from this view you can create the CANopen functionality.
You can add up to 15 CANopen slaves and add inputs and outputs on each slave (Digital and Analogue).
Advanced configuration of a CANopen slave can be done by using SDO:s (Service Data Object).
For more information about CANopen see general available sources.
Figure 5:2:4 CANopen configuration view
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6 Component view
6.1 General
The component view is where components are deployed and connected. A palette displaying all components is available
in the view. To add a component, select the component from the Palette and place it on your work space with the mouse.
Remark:
Figure 6:1 Component view Figure 6:2 Palette
Components may be dragged within a page to change the layout. Each page can be resized vertically.
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The following table describes some reoccurring terminology in this manual.
Name Symbol Description

Output tag An Output tag is an intermediate variable used for making
the program more readable and efficient.
Note. Changing the name of an Output tag must be followed
by a change of the corresponding Input tag(s)
Input tag An Input tag is used to connect to an existing Output tag.
Note. Changing the name(s) on Input tag(s) must be
followed by a change of the corresponding Output tag.
Component A component contains logic. The components range from
simple Boolean (AND, OR etc) to those with full
functionality specifically for Spreaders (APS etc.). Some of
the components contain parameters. By double clicking (or
right clicking and selecting properties) the component, its’
properties/parameters are displayed and can be edited. A
component also carries component connection points (round
circles).
A red coloured connection indicates that it has to be
Component connection connected before a compilation can be performed. Once the
connection point is connected it turns white. This means that
it is connected correctly. If a connection point is white
although it is not connected it is optional to connect it or not.
Output port A connection to a physical output. The displayed name is the

Item identifier found in the Pin configuration view. Multiple
connections are not possible for an Output port.
Input port A connection to a physical input. The displayed name is the
Item identifier found in the Pin configuration view.
Multiple connections A multiple connection to same Input port is indicated with
two vertical lines on the connection. This is made to remind
the user that the Input port has been connected at least once
before.
Component connection Information about the generic name of the component
information connection is shown above each connection point when
turned on. The function can be turned on/off from the
Settings menu.
6.2 Page functionality

One page contains one set of interconnected components with no feedback in the connections. Reuse of signals may be
accomplished by adding variable tags, and referring to those tags wherever necessary.
The component view provides the following functionality:
6.2.1 Adding pages

By clicking on the last page or by placing a component on the last page will add a new page below it.
6.3 Component functionality

In each page, components may be manipulated. Operations on components are:
6.3.1 Adding a component

This operation adds the component currently selected in the palette to a page. Simply click the desired component and
then click the location you wish to place this component on the current page you’re working on.
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6.3.2 Moving a component

Moving a component is a matter of dragging it around using the mouse.
6.3.3 Selecting multiple components

Multiple selection of components is possible using key modifiers (shift / ctrl).
6.3.4 Cutting / coping / pasting components

The copied and cut components will be placed on the clipboard, allowing components to be pasted on pages in the same
application or in other ABE applications.
6.3.5 Delete a component

By selecting a component and pressing delete it is removed from the page.
6.3.6 Connecting / disconnecting components

Drawing a line from one connection point to another makes connections between components.
One can also connect a component by right clicking a connection point and selecting a connection from the available lists
displayed (I/O, Components instances, Tags).
Clicking with the right mouse button over a connected connection point will give you the option to disconnect.
6.3.7 Online monitoring

Online monitoring is performed under Component view.
The same spreader program must be present in both ABE and SCS2. If you are not sure about this, you can always
download your current spreader program to the SCS2 or upload the spreader program from the SCS2.
Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.
Start online monitoring by pressing the Start online monitoring button.
Automatic update will be performed at an interval specified by Update interval, if Auto is checked
The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or
less time depending on the number of present components and connections in visible Page(s). A progress bar appears
above the buttons, when adding the components, to show you current status.
Stop online monitoring by pressing the Stop online monitoring button (same button as Start online monitoring button).
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7 Load view
7.1 General
The load view provides functionality to download and upload Spreader programs. The connection to the system is
selected in the connection box; the possible choices are, Com1 and Com2. Current status of the transfer is displayed in the
three progress bars.
Figure 7:1 Load view
7.2 Functionality
When the download button is pressed the user is prompted to point out the file to download to the system. It has to be a
compiled downloadable program file (*.spr-file). The current status of a download process from the PC to the system is
shown in the top progress bar. The distribution transfer between nodes is shown in the two progress bars at the bottom of
the page. The upload button allows the user to retrieve a program file from a connected system and save it to a file.
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8 Components
Terminology:
In this section the follow terms are used:
False = 0 = logical low level
True = 1 = logical high level
Parameter – “Instance name”:

Every component used in a project will be given a unique instance name, which can be seen by clicking the right mouse
button on a component and selecting properties. This unique instance name is seen in the field next to the title “Instance
name”. The instance name is used to be able to trace every component instance throughout the project. The name can be
altered, but no two instances of a component can have the same name, since this is the ID used by the system to determine
the interconnection between components.
State transition diagrams:

The state transition diagrams describe the behaviour of the components in general. Terminology in the diagrams is not the
same as in the port listings found in corresponding subsections. The text found in the diagrams is more explicit than the
complete listing.
Example: In the state transition diagram for TLC4 the following text tag can be found: “not All unlocked”
This text tag is equal to NOT (Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4).
The latter expression is rather big and makes the diagram difficult to understand.
Descriptions (when relevant) like the one above will be made for those sections that contain State transition diagrams.
8.1 Controllers
8.1.1 TLC4 – Twistlock Controller 4

The Twistlock Controller 4 (TLC4) is used to control four Twistlocks at the same time. This component incorporates the
functionality and interlocks for a standard Twistlock operation with four Twistlocks. The component prevents the
Twistlock from changing state unless the landed pins have been active for the specified time, it also prevents pre-selection
of unlock and always keeps the outputs from the component active. Apart from the pure functionality of this component it
also sends event and warning messages to the log function of the system.
8.1.1.1 State transition diagram

“Not All unlocked” = NOT (Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4)
“All unlocked” = Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4
“Unlock after landed” = when an unlock command is given after landed on all corners (and delay has elapsed if any)
“Lock after landed” = when a lock command is given after landed on all corners (and delay has elapsed if any)
States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
This state is reached every time the system is starting up or when DISABLED state is left.
A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states).
LOCK_ALL:
Lock all Twistlocks.
UNLOCK_ALL:
Unlock all Twistlocks.
IDLE:
When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not
changed from previous state.
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For all s tates :

Trans ition is m ade to DISABLED s tate if
SpreaderStop = 1or Enable = 0
LOCK_ALL
[ Lock after landed OR

(landed override AND
Lock) ]
[ not All unlocked ] [ All locked ]
[ Lock after landed OR [ Unlock after landed OR

STARTUP
(landed override AND (landed override AND
Lock) ] IDLE
Unlock) ]
[ SpreaderStop = 0, Enable = 1 ]
[ All unlocked ]
[ All unlocked ]
DISABLED
[ Unlock after landed

OR (landed override
AND Unlock) ]
UNLOCK_ALL
Figure 8:1 State transition diagram: TLC4
8.1.1.2 Input ports
Input Type Description

Landed override Digital Overrides landed signals. Makes it
possible to unlock/lock if not all
sensors are active. This port must be
connected if enabled in hardware
configuration.
Enable Digital Enables component. If set to false
component will set all outputs to
false. Default value if not connected
is true (i.e. no effect).
Unlock command Digital Unlock command to unlock all
Twistlocks.
Lock command Digital Lock command to lock all
Twistlocks.
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Unlocked 1,...,Unlocked 4 Digital Sensor input from Twistlocks. Status

on unlocked sensor 1 to 4.
Locked 1,..., Locked 4 Digital Sensor input from Twistlocks. Status
on locked sensor 1 to 4.
Landed 1,..., Landed 4 Digital Sensor input from Twistlocks. Status
on landed sensor 1 to 4
8.1.1.3 Output ports
Output Type Description

Unlock Digital Unlock signal to all Twistlocks.
Lock Digital Lock signal to all Twistlocks.
Locked signal Digital All Twistlocks are locked.
Unlocked signal Digital All Twistlocks are unlocked.
Landed signal Digital All Twistlocks are landed.
8.1.1.4 Parameters
Parameter Unit Description

Delay Milliseconds Time after all landed sensors are true
[ms] and lock or unlock command will be
able to execute.
Timeout Twistlocks Milliseconds Time until a warning message will be
[ms] prompted if not all sensors are made
follow an output from the
component. (e.g. Locked 1,...,
Locked 4 shall become true within
this time when a lock output has
gone high.)
Timeout landed Milliseconds Time from the first landed input has
[ms] gone active until the system should
expect all the landed inputs active
and vice versa, the time from which
the first landed signal goes low until
all landed signals should have gone
low
Enable logging Digital If set to true (checked) the logging of
messages will be turned on otherwise
no logging will occur.
8.1.1.5 Message logging

This component generates the following messages stored in the fault and event log onboard the SCS2. The message log
can be turned on/off in the parameter settings view via the check box Enable logging.
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Code Message Description

60 TLC_NO_SENSOR No twist-lock sensor inputs active during
system start.
61 TLC_MULTIPEL_SENSOR One twist-lock indicating both locked and
unlocked.
62 TLC_LOCKED_SENSOR_MISSING Timeout while locking. Locked signal has
not been received after output to valve.
63 TLC_LOCKED_SENSOR_LOST Locked sensor lost during operation.
Sensor lost without command/output when
Twistlocks are all locked.
64 TLC_UNLOCKED_SENSOR_MISSING Timeout while unlocking. Unlocked signal
has not been received after output to valve.
65 TLC_UNLOCKED_SENSOR_LOST Unlocked sensor lost during operation.
Twistlocks are all unlocked.
66 TLC_LANDED_SENSOR_MISSING All landed sensors not received after first
landed and timeout.
67 TLC_LANDED_SENSOR_STUCK Landed sensor not released when the other
sensors not active and a timer has timed
out
118 TLC_LANDED_OVERRIDE_ACTIVAT When override input is set to true and
ED previous state is false.
119 TLC_LANDED_OVERRIDE_DEACTIV When override input is set to false and
ATED previous state is true.
175 TLC_LOCK_COMMAND Twist-lock lock command received
176 TLC_UNLOCK_COMMAND Twist-lock unlock command received
177 TLC_LOCKED All Twistlocks have been locked
178 TLC_UNLOCKED All Twistlocks have been unlocked
244 TLC_LANDED The spreader has been landed.
245 TLC_UNLANDED The Spreader has been totally lifted (not
landed)
8.1.2 TLC8 – Twistlock Controller 8

The Twistlock Controller 8 (TLC8) is used to control eight Twistlocks at the same time. This component incorporates the
functionality and interlocks for a Twistlock operation with eight Twistlocks. The component prevents the Twistlock from
changing state unless the landed pins have been active for the specified time, it also prevents pre-selection of unlock and
always keeps the outputs from the component active. Apart from the pure functionality of this component it also sends
event and warning messages to the log function of the system.

Twin is down (two containers):
“not All unlocked” = NOT (Unlocked 1 AND Unlocked 2,..., AND Unlocked 8)
“All unlocked” = Unlocked 1 AND Unlocked 2,..., AND Unlocked 8
Twin is up (single container):

“not All unlocked” = NOT (Unlocked 1 AND Unlocked 2,...,AND Unlocked 4)
“All unlocked” = Unlocked 1 AND Unlocked 2,..., AND Unlocked 4
“Unlock after landed” = when an unlock command is given after landed on all corners (and delay has elapsed if any)
“Lock after landed” = when a lock command is given after landed on all corners (and delay has elapsed if any)
States:
DISABLED:
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STARTUP:
LOCK_ALL:
Lock single and twin Twistlocks.
LOCK_SINGLE:
Lock single Twistlocks.
UNLOCK_ALL:
Unlock single and twin Twistlocks.
UNLOCK_SINGLE:
Unlock single Twistlocks.
IDLE:
When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not
changed from previous state.
For all states: LOCK_ALL LOCK_SIN LE

T ransition is m ade to DISABLED state if
[ T in is do n ]
[ T in is up ]
[ All locked ]
[ All locked ]
[ Unlock after landed OR

Unlock) ]
[ Unlock after landed
ST ART UP [ Lock after landed OR OR (landed override
[ Lock after landed OR
(landed override AND IDLE AND Unl ock) ]
Lock) ] Lock) ]
enable = 1
[ All unlocked ]
DISABLED [ All unlocked ]
[ T in is do n ]
T in is up
UNLOCK_SIN LE
UNLOCK_ALL
Figure 8:1 State transition diagram: TLC8
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8.1.2.2 Input ports

Landed override Digital Overrides landed signals. Makes it
possible to unlock/lock if not all
sensors are active. This port must be
connected if enabled in hardware
configuration.
Unlock command Digital Unlock command to unlock all
Twistlocks.
Lock command Digital Lock command to lock all
Twistlocks.
Twin unlocked 1 Digital Sensor input from Twistlocks. Status
… on unlocked sensor
Twin unlocked 4
Single unlocked 1 Digital Sensor input from Twistlocks. Status
… on unlocked sensor
Single unlocked 4
Twin locked 1 Digital Sensor input from Twistlocks. Status
… on locked sensor
Twin locked 4
Single locked 1 Digital Sensor input from Twistlocks. Status
… on locked sensor
Single locked 4
Twin landed 1 Digital Sensor input from Twistlocks. Status
… on landed sensor
Twin landed 4
Single landed 1 Digital Sensor input from Twistlocks. Status
… on landed sensor
Single landed 4
Twin is up Digital Input signal telling that Twinboxes
are up. Single Twistlocks are enabled
only.
TTDS Fault Digital Input signal telling that there is a
TTDS fault. Disables lock
operations.
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Unlock single Digital Unlock signal to single Twistlocks.

Unlock twin Digital Unlock signal to twin Twistlocks.
Lock single Digital Lock signal to single Twistlocks.
Lock twin Digital Lock signal to twin Twistlocks.
Locked signal Digital All Twistlocks are locked.
Unlocked signal Digital All Twistlocks are unlocked.
Landed signal Digital All Twistlocks are landed.
8.1.2.4 Parameters

Delay Milliseconds Time after all landed sensors are true
[ms] and lock or unlock command will be
able to execute.
Timeout Twistlocks Milliseconds Time until a warning message will be
[ms] prompted if not all sensors are made
follow an output from the
component. (e.g. Locked single 1,...,
Locked single 4 shall become true
within this time when a lock output
has gone high.)
Timeout landed Milliseconds Time from the first landed input has
[ms] gone active until the system should
expect all the landed inputs active
and vice versa, the time from which
the first landed signal goes low until
all landed signals should have gone
low
Enable logging Digital If set to true (checked) the logging of

60 TLC_NO_SENSOR No twist-lock sensor inputs active during
system start.
61 TLC_MULTIPEL_SENSOR One twist-lock indicating both locked and
unlocked.
62 TLC_LOCKED_SENSOR_MISSING Timeout while locking. Locked signal has
not been received after output to valve.
63 TLC_LOCKED_SENSOR_LOST Locked sensor lost during operation.
Twistlocks are all locked.
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64 TLC_UNLOCKED_SENSOR_MISSING Timeout while unlocking. Unlocked signal

has not been received after output to valve.
65 TLC_UNLOCKED_SENSOR_LOST Unlocked sensor lost during operation.
Twistlocks are all unlocked.
66 TLC_LANDED_SENSOR_MISSING All landed sensors not received after first
landed and timeout.
67 TLC_LANDED_SENSOR_STUCK Landed sensor not released when the other
sensors not active and a timer has timed
out
118 TLC_LANDED_OVERRIDE_ACTIVAT When override input is set to true and
ED previous state is false.
119 TLC_LANDED_OVERRIDE_DEACTIV When override input is set to false and
ATED previous state is true.
175 TLC_LOCK_COMMAND Twist-lock lock command received
176 TLC_UNLOCK_COMMAND Twist-lock unlock command received
177 TLC_LOCKED All Twistlocks have been locked
178 TLC_UNLOCKED All Twistlocks have been unlocked
244 TLC_LANDED The spreader has been landed.
245 TLC_UNLANDED The Spreader has been totally lifted (not
landed)
8.1.3 FAC – Flipper Arm Controller

The FAC component is used for grouping and controlling a number of Flippers determined by a parameter of the
component. The function sets either the up or down output at all times depending on the parameter settings. The inputs to
the component generate event messages to the onboard log if enabled.
States:
DISABLED:
STARTUP:
IDLE:
This state is reached emedeately after UP or DOWN states have been reached.
UP:
All Flippers are sent up.
DOWN:
All Flippers are sent down.
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For all s tates :

UP
[ UpCom m and ]
START_UP IDLE
[ Do nCom m and ]
DISABLED DO N
Figure 8:1 State transition diagram: FAC
8.1.3.2 Input ports

Up command Digital Command to send all Flippers up.
Down command Digital Command to send all Flippers down.

Flipper up 1,..., Flipper up n Digital Up signal to Flipper 1 to n. The
number of Flippers (n) is derived
from the parameter Number of
Flippers.
Flipper down 1,..., Flipper down n Digital Down signal to Flipper 1 to n. The
number of Flippers (n) is derived
from the parameter Number of
Flippers.
8.1.3.4 Parameters

Number of Flippers Number The number of Flippers to be
controlled.
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Operation mode Option Impulse (only impulse required for

the command to execute) or Constant
(constant command required).
Enable logging Option If set to true (checked) the logging of


246 FAC_UP_COMMAND Flipper up command received
247 FAC_DOWN_COMMAND Flipper down command received
8.1.4 DPS – Discrete Positioning System

The DPS is used for controlling the chain telescope of a Spreader with proximity switch or screw limit switch box
indicating the stops. The component can be used both with telescopic system using direct commands for each position as
well as systems using expand/retract commands to increment/decrement between the positions. The number of positions
are chosen via a component parameter. Parts of its’ behaviour such as if it requires impulse commands or constant
commands etc are selected by parameters. The intermediate positions are designed to have two sensors per stop but will
perform correctly with one sensor per intermediate position provided it is connected (in the software) to both the inputs of
that position on the component. The outputs of the component are interlocked to unlocked and landed. The feedback from
the component is a signal indicating what position has bee reached as well as a signal indicating that any valid stop has
been reached. The component generates a number of events and warnings if positions aren’t reached within a parameter
adjusted time etc.
The DPS component is equipped with an “fast I/O concept”, this means that the component sampels the input sensors at a
higher frequency and sets the actuators according to the internal logic. This will improve the overall performance of the
component. To utilise this feature please note that the position sensors and actuators must be physically connected to the
same node and that no logic is to be placed on the components outputs (Expand, Retract).
If sensors and actuators not connected to the same node the “fast I/O concept” will be disabled.
States:
DISABLED:
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
EXPAND:
Expanding to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X
command is given. A transition is made to IDLE state when next stop is reached.
RETRACT:
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Retracting to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X
command is given. A transition is made to IDLE state when next stop is reached.
CONSTANT REPEAT:
When stopped at a position a new constant command is required to go to another position. Depressed keys or similar must
be released before a new command will be excepted.
Example:
1. Expand command is given.
2. Next stop is reached.
3. The telescope stops.
4. Expand command is released.
5. New expand command is given.
6. The telescope continues.
DELAY:
A delay is made for a time defined by Stop delay time (parameter). This delay is only performed if Delay is set in
Operation mode (parameter) else ignored.
“currentCommand” = is always EXPAND or RETRACT. The command inputs Retract / Expand command or Return to
position X. These command inputs are internally converted to EXPAND or RETRACT depending on current position
and desired position.
For all s tates :

[ desiredStop = currentStop, [ desiredStop = current

Operation m ode = Delay ] E PAND Stop, Operation m ode =
Cons tant repeat ]
[ currentCom m and = E PAND ]
[ Dela perform ed ] CONSTANT REPEAT

DELA IDLE [ com m andInput =
NO_CMD ]
[ currentCom m and = RETRACT ]
[ desiredStop = currentStop,
Operation m ode = Cons tant repeat ]
RETRACT
[ desiredStop = currentStop,
Operation m ode = Delay ]
START_UP DISABLED
[ SpreaderStop = 0,
Enable = 1 ]
Figure 8:1 State transition diagram: DPS
8.1.4.2 Input ports
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Expand command Digital Input command to expand telescope
to next stop.
Retract command Digital Input command to retract telescope
to next stop.
Return to position 0 Digital Input command to expand telescope
… to predefined stop. The number of
Return to position n predefined stops is set by the
parameter Number of stops.
Sensor 0 Digital Sensor input.
...
Example with 4 stops:
Sensor n
Stop number 1 has Stop sensor 1,
Stop number 2 has Stop sensor 2 + 3,
Stop number 3 has Stop sensor 4 + 5,
Stop number 4 has Stop sensor 6.
Etc..
Any landed Digital Sensor input from landed sensors.
Prevents telescoping when landed.
All unlocked Digital Sensor input from unlocked sensors.
Permits telescoping when unlocked.
Slave Digital Enables slave mode. Telescope will
run at full speed, only Retract and
Expand commands are enabled and
no stops are enabled

Expand Digital Output to expand telescope.
Retract Digital Output to retract telescope.
In position 0,..., Reached stop n Digital Output signal indicating that the
specific valid stop has been reached.
In position Digital Output signal indicating that a valid
stop has been reached.
8.1.4.4 Parameters
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Timeout Milliseconds Time permitted from when an output

[ms] is turned on until a valid position
should be reached. If this time is
exceeded the motion will be stopped
and a warning generated.
Operation mode Option Impulse, Delay and Constant repeat.
Delay at each stop Milliseconds Time the telescope is delayed
[ms] (stopped) at each stop.
Number of stops Number The number of stops in use.
Enable logging Option If set to true (checked) the storing of
no generated messages will be stored.


68 DPS_TIMEOUT No valid stop reached within timeout
time.
69 DPS_SENSOR_MISSING The expected sensor has not been
reached within specified sequence.
70 DPS_SENSOR_LOST Position sensor has been lost without
any command given
71 DPS_MULTIPEL_SENSOR More than one position sensor active
simultaneously.
179 DPS_EXPAND_COMMAND Expand command received
180 DPS_RETRACT_COMMAND Retract command received
181 DPS_GOPOS_COMMAND A command to go to a certain
position received
182 DPS_STOP_REACHED A valid position has been reached
8.1.5 Tower – Head block

The Tower component is used to adjust the point of gravity.
States:
DISABLED:
STARTUP:
IDLE:
FEED_LEFT:
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Feeds the Tower to the left.
FEED_RIGHT:
Feeds the Tower to the right.
CENTER:
Centres the tower. The Tower is centred when both At left sensor and At right sensor is true.
DELAY:
A delay is performed for a time defined by Direction change time (parameter).
or all s tates
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
D_ D_ I
[ eed ri t]
[ eed le t ]
S _ ID
[ SpreaderStop = , na le = ]
[ Center ]
[ Delay per orm ed ]
DIS D
C N D
Figure 8:1 State transition diagram: Tower
8.1.5.2 Input ports

Enable right Digital Enables feeding in right direction.
Default value if not connected is true
(i.e. no effect).
Enable left Digital Enables feeding in left direction.
(i.e. no effect).
Right end sensor Digital Position sensor input.
At right sensor Digital Position sensor input.
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At left sensor Digital Position sensor input.

Left end sensor Digital Position sensor input.
Right command Digital Input command to feed head block
right.
Left command Digital Input command to feed head block
left.
Centre command Digital Input command to feed head to the
centre position.

In centre Digital Output signal telling Head block is in
centre position.
At right side Digital Output signal telling Head block is to
the right.
At left side Digital Output signal telling Head block is to
the left.
Feed right Digital Output signal to feed Head block
right.
Feed left Digital Output signal to feed Head block left.
8.1.5.4 Parameters

Operation mode Option Constant or Impulse. Impulse is only
valid for the Centre command
Delay Milliseconds Time before a change of direction
[ms] will take effect.
Timeout Milliseconds Time permitted from when an output
[ms] is turned on until a valid position
exceeded the motion will be stopped.
Use end stops Option If set true (checked) Right end sensor
and Left end sensor does not need to
be connected.

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325 TOWER_CENTER_COMMAND Centre command is given.
326 TOWER_LEFT_COMMAND Feed left command is given.
327 TOWER_RIGHT_COMMAND Feed right command is given.
328 TOWER_REACHED_CENTER_POS Tower has reached centre position.
329 TOWER_REACHED_LEFT_POS Tower has reached left position.
330 TOWER_REACHED_RIGHT_POS Tower has reached right position.
369 TOWER_TIMEOUT Tower has not reached the desired
position within the time limit.
8.1.6 APS – Automatic Positioning System

The APS component is used for positioning the chain telescope using an absolute encoder input to read the position of the
chain. Due to the feedback from the sensor, self-correcting is possible if the Spreader is knocked out of position. It is
possible to use both proportional controls (PWM) as well as on/off control with this component. The component can be
used both with telescopic system using direct commands for each position as well as systems using expand/retract
commands to increment/decrement between the positions. The number of positions is chosen via a component parameter
as well as are certain parts of its’ behaviour such as if it requires impulse commands or constant commands etc. The
absolute value (count) for each position is done via teach in functionality.
States:
DISABLED:
STARTUP:
IDLE:
Expand command or Go position command (depending on current position) makes a transition to EXPAND state.
Retract command or Go position command (depending on current position) makes a transition to RETRACT state.
EXPAND:
Expands telescope.
PWM expand output is set to maximum (High speed) if not in Low speed window or in Stop window.
PWM expand output is set to minimum (Low speed) if in Low speed window.
PWM expand output is set to zero if in Stop window.
Digital expand output is set to false if in Stop window else true.
RETRACT:
Retracts telescope.
PWM retract output is set to maximum (High speed) if not in Low speed window or in Stop window.
PWM retract output is set to minimum (Low speed) if in Low speed window.
PWM retract output is set to zero if in Stop window.
Digital retract output is set to false if in Stop window else true.
DELAY:
Performs a delay (Stop delay time) at each stop if Delay is selected in Operation mode (parameter)
Expand and retract outputs are set to false in this state.
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CONSTANT_REPEAT:
A new Expand or Retract command must be given to leave this state if Constant repeat is selected in Operation mode
(parameter).
Expand and retract outputs are set to false in this state.
or all s tates
ND [ Operation m ode = Delay ] D
[ desired os ition
current os ition ]
[ Operation m ode = [ Operation m ode = Delay,

Im puls e, des ired osition des ired os ition = current os ition ]
= current os ition ]
[ Delay per orm ed ]
S ID
[ no utton is pres s ed ]
[ Operation m ode = Im puls e,

des ired os ition = current
os ition ] [ Operation m ode = Cons tant repeat,
des ired os ition = current os ition ]
[ desired os ition
current os ition ]
DIS D [ Operation m ode =

C Cons tant repeat ] CONS N
Figure 8:1 State transition diagram: APS
8.1.6.2 Teaching telescope positions

This component has to be taught the absolute value (encoder count) of each position. This is done by having the Teach
input go high and at the same time giving the command of the current position to be taught. The current value of the
encoder is then saved onboard the Spreader. All positions, that have been enabled via the parameter Number of stops,
have to be taught a value.
8.1.6.3 Input ports
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Teach Digital Command to teach in new positions.
When this signal is true any Go
position command will store a new
position for corresponding stop.
Slave mode Digital Enables slave mode. Telescope will
run at full speed, only Retract and
Expand commands are enabled and
no stops are enabled.
Hooks are up Digital Input signal indicating that all hooks
are in up position. Only used for twin
telescopic Spreaders. I.e. if nothing is
connected here telescoping is
permitted, can also be used as a
general permit.
Any landed Digital Input result from landed sensors.
Go position 0 Digital Command to feed to defined
… positions 0,...,n.
Go position n
Retract command Digital Command to retract telescope.
Expand command Digital Command to expand telescope.
Current position Analogue Scaled input signal of the current
position.

Stop position0 Analogue Output signal indicating the stored
… positions for the corresponding stop.
Stop position n
In position Digital Output signal indicating that a valid
stop has been reached.
In position 0 Digital Output signal indicating that the
… specific valid stop has been reached.
In position n
PWM retract PWM PWM output to control the telescope.
Range 0-1000
PWM expand PWM PWM output to control the telescope.
Range 0-1000
Digital retract Digital Digital output to control the
telescope.
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Digital expand Digital Digital output to control the

telescope.
Digital high speed Digital Digital output for high speed
telescoping in two-speed system.
8.1.6.5 Parameters

Delay at each stop Milliseconds Delay time at each stop if Expand or
[ms] Retract command is given and Delay
is enabled under Operation mode.
Timeout Milliseconds Time until from when an output is
[ms] turned on until a valid position
Number of stops Number The number of stops enabled.
Auto correction Option If enabled the APS will feed back the
telescope to its original position if it
of some reason has got out of
position.
Operation mode Option Impulse: sequence completes until a
new command is given
Delay: delay at each stop
Constant repeat: when a stop is
reached a new expand or retract
command must be given.
Stop window Millimetre Distance from defined stop to be
considered as a stop.
[mm]
Signal window Millimetre Window around the desired position
[mm] in which a signal indicating that the
correct position has been reached is
given.
Impact range Millimetre Hysterisis for impact detection.
[mm]
Impact off delay timer Milliseconds Delay after impact detected to run.
[ms]
Length of travel Millimetre Distance between minimum and
maximum positions.
[mm]
Time of telescope Milliseconds Time between minimum and
maximum positions.
[ms]
Ramp Gain Number Ramp gain.
[value *1000]
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Ramp offset Millimetre Ramp offset for stop speed

[mm]
Time to reach max speed Milliseconds The time it shall take to reach max
speed.
[ms]
Proportional Gain Number Proportional part of the PI regulator
[value *1000]
Integral Gain Number Integral part of the PI regulator
[value *1000]
PWM value for teach Number PWM output when teach enabled.
Reverse Min PWM output Number Minimum value on PWM that causes
a reversed movement.
Reverse Max PWM output Number Maximum value on PWM that causes
a reversed movement
Forward Min PWM output Number Minimum value on PWM that causes
a forward movement.
Forward Max PWM output Number Maximum value on PWM that causes
a forward movement.

The following messages are generated by this component. This component generates the following message stored in the
fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check
box Enable logging.

183 APS_TIMEOUT The telescope hasn't reached its' position within time
limit.
184 APS_EXPAND_COMMAND Expand command received
185 APS_RETRACT_COMMAND Retract command received
186 APS_GOPOS_COMMAND Command to go to a specific position received
187 APS_STOP_REACHED The desired position reached
272 APS_TEACH_COMMAND Teach in command received
396 APS_IMPACT_ON Impact is detected
397 APS_AUTOCORR_ON Spreader is auto correcting
398 APS_IN_VALUE_OUT_OF_T The position value is not within the teached range.
EACH_RANGE
399 APS_IMPACT_OUT_OF_SIG_ Spreader is bumped out of signal window.
WIN
8.1.7 MPS – Memory position system

The MPS component stores either a predefined value or a value set during run time and can then position the twin
telescope to this/these positions on given commands. The MPS uses an absolute input value and can either be used to
return the twin telescope to a number of predefined positions (taught in and stored in the NVRAM). The driver also has
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the possibility of storing the current position in a volatile memory of the SCS2 and then returning to this position via a
command until the power is cycled or a new position is stored.
States:
DISABLED:
STARTUP:
IDLE:
Expand command, Returned to logged position command (depending on current position) and Go to predefined position
(depending on current position) makes a transition to EXPAND state.
Retract command, Returned to logged position command (depending on current position) and Go to predefined position
(depending on current position) makes a transition to RETRACT state.
EXPAND:
Expands the Twin boxes until position is within range Stop window from desired stop.
RETRACT:
Retracts the Twin boxes until position is within range Stop window from desired stop.
or all s tates
[ desired os ition current os ition ]
[ desired os ition = current os ition ]
S ID
[ desired os ition = current os ition ]

[ desired os ition current os ition ]
DIS D
ND
Figure 8:1 State transition diagram: MPS
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8.1.7.2 Input ports

Current position Analogue Scaled input signal reading the
current position.
Return to predefined position 0 Digital Command to feed Twin boxes to
... predefined position 0,...,n
Return to predefined position n
Returned to stored position 0 Digital Command to feed Twin boxes to

... logged position 0,...,n
Returned to stored position n
Store new position 0 Digital Command to log new positions.
... When this signal is true the current
Store new position n position will be stored in the RAM of
the SCS2.
Teach Digital Command to teach in new positions.
When this signal is true any Go to
pre-defined position command will
store a new position for
corresponding stop.

Current reference position Analogue Signal indicating the currently
desired position.
Predefined position 0 Analogue Signal indicating the positions for the
… corresponding predefined stop.
Predefined position n
Predefined position 0 Analogue Signal indicating the positions for the
… corresponding predefined stop.
Predefined position n
Logged position 0 Analogue Output signal indicating the positions
… for the corresponding logged stop.
Logged position n
In position Digital Output signal indicating that any
position has been reached & logged
or predefined).
Expand Digital Output signal to expand Twin boxes.
Retract Digital Output signal to retract Twin boxes.
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8.1.7.4 Parameters

Stop window Millimetre Offset from stop to be considered as
[mm] a stop.
Operation mode Option Impulse: sequence completes until a
new command is given
Constant: when a stop is reached a
new expand or retract command must
be given.
Predefined positions Number The number of stops that will be
stored in none volatile memory. (I.e.
positions will be available after
shutting down system.)
Storable positions Number The number of stops that will be
stored in volatile memory. (I.e.
positions will be lost when shutting
down system.)
Timeout Milliseconds Time from when an output is turned
[ms] on until a valid position should be
reached. If this time is exceeded the
motion will be stopped and a warning
generated.

box Enable logging.

281 MPS_TEACH_PREDEF_POS Teach command received.
282 MPS_GO_PREDEF_POS Command to go to a pre-defined position has
been received.
280 MPS_TEACH_LOGGED_POS A command to store a new value for a log
position has been received.
284 MPS_GO_LOGGED_POS A command to return to a log position has been
received.
285 MPS_TIMEOUT The twin-legs haven't reached their requested
position within time limit.
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8.1.8 Twin Telescope

The Twin Telescope component transfers the commands to expand and retract the twin telescope to the necessary outputs.
The component, although it doesn’t hold much functionality, is useful for the event log.
States:
DISABLED:
STARTUP:
IDLE:
Expand command makes a transition to EXPAND state if In 45ft sensor is false.
Retract command makes a transition to RETRACT state if one not In zero left sensor is true and if not In zero right
sensor is false.
EXPAND:
Expands the Twin boxes as long as Expand command is given and In 45ft is false.
RETRACT:
Retracts the Twin boxes as long as Retract command is given and both In zero left and In zero right sensors are false.
or all s tates
ND
[ pand, in os ]
[ pand O in os ]
S ID
[ etract O in ero os e t, in
[ SpreaderStop, na le ] ero os i t ]
[ etract, in ero os e t,
in ero os i t ]
DIS D C
Figure 8:1 State transition diagram: Twin Telescope
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8.1.8.2 Input ports

In 45ft Digital Sensor input signal.
In zero right Digital Sensor input signal.
In zero left Digital Sensor input signal.
Retract command Digital Command input to retract the twin
boxes.
Expand command Digital Command input to expand the twin
boxes.

Retract Digital Output signal to retract twin boxes.
Expand Digital Output signal to expand twin boxes.
8.1.8.4 Parameters

Timeout Milliseconds Time until from when an output is
[ms] turned on until a valid position

box Enable logging.

273 TWINTELE_EXPAND_COMMAND Expand command received
274 TWINTELE_RETRACT_COMMAND Retract command received
275 TWINTELE_REACHED_ZERO_LEFT Left console reached zero gap position
276 TWINTELE_REACHED_ZERO_RIGHT Right console reached zero gap position
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277 TWINTELE_EXPANDING Twinlegs expand in motion
278 TWINTELE_RETRACTING Twinlegs retract in motion

279 TWINTELE_TIMEOUT Hasn't reached an end stop when in motion
within time limit
8.1.9 TwinUpDown
The TwinUpDown component is designed to be used on the twin telescopic Spreaders. The component performs the twin
up and twin down sequences automatically upon the commands twin up and twin down. The sequence for twin down
consists of the twin units separating until the Left attach & right attach permits have been made. Thereafter the hooks
situated on the tension rod are lowered and finally the twin boxes are lowered. The sequence for twin up consists of the
hooks on the tension rod being raised followed by the twin boxes being raised. The twin consoles are now retracted until
the zero position switches are made, the retract output is active for a short off-delay after that to ensure that both units are
fully retracted. When a complete up sequence has been performed a pulse is given on the output “ Twin up ready pulse ”,
which in turn can be used for instance to run the Spreader back to the correct single 40ft position.
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IN_ IN_DO N
[ all in p oo e t [ all in p oo [ t inDo n e ues tM ]
Disconnected oo i t e tDis connected
Disconnected ] IS _ O S
oo i tDis connected ]
CONN C
[ all in p ] [ all in p ]
[ oo e tConnected oo
[ all in p i tConnected ]
oo e tDis connected
IS _ OO S oo i t
Disconnected ]
[ oo e tDis connected
oo i tDis connected ] O S_DO N
[ t inIn ero os e t
t inIn ero os i t ] INC _IN
[ las t in pStateM = O
_D _INC t inIn ero [ any in p ] [ any in p ]
os e t t inIn ero os
i t ener is eInc InM ]
O D_DO N
O D_
O _D _INC
[ t inIn ero os e t t inIn
ero os i t delayM is im eout ]
rans ition to ID s tate i rans ition to ID s tate i
t inDo nCom m and t in pCom m and
[ t in pCom m and ]
[ t inDo nCom m and ] [ t inDo n e ues tM t in

Do nCom m and oo e t
Connected oo i tConnected ]
ID
[ any in p oo
e tConnected oo [ t in p e ues tM ] [ any in p oo
i tConnected ] e tConnected oo
i tConnected ]
or all s tates
[ SpreaderStop = , na le = ] DIS D
Figure 8:1 State transition diagram: TwinUpDown
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8.1.9.2 Input ports

Twin box up 1 Digital Sensor input indicating that Twin
… boxes are up.
Twin box up 4
Hook connected right Digital Sensor input indicating that right
hook is down.
Hook connected left Digital Sensor input indicating that left hook
is down.
Right attach permit Digital Sensor input indicating that position
has been reached to attach twin boxes
on right side.
Left attach permit Digital Sensor input indicating that position
has been reached to attach twin boxes
on left side.
Hook disconnected right Digital Sensor input indicating that hook is
up on right side.
Hook disconnected left Digital Sensor input indicating that hook is
up on left side.
Twin in zero right Digital Sensor input indicating that Twin
boxes has reached zero position on
right side.
Twin in zero left Digital Sensor input indicating that Twin
boxes has reached zero position on
left side.
Chain in 40ft Digital Sensor input indicating that chain is
in 40ft position.
Permit twin down Digital Permits down motion if set to true.
Permit twin up Digital Permits up motion if set to true.
Twin down command Digital Command to send Twin boxes down.
Twin up command Digital Command to send Twin boxes up.
8.1.9.3 Output port

Twin up ready pulse Digital Signal telling that up sequence is
completed.
Twin down Digital Signal to lower Twin boxes.
Twin up Digital Signal to raise Twin boxes.
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Disconnect twin unit left Digital Signal to disconnect left hook.

Disconnect twin unit right Digital Signal to disconnect right hook.
Connect twin unit left Digital Signal to connect left hook.
Connect twin unit right Digital Signal to connect right hook.
Inch to zero gap Digital Signal to inch in Twin boxes.
Inch to connect left Digital Signal to inch out left Twin box.
Inch to connect right Digital Signal to inch out right Twin box.
8.1.9.4 Parameters

Timeout Twin down Milliseconds Time until a warning message will be
[ms] prompted if sequence doesn’t
complete.
Timeout hook Milliseconds Time until a warning message will be
complete.
Timeout Twin inching Milliseconds Time until a warning message will be
complete.

box Enable logging.

255 TWIN_BOXES_UP_TIMEOUT Twin boxes have failed to get to their
upper position within time limit.
256 TWIN_HOOK_LEFT_UP_TIMEOUT Left hook has failed to reach its' upper
257 TWIN_HOOK_RIGHT_UP_TIMEOUT Right hook has failed to reach its' upper
258 TWIN_ATTACHLEFT_TIMEOUT Twin boxes left timed out when
expanding to their attach position. Failed
to reach switch within time limit.
259 TWIN_ATTACHRIGHT_TIMEOUT Twin-boxes right timed out when
expanding to their attach position. Failed
to reach switch within time limit.
260 TWIN_HOOK_LEFT_DN_TIMEOUT Left hook has failed to reach its' lower
position (connect) within time limit.
261 TWIN_HOOK_RIGHT_DN_TIMEOUT Right hook has failed to reach its' lower
position (connect) within time limit.
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262 TWIN_BOXES_DOWN_TIMEOUT Twin-boxes have failed to get to their

lower position within time limit.
263 TWIN_TWIN_SENSOR_LOST Twin up sensor lost unexpectedly. (not
due to output).
264 TWIN_BOXES_UP_SENSOR_LOST Twin up sensor received when twin-
boxes are down.
265 TWIN_HOOK_DN_LEFT_SENSOR_LOST Left hook down sensor lost
unexpectedly.
266 TWIN_HOOK_DN_RIGHT_SENSOR_LOST Right hook down sensor lost
unexpectedly.
267 TWIN_HOOK_UP_LEFT_SENSOR_LOST Left hook up sensor lost unexpectedly.
268 TWIN_HOOK_UP_RIGHT_SENSOR_LOST Right hook up sensor lost unexpectedly.
286 TWIN_UP_COMMAND Twin up command has been received.
287 TWIN_DOWN_COMMAND Twin down command has been received.
288 TWIN_BOXES_ARE_UP Twin boxes have reached their upper
position.
289 TWIN_BOXES_ARE_DOWN Twin boxes have reached their lower
position.
8.1.10 PID
8.1.10.1 Overview
The PID components are used to control fast processes, e.g. positioning, syncronisation and control of hydraulic cylinders
with special requirements.
Each PID component controls a single cylinder, but usually they ared used in pair and then 2 PID components are needed.
The PID component have the following features:
Position control
Velocity control
Syncronisation of two cylinders
Acceleration limitation
These features are described in the following sections 8.1.10.2-8.1.10.5.
The implementation and hands-on configuration are described in section 8.1.10.6.
8.1.10.2 Position control

The PID component can use either position mode or velocity mode depending on which way to coontrol it. In position
mode you give a reference position in millimeters. Then the cylinder moves to that position as fast as possible with
configured constraints. The constraints are defined by the Acceleration limit (see 8.1.10.5).
The position mode can be activated in run time.
8.1.10.3 Velocity control

In velocity mode you give a reference velocity in percent (range –100 to 100) of the maximum speed. The cylinder then
moves in correct direction and at reference speed. When giving a new reference speed the cylinder reaches that speed as
fast as possible with configured constraints. The constraints are defined by the Acceleration limit (see 8.1.10.5).
The velocity mode can be activated in run time.
When you control the cylinder movement with a joystick velocity mode is the best way to do it.
8.1.10.4 Syncronisation of two cylinders

Some systems want to syncronise two cylinders so that they move in parallel. A syncronisation regulator is available in
the PID to handle this.
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There are two different kind of syncronisation modes:

Parallel sync
Non-parallel sync
Parallel sync is used when the cylinders must be parallel all the time. In run time you can set the difference in position
between the two cylinders. Usually this is set to zero. Parallel sync is valid for both positions mode and velocity mode.
Non-parallel sync is used when the cylinders shall move syncronised, but not in parallel. In position mode this means
that when you can move the two cylinders from separate source positions to two other separate destination positions
during the same amount of time. This means that they can move in the same direction or in different directions.
In velocity mode you can move the cylinders syncronised at a certain speed without loosing their difference in position.
You can either move them in the same direction or in different directions.
8.1.10.5 Acceleration limitation

Some systems cannot handle too high acceleration in the cylinder movements. Therefore an acceleration limiter is
installed and can be used. The limiter works for both acceleration and retardation.
The limiter is always active, independent of position/velocity mode or syncronisation mode.
8.1.10.6 Implementation
Each node are equipped with two PID components that can be used.
Each PID can control a single cylinder. All parameters for each cylinder are located in the corresponding PID. To identify
the two PIDs each component has a parameter called Regulator index which has to be set to 0 and 1 respectively.
When using sync mode both PID components cooperate and the sync parameters are taken from PID0.
For more detailed information about the implementation, it is reffered to a special document describing the PID
component and AutoTuner component.
8.1.10.7 Input Ports

Enable Digital Enables regulator if set true.
Regulator mode Digital Sets the operational mode,
POSITION (Low level, 0) or
VELOCITY (High level, 1).
Sync parallel mode Digital
Synchronise Digital
Reference value Analogue Reference value. This signal is scaled

within the component and must not
be pre-scaled or scaled to desired
value.
(Port not visible in ABE)

Sensor value Analogue Depending on regulator index the
sensor signal will be read from either
analogue input 0 or analogue input 1.
This signal is scaled within the
component and must not be pre-
scaled.
8.1.10.8 Output Ports
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Retract output (PWM) Analogue The actual value sent to the PWM
when retracting.
Remark: This output is not really
needed cause the regulator will work
anyway. This output is used to
connect to other components for
reference only.
Expand output (PWM) Analogue The actual value sent to the PWM
when expanding.
Remark: This output is not really
needed cause the regulator will work
anyway. This output is used to
connect to other components for
reference only.
Retracting Digital This signal indicates that the
regulator is retracting.
Expanding Digital This signal indicates that the
regulator is expanding.
(Ports not visible in ABE)

PWM 0 Analogue Used for forward output (PID 0 which
is the same as Regulator index 0).
PWM 1 Analogue Used for reverse output (PID 0 which
PWM 2 Analogue Used for forward output (PID 1 which
PWM 3 Analogue Used for reverse output (PID 1 which
8.1.10.9 Parameters

Filter weight Percent The percentage weight of the
previously filtered signal.
[%]
Aim window Millimetres The distance from the reference
position where to aim for the non-
[mm]
linear regulator. It is only used in
Position mode.
Rate limiter gain Number This should be the frequency [Hz],
i.e. 1/sample interval.
Fraction of square root Percent Fraction of the non-linear regulator
signal to use. Should be between 60-
[%]
90.
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Switch window Millimetres Distance from reference position

where to switch from the non linear
[mm]
regulator to the PI regulator. This
parameter must be higher than the
Aim window parameter. It is only
used in Position mode.
Time to reach input Milliseconds Time to reach full effect of reference
velocity. It is only used in Velocity
[ms]
mode.
Sync max integrator Percent Maximum integrator percent in sync
mode. It is only used in Sync mode.
[%]
Sync Integral (I) Number Integral part in sync regulator. It is
only used in Sync mode.
[value * 1000]
Sync Proportional (P) Number Proportional part in sync regulator. It
is only used in Sync mode.
[value * 1000]
Sample interval Milliseconds Sampling interval.
[ms]
Velocity window Percent When regulating velocity and if the
Reference value is inside Velocity
[%]
window it is interpreted as zero.
Position window Millimetres When regulating position the
cylinder will stop when it reaches
[mm]
reference position +/- Position
window.
Device length Millimetres Length of cylinder that is to be
controlled.
[mm]
Insignal max Number Maximum insignal from analogue
input.
Insignal min Number Minimum insignal from analogue
input.
R Half PWM time Milliseconds Time for transportation between
[ms] Device length and 0 at R Half PWM.
R Max PWM time Milliseconds Time for transportation between
[ms] Device length and 0 at R Max PWM.
R Min PWM Number Minimum PWM output that causes
movement of piston. (Lower
threshold limit).
R Half PWM Number PWM output between R Min PWM
and R Max PWM.
Approx. (R Min PWM + R Max
PWM) / 2
R Max PWM Number Minimum PWM output at max
speed. (Upper threshold limit).
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F Half PWM time Milliseconds Time for transportation between 0

[ms] and Device length at F Half PWM.
F Max PWM time Milliseconds Time for transportation between 0
[ms] and Device length at F Max PWM.
F Min PWM Number Minimum PWM output that causes
movement of piston. (Lower
threshold limit).
F Half PWM Number PWM output between F Min PWM
and F Max PWM.
Approx. (F Min PWM + F Max
PWM) / 2
F Max PWM Number Minimum PWM output at max
speed. (Upper threshold limit).
Pos. Integral (I) Number Integral part of PI regulator. Only
used in Position mode.
[value * 1000]
Pos. Proportional (P) Number Proportional part of PI regulator.
Only used in Position mode.
[value * 1000]
Acceleration limit Milliseconds Minimum time for valve to open full
and to close full.
[ms]
Regulator index Number Index 0 corresponds to PWM0,
PWM1 and analogue input 0.
Index 1 corresponds to PWM2,
Node Option Location of regulator. Choose
between B1 – B8 and A1 – A4.
Store mode Option Select which parameters to use:
ALL PARAMS: use all parameters
from NVRAM stored by AutoTuner
REGULATOR PARAMS: use only
the regulator parameters from
NVRAM stored by AutoTuner
LINEAR PARAMS: use only linear
parameters from NVRAM stored by
AutoTuner
ABE ONLY: use parameters only
from Spreader program file
8.1.11 AutoTuner
This component is intended as a help when setting up the PID component. It will automatically move the cylinder(s) and
measuring it’s characteristics when component is enabled. If one intentions are to synchronize two cylinders with PID
components, it’s possible to adapt the two cylinders with the use of this component. This is done by enabling the check
box Prepare for sync parameter.
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The AutoTuner will store it’s measured parameters in the onboard NVRAM. These parameters can then be uploaded and
monitored/transferred to the matching PID component. It is important that the Record name is identical to the PID that is
supposed to use the auto tuned parameters.
For more detailed information about the implementation, it is reffered to a special document describing the PID
component and AutoTuner component.
8.1.11.1 Input ports

Enable Digital Enables component if set true. When
the enable input goes from 0 to 1 the
auto tune procedure is restarted.
Slave Analogue Sensor input signal for the slave
cylinder. Only needed if prepare for
sync is checked.
Main Analogue Sensor input signal for the cylinder to
auto tune.

Finished Digital Output for telling when tuning is
complete.
Slave Retract Analogue Output for retracting slave cylinder.
Only needed if prepare for sync is
checked. This shall be connected to
the PWM output for the slave
cylinder.
Slave Expand Analogue Output for expanding slave cylinder.
Only needed if prepare for sync is
checked. This shall be connected to
the PWM output for the slave
cylinder.
Main Retract Analogue Output for retracting main cylinder.
This shall be connected to the PWM
output for the cylinder to auto tune.
Main Expand Analogue Output for expanding main cylinder.
This shall be connected to the PWM
output for the cylinder to auto tune.
8.1.11.3 Parameters
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Position window Millimeter When regulating position the

cylinder will stop when it reaches
[mm]
reference position +/- Position
window.
Velocity window Percents When regulating velocity and if the
Reference value is inside Velocity
[%]
window it is interpreted as zero.
Sync Proportional [P] Number Proportional part in sync regulator. It
is only used in Sync mode.
[value * 1000]
Sync Integral [I] Number Integral part in sync regulator. It is
only used in Sync mode.
[value * 1000]
Sync max integrator Percents Maximum integrator percent in sync
mode. It is only used in Sync mode.
[%]
Time to reach input Milliseconds Time to reach full effect of reference
velocity. It is only used in Velocity
[ms]
mode.
Fraction of square root Percents Fraction of the non-linear regulator
signal to use. Should be between 60-
[%]
90.
Filter weight Percents The percentage weight of the
previously filtered signal.
[%]
Natural frequency Number
[value * 1000]
Moderation factor Number
[value * 1000]
Regulator index Number Index 0 corresponds to PWM0,
Index 1 corresponds to PWM2,
Sample interval Milliseconds Sampling interval.
[ms]
Acceleration limit Milliseconds Minimum time for valve to open full
and to close full.
[ms]
Device length Millimetre Length of cylinder that is to be
controlled.
[mm]
Timeout Milliseconds Timeout for a full cylinder stroke.
This parameter must be greater than
[ms]
the tiem it takes for the cylinder to
perform a full stroke.
Record name Text The instance name of the matching
PID component.
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Prepare for sync Option This shall be enabled when using

syncronisation between two
cylinders. Adapts the faster cylinder
to the slower one.

fault and event log onboard the SCS2.

385 AUTOTUNER_STORED_IN_NVRAM The component has stored it’s
parameters in NVRAM.
8.2 AnyBus
8.2.1 Introduction
Apart from the parallel I/O of the nodes, each node can be equipped with an AnyBus card used for external buses. This
card is fitted into the node on the connector at the right side of the board when the cover is off. By using the Anybus the
crane can utilise the SCS2 as an integrated slave on the PLC network or an Anybus card can be used as a Master bus for
an internal I/O bus on the Spreader. The principal behind the Anybus is that the interface card translates a number of
different bus protocols to a standardised format on the address and data bus of the node. To change between different
buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please
view the user manual for that specific card and the electrical documentation for your specific project.
The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes
out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the
Master and the SCS2 slave for the bus to work correctly. For each project a document has to be sent to the customer
describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the
SCS2 is an output from the master in the crane.
8.2.1.1 Mapping of I/O
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it is possible to use a number of bytes for diagnostic information in the form codes. The diagnostics
are handled by the Anybus System component. The code sent will be equivalent with the code displayed in the onboard
display, hence there will be three levels of this code INFO, WARNING, ERROR. Apart from the code and the byte for
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indicating the type of code a counter will be incremented each time a code is sent. The counter is a 16bit value and
therefore will begin from 0 if the counter overflows. The value of this counter will be sent each time that a new diagnostic
message is transmitted. The start position of the diagnostic areas is configurable.
8.2.1.2 Spreader diagnostic area.

The byte numbers below should be added to the offset defined in the Anybus System component.
Byte 0 => Type of error (info, warning, error)
Byte 1 => Node ID (the number of the node from which the message originates)
Byte 2-3 (WORD) => Diagnostic code
Byte 4-5 (WORD) => Sub Code for diagnostics
Byte 6-7 (WORD) => Sequential counter value (message number)
8.2.1.3 System diagnostic area.

This part is named the assert diagnostics and is basically only used to find discrepancies in the SCS2 system. The
objective of it is mainly for Bromma Conquip AB’s R&D to identify unforeseen weaknesses in the system. If the
customer wishes to implement/decode this it can help Bromma Conquip AB improve its’ equipment further, however the
customer might find little or no use in this information on their own behalf. The assert part is configured in the following
way.
The byte numbers below should be added to the offset defined in the Anybus System component.
Byte 0 => Node ID
Byte 1-2 (WORD) => Row Number (of source code)
Byte 3-8 (3 x WORD) => Filename (1:st 6 char.)
Byte 9-10 (WORD) => Sequential counter
The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The
assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader.
These assignments are documented in the electrical documentation of the project.
Input Segment
The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and
set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.
8.2.2 Anybus System

The Anybus system component has the ability to handle downloading of new spreader program (*.spr).
Note: To be able to download a spreader program via Anybus a specific PC software is needed.
8.2.2.1 Input ports

Download start Digital If set true, component expects
download data on Anybus.
8.2.2.2 Parameters
Node Node id The node identity of the node where
the Anybus interface is located.
Log active Option Indicates if the log should be
exported to the Anybus interface or
not.
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Log address 0-63 The Anybus output address in the

access area where the log should be
exported.
Assert active Option Indicates if the assert log should be
exported to the Anybus interface or
not.
Assert address 0-63 The Anybus output address in the
access area where the assert log
should be exported.
8.2.3 Output Word
8.2.3.1 Input ports

IN Analogue Input from analogue input port.
8.2.3.2 Parameters

Note Text Free text field. Use this field for
notes about the Anybus port.
Word number Number Word in Anybus interface to which
the value from ”IN” is to be
transferred to.
8.2.4 Output Byte
8.2.4.1 Input ports

IN Analogue Input from analogue input port.
8.2.4.2 Parameters

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Byte number Number Byte in Anybus interface to which

the value from ”IN” is to be
transferred to.
8.2.5 Output Bit
8.2.5.1 Input ports

IN Digital Input from digital input port.
8.2.5.2 Parameters

Byte number Number Start byte in Anybus interface.
Bit number Number Bit number of the chosen byte in
Anybus interface.
8.2.6 Input Word

OUT Analogue The word number from the Anybus
interface that is to be transferred to
the “OUT” value.
8.2.6.2 Parameters

Word number Analogue The word within the Anybus
interface from which
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8.2.7 Input Byte

OUT Analogue The byte number from the Anybus
interface that is to be transferred to
the “OUT” value.
8.2.7.2 Parameters

8.2.8 Input Bit

OUT Digital Digital value from Anybus interface.
8.2.8.2 Parameters

Bit number Number Bit number in Anybus interface.
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8.3 CANopen
8.3.1 Introduction
CANopen is a field bus protocol based on CAN and provides a flexible and powerful open industrial communication
solution.
Apart from the parallel I/O of the nodes the SCS2 master node can control up to 15 CANopen slaves. The SCS2 master
node act’s as a CANopen master, this includes network management, SDO services and PDO handling.
The SCS2 master node processes the CANopen slave data i.e reads inputs and controls outputs.
All configuration of the CANopen functionality is made in the CANopen IO configuration view described in section
5.2.4. Note that the components described in the following section is not visible in the component palette.
The following components is used to create CANopen IO and SDO objects.
8.3.2 PDO Read Bit

OUT Digital Digital value from CANopen slave
8.3.2.2 Parameters

Slave node ID Number Node id of CANopen slave
PDO number Number PDO number
Byte Number Number Byte in PDO
Bit number Number Bit in byte
8.3.3 PDO Read

OUT Analogue Analogue value from CANopen slave
8.3.3.2 Parameters

Start Byte in PDO Number Start Byte in PDO
Start Bit number Number Start bit in Byte
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Data Length Number Length of data
8.3.4 PDO Write Bit
8.3.4.1 Input ports

Input Digital Digital value written to CANopen
slave
8.3.4.2 Parameters

Byte in PDO Number Byte in PDO
Bit number Number Bit in Byte
8.3.5 PDO Write
8.3.5.1 Input ports

Input Analogue Analogue value written to CANopen
slave
8.3.5.2 Parameters

Start Byte in PDO Number Start Byte in PDO
Start Bit number Number Start Bit in Byte
Data Length Number Length of data
8.3.6 SDO Write
8.3.6.1 Parameters

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OD index Number Index in OD (dec)

OD sub index Number Sub index in OD
Value Number Value written to OD
Size of data Option Unsigned 8: The size of data(value)
is 1 byte
Unsigned 16: The size of data(value)
is 2 byte
Unsigned 32: The size of data(value)
is 4 byte
Sequence number Number Specifies in which order all SDO
objects will be sent
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8.4 Guards
8.4.1 Spreader stop

The Spreader stop component stops all output functions from Spreader specific components, controllers, and causes them
to go back to a boot state upon the release of the Spreader stop. It also generates a message to the log
8.4.1.1 Input ports

IN Digital Command to stop spreader.
true = spreader stops
false = spreader stop resumed
8.4.1.2 Parameters


box Enable logging

97 SPREADER_STOP Spreader stop has been activated/deactivated.
0 = deactivated, 1 = activated.
8.4.2 TTDS -Twin Twenty Detection System

The TTDS component implements the functionality of the twin twenty detection system, which is used to prevent lifting
two twenty foot containers in a forty foot single lift position. The function should only be active to prevent wrongful
lifting and not to actively control any other device. The logic is based on the Bromma seven sensor system and the output
can be used to interlock the Twistlocks, but should also always when possible be sent to the crane. Since the logic is
designed to be fail-safe, any type of fault of sensor or a misreading by the sensor will trigger the output and therefore an
override has been implemented. For details regarding the TTDS system functionality see separate manual. The TTDS
component generates log messages every time an override has been used.
8.4.2.1 Input ports

Override Digital Overrides TTDS result.
true = output (Twin) is always false
false = normal output
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Sensor 1 Digital Input from TTDS sensors.

...
Sensor 7

OUT Digital true = two containers detected
false = one or none detected

The following messages are generated by this component. This component generates the following messages stored in the
box Enable logging.

290 TTDS_OVERRIDE_ACTIVATED Override request received.
291 TTDS_OVERRIDE_DEACTIVATED Override request ended.
8.4.3 Analogue guard

The Analogue guard is intended for use of monitoring a specific analogue value. A window around the min/max values
can be defined. This component generates a log message classified as a warning, which is user defined. There are 10 (0-9)
unique message tags to choose from and they generate the messages 146 – 155 within the log system. Apart from sending
a message to the log, an output can trigger any other event if the input value exceeds the ranges specified in the
parameters of the component.
8.4.3.1 Input ports

IN Analogue Analogue value from other
component or analogue input port.

OUT Digital Signal indicating that Analogue input
has gone outside lower or upper limit
longer than the specified time Delay.
8.4.3.3 Parameters
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Note Text Descriptive string indicating the

function of the component. (Only
registered within ABE as memory
note)
Delay Milliseconds Time until warning message is
[ms] prompted if Analogue input has gone
out of boundaries.
Lower limit Number Lower limit of allowable input range.
Upper limit Number Upper limit of allowable input range.
Warning code Option Warning code that will identify the
component. (Same code can be used
for different components.)

box Enable logging.

146 USERDEFINED_0 User chooses what message to use. The messages
… ... generated in the log are identified as 146-155 when read
155 USERDEFINED_9 out of the log.
8.4.4 Digital guard

The Digital guard triggers a user-defined message to be stored in the log.
8.4.4.1 Input ports

IN Digital Digital value from other component
or digital input port.
8.4.4.2 Parameters

Note Text Descriptive string indicating the
function of the component. (Only
registered within ABE as memory
note)
Input NO/NC Option Normally open or normally closed
behaviour on input.
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Delay Milliseconds Time until warning message is

[ms] prompted if digital value is true or
false (depending on input NO / NC
setting).
Warning code Option Warning code that will identify the
component. (Same code can be used
for different components.)

box Enable logging.

146 USERDEFINED_0 User chooses what message to use. The messages generated
… ... in the log are identified as 146-155 when read out of the log.
155 USERDEFINED_9
8.5 Gates
This section contains the simple Boolean instruction set.
8.5.1 AND
This function block performs the function of the logical AND with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 0
1 0 0
1 1 1
8.5.1.1 Input ports

IN0 Digital Digital value from other component
... or digital input port.
IN n

OUT Digital Digital output result from AND
operation.
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8.5.1.3 Parameters

Number of inputs Number Number of inputs on component.
8.5.2 NAND
This function block performs the function of the logical NAND with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 1
0 1 1
1 0 1
1 1 0
8.5.2.1 Input ports

IN 0 Digital Digital values from other component
IN n

OUT Digital Digital output result from NAND
operation.
8.5.2.3 Parameters

8.5.3 NOR
This function block performs the function of the logical NOR with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 1
0 1 0
1 0 0
1 1 0
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8.5.3.1 Input ports

IN n

OUT Digital Digital output result from NOR
operation.
8.5.3.3 Parameters

8.5.4 OR
This function block performs the function of the logical OR with the number of inputs specified in the parameter settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 1
1 0 1
1 1 1
8.5.4.1 Input ports

IN n

OUT Digital Digital output result from OR
operation.
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8.5.4.3 Parameters

8.5.5 NOT
This function block performs the function of the logical NOT with the number of inputs specified in the parameter
settings.
Basic function
IN OUT
0 1
1 0
8.5.5.1 Input ports


OUT Digital Digital output result from NOT
operation.
8.5.6 XOR
This function block performs the function of the logical XOR (exclusive or) with the number of inputs specified in the
parameter settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 1
1 0 1
1 1 0
8.5.6.1 Input ports

IN 0 Digital Digital value from other component
IN 1 Digital Digital value from other component
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OUT Digital Digital output result from XOR
operation.
8.5.7 SR Latch
This function block performs the function of the logical SR latch with the number of inputs specified in the parameter
settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input.
If both inputs are on simultaneously this latch will reset (output goes low).
8.5.7.1 Input ports

Set Digital Digital value from other component
Reset Digital Digital value from other component

OUT Digital Digital output result from SR latch.
8.5.8 RS Latch
This function block performs the function of the logical RS latch with the number of inputs specified in the parameter
settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input.
If both inputs are on simultaneously this latch will set (output goes high).
8.5.8.1 Input ports

Set Digital Digital value from other component
Reset Digital Digital value from other component

Result Digital Digital output result from RS latch.
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8.5.9 Logical gate

The Logical gate component is used if one wishes to perform logical operations (bit wise) on two analogue values.
Each analogue input is represented as a 32 bit value.
8.5.9.1 Input ports

component will set Result to zero.
(i.e. enabled all time).
IN 1 Analogue Input value 1.
IN 2 Analogue Input value 2.

Result Analogue Result of logical operation.
8.5.9.3 Parameters

Operation mode Option Determents type of logical operation
preformed on IN 1 and IN 2. The
operations available are AND, OR
and XOR.
8.6 Digital
8.6.1 OD Timer – On Delay Timer

The On Delay Timer is used to delay a signal from input to output.
8.6.1.1 Input ports

or digital input port. Starts the timer
on positive flank.
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OUT Digital Digital output that goes high if the

input is high and the specified time
has elapsed.
8.6.1.3 Parameters

Delay Milliseconds Time that the in put signal is to be
[ms] delayed before the output goes high
8.6.2 UpDn Counter – Up Down Counter

The Up Down Counter increments each time the UP input transits from low to high and decrements each time the DOWN
input transits from low to high. The RESET input takes the counter value to zero.
The range of the counter is from 0 to 231-1 (=2147483647).
8.6.2.1 Input ports

Up Digital Increments the counter value
Down Digital Decrements the counter value
Reset Digital Sets the counter value to zero

OUT Digital OUT = 1 (high) when the counter
value is equal to or above the
specified value in the parameter
listing
Counter value Analogue The current value of the counter
8.6.2.3 Parameters

Trigger count Digital The counter value when the digital
output goes high. The output is on
when the counter value is equal to or
above this value.
8.6.3 OSC - Oscillator

The oscillator purely switches the output on and off with specified duty cycle adjusted in the parameters.
8.6.3.1 Input ports
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OUT Digital Clock pulse output.
8.6.3.3 Parameters

Cycle time Milliseconds Cycle time for Clock output.
[ms]
8.6.4 Split
The split component is used to generate two or more signals available for connection from one signal line. I.e. it can in
many cases replace the use of intermediate variables, since the signal value of the input and the outputs are always the
same.
8.6.4.1 Input ports


OUT 0 Digital Outputs have same status as the IN
… input port
OUT n
8.6.4.3 Parameters

Number of outputs Number Number of outputs on component.
8.6.5 Pulse
The Pulse component is used to generate a pulse. The duration of the pulse is set by a parameter. The pulse can be trigged
on either positive or negative flank. The pulse is restarted if an new active flank is detected during the pulse.
An output indicating time left until pulse is unlit is also available.
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8.6.5.1 Input ports

Input Digital Trigger for starting pulse.

Time remaining Analogue Time remaining (ms) until pulse is
unlit.
Output Digital Pulse output.
8.6.5.3 Parameters

Active flank Option Determines active flank of trigger,
POS or NEG.
Length of pulse Milliseconds Duration of pulse.
[ms]
8.7 Miscellaneous
8.7.1 Constant
The Constant component is used to store a Boolean or Analogue value as a constant variable to use within the logic. Note
that any other value than zero is considered as a logical one when using this component for digital purposes.

Digital Digital Constant value > 0 : Digital output
= true
Constant value = 0 : Digital output
= false
Analogue Analogue Analogue output = Constant value
8.7.1.2 Parameters
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Value Number Value to put on output ports.
8.7.2 Dead end

The Dead End component is used when one has to make a system where one or more of the mandatory outputs cannot be
used for some reason. By connecting the Mandatory output from another component to the Dead end component that
signal is terminated. This can be useful when controller components are to be used purely for log purposes and one
doesn’t want the logic to control the outputs.

Digital IN Digital Terminates a digital connection.
Analogue IN Analogue Terminates an analogue connection.
8.7.3 Spreader properties
8.7.3.1 Input ports

Twin boxes are down Digital Input port telling that twin boxes are
down.
Landed Digital Input port telling that spreader has
landed.
Locked Digital Input port telling that all Twist locks
are locked.
Unlocked Digital Input port telling that all Twist locks
is unlocked.
Pump 1 on Digital Used for activating the clock for
drive time 1. When this input is
active the clock for drive time 1
counts.
counts.
counts.
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Number of lock operations on twin Analogue Number of lock operations

performed on twin Twist locks.
Saved in external EEPROM.
Number of lock operations on single Analogue Number of lock operations
performed on single Twist locks.
Number of containers Analogue Number of containers handled. When
twin is down this number is
incremented by two. Saved in
external EEPROM.
Spreader serial number Analogue Spreader unique number. User
defined. Read from external
EEPROM.
Drawing number Analogue Spreader unique number. User
defined. Read from parameter
Drawing number.
Counter clock pulse Digital Clock pulse that toggles from false to
true when container is handled.
When a new sequence is ended
output goes back to false.
Drive time 1 HI Word Analogue Accumulated drive time since
delivery. The time is only measured
when pump 1 is active. The time is
divided into two words (2x16bits)
where this output is the high word.
Drive time 1 LO Word Analogue Accumulated drive time since
where this output is the low word.
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8.7.3.3 Parameters

Drawing number Number User defined number. Number is
used to present the drawing number
of the spreader.

box Enable logging.

318 SPREADER_PROPERTIES_READ_E Last saved properties are read from
EPROM EEPROM.
319 SPREADER_PROPERTIES_READ_D System has read properties from NVRAM.
S
320 SPREADER_PROPERTIES_DIFF Spreader properties read from EEPROM
and NVRAM differ.
321 SPREADER_PROPERTIES_SET_EEP System succeeded to write properties to
ROM_OK EEPROM.
322 SPREADER_PROPERTIES_SET_EEP System failed to write properties to
ROM_FAIL EEPROM.
323 SPREADER_PROPERTIES_NEW_N System detected that a new node is
ODE_TO_EEPROM connected since last shut down.
8.7.4 Memory
The Memory component is used when one wishes to write or read an analogue value from or to the NVRAM.
8.7.4.1 Input ports
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component will set the Analogue
OUT to zero. Default value if not
connected is true (i.e. no effect).
Write Digital If set true, component reads
Analogue IN and writes to NVRAM.
Read Digital If set true, component reads from
NVRAM and writes to Analogue
OUT.
Analogue IN Analogue Analoge value that is to be stored.

Analogue OUT Analogue Value stored in NVRAM.
8.7.5 Digital buffer

The Digital buffer component buffers digital values for a selected amount of execution cycles.
8.7.5.1 Input ports

Digital IN Digital Digital value that is to be buffered.

OUT 0 Digital Buffered values. The input value is
shown on OUT 0 the next cycle. The
..
same value is shown on OUT 1 the
OUT n next cycle and so on.
8.7.5.3 Parameters

Number of samples to hold Number Number of cycles to remember.
8.7.6 Analogue buffer

The Analogue buffer component buffers analogue values for a selected amount of execution cycles.
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8.7.6.1 Input ports

zero. Default value if not connected
Analogue IN Analogue Analogue value that is to be buffered.

OUT 0 Analogue Buffered values. The input value is
shown on OUT 0 the next cycle. The
..
same value is shown on OUT 1 the
OUT n next cycle and so on.
8.7.6.3 Parameters

Number of samples to hold Number Number of cycles to remember.
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8.8 Analogue
The Analogue components are used to work with analogue values.
8.8.1 RS485 port

This component is used to access the RS485 interface. Depending on what protocol is chosen from the parameter view
the component can be used for a variety of purposes.

OUT Analogue Analogue value of output from
sensor
8.8.1.2 Parameters

Protocol Option Type of protocol used (i.e. vendor
specific protocol). Only SLIN is
implemented SSI is implemeted.
Node Option Node the RS485 sensor is connected
to.
Code Type Option Applys only if SSI protocol is
selected
Input resolution Number Applys only if SSI protocol is
selected. Specifies the resolution of
the component.
8.8.2 IN0 > IN1
8.8.2.1 Input ports

IN 0 Analogue Input
IN 1 Analogue Input

OUT Digital IN 0 > IN 1 gives OUT = 1
IN 0 <= IN 1 gives OUT = 0
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8.8.3 IN0 * IN1
8.8.3.1 Input ports

IN 0 Analogue Input
IN 1 Analogue Input

OUT Analogue OUT = IN 0 * IN 1
8.8.4 IN0 / IN1

Note. Always avoid division by zero.
8.8.4.1 Input ports

IN 0 Analogue Nominator input
IN 1 Analogue Denominator input

OUT Analogue OUT = IN 0 / IN 1
8.8.5 IN0 – IN1
8.8.5.1 Input ports

IN 0 Analogue Input
IN 1 Analogue Input

OUT Analogue OUT = IN 0 – IN 1
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8.8.6 IN0 + IN1
8.8.6.1 Input ports

IN 0 Analogue Inputs to be added together
...
IN n

OUT Analogue OUT = IN 0 + IN 1+, …,+ IN n
8.8.6.3 Parameters

Input counter Number Number of input ports on component.
8.8.7 Scale
The Scale components scales a analogue value according to the formula,
OUT = ((scaledMax – scaledMin)/(INMax-INMin))*(IN - INMin) + scaledMin,
which performs a linear scaling with an offset according to OUT = k*IN + m.
8.8.7.1 Input ports

IN Analogue Analogue value from other
component or analogue input port.

OUT Analogue Scaled analogue value with
constraints from parameter listing.
8.8.7.3 Parameters

Max value after scale Number Largest scaled value.
Min value after scale Number Smallest scaled value.
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Max value of input Number The maximum value of input.

Min value of input Number The minimum value of input.
8.8.8 AnalogueLatch
The Analogue latch is a component that stores a value internally when triggered by a digital input. The value stored in an
internal variable can be read at the output of the component. As long as the digital trigger input is active the input value is
directly transferred to the output value and as soon as the digital input goes low the output value remains constant at the
current value until a new digital command is given.
8.8.8.1 Input ports

IN Digital Input that trigger the component to
read the value IN Value.
IN Value Analogue Input value that is read and stored in
the component

OUT Analogue The stored value of the component
8.8.9 Filter
The Filter component is used to filter analogue signals from noise.
8.8.9.1 Input ports

Analogue IN Analogue Unfiltered signal.

Analogue OUT Analogue Filtered signal.
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8.8.9.3 Parameters

Filter type Option Determines type of filter. Only
MOVING AVR is implemented.
Filter weight Number [%] Determents how many percents of
previous filtered signal that is to be
used.
8.8.10 AuxAnalogue
This component implements two more analogue inputs.

Port 5 Analogue Analogue value
Port 4 Analogue Analogue value
8.8.10.2 Parameters

Node Option Specifies the node.
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9 Tutorial
This tutorial will guide you through the process of designing a Spreader program using ABE.
Steps covered in this tutorial.
Creating a new project
System view
Pin configuration
Component view
Load view
Step 1: Creating a new project

Start ABE from your Start menu if it isn’t already started. If you just started ABE you already have a project created for
you, If not create a new one by clicking the button showed in the picture below.
Figure 9:1 Create project
Step 2: System view

Activate the node B2 by checking corresponding Active checkbox. Node B1 is always present in the system.
Figure 9:2 Activating nodes
Fill in the Value fields in the parameter listing. Note that some of the fields are not editable.
Figure 9:3 Setting system parameters
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Step 3: Pin configuration

All present nodes are visible as tabs in this view. Make sure tab B1 is activated in the view. Give Port id# 1 and 2 the
following names. Comment field is optional.
Figure 9:4 Setting item identifiers on node B1
Make sure tab B2 is activated in the view and do the same for Port id# 1 to 4.
Note: The red colour of the fields indicates that the ports are not yet connected.
Figure 9:5 Setting item identifiers on node B2
Step 4: Component view

Select the FAC component from the available component pallet.
Figure 9:6 Choosing component
If available components pallet is not visible. Activate it by clicking at the Components button shown in picture below.
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Figure 9:7 Bringing up Available components
Place the component on Page 1 in the view.
Figure 9:8 Default look of FAC component
Note: Connections with red colour indicate that they are not yet connected. Connections with white colour indicate that
they are optional to connect.
Double click on the component to open Properties for the FAC component. Change the property Number of Flippers to 2.
Figure 9:9 Changing properties for FAC component
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The new appearance for the component should look like this:
Figure 9:10 Look of FAC component after changing number of flippers
By placing the pointer over the component or one of its connections a hint (tool tip) will appear. The hint tells you about
the properties for the component or its connection.
Figure 9:11 Look of component hint
Click with your right mouse button over a connection on the component. A pop up menu will appear. Move the cursor as
shown in the picture below and click on your left mouse button over Flipper_Down.
Figure 9:12 Making component connections
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Your component should now look like this:
Figure 9:13 Appearance of a connection
Continue with the remaining connections until you have all connections connected.
If you want to disconnect a connection you click over the connection with your right mouse button and choose disconnect
when it appears.
When your system is complete there should not be any red coloured connections in the Component view or Item
identifiers in the Pin configuration view.
Your Component view should look like Figure 12 when all your connections are made.
Figure 9:14 Appearance of a connection
Now you are ready to generate downloadable Spreader program file. Select Compile from the File menu.
If the following message box appears your system is not configured properly. Look for red coloured connections or item
identifiers. If port is configured to be used but isn’t you must delete it.
Save the output file (when compiling the spreader program) with the name “tutorial.spr”.
Figure 9:15 The Spreader program contains errors
When you have generated your downloadable program file it can be found at the location where it was saved. You must
not edit this file.
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Step 5: Load view
Downloading spreader programs

1. Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.
In the picture below COM1 is selected.
Figure 9:16 Select Connection
2. Press the Download button.

3. Point out the spreader program that you want to download. (Spreader programs have extension *.spr).
4. Observe the status bars. If connected node is the master node no distribution between nodes will appear. If not the
master node is the point of connection the spreader program will first be downloaded to the local node (connected
node) and than distributed to the master node.
Uploading spreader programs
2. Press the Upload button.

The two following dialogues will appear in sequence.
Answer Yes to the first dialog if you are working on anything that you want to save else No.
Figure 9:18 Save current spreader program
Answer Yes to the second dialog to open the uploaded spreader program in the editor. (If you press No, you have to
manually open the uploaded spreader program.)
Figure 9:19 Open spreader program in ABE
3. Observe the status bar ABE --> Connected node.

When 100% is reached the uploaded spreader program will appear in the editor.
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Step 6: Online monitoring
Online monitoring is performed under Component view.
1. Make sure you have the same spreader program in ABE and SCS2. If you are not sure about this, you can always
download your current spreader program or upload the spreader program from the SCS2 (see Step 5).
3. Make sure Auto is not checked.
Figure 9:21 Deselect Auto option
If Auto is checked, automatic update will be performed at an interval specified by Update interval.
4. Start online monitoring
Figure 9:22 Start online monitoring
The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or
less time depending on the number of present components and connections in visible Page(s). A progress bar appears
above the buttons, when adding the components, to show you current status.
Once the online monitoring is started, the design window is locked for editing. If you want to monitor another part of
your design (not visible at the moment); you have to stop the online monitoring and then scroll to that part and start the
monitoring again.
5. Update online values by pressing the Update button.
Figure 9:23 Updated online values
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6. Stop online monitoring by pressing button as shown below.
Figure 9:24 Stop online monitoring
o tutorial
This tutorial will guide you through the process of configuring a Spreader program containing CANopen functionality.
The tutorial covers the following steps:
Add a CANopen slave
Add an input
Connecting input to Spreader logic
Step 1: Add a CANopen slave

In the Component view activate the CANopen configuration view by clicking CANopen IO button.
In this view click the Add slave button.
Figure 1. Add slave button
When this button is clicked the following view appears.

Here you can configure:
¾ Type of slave (predefined connection set or not).
¾ The name of the slave
¾ Slave options (CRITICAL or NON CRITICAL).
¾ Adress of slave 1-126
Click OK button when done
Figure 2. Slave properties
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Step 2: Add a CANopen input

Make sure that the I/O leaf in the tree view is selected as in the picture below.
Click on the Add input button.
Figure 2. Add input
The following view appears.
Figure 3. Input properties
In this view the properties of this input is set.

¾ Name of the input (in this example IN_1)
¾ PDO number
¾ Byte number
¾ Bit number
¾ Data length
Click OK button when done
The CANopen I/O configuration view now looks like the picture below.
Figure 4. CANopen I/O cunfiguration view after input is added
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Step 3: Connecting CANopen input to Spreader logic

When no more configuration is to be done click the OK button to return to the Pin configuration view
Add a component to page and right click on the input to bring up the pop up window
Select the CANopen menu and the slave on where the input is configured and click on your left mouse button.
Figure 5. Making component connections
Your component should now look like this:
92(92) © 2000
User Manual
BMS - Light
Version 1.0
Revision Issued by Date Measures

PA1 Gunnar Ohlsson, CC Systems AB 2000-08-22 First draft.
PA2 Gunnar Ohlsson, CC Systems AB 2000-10-13 Added modem functions.
PA3 Gunnar Ohlsson, CC Systems AB 2000-10-23 Changes in GUI. Cancel buttons added. Height changed
on cells in string grids.
PA4 Gunnar Ohlsson, CC Systems AB 2001-01-10 Changes in GUI. Cancel button moved. Some Anybus
functions added.
PA5 Hans Svanfeldt, CC Systems AB 2001-10-29 New pages added. CAN tester, Boot loader.
A Ken Lindfors, CC Systems AB 2002-06-12 Minor changes after release of System 1.04.
B Hans Svamfeldt, CC Systems AB 2003-06-11 Minor changes after release of System 1.05.
C Hans Svamfeldt, CC Systems AB 2004-08-10 Minor changes after release of System 1.07.
Printed: 04-8-12 9.15

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Ta l o o t t
1 Introduction ................................................................................................................................................................... 3
2 Installing BMS – Light .................................................................................................................................................. 3
2.1 HW requirements................................................................................................................................................... 3
2.2 Installation ............................................................................................................................................................. 3
2.3 Disclaimer.............................................................................................................................................................. 3
3 User interface................................................................................................................................................................. 4
3.1 Menu (top toolbar) options: ................................................................................................................................... 4
3.2 Status bars in main window................................................................................................................................... 5
4 Download view.............................................................................................................................................................. 6
5 Get log view .................................................................................................................................................................. 7
5.1 Filtering constraints ............................................................................................................................................... 8
6 I/O status view............................................................................................................................................................... 9
7 Misc. view ................................................................................................................................................................... 10
Anybus view........................................................................................................................................................................ 11
8 Spreader info view....................................................................................................................................................... 12
9 CANopen IO view ....................................................................................................................................................... 13
10 Upload view............................................................................................................................................................. 14
11 Advanced................................................................................................................................................................. 15
11.1 CAN Tester.......................................................................................................................................................... 15
11.2 Boot Loader ......................................................................................................................................................... 17
11.3 Asserts ................................................................................................................................................................. 18
11.4 POM Loader ........................................................................................................................................................ 19
11.5 Bluetooth ............................................................................................................................................................. 19
11.6 CANopen services ............................................................................................................................................... 20
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tro u tio
The BMS is a software tool used for monitoring and handling the Bromma system SCS2. This manual assumes the user
has good knowledge of the SCS2 system as well as Windows environments.
talli i t
HW requirements
x An Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000.
x At least one serial communication port available (COM1 or COM2).
x At least 1Mb of free disk space.
Installation
x Close any other applications running under Windows.
x Insert the first disc into your disc station (if installing from disc)
x Run the file BMSSetup.exe from the BMS folder on your provided disk.
x Follow the instructions on the screen.
Disclaimer
Copyright Bromma Conquip AB. All rights reserved.
Products and company names mentioned herein may be trademarks or trade names of their respective owners.
Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes
and improvements to any of the products described in this manual without prior notice.
Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.
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ri t ra
Menu (top toolbar) options:
File:
Exit --- Terminates the application.
View:
Activates selected tab [Download, Get log, I/O status, Misc., Anybus, Spreader info, Upload]
Tools:
Connect serial cable: activates selected communication port [COM1, COM2].
Connect modem: activates modem connected to selected communication port [COM1, COM2].
The dialog below is used for making the connection. Once a connection has been made the dialog window disappears.
The BMS commands are working via the modem if the modem has connected successfully.
Modem connection
Connect to node: connects BMS to selected node [B1, B2,..., B8, A1, A2, A3, A4]. This connection is made over RS232
link through the CAN bus. Normally select Local node.
Advanced options: Intended for Bromma R&D personnel.
Help:
About: shows the version of the BMS.
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Status bars in main window
1. Status of last performed operation. Intended for Bromma personnel.

2. Status of current operation.
3. Serial cable connection (COM1 or COM2).
4. Destination node (normally Local node) of all operations.
5. Status of serial cable connection.
2
3
1 4 5
Main window
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o loa i
This tab is used to download the entire system program to the system. Note. It takes a considerable amount of time to
update the system program and therefore make sure that the system can be down for this amount of time.
1. Transfer status from BMS to the connected node [4]. PC downloading to the connected node.
2. Transfer status from connected node [4] to node [5]. Distribution of the program via the bus lines to the other nodes
on the bus.
3. Total transfer status. Status of complete system to be downloaded.
4. Connected node (to PC).
5. Receiving node when distributing between nodes.
6. Select file to download. Press here to select the file to be downloaded. When file is selected download process starts.
7. Cancels current transfer to connected node. The operation just cancels the feedback of transfer status if distribution
between nodes has started (i.e. the operation will not effect the transfer in this case).
7 5
Download view
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t lo i
This used to retrieve the onboard error and event log.
1. Gets next set of logged messages (max 128 messages each time its’ pressed)
2. Get all messages in log.
3. If checked, auto mode is on. Auto mode triggers the Next button [1] at an interval of X seconds defined by [4].
4. Interval for reading via auto mode in seconds.
5. Enable filtering. The filtered table is shown if checked. Filtering can be used to only view certain parts of the log.
6. Opens the Filtering constraint dialog. Select the type of filtering here.
7. Clears the log table on the PC. The log in the SCS2 remains unaffected.
8. Saves the entire log table in a comma separated text file. Can be opened in for instance in Wordpad, Excel etc.
9. Cancels current operation.
10. Load button. Loads and displays a saved log file.
6
4 1 2 5
9
8
7 10
Get log view
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Filtering constraints
Select the type of filtering for the log view in this view.
Checked Categories, Nodes, Sub codes and Codes will appear in the filtered table.
Ex: APS_TEACH_COMMAND (of category Info) is checked but not Info under Category. The message will therefor not
appear in the filtered table.
1. Message categories
2. Nodes that have reported messages.
3. Message codes for entire table
Filtering constraints
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tatu i
This view is used to read (and force) the I/O status of the SCS2.
1. Select node to view.

2. Enables override for I/O-port if checked. To force a value first check this box, then change the value and finally press
Write [4]
3. Current value/current overridden value of I/O.
4. Write current override values to system. Only the viewed node is written to. A write for each node is required if
values are to be forced on more than one node.
5. Read values from SCS2. All nodes are read at once (Selected node [1] is shown).
6. Enable automatic update of values. Triggers read operation [5] with interval determined by the value of: [6].
7. Update interval for Auto read [6].
Note. To restore a port to its default value if overridden:

Uncheck the corresponding I/O [2] and press Write [4]. (If a read operation is followed instead the unchecked port will be
checked by the SCS2.) All forced values are reset if the system is re-started.
1 3
4
5
6 7
8
I/O status view
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i i
This view is used to get and set general information of the SCS2.
1. Updates the Date and Time fields from the PC when pressed.
2. Set the time and date on SCS2 according to Date and Time fields.
3. Get current date and time from the SCS2. Displayed in Date and Time fields.
4. Get address key information from the node [5].
5. Destination of question.
6. Serial cable connection.
8. Get version information. Software version and protocol version for Boot and System program. The Boot program
version is Boot SW version and the System program version is System SW version. Don’t care about the COM
versions.
9. Reboots the system.
Ex. Serial cable [6] is connected via COM1 to B1 and Destination [5] is set to Local node (or B1, which would be the
same). B1 is configured to have E-stop and Redundancy block activated. This will give us the answer:
Key: 5
E-Stop: YES
Redundancy: YES
Module name: B1
8
2
7
6 5
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u i
The Anybus view shows the status of the I/O transferred over the fieldbus interface of the Anybus card.
1. Input data to SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field the
value of that byte in binary format.
2. Output data from SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field
the value of that byte in binary format.
3. Reads all Input data [1] and Output data [2] from Anybus interface.
5. Set DeviceNet master in Run mode. This operation can only be done when using a DeviceNet master.
6. Set DeviceNet master in Idle mode. This operation can only be done when using a DeviceNet master.
7. Select node where to Read [3] data from.
3
4
Anybus view
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r a ri o i
This view is used to administrate the external EEPROM that is mounted on some spreaders.
Key = generic name of memory area of EEPROM.
1. Shows the selected key in the Spreader info field [6]. This field can not be edited.
2. Shows the current value of corresponding Key [1].
3. Sets the Value [2] for selected Key [1].
4. Deletes the value for selected Key [1]. The Key [1] can not be deleted, just the value.
5. Updates the entire Spreader info [6] view on the PC.
6. Table of all Keys stored in external EEPROM.
1
2
5
7
4
3
Spreader info view
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o i
The CANopen view shows the status of the I/O transferred over the CANopen interface.
From this view its also possible to select individual or groups of I/O and override it/them.
1. Retrieves the CANopen I/Oconfiguration from the system

2. Updates the I/O status
3. Updates system with overridden I/O
4. Dropdown box for selection of which node to show I/O from
5. Enables override for I/O-port if checked. To force a value first check this box, then change the value and finally
press SetIO [3]
6. Current value/current overridden value of I/O
7. I/O port identifier
8. Cancels current operation
9. Enable automatic update of values. Triggers read operation [2] with interval determined by the value of: [10]
10. Update interval for Auto [9]
Note. To restore a port to its default value if overridden:

Uncheck the corresponding I/O [5] and press SetIO [3]. All forced values are reset if the system is re-started.
5
4
1
2
3
7 9
6
10
CANopen IO view
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loa i
This view is for Bromma R&D personnel only. It is used to upload memory blocks from the SCS2.
Upload view
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a
These six sub views are mainly intended for Bromma’s R&D personnel only.
CAN Tester
This view holds the functionally of the CAN Tester. To be able to use the CAN Tester the master node has to be keyed as
Test. See the SCS2 manual for information.
The main functionality is as follows:

x Every node connected to the CAN network is tested.
x Each connected node is tested for a pre-selected time at each selected bit rate.
x When a node is tested the next node is tested at the same bit-rate and during the pre-selected time.
x The test results are sent back to the CAN Tester and are displayed in the list.
1. Selects the bit-rates that are to be tested.

2. Sets the duration time of each test.
3. Shows the additional information that are used when saving the results.
4. Saves the results as a *.csv or a *.txt file.
5. Starts the test.
6. Sows status of the CAN test.
7. Closes dialog.
8. Result field showing which node that is tested.
9. Result field showing what bit-rate the test used.
10. Result field showing the minimum of retransmissions during test.
11. Result field showing the average of retransmissions during test.
12. Result field showing the maximum of retransmissions during test.
13. Result field showing the total number of messages sent during test.
14. Result field showing the total numbers of retransmissions during test.
15. Result field showing the total numbers of bus offs occurred during test.
16. Result field showing the total numbers of messages not answered during test.
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8 9 10 11 12 13 14 15 16
4
7
5
CAN Tester view
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Boot Loader
The Boot Loader view is used to download new boot program to connected node.
1. Selects the file that is to be downloaded (*.s19).

2. Downloads the selected file.
3. Progress bar showing percentage completed.
4. Cancels the download.
5. Closes dialog.
3
1 2 4 5
Boot Loader view
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Asserts
The asserts view holds the functionality of reading asserts from the SCS2 . It is used for detecting unexpected system
events.
Asserts view
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POM Loader
The POM Loader view is used for downloading new power monitoring programs to the SCS2 .
POM Loader view
Bluetooth
From this dialog it’s possible to configure and manage Bluetooth settings.
Note that the configuration possibilities only works with Bromma Conquip’s own Serial port adapter.
Bluetooth configurator view
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CANopen services
From this view it’s possible to perform read and write actions to CANopen slave nodes OD (Object Dictionary).
The read and write actions uses the SDO (Service Data Objects) concept of CANopen. For a more detailed description of
CANopen and it’s functionality it’s referred to more specific documentation.
1. Page containing the read functionality

2. Page containing the write functionality
3. Selection of CANopen node to read/write from/to. The SCS2 master node has address 127.
4. Index in OD. (Dec.)
5. Sub index in OD (Dec.)
6. Read value/ value that is to be written
7. Reads/writes value
8. Cancels current command
9. Closes the dialog
10. Status of current command
7
9 8
10
CANopen services view
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Spreader Control System
2:nd generation
2
SCS
a ual
i
1 GENERAL ...................................................................................................................................................................3
1.1 OVERVIEW ...............................................................................................................................................................3
1.2 REFERENCES ............................................................................................................................................................3
1.3 DICTIONARY AND ABBREVIATIONS ..........................................................................................................................3
1.4 DOCUMENT LAYOUT ................................................................................................................................................3
2 INTRODUCTION .......................................................................................................................................................4
2.1 GENERAL .................................................................................................................................................................4
2.2 THE NODES ..............................................................................................................................................................5
3 SOFTWARE ................................................................................................................................................................6
3.1 BOOT PROGRAM .......................................................................................................................................................6
3.2 SYSTEM PROGRAM ...................................................................................................................................................6
3.3 SPREADER PROGRAM ...............................................................................................................................................6
4 HARDWARE OVERVIEW........................................................................................................................................7
4.1 I/O LED’S ................................................................................................................................................................7
4.2 DISPLAY ...................................................................................................................................................................7
4.2.1 Event categories.............................................................................................................................................8
4.2.2 Message format..............................................................................................................................................8
4.2.3 Priority of displayed messages ......................................................................................................................9
4.3 GROUND CONNECTION .............................................................................................................................................9
4.4 THE X1 AND X3 CONNECTORS .................................................................................................................................9
4.4.1 X1 I/O connector..........................................................................................................................................10
4.4.2 X3 I/O connector..........................................................................................................................................11
4.5 THE X2 CONNECTOR ..............................................................................................................................................13
4.5.1 Main Supply .................................................................................................................................................13
4.5.2 CAN .............................................................................................................................................................13
4.5.3 Address Key .................................................................................................................................................14
4.5.4 Analogue Inputs ...........................................................................................................................................15
4.5.5 PWM Outputs...............................................................................................................................................15
4.5.6 External Spreader Memory..........................................................................................................................15
4.5.7 RS 485 and SSI.............................................................................................................................................16
4.5.8 Additional Jumper Group ............................................................................................................................16
4.6 THE X4 CONNECTOR .............................................................................................................................................17
4.6.1 AnyBus .........................................................................................................................................................18
4.6.2 Two auxiliary Analogue Inputs ....................................................................................................................18
4.7 THE X5 CONNECTOR .............................................................................................................................................19
4.7.1 RS-232..........................................................................................................................................................19
4.8 THE REDUNDANCY FUNCTION ............................................................................................................................... 19
4.9 FIELD BUS CONNECTIONS.......................................................................................................................................20
4.9.1 Mapping of I/O ............................................................................................................................................20
4.10 SPREADER STOP ................................................................................................................................................21
4.11 FAULT FINDING TABLE ......................................................................................................................................22
5 SOFTWARE TOOLS................................................................................................................................................23
5.1 OVERVIEW .............................................................................................................................................................23
5.2 ABE.......................................................................................................................................................................23
5.3 BMS ......................................................................................................................................................................23
6 MISCELLANEOUS ..................................................................................................................................................24
a ual © ro a o ui
il ri t
Manual SCS2
Andy Lewis 2004-12-08 13:51 11 3(55)
6.1 DATA SHEET ...........................................................................................................................................................24

6.2 DIMENSIONS...........................................................................................................................................................25
7 APPENDIX A (ERROR MESSAGES) ....................................................................................................................26
1 General
1.1 Overview
This document serves as a user manual and shall be used by the surveillance and maintenance operators of the Bromma
SCS2. Software as well as hardware routines and descriptions are covered in this document.
1.2 References
Location where to find the latest revision of this document: http://www.bromma.com/backyard/
1.3 Dictionary and abbreviations

ABE Application Builder Environment. A tool for building control logic. See separate manual for details.
BMS Bromma Monitoring System. A tool for monitoring the SCS2. See separate manual for details.
Boot program The part of the software in the SCS2 that is executed at power up. This part is responsible for the
loading of the program verifying that the system is set up correctly.
CAN Controller Area Network. A two wire serial bus used for high speed, high reliability communication.
PWM Pulse Width Modulator.
Spreader Program The control logic that controls the functionality of the SCS2.
SCS2 Spreader Control System generation 2. The control system described in this user manual. The system
will be referred to as SCS2 in this document.
System Program The program that serves as a base for the execution and control of the spreader program.
SSI Synchronous Serial Interface – sensor interface
1.4 Document layout

Chapter 3, System overview, gives a brief description of the SCS2.
Chapter 4, Software, describes how the different software parts correlates.
Chapter 5, Hardware overview, describes the hardware in the SCS2.
Chapter 6, External interfaces, describes all the external interfaces in the SCS2.
Chapter 7, Software tools, describes the supporting tools to the SCS2.
Appendix A, Error messages, shows all error messages and their meaning.
Manual 3 © 2004 Bromma Conquip AB

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2 ntrodu tion
The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided
to develop a new and highly advanced communications system a close look at the available bus systems revealed a
number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical
roughness.
Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough
Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface
that complies with European and international standards for control equipment in this area. The SCS2 solution is a single
control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are
simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable
architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money.
SCS2 includes the following features:
A bus system able to handle 528 I/O ports (programmable input or output).
Up to four analogue inputs with 12 bit resolution.
Four PWM outputs for proportional solenoids.
One general purpose RS485 channel OR SSI channel.
Communication with the help of a standard spreader cable — no screening, no twisted pair.
A system that withstands the repeated shocks and vibrations suffered by spreaders.
A system able to operate in tropical heat and arctic cold.
Choice of different field bus interfaces (ProfiBus, Interbus-S, Device Net….)
Optional duty cycle input
2.1 General
As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS
and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or
you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable
performance in the particularly challenging environment of container handling the system corporate four basic elements:
Crane Node1 A device directly interfacing with the crane’s control systems, computer and
monitoring screens, providing an optional serial bus interface for
programming or diagnostic communications, as well as an interface to the
spreader node.
Crane-Spreader Communications Link A two-wire conventional cable CAN communications between the crane
control system and the spreader.
Spreader Node A device that interfaces directly with the spreader’s sensors, supports discrete
signals, and acts as the Master node.
Sensors and Switches Conventional sensors, switches, and actuators on the spreader.
The system is divided into several hardware units called nodes. The nodes are located on the spreader and in the crane.
The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the
1
For details regarding separate dedicated crane fieldbus gateway, see separate manual
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number of I/O needed. The nodes are all equals, both in software as well as in hardware. This reduces spare parts and
enables easy-to-change procedures.
The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered
from 0 to 11 where:
0 is the master called B1
1-7 are slave nodes located on the spreader called B2-B8
8-11 are slave nodes located in the crane called A1-A4.
Crane
I/O
Slave A1 ... Slave A4
2
CAN network (BCAN) SCS
I/O B1 Master B2 Slave ... B8 Slave
Spreader
Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally
via a CAN network.
2.2 The Nodes
The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master.
There must be only one master node in the system and the rest are slaves.
The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master, but can also
have distributed functions such as regulators.

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3 So tware
The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.
3.1 Boot Program

When the power is applied to the Boot Program starts to run. It will take approximately 5 seconds to boot up the system.
During system Program updates it will take longer.
The Boot program is responsible for

Initialising hardware
Checking that all the system Programs match.
Checking that the emergency stop and redundancy settings are correct
Performing a program downloads.
3.2 System program

After the Boot program is finished, the System program will run, until the system is switched off. The System program is
responsible for
Executing the Spreader program (only on Master node)
Supporting any connected PC via the com-port
Monitoring the supply voltage and some internal voltages
Handling in the event log
Reading and writing I/O
3.3 Spreader Program

The Spreader Program is the program logic that controls the spreader. This program is created in ABE, see chapter 5.2 for
a brief description.
Manual © 2004 Bromma Conquip AB

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4 ardware er iew
2
Below is a picture of a SCS node. The different parts are explained in the following chapter.
Bus/AI RS232 Display &

I/O LED (X4) (X5) Power
X1- I/O X2- I/O, bus X3- I/O 1-48 LEDS
Connector & supply Connector
Connector
4.1 I/O LED’s

The I/O LED’s indicate the current status of the corresponding I/O module. The LED is powered from the secondary (5V)
of the module.
4.2 Display
The display shows three pages of information where each page has a maximum of 8 characters. Each page is shown for 1
second. The pages show the following:
Node ID and System program version. Format: <Node ID><Version>.
Elapsed time running since power on. Format: DDD HHMM where DDD is the number of days, HH the number of hours
and MM the number of minutes.
Message page. The message page shows numeric information only, which has to be translated into comprehensive plain
text manually. The meaning of this page is explained in the rest of this section.
There are also four red LED’s in the bottom of the display window indicating the supply voltage level. Four different
levels are indicated and the ideal voltage is when all LED’s are lit.
LED1 – 11V, FAIL

LED2 – 14V, WARNING 2
LED3 – 17V, WARNING
LED4 – 21V, OK
It is not recommended to run the system below the OK level though it still seems to work fine. Attached devices may
malfunction at lower voltages thus making the system unreliable. The green LED is the “power on” indicator.

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4.2.1 Event categories

There are three categories of information displayed on the event page: information, warning and error.
Type Prefix Example Note

Error E E102 Any error message would shut down the system. All outputs are
turned off and the program is halted. Error messages will begin with
an E.
Warning W W60 Warning shows information about the system status that is of high
importance. The system keeps on running. Warning messages will
begin with a W.
Information I I59 Information shows progress in the system. Examples of information

that could qualify to be displayed as information:
Program load status (how many percent are completed), version
verification info, BMS connected, etc. Informational messages will
begin with an I.
Information
4.2.2 Message format

The display can show 8 characters. These are used in the following format:
LTTTSSSS
L = Level type
TTT = Message type
SSSS Su type
ample:
102 rror in initialisin t e ardware
1 1 arnin indi atin t at a twistlo is indi atin lo ed and unlo ed e su ode indi ates t at it is orner 1
5 n ormation t at t e system as started
Level type
The level type can be one of the following: I = Information, W = Warning, E = Error
Message type
The message type represents the cause of the message. Examples of message types are System started, Wrong system
version and I/O error.
All these types are described in appendix A.
Sub type
The sub type is used to specify more detailed information about the message type. The sub types have different meanings
for all message types. For example does sub type 14 together with message type 47 mean I/O error on digital port 14
instead of just I/O error.
These sub types are described in appendix A.

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4.2.3 Priority of displayed messages

Only the latest event is displayed at a time. When the display shows a warning and an event occurs which would show
information, the warning has higher priority and is thereby left on the display. The same relationship goes for error-
information and error-warning.
Priority in descending order:
Error
Warning
Information
Note that warnings are cleared from the display after at least 10 messages of informational type have passed and the
warning message is older than 15 minutes. Error messages are cleared by resetting the system.
4.3 Ground connection

The node chassis must be properly connected to protective earth. A grounding bolt is placed on the right hand side of the
node for this purpose.
4.4 The X1 and X3 connectors

There are 48 digital ports on a node. Each port can be configured as either input or output via software. The ports 1 to 44
are joined in groups of 4 resulting in 11 groups. Each group has a “Common” junction. See the connector part for more
detailed information. Ports 45 to 48 are single I/O.

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4.4.1 X1 I/O connector

Name Description X1 pin number
I/O-1 General purpose input or output / Unlocked_0 31
I/O-5 General purpose input or output / Locked_0 3



I/O-17 General purpose input or output / Landed_left_0 10

I/O-18 General purpose input or output / Landed_left_1 20
I/O-19 General purpose input or output / Landed_right_0 30
I/O-20 General purpose input or output / Landed_right_1 40
I/O-212 General purpose input or output / Lock_left 46

I/O-22 General purpose input or output / Lock_right 47
I/O-23 General purpose input or output / Unlock_left 49
I/O-24 General purpose input or output / Unlock_right 48
2
Redundancy remark.
I/O signals 21 – 24 are affected by the redundancy safety functionality. See chapter 4.8

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To make linking of common supplies easier the X1 connector also has groups if pins linked together to be used basically
as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding
switches/valves with common potential.
X1 - Pin number Link configuration X1 - Pin number Link configuration

12 17
13 18
14 19
22 27
23 28
24 29
32 37
33 39
34 38
45 36
4.4.2 X3 I/O connector





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X3 - Pin number Link configuration X3 - Pin number Link configuration

12 17
13 18
14 19
22 27
23 28
32 29
33 37
34 38
39

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4.5 The X2 connector

The X2 connector has a jumper group to be used for supply voltage to the different analogue sensors.
4.5.1 Main Supply

24Volt AC or DC power supply for the node. The signals are doubled in the connector due to the current limit of single
pins. DC voltage can be applied either way.
Name Pin number in connector

24INA X2/42
24INA X2/43
24INB X2/45
24INB X2/44
4.5.2 CAN
The two CAN nets are placed in the X2 connector. The first net use Bromma CAN (BCAN) voltage levels and the second
net use standard CAN voltage levels. The standard CAN net has to be terminated with external resistors.

CAN High 1 X2/30
CAN Low 1 X2/40
CAN High 2 / Reserved3 X2/50
CAN Low 2 / Reserved3 X2/20
CAN GND 2/ Reserved3 X2/48
3
CAN channel is std CAN for CAN-Open installations
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4.5.3 Address Key

All nodes must have a unique identity. This is read from the Id pins ID0 – ID4 where pins being connected to the ground
pin corresponds to ”zeroes” and pins left unconnected are considered ”ones”.

ID4 X2/49
ID3 X2/39
ID2 X2/29
ID1 X2/19
ID0 X2/9
Ground X2/10
Configuration
Since all nodes are the same in reference to the software as well as hardware you have to configure them to carry different
roles. Setting the address key configures the role of the node. The address key has two other functions as well, enabling
Spreader stop and enabling redundancy block. These functions are described in chapters 4.10 and 4.8.
The address key setting is described in the following table:
Key input Node Spreader Redundancy block and Pins to be linked together in Node number identifier
stop
name override of landing X2 connector when viewing Display and
pins Log
00000 Test 10,9,19,29,39,49
00001 A1 No No 10,19,29,39,49 8
00010 A2 No No 10,9,29,39,49 9
00011 A3 No No 10,29,39,49 10
00100 A4 No No 10,9,19,39,49 11
00101 B1 Yes Yes 10,19,39,49 0
00110 B1 Yes No 10,9,39,49 0
00111 B1 No Yes 10,39,49 0
01000 B1 No No 10,9,19,29,49 0
01001 B2 Yes Yes 10,19,29,49 1
01010 B2 Yes No 10,9,29,49 1
01011 B2 No Yes 10,29,49 1
01100 B2 No No 10,9,19,49 1
01101 B3 No No 10,19,49 2
01110 B4 No No 10,9,49 3
01111 B5 No No 10,49 4
10000 B6 No No 10,9,19,29,39 5
10001 B7 No No 10,19,29,39 6
10010 B8 No No 10,9,29,39 7
10011- Not
11110 Used
11111 Test None
Example
Here are three examples of how to set the address key:
A node with id B1 without redundancy block or emergency stop has the address key 01000.
A node with id B2 with both redundancy block and emergency stop has the address key 01001.
A node with id A2 (cannot have redundancy block or emergency stop enabled) has the address key 00010.

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4.5.4 Analogue Inputs

There are two analogue inputs on each node via the X2 connector (the other two are via the X4 connector). Each signal
has its own 10V-reference voltage output, ground reference and sensor signal that should be connected to the sensor
device.

Analogue in 1 X2/18
10Vref 1 X2/28
Signal ground 1 X2/8
Analogue in 2 X2/17
10Vref 2 X2/27
Signal ground 2 X2/7
4.5.5 PWM Outputs

There are four PWM outputs for driving external loads, for example proportional hydraulic valves. Each output has two
connections, one in and one out. The load should be connected between these, since it is a current loop.

PWM out 1 X2/3
PWM in 1 X2/4
PWM out 2 X2/2

PWM in 2 X2/1
PWM out 3 X2/21

PWM in 3 X2/11
PWM out 4 X2/31

PWM in 4 X2/41
4.5.6 External Spreader Memory

An external EEPROM memory can be mounted on the spreader for spreader id and/or user defined purpose. The memory
is connected as below.
Name Pin number in connector Cable

10V supply X2/36 Red
Serial data X2/16 Blue
Serial clock X2/26 Green
Signal ground X2/6 Black

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4.5.7 RS 485 and SSI

The RS 485 connection can be used for external sensors or user defined purpose. The SSI connection can be used with
external sensors with up to 25 bits data length. The hardware and the pins in connector X2 are shared between RS 485
and SSI. Therefore it is only possible to use one of these connections at a time.
When used as a RS 485 the following pins are used:

Channel A X2/38
Channel B X2/37
When used as SSI the following pins are used:

Clock+ X2/38
Clock- X2/37
Data+ X2/15
Data- X2/25
4.5.8 Additional Jumper Group

X2 - Pin number Link configuration

22
23
32
33
34

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4.6 The X4 Connector

The X4 connector can be configured for field bus operation or one of three alternative functions. The alternatives are a RS
232 serial port, two additional analogue inputs or a duty cycle input. The function is selected by connecting different pin
headers to connector CN103. To find these pin headers the SCS2 node must be opened. The figure below shows the
relative placement of the pin headers. In each pin header the pins are number 1 to 5 or 1 to 10. In the figure a pin with a
circle to the left is number one in that header.
Field bus operation is selected by connecting the field bus connector on the Anybus card with pin header CN103. The RS
232 serial port is selected by connecting CN100 and CN103. The two additional analogue inputs are selected by
connecting CN105 and CN103. Finally the duty cycle input is selected by connecting CN104 with CN103.
Front view of connectors inside node.

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4.6.1 AnyBus
The AnyBus connector is used to interface any of the fieldbus types used apart from BCAN.

A-Line X4/2
B-Line X4/1
GND-BUS X4/3
4.6.2 Two auxiliary Analogue Inputs

These two analogue inputs use the same ground and 10 V reference voltages as the two analogue inputs in connector X2.
The input range is either 0 to 10 V or 0 to 20 mA. The 0 to 20 mA range is selected for channel 1 by jumpering pin
number 1 and 2 in CN106 and for channel 2 by jumering pin number 4 and 5 in CN106. If no jumpers are added on
CN106 the voltage range, 0 to 10 V range is selected as default. In the 0 to 20 mA range a 500 Ohm resistor is used
internally and therefore the current being measured must be capable of driving 20 mA at 10 V to utilise the full 0 to 20
mA range.

GND X5/1
GND X5/2
Analogue Input 1 X5/5
Analogue Reference 10 V X5/3
Analogue Input 2 X5/4

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4.7 The X5 Connector
4.7.1 RS-232
The RS-232 connector, called BMS port, is located to the right of the node and is used only for this purpose.

TxD X5/1
RxD X5/2
RTS X5/5
CTS X5/3
GND X5/4
4.8 The Redundancy Function

For safety reasons the hardware is designed to override the operator commands in some occasions. This is to prevent the
operator from making wrong commands by accident when the spreader is not landed, prohibiting dangerous results.
C D
B
A E
The commands either from a remote node on the network or the local node itself.
The CPU and the system software as well as the application specific software (Spreader program).
The redundancy block of hardware static logic. The block has two functions, to make sure the twistlocks are energised
correctly at boot and to prevent the software from changing between lock and unlock when not landed during operation.
At boot the redundancy block checks the sensor status and determines if the twistlock valves are to be energised and in
what direction. After a correct landing and a transition between lock/unlock the redundancy block goes passive only
preventing the software to change between lock and unlock unless the Spreader is properly landed. In this state the
redundancy can be viewed as two relay contacts, where only one contact is closed at a time permitting the twistlock
outputs. The only way of overriding the logic of the redundancy block is to energise a specific I/O (landed override) on
that particular node.
The outputs to the lock/unlock valves
The sensor signals from landed, locked and unlocked.
To enable the redundancy the address key on B1 or B2 is used, this then automatically means you have to use input 48 as
Landed override to be able to override the hardware logic. The landed override signal sets the spreader in landed mode
and thereby temporarily disables the redundancy block.

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4.9 Field bus Connections.

Apart from the parallel I/O of the nodes, each node can be equipped with an AnyBus card used for external buses. This
card is fitted into the node on the connector at the right side of the board when the cover is off. By using the AnyBus the
crane can utilise the SCS2 as an integrated slave on the PLC network or an AnyBus card can be used as a Master bus for
an internal I/O bus on the Spreader. The principal behind the AnyBus is that the interface card translates a number of
different bus protocols to a standardised format on the address and data bus of the node. To change between different
buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please
view the user manual for that specific card and the electrical documentation for your specific project.
Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer
SCS2 is an output from the master in the crane.
4.9.1 Mapping of I/O
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent
will be equivalent with the code displayed in the onboard display; hence there will be three levels of this code INFO,
WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented
each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value
of this counter will be sent each time that a new diagnostic message is transmitted.


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way.
Byte 8 => Node ID
Byte 9-10 => Row Number (of source code)
Byte 11-16 => Filename (1:st 6 char.)
Byte 17-18 => sequential counter
These assignments shall be are documented in the electrical documentation of the project.
Input Segment
4.10 Spreader Stop

A Spreader stop function can be used in the system.
This is performed by enabling Spreader stop using the address key on B1 or B2 and connecting the signal from the
spreader stop button to digital port 47 on the corresponding node (B1 or B2).
The spreader stop configuration must correspond to the spreader stop setting in the spreader program. This means that if
and only if the spreader stop on a node is enabled, digital port 47 must be connected to the Spreader Stop component in
the spreader program.

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4.11 Fault Finding table

Symptom What to do Comment
Power Supply
Node won’t start. No text appears in Measure the main supply. The voltage The green and all red LED’s in the
the display after power-on. should exceed 17V AC or DC. display should be lit.
RS-232
BMS system can not communicate Probe TxD and RxD lines with Data lines should show square waves
with the node. oscilloscope while trying to between –10V to +10V relative to
communicate. GND pin.
CAN
The node can not communicate with Probe bus lines with oscilloscope.
the other nodes. CAN high should show square waves
pointing downwards and CAN low
should be showing square waves
pointing upwards.
Digital Ports
Input signal fault Check if LED indicator on I/O module The LED should be lit when current
responds to sensor signal. flows through the module.
Check the Common connection for
correct supply.
Output signal fault Check if LED indicator on I/O module The LED should be lit when the circuit
responds to command. is closed.
Check the load for proper connection The load should be connected between
and grounding. the modules out pin and ground.
Check for broken fuse on the I/O
module.
Check the Common connection for The supply voltage depends on the
correct supply. type of load. 220V,110V,24V or other.
Node ID
The node stops at start-up with Node Measure the voltage of all ID pins. 5V This can indicate that the node has
Id displayed. represent ones and 0V represents wrong id strapped telling the node to
zeroes. The measures should indicate participate in the system with wrong
the expected id. role.
Analogue Inports
Analogue input signal appears to be Check the reference voltage relative to There should be exactly 10V
faulty. the GND. difference between them.
Check if the node chassis is properly This is very important in an AC driven
grounded to the spreader. system.
PWM Outports
PWM output appears to be faulty. Check the load for errors.
Try another load.

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5 So tware tools
5.1 Overview
There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given
below.
5.2 ABE
ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls
the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.
5.3 BMS
BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the
SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.

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Mis ellaneous
6.1 Data sheet
Parameter Note Min Max Unit
Operating voltage Pin X2 42-44 17 40 V AC/DC

Current consumption Depending on number and type of I/O modules 300 800 mA
Power monitoring Level and quality measurement of voltage.
Indicated via LED’s. (faults stored in log)
0
Temperature Operating temperature -40 +85 C
Internal temperature monitoring
IP67
EMC conformity In accordance with 89/336/EEC:
EN 50081-2: 1993
EN 50082-2: 1995
EN 61000- 4- 6: 1996
EN 61000-4-8:1993
ENV 50204: 1995
EN 61000- 4- 4: 1995
EN 61000- 4- 2: 1995
Controller 32bit controller running at 16MHz quartz
Memory Program 1.4Mb
Log/NVRAM 128kb
External EEPROM 256byte
Time 1*realtime clock
PWM current output 4*Current controlled. Short circuit protected. 0 2,5 A
Analogue inputs 12 bit resolution voltage/current 0 10 V
10V reference voltage output
SSI serial 300 kHz
I/O 48 programmable Voltage depending on type of module used. 12 230 V AC/DC
Galvanic isolation. LED indication.
SC/OL protected 3A.
Scan time System scan time 50 ms
Node scan time 5 ms
Serial interfaces BCAN – Bromma CAN based bus
RS485 – Asynchronous for sensors etc.
RS232 – For PC communication
Field bus slave to those field buses supplied by
HMS.
Diagnostics System diagnostics
Spreader functionality diagnostics
8 character display for messages & information
Power level via LED’s
Event and error log
FB programming Basic binary functions (AND, OR etc.)
Basic Analogue functions (compare, add etc.)
Basic controller functions(PWM, regulators etc.)
Spreader controller functions

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6.2 Dimensions
Figure 1 All dimensions in mm

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Appendi A ( rror messa es)

The error messages, which are generated by the system, can be viewed in the display as well as in the log (using the
BMS). It is the same information in both interfaces and is explained in this appendix in the table below.
Nu level Description of code Description of sub code Consequence Hints

m.l
cod
e
0
1 WARNING Failed reading temperature .
2 spare 0 .
3 spare 1 .
4 spare 2 .
5 spare 3 .
6 ERROR Two different PCs' trying to Id of one of the node System is brought into Ensure that only
download to the system connected to the PC failsafe mode. one PC is
downloading
7 spare 4 .
8 spare 5 .
9 spare 6 .
10 spare 7 .
11 spare 8 .
12 ERROR Program memory failure, HW . System is brought into failsafe mode.
fault
13 ERROR No response from slave when . System is brought into Ensure that all
initialising system failsafe mode. slave are
powered up &
correctly
addressed
14 ERROR Boot sequence failed . System is brought into Restart system
failsafe mode.
15 spare 9 .
16 spare 10 .
17 spare 11 .
18 spare 12 .
19 spare 13 .
20 ERROR Downloading error, connection . System is brought into reload program
broken failsafe mode.
21 spare 14 .
22 ERROR Memory collides when . System is brought into recompile and
downloading program failsafe mode. download
program again
23 spare 15 .

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24 spare 16 .
25 spare 17 .
26 spare 18 .
27 spare 19 .
28 WARNING No data in program/system . System cannot start Contact Bromma
memory
29 spare 20 .
30 WARNING Checksum of memory corrupt .
31 ERROR HW fault on memory . System is brought into Contact Bromma
failsafe mode. if problem
persists
32 spare 21 .
33 spare 22 .
34 ERROR System init. Display. This error The error codes during the system boot phase that have caused the
code accumalates and displays system to go into failsafe mode
the errors ocurred during the
system boot, since no reporting
is done until the system has
started.
35 ERROR System failed in reading . System is brought into reload and
spreader program from memory failsafe mode. restart
36 ERROR No spreader program residing in . System is brought into download
memory failsafe mode. program
37 ERROR System failed to run spreader . System is brought into reload proram
program failsafe mode.
38 ERROR Spreader program object . System is brought into Check spreader
instances failed failsafe mode. program. If
problems persist
contact Bromma
problems persist
contact Bromma
problems persist
contact Bromma
41 ERROR Spreader program object . System is brought into Check spreader.
instances failed failsafe mode. If problems
persist contact
Bromma
problems persist
contact Bromma

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problems persist
contact Bromma
44 WARNING I/O message lost .
45 ERROR Memory failure . System is brought into Restart system.
failsafe mode. If problems
persist contact
Bromma
46 spare 23 .
47 spare 24 .
48 spare 25 .
49 spare 26 .
50 ERROR Failed to configure I/O on node The node ID which has System is brought into restart
generated the error failsafe mode.
51 ERROR Duplicate answers on I/O The node ID which has System is brought into restart
configuration from the same generated the error failsafe mode.
node when initialising system
52 ERROR System initialising error when The node ID which has System is brought into restart
configuring nodes I/O generated the error failsafe mode.
54 spare 27
56 ERROR No answer when master . System is brought into check

requesting configuration failsafe mode. connections
information during intitialisation between nodes.
Restart
Restart
Restart
59 INFO System started .
60 WARNING TWL - No twistlock sensor . Message stored in log and check wiring,
inputs active during system start displayed on Spreader sensors and
connectors or
mechanical
reasons

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61 WARNING TWL - One twistlock indicating ID no. of the twistlock Message stored in log and check for
both locked and unlocked which generated the displayed on Spreader damaged sensors
warning and sensor
adjustment or
mechanical
reasons
62 WARNING TWL - timeout locking. Locked ID no. of the twistlock Message stored in log and check sensor,
signal has not been received which generated the displayed on Spreader valves and/or
after output to valve warning wiring or
mechanical
reasons
63 WARNING TWL - Locked sensor lost ID no. of the twistlock Message stored in log and check for
during operation. Sensor lost which generated the displayed on Spreader damaged sensors
without command/output when warning and sensor
twistlocks are all locked adjustment or
mechanical
reasons
64 WARNING TWL - timeout unlocking. ID no. of the twistlock Message stored in log and check sensor,
Unlocked signal has not been which generated the displayed on Spreader valves and/or
received after output to valve warning wiring or
mechanical
reasons
65 WARNING TWL - Unocked sensor lost ID no. of the twistlock Message stored in log and check for
during operation. Sensor lost which generated the displayed on Spreader damaged sensors
without command/output when warning and sensor
twistlocks are all unlocked adjustment or
mechanical
reasons
66 WARNING TWL - all landed sensors not ID no. of the twistlock Message stored in log and check for
received after first landed and which generated the displayed on Spreader damaged sensors
timeout. warning and sensor
adjustment or
mechanical
reasons
67 WARNING TWL - landed sensor not ID no. of the twistlock Message stored in log and check for
released when the other sensors which generated the displayed on Spreader damaged sensors
not active and a timer has timed warning and sensor
out adjustment or
mechanical
reasons
68 WARNING TELESCOPE - prox. type. No . Stops the telescope and check for
valid sensor found within displays/stores message damaged sensors
timeout limit after output has and sensor
been activated adjustment or
mechanical
reasons
69 WARNING TELESCOPE - prox. type. ID no. of the sensor Stops the telescope and check for
Wrong sensor in telescoping missing which displays/stores message damaged sensors
sequence reached generated the warning and sensor
adjustment or
mechanical
reasons

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70 WARNING TELESCOPE - prox. type. The ID no. of the lost Message stored in log and displayed on
position sensor is lost without an sensor Spreader
output.
71 WARNING TELESCOPE - prox. type. Two ID no.s. of the sensors Message stored in log and check for
different position sensors displayed on Spreader damaged sensors
indicating simultaneously and sensor
adjustment or
mechanical
reasons
72 ERROR Duplicate answers from one The node ID which has System is brought into restart (check
node during boot verification generated the error failsafe mode. address keying)
73 ERROR Wrong boot version in a node The node ID which has System is brought into contact Bromma
generated the error failsafe mode.
74 ERROR No answer when master The node ID which has System is brought into restart
requesting boot version. generated the error failsafe mode.
75 spare 28
76 spare 29
77 spare 30
78 spare 31 .
79 spare 32 .
80 ERROR Wrong node answered request The node ID which has System is brought into restart
from master to check if pc was generated the error failsafe mode.
connected
81 ERROR No answer after master request The node ID which has System is brought into restart, check
to check PC port (RS232) generated the error failsafe mode. connections
82 ERROR Unable to download program . System is brought into retry
failsafe mode.
83 ERROR Unable to download program . System is brought into Check spreader
(checksum failure) failsafe mode. program. If
problems persist
contact Bromma
84 WARNING Onboard realtime clock time .
couldn't be read
85 WARNING Onboard realtime clock time .
couldn't be set
86 INFO minimum system CPU cycle time in ms Message stored in log and displayed on
time. Periodically reported every Spreader
half hour. The counter is reset
after reporting.
87 INFO maximum system CPU cycle time in ms Message stored in log and displayed on
time. Periodically reported every Spreader
half hour. The counter is reset
after reporting.
88 INFO average system CPU cycle time. time in ms Message stored in log and displayed on
Periodically reported every half Spreader
hour. The counter is reset after

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reporting.
89 spare 33 .
90 INFO The number of control loops The number of the Message stored in log and displayed on
exceeding 100ms for th last half counter Spreader
hour. The counter is reset after
reporting
91 spare 34 .
92 spare 35 .
93 spare 36 .
94 ERROR No operative system in Node . Systems fails to start contact Bromma
95 ERROR Duplicate answer on The node ID which has System is brought into check adress key
determining Spreader stop set up generated the error failsafe mode.
96 ERROR No answer on Master request for . System is brought into check adress key
"Spreader stop" configuration failsafe mode.
97 INFO Spreader stop has been 0= activated Message stored in log and displayed on
activated/deactivated 1=deactivated Spreader
98 spare 37 .
99 spare 38 .
100 ERROR Spreader program fault . System is brought into
recompile and
failsafe mode. reload spreader
program
101 WARNING CAN message buffer is full The first message type Message stored in log and displayed on
in the buffer Spreader
102 ERROR System failed to initialise HW . System shutdown contact Bromma

103 spare 39 .
104 spare 40 .
105 ERROR Onboard NV RAM failed . System is brought into check
memory test failsafe mode. battery/restart/co
ntact Bromma
106 spare 41 .
107 WARNING 10V reference voltage too low Actual voltage *10 Message stored in log and check supplies
displayed on Spreader
108 WARNING 12V internal supply too low Actual voltage *10 Message stored in log and check supplies

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109 ERROR Battery voltage too low Actual voltage *10 Message stored in log and check battery
110 ERROR The System failed to lock th I/O . System is brought into restart
on a node during system init. failsafe mode.
111 spare 42
112 spare 43 .
113 spare 44 .
114 INFO System is shutting down .
115 INFO System shutdown has been .
completed
116 spare 45 .
117 spare 46 .
118 INFO Landed override has been .
activated
119 INFO Landed override has been .
deactivated
120 spare 47 .
121 spare 48 .
122 spare 49 .
123 spare 50 .
124 spare 51 .
125 spare 52 .
126 spare 53 .
127 spare 54 .
128 spare 55 .
129 ERROR Spreader program fault or load . System is brought into check and
file has been korrupted failsafe mode. recompile
spreader
program.
Reload. /contact
Bromma
spreader
program.
Reload. /contact
Bromma
spreader
program.
Reload. /contact
Bromma

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132 spare 56 .
133 spare 57 .
134 spare 58 .
135 spare 59 .
spreader
program.
Reload. /contact
Bromma
137 spare 60 .
138 spare 61 .
139 spare 62 .
140 WARNING Unknown CAN message The ID type of the Message stored in log and displayed on
received message Spreader
141 INFO CAN messages missed. The count of the Message stored in log and displayed on
Cyclically reported. missed messages Spreader
142 ERROR Two nodes within the system The ID which is System is brought into check and
have the same ID/adress duplicate failsafe mode. correct the
adress key
143 WARNING 10V reference voltage is too Voltage * 10 Message stored in log and check supplies
high displayed on Spreader
144 WARNING 12V internal voltage is too high Voltage * 10 Message stored in log and check supplies
145 WARNING Battery voltage is too high Voltage * 10 Message stored in log and check supplies
146 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.

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156 spare 63 .
157 spare 64 .
158 spare 65 .
159 spare 66 .
160 spare 67 .
161 WARNING CAN error . Message stored in log and displayed on
Spreader

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162 WARNING RS232 error . Message stored in log and displayed on

Spreader
163 WARNING Power monitor P1 = sensor . Message stored in log and check supplies
supply voltage. Warning 1 = displayed on Spreader
Voltage < 21V
164 ERROR Power monitor P1 = sensor . System is taken down check supplies
supply voltage. ERROR = into idle mode. Ie if the
Voltage below permissive system voltage comes up
voltage of system. again it wakes otherwise
is prepared to shut down
165 WARNING Power monitor P2 = internal . Message stored in log and check supplies
Voltage < 21V
166 ERROR Power monitor P2 = internal . System is taken down check supplies
logic supply voltage. ERROR = into idle mode. Ie if the
167 WARNING Power monitor P3 = PWM . Message stored in log and check supplies
Voltage < 21V
168 ERROR Power monitor P3 = PWM . System is taken down check supplies
supply voltage. ERROR = into idle mode. Ie if the
169 WARNING System failed to read/write to a ID of port: Message stored in log and check supplies
I/O port Digital=0+port_no, displayed on Spreader
Analogue=100+port_n
o, PWM=200+port_no,
encoder=300+port_no.
170 spare 68 .
171 spare 69 .
172 spare 70 .
173 spare 71 .

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174 ERROR No answer when on general . Message stored in log and displayed on
information request between Spreader
nodes.
175 INFO TWL - twistlock lock command . Message stored in log and displayed on
received Spreader
176 INFO TWL - twistlock unlock . Message stored in log and displayed on
command received Spreader
177 INFO TWL - twistlock has been . Message stored in log and displayed on
locked Spreader
178 INFO TWL - twistlock has been . Message stored in log and displayed on
unlocked Spreader
179 INFO TELESCOPE - prox. type. . Message stored in log and displayed on
Expand command received Spreader
180 INFO TELESCOPE - prox. type. . Message stored in log and displayed on
Retract command received Spreader
181 INFO TELESCOPE - prox. type. The ID of the position Message stored in log and displayed on
Command to go to a speceific requested Spreader
position has been received
182 INFO TELESCOPE - prox. type. The The ID of the position Message stored in log and displayed on
desired position has been requested Spreader
reached
183 WARNING TELESCOPE - automatic type. 0 = Desired position The telescopic motion is check sensor,
The telescope hasn't reached its' not reached within time stopped until a new pressure,mechan
position within time limit limit. command is given. ics. If necessary
1 = telescope has not Message stored in log and calibrate system.
moved more than 1 cm displayed on Spreader
during 3 seconds.
184 INFO TELESCOPE - automatic type. . Message stored in log and displayed on
expand command received Spreader
Retract command received Spreader

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186 INFO TELESCOPE - automatic type. The ID of the position Message stored in log and displayed on
Command to go to a specific requested Spreader
position received
187 INFO TELESCOPE - automatic type. The ID of the position Message stored in log and displayed on
The desired position reached requested Spreader
188 INFO The year has been set current value (year) Message stored in log and displayed on
Spreader
189 INFO The month has been set current value (month) Message stored in log and displayed on
Spreader
190 INFO The day/date has been set current value (date) Message stored in log and displayed on
Spreader
191 INFO The time of day (hour) has been current value (hour) Message stored in log and displayed on
set Spreader
192 WARNING Nocontact with the master for The ID of the node Message stored in log and check
10s which doesn't have displayed on Spreader connections
contact
193 ERROR Message reported during boot. . restart (check

Unknown role address keying)
194 INFO Information request (system . Message stored in log and displayed on
boot functionality) Spreader
195 INFO Download request active . Message stored in log and displayed on
(system boot functionality) Spreader
196 INFO Information request received . Message stored in log and displayed on
197 INFO set time request received . Message stored in log and displayed on
198 INFO Boot version request received. . Message stored in log and displayed on
199 spare 72 .

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200 INFO Download flag request received. . Message stored in log and displayed on
201 spare 73 .
202 spare 74 .
203 spare 75 .
204 spare 76 .
205 INFO Check flash memory request . Message stored in log and displayed on
received. (system boot Spreader
functionality)
206 INFO Restart node request received. . Message stored in log and displayed on
207 INFO System start init. (system boot . Message stored in log and displayed on
functionality) Spreader
208 INFO System look for downloadflag. . Message stored in log and displayed on
209 INFO Send datablock request. (system . Message stored in log and displayed on
210 INFO Received datablock. (system . Message stored in log and displayed on
211 INFO Download in progress percentage of progress shown on Spreader display

downloaded data
212 INFO copy serial information to flash . Message stored in log and displayed on
memory Spreader
213 spare 77 .
214 spare 78 .
215 ERROR No answer when waiting for . System is brought into failsafe mode.
present nodes response
216 INFO Inforamtion on present nodes . Message stored in log and displayed on
has been received Spreader
217 ERROR Download timeout . System is brought into reload

failsafe mode.
218 spare 79 .

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219 ERROR No answers or inconsistent . System is brought into failsafe mode.

answers from system members
during boot
220 ERROR The size of received data is to . System is brought into failsafe mode.
large. Boot message
during boot
during boot
during boot
during boot
during boot
during boot
227 spare 80 .
during boot
229 INFO Spreader error and event log has . Message stored in log and displayed on
been cleared Spreader
230 ERROR Failed to set up spreader destination of error System is brought into Check spreader
program correctly failsafe mode. program. If
problems persist
contact Bromma
231 ERROR Spreader program download . System is brought into Check spreader
error failsafe mode. program. If
problems persist
contact Bromma
232 ERROR Spreader program download . System is brought into Check spreader
error failsafe mode. program. If
problems persist
contact Bromma
233 INFO Power monitor P1 = sensor . Message stored in log and displayed on
supply voltage. OK Spreader
234 INFO Power monitor P2 = internal . Message stored in log and displayed on

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235 INFO Power monitor P3 = PWM . Message stored in log and displayed on
236 INFO Reboot (restart) request sent . Message stored in log and displayed on
from master to slaves. Happens Spreader
when slaves are powered on
before master at system start
237 INFO System has been taken down to . Message stored in log and displayed on
idle mode. Ie waiting to wake Spreader
up.
238 Spare 81 .
239 INFO System failed to cancel . Message stored in log and displayed on
shutdown process Spreader
240 INFO No answer when attempting to . Message stored in log and displayed on
cancel shutdown process Spreader
241 INFO System received timeout when . Message stored in log and displayed on
attempting to cancel shutdown Spreader
process
242 INFO System shutdown aborted . Message stored in log and displayed on
Spreader
243 spare 82 .
244 INFO TWL - The spreader has been . Message stored in log and displayed on
landed Spreader
245 INFO TWL - The Spreader has been . Message stored in log and displayed on
totally lifted (not landed) Spreader
246 INFO FLIPPER - flipper up command . Message stored in log and displayed on
received Spreader
247 INFO FLIPPER - flipper down . Message stored in log and displayed on
248 WARNING Power monitor P1 = sensor . AI can start to flicker. Message stored in
supply voltage. Warning 2 = log and displayed on Spreader
Voltage < 17V

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249 WARNING Power monitor P2 = internal . AI can start to flicker. Message stored in
Voltage <17V
250 WARNING Power monitor P3 = PWM . AI can start to flicker. Message stored in
Voltage < 17V
251 ERROR System failed to initialise fielbus . System is brought into failsafe mode.
interface
252 ERROR Duplicate answers when setting . System is brought into failsafe mode.
up fieldbus interface
253 ERROR No answer when configuring . System is brought into failsafe mode.
fieldbus interface
254 WARNING System failed in locking .
fieldbus interface
255 WARNING TWIN195 - twinboxes have ID of the twin box Message stored in log and check
failed to get to their upper failing displayed on Spreader solenoids/mecha
position within time limit nics/sensors
256 WARNING TWIN195 - left hook has failed . Message stored in log and check
to reach its' upper position displayed on Spreader solenoids/mecha
within time limit nics/sensors
257 WARNING TWIN195 - right hook has failed . Message stored in log and check
to reach its' upper position displayed on Spreader solenoids/mecha
within time limit nics/sensors
258 WARNING TWIN195 - twin boxes left . Twin down sequence check
timed out when expanding to stopped. Have to return solenoids/mecha
their attach position. Failed to Spreaer to twin up nics/sensors
reach switch within time limit position. Message stored
in log and displayed on
Spreader
259 WARNING TWIN195 - twin boxes right . Twin down sequence check
timed out when expanding to stopped. Have to return solenoids/mecha
their attach position. Failed to Spreaer to twin up nics/sensors
reach switch within time limit position. Message stored
in log and displayed on
Spreader
260 WARNING TWIN195 - left hook has failed . Message stored in log and check
to reach its' lower position displayed on Spreader solenoids/mecha
(connect) within time limit nics/sensors

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261 WARNING TWIN195 - right hook has failed . Message stored in log and check
to reach its' lower position displayed on Spreader solenoids/mecha
(connect) within time limit nics/sensors
262 WARNING TWIN195 - twinboxes have ID of the twin box Message stored in log and check
failed to get to their lower failing displayed on Spreader solenoids/mecha
position within time limit nics/sensors
263 WARNING TWIN195 - twin up sensor lost ID of the twin box Message stored in log and check
unexpectedly. (not due to failing displayed on Spreader solenoids/mecha
output) nics/sensors
264 WARNING TWIN195 - twin up sensor ID of the twin box Message stored in log and check
received when twinboxes are failing displayed on Spreader solenoids/mecha
down nics/sensors
265 WARNING TWIN195 - left hook down . Message stored in log and check
sensor lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
266 WARNING TWIN195 - right hook down . Message stored in log and check
sensor lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
267 WARNING TWIN195 - left hook up sensor . Message stored in log and check
lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
268 WARNING TWIN195 - right hook up sensor . Message stored in log and check
lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
269 ERROR System failed to init. RS485 Node ID System is brought into restart / contact
failsafe mode. Bromma
270 ERROR Duplicate answers in system Node ID System is brought into restart / contact
when setting up RS485 failsafe mode. Bromma
271 ERROR System timed out when trying to . System is brought into restart / contact
configure RS485 failsafe mode. Bromma
Teach in command received Spreader
273 INFO TWINTELESCOPE - expand . Message stored in log and displayed on

274 INFO TWINTELESCOPE - retract . Message stored in log and displayed on


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275 INFO TWINTELESCOPE - left . Message stored in log and displayed on

console reached zero gap Spreader
position
276 INFO TWINTELESCOPE - right . Message stored in log and displayed on

console reached zero gap Spreader
position
277 INFO TWINTELESCOPE - twinlegs . Message stored in log and displayed on

expand in motion Spreader
278 INFO TWINTELESCOPE - twinlegs . Message stored in log and displayed on

retract in motion Spreader
279 WARNING TWINTELESCOPE - hasn't . motion is stopped. check

reached an endstop when in Message stored in log and pressure/mechan
motion within time limit displayed on Spreader ics(lubrication)/s
ensor/valves
280 spare 83 .
281 INFO TWINMPS - teaching a pre- The ID of the position Message stored in log and displayed on
defined position teached Spreader
282 INFO TWINMPS - command to go to The ID of the position Message stored in log and displayed on
a pre-defined position has been requested Spreader
received
283 INFO TWINMPS - A command to . Message stored in log and displayed on

store a new value for a log Spreader
position has been received
284 INFO TWINMPS - A command to The ID of the position Message stored in log and displayed on
return to a log position has been requested Spreader
received
285 WARNING TWINMPS - the twinlegs . Motion is stopped. check

haven't reached their requested Message stored in log and pressure/mechan
position within time limit. displayed on Spreader ics(lubrication)/s
ensor/valves
286 INFO TWIN195 - twin up command . Message stored in log and displayed on
has been received Spreader
287 INFO TWIN195 - twin down . Message stored in log and displayed on
command has been received Spreader

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288 INFO TWIN195 - twin boxes have . Message stored in log and displayed on
reached their upper position Spreader
289 INFO TWIN195 - twin boxes have . Message stored in log and displayed on
reached their lower position Spreader
290 INFO TTDS - override request . Message stored in log and displayed on
received Spreader
291 INFO TTDS - override request ended . Message stored in log and displayed on
Spreader
292 WARNING Buffer full transferring serial . Message stored in log and displayed on
port info over CAN bus Spreader
293 WARNING No answer when transferring . Message stored in log and displayed on
serial port info over Can bus Spreader
294 ERROR Failed to communicate with . System is brought

RS485 into failsafe mode.
295 spare 84 .
296 spare 85 .
297 spare 86 .
298 ERROR Failed reading spreader System is brought into Check spreader
program. failsafe mode. program. If
problems persist
contact Bromma
299 spare 87
300 spare 88
301 WARNING RS485 not functioning as Depending on type of Message stored in log and displayed on
intended sensor/device Spreader
302 WARNING AnyBus not functioning as Depending on type of Message stored in log and displayed on
intended sensor/device Spreader
303 WARNING Error in locking AnyBus setup Node ID

304 WARNING Timeout when trying to lock
AnyBus setup
305 WARNING Wrong node answered when locking AnyBus setup
306 INFO Spreader properties Number of containers Message stored in log and

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loaded/unloaded displayed on Spreader

307 WARNING AnyBus external bus failure Message stored in log and
308 WARNING AnyBus Status ok Message stored in log and
309 WARNING AnyBus external bus ok Message stored in log and
310 WARNING Wrong node answered when EEPROM setup
311 ERROR Timeout when expecting answer from node on EEPROM
312 WARNING Spreader properties

318 WARNING Read EEPROM failure
319 WARNING Read NVRAM failure
320 WARNING EEPROM checksum failure
321 INFO Spreader properties EEPROM
set ok
322 WARNING EEPROM set failure
323 INFO Spreader properties EEPROM attached to new node
324 INFO RS485 status ok

325 INFO Gravity point to centre
command
326 INFO Gravity point to left side
command
327 INFO Gravity point to right side
command
328 INFO Gravity point has reached the .
centre position
left end stop
right endstop
331 WARNING RS485 absolute sensor wrap .
around warning. Sensor too near
the value where it wraps around
and begins from zero again.

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332 WARNING RS485 absolute sensor has .

wrapped around. The value has
gone from maximum to
minimum in one CPU cycle.
333 INFO Added value to NVRAM .
successfully
334 WARNING Spreader stop configuration node that reported the problem
mismatch
335 WARNING Missed message on bus node from which an answer is expected
regarding digital I/O
regarding analogue I/O
regarding encoder data
regarding AnyBus message
regarding RS485 data
340 WARNING No contact with the node for 3s. node from which an answer is expected
specified by the Sub code
341 ERROR Error when trying to dowload .
program
342 ERROR Node is missing on the bus node that is missing
during system start.
343 ERROR Inclination sensor initialisation node that failed to initialise the sensor
error
344 ERROR Timeout when trying to node that failed to initialise the sensor
intitialise the inclination sensor
regarding inclination sensor
346 INFO Node bus communication ok. .
BCAN ok
347 INFO BCAN bus status warning. .
348 WARNING BCAN bus communication off. .
349 ERROR AnyBus Spreader/systems node from which an answer is expected
diagnostic area failed to set up.
350 ERROR Timeout when trying to set up
AnyBus Spreader/system
diagnostic area
351 ERROR AnyBus Assert diagnostic area node from which an answer is expected
failed to set up
352 ERROR Timeout when trying to set up
AnyBus Assert diagnostic area.

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353 INFO Present nodes shown in sub code bitwise OR for all included nodes. 12bit Value
354 INFO AnyBus slave card plugged in

node ID holding the
card
355 INFO AnyBus Master card plugged in node ID holding the
card
356 WARNING AnyBus card missing node ID of the node missing the card
357 INFO AnyBus Input data area size size of data area (bytes)
358 INFO AnyBus output data area size size of data area (bytes)
359 ERROR Hardware initialisation failed psu_mon.=1, temp_sens.=2, realtime_clock=3
(system prog.)
360 ERROR NVRAM full. No space left for .

Storage
361 ERROR NVRAM checksum Error .
362 ERROR OS code. Operating system fatal code from OS call Bromma
error
363 ERROR OS subcode.Operating system code from OS call Bromma
fatal error
364 ERROR OS extra.Operating system fatal code from OS call Bromma
error
365 ERROR Local regulator (PID) failed. node ID that failed to restart
initialise the regulator
366 ERROR Local regulator (PID) timeout . retstart
367 ERROR Error in interpreting the spreader . Check versions
program. Parameter mismatch of system and
between system and ABE file. ABE.
368 ERROR Error in recognising a . Check versions

component downloaded with the of system and
spreader program ABE.
369 WARNING Gravity point haven't reached .
the requested position within
time limit.
regarding regulator data.
371 ERROR Error in locking regulator setup .
372 INFO The Spreader info has been set. The index of the field
which is set.
373 INFO The Spreader info has been set. The value of the field
which is set. The
logged value is in the
range 0-9999. This
range limit has nothing

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to with the actual value

set in the Spreader info.
374 INFO The time of day (minute) has Current value (minute) Message stored in log and displayed on
been set Spreader
375 INFO Received a change bitrate Requested bitrate

request. Boot message.
376 WARNING TWIN195-Multiple sensor Message stored in log and displayed on

values from left hook Spreader
377 WARNING TWIN195-Multiple sensor Message stored in log and displayed on

values from right hook Spreader
378 WARNING Codeloading via anybus failed. node ID that failed to Message stored in log and displayed on
(start sequence) handle start sequence. Spreader
(download sequence) download. Spreader
(finish sequence) handle finish sequence. Spreader
381 WARNING Disabeling outputs failed. node ID that failed to Message stored in log and displayed on
disable outputs. Spreader
382 WARNING No answer when attempting to Message stored in log and displayed on
disable outputs. Spreader
383 WARNING Enabeling outputs faild. node ID that failed to Message stored in log and displayed on
enabeling outputs. Spreader
384 WARNING No answer when attempting to Message stored in log and displayed on
enabeling outputs. Spreader
385 INFO AutoTuner stored in NVRAM Regulator index. Message stored in log and displayed on
Spreader

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386 INFO Tandem - Teaching a pre- The ID of the position Message stored in log and displayed on
defined position teached Spreader
387 INFO Tandem - A command to store a Message stored in log and displayed on
new value for a log position has Spreader
been received
388 INFO Tandem - command to go to a The ID of the position Message stored in log and displayed on
pre-defined position has been requested Spreader
received
389 INFO Tandem - A command to return The ID of the position Message stored in log and displayed on
to a log position has been requested Spreader
received
390 WARNING Tandem - Cylinder position has The ID of the cylinder Message stored in log and displayed on
changed more than allowed. Spreader
391 INFO Tandem – Both landside and Message stored in log and displayed on
waterside spreaders enabled Spreader
392 INFO Tandem – Landside spreader Message stored in log and displayed on
enabled Spreader
393 INFO Tandem – Waterside spreader Message stored in log and displayed on
enabled Spreader
394 INFO TandemPush – A push Message stored in log and displayed on

395 INFO TandemPush – Inner position Message stored in log and displayed on
reached. Spreader
396 INFO TELESCOPE – Impact detected Message stored in log and displayed on
Spreader
397 INFO TELESCOPE – Telescope is Message stored in log and displayed on

autocorrecting Spreader
398 WARNING TELESCOPE – Sensor value is Message stored in log and displayed on
out of range Spreader

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399 INFO TELESCOPE – Bumped out of Message stored in log and displayed on
signal window Spreader
400 INFO TWL – TTDS active Message stored in log and displayed on
Spreader
401 WARNING TWL – Lock attempt with Message stored in log and displayed on
TTDS active Spreader
402 INFO Digital I/O configured on an Node id on where I/O Message stored in log and displayed on
AnybusGateway configured Spreader
403 INFO Analogue I/O configured on an Node id on where I/O Message stored in log and displayed on
404 INFO PWM configured on an Node id on where I/O Message stored in log and displayed on
405 INFO ASC – Antisway sytem active Message stored in log and displayed on
Spreader
406 INFO ASC – Antisway sytem ready Message stored in log and displayed on
Spreader
407 INFO ASC – Antisway sytem failed Message stored in log and displayed on
Spreaderi
408 spare 88
409 ERROR OS extra 2.Operating system code from OS call Bromma

fatal error
410 INFO Current hardware version HW type Type of hardware version.

5 = SCS2 revision
4 = SCS2
6 = Anybus gateway
411 WARNING Strange parameter saved in Parameter No. The PID component found a strange
NVRAM. (AutoTuner) parameter saved in NVRAM. The PID
component uses the ABE parameters
instead.

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412 WARNING Auto Tuner – Finished but failed Parameter No. Some parameters could not be calculated.
to calculate some parameters Check sensors etc.
413 ERROR CANopen – Failed to initialize

the software.
414 ERROR CANopen – Failed to configure Check spreader program

PDO
415 ERROR CANopen - Error in locking

CANopen setup
416 INFO CANopen – Node removed from Node number Message stored in log and displayed on
heartbeat list Spreader
417 INFO CANopen – New node added to Node number Message stored in log and displayed on
heart beat list Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
418 INFO CANopen – Boot message Node number Message stored in log and displayed on
received from node Spreader. See more specific literature
419 INFO CANopen – Node stopped Node number Message stored in log and displayed on
Spreader. See more specific literature
420 INFO CANopen – Node in operational Node number Message stored in log and displayed on
state Spreader. See more specific literature
421 INFO CANopen – Node in Node number Message stored in log and displayed on
preoperational state Spreader. See more specific literature
422 WARNING CANopen – Heartbeat failed on Node number Message stored in log and displayed on
node Spreader. See more specific literature
423 ERROR CANopen – To many slaves in Message stored in log and displayed on
use Spreader. Check spreader program.
424 ERROR CANopen – Failed to configure Message stored in log and displayed on
SDO Spreader. Check spreader program.

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425 WARNING CANopen – Failed to send SDO Node number Message stored in log and displayed on
Spreader. Check spreader program.
426 WARNING CANopen – Bus off occured Message stored in log and displayed on
Spreader.
427 ERROR CANopen – Failed to change the Message stored in log and displayed on
bitrate on CAN interface Spreader.
428 Spare 89
429 Spare 90
430 Spare 91
431 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 1 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
slave user manual
slave user manual
slave user manual
slave user manual
436 INFO CANopen – Slave OK Node number Message stored in log and displayed on
slave user manual
437 WARNING CANopen – Generic error Node number Message stored in log and displayed on
slave user manual

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438 WARNING CANopen – Current Node number Message stored in log and displayed on
439 WARNING CANopen – Current, device Node number Message stored in log and displayed on
input side Spreader. See more specific literature
440 WARNING CANopen – Current, inside Node number Message stored in log and displayed on
device Spreader. See more specific literature
441 WARNING CANopen – Current, device Node number Message stored in log and displayed on
output side Spreader. See more specific literature
442 WARNING CANopen - Voltage Node number Message stored in log and displayed on
443 WARNING CANopen – Mains voltage Node number Message stored in log and displayed on
444 WARNING CANopen - Voltage inside Node number Message stored in log and displayed on
445 WARNING CANopen – Voltage output Node number Message stored in log and displayed on
446 WARNING CANopen - Temperature Node number Message stored in log and displayed on
447 WARNING CANopen – Temperature Node number Message stored in log and displayed on
ambient Spreader. See more specific literature
448 WARNING CANopen – Temperature device Node number Message stored in log and displayed on
449 WARNING CANopen – Hardware device Node number Message stored in log and displayed on
450 WARNING CANopen – Software device Node number Message stored in log and displayed on

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451 WARNING CANopen – Software inside Node number Message stored in log and displayed on
452 WARNING CANopen – software user Node number Message stored in log and displayed on
453 WARNING CANopen – Data set Node number Message stored in log and displayed on
454 WARNING CANopen – Additional module Node number Message stored in log and displayed on
455 WARNING CANopen - Monitoring Node number Message stored in log and displayed on
456 WARNING CANopen – CAN overrun Node number Message stored in log and displayed on
457 WARNING CANopen – CAN error passive Node number Message stored in log and displayed on
458 WARNING CANopen – Lifeguard or Node number Message stored in log and displayed on
heartbeat Spreader. See more specific literature
459 WARNING CANopen – Recover from bus Node number Message stored in log and displayed on
off Spreader. See more specific literature
460 WARNING CANopen - Transmit COB id Node number Message stored in log and displayed on
461 WARNING CANopen – General Node number Message stored in log and displayed on
communication Spreader. See more specific literature
462 WARNING CANopen – General protocol Node number Message stored in log and displayed on
463 WARNING CANopen – PDO not processed Node number Message stored in log and displayed on

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464 WARNING CANopen – PDO length Node number Message stored in log and displayed on
exceeded Spreader. See more specific literature
465 WARNING CANopen – External error Node number Message stored in log and displayed on
466 WARNING CANopen – Additional Node number Message stored in log and displayed on
functions Spreader. See more specific literature
467 WARNING CANopen – Device specific Node number Message stored in log and displayed on
slave user manual
468 WARNING CANopen – Node missing Node number Check CAN connections and spreader
program.
469 INFO CANopen – Node id changed Changed to node Message stored in log and displayed on
number Spreader.
470 WARNING CANopen – Node id chage Node number Message stored in log and displayed on
failed Spreader.
471 WARNING TTDS – No sensors - Message stored in log and displayed on

Spreader

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Spreader Control System
2:nd generation
2
SCS Anybus Gateway
e 10 05-03-08
2
Manual SCS Any us Gateway
Andy Lewis 2005-03-08 10:41 11 2(13)
1 General ......................................................................................................................................................................... 3
1.1 OVERVIEW ............................................................................................................................................................... 3
1.2 DICTIONARY AND ABBREVIATIONS .......................................................................................................................... 3
1.3 DOCUMENT LAYOUT ................................................................................................................................................ 3
2 Introduction ................................................................................................................................................................. 4
2.1 GENERAL ................................................................................................................................................................. 4
2.2 THE NODES .............................................................................................................................................................. 5
3 Software........................................................................................................................................................................ 5
3.1 BOOT PROGRAM ...................................................................................................................................................... 5
3.2 SYSTEM PROGRAM ................................................................................................................................................... 5
3.3 SPREADER PROGRAM ............................................................................................................................................... 6
4 Hardware Overview .................................................................................................................................................... 6
4.1 BCAN - STATUS LEDS ........................................................................................................................................... 6
4.2 THE ANY BUS CARD ................................................................................................................................................. 6
4.3 POWER CONNECTOR ................................................................................................................................................. 6
4.4 BCAN CONNECTOR ................................................................................................................................................. 7
4.5 NODE ADDRESS KEY SWITCHES ................................................................................................................................ 7
4.6 SERIAL PORT CONNECTOR ........................................................................................................................................ 7
4.7 GROUND CONNECTION ............................................................................................................................................. 7
4.8 FIELD BUS CONNECTIONS. ....................................................................................................................................... 8
4.8.1 Mapping of I/O .............................................................................................................................................. 8
4.9 FAULT FINDING TABLE........................................................................................................................................... 10
5 Software tools............................................................................................................................................................. 10
5.1 OVERVIEW ............................................................................................................................................................. 10
5.2 ABE....................................................................................................................................................................... 10
5.3 BMS ...................................................................................................................................................................... 10
6 Miscellaneous ............................................................................................................................................................. 11
6.1 DATA SHEET........................................................................................................................................................... 11
6.2 DIMENSIONS .......................................................................................................................................................... 12
7 Appendix A (Error messages)................................................................................................................................... 13
Manual 2 2005 Bromma Conquip AB

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1 General
1.1 Overview
This document serves as a user manual and shall be used by the those installing and using the Bromma SCS2 Anybus
Gateway. Software as well as hardware routines and descriptions are covered in this document.
1.2 Dictionary and abbreviations

ABE Application Builder Environment. A tool for building control logic.
BMS Bromma Monitoring System. A tool for monitoring the SCS2.
Boot program The part of the software in the SCS2 that is executed at power up. This part is responsible for the
loading of the program verifying that the system is set up correctly.
CAN Controller Area Network. A two wire serial bus used for high speed, high reliability communication.
PWM Pulse Width Modulator.
Spreader Program The control logic that controls the functionality of the SCS2.
SCS2 Spreader Control System generation 2. The control system described in this user manual. The system
will be referred to as SCS2 in this document.
System Program The program that serves as a base for the execution and control of the spreader program.
Anybus Gateway A node that can be used in the Spreader Control System generation 2.
1.3 Document layout

Chapter 3, System overview, gives a brief description of the SCS2.
Chapter 4, Software, describes how the different software parts correlates.
Chapter 5, Hardware overview, describes the hardware in the SCS2.
Chapter 6, External interfaces, describes all the external interfaces in the SCS2.
Chapter 7, Software tools, describes the supporting tools to the SCS2.
Appendix A, Error messages, shows all error messages and their meaning (see main SCS2 manual for details).

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2 ntrodu tion
The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided
to develop a new and highly advanced communications system a close look at the available bus systems revealed a
number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical
roughness.
Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough
Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface
that complies with European and international standards for control equipment in this area. The SCS2 solution is a single
control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are
simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable
architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money.
2.1 General
As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS
and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or
you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable
performance in the particularly challenging environment of container handling the system corporate four basic elements:
Crane Node A device directly interfacing with the crane’s control systems, computer and
monitoring screens, providing an optional serial bus interface for
programming or diagnostic communications, as well as an interface to the
spreader node.
Crane-Spreader Communications Link A two-wire conventional cable CAN communications between the crane
control system and the spreader.
Spreader Node A device that interfaces directly with the spreader’s sensorsand actuators.
One of the Spreader nodes normally acts as Master.
Sensors and Switches Conventional sensors, switches, and actuators on the spreader.
The system is divided into several hardware blocks called nodes. The nodes are located on the spreader and in the crane.
The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the
number of I/O needed.
The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered
from 0 to 11 where:
0 is the master called B1

1-7 are slave nodes located on the spreader called B2-B8
8-11 are slave nodes located in the crane called A1-A4.

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Crane PLC
Crane field bus
Anybus Gateway A1
CAN network (BCAN) SCS2
I/O B1 Master B2 Slave ... B8 Slave
Spreader
Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally
via a CAN network.
2.2 The Nodes
The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master.
There must be only one master node in the system and the rest are slaves.
The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master.
3 So tware
The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.
3.1 Boot Program

When the power is applied to the Boot Program starts to run. It will take approximately 5 seconds to boot up the system.
During system Program updates it will take longer.
The Boot program is responsible for

Initialising hardware
Verifying that all system versions match.
Performing a program download
3.2 System program

After the Boot program is finished, the System will execute until the system is switched off. The System program is
responsible for
Interpreting the Spreader program (only on Master node)
Supporting any connected PC-connection via the RS232 port
Monitoring the supply voltage and some internal voltages
Logging events in the event log
Reading input signals and writing output signals

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3.3 Spreader Program

The Spreader Program is the specific application program that controls the spreader. This program is created in ABE, see
chapter 5.2 for a brief description.
4 ardware er iew
Figure2 is a SCS2 Anybus Gateway node equiped with a Profibus slave card. The different parts are explained in the
following chapter. This view shows a Profibus card, this can naturally be exchanged for any other available fieldbus.
AnyBus
(Profibus) card
Status LEDs
status LEDS
AnyBus Power connector

(Profibus) card
address BCAN connector
selectors
AnyBus
(Profibus) card Node address key
terminator switches
switch
Serial port connector
AnyBus
(Profibus) card
fieldbus
connector
Figure 2. The SCS2 Anybus Gateway node equiped with a Profibus slave card.
4.1 BCAN - Status LEDs

There are three green LEDs for Power, BCAN and Anybus indicating operating status and one red LED indicating error
status.
Power LED is lit when power is applied and system starts to execute.
BCAN LED is lit when the BCAN communication interface is operating normally and flashing when the communication
interface is not working as inteded.
Anybus LED is flashing when the Anybus interface is not configured and lit when configured and operating normaly.
Error LED is unlit when system is running normally and lit when an error has occurred.
4.2 The Any bus card

For details regarding the specific field bus card connection, termination, addressing and status LED’s, please see the
separate manual for that specific type of card.
4.3 Power connector

The power connector is a Phoenix Contact 2-pin header (MC1,5/2-G-3,81).
Name Description Pin number

VCC 10 to 28 V DC 1
GND Ground 2
Manual 2005 Bromma Conquip AB

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4.4 BCAN connector

The BCAN connector is a Phoenix Contact 3-pin header (MC1,5/3-G-3,81).

CAN H CAN high 1
CAN L CAN low 2
CAN GND CAN ground, not required by BCAN 3
4.5 Node address key switches

There are five switches selecting node address, where the DIP switch 1 corresponds to LSB.
The nodes are addressed according to the following table:
DIP setting Node Spreader Redundancy block and override

stop
0=off, 1=on name of landing pins
00000 Test
00001 A1 No No
00010 A2 No No
00011 A3 No No
00100 A4 No No
00101 B1 Yes Yes
00110 B1 Yes No
00111 B1 No Yes
01000 B1 No No
01001 B2 Yes Yes
01010 B2 Yes No
01011 B2 No Yes
01100 B2 No No
01101 B3 No No
01110 B4 No No
01111 B5 No No
10000 B6 No No
10001 B7 No No
10010 B8 No No
10011-11110 Not Used
11111 Test
4.6 Serial port connector

The serial port connector is a standard DSUB 9-PIN female connector. A pin-to-pin cable is needed when connecting the
SCS2 Anybus Gateway to a computer serial port.

Tx Transmitted data RS-232 2
Rx Received data RS-232 3
Signal GND Ground 5
CTS Clear to send RS-232 7
RTS Request to send RS-232 8
Not connected Not connected 1, 4, 6, 9
4.7 Ground connection

The SCS2 Anybus Gateway chassis must be properly connected to protective earth, for example by mounting the unit on a
grounded DIN rail.

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4.8 Field bus Connections.

By using the AnyBus the crane can utilise the SCS2 as an integrated slave on the PLC network or an AnyBus card can be
used as a Master bus for an internal I/O bus on the Spreader. The principal behind the AnyBus is that the interface card
translates a number of different bus protocols to a standardised format on the address and data bus of the node. To change
between different buses one can then simply change the type of interface card. For details regarding configuration of a
specific bus, please view the user manual for that specific card and the electrical documentation for your specific project.
Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer
SCS2 is an output from the master in the crane. Hence the crane PLC and the AnyBus card must have corresponding
addresses and the nymber of bytes configured for input/output data have to be the same on both sides of the
communication link i.e. the crane PLC and the SCS2.
4.8.1 Mapping of I/O
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent
will be equivalent with the code displayed in the onboard display, hence there will be three levels of this code INFO,
WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented
each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value
of this counter will be sent each time that a new diagnostic message is transmitted.


way.
Byte 8 => Node ID
Byte 9-10 => Row Number (of source code)
Byte 11-16 => Filename (1:st 6 char.)
Byte 17-18 => sequential counter

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These assignments shall be are documented in the electrical documentation of the project.
Input Segment

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4.9 Fault Finding table

Symptom What to do Comment
Power Supply
The node won’t start. The power LED Measure the main supply. The voltage The power LED should be on.
is off. should exceed 10V DC and be less
than 30V DC.
RS-232
BMS system can not communicate Probe TxD and RxD lines with Data lines should show square waves
with the node. oscilloscope while trying to between –10V to +10V relative to
communicate. Ensure that connection GND pin.
cables aren’t damaged.
CAN
The node can not communicate with Probe bus lines with oscilloscope. Check that CAN high and CAN low
the other nodes. CAN high should show square waves are not mixed up.
pointing downwards and CAN low
should be showing square waves
pointing upwards.
Node ID
The unit stops at start-up. Check selected node ID. This can indicate that the node has
wrong id strapped telling the node to
participate in the system with wrong
role.
5 So tware tools
5.1 Overview
There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given
below.
5.2 ABE
ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls
the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.
5.3 BMS
BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the
SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.

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Mis ellaneous
6.1 Data sheet
Parameter Note Min Max Unit
Operating voltage Power connector 10 28 V DC

Current consumption Operating voltage 24 V DC 50 200 mA
0
Temperature Operating temperature -20 +85 C
EMC conformity In accordance with 89/336/EEC:
EN 61000-6-4:2001 (Emission requirements)
EN 55011 (Radiated emission)
EN 61000-6-2:2001 (Immunity requirements)
EN 61000-4-2 (Immunity: ESD)
EN 61000-4-3 (Immunity: RF electromagnetic field)
EN 61000-4-4 (Immunity: Fast transients)
EN 61000-4-5 (Immunity: Surge) (2)
Controller 32bit controller running at 16MHz quartz
Memory Program 1.4Mb
Log 128kb
Scan time System scan time 50 ms
Node scan time 5 ms
Serial interfaces BCAN – Bromma CAN based bus
RS232 – For PC communication
Field bus slave to those field buses supplied by
HMS.
Diagnostics System diagnostics
Spreader functionality diagnostics
Event and error log
FB programming Basic binary functions (AND, OR etc.)
Basic Analogue functions (compare, add etc.)
Basic controller functions(PWM, regulators etc.)
Spreader controller functions
Note 2) For compliance with EN 61000-6-2 the power cable and the serial port cable have to be limited to 10 meters in
length

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6.2 Dimensions
Figure 3. The SCS2 Anybus Gateway node equiped with a Profibus slave card. All dimensions are in mm.

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Appendi A ( rror messa es)

The error messages, which are generated by the system, can be viewed in the display as well as in the log (using the
BMS). See main system manual for list of codes.

11  Fault finding diagnostics
Fault finding in hydraulic system

NOISY PUMP OR EXCESSIVE HEAT
 Check oil level and that filter is clean.
 Check that pump is functioning correctly as illustrated in the "system test".
 Particularly check that setting of pressure relief valves are correct (as
enclosed sheet) and that the pump suction line (inlet) is not blocked.
 Pump suction is checked by removing drain line and measuring flow at
running pressure of 100 BAR.
 Maximum flow should be 1 litre/min. If greater than this, replace the pump.
TWISTLOCKS DO NOT OPERATE

 Check manual operation of the solenoid valve.
 If twistlocks work then check electrical supply & solenoid.
NOTE! Blockading pin must be in the "up" position!
IF TWISTLOCKS DO NOT WORK

 Check that pump pressure is correct.
 Check pressure relief valve.
 When valve is operated manually the pressure should remain at working
pressure. If it decreases check the seals in the cylinder.
 Remove the cylinder and ensure that the twistlocks are free to rotate.
 Check directional valve.

rev.
Fault finding in electrical system
HYDRAULIC PUMP MOTOR STOPPED
Possible cause Action______________ ____
 3 phase supply missing.  Check cable, plug, socket.
 Motor contactor not functioning.  Check crane control signal.
 Feed from crane missing.  Check connection.
HYDRAULIC PUMP MOTOR RUNS BUT KEEPS TRIPPING OUT

Possible cause Action________________ __
 Pump pressure too high or pump faulty.  Refer to Hydraulic section.
 Pump motor faulty.  Change motor.
 Motor supply has one missing phase.  Check to find where supply is
connected and repair.
TWISTLOCKS WILL NOT LOCK/UNLOCK

Possible cause__________________ Action________________ __
 Pumps stopped.  Check pump procedure.
 Crane spreader is fitted with the safety  Check that the spreader is correctly
feature  only work with all four landing landed on the container.
switches actuated.
 If timer fitted  timer faulty set wrongly.  Replace or set to 0,5 or 2 sec.
 Check if fault is hydraulic by  Refer to hydraulic section.
operating valve by hand.
 Check supply to solenoid  if yes.  Replace solenoid.
 Check leads and plugs to solenoids.  Repair or replace
 Check blockading circuit.  Check relays, check limit switch and
adjust or replace. Check connection.
 Check supply at B and C junction boxes.  Check connections. Replace main
supply cable.
FLIPPER WILL NOT OPERATE

Possible cause Action________________ __
 Pump stopped.  Check pump procedure.
 Check if fault is mechanical or hydraulic  Carry out mechanical hydraulic
by operating valve by hand. procedure.
 Check supply to solenoid  if yes.  Replace solenoid.
 Check flipper supplies from crane.  Check crane controls. Check plugs,
socket and cable.

rev.
12  Appendices
Units & conversion tables

LENGTH
1 ft = 0,3048 m
1m = 3,2808 ft
1 in = 25,4 mm
1 mm = 0,03937 in
WEIGHT
1 lb = 0,4536 kg
1 kg = 2,2046 lb
1 ton = 1 t = 2000 lb = 907 kg = 0,893 Lt= 0,907 tonne
1 Lt = 2240 lb = 1016 kg = 1,016 tonne = 1,120 ton
1 tonne = 1 mT = 2204 lb = 1000 kg = 0,9842 Lt = 1,103 ton
VOLUME
1l = 0,21997 UKgal = 0,26417 USgal
PRESSURE
1 bar = 10 N/cm2 = 1,02 Kp/cm2 = 14,503 lbf/in2
POWER
1 Hp = 0,746 kW
1 kW = 1,341 Hp
TORQUE
1 Kpm = 9,81 Nm = 7,233 lbf
FORCE
1 Kgf = 1 kp = 9,81 N = 2,2046 lbf
TEMPERATURE
dgr C = 5 •(dgr F-32)
9
A = ampere l = litre
o
C = degrees centigrade lb = pound
c/s = cycles per second lbf= pound force
o
F = degrees Fahrenheit m = meter
ft = foot min= minute
gal = gallon n = newton
Hp = horse power s = second
Hz = hertz t = tonne
in = inch v = volt
kg = kilogramme w = watt
Kgf = kilopond force m = micron

rev.
Hydraulic symbols

rev.
Electrical symbols

rev.

AD - 001 - EN Spreader BROMA

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ADDITIONAL DEVICES EN

002 - 04.06.2012 / lwnkia0

AIR CONDITION TOWER CABIN

Have a question? Need Help?

DEALER NAME ___________________________________________________________

TELEPHONE __________________________________ PURCHASE DATE _____________

MODEL/CATALOG NO.* ______ SERVICE/DISCRETE NO.* _______ SERIAL NO.* _______

* Printed on nameplate. See Fig 7.

A FEW WORDS ABOUT YOUR NEW

In addition to cooling or heating the room, this

1. Initial power or power failure display

In timer active mode, the unit will start-up

The power to your unit is controlled by the

If the ON/OFF button is pressed again, the unit

2. Check available power supply and resolve any

3. An individual branch circuit and single

4. For your safety and protection, this unit is

5. The wall outlet you select must match the

NOTE: Power cord is 55 in. long and extends

6. Follow fuse specifications indicated on unit

NOTE: Unit model/catalog number,

MODE SELECTION ENERGY SAVER

If you want the louvers to remain in a fixed position,

UNIT DOES NOT START

WATER DRIPPING INSIDE

· Dirty filter. · Remove and clean filter.

UNABLE TO ACCESS FILTER

MESSAGE DISPLAY CODES MEANING

· Room air thermistor failure. Contact your dealer

Model/Catalog No. _________________________

Service/Discrete No.________________________ Unit Serial No. __________________________

Date of Installation ________________________ Installed By: ___________________________

Name of Owner ___________________________ Address of Installation ____________________

Remove the screws

Change the filter.

For installation reverse the order.

Maintenance Instruction and Spare Parts List

Drawing No.: G-3839-00

Ident No.: 10019878

1.0 Assembly of the Drum.......................................................................................................3

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 25.02.2004 Drawn by.: Chr. Fricke

ATTENTION: Technical operations should only be carried out by quali-

1.0 Assembly of the Drum

2.0 Drum Body Dimensions

3.0 Observance at Spiral Type Drum Body

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

Note! Please considered the operating manual and handling instruc-

4.0 Connection of the Main Power Cable

5.0 Connection of the Payout Cable

6.0 Checks before Commissioning

a.) check cable glands for proper sealing

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

b.) Hydraulic Motor

See maintenance instruction B+E 00 051.

c.) Bevel Gearbox

See maintenance instruction B+E 00 060.

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

8.0 Liability for Faults

10.0 Spare Parts List

1 G-3232-20a-00-1-4 drum body Ø 1470 x Ø 2600 x 33 1

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

Item Drawing-/Article-no. Description Piece

19 X5490-0008 hydraulic motor 1

TELEPHONE ______________________ PURCHASE DATE _

MODEL/CATALOG NO.* __ SERVICE/DISCRETE NO.* _ SERIAL NO.* _____

Service/Discrete No. Unit Serial No. __

Date of Installation Installed By: ___

Name of Owner _______ Address of Installation

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 25.02.2004 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 18.12.2006 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 04.03.2005 Drawn by.: Chr. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 22.08.2006 Draw.: C. Fricke

*CTVOCPP-ÑPKI76676 Graben-Neudorf Date: 25.03.2008 Drawn by Lippmann

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann

*CTVOCPP-ÑPKI76676 Graben-Neudorf date: 25.03.2008 draw.: Lippmann