Contents

Contents (Part 2)

Foreword (Part 2)

Notes for the Operator

1 Notes on Safety
1 Notes on Safety ....................................................................... 1
1.1 General Recommendations for the Lubrication and
Maintenance Tasks ................................................................. 1
1.2 Notes on Safety ....................................................................... 5
1.3 Recurrent Inspections of the Crane ......................................... 9
1.4 Measures to Ensure Safe Operating Periods ........................ 10
1.4.1 General .................................................................................. 10
1.4.2 Theoretical Service Life ......................................................... 10
1.4.3 Actual Operating Conditions .................................................. 11
1.4.3.1 Determining the Operating Conditions (Load Spectrum) ....... 11
1.4.3.2 Operating Hours of the Hoists per Inspection Interval ........... 11
1.4.4 Determining the Spent Share of the Theoretical Service Life
of the Winches ....................................................................... 13
1.4.5 Documentation....................................................................... 15

2 Fuels and Lubricants

3 Capacities

4 Lubrication and Maintenance Schedule

4 Lubrication and Maintenance Schedule ................................... 2
4.1 Initial Lubrication and Maintenance .......................................... 2
4.2 Regular Routine Lubrication and Maintenance ........................ 3
4.3 Maintenance List ...................................................................... 4

5 Drive
5 Drive ........................................................................................ 1
5.1 Engine Perkins Phaser 210 TI ................................................. 1

6 Transmission
6 Transmission ........................................................................... 1
6.1 Drive Gear - Checking and Topping Up the Oil Level .............. 1
6.2 Changing the Oil in the Drive Gearbox and Replacing the Filter .. 4
6.3 Distributor Gear - Checking and Topping Up the Oil Level ...... 7
6.4 Distributor Gear - Changing the Oil .......................................... 7

7 Joint Shafts
Date: 08.CW/05

7 Joint Shafts .............................................................................. 1

7.1 Flange Connections ................................................................. 1
7.2 Lubricating the Joint Shafts ..................................................... 1
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 Contents

8 Axles
8 Axles ........................................................................................ 1
8.1 Checking and Tightening the Axle Fixings ............................... 1
8.2 Lubricating the Axles ............................................................... 2
8.3 Steering and Track Arm ........................................................... 2
8.4 Axle Drive - Checking and Topping Up the Oil Level ............... 3
8.5 Wheel Hub Drive - Checking and Topping Up the Oil Level .... 4
8.6 Axle Drive - Changing the Oil .................................................. 4
8.7 Wheel Hub Drive - Changing the Oil ........................................ 5
8.8 Wheel Hub Bearing - Changing the Grease ............................ 6
8.9 Suspension Cylinders ............................................................. 6

9 Steering
9 Steering ................................................................................... 1
9.1 Steering Components .............................................................. 1
9.2 Lubricating the Steering Components ..................................... 1
9.3 Replacing the Hoses................................................................ 2
9.4 Angular Gear ........................................................................... 2
9.5 Lubricating Independent Rear Axle Steering ........................... 2

10 Braking System
10 Braking System........................................................................ 1
10.1 Check brake linings for wear ................................................... 2
10.2 Renew brake linings ................................................................ 2
10.3 Replace brake drums............................................................... 3
10.4 Perform brake function check .................................................. 3
10.5 Check expanding cylinder........................................................ 3
10.6 Replace other brake parts ....................................................... 3
10.7 Air Drier with Integrated Pressure Regulator ........................... 4
10.8 Draining Water from the Air Tanks........................................... 4

11 Wheels and Tyres

11 Wheels and Tyres .................................................................... 1
11.1 Tightening the Wheel Nuts ...................................................... 1
11.2 Tyres - Checking Pressure and Tread Depth and
Checking for Damage .............................................................. 1

12 Hydraulic System
12 Hydraulic System ..................................................................... 1
12.1 Hydraulic Tank - Checking and Topping Up the Oil Level ....... 2
12.2 Hydraulic Tank - Filter .............................................................. 3
12.3 Hydraulic Tank - Replacing the Aeration Filter ...................... 12
12.4 Changing the Hydraulic Oil .................................................... 13
12.5 Hydraulic System - Pressure Accumulator, Checking the
Date: 08.CW/05

Preliminary Gas Tension ....................................................... 15

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 Contents

13 Outriggers
13 Outriggers ................................................................................ 1
13.1 Lubricating the Sliding Surfaces on the Outrigger Struts ......... 1

14 Electrical System
14 Electrical System .................................................................... 1
14.1 Checking the Lighting System ................................................. 1
14.2 Replacing the Headlamp Bulbs ............................................... 1
14.3 Servicing the Battery ................................................................ 1

15 Fuel System
15 Fuel System ............................................................................. 1

16 Air Intake and Cooling System

16 Air Intake and Cooling System ................................................ 1

17 Piston Rods
17 Piston Rods ............................................................................. 1

18 Optional Equipment
18 Optional Equipment ................................................................. 1
18.1 Refilling the Central Lubrication System .................................. 1

19 Visual Inspections
19 Visual Inspections .................................................................... 1

20 Slew Ring
20 Slew Ring................................................................................. 1
20.1 Lubricating the Bearing ............................................................ 1
20.2 Lubricating the Gear Ring ........................................................ 1
20.3 Check slew ring bolt connections ............................................ 2

21 Slew Gear
21 Slew Gear ................................................................................ 1
21.1 Slew Gear Mechanism - Checking and Topping Up the Oil Level ... 1
21.2 Slew Gear Mechanism - Changing the Oil ............................... 1
21.3 Checking and Tightening the Screw Connections ................... 2
Date: 08.CW/05

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 Contents

22 Hoists
22 Hoists ....................................................................................... 1
22.1 Hoist Gear - Checking and Topping Up the Oil Level .............. 1
22.2 Hoist Gear - Changing the Oil .................................................. 2
22.3 Lubricating the Rope Drum Bearing ........................................ 3
22.4 Checking and Tightening the Screw Connections ................... 3
22.5 Lubricating the Hook Block ...................................................... 4
22.6 Checking the Gear Oil ............................................................. 5
22.7 Determination of the spent share of the theoretical service life .. 5

23 Luffing Gear
23 Luffing Gear ............................................................................. 1
23.1 Luffing Cylinders - Lubricating the Foot and Piston Bearings .. 1

24 Equipment
24 Equipment ............................................................................... 1
24.1 Main Boom - Lubricating the Linings ....................................... 1
24.2 Main Boom - Lubricating the Sliding Surfaces ......................... 1
24.3 Lubricating the Basic Bolts on the Main Boom ........................ 2
24.4 Lubricating the Hoist Ropes ..................................................... 2
24.5 Checking and Replacing the Hoist Ropes ............................... 3
24.6 Checking the Main Boom for Weld Cracks .............................. 3
24.7 Main Boom - Adjusting the Rope Drive ................................... 5
24.8 Main boom - Visual Inspection of the Extending and
Retracking Ropes .................................................................... 6
24.9 Inspect Rope Track Rollers ..................................................... 8
24.10 Checking the Sheaves ............................................................. 8
24.11 Sheaves - Checking the Roller Bearing ................................... 9
24.12 Checking the Pins for Cracks ................................................ 10
24.13 Checking the Draw Bars (Schackle on the Main Boom
Extension) ............................................................................. 10
24.14 Lubricate Main Boom Extension Bolts ................................... 12

25 Heating
25 Heating .................................................................................... 1
25.1 Checking and Filling Up the Fuel Tank .................................... 1
25.2 Checking the Fuel Feed and Cleaning the Fuel Filter
if Necessary ............................................................................ 1
25.3 Checking and Replacing the Glow Plug .................................. 2
25.4 Fine dust filter .......................................................................... 3
Date: 08.CW/05

bs_e075-2000 4/4
 Foreword

Part 2: Lubrication and Maintenance Instructions for the Crane

For you,

This instruction manual is provided for the benefit of personnel carrying out
maintenance work, and includes information required for maintenance and
lubrication of the machine and all special equipment.

The information contained in this manual is correct with regard to the

equipment at the time of publication. Data, diagrams and di mensions are
subject to change as a result of technical development.
No liability can be accepted for damage resulting from incorrect
maintenance.
The maintenance work which is described in this manual may only be
carried out by appropriately trained and qualified personnel.

In these lubrication and maintenance instructions you will find the titles or
the respective symbols "Danger", "Caution", "Note" and "Environment" used
as follows:

DANGER !
"Danger" is used for operating procedures where failure to observe
the prescribed assembly sequence or the stipulations made may
result in the death of or injury to persons.

CAUTION !
"Caution" is used for operating procedures, mounting se quences
etc. where failure to observe the stipulations made may result in
damage to the crane or equipment.

NOTE:
"Note" is used to indicate an important operation or mounting procedure or
to draw attention to further information.
Date: 08.CW/05

ENVIRONMENT:
This symbol is used when an action serves to protect the
environment or avoid unnecessary pollution.
e075-2002 1/3
2/3
e075-2002
Date: 08.CW/05
 Foreword

General Recommendations Regarding Lubrication and Maintenance

Tasks

- Thoroughly clean all nipples, caps and plugs before greasing.

- Refill the fuel tank at the end of each working day, in order to prevent
condensation.

- Renew the gaskets for drain, filler, inspection plugs and fil ters, before
replacing the screws or filter.

- The oil can be drained more easily from individual units if it is drained at
operating temperature.

- Ensure that the crane is kept clean at all times, i.e. free of flammable
substances. In particular, the crane must be clea ned thoroughly
following maintenance work on the hydraulic system, the engine or the
fuel system. Cleaning is best car ried out with a steam cleaner.

- After cleaning the crane, grease all lubricating points.

When dry, spray the slew gear teeth with the recommended grease.

- Never carry out welding repairs without first consulting our Customer
Service Department responsible for cranes.
Repair work carried out incorrectly may cause serious damage, resulting
in extensive repairs at considerable cost.

Please contact the Customer Service Department immediately if you

discover cracks in the steelwork of your crane.
Describe the course of the crack as closely as possible (enclose
photograph, page from spare parts catalogue etc.).
Date: 08.CW/05

e075-2002 3/3
 Notes for the Operator

The safety instructions for the lubrication and maintenance

tasks for the crane chassis can be found in Section 1.

The specifications for the quality of the lubricant can be found

in Section 2.

The capacities of the individual units are listed in Section 3.

All the service points, ordered according to service intervals,

are listed in section 4.

Service points without fixed service intervals are listed under

"as required".

Service intervals should be determined by the kilometres

driven. Calendrical specifications (daily, weekly, monthly etc.)
can be used. Servicing at the corresponding service intervals
is always carried out at the first specification reached (mileage
or calendrical option).

The servicing activities listed in Section 4 can be found in more

detail in Section 5 - 25.

Definitions:

Service Point = Unit or point on which the maintenance

stipulated is to be carried out (e.g.
engine, grease point).

Service Interval = Number of kilometres after which the

stipulated service task is to be
repeated (e.g."every 1000 km": at
1000, 2000, 3000, 4000, 5000
kilometres driven, etc.; "every 5000
km": at 5000, 10000, 15000, 20000
kilometres driven, etc.).
Date: 08.CW/05

e075-2004 1/1
 Notes on Safety 1

1 Notes on Safety

1.1 General Recommendations for the

Lubrication and Maintenance Tasks

Undertake the prescribed adjustment and

maintenance tasks at the prescribed times and
observe the details regarding the replacement of
components.

Ensure that all handles, steps, rails, platforms,

stages and laders remain free from dirt, snow and
ice at all times.
(Z075 200)
Z 075 200

Ensure that the crane is kept clean at all

times, i.e. free of flammable substances.
In particular, the crane must be cleaned
thoroughly of any oil, fuel or cleaning
agents following maintenance work on the
hydraulic system, the engine, or the fuel
system. Cleaning is best carried out with
a steam cleaner.
(Z 160 002)

Z 160 002

- Thoroughly clean all nipples, caps and plugs

before greasing.
(Z 160 001)
Date: 50.CW/96

Z 160 001

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1

- Refill the fuel tank at the end of each

working day.
(Z 160 017)

Sufficient ventilation has to be ensured

when the tank is filled. The tank is not to be
filled with the engine running.

Z 160 017

- Renew the sealing rings for drain, filler,

inspection plugs and filters, before replacing
the screws or filter.
(Z 160 007)

The oil can be drained more easily from

individual units if it is drained at operating
temperature.

When the operating temperature is

reached, switch the engine off and
remove the key.
Z 160 007

After cleaning the engine bay, check all

- fuel lines
- engine oil lines
- hydraulic oil lines

for leaks, loose connections, worn patches and

damage.

Repair any damage immediately.

(Z 160 003)
Date: 50.CW/96

Z 160 003

2/16 bs_e075-2010
 Notes on Safety 1

After cleaning the crane, grease all grease points.

When dry, spray the slew gear teeth with the

recommended grease.
(Z 160 010)

Z 160 010

Check all electrical lines, push-on connections

and connection terminals to ensure that they are
secure and undamaged.

Repair any damage immediately.

(Z 160 504)

Z 160 504
Date: 50.CW/96

bs_e075-2010 3/16
a / 43/98
1

Fire extinguishers must be full and ready for use.

(Z 160 009)

Z 160 009

Never carry out welding repairs without

first consulting our Customer Service
Department responsible for cranes.
Repair work carried out incorrectly may
cause serious damage, resulting in exten-
sive repairs at considerable cost.
(Z 160 005)

Please contact the Customer Service

Department immediately if you discover cracks
in the steelwork of your crane. Describe the
Z 160 005 course of the crack as closely as possible
(enclose photograph, page from spare parts
catalogue, etc.). Date: 50.CW/96

4/16 bs_e075-2010
 Notes on Safety 1

1.2 Notes on Safety

The diesel engine must always be switched off

before lubrication and maintenance tasks are
carried out, with the exception of tasks which
must be carried out with the engine running.
(Z 075 213)

Z 075 213

Before carrying out any lubrication or

maintenance tasks, switch off the engine and
remove the keys.

The residual energy or stored energy wich

must still be present after the crane has been
shut down must be conducted away without
danger to the persons concerned (e.g. via an
earth conductor).

Check that the crane is free of faults.

(Z 075 215)

Z 075 215

Lubrication and maintenance tasks may only be

carried out if the working equipment has been
made secure by placing it on the ground, by
extending the outriggers or by any other
appropriate means.
(Z 075 218)
Date: 50.CW/96

Z 075 218

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1

Before carrying out any lubrication or

maintenance tasks, place a warning sign in the
driver's cab and ensure that no unauthorized
persons can set the crane in operation
(e.g. lock the cab doors and remove the
contact keys).
(Z 075 214)

Z 075 214

DANGER OF INJURY
when hydraulic oil escapes under high
pressure.
Therefore, before carrying out any work
on the hydraulic system, depressurise it.

i.e. - boom lowered

- vehicle supported on outriggers
- axles lowered

(Z 160 018)
Z 160 018

Wear safety clothing, protective goggles,

respiratory mask and other protective
equipment if necessitated by the working
conditions.
(Z 160 011)

Do not allow unauthorized persons near

the equipment whilst carrying out maintenance
or lubrication tasks.

Work which could affect the operational

Date: 50.CW/96

and road safety of the crane must only be

carried out by trained personnel.
Z 160 011

6/16 bs_e075-2010
 Notes on Safety 1

If it is necessary for one or more persons to be

located on the crane for maintenance work,
they must maintain visual contact with the crane
driver at all times.
(Z160 023)

Z 075 223

DANGER OF INJURY
Always wear protective gloves when
handling and guiding the ropes.
Only use a wooden rod to guide moving
ropes.

(Z 160 024)

Z 160 024

Store oil-impregnated rags and flammable

materials so that they cannot be ignited,
alternatively remove from the area.
(Z 160 016)

Oils that are drained off must be stored in

suitable containers and disposed of
correctly.

These safety instructions are to be

Date: 50.CW/96

observed whenever the crane is operated or

repaired.
Z 160 016

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1

After service and maintenance work has

been carried out, check that all safety devices
have been replaced and are in full working
order.

(Z 075 200)

Z 075 200

After service and maintenance work has

been carried out, check that there are no tools
or loose components on the crane.

(Z 160 027)

Z 160 027

If you vuse electrical equipment for

servicing and maintenance work, check this
equipment to ensure to ensure that it is
functioing correctly and is free of faults.

(Z 160 083)
Date: 50.CW/96

Z 160 083

8/16 bs_e075-2010
 Notes on Safety 1

1.3 Recurrent Inspections of the Crane Carrying out the inspection

The company which is operating the crane The recurrent inspection is essentially a visual
must have the crane inspected at least once a and performance inspection which essentially
year by a "Sachkundiger" - person with a includes:
sound knowledge of crane technology, defined
by VBG 9 - and at least every 4 years by a - Checking the identity of the crane against
"Sachverständiger" - authorized expert, defined the details in the inspection book
by VBG 9 - (ISO 9927-1, VBG 8, VBG 9, 9a). (crane log-book).

- Checking the condition of the components

and equipments with regard to damage,
wear, corrosion or other changes.
Within the framework of this inspection,
the theoretical remaining service life of - Checking the sfety equipment and the
the winches must be determined. brakes for completeness and effectiveness.
Observe Section 1.4.

The following details are based on the

instuctions given in the accident preventions The results of these inspections must be
for "cranes" (VBG 9 and 9a) regarding recurrent recorded in the log-book and must be
inspections of the crane and they provide a certified by the inspector.
general view.

The VBG 9 inspections do not

affect the national and international
regulations applicable.

Inspection interval

Cranes must be checked by a "Sachkundiger"

where necessary according to the applications
of use and the operating conditions, but must
be checked at least once a year.
An inspection must be carried out at least once
every 4 years by a "Sachverständiger".
Date: 50.CW/96

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1

1.4 Measures to Ensure Safe

Operating Periods

1.4.1 General 1.4.2 Theoretical Service Life

In accordance with the accident prevention The Design engineer has assumed certain
regulations for winches, lifting and dragging operating conditions in calculating and
equipment (VBG 8),the crane operator is dimensioning the winches on your crane.
obliged to carry out an inspection of the crane
at least once a year (also see ISO 9927-1). The winches on your crane are classified
as follows (ISO 4301/1, FEM 1.001,
The spend share of the theoretical service DIN calculation principles for power units):
life for the winches must also be determined.
The crane operator must employ a specialist - Power unit group: M............
for the purpose if necessary.
- Load spectrum: Q............ (L........)

- Load spectrum factor: Km=.......

This regulation is legally binding within A theoretical service life, D, is thus calculatet.
the scope of the accident prevention
regulations of the trade association.
Outside of this realm, the crane The values applicable must be taken from
manufacturer recommends that the the "Monitoring the Winches" table given in the
procedures listed are also observed. crane log-book.

Date: 50.CW/96

10/16 bs_e075-2010
 Notes on Safety 1

1.4.3 Actual Operating Conditions

Before the spent share of the theoretical

The theoretical service life must not be service life of the winches can be determined,
equated with the real (actual) service life the actual operating conditions
of a winch. (load spectrum) and the operating hours of
In addition, the real service life of a winch the hoists per inspection interval must be
is affected by a number of external determined.
influences, for example:

- Overloading through not using the 1.4.3.1 Determining the Operating

crane as intended. Conditions (Load Spectrum)
- Insufficient maintenance: the oil is
The load spectrum of the crane is divided into
not changed in good time.
groups (also see ISO 4301/1, FEM 1.001).
From knowledge of the actual operating
- Maloperation such as extreme
conditions, one of the load spectrums listed
acceleration or deceleration of the
below must be selected and recorded in the
load or the load falling into the
crane log-book for the relevant inspection
ropes.
interval.
- Maintenance mistakes such as
1.4.3.2 Operating Hours of the Hoists
using the wrong oil, incorrect oil fill
or contamination when changing the per Inspection Interval
oil.
Determine the effective number of operating
- Mounting mistakes when hours per inspection interval (Ti). This must be
undertaking repairs or maintenance. recorded in the crane log-book for the relevant
inspection interval.
- Leaks not taken into consideration.
For mobile cranes used for erection operation,
- Incorrectly adjusted safety the share of the hoist winches is generally
equipment. 20 % of the total operating hours for the
superstructure and 12 % of the total operating
- Concealed damage caused by hours for the entire crane.
accidents.

- Extreme ambient conditions such as

low or high temperatures,
aggressive atmosphere, dust and dirt.
Date: 50.CW/96

bs_e075-2010 11/16
 1
Load Load
spectrum spectrum

12/16
class Definition Shares of operating time factor Graph
Last / Load %
low Power units or parts thereof 10% of operating time under highest Km = 0.125
Q1 subject to highest loading load (dead load + 1/1 load capacity)
L1 only as exception but routinely 40% of operating time under
only subject to very low dead load + 1/3 load capacity
loading 50% of operating time only under
dead load
Laufzeit
%
Operating time

1 Last / Load %
medium Power units or parts thereof /6 of operating time under highest Km = 0.25
Q2 subject to highest loading load (dead load + 1/1 load capacity)
1
L2 quite often but routinely only /6 of operating time under
subject to low loading dead load + 2/3 load capacity
1
/6 of operating time under
dead load + 1/3 load capacity
50% of operating time only under Laufzeit
%
dead load Operating time

high Power units or parts thereof 50% of operating time under highest Km = 0.5 Last / Load %

Q3 often subject to highest load (dead load + 1/1 load capacity)

L3 loading and routinely 50% of operating time only under
subject to medium loading dead load

Laufzeit
%
Operating time

Last / Load %
very Power units or parts thereof 90% of operating time under highest Km = 1
high regularly subject to loading load (dead load + 1/1 load capacity)
Q4 in the realm of highest loading 10% of operating time only under
L4 dead load

Laufzeit
%
Operating time

bs_e075-2010
Date: 50.CW/96
 Notes on Safety 1

1.4.4 Determining the Spent Share of

the Theoretical Service Life of the
Winches
A general overhaul must, however, be
undertaken 10 years at the every latest
For the inspection interval i (1 year max. as per
after the initial commissioning of the
ISO 9927-1 or VBG 8), the spent share of the
crane.
theoretical service life is calculated from the
formula:
The general overhaul must be arranged
by the crane manufacturer (or by persons
kmi authorized by the manufacturer) and must
Si = x Ti be documented in the log-book.
km
A new theoretical service life is then
Si = spent share of theoretical service life declared by the manufacturer or persons
authorized by the manufacturer following
Kmi = load spectrum factor for inspection the general overhaul.
interval "i" as per Section1.4.3.1
The max. period until the next general
Km = load spectrum factor which formed the overhaul is always a max.of 10 years.
basis of calculation for the winch

Ti = effective operating hours for inspection

interval "i" as per Section 1.4.3.2

After each inspection interval, the spent share

is deducted from the theoretical remaining
service life (see example in Section 1.4.5).
Observe the following:

- If the theoretical service life remaining is

not expected to be sufficient for the next
operating period, a general overhaul of the
winch must be undertaken.

- If the theoretical service life, D, is achieved,

the winch must only be continued to be
operated following a general overhaul.
Date: 50.CW/96

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 1

14/16
Monitoring the Winches

Table for determining the theoretical remaining service life for winch AC xxx................................
Crane type: 00000..........................
Construction number: 00.00.00......................
Initial commissioning: 0815............................
Serial number of winchgear as per serial plate: ....................................
Design specifications of winch (see crane certification log):
Power unit group: M 3..........................................
Load spectrum: Q 1........................(L...............)
Load spectrum factor: Km = 0,125...................................
Theoretical service life: D = 3200....................................

The (crane) user is liable for the correctness of the information!

Inspection Date of initial Operating Load spectrum Operating Operating Operating Operating Operating hours Spent share of the Theoretical Name of Signed Notes
No. commissioning conditions factor hours elapsed hours elapsed hours elapsed hours elapsed elapsed for the theoretical service remaining inspector
/ date of since last for the entire for the for the for the winch winch since last life, Di service life
inspection inspection (load crane superstructure superstructure inspection, T i
spectrum) since last Si = Kmi / Km * T i Di = Di-1 - Si
inspection
"i" Kmi [h] [h] [h] [h] [h] [h] [h]
0 10. 08. 94 - - - 0 - - - 3200 -

1 05. 06. 95 L1 0,125 - 800 800 - 160 160 3040 Meier

(20% v. 800)
2 20. 05. 96 L3 0,5 - 2000 1200 - 480 1920 1120 Müller
(40% v. 1200)
3 18. 05. 97 L2 0,25 - 3000 1000 - 300 600 520 Müller
(30% v. 1000)

Caution: A general overhaul must be undertaken at least every 10 years Si = Spent share of theoretical service life since last inspection
Di = Theoretical remaining service life
Di-1 = Theoretical remaining service life after previous inspection
General overhaul undertaken on : ........................................... Km = Load spectrum factor which formed the basis of calculation for the winch.
This factor must be taken from the crane certification log.
Kmi = Load spectrum factor for inspection interval "i"
Ti = Effective operating hours for inspection interval "i"

For further notes, see Section 1 in the Lubrication and Maintenance Instructions for the Superstructure

Z 29 555

bs_e075-2010
Date: 50.CW/96
 Notes on Safety 1

1.4.5 Documentation
(Z 29 555)

The crane operator is responsible for Inspection No. 1 (year 1)

documenting how the spent share of the
theoretical service life for the winches has been The crane has been used for erection purposes
determined. for the past year:

The forms required for this purpose are - Load spectrum L1, i.e. Km1 = 0.125
enclosed in the crane log-book:
800 h are recorded on the superstucture hour
- Specimen table (Z 29 555) meter. The winch has been in operation for
approx. 20 % of this time, i.e. T1 = 160 h
- Tables for each winch.
The theoretical remaining service life of The spent share S1 of the theoretical service life
each winch must be documented using for the first inspection is thus:
these tables.
Km1 0.125
S1 = x T1 = x 160 h = 160 h
The specimen table is clarified by the following Km 0.125
exemple:
The value for the load spectrum factor
(here: Km = 0.125) and the theoretical service
life (here: D = 3200 h) are recorded at the top of
the relevant table.

Theoretical remaining service life after the

first year:

D1 = D - S1 = 3200 h - 160 h = 3040 h

Date: 50.CW/96

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1

Inspection No. 2 (year 2) Inspection No. 3 (year 3)

The crane has been used for harbour unloading The crane has been used for erection operation
operation: and occasionally for harbour unloading
operation:
- Load spectrum L3, i.e. Km2 = 0.5
-Load spectrum L2, i.e. Km3 = 0.25
2000 h are recorded on the superstructure hour
meter, i.e. during this period: 2000 h - 800 h 3000 h are recorded on the superstructure
(used in first year of operation) = 1200 h. hour meter, i.e. during this period:
3000 h - 2000 h (used in the first two years of
The winch has therefore been in operation for operation) = 1000 h.
approx. 40 % of this time, i.e. T2 = 480 h.
The winch has been in operation for approx.
30 % of this time, i.e. T3 = 300 h.
The spent share S2 of the theoretical service life
for the second inspection interval is thus:
The spent share S3 of the theoretical service
life for the third inspection interval is thus:

Km2 0.5
S2 = x T2 = x 480 h = 1920 h
Km 0.125 km3 0.25
S3 = x T3 = x 300 h = 600 h
km 0.125

Theoretical remaining service life after the

second year: Theoretical remaining service life after the
third year:
D2 = D1 - S2 = 3040 h - 1920 h = 1120 h
D3 = D2 - S3 = 1120 h - 600 h = 520 h

It must now be assessed whether the

theoretical remaining service life is expected
to be sufficient for the next period of operation.
If this is not the case, a general overhaul must
be undertaken (see Section 1.4.4).
Date: 50.CW/96

16/16 bs_e075-2010
 Date: 50.CW/96

Monitoring the Winches

bs_e075-2010
Table for determining the theoretical remaining service life for winch ......................................
Crane type: ....................................
Construction number: ....................................
Initial commissioning: ....................................
Serial number of winchgear as per serial plate: ....................................
Design specifications of winch (see crane certification log):
Power unit group: M ............................................
Load spectrum: Q ..........................(L...............)
Load spectrum factor: Km = ............................................
Theoretical service life: D = ............................................

The (crane) user is liable for the correctness of the information!

Inspection Date of initial Operating Load spectrum Operating Operating Operating Operating Operating hours Spent share of the Theoretical Name of Signed Notes
No. commissioning conditions factor hours elapsed hours elapsed hours elapsed hours elapsed elapsed for the theoretical service remaining inspector
/ date of since last for the entire for the for the for the winch winch since last life, Di service life
inspection inspection (load crane superstructure superstructure inspection, T i
spectrum) since last Si = Kmi / Km * T i Di = Di-1 - Si
inspection
"i" Kmi [h] [h] [h] [h] [h] [h] [h]

Caution: A general overhaul must be undertaken at least every 10 years Si = Spent share of theoretical service life since last inspection
Di = Theoretical remaining service life
Di-1 = Theoretical remaining service life after previous inspection
General overhaul undertaken on : ........................................... Km = Load spectrum factor which formed the basis of calculation for the winch.
This factor must be taken from the crane certification log.
Kmi = Load spectrum factor for inspection interval "i"
Ti = Effective operating hours for inspection interval "i"

17/16
Notes on Safety 1

For further notes, see Section 1 in the Lubrication and Maintenance Instructions for the Superstructure
 Fuels and Lubricants 2

Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards

2.1 Engine Engine Oil See regulations for fuels and API CD
Multigrade Oil lubricants contained in the CCMC D4
instructions for operation of the
engine Perkins Phaser 210 TI

2.2 Cooling Water / Protection See regulations for fuels and 50 % Water
System Anti-Corrosive lubricants contained in the 50 % Antifreeze
Antifreeze instructions for operation of the
mixture engine Perkins Phaser 210 TI

2.3 Hydraulic Hydraulic Oil -20 to +40 ATF-Typ A Suffix A

System or Dexron II

0 to +60 68 HLP (D) acc.

DIN 51524 additionally
with detergend quality

2.4 Angular Gear Hydraulic Oil -20 to +40 ATF-Typ A Suffix A

or Dexron II

2.5 Fuel Tank Premium See DIN 51 601

Diesel Fuel 0 to +50 regulations ASTM D 975
for fuels and (No.1D + 2D)
lubricants VV-F-800a
Winter -25 to 0 contained in (DF-A,DF-1
Diesel Fuel the instructions and DF-2)
for operation B.S.2869 A1
of the engine (A2 if necess.)

2.6 Drive Gear Engine Oil -20 to +15 SAE 10 W C-4

0 to +25 SAE 30 C-4

-15 to +45 SAE 15 W 40 C-4

Gear Oil -32 to +48 ATF Typ A Suffix A

or Dexron II

2.7 Slew Gear Hypoid -20 to +40 API - GL 4 or 5

Mechanism Gear Oil SAE 80W - 90
or SAE 90
Date: 42.CW/01

For ambient temperatures below those given in the table, please refer to the figures given in
the operating instructions of the original manufacturer.

bs_e075-2020 /b 1/2
2

Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards

2.8 Hoist Gear Gear Oil -15 to +35 VG 100 DIN 51519
CLP 100 ISO-VG
Shell Tellus 100

2.9 Axles, Axle Drive Hypoid -15 to +35 SAE 90 API- GL -5

with Intermediate Gear Oil
Transmission

2.10 Lubricating Lithium Base -15 to +120 NLGI Class 2 DIN 51825 T3
Nipples Saponified KP 2 K
H.P. Grease
with Mineral
Oil Base

2.11 Slew Ring Spray Grease - Special Adhesive Demag

Teeth Grease Order No.:
00605898

2.12 Ropes Spray Grease - Special Adhesive Demag

Grease Order No.:
083 371

2.13 Main Boom Grease, -40 to +140 Demag

Sliding Surfaces, Berulub PAL 1 Order No.: (1 kg)
Outrigger Struts 654 069 40

2.14 Piston Rods GLEITMO 350 Spray Grease Demag

Order No.:
604 106 40

2.15 Independent Voler Demag

Rear axle Full assembly Order No.: (1 kg)
steering paste 002 025 12

For ambient temperatures below those given in the table, please refer to the figures given in
the operating instructions of the original manufacturer.
Date: 42.CW/01

2/2 bs_e075-2020 /b
a / 27/02
 Capacities 3

Housing or System Metric Capa- US Capacity Initial Fill Up

city (Litres) (Gallons)

Engine Perkins Phaser 210 TI 17.50 4.60 Shell RIMULA TX

with Filter Change

Hydraulic System 345.00 91.00 ATF...:Shell Donax TM

Hydraulic Tank Typ A Suffix A or
HLP(D)...:Shell Hydrol Do 68

Fuel Tank 260.00 68.60 Diesel Fuel

Fuel Tank for Heating 10.00 2.60 Diesel Fuel

Drive Gear
with Filter Change 22.00 5.80 Shell RIMULA TX
Oil Radiator 10.00 2.60 Shell RIMULA TX

Distributor Gear 6.40 1.70 TOTAL

EP -B

Slew Gear 3.00 0.80 Shell Gear Oil 90 LS

Hoist Gear 1.20 0.30 Shell Tellus 100

Axle 1 Axle Drive 20.00 5.30 TOTAL

Wheel Hub Drive 2 x 1.50 2 x 0.40 EP -B

Axle 2 (for 4 x 4) Axle Drive 20.00 5.30 TOTAL

Wheel Hub Drive 2 x 1.50 2 x 0.40 EP -B

Angular Gear Steering 2 x0.15 2 x 0.05 Shell Donax TM Typ A Suffix A

Radiator 50.00 13.20 50% Water

50% Glysantin

Expansion Tank for Heating 12.00 3.10 50% Water

50% Glysantin

The capacities given are approximate. For more exact measurements, checks should be
Date: 04.CW/98

carried out at the specified inspection points, such as the inspection plugs, dipsticks and screens.

bs_e075-2030 /a 1/1
 Lubrication and Maintenance Schedule 4
Stand: 49.KW/96

bs_e075-2040 1/11
4

4 Lubrication and Maintenance

Schedule

The lubrication and maintenance intervals

are divided into two types of interval.

The sections concerned with driving opera-

Interval / Kilometres driven tions alone are given in kilometres.
Daily 50 500 1.000 5.000 10.000 20.000 40.000

1x

The sections concerned with crane opera-

tions are given in operating hours.

Interval / Operating hours

Daily 50 100 250 500 1.000 1.500 3.000 we

1x

4.1 Initial Lubrication and Maintenance

Lubrication and maintenance tasks which are to

be carried out before regular routine
maintenance are marked on the maintenance
schedule with "1X".

Fuel / Interval / Kilometres driven

Lubricants Daily 50 500 1.000 5.000 10.000 20.000

1x
Stand: 49.KW/96

2/11 bs_e075-2040
 Lubrication and Maintenance Schedule 4

4.2 Regular Routine Lubrication and

Maintenance

The following service intervals apply to cranes

operated under normal ambient and operating
conditions.
Adjustment should be made to the servicing
Fuel / Interval / Kilometres driven intervals when the crane is operated under
Lubricants Daily 50 500 1.000 5.000 10.000 20.000 abnormal conditions.

Regular routine lubrication and maintenance

tasks are marked on the maintenance schedule
with an "X".

- When carrying out more comprehensive

maintenance work, e.g. "at 10,000 km", such
work which is carried out at the shorter intervals
Fuel / Interval / Kilometres driven
and which coincides with the present interval
Lubricants Daily 50 500 1.000 5.000 10.000 20.000 should naturally also be carried out.

- In the above example, maintenance work for

x x "at 1,000 km" should also be carried out at the
same time.
Stand: 49.KW/96

bs_e075-2040 3/11
 4
4.3 Maintenance List

4/11
b / 14/98
bs_e075-2040
Stand: 49.KW/96
 Lubrication and Maintenance Schedule 4
Stand: 49.KW/96

bs_e075-2040 5/11
4

Stand: 49.KW/96

6/11 bs_e075-2040
c / 02/01
 Lubrication and Maintenance Schedule 4
Stand: 49.KW/96

bs_e075-2040 7/11
4

Stand: 49.KW/96

8/11 bs_e075-2040
 Lubrication and Maintenance Schedule 4
Stand: 49.KW/96

bs_e075-2040 9/11
4

Stand: 49.KW/96

10/11 bs_e075-2040
 Lubrication and Maintenance Schedule 4
Stand: 49.KW/96

bs_e075-2040 11/11
e/ 27/02
 Drive 5

5 Drive

5.1 Engine Perkins Phaser 210 TI

For information and instructions on the

maintenance of the engine, please refer to the
engine manufacturer's operating manual.
(see section 3 of this documentation)

(Z 075 242)

Z 075 242

Legend:

Oil filter
(Z 075 225)

Z 075 225
Date: 30.CW/96

bs_e075-2050 1/1
 Transmission 6

6 Transmission

To make the oil check easier, the

transmission must be kept clean.
Regularly check the screw and oil lines.

1- Drive Gear
2- Distributor Gear

(Z 075 282)

Z 075 282

Ensure that the vehicle is in the horizontal

position.

Before the oil check is carried out, the

crane should be secured with blocks to
prevent any rolling movement.

(Z 160 077)

Z 160 077

6.1 Drive Gear - Checking and Topping

Up the Oil Level

With this transmission, an oil check can

either be carried out when the oil is warm or cold.

Cold check
(Following a prolonged engine lay-off period)

The cold check is made to determine

wether the transmission is sufficiently filled with
Date: 30.CW/96

oil to be able to carry out a warm oil check.

Carry out the oil checks as follows:

bs_e075-2060 1/8
6

- Start the engine and allow it to run for at

least 1 minute.

- Select gear range Drive "D" and then

reverse gear "R" to remove any air from the
oil system.
Then place in neutral "N" and allow the
engine to idle (500 to 800 rpm).

(Z 075 390)

Z 075 390

Clean the edge of the filler pipe before

replacing the oil dipstick in the filler neck to
ensure that the oil system is not contaminated.

- Remove the dipstick from the level pipe and

wipe off with a non-fibrous cloth.
then reinsert the dipstick fully before
removing a second time.
(Z 163 029)

Z 163 029

- The oil level must be in the cold range "C - D"

If the oil does not come up this level, more oil
must be added.
(Z 163 030)

With engine at a standstill, the oil level

displayed may be too high because the lines have
been emptied.

At the first available opportunity, carry

out a check of the oil level while warm, i.e.
Date: 30.CW/96

with the engine at normal operating

temperature (71 - 93° C)
Z 163 030

2/8 bs_e075-2060
a /35/98
 Transmission 6

Warm check
(When the gear oil is at operating temperature is
71o - 93oC)

Carry out the oil checks as follows:

- Switch the selector keypad to neutral "N"

and allow the engine to idle (500 to 800 rpm).

If the oil level is not at the top of the warm

range "A-B", the oil must be topped up,
Z 163 030 otherwise demage will occur in the gear
system.
(Z 163 030)
Date: 30.CW/96

bs_e075-2060 3/8
6

6.2 Changing the Oil in the Drive

Gearbox and Replacing the Filter

For replacement intervals see section 4

"Lubrication and Maintenance schedule"
Depending on operating conditions an
earlier oil or filter change may be necessary.
The oil must be changed if there are any signs
of contamination or high temperatures-
conditions indicated by discolouring, strong
smells or oil inspections.

Replace the filter each time the oil is changed.

Z 163 045 (Z 163 045)

The oil should be drained when the drive

gear is at operating temperature; therefore the
oil is best drained immediately following road
travel.

Change the oil as follows:

- Ensure that the vehicle is in the horizontal

position and engage the parking brake.
(Z 075 392)

- Engine switched off

Z 075 392

- Secure the vehicle with blocks to prevent

any rolling movement.
(Z 160 077)
Date: 30.CW/96

Z 160 077

4/8 bs_e075-2060
a /35/98
 Transmission 6

- Unscrew the oil drain plug and drain off the oil.
(Z 163 081)

Oils whitch are drained off should be

caught in suitable containers and disposed
off appropriately.

If coolant is found to be in the gear oil, the

oil must be analysed. Contact the
company, Allison. The gearbox might have
Z 163 081 to be replaced.

- Replace the filter cartridges (2 pieces)

(Z 163 046)
- Push an the filter cover by hand and tighten
the screws.

The filter cover must not be tightened

using the screws as it may otherwise
break.

The tightening torque of the cover screws is

between 51 Nm and a maximum of 61 Nm.

Z 163 046

- Screw in the clean oil drain plug, fitted with

new sealing ring.
(Tightening torque = 50 Nm)
(Z 160 007)
Date: 30.CW/96

Z 160 007

bs_e075-2060 5/8
6

- Fill in oil.
(Z 163 031)

Z 163 031

- Switch the selector keypad to neutral "N"

- Start the engine and leave it running at idle

speed until the temperature of the drive gear
for a warm check is reached and then make
the oil check like it is written in section 6.1.
(Z 075 291)

If the oil level is too low, malfunctions and

damage will occur in the gear system. If
too high, drive performance will be
decreased.
Z 075 291

Date: 30.CW/96

6/8 bs_e075-2060
 Transmission 6

6.3 Distributor Gear - Checking and

Topping Up the Oil Level

(Z 075 283)

Z 075 283

- Remove screw from the inspection/filler

opening.

(Z 075 284)

The distributor gear is filled correctly when

the oil level reaches up to the lower edge of the
inspection opening or the filler neck.

- If the oil level is too low, unscrew the filler

plug and fill in oil.

If the oil check is carried out when the

gear is warm, ensure that oil does not spill over
Z 075 284
when the inspection plug is opened.
6.4 Distributor Gear - Changing the Oil

The oil should be drained when the drive

gear is at operating temperature; therefore the
oil is best drained immediately following road
travel.

Change the oil as follows:

- Remove the oil filler plug (1) and the oil

drain plug (2).
Date: 30.CW/96

(Z 075 285)

Z 075 285

bs_e075-2060 7/8
6

- Drain off the old oil.

Oils whitch are drained off should be

caught in suitable containers and
disposed off appropriately.

- Clean the plug, replace the old seal and

screw the plug back in.
(Z 160 007)

Z 160 007

- Fill new oil into the distributor gear until it

overflows from the filler/inspections opening.
(Z 075 286)

- Then screw filler plug back in.

Z 075 286

- Remove the breather (3), clean it and

replace it once more.
(Z 075 287)
Date: 30.CW/96

Z 075 287

8/8 bs_e075-2060
 Joint Shafts 7

7 Joint Shafts

7.1 Flange Connections

Check and, if necessary, tighten the screws

and nuts on the flange connections.
Tightening torque:

- screws M12x1.5 : 112 Nm

(Z 160 103)

Z 160 103

7.2 Lubricate the Joint Shafts

Lubricate the joint shafts at the corresponding

nipples.
(Z 160 104)

On maintenance-free joint shafts there is

no nipple on the sliding part.

Z 160 104

Lubricate the slider.

(Z 160 102)
Date: 27.CW/94

Z 160 102

bs_e908-3070d /a 1/1
 Axles 8

8 Axles

8.1 Checking and Tightening the Axle

Fixings

- Check and, if necessary, tighten the screws

on the axle brace collars.

The correct torque is as follows:

- Screw M12 x 1,5 : 112 Nm

Z 160 105 (Z 160 105)

- Tighten the fixing screws on the axle braces

using a torque spanner.

The correct torque is as follows:

- Screw M18 : 410 Nm

(Z 160 106)

Z 160 106

Before replacing the screws:

* Clean the threaded hole and surface areas.

* Smear the screw head and screw thread
with oil or grease.
(Z 160 107)

Do not use MoS2 !

Date: 49.CW/96

Z 160 107

bs_e075-2080 1/6
8

8.2 Lubricating the Axles

- Steering knuckle bearing

- Grease the upper part of the steering

knuckle bearing.
(Z 160 108)

Z 160 108

- Grease the lower part of the steering

knuckle bearing.
(Z 160 109)

Z 160 109

8.3 Steering and Track Arm

- Check the screws and tighten as necessary.

(Z 160 110)
Date: 49.CW/96

Z 160 110

2/6 bs_e075-2080
 Axles 8

8.4 Axle Drive - Checking and Topping

Up the Oil Level

- Axle 1
(resp. Axle 1 and Axle 2 for drive variant 4 x4)
(Single Axle Drive with Integrated Lock)

Check the oil level as follows:

The vehicle must be in the horizontal

position before the oil check is carried out.
(Z 075 363)

Z 075 363

- Remove screw (2) from the inspection/filler

opening.
(Z 160 125)

The axle gear is filled correctly when the

oil level comes up to the sill on the inspection
opening.

- If the oil level is too low, unscrew the

filler plug and fill in oil.

Z 160 125

If the oil check is carried out when the

gear is warm, ensure that oil does not spill over
when the inspection plug is opened.

(Z 160 126)
Date: 49.CW/96

Z 160 126

bs_e075-2080 3/6
a / 30/98
8

8.5 Wheel Hub Drive - Checking and

Topping Up the Oil Level

- Drive the vehicle forwards or backwards

until the oil drain plug (1) is at the lowest
point. (Marking is horizontal)

- Remove the oil inspection plug (2).

The oil level must come up to the sill of the
inspection opening. Top up if necessary.

(Z 160 117)

Z 160 117

8.6 Axle Drive - Changing the Oil

- Axle 1
(resp. Axle 1 and Axle 2 for drive variant 4 x4)
(Single Axle Drive with Integrated Lock)

- Drain plug (1) and filler/inspection plug (2)

must be unscrewed when an oil change is to
be carried out.
(Z 160 121)
- Drain off the old oil.

Z 160 121
Oils whitch are drained off should be
caught in suitable containers and
disposed off appropriately.
- Clean the screw and fit a new sealing ring.
(Z 160 007)
Date: 49.CW/96

Z 160 007

4/6 bs_e075-2080
 Axles 8

- Fill new oil into the axle housing until it

overflowns from the filler/inspection opening.
(Z 160 124)

- Then screw filler plug back in.

Z 160 033

8.7 Wheel Hub Drive - Changing the Oil

- Drive the vehicle forwards or backwards

until the oil drain plug (1) is at the lowest
point.

- Unscrew the drain plug (1) and the oil

inspection/filler plug (2) and drain off the
old oil. (Z 160 117)

Oils whitch are drained off should be

Z 160 117 caught in suitable containers and
disposed off appropriately.
- Clean the plug, replace the old seal and
screw the plug back in.

- Fill in new oil up to the sill of the inspection

opening.
(Z 160 118)

- Next clean the filler plug or inspection plug,

replace the sealing rings and screw back in.
Date: 49.CW/96

Z 160 118

bs_e075-2080 5/6
8

8.8 Wheel Hub Bearing - Changing the

Grease

- Axle 2

- Dismantle the wheel hub.

(Z 160 128)

Z 160 128

- Thoroughly clean the inside and outside of

the wheel hub, removing any traces of
old grease.

- Fill the hub cap with grease until it is 3/4 full.

(Z 160 131)

- Screw on the hub cap.

Z 160 131

8.9 Suspension Cylinders

- Lubricate the swing bearing.

(Z 160 127)
Date: 49.CW/96

Z 160 127

6/6 bs_e075-2080
 Steering 9

9 Steering

9.1 Steering Components

- Check the steering components are

sufficiently tightened

- Check that all the screws on the steering

components are sufficiently tightened and
tighten any loose screws as required.
(Z 075 232)

Z 075 232

9.2 Lubricating the Steering

Components

- Lubricate the joint shafts

- Grease the lubricating nipples on the

joint shafts.
(Z 075 231)

- Lubricating and Checking the

Steering Cylinder

- Lubricate the swing supports if nipples are

Z 075 231 provided.

Check that all screws and hydraulic lines

are tightly fitted.
If the working cylinder has been fitted at a
later stage (e.g. after repair work), it should
be inspected after the first 1000 km.
(Z 160 136)
Date: 02.CW/01

Z 160 136

bs_e075-2090 /b 1/2
9

9.3 Replacing the Hoses

Even if there is no sign of damage, the

hose lines should be replaced at the latest
after 4 years.
(Z 160 136)

Z 160 136

9.4 Angular Gear

If the angular gears above and below the

rotary joint are installed subsequently (e.g.
following repairs), the angular gears should be
refilled with hydraulic oil (see Section 2 - Fuels
and Lubricants and Section 3 - Capacities).

9.5 Lubricating Independent Rear Axle

Steering

To ensure faultless operation while releasing

and locking the crab walk lock, the locking pin
(1) and the fork (2) of the axle must be
lubricated.
To do so, release crab walk lock and fully turn
the crab walk steering to the right-hand side.
Then lubricate fork and locking pin.
(Z 501 320)

Before resuming road travel, switch off

Date: 02.CW/01

independent rear axle steering and lock.

The indicator light (98, H356.2) may not
Z 501 320 light up.

2/2 bs_e075-2090 /b
 Braking System 10

10 Braking System

Safety instructions

The brakes are a paramount safety

system; the brake system may fail if work
has not been carried out properly.

Service and repair work require

specialised knowiedge and may only be
carried out by appropriately trained
personnel.

Vehicles requiring authorisation

The traffic regulations of the land in question

must be observed by those vehicles whitch are
authorised to use public roads. For this, a
special brake check with an internal inspection
of the individual parts must be undertaken,
which entails removing the brake drum.

Vehicles not requiring authorisation

are to be inspected at least once a year by a

specialist in accordance with the appropriate
accident prevention regulations.

Repair sets

Various repair sets are available for

maintenance purposes.
Only original parts may used.
Stand: 32.KW/98

bs_e908-3100d /c 1/4
10

Wear in brake linings

Each new brake lining must be worn in so that

it achieves maximum braking efficiencey. This
is achieved by interval braking at low to medi-
um speed; sudden braking is not acceptable for
this purpose. The maximum brake drum
temperature of 200 degrees C may not be
exceeded during this procedure. The
temperature rise resultant from any one brake
actuation may not exceed 15 % of the maximum
value.
When wearing in new linings, protracted
braking and repeated sudden braking at high
speeds are to be avoided.

10.1 Check brake linings for wear

Drum brakes

- Remove plug.
(Z 36 580)
- Brake lining wear can be ascertained by
looking through the inspection holes in the
cover plate.
Z 36 580 - Changing brake linings: after reaching the
wear edge.
- Minimum lining thickness: d = 4,5 mm.
(Minimum thickness for overlarge brake
linings - (necessary for re-lathed drums:
d = 5,5 mm.)
(Z 36 581)

10.2 Renew brake linings

d

For worn or oiled brake linings always replace

both brakes on an axle and always use a
consistent quality of lining per axle.
Ensure that only linings cleared for release are
Stand: 32.KW/98

used.

Z 36 581

2/4 bs_e908-3100d /c
 Braking System 10

10.3 Replace brake drums

Brake drums

They may only be worn down to the minimum

permitted thickness.
Brake drums may only be re-lathed to a value
of 0.75 % greater than the nominal diameter.

10.4 Perform brake function check

Press brake pedal slowly and check if brake

shoe connects with drum an by means of the
inspection holes. The brake shoe must return to
its original position immediately that the pedal
is released.

10.5 Check expanding cylinder

Clean all parts with spirit or a suitable cleaning

agent at the latest two years after being put into
service, replacing all defectives and spring
washers.
Assemble using Paragon EP 2 (DEA) lubricant
or equivalent.
At the same time, renew the bellows.

10.6 Replace other brake parts

Compression springs, draw springs and sealing

rings, protective caps and bellows must be
replaced at least every two years.
Stand: 32.KW/98

bs_e908-3100d /c 3/4
10

10.7 Air Drier with Integrated Pressure

Regulator

Replacing the granulate cartridge (1)

The air drier must be depressurized.

(Let off pressure, for example by actuating
the drain valve, Section 10.8)

Z 160 167
Remove the cartridge (1) from the housing (2)
by turning it to the left.
(If required, use strap wrench - 160)
(Z 160 167)

Before screwing in a new cartridge, lightly

grease the sealing ring (4) and then thread pins
(5) (replace the seal if it is damaged).
(Z 160 168)

Read the instructions on the cartridge.

The tightening torque for the cartridge is 15

Nm.
Z 160 168

10.8 Draining Water from the Air Tanks

Air tanks with a manual drain valve are to

be drained by the operator, e.g. if the air drier
does not work properly, or after 5 years.

- When the drain valve pin is pressed or

pulled sideways the rocker valve opens and
the condensation can escape from the tank.
Stand: 32.KW/98

(Z 160 145)

Z 160 145

4/4 bs_e908-3100d /c
 Wheels and Tyres 11

11 Wheels and Tyres

11.1 Tightening the Wheel Nuts

The wheel nuts should be tightened every 10,000

km.

The wheel nuts must be tightened 50 km and

5,000 km after a wheel change has taken place.
(Z 160 150)

Z 160 150 The torque for wheel nuts with pressure discs is
600 Nm.

When fitting new wheel nuts, ensure that both

the wheel nuts and the bolts are in the same
condition as when delivered, i.e. coated with
only a thin film of anti-corrosive oil.
Oil or grease on the thread or surface (nut/
washer) will lead to overtightening of the wheel
bolts at the above torque and must be avoided
at all times.

(Z 161 132)
Z 161 132

11.2 Tyres - Checking Pressure and Tread

Depth and Checking for Damage

Type Tyre pressure

425/65 R 22,5 10 bar

14.00 R 25 9 bar
Date: 30.CW/96

bs_e075-2110 1/1
 Hydraulic System 12

12 Hydraulic System

Ensure that all lines and hoses are at

sufficient distance toward hot engine parts
(e.g. turbocharger) and are laid so that they
do not chafe.

If lines and hoses are found damaged due

to mechanical, thermal or other effects,
they must be replaced.

Check all hoses regulary for damages.

If any damages - even if they are minor - are
detected when performing this visual check the
damaged hoses have to be replaced
immediately.

Even if no damages are detected the

hoses have to be replaced at the latest after
4 years.
Date: 30.CW/96

bs_e075-2120 1/17
12

12.1 Hydraulic Tank - Checking and

Topping Up the Oil Level

The hydraulic tank contains the general oil

supply for all hydraulic components.

When checking the oil level:

- Position the crane on level, flat ground.

- Crane in the travel position.
- Suspension cylinders retracted.
- Switch off the engine.
(Z 075 230)
Z 075 230

- Read the oil level off the dipstick.

(Z 162 152)

Z 162 152

- If the oil level is below the mark, it should be

topped up.
(Z 160 153)

Find the cause of the oil loss and rectify

immediately.

If there are three markings on the dipstick,

the centre marking indicates the max. level.
Date: 30.CW/96

Z 160 153

2/17 bs_e075-2120
 Hydraulic System 12

12.2 Hydraulic Tank - Filter

1 - Return oil filter 1

2 - Return oil filter 2

3 - HP filter

(Z 075 249)

Z 075 249

For replacement intervals see Section 4

"Lubrication and Maintenance Schedule".

If one of the filters needs to be cleaned or

replaced between the specified intervals, this
will be indicated by the indicator light on the
dashboard.

(Z 075 284)

Z 075 284
Date: 30.CW/96

bs_e075-2120 3/17
12

In order to find out which filter needs to be

changed or cleaned, you must remove the
plugs on the pressure switches of the return
oil filters one after the other and watch the
indicator light on the dashboard.

(see Z 163 157, Z 075 247, Z 075 248)

Z 163 157

Z 075 247

- Clean the housing of return oil filters 1

and 2 and replace the filters elements.
(075 250)

To clean the filter barrel and to replace the

paper elements, the filter units of retutn filters 1
and 2 must be removed.

DANGER OF INJURY
from high hydraulic oil pressure.
Date: 30.CW/96

Therefore switch off the engine before

Z 075 250 working on the hydraulic system.

4/17 bs_e075-2120
 Hydraulic System 12

- Return oil filter 1

- While paying attention to the sealing ring (5),

release the cover (1) by means of an
appropriate tool and then unscrew the cover.

(Z 160 170)

Z 160 170

- While paying attention to the O-ring (6),

remove the filter unit (2) from the head piece.

- Remove and dispose of the paper element (8)

in the barrel (2).
(Z 160 257)

Z 160 257

- Wash out the barrel (2) with diesel oil or

petrol of a suitable grade for cleaning
purposes.
(Z 160 160)
Date: 30.CW/96

Z 160 160

bs_e075-2120 5/17
12

- The return filter is fitted as it is removed, but

in reverse order.

Before fitting, the sealing rings (5) and (6)

should be checked to ensure that they are in
good condition.
Replace any damaged parts.
(Z 160 161)

Z 160 161

Before a new paper element is fitted in

the barrel, ensure that the number on the
paper element corresponds to that on the
relevant spares list.
(Z 160 162)

Z 160 162

When screwing on the filter cover (1),

ensure that the O-ring (5) is correctly positioned
in the groove of the filter cover.
(Z 160 170)

Carry out a test run to ensure that the

filter is fitted correctly.
Date: 30.CW/96

Z 160 170

6/17 bs_e075-2120
 Hydraulic System 12

- Return oil filter 2

- Loosen the hexagon nuts (1) with wrench

SW 17 and remove them together with the
spring washers.
(Z 160 250)

- Then remove the filter cover (2) while paying

attention to the sealing ring (Z 160 251,
item 3) situated underneath.

Z 160 250

- While paying attention to the O-ring (6), pull

the filter unit (4) out of the head piece by
means of the handle (5).
(Z 160 251)

It is advisable to set the filter unit down on

the head piece until the oil in the filter has run
out via the paper elements.

Z 160 251

- Place the filter unit (4) on a solid base, press

the handle (5) downwards and return it
approximately 60o to the left or the right.
- Remove the handle (5) with the attached
valve, clean the latter in diesel oil or
petroleum ether and place it on a clean base.
(Z 160 252)
Date: 30.CW/96

Z 160 252

bs_e075-2120 7/17
12

- Remove paper elements which are marked

with a P before the element number from the
filter tube and dispose of them.
(Z 160 253)

The element number of the replacement

paper element with the above-mentioned
code letters must correspond to the
associated element number on the spares
list of the filters.
Z 160 253

- Pour the residual oil out of the filter tube into

a container for used oil and rinse out the
filter tube with diesel oil or petroleum ether.

In filters which have a magnet system, the

latter is accomodated in the filter cover.
Remove the dirt with a cleaning rag and diesel
oil or petroleum ether. Place the cleaned filter
cover with the magnet system on a clean base.

- The return oil filter 2 is assembled in the

reverse seqence.

Before assembly, seals (3) and (6) must

be checked to ensure that they are in perfect
condition and positioned correctly. Replace
damaged parts. Fit new paper elements in the
filter tube. Press the handle between the
locking plates fastened at the top of the filter
tube downwards and turn it until it has locked in
position in the slots in the cams.
(Z 160 251)
Date: 30.CW/96

On the test run, check that the filter is not

Z 160 251 leaking.

8/17 bs_e075-2120
 Hydraulic System 12

- Cleaning the High Pressure Filter and

Replacing the Element

- Switch off the engine

- Place a suitable container beneath the filter (3)

to catch any oil that might run off.
(Z 075 251)

Z 075 251

- Unscrew the socket housing.

Apply key SW (32) to the bottom of the
socket housing.
(Z 160 176)

- Drain off the remaining oil from the bottom of

the socket housing and dispose of it.

- Wash out the socket housing with diesel oil

or petrol of a suitable grade for washing
purposes.

Z 160 176

- Remove and dispose of the dirtied paper

element (2) from the outlet pipe (3) by moving
it gently from side to side and pulling it
downwards.
(Z 160 177)
Date: 30.CW/96

Z 160 177

bs_e075-2120 9/17
12

- Replace O-Rings (5) and (6).

(Z 160 178)

Z 160 178

- Apply new paper element (2) on the outlet

pipe (3).
(Z 160 179)

Z 160 179

- Fill the socket housing (1) until about half full

with clean hydraulic oil, carefully place the
filter barrel over the filter element (2) and...
(Z 160 193)
Date: 30.CW/96

Z 160 193

10/17 bs_e075-2120
 Hydraulic System 12

... screw in fully into the head piece and tighten

with a wrench.
(Z 160 194)

Carry out a test run to ensure that the filter

is fitted correctly.

Z 160 194
Date: 30.CW/96

bs_e075-2120 11/17
12

12.3 Hydraulic Tank - Replacing the

Aeration Filter

The aeration filter must be changed more

regularly in especially harsh operating
conditions.
(Z 075 252)

Z 075 252

- Unscrew the filter and dispose of

appropriately.
(Z 160 188)

Z 160 188

- Screw on the new filter.

(Z 160 189)
Date: 30.CW/96

Z 160 189

12/17 bs_e075-2120
 Hydraulic System 12

12.4 Changing the Hydraulic Oil

The vehicle should be level and the

engine switched off.

- Close the main hydraulic stop valve (1) and

shut-off valves (2).
(Z 075 253)

Z 075 253

- Unscrew the unions (3) from the discharge

connections on the lower side of the
hydraulic tank, drain the oil into suitable
containers and dispose of appropriately.
(Z 075 254)

Z 075 254

- If necessary, clean the hydraulic oil tank.

(Z 075 256)
Date: 30.CW/96

Z 075 256

bs_e075-2120 13/17
12

- Screw the screw connections (3) back on.

(Z 075 254)

This seals the hydraulic tank again.

Z 075 254

- Fill in new hydraulic oil (also see section 12.1).

(Z 075 258)
- Open the main hydraulic stop valve (1) and
shut-off valves (2) once more
(Z 075 253)

When oil is filled into the hydraulic system

there is a danger of dirt particles
contaminating the hydraulic oil circuit.
In order to prevent malfunctions in the
system caused by impurities, ensure that
Z 075 258
the initial fill up and subsequent fill ups are
carried out under extremely clean
conditions.
If necessary, first pass the hydraulic oil
through a filter.
Date: 30.CW/96

14/17 bs_e075-2120
 Hydraulic System 12

12.5 Hydraulic System -

Pressure Accumulator, Checking
the Preliminary Gas Tension

The pressure accumulators fitted in the

hydraulic system of the crane are diaphragm or
bubble-type accumulators with nitrogen filling.

They are fitted in the following components:

- Hydraulic suspension system of the chassis
- Pilot control circuit of the superstructure
hydraulics

The corresponding components can only

function fault-free if the integrated pressure
accumulaters are charged with the correct
preliminary gas tension.

The preliminary gas tension must be checked

at regular intervals.

To check the preliminary gas tension,

a filling and test device for diaphram and
bubble-type accumulators is required.

This inspection may only be carried out by

specialist personnel who are trained in the
use of the filling and test equipment.
Date: 30.CW/96

bs_e075-2120 15/17
12

To check and fill the pressure accumulator,

1 proceed as follows:
2
- Hydraulic suspension system of the
chassis:
Retract all suspension cylinders up to the
stop thus emptying all suspension circuits
and depressurizing them.
The pressure accumulator must be
completely emptied of hydraulic fluid.

- Pilot control circuit of the superstructure

hydraulics:
"X" Switch off the drive motor on the
Z 30 640 superstructure and switch the ignition key to
the "0" position.
Depressurize the hydraulic system.
The pressure accumulator (2) must be
completely emptied of hydraulic fluid.
(Z 30 640)
Check this on the mini-gauge connection "X"
of the respective suspension circuit or at the
pilot control circuit using a manometer.
(0 bis 10 bar)

If the pressure gauge does not indicate a

pressure level, the system is not under
pressure.

- Remove the protective device (1) on the gas

valve of the pressure accumulator (2) and
screw on the filling and test device (3).

3 - Open the gas valve over the screwed-on

filling and test device and read off the charge
pressure on the pressure gauge of the
testing device.
1
- If there is insufficient initial pressure, the
2 pressure accumulator must be filled up with
nitrogen via the filling device (3) up to the
corresponding initial pressure.
2 (Z 30 194)
Date: 30.CW/96

After the initial fill-up, wait approximately two to

three minutes.
Z 30 194 Check the preliminary pressure again and top
up as necessary.

16/17 bs_e075-2120
 Hydraulic System 12

When filling up the preliminary gas tension

1 on the pressure accumulator observe the
2 pressure gauge on the mini-gauge connection "X".
The pressure in the corresponding hydraulic
circuit resp. hydraulic circuit of the suspension
must not rise.
If this is the case, the suspension circuit must
be emptied again and the preliminary gas
tension at the pressure accumulator checked
again.
If the same occurs again, the diaphragm in the
pressure accumulator is defective. The
pressure accumulator must be replaced.
"X" Z 30 640 (Z 30 640)

Driving with insufficient preliminary gas

tension or defective pressure accumulators
can lead to damage to the chassis or the
axles.

If a large fall in pressure (approx. 50 %) is

measured during the initial inspection of the
preliminary pressure, the pressure accumulator
must be checked again after approximately
three to four weeks.
If a further fall in pressure is measured, the
pressure accumulator must be replaced.

Only NITROGEN may be used to fill the

3 pressure accumulator.
A pressure reducer (5) must be fitted to the
nitrogen link.
Pressure accumulators may only be
5 repaired by the manufacturer or by
approved workshops.
The pressure accumulator must be
approved by an expert following repair
work.
2 A new test certificate must be produced for
4 the pressure accumulator.
Date: 30.CW/96

(Z 30 641)
Z 30 641

bs_e075-2120 17/17
 Outriggers 13

13 Outriggers

13.1 Lubricating the Sliding Surfaces on

the Outrigger Struts

Lubricate the upper guide strips and the

underside of the outrigger struts.
(Z 160 218)

Z 160 218
Date:25.CW/94

bs_e908-3130d /a 1/1
 Electrical System 14

14 Electrical System

14.1 Checking the Lighting System

Check that the system is functioning correctly

and repair any faults immediately.
(Z 075 201)

Z 075 201

14.2 Replacing the Headlamp Bulbs

The headlamp bulbs can be replaced from the

rear without having to remove the headlamp.
(Z 160 203)

Z 160 203

14.3 Servicing the Battery

For notes on servicing please see the

operating instructions of the engine
manufacturer.
(Z 160 502)
Date: 51.CW/96

Z 160 502

bs_e075-2140 1/1
 Fuel System 15

15 Fuel System

Fuel tank

Drain off the water and sediment.

In order to drain the residue which has

accumulated in the fuel tank, open the drain
plug and drain off at least 1 l. of fuel.
(Z 075 224)

Z 075 224

Fuel filter

1- Hand pump
2- Fuel Stage Filter
(Z 075 226)

For notes on maintenance, please refer to

the maintenance and operating instructions for
the diesel engine contained in Part 3.

Z 075 226
Date: 30.CW/96

bs_e075-2150 1/1
 Air Intake and Cooling System 16

16 Air Intake and Cooling System

Empty the dust collector of the air filter.

Switch off the engine.

The dust collection cap of the air filter should

be emptied daily, especially when the dust content
of the air is high. The dust collection cap must
otherwise be emptied weekly.

Z 162 039 Release clamps (1), and remove dust collector

together with cover.
(Z 162 039)

Remove cover (3) from dust collector (2) and

empty and clean. Reassemble in reverse order.
The fork bolt on the dust collector and the groove
on the cover must interlock (see arrows).
(Z 160 037)

Z 160 037

Service the air filter.

Never service the air filter when the engine

is running. Service the element as soon as
the indicator light comes on with the
engine running or at least every 2 years.
(Z 075 246)
Date: 51.CW/96

Z 075 246

bs_e075-2160 1/4
16

Remove the filter element.

(Z 162 052)

Z 162 052

Clean and inspect the filter element.

(Z 160 053)

The filter element must be replaced after it

has been cleaned 4-5 times, however at lost every
2 years or as soon as it becomes clogged with
soot.

For more informations refer to the engine

manufacturer´s operating manual.

Z 160 053

Clean the filter barrel of any dirt, but do not pass

compressed air across it.
(Z 162 078)
Date: 51.CW/96

Z 162 078

2/4 bs_e075-2160
 Air Intake and Cooling System 16

Replacing the safety cartridge

- Optional equipment -

After the filter element has been cleaned five

times, the safety cartridge must also be replaced
as follows:

Unscrew fixing nut of the safety cartridge.

(Z 162 071)

Z 162 071

Change the safety cartridge.

(Z 162 072)

The safety cartridge must always be replaced.

It should never be cleaned.

Z 162 072
Date: 51.CW/96

bs_e075-2160 3/4
16

Cleaning the cooling system

Pass compressed air through the cooling system

at a moderate pressure against the air flow (to
ensure the cooling elements are not damaged), or
wash out with water, until cooling elements are
completely free from impurities (dust, insects,
etc.).
(Z 160 019)

Z 160 019

If the coolant rises to an unusually high

temperature at normal ambient temperatures
although the cooling system exterior has been
cleaned and there are no other malfunctions,
the cooling system interior may be
contaminated.
(Z 075 245)

In this instance the cooling system must und-

ergo a thorough cleaning, whereby the entire
cooling circuit is degreased, decalcified and
derusted.

Further details can be found in the engine

Z 075 245 manufacturer's operating instructions.

Check the coolant level and top up as

necessary.

Open the cap of the engine cooling system

only when the coolant is at a temperature
of below 90 oC.
(Z 160 021)
Before the onset of winter check the coolant
for anti-freeze.
Date: 51.CW/96

For more informations refer to the engine

Z 160 021 manufacturer´s operating manual.

4/4 bs_e075-2160
 Piston Rods17

17 Piston Rods

Apply protective grease to exposed

chrome surfaces.
Despite being of the highest quality, surfaces
may be susceptible to corrosion in an agressive
environment. If the crane is out of operation for
more than one day, exposed surfaces should
be protected against corrosion by applying
acid-free protective grease ("GLEITMO 350" is
recommended, order number for aerosol:
604 106 40).
(Z 160 137)
Z 160 137
Date:13.CW/94

bs_e908-3170d 1/1
 Optional Equipment 18

18 Optional Equipment

18.1 Refilling the Central Lubrication

System

Fill up the reservoir (1) of the central lubricating

pump via refill nipple (2) on the lube filter using
a standard grease pump or lever type hand
gun.
(Z 075 208)

Never exceed the max. level.

Z 075 208
Date: 51.CW/96

bs_e075-2180 1/1
 Visual Inspections 19

19 Visual Inspections

The following points should be observed every

day before driving the crane:

- Check the covers and panels for damage.

Check for loose or missing screws.
(Z 075 270)

Z 075 270

- Check the entire hydraulic system for

damage and leaks and check the oil level.
(Z 075 271)

Z 075 271

- Check the engine for oil or fuel leaks and for

clogging.
(Z 075 272)

- Careful attention to the oil level and the

connections for the electronic and hydraulic
circuits of the transmission is most
important.

- Check the oil cooler for clogging.

Date: 30.CW/96

Z 075 272

bs_e075-2190 1/2
19

- Check the instruments and displays for

damage.
(Z 075 273)

Z 075 273

- Check the lighting system for damage.

(Z 075 274)

Z 075 274

- Check the functioning of the windscreen

washing assembly at least once a week.
The supply tank must always be filled with
water.
(Z 160 365)

Before the start of the cold season,

antifreeze in a quantity corresponding to the
temperature must be added to the water.
Date: 30.CW/96

Z 160 365

2/2 bs_e075-2190
 Slew Ring 20

20 Slew Ring

20.1 Lubricating the Bearing

The bearings of the slewing rim are greased

via 4 lubricating nipples on the slew ring.
(Z 075 300)
(If the roller bearing slewing rim is greased
via a lubricant distributor, the lubricating
nipple is located in the hydraulic bracket
behind the cab)

Lubricating Procedure:
Z 075 300 Grease the slewing rim via the lubricating
nipples, then slew the superstructure through
360° and grease the lubricating nipple once
again.
Following the second lubricating procedure,
lubricant must be emitted along the whole
circumference of the slewing rim forming a
collar of grease.

20.2 Lubricating the Gear Ring

Where uncovered areas are visible on the teeth

edges, these should be sprayed immediately
with special adhesive grease.
(Z 160 301)
Date: 19.CW/98

Z 160 301

bs_e075-2200 /a 1/2
20

20.3 Check slew ring bolt connections

Using a torque wrench, check the tightness of

the bolts by applying torque specified.
(Z 160 302)

Bolts which can be turned using the

torque specified must be unscrewed and
checked.
If the bolt in question is waisted, it must
be replaced with a new one.
Z 160 302

Item Dimension Material Torque

Item 1 M 20 x 90 10.9 510 Nm

The above-mentioned screws should be

clean and lightly greased when fitted.

Date: 19.CW/98

2/2 bs_e075-2200 /a
 Slew Gear 21

21 Slew Gear

21.1 Slew Gear Mechanism - Checking

and Topping Up the Oil Level

Unscrew the filler plug.

If the oil level is below the lower mark, the oil
must be topped up.
(Z 160 303)

Z 160 303

21.2 Slew Gear Mechanism - Changing

the Oil

Unscrew the filler plug.

(Z 160 303)

Unscrew the drain plug and drain off the gear

oil.
(Z 160 306)

Oils which are drained off should be caught

Z 160 306 in suitable containers and disposed off
appropriately.
After all the oil has been drained off, screw the
cleaned drain plug back in.

Fill in new oil through the filler neck until the oil
level reaches the upper mark on the dip stick.
(Z 160 307)

Clean the gear with flushing oil before

filling with new oil.
Date: 07.CW/02

Z 160 307

bs_e908-3210d /g 1/2
21

21.3 Checking and Tightening the

Screw Connections

Check the torque of the screws using a torque

wrench.
Tighten the screws as necessary.
(Z 160 309)

AC Item Dimension Material Torque

Item 1 M 14 x 30 8.8 118 Nm

25 / 75 Item 2 M 10 x 35 10.9 63 Nm
30 Item 2 M 10 x 35 10.9 63 Nm
Z 160 309 40-1/115 Item 2 M 10 x 35 10.9 63 Nm
40 / 95 Item 2 M 10 x 70 12.9 73 Nm
50-E/150 Item 2 M 10 x 70 12.9 73 Nm
50 /155 Item 2 M 10 x 70 12.9 73 Nm
50-1 Item 2 M 10 x 70 12.9 73 Nm

The above-mentioned screws should be

clean and lightly greased when fitted.

When new screws are fitted, the thread

and head should be smeared with MoS2 paste.

Z 160 313 (Z 160 313)

Date: 07.CW/02

2/2 bs_e908-3210d /g
 Hoists 22

22 Hoists

22.1 Hoist Gear - Checking and Topping

Up the Oil Level

Check the oil level through the inspection glass.

The oil level should be checked

immediately after commencing operations,
while the gear is at a standstill, as a
considerable quantity of the oil is distributed
throughout the inner parts of the housing during
operation.
Z 075 310
The correct oil level is reached when, with the
crane in a level, horizontal position, the oil is
level with the "max." marking on the inspection
glass.
(Z 075 310)

If the oil level is too high, the oil in the hoist

gear must be drained off and new oil filled in.

If the level is below the minimum marking

proceed as follows:

- Remove the filler plug (1) at the upper end

of the inspection glass.
(Z 075 311)
Z 075 311
- Using a funnel or hose, fill in oil up to the
"max." marking on the inspection glass.
(Z 075 310)

See section 22.2 and section 2 "Fuels and

Lubricants" for the correct oil types.

- Screw the filler plug (1) back in.

If inspection reveals a continual loss of oil,

Date: 30.CW/96

operations must be halted and the system

dismantled.

bs_e075-2220 1/5
22

22.2 Hoist Gear - Changing the Oil

Use the oil grade given in section 2 "Fuels and

Lubricants" or on the serial plate. It is
preferable to use an oil of a higher viscosity
rather than using a thinner oil.
Different oil types should not be mixed, even if
they come from the same manufacturer.

Fully synthetic oils may only be used

with acidproof seals and a sufficiently resistant
inner coating.

Z 075 311 The oil should be changed when it is warm, i.e.

after a longer operating period, as follows:

- Remove the filler plug (1) at the upper end

of the inspection glass.
- Remove the drain plug (2) at the lower end
of the inspection glass (Z 075 311)
and drain off the oil into a suitable
container.
(Z 075 312)

Oils which are drained off should be

caught in suitable containers and disposed
off appropriately.
Z 075 312
- After all the oil has run out, reinsert the
cleaned screw plug.
- Fill in new oil as described in section 22.1.
(Z 075 313)
- Reinsert the cleaned oil filler plug.
Date: 30.CW/96

Z 075 313

2/5 bs_e075-2220
 Hoists 22

22.3 Lubricating the Rope Drum Bearing

Grease lubricating nipple.

(Z 163 316)

Lubricat until lubricant is emitted evenly

at the seal.

Z 163 316

22.4 Checking and Tightening the

Screw Connections

The torque for the screws is as follows:

Item Dimension Material Torque

Item 1 M 8 x 20 8.8 23 Nm

(Z 075 315)

Z 075 315

Item Dimension Material Torque

Item 2 M 12 x 35 10.9 108 Nm

Item 3 M 12 x 40 10.9 108 Nm

(Z 075 314)

The same values apply for hoist 2 as for

hoist 1.
Date: 30.CW/96

When new screws are fitted, the thread and

head should be smeared with KP2K roller bearing
Z 075 314 grease.

bs_e075-2220 3/5
22

22.5 Lubricating the Hook Block

The lubricating nipples on the hook block

should be smeared before the crane is put
into operation and thereafter every 50 operating
hours.
(Z 160 318)

Z 160 318

Date: 30.CW/96

4/5 bs_e075-2220
 Hoists 22

22.6 Checking the Gear Oil

The gear oil which is drained off should be

checked once a year.
The gear oil should be drained onto a filtering
tile and inspected for e.g. large grained solid
waste using a magnifying glass. Only foreign
substances (max. 0.15 % of the total volume
of oil) containing fine abrasions with a particle
size of less than 25 micrometers are
permissible. If large grained abrasions (more
than 25 micrometers) or surface flaking from
the faces of the teeth are detected, the gear
must be dismantled back to the drive,
regardless of the volume of the foreign
substances. The faces of the gear teeth should
be visually inspected. After the run-in period
and with normal wear, the surface of the tooth
face should be smooth, bright and shining.
In the case of any other irregularities such as
attrition, scoring, scuffing, pitting, flaking,
cracking and plastic deformation, the gear
wheels should be replaced or a complete
overhaul should be carried out.
In this instance please refer to the Customer
Service Department.

22.7 Determination of the spent share

of the theoretical service life

A detailled description is given in chap. 1

"Notes on safety", point 1.4.4.
Date: 30.CW/96

bs_e075-2220 5/5
 Luffing Gear 23

23 Luffing Gear

23.1 Luffing Cylinders - Lubricating the

Foot and Piston Bearings

Grease the foot bearing via two lubricating

nipples.
(Z 160 319)

Z 160 319

Grease the piston rod bearing via one

lubricating nipple.
(Z 160 320)

Z 160 320
Date: 13.CW/94

bs_e908-3230d 1/1
 Equipment 24

24 Equipment

24.1 Main Boom - Lubricating the

Linings

The upper guideways of the boom sections

are lubricated via the lubricating nipples
situated in the upper bearing.
(Z 160 321)

Z 160 321

The basic boom section and the boom section

each have a lubricating opening on the left and
right-hand side. Extend the telescopic sections
of the horizontally positioned boom so that the
linings of the smaller boom section can be
lubricated through the opening in the larger
boom section.
Commence with the first boom section.

One lubricating nipple must be smeared

on either side of each boom section.
(Z 160 322)
Switch off engine as otherwise
Z 160 322 there is the danger of crushing

24.2 Main Boom - Lubricating the

Sliding Surfaces

Extend all the boom sections with the boom in

the horizontal position.

RISK OF CRANE OVERTURNING !

When extending, observe the load table.
Date: 27.CW/02

Then coat the lower guideways with grease

using a brush.
Z 160 323 (Z 160 323)

bs_e075-2240 /c 1/12
24

24.3 Lubricating the Basic Bolts on the

Main Boom

Smear the two lubricating nipples.

(Z 160 327)

Z 160 327

24.4 Lubricating the Hoist Ropes

To increase their life expectancy and to protect

against rust, the ropes should be liberally
coated with grease.
It is not sufficient to lightly coat the ropes; the
grease must penetrate through.
(Z 075 328)

This measure should be carried out when

the ropes are reeved.

Z 075 328

In very dusty working environments, the

layer of dust on the ropes and the rope
protection equipment must be removed,
otherwise the equipment will deteriorate at a
much faster rate.
(Z 075 329)

DANGER OF INJURY
Always wear protective gloves when
handling and guiding the ropes.
Date: 27.CW/02

Z 075 329

2/12 bs_e075-2240 /c
 Equipment 24

24.5 Checking and Replacing the

Hoist Ropes

Observe the relevant DIN specifications or

other national regulations.
(Z 160 330)

Z 160 330

Spin problems can occur when fitting a

hoist rope which has never been subjected
to a load before. We therefore recommend
the use of a spin stabiliser in such cases.
(Example: see Z 075 361)

Z 075 361

24.6 Checking the Main Boom for

Weld Cracks

In order to prevent breakage, the weld

joints on the main boom are to be inspected for
cracks once a year.
(Z 160 331)
Date: 27.CW/02

Z 160 331

bs_e075-2240 /c 3/12
24

If any crack formations are detected, the

necessary repair instructions should be
requested from the Engineering Customer
Service Department.
An exact description of the course of the crack
should be given (relevant page from the spares
catalogue, photos, sketches , etc.).
(Z 160 332)

Z 160 332

Weld repairs may only be carried out by a

qualified welder.

(Z 160 333)

Z 160 333
Date: 27.CW/02

4/12 bs_e075-2240 /c
 Equipment 24

24.7 Main Boom - Adjusting the Rope

Drive

Proceed for this as follows:

Telescope the main boom in and then

telescope it out by a few centimetres so that the
retracking rope is relieved.

- Release lock nuts (1).

- Re-tension the ropes by tightening

adjusting nuts (2) to a torgue of approx.
Z 075 334 150 Nm.
Telescope the main boom in and out
once or twice and repeat the tensioning
procedure.

- Guard adjusting nuts with lock nuts (1).

(Z 075 334)

When telescoping in, the first boom section,

which is retracted and extended via a telescopic
cylinder, must reach the stop at the same time
as the two other boom sections which are
retracted and extended via the rope drives.
For this, the air gaps between the stops in front
of the two last boom sections must be filled in
by screwing on lining plates.
If the stops of the rope-driven boom sections
are reached before the stops of the cylinder-
driven boom section, the boom must not be
retracted further.
Retracking ropes 1 and 2 will otherwise be
stetched and the deflection rollers may be
Date: 27.CW/02

damaged.
(Z 075 336)
Z 075 336

bs_e075-2240 /c 5/12
24

In order to avoid this, lining plates must be

screwed onto the stop in front of the cylinder-
driven boom section or the lining plates in front
of the last two boom sections must be removed
accordingly.

When the ropes have been tensioned, the

transport position of the main boom extension
may have to be readjusted.

24.8 Main Boom - Visual Inspection of

the Extending and Retracking
Ropes

Inspect the ropes regularly for damage.

- Extend the inner boom sections so that the

inspection openings are aligned.
- Using a powerful torch, perform a visual
inspection of the rope end connections, the
retracking rope ES 1, and the extending
rope AS 1 as possible.
(Z 160 339, Z 160 338)
Z 160 339
Follow the relevant DIN specifications or
other national regulations.
Date: 27.CW/02

Z 160 338

6/12 bs_e075-2240 /c
 Equipment 24

For visual inspection of extending rope AS 2,

remove cover and inspect rope as thoroughly
as is possible.
(Z 160 340, Z 075 341)

Z 160 340

All main boom ropes must be inspected every

time the main boom is disassembled, or at least
every four years, simultaneous with
replacement of hose lines.

Ropes must be replaced as soon as they are

discovered to be damaged.

Follow the relevant DIN specifications or

other national regulations.

Z 075 341
Date: 27.CW/02

bs_e075-2240 /c 7/12
24

24.9 Inspect Rope Track Rollers

Check all main boom and main boom extension

rope track rollers regularly for wear abd ease of
motility in turning. If clear wear tracks are
visible on the track rollers, they must be
replaced.

Rope track rollers which are split by hoist

ropes pose the danger of crane parts
falling from a great height.
(Z 160 500)
Z 160 500

24.10 Checking the Sheaves

y y
Regularly check all sheaves for any sign of
damage, for example cracks, scoring or similar
d damage.
x

Sheaves with this type of damage must be

replaced immediately.

Also check all sheaves regularly for wear.

If the rope groove has worn in more than 3 mm
compared with a new sheave (x)
Z 160 543
or
the lateral surface (y) up to the rope (d) has
worn in more than 5 mm, the sheave must be
replaced.
(Z 160 543)
Date: 27.CW/02

8/12 bs_e075-2240 /c
 Equipment 24

24.11 Sheaves - Checking the Roller

Bearing

Inspect all sheaves on the main boom head and

on all additional equipment once a year for the
following:

- Discharge of grease
- All bearing seals are fitted correctly
- All circlips are fitted correctly
- Running noises, rolling resistance
- Bearing play

Z 160 343 (Z 160 343)

If any faults are discovered on the roller

bearings, the sheave must be replaced.
(Z 160 344)

In this instance, please inform the

Customer Service Department .

Z 160 344

If inspection reveals a damaged circlip, the circlip

must be replaced.
(Z 160 345)

Original Demag circlips with chamfered

edges must be used.
Date: 27.CW/02

Z 160 345

bs_e075-2240 /c 9/12
24

24.12 Checking the Pins for Cracks

Check all pins for cracks regularly, e.g. during

assembly and dismantling.
(Z 160 353)

Z 160 353

24.13 Checking the Draw Bars (Schackle

on the Main Boom Extension)

The draw bars must be inspected by an

expert at least once a year (in accordance
with accident prevention regulations for
the operation of load lifiting equipment /
VBG 9).
The bars should also be inspected by an
expert between these intervals if
necessitated by the operating conditions.

As the inspection intervals are generally

related to operating conditions, if the crane
is in operation for longer perids of time the
intervals should be reduced accordingly.
Records should be kept of the inspections
(e.g. in the crane log book).

It may be necessary to dismantle the draw

bars to be able to inspect them correctly.

The draw bars must be inspected in their

entirety, i.e. all hidden surfaces and bores
Date: 27.CW/02

must also be inspected.

(Z 160 348)
Z 160 348

10/12 bs_e075-2240 /c
 Equipment 24

The following inspections should be carried out:

- Checking for cracks:

The draw bars should be checked regularly for

cracks.
A surface crack test (e.g. magnaflux test) must
be carried out at least once every year.
Should cracks be found during the inspection of
a draw bar, the draw bar must be replaced.

Repairs are prohibited.

- Checking the length:

The draw bars are designed so that no perma-

nent elongation occurs, even under test load.
No measurable change in length is permitted as
this would impair the function of the bars.
The length of the bars must be measured to
ensure that they have not become overloaded
or damaged.
The upper limit for performance capability (as
for "Condition of ropes for replacement") is a
change in length of 0.05 %.

If a change in lenth of >0.05 % is measured,

the tension bracket must be replaced.

The original length of the bugles on the main

boom extension is L = 616 mm.
(Z 075 352)
Date: 27.CW/02

Z 075 352

bs_e075-2240 /c 11/12
24

- Checking for wear:

Check the pin locks, pins and bores for signs of

wear.
It must be ensured that the pin locking
mechanism is functioning correctly.

- Checking for plastic deformation:

If plastic deformation doccurs (e.g. bending),

the draw bars may no longer be used.

- Checking the paintwork:

The paintwork must be checked regularly for

signs of corrosion.
Damaged areas should be restored.
The draw bar bearing must not come into
contact with aggressive agents (e.g. sea water).

24.14 Lubricate Main Boom Extension

Bolts

Check all bolts e.g. retaining bolts and

bell cranks on the main boom extension for
ease of operation and lubricate if necessary.
(Z 163 823)
Date: 27.CW/02

Z 163 823

12/12 bs_e075-2240 /c
 Heating 25

25 Heating

The manufacturer's operating instructions

for the D5S Eberspächer auxiliary heater
must be followed.
(Z 160 211)

Z 160 211

25.1 Checking and Filling Up the

Fuel Tank

Check the fuel tank regularly during the heating

period and fill up with diesel fuel if necessary.
(Z 160 357)

Z 160 357

25.2 Checking the Fuel Feed and

Cleaning the Fuel Filter if Necessary

The fuel strainer should be cleaned with the fuel

tank empty:

- Remove the shut-off valve

- Clean the installed fuel strainer

- Refit the shut-off valve.

Date: 12.CW/98

(Z 075 357)

Z 075 357

bs_e030-2250 /a 1/3
25

25.3 Checking and Replacing the

Glow Plug

Clean the glow plug before the beginning of the

heating period as follows:

- Remove the cap, loosen hexagonal screw

M4 and remove the spark cable.
(Z 160 358)

Z 160 358

- Unscrew the glow plug using wrench SW 19.

(Z 160 359)

Z 160 359

- Inspect the glow plug and replace if

necessary.

Before replacing the glow plug, clean the

glow plug socket.
When the plug is removed, pass compressed
air (less than 5 bar) through the fuel connector
and the vent opening for the glow plug.
(Z 160 360)

- Screw the glow plug back in.

Date: 12.CW/98

Z 160 360

2/3 bs_e025-2250 /a
 Heating 25

25.4 Fine dust filter

In order to maintain the heating at full

performance, the fine dust filter must be
exchanged when soiled.
For this, remove bolts (1), (numbering four) and
change fine dust filter.
(Z 075 362)

Z 075 362
Date: 12.CW/98

bs_e030-2250 /a 3/3