Download PDF: Terex Demag Crane CC 2500-1 Lubrication Manual

Index

059--2000

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.4 1.5 1.6

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel Selection and Qualifications . . . . . . . . . . . . . . . . . . . . . . .

Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Risks from Crushing / Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Risks from Entanglement and Dragging . . . . . . . . . . . . . . . . . . . . . .

Danger Due to Slipping, Tripping, Falling . . . . . . . . . . . . . . . . . . . . .

Risks From Thermal Influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas, Dust, Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Risks From Residual Energy in the Hydraulic System . . . . . . . . . .

Before Commencing Lubrication and Maintenance Work . . . . . . .

Carrying Out Lubrication and Maintenance Work . . . . . . . . . . . . . .

Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 5 5 5 5 7 7 7 9 13 17

2

Oils, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3

--

4 4.1 4.2 4.3 4.4 4.5

Lubrication and Maintenance Schedule . . . . . . . . . . . . . . . . . . .

Initial Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular, Routine Lubrication and Maintenance . . . . . . . . . . . . . . . .

Tips on Maintenance of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures for Maintaining the Crane . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 5 5 9

5 5.1 5.2 5.3 5.4 5.5

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Distributor Gear -- Checking the Oil Level . . . . . . . . . . . . . . .

Pump Distributor Gear -- Changing the Oil . . . . . . . . . . . . . . . . . . . .

Checking the Pump Distributor Gear for Leaks . . . . . . . . . . . . . . . .

Pump Distributor Gear -- Checking the External Screw Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 7 7

6 6.1 6.2 6.3 6.3.1 6.3.2 6.4

Roller Bearing Slewing Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Roller Bearer Slewing Rim . . . . . . . . . . . . . . . . . . . .

Lubricating the Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Screws of the Slewing Rim . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Torque of the Screws . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick--Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 7 7 7 11

7 7.1 7.2 7.3

Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slew Gear -- Checking the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Slew Gear Mechanism Screw Connections . . . . . . .

Slew gear mechanism visual inspection . . . . . . . . . . . . . . . . . . . . . .

3 5 7 7

9

1

Index

8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 10 10.1 10.2 10.3 10.4 10.5 10.6 11 11.1 11.2 11.3 11.3.1 11.4 11.4.1 11.4.2 11.4.3 11.5 11.5.1 11.5.2 11.5.3

059--2000

Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoist 1 and 2 -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . .

Hoist 1 and 2 -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoist 3 -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoist 3 -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reeving Winch -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . .

Reeving winch -- checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoists and Reeving Winch -- Lubricating the Rope Drum Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoists and Reeving Winch -- Checking the Brakes . . . . . . . . . . . . .

Hoists and Reeving Winch -- Checking and Retightening the Screw Connections if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hoist Limit Switch and Lower Limit Switch -- Checking Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 9 11 15 17 19 19 23 25

Luffing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Luffing Gear 1 -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . .

Luffing Gear 1 -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .

Luffing Gear 2 -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . .

Luffing Gear 2 -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .

Luffing Gear 1 and 2 -- Lubricating Rope Drum Bearings . . . . . . .

Luffing Gears -- Checking the Brakes . . . . . . . . . . . . . . . . . . . . . . . .

Luffing Gears -- Checking the Screw Connections and Re--tightening if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 7 11 13 17 17

Derricking Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking Gear -- Checking the Oil Level . . . . . . . . . . . . . . . . . . . . .

Derricking Gear -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking Gear -- Lubricating the Rope Drum Bearings . . . . . . . .

Derricking Gear -- Lubricate Sheaves . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Derricking Gear Brakes . . . . . . . . . . . . . . . . . . . . . . . .

Derricking Gear -- Checking the Screw Connections and Retightening if Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 7 7 9

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Hydraulic Cylinders on the Superstructure and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Boom Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information on Operation and Assembly . . . . . . . . . . . . . .

Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Roller Bearings on the Sheaves . . . . . . . . . . . . . . . .

Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Sheave Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

15 3 3 5 7 7 9 11 13 13 29 29 31 31

2

Index

12 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 12.13.1 12.13.2 12.13.3 12.13.4 12.14 12.14.1 12.14.2 12.15 12.15.1 12.15.2 12.15.3 12.15.4 13 13.1 13.1.1 13.1.2 13.2 13.3 13.4 13.4.1 13.4.2 13.4.3 13.4.4 13.4.5

059--2000

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Hydraulic Oil Reservoir -- Checking the Oil Level . . . . . . . . . . . . . .

3 Hydraulic Oil Reservoir -- Replacing the Return Oil Filter . . . . . . .

5 Hydraulic Oil reservoir -- Replacing the Aeration Filter . . . . . . . . . .

5 Leak Oil Circuit -- Return Oil Filter -- Cleaning the Filter Element .

7 Hydraulic Pump -- Changing the Add--on Filter . . . . . . . . . . . . . . . .

9 Replacing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Checking the Hydraulic System for Leaks . . . . . . . . . . . . . . . . . . . .

13 Hydraulic System -Checking the Flexible Pressure Tubing . . . . . . . . . . . . . . . . . . . . . . .

15 Hydraulic System -- Changing Pressure Hoses . . . . . . . . . . . . . . . .

15 Hydraulic System -- Handling the Hose Couplings . . . . . . . . . . . . .

17 Hydraulic System -Checking the Accumulator Initial Gas Pressure . . . . . . . . . . . . . . .

19 Lower Luffing Mast Back Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 Lower Luffing Mast Back Stops -- Checking the Oil Level . . . . . . .

23 Bleeding Outrigger Cylinder Lower Luffing Mast -Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 Checking the Lower Luffing Mast Back Stops for Leaks . . . . . . . .

29 Lower Luffing Gear Back Stops -Checking the Screw Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 Outrigger Cylinder for Outrigger Strut LF . . . . . . . . . . . . . . . . . . . . .

31 Support Cylinder for Support LF – Check Oil Level, Deaerate Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 Outrigger Cylinder for Outrigger Strut LF -- Filling With Oil (After Repairs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 Outrigger Cylinder Fly Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 Outrigger Cylinder Fly Jib -- Checking for Leaks . . . . . . . . . . . . . .

35 Outrigger Cylinder Fly Jib -- Checking the Oil Pressure . . . . . . . . .

35 Outrigger Cylinder Fly Jib -- Checking the Gas Pressure . . . . . . . .

35 Correcting the Oil and/or Gas Pressure and Filling the O utrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 Heating and Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the System is Functioning Correctly . . . . . . . . . . . . . . . .

Checking the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Diagnosis with the Heating Timer . . . . . . . . . . . . . . . . . . . . . .

Checking the Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching on the Air Conditioning Equipment . . . . . . . . . . . . . . . . .

Servicing the Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . .

Having the Air Conditioning Equipment Checked . . . . . . . . . . . . . .

Error Diagnosis for Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Diagnosis for Heat Conditioning Unit . . . . . . . . . . . . . . . . . . . .

3 3 5 5 17 17 19 19 19 23 23 25

3

Index

14 14.1 14.2 14.2.1 14.2.2 14.3 14.4 14.5

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Limit Switch -- Check Function . . . . . . . . . . . . . . . . . . . . . . . .

Hoist Limit Switch -- Checking Functionality . . . . . . . . . . . . . . . . . . .

Checking the Slip Ring Contacts on the Rope Winches and on the Rotary Joint to the Undercarriage . . . . . . . . . . . . . . . . . . . . .

Precautionary Measures Against Cable Fires . . . . . . . . . . . . . . . . .

Fuse Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 11

15 15.1 15.2 15.3 15.4 15.5

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter -- Emptying the Inspection Glass . . . . . . . . . . . . . . . . . . .

Fuel Filter -- Changing the Filter Element . . . . . . . . . . . . . . . . . . . . .

Draining Off Water and Residue From the Fuel Tank . . . . . . . . . . .

Fuel System, Checking the Lines . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refuelling With a Fuel Tank Filling System (Optional) . . . . . . . . . .

3 5 5 9 9 11

16 16.1 16.2 16.3 16.4 16.4.1 16.4.2 16.5

Cooling, Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . .

Check the Coolant and Top up as Necessary . . . . . . . . . . . . . . . . .

Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change Cooling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change or Replace the Filter Element of the Air Filters . . . . . . . . .

Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 7 11 11 13 15

17 17.1

Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exposed Chrome Surfaces -- Applying Protective Grease . . . . . .

1 1

18 18.1 18.2

Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Windscreen Washing Assembly . . . . . . . . . . . . . . . . .

Filling Up the Supply Tank of the Windscreen Washing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Cab Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3

18.3

059--2000

3 3 3 3 3

3 5

4

Index

19 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.9.1 19.9.2 19.9.3 19.9.4 19.9.5

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Final Drive Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Oil in the Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Front Idlers, Track and Carrier Rollers . . . . . . . . . . . . .

Lubricating the Connecting Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Hydraulic Cylinders on the Undercarriage . . . . . .

Tensioning the Crawler Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Track Pins on the Track Type Undercarriage and Checking the Track Tension in the Case of Running Noises . . . . .

Checking the Screw Connections and Retightening if Necessary Central Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Central Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank of the Central Lubrication System . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 15 17 17 17 19 21 23

20 20.1 20.2 20.3 20.4 20.4.1 20.4.2 20.4.3 20.4.4 20.4.5 20.5 20.5.1 20.5.2 20.6 20.6.1 20.6.2 20.7 20.8 20.9 20.10

Counterweight Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate Ball Bearing Slewing Rim . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Screws of the Slewing Rim . . . . . . . . . . . . . . . . . . . . .

Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slew Gear Mechanism -- Checking the Oil Level . . . . . . . . . . . . . .

Slew Gear Mechanism -- Changing the Oil . . . . . . . . . . . . . . . . . . . .

Slew Gear Mechanism -- Checking the Disc Brake . . . . . . . . . . . . .

Checking the Slew Gear Mechanism Screw Connections . . . . . . .

Slew Gear Mechanism Visual Inspection . . . . . . . . . . . . . . . . . . . . .

Final Drive -- Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rigid Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Drive -- Replace Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rigid Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating the Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Tyre Air Pressure, Tread and Rims . . . . . . . . . . . . . . . . . . . .

Checking Tyre Wheel Nuts, Tightening if Required . . . . . . . . . . . . .

Checking Welds for Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 5 7 7 7 9 11 11 13 13 15 17 17 21 23 25 27 29

21 21.1 21.2

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visual Check -- Superstructure and Crawler Chassis . . . . . . . . . . .

Visual Checks on the Superlift Counterweight Supporting Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visual Check -- Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3

21.3

059--2000

3 3 5 7 7 7 9

3 5

5

Index

059--2000

22 22.1 22.1.1 22.1.2 22.1.3 22.1.4 22.1.5 22.1.6 22.1.7

Examinations of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recurring Crane Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of Load--Bearing Steel Constructions . . . . . . . . . . . . . . .

Inspection of the Disc Wheels (Rims) . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of the Winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 17 61 63 77 79 81 95

23 23.1 23.1.1 23.1.2 23.2 23.2.1 23.3

Central Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Interval and Operating Times . . . . . . . . . . . . . . . . . . . . .

Initiation of an Additional Lubrication Impulse . . . . . . . . . . . . . . . . .

Servicing Central Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .

Filling the Tank of the Central Lubrication System . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 5 7 11 13 15 17

6

Foreword

Foreword Part 2: Lubrication and Maintenance Instructions for the Crane For you, the person responsible for maintenance: we have provided this manual, which includes necessary information for machine lubrication and maintenance, including that for optional equipment.

The information contained in this manual corresponds to the state of machine engineering at the time the manual was drawn up. Deviations in the specifications, diagrams and measurements are possible, due to technical advances.

No responsibility can be accepted for damage caused by maintenance errors.

The headings and corresponding symbols “Danger”, “Caution”, “Note” are used in these maintenance and lubrication instructions as follows: DANGER “Danger” is used for maintenance procedures where failure to observe the stipulations made, may result in death or injury.

Caution “Caution” is used for maintenance procedures where failure to observe the stipulations made may result in damage to the machine or equipment.

NOTE: “Note” is used to indicate an important maintenance procedure or to draw attention to further information.

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Foreword

Explanation of terms Maintenance point Unit or point where the prescribed maintenance is to be carried out (e.g. engine, lubrication point).

Maintenance interval Number of operating hours after which the prescribed maintenance is always to be carried out. So “every 10 hours”, for example, means that the particular maintenance task is to be carried out every 10, 20, 30 etc. operating hours.

General recommendations for lubrication and maintenance tasks −

Clean all nipples, caps and plugs thoroughly before lubrication.

−

Fill up the fuel tank at the end of each working day to prevent condensation forming.

−

Before the drain plugs, filler plugs, check plugs and filters are reinserted, renew the seals.

−

It is easier to change the oil on all units when it is still warm from operation.

−

Ensure that the crane is kept clean at all times, i.e. free of all flammable materials. Particularly following maintenance work on the hydraulics, the engine and the fuel system, the crane must be cleaned thoroughly; this is best done with a steam jet.

−

Each time the crane is cleaned, grease all lubrication points.

Once dry, spray the slew ring toothing with the prescribed grease.

−

Never carry out weld repair work without speaking to our “Customer Service Cranes” department first. Non--professional weld repair work may result in further, severe damage, entailing a great deal of time and money in repairs.

Please contact our “Customer Service Cranes” department immediately if you discover cracks in the steelwork of the crane.

Please give an exact a description as possible of the shape of the crack (Enclose a photo, page from the spare parts catalogue etc.).

059--2002--011_en

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Safety Instructions 1

059--2010--050b

1/17

1

Z 59 992

2/17

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Safety Instructions 1

1

Safety Instructions

1.1

General This Chapter “Safety Instructions” provides a concentrated and general overview of risks that occur when carrying out lubrication and maintenance instructions on the crane.

In the corresponding sections of the lubricating and maintenance instructions these safety instructions are taken up and explained and applied.

Carry out the prescribed adjustment and maintenance work at the specified times and make sure that parts are replaced according to schedule!

Keep all handles, steps, rails, platforms, stages and ladders free of dirt, snow and ice!

Wear safety clothing, goggles, face mask and other safety equipment as required by the working conditions!

Do not allow unauthorised people near the crane during lubrication and maintenance work!

Spare parts must correspond to the technical requirements specified by the manufacturer. Therefore only use original spare parts!

It may be that the crane equipment needs to be inspected and reauthorised for use.

The safety instructions listed for lubrication, maintenance and adjustment work must be observed for all maintenance and repair work.

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1

Z 30 300

Z 29 801

4/17

Z 29 803

059--2010--050b

Safety Instructions 1

1.2

Personnel Selection and Qualifications Maintenance and setting work may only be carried out by specialist personnel!

This especially applies for work carried out on the electric, hydraulic, travel gear and brake systems.

1.3

Particular Hazards At some points, for which the listed hazards are avoided during operation by the use of existing safety clearances or covers, special care is required when carrying out lubrication and maintenance work.

Observe the requirements listed in the corresponding sections of the lubricating and maintenance instructions where the work is described.

1.3.1

Risks from Crushing / Shearing (Safety sign: Z 30 300) The affected points are:

1.3.2

−

Main boom and fly jib

−

Luffing masts

−

Roller bearing slewing rim

−

Slew gear pinion

Risks from Entanglement and Dragging (Safety sign: Z 29 801) The affected points are: −

1.3.3

Ropes for winches / all sheaves / hook blocks / fixed-- and flying bridle

Danger Due to Slipping, Tripping, Falling (Safety sign: Z 29 803) Only the catwalks and ladders described may be used. Here there are sufficient places to hold on to and the catwalks are of a non--slip design (e.g. sanding, checkered plating etc.).

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Safety Instructions 1

1.3.4

Risks From Thermal Influences The affected points are: −

1.3.5

Engine with exhaust system

Gas, Dust, Smoke When refuelling, make sure that there is sufficient ventilation.

1.3.6

Risks From Residual Energy in the Hydraulic System In certain situations, e.g. damage to the hydraulic components such as pipes, hoses, valves etc. the machinery may come to a standstill. A part of the system then remains under pressure.

It is then not always possible to relieve the pressure.

In such cases, an auxiliary crane is required to dismantle the crane.

Such work must only be undertaken through our service department.

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Safety Instructions 1

1.4

Before Commencing Lubrication and Maintenance Work Inform the operating personnel and appoint a supervisor!

Shut off the diesel engine!

The diesel engine may only be left running for lubrication and maintenance work which requires it to be running.

Secure the working equipment by setting it down on the ground, setting on outriggers (make sure that the ground has sufficient load--bearing capacity) or carrying out similar measures to prevent movement!

Make sure that the crane cannot be started by unauthorised persons (e.g. lock cab doors, remove the battery switch and ignition key) and fit corresponding warning plates.

Before carrying out lubrication and maintenance work, remove the battery switch and ignition key from the electrical system.

Clean the crane, in particular connections and unions, to remove any oil, fuel or other agents before commencing maintenance!

Do not use aggressive cleaners! Use non--fibrous cleaning cloths!

Before cleaning the crane with water or steam jet (high--pressure cleaner) or other cleaners, cover/tape up all openings which might be adversely affected by water, steam or cleaning agents (from a safety or functional point of view) (e.g. switch cabinets)!

After cleaning, remove the covers/taping completely and check to make sure that the areas are free of water!

After cleaning, check all fuel, engine oil--, and hydraulic oil lines for leaks, loosened connections, sheared points and damage!

Rectify any faults immediately.

As oil can be emitted during maintenance and assembly work, suitable collecting vessels and binding agents must be placed ready.

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1

Z 18 094

10/17

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Safety Instructions 1

Fire prevention (Z 18 094) Preventative measures against the risk of fire

¡ Keep the crane clean, in particular from combustible materials. Following maintenance work on the hydraulic system, the engine and fuel system, clean the crane thoroughly.

Remove all residues of oil, fuel or cleaners.

© After cleaning the engine compartment, all − fuel lines − engine oil lines − hydraulic oil lines for leaks, loosened connections, shearing points and damage.

Rectify any damage found immediately.

¢ Check all electrical lines, plug connections and connection clamps for loose fastenings and damage.

Rectify any damage found immediately.

£ Check the turbo--charger mounting..

Check the exhaust-- and air inlet lines as well as lubricant feed and return lines for leaks. Rectify any faults that are found immediately.

¤ Fire extinguishers must be filled and ready for use.

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1

12/17

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Safety Instructions 1

1.5

Carrying Out Lubrication and Maintenance Work To carry out lubrication and maintenance work, a suitable workshop and equipment setup is required.

Observe the regulations and instructions in the operating instructions.

The term “operating instructions” refers to the operating instructions and the lubrication and maintenance instructions.

Cordon off the required area generously.

Individual parts and larger assembly groups must be secured on lifting devices when being replaced and must be secured to prevent any risk of damage or injury. Only use suitable lifting gear that is fully operational and has sufficient load--bearing/lifting capacity! Do not stand, walk or work under suspended loads.

Appoint only experienced personnel to attach loads and provide signals to crane operators! The banksman must be within sight of the operator or have verbal contact with him (refer to section 1 “Safety Instructions” in the operating instructions of the crane, part 1 of these documents).

When carrying out assembly work above head height, use the climbing aids and work platforms provided or other such equipment which is designed with safety in mind. Never use machine parts to help you climb up the crane equipment. Make sure that you are wearing a safety harness when working at height on the crane.

Always tighten up loose screw connections during maintenance and servicing work.

If safety equipment needs to be dismantled during maintenance work, it must be reassembled and checked immediately following completion of such work.

Make sure that all operating agents and other consumables as well as replacement parts are disposed of in an environmentally-friendly and safe manner.

Make sure that oily rags and easily combustible materials are stored away from fire hazards and are removed appropriately.

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Safety Instructions 1

The electrical equipment of the crane must be inspected / checked regularly. Deficiencies such as loose connections and burned cables must be rectified immediately.

Work on electrical systems or operating media may only be carried out by qualified electricians or trained personnel under the supervision of a qualified electrician in accordance with electro--technical regulations.

Use only original fuses with the prescribed current strength! For faults in the electrical power supply, shut down the crane immediately.

Check all leads, hoses and unions of the hydraulics-- and pneumatic system regularly for leaks and externally recognisable damage. Rectify (have rectified) any damage immediately.

Work on the hydraulic equipment may only be carried out by persons with special knowledge and experience in hydraulics (the system must be depressurised)!

Sprayed oil can lead to injuries and fires!

When handling oils, grease and other chemical substances, observe the safety regulations relevant to the product.

Caution when handling hot consumables (risk of scalding and burns).

Make sure that no tools are forgotten following the completion of work! Falling or projected tools are a DANGER TO LIFE AND LIMB! Observe the prescribed schedules for routine inspections (see section 22.1)!

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1.6

Repair Work These lubrication and maintenance instructions do not contain information on how to carry out repair work.

If required, contact our customer service department.

Nevertheless, below are some general safety instructions in this regard.

059--2010--050b

−

Only carry out welding, burning and grinding work on the crane when express permission has been given to do so (e.g. there can be a high risk of fire and explosions).

−

Before welding, burning and grinding, clean the crane and its surroundings of dust and combustible materials and ensure that sufficient ventilation is provided (risk of explosions)!

−

When working on the hydraulics system, sections of the system that need to be opened must be depressurised before work is commenced.

−

Do not, without permission from the manufacturer, make any changes, additions or modifications to the crane, which might impair the safety of the crane! This also applies to the installation and setting of safety devices and --valves and to the welding of load--bearing components!

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Oils, Lubricants and Capacities 2

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2

2/11

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Oils, Lubricants and Capacities 2

2 Filling point

Section 5.1 Drive Motor

With filter change Section 5.3 Pump distributor gear

Oils, Lubricants and Capacities

Capacities in litres (in US gallons)

28.00 (7.39) max.

34.00 (8.98)

7.00 (2.51)

Section 6.1 Roller bearing slewing rim (lubrication by the central lubrication system)

--

Section 6.2 Slew ring toothing

--

Section 8.2, 9.2 transmission, hoists, luffing gear

9.20 (2.43 each)

Section 8.6 transmission reeving winch

1.10 (0.29)min

Section 8.7, 9.5 Bearing, hoist, Reeving Winch, luffing gear

--

Fuels and lubricants

Ambient temperature range

Initial fill--up

Quality regulations See fuels and lubricants regulations in the operating and maintenance instructions for the engine OM 501 LA, sheet 225.6 or 228.5 and in the Mercedes--Benz fuels and lubricants regulations.

Engine oil 5W -- 30 ACEA E4--98 API CF--4

Mercedes--Benz Sheet 228.5 or 228.51

Transmission oil ISO VG 220 DIN 51517.3 -- CLP

“Shell Omala 220”

High pressure grease NLGI class 2 DIN 51825, part 3 KP2K

“Shell Alvania EP 2”

Special adhesive grease

--25°C to + 40°C --13°F up to +104.0 °F

“CEPLATTYN Eco S” item no 022 183 12

Transmission oil ISO VG 220 DIN 51517.3 -- CLP

“Shell Omala 220”

High pressure grease NLGI class 2 DIN 51825, part 3 KP2K

“Shell Alvania EP 2”

The specified capacities are approximate values. For an accurate measurement, service and operating personnel must carry out checks using the inspection points, inspection plugs, dipsticks and inspection windows provided.

Additional consumables specifications on request. If consumables are used which do not satisfy these requirements, damage may result for which we shall not be held liable even within the warranty period.

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Oils, Lubricants and Capacities 2

Continued: Oils, Lubricants and Capacities Filling point

Section 10.2 Transmission, derricking gear Section 11.1 Back stroke locking cylinder: Main Boom, Fly jib, superlift mast (lubrication by the central lubrication system) Section 11.2 Lubricating nipple: main boom, (foot bearing lubrication by central lubrication system) fly jib, superlift mast Lubricating nipplefoot baring: A--frame superlift mast (lubrication by central lubrication system) Section 11.3 lubricating nipple, hook blocks Section 11.4 Ropes Chapter 11.5 Rope sheave bearing

Capacities in litres (in US gallons)

Fuels and lubricants

Ambient temperature

Initial fill--up

Quality regulations

16.50 (4.36)

Transmission oil ISO VG 220 DIN 51517.3 -- CLP

“Shell Omala 220”

--

Corrosion protection spray

“DECORDYN 350” Item no. 604 106 40

--25°C to + 40°C --13°F up to + 104.0 °F

--

--

“Shell Alvania EP 2”

High pressure grease NLGI class 2 DIN 51825, part 3 KP2K

---

--

Spray grease (special adhesive grease) Low--temperature grease NLGI class 2 DIN 51825, part 3 KE2K--50

--25°C to + 40°C --13°F up to + 104.0 °F

--25°C to + 40°C --13°F up to + 104.0 °F --50°C to +40°C --13°F to + 104.0°F

“Shell Alvania EP 2”

“Shell Alvania EP 2” “Elaskon 30” ID No. 240 910 12 “Klüber ISOFLEX LDS 18 Spezial A” ID No. 609 441 40

The specified capacities are approximate values. For an accurate measurement, service and operating personnel must carry out checks using the inspection points, inspection plugs, dipsticks and inspection windows provided.

Additional consumables specifications on request. If consumables are used which do not satisfy these requirements, damage may result for which we shall not be held liable even within the warranty period.

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Oils, Lubricants and Capacities 2

Continued: Oils, Lubricants and Capacities Filling point

Roller set in the Superstructure (lubrication by the central lubrication system Section 12.6 Hydraulic system (with tank)

Capacities in litres (in US gallons)

--

Fuels and lubricants

Initial fill--up

Quality regulations High pressure grease NLGI class 2 DIN 51825, part 3 KP2K Hydraulic oil ISO VG 32 DIN 51524.3 -- HVLP

950,00 (250.96)

Ambient temperature

Hydraulic oil ISO VG 46 DIN 51524.3 -- HVLP

--25°C to +40°C --13°F to + 104.0°F

“Shell Alvania EP 2”

--25°C to 25°C --13°F to 77°F

--10°C to 30°C +14°F to 86°F

“Shell Tellus TX 46”

Hydraulic oil ISO VG 68 DIN 51524.3 -- HVLP Section 12.13 Support cylinder, Lower luffing mast Sect. 12.14 Support cylinder, outrigger strut Section 12.15 Outrigger cylinder, fly jib Section 14.3 Slip ring contacts, rope drum Section 15 fuel system Superstructure Fuel tank in the undercarriage

17.00 (4.49) 2.0 (0.528)

Hydraulic oil ISO VG 32 DIN 51524.2 -- HLP

--5°C to 40°C +23°F to 104°F

--25°C to +40°C --13°F to + 104.0°F

“Shell Tellus oil 32”

je 2.91 (0.77 each)

Hydraulic oil ISO VG 46 DIN 51524.2 -- HLP

--

Contact spray

--25°C to +40°C --13°F to + 104.0°F

Contact spray 61 ID No. 174 427 40

450.00 (118.80)

Diesel fuel See engine’s fuel regulations sheet 132.3

--25°C to +40°C --13°F to + 104.0 104.0°F F

Diesel fuel

950.00 (250.96)

“Shell Tellus TX 46”

The specified capacities are approximate values. For an accurate measurement, service and operating personnel must carry out checks using the inspection points, inspection plugs, dipsticks and inspection windows provided.

Additional consumables specifications on request. If consumables are used which do not satisfy these requirements, damage may result for which we shall not be held liable even within the warranty period.

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Oils, Lubricants and Capacities 2

Continued: Oils, Lubricants and Capacities Filling point

Section 16 Cooling system -- engine -- equalising tank

Section 19.2 Undercarriage, final drive -- transmission without brake

Capacities in litres (in US gallons) 24.00 (6.34) 16.50 (4.36) 7.50 (1.99)

Fuels and lubricants

Ambient temperature

Initial fill--up

Quality regulations

See consumables regulations for the engine Sheet 310

je 22.00 (5.80 each)

Transmission oil ISO VG 220 DIN 51517.3 -- CLP

Section 19.3 undercarriage, central lubricating system (idler, bottom rollers top rollers)

--

Grease paste NGLI class 1

Section 19.5 Undercarriage, hydraulic cylinder of the track tension equipment of the outriggers

--

Corrosion protection spray

50 % water / 50 % glysantine Sheet 325.2

“Shell Omala 220”

--25°C to +40°C --13°F to + 104.0°F

“GLEITMO 805K--1” ID No. 634 758 40

“DECORDYN 350” Item no. 604 106 40

The specified capacities are approximate values. For an accurate measurement, service and operating personnel must carry out checks using the inspection points, inspection plugs, dipsticks and inspection windows provided.

Additional consumables specifications on request. If consumables are used which do not satisfy these requirements, damage may result for which we shall not be held liable even within the warranty period.

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Oils, Lubricants and Capacities 2

Continued: Oils, Lubricants and Capacities Filling point

Sect. 20.2 Counterweight vehicle, differential and final drive Disc brake Sect. 20.3 Counterweight vehicle, grease nipple for the ball bearing slewing Sect. 20.4 Counterweight vehicle, pivoting transmission Section 20.5 dolly slew ring toothing

Capacities in litres (in US gallons) je 95.00 (25.08 each) 0.25 (0.06)

--

je 3.5 (0.92 each)

--

Fuels and lubricants

Ambient temperature

Initial fill--up

--25°C to +40°C --13°F to + 104.0°F

“Mobil Mobilube HD--A 85W--90”

Quality regulations Transmission oil SAE 90 MIL--L--2105B API--GL 5--90 Hydraulic oil ISO VG 32 DIN 51524.2 -- HLP High pressure grease NLGI class 2 DIN 51825, part 3 KP2K Transmission oil ISO VG 150 DIN 51517.3 -- CLP Special adhesive grease

“Shell Telllus 32”

“Shell Alvania EP 2”

--25°C to +40°C --13°F to + 104.0°F “Mobilgear 629”

“CEPLATTYN Eco S” item no 022 183 12

The specified capacities are approximate values. For an accurate measurement, service and operating personnel must carry out checks using the inspection points, inspection plugs, dipsticks and inspection windows provided.

Additional consumables specifications on request. If consumables are used which do not satisfy these requirements, damage may result for which we shall not be held liable even within the warranty period.

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4.5 059--2041--95

Item

Maintenance List Task

Consumables Section 2

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

5 5.1 5.2

x

x

x x

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Lubrication and Maintenance Schedule 4

Drive Engine: MERCEDES BENZ (OM 501 LA) see operating instructions of the engine manufacturer Pump distributor gear -- checking the oil x level 5.3 Pump distributor gear -- changing the oil 1x 5.4 Checking the Pump Distributor Gear for x Leaks 5.5 Pump distributor gear -- checking the exx ternal screw connections 6 Roller Bearing Slewing Rim 6.1 Lubricating the Roller Bearer Slewing Rim x 6.2 Lubricating the ring gear x 6.3 Checking screwed connections 7 Slew gear 7.1 Slew Gear Mechanism -- Checking the Oil x Level 7.2 Slew gear mechanism -- changing the oil 1x x 7.3 Slew Gear -- Checking the Brake 7.4 Checking the slew gear mechanism screw x connections 7.5 Slew gear mechanism visual inspection x 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

8 8.1 8.2 8.3 8.4 8.5 8.6 8.7

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

x x x x x

x

x x x x x x

10/16

Lubrication and Maintenance Schedule 4

Hoists Hoists 1 and 2 -- checking the oil level x Hoist 1 and 2 -- changing the oil 1x x Hoist 3 -- checking the oil level x Hoist 3 -- changing the oil 1x x Reeving winch -- checking the oil level x Reeving Winch -- Checking the Oil 1x Hoists and reeving winch -- lubricating the x x bearing 8.8 Hoists and reeving winch -- checking the brakes 8.9 Hoists and reeving winch -- checking and x retightening the screw connections if necessary 8.10 Hoist limit switch and lower limit switch checking functionality 9 Luffing Gears 9.1 Luffing gear 1 -- checking the oil level x 9.2 Luffing Gear 1 -- Changing the Oil 1x x 9.3 Luffing gear 2 -- checking the oil level x 9.4 Luffing gear 2 -- changing the oil 1x x 9.5 Luffing gear -- lubricating bearings x x 9.6 Luffing gear -- checking brakes 9.7 Luffing gear -- checking screwed connecx tions 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

10 10.1 10.2 10.3

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

x x x

x

x x

x x

x x

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Lubrication and Maintenance Schedule 4

Derricking Gear Derricking gear -- checking the oil level x Derricking Gear -- Changing the Oil 1x x Derricking Gear -- Lubricating the Rope Drum Bearings.

10.4 Checking the derricking gear brakes 10.5 Derricking Gear -- Checking the Screw x Connections and Retightening if Necessary 11 Equipment 11.1 Maintaining the Hydraulic Cylinders on the x Superstructure and Equipment -- main boom -- Superlift mast -- luffing fly jib -- mounting cylinder 11.2 Lubricating the boom bearings x 11.3 Hook blocks -- lubricating bearings x 11.4 Ropes 11.4.1 Lubricating the Ropes 11.4.2 Cleaning the Ropes 11.5 Sheaves 11.5.1 Checking the sheave bearing x 11.5.2 Check sheaves x 11.5.3 Lubricating the sheave bearing 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

12 12.1

x x x x

x

x x x

x

x

x

Lubrication and Maintenance Schedule 4

12/16

Hydraulic System Hydraulic Oil Reservoir -- Checking the Oil x Level 12.2 Hydraulic oil reservoir -1x 1x 1x x replacing the return oil filter 12.3 Hydraulic Oil Reservoir -1x 1x 1x x Replacing the Aeration Filter 12.4 Return oil filter -- cleaning the filter x element 12.5 Hydraulic Pump -- Changing the Add--on x Filter 12.6 Change hydraulic oil 12.7 Bleeding the Hydraulic System 12.8 Checking the hydraulic system for leaks x 12.9 Hydraulic System -x Checking the Flexible Pressure Tubing 12.10 Hydraulic system -At least every 6 years replacing the flexible pressure tubing 12.11 Hydraulic system -- checking accumulator x gas preliminary tension 12.12 Lower luffing mast back stops 12.12.1 Lower luffing mast back stops -x checking the oil level 12.12.2 Lower Luffing Mast Back Stops -- Changing the Oil 12.12.3 Checking the Lower luffing mast back stops for leaks 12.12.4 Support cylinders luffing mast -- checking screwed connections 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6* x x x x x

x

x

x

Lubrication and Maintenance Schedule 4

13/16

12.14 Outrigger Cylinder Fly Jib 12.14.1 Outrigger cylinder fly jib -- checking for leaks 12.14.2 Outrigger cylinder fly jib -- checking the oil pressure 12.14.3 Outrigger cylinder fly jib -- checking the gas pressure 12.14.4 Outrigger cylinders fly jib -- correction of the oil and / or gas pressure and filling the outrigger cylinder 13 Heating and Air conditioning 13.1 Heating -- checking function x outside heating period 13.2 Checking the Water Level x daily during heating period 13.3 Replacing the Heat Exchanger Every 10 years 13.4 Air Conditioning 13.4.1 Air conditioning equipment -- checking x function 13.4.2 Servicing the Air Conditioning Equipment x -- Visual Inspection 13.4.3 Air conditioning equipment -- have at least 2x per year checked in garage 14 Electrical System 14.1 Checking lighting system x 14.2 Checking the limit switch 14.2.1 Lower limit switch -- function test x 14.2.2 Hoist limit switch -- function test x 14.3 Winches -- checking slip ring contacts x 14.4 Precautionary Measures Against Cable x Fires 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

15 15.1 15.2 15.3 15.4 16 16.1 16.2 16.3 16.4

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

x x x x

x x x x

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Lubrication and Maintenance Schedule 4

Fuel System Emptyfuel filter -- inspection glass Fuel filter -- replace filter element Fuel tank -- draining off residue x Fuel System, Checking the Lines x Cooling-- intake and exhaust system Cooling system -- checking fluid level x Check and clean cooling system x Cooling system -- change coolant see operating instructions of the engine manufacturer Cleaning and replacing the air filter elat least every 2 years ement 16.5 Exhaust System Visual Inspection x 17 Piston Rods 17.1 Lubricate exposed chromium surfaces 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*

18 18.1

x

x x x

x x

x x

Lubrication and Maintenance Schedule 4

15/16

Crane Operator’s Cab Windscreen washing assembly -- checkx ing the function 18.2 Windscreen washing assembly -- checkx ing supply tank, filling as required 19 Undercarriage 19.1 Checking the Final Drive Oil Level x 19.2 Changing the Oil in the Final Drive 1x x 19.3 Lubricating front idlers, track and carrier Lubrication by central lubricating system rollers 19.4 Lubricating the connecting pins 19.5 Servicing the hydraulic cylinder x 19.6 Track group -- checking track tension, x tighteningas required 19.7 Track group -- lubricating link pins x 19.8 Checking screwed connections x x 19.9 Central lubricating system Servicing, filling, setting and troubleshooting as required 20 Counterweight Dolly 20.1 Lubricate ball bearing slewing rim 20.2 Lubricating the ring gear x 20.3 Checking the screws of the slewing rim 20.4 Slew gear 204.1 Slew Gear Mechanism -- Checking the Oil x Level 20.4.2 Slew gear mechanism -- changing the oil 1x x 20.4.3 Slew gear mechanism -- checking the disc brake 20.4.4 Checking the slew gear mechanism screw x connections 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

059--2041--95

Item

Task

Consumables Section 2

20.4.5 20.5 20.6 20.7 20.8 20.9 21 21.1

Slew gear mechanism -- visual check Final drive -- checking oil level Final drive -- changing oil Check tyre air pressure, tread and rims Checking tyre wheel nuts, tightening if required Check welds for cracks Visual Checks Visual check -- superstructure and crawler chassis Visual check -- counterweight framework Visual check -- equipment Examinations of the Crane Repeated crane inspections

Interval (operating hours) 1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6* x x x x 1x

1x

1x

x x

x

x x

x x

x x x

x x

x

16/16

Lubrication and Maintenance Schedule 4

21.2 21.3 22 22.1 21.2 21.3 1* -- daily before commencing work 2* -- weekly 3* -- monthly 4* -- at least once a year 5* -- as required, -- for main boom and fly jib components as well as SL mast components before each erecting procedure 6* -- With regard to this maintenance interval, observe also the cautionary notes in section 11.9

Lubrication and Maintenance Schedule 4

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4

2/16

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Lubrication and Maintenance Schedule 4

4

Lubrication and Maintenance Schedule

4.1

Initial Lubrication and Maintenance Lubrication and maintenance that occurs before the regular, routine tasks, are marked on the maintenance list with “1X”.

At the specified point, they must be carried out once.

4.2

Regular, Routine Lubrication and Maintenance Regular, routine lubrication and maintenance are marked on the maintenance list with “X”.

They must be carried out at the specified point and then repeated regularly at this interval.

For example, an “X” in the column 250 operating hours means that the corresponding work must be carried out every 250 operating hours, i.e. after 250, 500, 750 etc. operating hours.

The following details about maintenance intervals apply to all machines that are exposed to normal operating and environmental influences. For special operations, the maintenance intervals must be adapted to the operating conditions.

For larger maintenance tasks, for example “every 1000 operating hours”, other maintenance and servicing work must of course also be carried out which occurs at smaller intervals and which coincides with the larger maintenance task.

For the above example, this means that “every 500 operating hours” and intervals shorter than this must be carried out at the same time.

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4

4/16

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Lubrication and Maintenance Schedule 4

4.3

Tips on Maintenance of the Crane The objective of maintenance work on the crane is to:

4.4

−

ensure operational readiness

−

maintain performance levels

−

avoid down times

−

maintain the value of the crane

−

reduce repair costs

Measures for Maintaining the Crane 1. Inspections of the condition of the crane Inspections of the condition of the crane are visual checks at regular intervals in accordance with the lubrication and maintenance schedule by the crane driver.

For example: − Checking the oil levels and oil quality − Checking the display and monitoring instruments − Checking the tank and filtering systems to ensure that they are clean and fully functional − Checking hoses and lines for leaks and damage − Checking bearings for sufficient lubrication and abnormal play − Checking drive mountings (transmission, engines, valves) − Checking ropes for lubrication, dirt and wear These regular visual checks can often detect damage early on, allowing problems to be quickly rectified.

This means that down times are avoided during operation of the crane.

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4

6/16

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Lubrication and Maintenance Schedule 4

2. Preventative Maintenance Preventative maintenance involves measures that are carried out as part of “inspections of the condition of the crane”.

Inspections of the condition of the crane enable wear, damage or defects to be recognised and remedied early on.

This can help avoid downtimes and repairs during regular operation of the crane.

The tasks involved in inspections of the crane condition include visual and functional checks of the assembly groups of the superstructure and chassis as well as a desired / actual value comparison of measurable variables.

These tasks must be carried out by a sufficiently trained specialist.

Various measures must be carried out.

For example: − Checks on the safety devices − Comparison of desired / actual values in the hydraulics and electrical systems. − Checks on the function of the hydraulic and electrical system. − Checks on the nitrogen charge pressure of the integrated accumulator. − Quality analysis of the hydraulic and transmission oil. − Checks on the individual drives for noise and vibration levels. − Checks on the bearings for damage and wear. − Checks on the crane equipment for damage and wear. − Checks on the ropes for damage and wear.

The exact visual and functional checks with the corresponding results must be entered in the “crane inspection log book for crawler--mounted cranes”.

A report is drawn up for these inspections. This inspection report then forms the basis for any repair work that may be required.

Important for the success of such measures is the correct implementation, the regular repetition and documentation of the inspections.

For information in this regard, please contact our customer service department in Zweibrücken, Germany.

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4

8/16

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Drive 5

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1/9

5

1 2-- FRONT

C

Crankshaft centre

DB 616 240 00 18 DB 300 240 05 18

B

3 Z 55 489

1

2

Z 55 490

2/9

059--2050--050a_en

Drive 5

5

Drive Danger of burning and scalding!

Observe the cooling--off period of 60 minutes before undertaking maintenance in the engine area.

5.1

Engine Please see the instructions and notes on maintaining the engine OM 501 LA given in the operating instructions from the engine manufacturer.

The operating instructions for the engine and a maintenance log-book are enclosed in Part 4 of this service literature.

Legend: (Z 55 489) 1 3

Dipstick Oil drain

Legend: (Z 55 490) 1 2

Dipstick Oil filler

Starter During cleaning work it must be observed that −

when fitted, no water jet is directly aimed the starter and,

−

when removed, the starter is cleaned with the mouth of the bearing pointing downwards, i.e. suspended,

to ensure that no moisture can penetrate the interior of the solenoid.

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3/9

5

2

3

2

1

4/9

Z 39 227

059--2050--050a_en

Drive 5

5.2

Pump Distributor Gear - Checking the Oil Level (Z 39 227) 1.

For checking the oil level screw out the filler plug with dip stick (2). The oil should reach the marking “Max”.

Under no circumstances must the oil fall below the min. mark.

Top up the oil, see Section 5.3, “Changing the Oil”.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and the pump distributor gear dismantled.

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5

2

3

2

1

6/9

Z 39 227

059--2050--050a_en

Drive 5

5.3

Pump Distributor Gear - Changing the Oil (Z 39 227) 1.

Remove drain plug (1) and drain off the oil into a suitable container.

2.

Remove filler plug with oil dip stick (2).

3.

Rinse the pump distributor gear with flushing oil (clean, warmed oil) to remove all traces of dirt from the pump distributor gear.

4.

Clean drain plug (1) and screw back in.

5.

Fill oil into the gear.

6.

Check the oil level using the dip stick.

Oil level must reach “Max” marking. After the pump distributor gear has run for 15 minutes, check the oil level.

5.4

7.

Clean filler plug with oil dipstick (2) back in.

8.

Clean the aeration filter (3).

Checking the Pump Distributor Gear for Leaks Check the flange connection for leaks.

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5

1.1 1.2

2 4

3

Z 42 122

8/9

059--2050--050a_en

Drive 5

5.5

Pump Distributor Gear - Checking the External Screw Connections (Z 42 122) Check the external screws on the gear housing and on the frame mount. Replace and/or tighten any missing or loose screws.

Screws for the pump and gear housing mount: No.

Size

1.1

M 16 x 1,5 x 45

10.9

280

206.53

with Loctite 222 X

1.2

10.9

280

206.53

X

10.9

108

79.66

X

3

M 16 x 1,5 x 40 M 12 x 1,5 x 40 M 20 x 55

10.9

510

376.16

4

M 16 x 40

10.9

265

195.45

2

059--2050--050a_en

Quality (Nm)

(lbf--ft)

X

9/9

Slew Ring Connection 6

059--2060--104

1/11

6

1 Z 42 123

Z 62 537

2/11

059--2060--104

Slew Ring Connection 6

6

Roller Bearing Slewing Rim When maintenance work is being carried out, there is a risk of being dragged in at the slew gear pinion (Z 62 537) -- in spite of the protective covering.

Observe the warning sign which is attached there!

Risk of crushing/shearing.

When carrying out the tasks described below, ensure that no maintenance personnel, with the exception of the crane operator (in the cab), are situated in the danger areas between the main boom, superstructure and chassis or between the superstructure and chassis once the engine has been switched on to carry out the necessary slewing and luffing movements.

6.1

Lubricating the Roller Bearer Slewing Rim (Z 42 123) The slew ring connection must be lubricated every 100 operating hours and following every cleaning.

The lubricating nipple (1) is located on the left--hand side of the superstructure outside.

If the crane is equipped with the option “Superstructure central lubricating system”, then this nipple is not present, and the lubrication is accomplished with the central lubricating system.

If the crane is cleaned using a steam jet cleaning machine or using a fixed jet of water, care must be taken to ensure that water does not penetrate into the slew ring connection.

The slew ring connection must subsequently be lubricated.

Always relubricate adequately so that a collar of grease forms around the entire extent of the gaps in the bearings.

When the superstructure is slewing slowly, lubrication can be undertaken from a safe location.

The crane operator and the person undertaking the lubricating must however always remain in communication by sight or by speech.

059--2060--104

3/11

6

Z 62 517

4/11

059--2060--104

Slew Ring Connection 6

6.2

Lubricating the Ring Gear (Z 62 517) Regularly lubricate the ring gear with special adhesive grease; at the latest, however, when there are exposed areas in the tooth flanks. See section 2, “Oils, Lubricants and Capacities”.

059--2060--104

5/11

6

2 1 3

.

“X”

”Y”

1

Z 39 230

6/11

059--2060--104

Slew Ring Connection 6

6.3

Checking the Screws of the Slewing Rim A visual inspection of the screws on the slewing rim must be undertaken before every erection procedure or at least once a week.

6.3.1

General (Z 39 230) Damage or material fatigue of the screws is ruled out under the following circumstances: 1.

Appropriate use of the crane in accordance with the operating instructions and the lifting capacity tables.

2.

Regular inspections of the screws in accordance with the procedure described below.

In the case of the crane being subject to extraordinary loading or in the case of an accident, consult our service department.

If the slewing rim is to be replaced, all the screws must also be replaced.

6.3.2

Checking the Torque of the Screws (Z 39 230) The preliminary tension of the screws must be ensured by regularly retightening to the prescribed torque The surface under the head and the thread of all fixing bolts must be lubricated with roller bearing grease “KP2K” before they are screwed in.

Reusing screws for cranes which are dismantled for transport purposes (without quick release) --

In principle the fixing bolts of the slewing rim must not be reused!

Observe the criteria on the following page.

059--2060--104

7/11

6

2 1 3

.

“X”

”Y”

1

Z 39 230

8/11

059--2060--104

Slew Ring Connection 6

The following criteria provide the stipulations for reusing them: (Z 39 230) 1.

Free from cracks − Perform an inspection for cracks.

2.

No heavy corrosion − Slight rust deposits must be removed before assembly.

3.

No channelling on the thread and on the surface under the head of the screw − Further treatment of light scoring is permissible ! − Channelling on the slewing rim in the area under the head must always be smoothed.

4.

No plastic deformation − For hexagon screws, the thread pitch must be measured over at least 10 threads “X”, including the first, thread “Y” which is not screwed in, from the shank on !

Checking the screws should be undertaken by a customer service specialist from Terex--Demag GmbH. Mark the bolts and the respective nuts with numbers before dismantling the crane.

If defective screws are found during the check, the position of the screws on the slewing rim is important in determining the cause of this.

Pos.

Fitting location

Size

1

OW / RDV

M 48 x 285

2

SVB / RDV

M 48 x 190

Torque (Nm)

(lbf--ft)

Spare part no.

126 134 99

7500

5531.71

179 635 12

SVB = Quick--disconnect RDV = Slew Ring Connection OW = Superstructure

059--2060--104

9/11

6

B 3

3 B

1

1 2 1 Schnitt B--B Cross section B--B

1

Z 57 112

10/11

059--2060--104

Slew Ring Connection 6

6.4

Quick-- Disconnect Lubrication Lubricate the quick release using the three lubricating nipples (1, Z 57 112).

Check the screws (Z 57 112) No.

059--2060--104

Torque

Size (Nm)

(lbf--ft)

2

M 20 x 1.5 x 100

500

368.78

3

M 12 x 45

108

79.66

11/11

Slew Gear 7

059--2070--050c_en

1/7

7

Z 29 081

2/7

059--2070--050c_en

Slew Gear 7

7

Slew Gear When maintenance work is being carried out, there is a risk of being dragged in at the slew gear pinion (Z 29 081) -- in spite of the protective covering.

Observe the warning sign which is attached there!

The slew gear mechanism has circulatory lubrication and is connected to the hydraulic oil circuit so that a separate oil level cheek and oil change is not required.

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7

1

2

Z 62 742

4/7

059--2070--050c_en

Slew Gear 7

7.1

Slew Gear - Checking the Brake (Z 62 742) Slew gear mechanism -- checking the disc brake Check the slew gear brake to make sure it is not leaking and that it is functioning perfectly.

In order to ensure a perfect braking effect, the disc brake on the slew gear must be checked at regular intervals.

If operation is not perfect, the defective parts must always be replaced and the brake cleaned before taking up work again.

This work may only be undertaken by a trained specialist.

In the case of work with insufficient braking effect,

RISK

OF

A

C C I D E N T S!

Releasing the disc brake without the tension arrangement can lead to serious injury.

Proceed as follows to check the slew gear brake:

059--2070--050c_en

1.

Start the superstructure engine and set to approx. 1200 min --1 (1200 rpm).

2.

Pull out plug from the solenoid valve Y8805 (2, Z 62 742).

This will prevent the brakes from opening.

3.

Actuate pressure increase, see Part 1 Sect. 7 page 7

4.

Slowly (not jerkily) actuate the “Slew gear” control lever (3) in the slewing direction to the right or left.

5.

Hold the “Slew gear” control lever (3) for approx. 10 sec. in the fully selected position and then release the control lever.

The crane must not however slew into the steered direction.

6.

If the crane remains in the original position, the slew gear brake is in order.

If not, the slew gear brake must be checked.

7.

Lower the speed back down, insert the plug onto the solenoid valve Y8805 and deactivate the pressure increase.

5/7

7

9

7

Z 55 496

6/7

059--2070--050c_en

Slew Gear 7

7.2

Checking the Slew Gear Mechanism Screw Connections (Z 55 496) As all fixing bolts are secured using Loctite, retightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

All screws without mechanical lock fittings must be secured with “Loctite 245”.

The thread and surface under the head of all screws with mechanical lock fittings must be lightly oiled for tightening purposes.

Torques of the gear housing screws: Size

Quality

M8

8.8

21

15.49

M 12

8.8

74

54.58

m16

8.8

177

130.55

Torque Ma (Nm) (lbf--ft)

with Loctite type

0245

Torques of the fixing bolts for the hydraulic motor and gear housing mount: No.

7.3

Size

Quality

Torque (Nm)

(lbf--ft)

7

M 16 x 60

10.9

265

195.46

9

M 12 x 35

10.9

108

79.66

Slew gear mechanism visual inspection (Z 55 496) Check the gear housing, lines and neck bearings for leaks.

The slew gear brake is maintenance--free.

If there are function errors, thermal stress or any repairs to the slew gear brake discs, springs and sealing elements must always be exchanged.

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7/7

Hoists 8

059--2080--083a

1/25

8

A

Ansicht “A” View “A”

1

Z 39 233

2/25

059--2080--083a

Hoists 8

8

Hoists Measures to achieve safe operating periods: In accordance with the German accident prevention regulations for winches, hoist and traction equipment, VBG 8, the operator of the crane is responsible for ensuring that a crane inspection is carried out at least once a year (see also ISO 9927--1).

The spent share of the theoretical service life for the winches must also be determined. The crane operator must employ an officially certified specialist for the purpose if necessary.

Where accident prevention regulations of the employer’s liability insurance association apply, this is required by law.

Outside of this area, the crane manufacturer recommends that the procedure listed is also observed.

See Section 22, “Examinations of the crane”, of these lubrication and maintenance instructions Risk of dragging.

When carrying out maintenance, inspection and assembly work, special care must be taken in this area as there is a risk of being caught and dragged into the equipment between the winches and hoist ropes.

8.1

Hoist 1 and 2 - Checking the Oil Level (Z 39 233) Unscrew oil level check plug (1).

The oil level is correct when the oil comes up to the inspection opening when the crane is horizontal.

Top up the oil if necessary.

Screw oil level check plug (1) back in.

Top up the oil, see Section 8.2, “Changing the Oil”.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

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8

A Einzelheit “X” Detail “X”

x

6

7 8

9

Ansicht “A” View “A”

3

1 2 Z 53 749

4/25

059--2080--083a

Hoists 8

8.2

Hoist 1 and 2 - Changing the Oil (Z 53 749) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

The oil change for hoists 1 and 2 should be undertaken when the main boom is lying on the ground.

1. Turn the rope drum so that the protection cap (7) can be seen through the hole (2) of the axle (9).

2. Unscrew the protection cap (7).

3. Position container for catching old oil.

4. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (2) and inserted onto the drain valve.

5. Unscrew oil level check plug (1).

6. Allow old oil to drain off into the prepared container.

Dispose of used oil in an environmentally friendly manner.

7. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

8. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

9. Turn the rope drum so that the protection cap (7) can be seen through the hole (3) of the axle (9).

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5/25

8

A Einzelheit “X” Detail “X”

x

6

7 8

9

Ansicht “A” View “A”

3

1 2 Z 53 749

6/25

059--2080--083a

Hoists 8

Continued: Changing the Oil (Z 53 749) 10. Unscrew the protection cap (7).

11. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (3) and fitted onto the drain valve.

12. Use funnel with flexible neck to fill new oil in through the oil drain pipe until it runs out of the oil level check hole (1).

13. Remove funnel.

14. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

15. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

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8

“A”

H3

“T” H3

1T

1A Z 42 124

8/25

059--2080--083a

Hoists 8

8.3

Hoist 3 - Checking the Oil Level (Z 42 124) Transport position “T” Unscrew oil level check plug (1T).

The oil level is correct when, with the crane horizontal and the main boom set down “horizontally” at 05″″ the oil comes up to the inspection opening.

Top up the oil if necessary.

Top up the oil, see Section 8.4, “Changing the Oil”.

Screw oil level check plug (1T) back in.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and the reeving winch dismantled.

Operation position “A” Unscrew the oil level check plug (1A).

The oil level is correct when, with the unit horizontal and the main boom standing at “steep” angle 85°° , the oil comes up to the inspection hole.

Top up the oil if necessary.

Top up the oil, see Section 8.4, “Changing the Oil”.

Screw oil level check plug (1A) back in.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and the reeving winch dismantled.

059--2080--083a

9/25

8

A Einzelheit “X” Detail “X”

x

6

7 8

9

Ansicht “A” View “A”

3

1 2 Z 53 749

10/25

059--2080--083a

Hoists 8

8.4

Hoist 3 - Changing the Oil (Z 53 749) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

The oil change for hoists 1 and 2 should be undertaken when the main boom is lying on the ground.

1. Turn the rope drum so that the protection cap (7) can be seen through the hole (2) of the axle (9).

2. Unscrew the protection cap (7).

3. Position container for catching old oil.

4. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (2) and inserted onto the drain valve.

5. Unscrew oil level check plug (1).

6. Allow old oil to drain off into the prepared container.

Dispose of used oil in an environmentally friendly manner.

7. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

8. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

9. Turn the rope drum so that the protection cap (7) can be seen through the hole (3) of the axle (9).

059--2080--083a

11/25

8

A Einzelheit “X” Detail “X”

x

6

7 8

9

Ansicht “A” View “A”

3

1 2 Z 53 749

12/25

059--2080--083a

Hoists 8

Continued: Changing the Oil (Z 53 749) 10. Screw the oil drain pipe (6) into the oil filler opening (3).

11. Use funnel with flexible neck to fill new oil in through the oil drain pipe until it runs out of the oil level check hole (2).

12. Screw oil level check plug back in.

13. Remove the funnel and unscrew the oil drain pipe (6) from the oil filler opening (3).

14. Screw in the screw plug (8) on the oil filler opening (3).

15. Screw in the protective screw (7) on the oil filler opening (3).

059--2080--083a

13/25

8

1

12

2

10

11 Z 45 779

14/25

059--2080--083a

Hoists 8

8.5

Reeving Winch - Checking the Oil Level (Z 45 779) Check the oil level on the inspection glass. This should always be done when the transmission is at a standstill and the oil has cooled down.

A considerable amount of oil is distributed on the inside of the gear housing during operation. Therefore as soon as the system has been commissioned, we recommend that the oil level be checked again, with the gear at a standstill, and topped up if necessary.

If the level is below the minimum marking proceed as follows: 1. Remove the filler plug (1) at the upper end of the inspection glass.

2. Using a funnel or hose, fill in oil up to the ’max.’ marking on the inspection glass See section 2 “Oils, Lubricants and Capacities” for the correct oil types.

3. Screw the filler plug (1) back in.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

059--2080--083a

15/25

8

1

12

2

10

11 Z 45 779

16/25

059--2080--083a

Hoists 8

8.6

Reeving winch - checking the oil (Z 45 779) Use the oil grade given in section 2 “Oils, Lubricants and Capacities” 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 acid--proof seals and a sufficiently resistant inner coating. Please refer to the Customer Service Department of Terex Demag.

The oil should be changed when it is warm, i.e. after a longer operating period, as follows: Risk of burning and scalding!

Both the surface of the gear and the oil which comes out may be very hot.

Avoid contact or wear appropriate protective clothing.

Transmissions 1. Remove the filler plug (1) at the upper end of the inspection glass.

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

3. Screw the drain plug (2) back in.

4. Fill in new oil as described in section 8.1.

5. Screw the filler plug (1) back in.

A considerable amount of oil is distributed on the inside of the gear housing during operation. Therefore as soon as the system has been commissioned, we recommend that the oil level be checked again, with the gear at a standstill, and topped up if necessary.

Motor clutch 1. Unscrew oil level check plug (18).

2. Remove oil drain plug (12) and drain the oil into a suitable tank.

3. Screw the oil drain plug (12) back in.

4. Unscrew oil filter plug (10).

5. Fill in new oil until it flows out of the oil level control opening.

6. Screw oil filter plug and oil level check plug back in.

059--2080--083a

17/25

8

1

3

Z 39 238

“B” B

Z 45 780

18/25

059--2080--083a

Hoists 8

8.7

Hoists and Reeving Winch - Lubricating the Rope Drum Bearings (Z 39 238) Hoist 1, 2 and 3: Lubricate the lubricating nipple (1) on the side of the rope drum facing the hoist gear.

Reeving winch: Lubricate the lubricating nipple (3) on the side of the rope drum facing the reeving winch gear.

8.8

Hoists and Reeving Winch - Checking the Brakes (Z 45 780) Check hoist brakes “B” for leaks and that they are functioning perfectly (see following page).

Hoist gear and reeving winch -- checking the disc brake In order to ensure a perfect braking effect, the disc brake on the hoist and on the reeving winch must be checked at regular intervals.

Defective or oiled--up discs in the case of brakes which have run dry force a reduction in the holding load.

The defective parts must always be replaced and the brake cleaned before taking up work again.

This work may only be undertaken by a trained specialist If all traces of oil cannot be completely removed from the disc linings, these linings must be replaced.

In the case of work with insufficient braking effect,

ACCIDENTS

MAY

O C C U R.

Releasing the disc brake without the tension arrangement can lead to serious injury.

059--2080--083a

19/25

8

1

x

2 X

Z 39 240

20/25

059--2080--083a

Hoists 8

Proceed as follows to check hoist brake “B” (or reeving winch brake): (Z 39 240) 1.

Start the superstructure engine and allow to run at a slightly higher idling speed.

2.

Load the corresponding hoist or reeving winch with the max. possible rope load of − approx. 14.6 t (32 kip) per fall for the hoist − approx. 2.5 t (5.5 kip) per fall for the reeving winch .

Rope load = load + load--handling device (hook block + load-handling equipment)

059--2080--083a

3.

Move the control lever for the corresponding hoist (or for the reeving winch) in the “Lift hoist” direction and lift the load from the ground.

4.

When the load is suspended freely on the hook, release the control lever for the corresponding hoist (or for the reeving winch) in the middle position.

5.

Attach marking “X” to the corresponding hoist drum (1) (or to the reeving winch) and to a point on the superstructure frame (2).

6.

Allow the load to hang freely for approx. 2 to 3 minutes with the superstructure engine running.

7.

The hoist drum (1) or the reeving winch (2) must not move during this period.

Marking “X” on the hoist drum (1) or on the reeving winch (2) must still correspond to the frame.

If this is not the case, check hoist brake “B” (or reeving winch brake).

21/25

8

1 5 4

2 3

Z 39 241

22/25

059--2080--083a

Hoists 8

8.9

Hoists and Reeving Winch - Checking and Retightening the Screw Connections if Necessary As all fixing bolts are secured using Loctite, re--tightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

All screws without mechanical lock fittings must be secured with “Loctite”.

The thread and surface under the head of all screws must be lightly oiled for tightening purposes using grease KP2K. Hoist H1, H2 and H3 (Z 39 241) Torques of the gear housing screws: Size

Quality

M 12

8.8

74

54.58

M 24

8.8

618

455.81

Torque Ma (Nm) (lbf--ft)

with Loctite type

638

Torques of the fixing bolts for the hydraulic motor and gear mount:

059--2080--083a

No.

Size

Quality

1

M 20 x 110

10.9

510

376.16

x

2

M 24 x 50

10.9

880

649.05

x

3

M 20 x 50

10.9

510

376.16

x

4

M 16 x 40

10.9

265

195.45

x

5

M 20 x 55

10.9

510

376.16

x

Torque Ma (Nm) (lbf--ft)

with Loctite 0245

23/25

8

2

4

3

1

Z 39 242

24/25

059--2080--083a

Hoists 8

Reeving winch (Z 39 242) As all fixing bolts are secured using Loctite, re--tightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

All screws without mechanical lock fittings must be secured with “Loctite 245”.

The thread and surface under the head of all screws must be lightly oiled for tightening purposes using grease KP2K. Torques of the fixing bolts for the hydraulic motor and gear mount:

8.10

No.

Size

Quality

1

M 12 x 30

10.9

117

86.29

x

2

M 10 x 35

10.9

68

50.15

x

3

M 8 x 20

10.9

31

22.86

x

4

M 12 x 40

10.9

108

79.66

x

Torque Ma (N/m) (lbf--ft)

with Loctite 0245

Hoist Limit Switch and Lower Limit Switch - Checking Functionality To carry out the functionality test, see Sect. 14.

059--2080--083a

25/25

Luffing Gears 9

059--2090--050b_en

1/23

9

1

Z 42 126

2

Z 42 127

2/23

059--2090--050b_en

Luffing Gears 9

9

Luffing Gears Measures to achieve safe operating periods: In accordance with the German accident prevention regulations for winches, hoist and traction equipment, VBG 8, the operator of the crane is responsible for ensuring that a crane inspection is carried out at least once a year (see also ISO 9927--1).

The spent share of the theoretical service life for the winches must also be determined. The crane operator must employ an officially certified specialist for the purpose if necessary.

Where accident prevention regulations of the employer’s liability insurance association apply, this is required by law.

Outside of this area, the crane manufacturer recommends that the procedure listed is also observed.

See Section 22, “Examinations of the Crane”, of these lubrication and maintenance instructions.

Risk of dragging.

When carrying out maintenance, inspection and mounting work, special care must be taken in this area as there is a risk of being caught and dragged into the equipment between the winches and hoist ropes.

Luffing gear 1 (1, Z 42 126) in the main boom foot section.

Luffing gear 2 (2, Z 42 127) in the mast foot section.

059--2090--050b_en

3/23

9

“T”

“A”

W1 W1

1T

1A

Z 42 128

4/23

059--2090--050b_en

Luffing Gears 9

9.1

Luffing Gear 1 - Checking the Oil Level (Z 42 128) Transport position “T” Unscrew oil level check plug (1T).

The oil level is correct when, with the crane horizontal and the main boom set down “horizontally” at 0°, the oil comes up to the inspection opening.

Top up the oil if necessary.

Top up the oil, see Section 9.2, “Changing the Oil”.

Screw oil level check plug (1T) back in.

Operation position “A” Unscrew oil level check plug (1A).

The oil level is correct when, with the crane horizontal and with the main boom at an angle 85°, the oil comes up to the inspection opening.

Top up the oil if necessary.

Top up the oil, see Section 9.2, “Changing the Oil”.

Screw oil level check plug (1A) back in.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

059--2090--050b_en

5/23

9

“T” W1

Detail “X” 6

7

Z X

8 View “Z” 3T 1T

2T

6/23

Z 55 497

059--2090--050b_en

Luffing Gears 9

9.2

Luffing Gear 1 - Changing the Oil (Z 55 497) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

The oil change is normally performed when the main boom or boom foot (transport position T) is set down horizontally or is removed.

1. Turn the rope drum so that the protection cap (7) can be seen through the hole (2) of the axle (9).

2. Unscrew protection cap (7).

3. Position container for catching old oil.

4. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted into hole (2T) and fitted onto the drain valve.

5. Unscrew oil level check plug (1T).

6. Allow old oil to drain off into the prepared container.

Dispose of used oil in an environmentally friendly manner.

7. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

8. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

9. Turn the rope drum so that the transmission opening can be seen through the hole (3T) of the axle (9).

059--2090--050b_en

7/23

9

“T” W1

Detail “X” 6

7

Z X

8 View “Z” 3T 1T

2T

8/23

Z 55 497

059--2090--050b_en

Luffing Gears 9

Continued: Changing the Oil (Z 55 497) 10. Unscrew protection cap (7).

11. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in the hole (3T) and fitted onto the drain valve.

12. Use funnel with flexible neck to fill new oil in through the oil drain pipe until it runs out of the oil level check hole (1T).

13. Remove funnel.

14. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

15. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

059--2090--050b_en

9/23

9

W2

1A

3A

2A

Z 55 498

10/23

059--2090--050b_en

Luffing Gears 9

9.3

Luffing Gear 2 - Checking the Oil Level (Z 55 498) --

--

Luffing gear 2 is fitted in the superlift mast foot section.

Due to this installation location, checking the oil level requires precise planning and the use of a personnel cage attached to an auxiliary crane.

For practical reasons, we recommend that the oil level be checked during assembly and dismantling of the crane.

Before the oil level can be checked: 1.

the main boom and fly jib must be placed on the ground, if they are fitted;

2.

The superlift mast must be placed in the 90° position.

Check the oil level when the superlift mast is in the 90° position.

Unscrew the oil level check plug (1A). The correct oil level is achieved when -- with the superlift mast in the 90° position -- the oil comes up to the inspection opening.

Top up the oil if necessary.

Top up the oil, see Section 9.4, “Changing the Oil”.

Screw oil level check plug (1A) back in.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

059--2090--050b_en

11/23

9

Detail “X” 6

7 “X”

1A 8

3A

2A Z 55 499

12/23

059--2090--050b_en

Luffing Gears 9

9.4

Luffing Gear 2 - Changing the Oil (Z 55 499) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

--

The oil should be changed on luffing gear 2 when the superlift mast is in the 90° position.

--

To carry out the oil change safely, you must plan the procedure carefully and use a personnel cage attached to an auxiliary crane.

--

For practical reasons, we recommend that the oil level be checked during assembly and dismantling of the crane.

Before the oil level can be checked: 1.

The main boom and fly jib must be placed on the ground, if they are fitted;

2.

The superlift mast must be placed in the 90° position.

Change the oil when the superlift mast is in the 90° position.

1. Turn the rope drum so that the protection cap (7) can be seen through the hole (2A) of the axle (9).

2. Unscrew protection cap (7).

3. Position container for catching old oil.

4. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (2A) and fitted onto the drain valve.

5. Unscrew the oil level check plug (1A).

6. Allow old oil to drain off into the prepared container.

Dispose of used oil in an environmentally friendly manner.

7. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

8. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

9. Turn the drum so that the transmission opening can be seen through the hole (3A) of the axle (9).

059--2090--050b_en

13/23

9

Detail “X” 6

7 “X”

1A 8

3A

2A Z 55 499

14/23

059--2090--050b_en

Luffing Gears 9

Continued: Changing the Oil (Z 55 499) 10. Unscrew protection cap (7).

11. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (3A) and fitted onto the drain valve.

12. Use funnel with flexible neck to fill new oil in through the oil drain pipe until it runs out of the oil level check hole (1A).

13. Remove funnel.

14. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

15. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is handtight.

059--2090--050b_en

15/23

9

1

Z 39 249

“B”

Z 39 250

16/23

059--2090--050b_en

Luffing Gears 9

9.5

Luffing Gear 1 and 2 - Lubricating Rope Drum Bearings (Z 39 249) Lubricate lubricating nipples (1) of rope drums W1 and W2.

9.6

Luffing Gears - Checking the Brakes (Z 39 250) Check luffing gear brakes “B” for leaks and that they are functioning perfectly (see following pages).

Luffing winch gear -- checking the disc brake In order to ensure a perfect braking effect, the disc brake on the luffing gear must be checked at regular intervals.

Defective or oiled--up discs in the case of brakes which have run dry force a reduction in the holding load.

The defective parts must always be replaced and the brake cleaned before taking up work again.

This work may only be undertaken by a trained specialist If all traces of oil cannot be completely removed from the disc linings, these linings must be replaced.

In the case of work with insufficient braking effect,

ACCIDENTS

MAY

O C C U R.

Releasing the disc brake without the tension arrangement can lead to serious injury.

059--2090--050b_en

17/23

9

“B”

Z 39 251

18/23

059--2090--050b_en

Luffing Gears 9

Proceed as follows to check luffing gear brake W1, W2: (Z 39 251) The luffing gear brake W1 can be checked (without superlift equipment): − when erecting the crane with maximum possible equipment (main boom + fly jib) or − when lifting maximum loads with other equipment variants .

The luffing gear brake W1, and W2 can be checked (with superlift equipment): − when erecting the crane with maximum possible equipment (main boom + fly jib + superlift mast) or − when lifting maximum loads with other equipment variants and superlift.

059--2090--050b_en

19/23

9

“B”

Z 39 251

20/23

059--2090--050b_en

Luffing Gears 9

W2 when erecting the crane with maximum possible equipment: (with and without superlift equipment) (Z 39 251) The retaining brakes on luffing gear 2 should be checked with every erection procedure with maximum equipment.

1.

Undertake the erection procedure as described in the assembly instructions (Part 3).

2.

Lift the last equipment part to remain on the ground during the erection procedure to just above the ground.

3.

Interrupt the erection procedure. − superstructure engine running, no movement triggered. − All control levers in the crane operator’s cab are in the middle position.

4.

Attach a marking to the corresponding rope drum (W1) W2 and to the (main boom foot section) superlift mast basic boom.

5.

Leave the crane in this position for approx. 2 minutes.

6.

Check the marking on the rope drum (W1) W2 and on the (main boom foot section) superlift mast basic boom: − no change in marking = brake in order − marking has changed (winch creeps) = brake not in order; repair the brake.

W1 and W2 when lifting maximum loads with other equipment variants: (with and without superlift equipment) 1.

Lift the load to just above the ground using the hoist (approx.

10 cm / 3.94 inches).

2.

Interrupt the lifting of the load. − superstructure engine running, no movement triggered. − All control levers in the crane operator’s cab are in the middle position.

3.

Change the radius slightly using W1.

4.

Leave the crane in this position to check the brake.

All the remaining steps are described in the section entitled

∗ when erecting the crane with maximum possible equipment (see above) from point 4 onwards.

059--2090--050b_en

21/23

9

1 5 4

2 3

Z 39 252

22/23

059--2090--050b_en

Luffing Gears 9

9.7

Luffing Gears - Checking the Screw Connections and Re-- tightening if Necessary As all fixing bolts are secured using Loctite, retightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

All screws without mechanical lock fittings must be secured with “Loctite”.

The thread and surface under the head of all screws must be lightly oiled for tightening purposes using grease KP2K. Luffing gears W1 and W2 (Z 39 252) Torques of the gear housing screws: Size

Quality

M 12

8.8

74

54.58

M 24

8.8

618

449.94

Torque Ma (Nm) (lbf--ft)

with Loctite type

638

Torques of the fixing bolts for the hydraulic motor and gear mount:

059--2090--050b_en

No.

Size

Quality

1

M 20 x 100

10.9

510

376.16

x

2

M 24 x 50

10.9

880

649.05

x

3

M 20 x 50

10.9

510

376.16

x

4

M 16 x 40

10.9

265

195.45

x

5

M 20 x 55

10.9

510

376.16

x

Torque Ma (Nm) (lbf--ft)

with Loctite 0245

23/23

Derricking Gear 10

059--2100--090_en

1/15

10

A

Ansicht “A” View “A”

3

1

2

Z 42 131

2/15

059--2100--090_en

Derricking Gear 10

10

Derricking Gear Measures to achieve safe operating periods: In accordance with the German accident prevention regulations for winches, hoist and traction equipment, VBG 8, the operator of the crane is responsible for ensuring that a crane inspection is carried out at least once a year (see also ISO 9927--1).

The spent share of the theoretical service life for the winches must also be determined. The crane operator must employ an officially certified specialist for the purpose if necessary.

Where accident prevention regulations of the employer’s liability insurance association apply, this is required by law.

Outside of this area, the crane manufacturer recommends that the procedure listed is also observed.

See section 22, “Examinations of the Crane”, of these lubrication and maintenance instructions Risk of dragging.

When carrying out maintenance, inspection and mounting work, special care must be taken in this area as there is a risk of being caught and dragged into the equipment between the winches and hoist ropes.

10.1

Derricking Gear - Checking the Oil Level (Z 42 131) Unscrew oil level check plug (2). The oil level is correct when, with the crane horizontal, the oil comes up to the inspection opening.

Screw oil level check plug (2) back in.

Top up the oil if necessary.

Top up the oil, see Section 10.2, “Changing the Oil”.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

059--2100--090_en

3/15

10

A

Detail “X”

6

Ansicht “A” View “A”

3

9

1

7

8

2

Z 55 951

4/15

059--2100--090_en

Derricking Gear 10

10.2

Derricking Gear - Changing the Oil (Z 55 951) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

The oil change is normally performed when the main boom is set down horizontally or is removed.

1. Turn the rope drum so that the protection cap (7) can be seen through the hole (2) of the axle (9).

2. Unscrew the protective cap (7) 3. Position container for catching old oil.

4. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (2) and inserted onto the drain valve.

5. Unscrew oil level check plug (1).

6. Allow old oil to drain off into the prepared container.

Dispose of used oil in an environmentally friendly manner.

7. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

8. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is hind--tight.

9. Turn the rope drum so that the protection cap (7) can be seen through the hole (3) of the axle (9).

059--2100--090_en

5/15

10

A

Detail “X”

6

Ansicht “A” View “A”

3

9

1

7

8

2

Z 55 951

6/15

059--2100--090_en

Derricking Gear 10

Continued: Changing the Oil (Z 55 951) 10. Unscrew the protective cap (7).

11. The drain valve (8) opens automatically if the oil drain pipe (6) is inserted in hole (3) and fitted onto the drain valve.

12. Use funnel with flexible neck to fill new oil in through the oil drain pipe until it runs out of the oil level check hole (1).

13. Remove funnel.

14. The drain valve (8) closes automatically if the oil drain pipe (6) is pulled out.

15. Clean the oil drain pipe (6) and screw on protection cap (7).

Only screw protection cap (7) on so that it is hind--tight.

10.3

Derricking Gear - Lubricating the Rope Drum Bearings (Z 55 951) Lubricate lubricating nipples (4) of rope drums.

10.4

Derricking Gear - Lubricate Sheaves Lubricate the lubricating nipples of the roller sets in the A--frame and on the superstructure.

If the crane is equipped with the option “Superstructure central lubricating system”, then the lubrication of the sheaves of the superstructure is performed by the central lubricating system.

059--2100--090_en

7/15

10

1

“B”

Z 42 133

8/15

059--2100--090_en

Derricking Gear 10

10.5

Checking the Derricking Gear Brakes Check derricking gear brakes “B” for leaks and that they are functioning perfectly (Z 42 133) Derricking gear -- checking the disc brake In order to ensure a perfect braking effect, the disc brake on the derricking gear must be checked at regular intervals.

Defective or oiled--up discs in the case of brakes which have run dry force a reduction in the holding load.

The defective parts must always be replaced and the brake cleaned before taking up work again.

This work may only be undertaken by a trained specialist If all traces of oil cannot be completely removed from the disc linings, these linings must be replaced.

In the case of work with insufficient braking effect,

RISK

OF

A C C I D E N T S!

Releasing the disc brake without the tension arrangement can lead to serious injury.

059--2100--090_en

9/15

10

1

“B”

Z 42 133

10/15

059--2100--090_en

Derricking Gear 10

Proceed as follows to check the derricking gear brake: (Z 42 133) The derricking gear brake can be checked (with and without superlift equipment): − when erecting the crane with maximum possible equipment (main boom + fly jib with and without superlift mast) or − when lifting maximum loads with other equipment variants. when erecting the crane with maximum possible equipment: (with and without superlift equipment) The retaining brakes on the derricking gear should be checked with every erection procedure with maximum equipment.

1.

Undertake the erection procedure as described in the assembly instructions (Part 3).

2.

Lift the last equipment part to remain on the ground during the erection procedure to just above the ground.

3.

Interrupt the erection procedure. − superstructure engine running, no movement triggered. − All control levers in the crane operator’s cab are in the middle position.

4.

Attach a marking “X” to the rope drum (1) on the derricking gear and to the superstructure frame (2).

5.

Leave the crane in this position for approx. 2 minutes.

6.

Check the marking “X” on the rope drum (1) and on the superstructure frame (2): − no change in marking = brake in order − marking has changed (winch creeps) = brake not in order; repair the brake.

059--2100--090_en

11/15

10

1

“B”

Z 42 133

12/15

059--2100--090_en

Derricking Gear 10

when lifting maximum loads with other equipment variants (with and without superlift equipment): (Z 42 133) 1.

Lift the load to just above the ground using the hoist (approximately 10 cm / 3.94 inches).

2.

Interrupt the lifting of the load. − superstructure engine running, no movement triggered. − All control levers in the crane operator’s cab are in the middle position.

3.

Leave the crane in this position to check the brake.

All the remaining steps are described in the section entitled

∗ when erecting the crane with maximum possible equipment (see page 9), from point 4 onwards.

059--2100--090_en

13/15

10

1 2

3 4

Z 42 134

14/15

059--2100--090_en

Derricking Gear 10

10.6

Derricking Gear - Checking the Screw Connections and Retightening if Necessary As all fixing bolts are secured using Loctite, retightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

All screws without mechanical lock fittings must be secured with “Loctite 245”.

The thread and surface under the head of all screws with mechanical lock fittings must be lightly oiled for tightening purposes.

Derricking gear: (Z 42 134) Torques of the gear housing screws: Size

Quality

M8

8.8

21

15.49

M 10

8.8

42

30.98

M 12

8.8

74

54.58

M 14

8.8

115

84.82

M 16

8.8

177

130.55

m20

8.8

358

264.05

Torque Ma (Nm) (lbf--ft)

with Loctite 0245

Torques of the fixing bolts for the hydraulic motor and gear mount:

059--2100--090_en

No.

Size

Quality

2

10.9

1000

737.56

x

4

M 24 x 2 x 60 M 16 x 50

10.9

265

195.45

x

3

M 20 x 55

10.9

580

427.78

x

1

M 24 x 80

10.9

1500

1106.34

x

Torque Ma (Nm) (lbf--ft)

with Loctite 0245

15/15

Equipment 11

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1/31

11

3

1

2

5

Z 55 950

2/31

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Equipment 11

11

Equipment

11.1

Maintaining the Hydraulic Cylinders on the Superstructure and Equipment Lubricating the Support Cylinders of the Main Boom and the Superlift Mast (Z 53 906) Lubricate the nipples on the support cylinders of the main boom (1) and Superlift mast (2).

If the crane is equipped with the optional “Superstructure central lubricating system”, the foot bearings of these cylinders are lubricated by the central lubricating system.

Lubricating the support cylinders of the fly jib Lubricate the nipples on the support cylinders of the fly jib (3).

Checking the support cylinders of the fly jib Check the support cylinders of the fly jib (3) for leaks and that they are functioning correctly.

Checking the mounting cylinder for the foldable A--frame (optional equipment) Check the mounting cylinder (5) for leaks and that it is functioning correctly.

Hydraulic cylinder piston rods Coat the exposed piston rods of the back stroke cylinders and mounting cylinder(s) with non--corrosive protective grease.

Despite their high quality, the appearance of corrosion cannot be ruled out in aggressive environments. If the crane is out of operation for more than one day, exposed chrome surfaces must be protected against corrosion by applying non--corrosive protective grease (Syntheso W--Spray, parts no. 621 699 40).

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11

Z 45 788

Z 42 137

Z 53 907

4/31

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Equipment 11

11.2

Lubricating the Boom Bearings Main boom (Z 45 788) Lubricate the nipples on the main boom -- foot bearing.

Fly jib (Z 42 137) Lubricate the nipples on the foot bearing in the connecting head.

A--frame (Z 53 907) Lubricate the nipples on the A--frame.

If the crane is equipped with the optional “Superstructure central lubricating system”, the A--frame foot bearings are lubricated by the central lubricating system.

Superlift mast Lubricate the nipples on the Superlift mast.

If the crane is equipped with the optional “Central lubricating system superstructure”, the Superlift mast foot bearing is lubricated by the central lubricating system.

Lubricate the connecting bolts of the intermediate sections on the main boom and fly jib and the connecting bolts of the bracing of the main boom and fly jib and of the Superlift equipment The connecting bolts to be driven into the corresponding bolt eyes must be well greased each time before the crane equipment is assembled.

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11

“B”

“A”

“C”

Z 55 954

6/31

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Equipment 11

11.3

Hook Block

11.3.1

Lubricating the Hook Blocks Risk of dragging.

When carrying out maintenance, inspection and mounting work, special care must be taken in this area as there is a risk of being caught and dragged in between the hook block pulleys and ropes.

Use the hand grips located on the hook blocks.

Lubricate all the lubricating nipples on the hook blocks (Z 55 954): “A” -- Hook block “Type 2x200” 14 sheaves “B” -- Hook block “Type 2x160” 10 sheaves “C” -- Hook block “Type 100” 3 sheaves

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11

8/31

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Equipment 11

11.4

Ropes Danger due to protruding rope wires.

When ropes are handled, protruding wires can cause injury.

Gloves should be worn as protection.

Risk of dragging.

When carrying out maintenance, inspection and mounting work, there is a risk of being caught and dragged into the equipment at the following points : ---

Rope to rope winches Rope to sheaves of the main boom or additional boom parts -- Rope to sheaves of the hook block -- Rope to sheaves on the fixed bridle / flying bridle Utmost care must therefore be taken.

Risk of rubbing and scraping.

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11

x A

B

C

Y Z 29 094

10/31

059--2110--104

Equipment 11

11.4.1

Lubricating the Ropes During manufacture, a cable receives intensive lubrication which provides protection against corrosion as well as improving the friction coefficient of the rope elements internally and between the cable and sheave or cable and drum. This initial lubrication lasts only for a limited period of time and must be repeated regularly.

Cables must be re--lubricated at regular intervals which correspond to the operating environment, especially in the areas where the cable bends. If the rope cannot be lubricated on operational grounds, a shorter lifespan is to be expected and the cables must be carefully monitored. The effects of lubrication and re--lubrication on the lifespan of the rope can be seen in figure (Z 29 094): x y a b c

Number of alternate bends (%) Tensile stress (N/mm2) greased and re--greased greased degreased

To increase service life and to protect against rust, the ropes must be kept very well greased. It is not sufficient to lightly coat the ropes, the grease must penetrate through.

This measure should be carried out when the ropes are reeved.

Lubrication is best carried out using non--acidic grease which has been thinned before use by heating.

The lubricant can be applied using various methods: -----

with a paint brush or glove applying in the area of a sheave passing through a lubricant trough using a pressure packing

It is important that cables are lubricated regularly from the very start and not only when the first signs of damage are discovered.

In addition, observe all existing standards (e.g. DIN 15 020) or national regulations.

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11

Z 30 316

Z 29 084

12/31

Z 29 085

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Equipment 11

11.4.2

Cleaning the Ropes Cables which are very dirty should be externally cleaned from time to time. This applies especially to cables which are used in a particularly abrasive environment or in the vicinity of chemically active materials.

11.4.3

General Information on Operation and Assembly Transport (Z 29 084, Z 29 085) When working with cables, problems can be encountered even at the delivery stage: the fork of the fork lift truck moves beneath the reel or into the rope bundle thereby damaging the cable surface.

(Z 29 084) Wherever possible, the cable, which is delivered in bundles or on reels, should not come into direct contact with a hook or with the fork of a fork lift truck. Rather, it should be raised by means of wide textile lifting slings, for example.

(Z 29 085) A reel is best raised by means of a rod placed through its central axis.

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11

Z 38 119

14/31

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Equipment 11

Bearing Cables should be stored in a cool, clean, dry and covered environment. The cables should not be stored directly on the ground but, for example, on pallets.

If it is not possible to store the cables under a roof, they must at least be covered so that they do not become damp.

A plastic film may provide protection against rain but will not however prevent condensation from forming beneath it which in turn cannot escape and will possibly damage the cables permanently.

In this instance a solution may, for example, be provided by using an intermediate layering made out of sack cloth.

When storing a large number of spare parts, the general rule should be: first in, first out. This means that the cables should be used in the same order as they are delivered. This will then prevent the instance of a cable first being used after several years in storage.

Mounting

When fitting a hoist rope which has never been subjected to a load before, spin problems may occur. We therefore recommend the use of a spin stabilizer in such cases (example: see Z 38 119).

When cables are mounted, always ensure that they are wound from the reel or bundle and onto the system without the cables becoming twisted or damaged externally.

Cable which is supplied in a bundle is either unwound by means of a swivel plate or rolled out on the ground. In case of the latter, the ground should be as clean as possible. Sand, for example, sticks to the lubricant on the cable and can lead to cable damage if it gets between the sheave and the cable on the equipment.

Cable which is wound on a reel is also preferably unwound using a swivel plate or from a trestle. Rolling the coil out on the ground, something which is often recommended in related literature, does not actually work very well in practice as the reel gives off increasingly less cable for the same distance rolled, making it necessary to pull the cable behind you.

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11

16/31

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Equipment 11

The cable must, however, under no circumstances be pulled from the reel or bundle laterally, as with this method a twist is created in each turn of the rope as it is unwound. Every rope twist alters the length of lay of the strands and cable and thereby the ratios of the rope element lengths and therefore ultimately the load distribution in the cable.

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11

Z 29 086

Z 29 087

18/31

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Equipment 11

(Z 29 086) Cable that is pulled laterally from the bundle or reel resists the torsion which acts on it and forms loops. When such a cable is placed under load, the loops are drawn together and form a kink, which is an irreparable deformation. Cables with kinks are no longer safe to be used and must be replaced.

Assembly Procedure The best way to mount cable differs from system to system. In every instance, the method should be chosen which, with a representative working schedule, is least likely to cause a rope torsion or damage to the cable through contact with structural components.

On certain equipment it may be advisable to remove the old cable first and then to fit the new cable. On other equipment, especially larger models, it is advisable to draw the new cable through with the old.

A further possibility, especially in the case of initial reeving, is to use a thinner auxiliary rope with which the actual cable can be drawn through.

In every case, it is necessary to consider whether it would be better to draw the cable through the whole rope reeving arrangement or first to reel it onto the rope drum directly from the bundle or reel and then reeve the cable by hand or by means of an auxiliary reeving rope.

If a rope end is fitted with a non--detachable rope end connection, it is only possible to draw the free end of the rope through the complete reeving arrangement.

Re--reeling (Z 29 087) Every cable takes on a certain bending tendency from the point of manufacture, where it is drawn from the stranding basket by means of delivering disks. It is then supplied to the customer bent in this direction. When re--reeling from the reel onto the rope drum, the cable must be wound in this direction.

If the rope strand is reeled on beneath the rope drum, the mounting reel should be set up so that the rope strand being reeled off also runs off beneath the reel and vice versa.

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11

20/31

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Equipment 11

If the cable is re--reeled against the directional tendency, the cable will either tend to turn between the reel and the rope drum or will turn later on when in operation in order to bend to the preferred direction. In both instances, structural changes in the cable can be caused.

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21/31

11

Z 29 088

Z 29 089

22/31

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Equipment 11

Drawing the cable by means of an auxiliary reeving rope If the new cable is to be drawn through by the cable which is to be removed or with an auxiliary reeving rope, it must be ensured that these ropes are securely fastened. In addition, it must also be ensured that the auxiliary rope cannot become twisted. For example, non--twisting cable types or triangular strand wire ropes are particularly suitable for use as auxiliary reeving ropes. When using conventional cables, they must at least have the same direction of lay as the cable which is being drawn.

Whenever a new cable is drawn through using the old cable, the two rope ends are often welded end to end. Such a connection can cause the torsion of the old rope built up during operation to be transferred to the new rope causing extensive damage even at the mounting stage.

This procedure is, however, problematic for other reasons: the weld connection does attain satisfactory values by use of special electrodes in the case of a tensile test on the straight strand, but due to the length of the fixed contact area, the cable can break due to the bending load caused when passing over the sheaves.

If the ropes are to be connected in this manner, the cables should be additionally secured using a rope stocking.

(Z 29 088) A less problematic method of connecting the cables is by means of two rings or chain links welded onto the cable ends. These are then connected by means of strands or thin ropes. Such a connection possesses a satisfactory load bearing capacity, can be bent and prevents the transfer of torsion from the old rope to the new. By using two strands, the number of turns in the strands following mounting will show to what degree the old cable on the equipment was twisted.

(Z 29 089) Connecting the cables by means of rope stockings offers a further possibility. Rope stockings are plaited rope strands which are pushed over the cable ends and secured with adhesive tape.

When under load, the rope stockings are drawn tighter and hold the cable ends by means of friction.

When an equal--lay rope is to be drawn, it must be ensured that the rope stockings can turn on the rope like a nut on a screw, in spite of the cord tensions. This can be achieved by first winding strong adhesive tape round the cable surfaces which are to be held by the rope stockings.

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11

Z 29 090

Z 29 091

Z 29 092

24/31

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Equipment 11

Winding on the rope under load To wind the cable onto the drum correctly it is very important in the case of multiple layer winding, and especially where so called lebus winding is used, that the cables are wound onto the drum under tension.

If the lower layers are too slack, the upper layers may be pressed in between the lower strands when the cable is placed under load. This can lead to extensive damage to the cable.

As the cable which is being reeled off may even become stuck at this point, the winding direction of the drum may be reversed suddenly, causing the downward moving load to be raised jerkily.

The cables should be pretensioned to approximately 1 to 2% of their minimal breaking force.

While, in many cases, it is sufficient to wind on the cable normally and then to unwind it and wind it on again with the aid of an external load, this is not possible in every instance, for example in the case of a slewing tower crane which has not yet reached its highest climbing height. In these instances the cable must be pretensioned at the mounting stage.

(Z 29 090, Z 29 091) This can be achieved by braking the reel flange using a board or by means of a brake disc attached to the reel. The brake cords (hemp ropes with a steel core) are supplied by the cable manufacturer.

(Z 29 092) It must not be attempted under any circumstances to pretension the rope by jamming it, for example, between two wooden planks.

The rope would be irreparably deformed due to structural changes.

Retracting Before a cable is placed in operation following its mounting, a certain number of load cycles with small partial loads must first be carried out. The cable should be “retracted” so that the cable elements can settle and adapt to their new environment.

Unfortunately, the opposite normally proves to be the case in practice: following mounting of the cable, overload checks are normally carried out with loads which are above the permissible load bearing capacity of the system.

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25/31

11

Z 29 093

26/31

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Equipment 11

Cutting into sections Often cables have to be cut into sections or shortened by the user. The cables can be cut in various ways. Up to a diameter of 8 mm (0.315 inch), cable cutters can be used. Mechanical or hydraulic cutters are also available for larger cable diameters. If, however, a power source is available, it is recommended that a pneumatic or electric right angle grinder be used.

In every instance, the cables must be carefully bound next to the point of separation to prevent fraying of the rope ends or changes in the cable and strand laying lengths. This especially applies when sectioning off low or non--twist cables, the strands of which are often purposefully left unformed by the cable manufacturer.

The rope ends must be bound using iron wire; insulating tape cannot prevent structural changes in the cables occurring.

(Z 29 093) First the separating point is marked using chalk or insulating tape.

One end of the seizing wire, approx. four times the cable diameter in length, is then placed along the length of the cable and then this wire and the cable are bound together starting at the separating point (a).

The cable is now bound tightly along a length of approx. three times the rope diameter (b).

The length of wire which has been bound is then pulled tight using pincers and is twisted together with the second wire end (c).

The length of the entwined wire ends is shortened to approx. the diameter of the rope using the pincers. The wire ends are then forced into a valley between two outer strands of the cable by banging them lightly. This prevents accidents.

Following corresponding preparation of the other side of the separating point, the cable can now be cut through (d).

Instead of one long winding, three windings approximately one cable diameter wide can be attached on either side of the separating point.

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11

Z 33 645

28/31

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Equipment 11

11.5

Sheaves

11.5.1

Checking the Roller Bearings on the Sheaves (Z 33 645) Risk of dragging.

When carrying out maintenance, inspection and mounting work, special care must be taken in this area as there is a risk of being caught up and dragged in between the sheaves and the ropes.

Inspect all sheaves once a year for the following: −

emergence of grease

−

seat of the bearing seals

−

seat of the circlips

−

running noises, rolling resistance

−

bearing clearance

If any deficiencies are detected, the roller bearing (2) of the corresponding sheave (1) must be replaced. If this is the case inform the customer service department of Terex Demag GmbH. If the inspection reveals a damaged circlip (3), the circlip must be replaced.

Only use original TEREX--DEMAG circlips with chamfered opening.

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29/31

11

“Y”

“Y”

“X”

Z 53 908

1

Z 53 909

30/31

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Equipment 11

11.5.2

Checking the Sheaves (Z 53 908) Check all sheaves for damage such as cracks, notches or similar damage.

Sheaves with such damage must be replaced immediately.

Also check all sheaves for wear: −

Lower tread ”X” max. 3 mm (0.12 inch) Dimension ”X” = Difference between ∅ lower tread new and ∅ lower tread current!

−

Side tread ”Y” max. 5 mm (0.20 inch) Dimension ”Y” measured between rope (S) and tread of sheave.

If the sheave is worn up to the wear limit, it must be replaced.

11.5.3

Lubricating the Sheave Bearing (Z 53 909) Lubricate each sheave using the lubricating nipple (1).

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Hydraulic System 12

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1/45

12

36

Z 53 910

1

Z 39 282

2/45

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Hydraulic System 12

12

Hydraulic System Risk of burns.

Note that temperatures can be high especially in parts of the hydraulic system under the covers.

Allow sufficient cooling time or wear appropriate overalls etc.

12.1

Hydraulic Oil Reservoir - Checking the Oil Level The oil level in the hydraulic oil reservoir can −

be checked by means of the indicator light (36, Z 53 910) in the cab or

−

at the level pipe (1, Z 39 282) on the hydraulic oil reservoir.

The oil level is correct when, with the crane horizontal,

059--2120--090a_en

−

the indicator light (36, Z 53 910) does not light up

−

the hydraulic oil comes up the “max” marking in the oil level tube (1, Z 39 282).

3/45

12

2 4

3

1

Z 39 283

Z 39 284

4 X

5

3

Z 53 913

4/45

Z 39 285

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Hydraulic System 12

12.2

Hydraulic Oil Reservoir - Replacing the Return Oil Filter (Z 39 283, Z 39 284, Z 53 913) To replace the paper filters, the filter elements must be removed.

1.

Lower the suspended load onto the ground and switch off the superstructure engine.

The system must be depressurised.

2.

Loosen the screws (1) and remove the filter cover (2).

3.

Remove the filter unit (3).

4.

Loosen the bayonet catch (4) and remove the paper filters (5).

5.

Replace the paper filters (5).

6.

Suspend the filter element (3) in the reservoir.

7.

Secure the filter cover (2) with screws (1).

This working procedure must be repeated for all filter units.

Following each repair to the hydraulic system, the filters should be cleaned and/or replaced after every 50 h.

Damaged seals must be replaced.

12.3

Hydraulic Oil reservoir - Replacing the Aeration Filter (Z 39 285) Unscrew the clogged filter element (X).

Screw on a new filter element.

The aeration filter should be replaced more frequently in the case of particularly unfavourable ambient conditions.

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12

1

4 2

3

Z 39 286

6/45

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Hydraulic System 12

12.4

Leak Oil Circuit - Return Oil Filter - Cleaning the Filter Element (Z 39 286) The filters are fitted in the return line on the hydraulic oil reservoir.

059--2120--090a_en

1.

Switch off the engine and depressurise the hydraulic system.

2.

Place a suitable container under the filter in order to collect any oil that escapes.

3.

Unscrew the filter cover (1).

4.

Remove the dirt collecting tray (2) together with the filter element (3) from the barrel (4).

5.

Remove the filter element (3) from the dirt collecting tray (2).

6.

Clean the dirt collecting tray (2).

7.

Insert the dirt collecting tray (2) and filter element (3) in the barrel (4) and screw the filter cover (1) on tightly.

8.

Start the engine and check the filter for leaks.

7/45

12

X

Z 55 955

8/45

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Hydraulic System 12

12.5

Hydraulic Pump - Changing the Add-- on Filter (Z 55 955) When the filter control light (36) in the crane operator’s cab lights up, the add--on filter must be changed.

Changing the add--on filter.

Unscrew the clogged filter (X).

Screw on a new filter with O--ring.

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9/45

12

4

3

4

1

2

Z 39 288

1

Z 39 282

10/45

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Hydraulic System 12

12.6

Replacing the Hydraulic Oil (Z 39 288) To change the oil, the crane must be in a horizontal position with the oil at operating temperature.

1.

Fit hose (1) onto the quick disconnect coupling (1) on the hydraulic tank (3) and drain the hydraulic oil into a suitable container.

Dispose of the hydraulic oil in an environmentally safe manner.

2.

Clean the hydraulic oil reservoir (3) and drain off the residue through oil drain (2).

3.

Release hose (1) from the quick disconnect coupling (2) and pour in fresh hydraulic oil.

4.

Screw on the dust cap of the quick disconnect coupling.

Fill the hydraulic tank up to the top marker (= rated filling level).

This marker applies at room temperature (approx. 20°C / 68°F) and when all cylinders are retracted (Z 39 282).

The lower marker (= minimum filling level) must not be undercut, even when all cylinders are extended, as otherwise the hydraulic pumps may be damaged (Z 39 282).

5.

059--2120--090a_en

Check to make sure that all tank shutoff points (4) are opened. All tank shutoff points (4) must be open.

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12/45

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Hydraulic System 12

12.7

Bleeding the Hydraulic System As a rule, the hydraulic system is bled automatically.

For this, allow the drive engine to run for approx. 10 minutes at a slightly increased idling speed (approx. 1000 rpm).

Do not actuate any pilot control levers.

Hydraulic pumps are connected during the depressurised cycle.

In order to prevent damage to seals and hydraulic elements, the system should be bled while depressurised.

If components of the hydraulic system are replaced during repairs, as a rule no particular instructions must be observed to bleed the hydraulic system following the approx. 10 minute long depressurised cycle.

All the functions are subsequently briefly run.

Hydraulic cylinders must be extended and retracted up to their respective final positions.

12.8

Checking the Hydraulic System for Leaks The lines and unions of the hydraulic pumps laid in the engine compartment must be replaced if damaged due to mechanical, thermal or other effects.

Ensure that all the lines and hoses are at a sufficient distance from hot engine parts (e.g. exhaust system) and are laid such that they do not chafe.

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12

1

2

Z 30 192

4 SH

20 ∅

NNNNNN 4SH 20 DIN 20 023 3Q94

1

14/45

2

3

4

5

Z 30 193

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Hydraulic System 12

12.9

Hydraulic System Checking the Flexible Pressure Tubing (Z 30 192) Check all the hoses regularly for leaks. Even if the slightest damage is found during this visual inspection, the defective hoses must be replaced immediately.

Examples of possible defects in the hoses:

12.10

1.

Damage to the outer layer (1) (scoured areas, cuts, cracks, etc.)

2.

Ageing of the material of the outer layer (1) (crack formation)

3.

Deformation which does not correspond with the natural shape of the hose (loosening of the layers, formation of holes, compressed areas, buckling areas, twisting).

4.

Leaks

5.

Requirements for fitting and installation not observed (see DIN 20 066 Part 4 “Fitting the Hoses”)

6.

Fixing of the hose to the hose fitting (2) damaged.

7.

Hose fitting (2) corroded, deformed or damaged.

8.

Storage time or usage period exceeded (see point 12.10)

Hydraulic System - Changing Pressure Hoses Even if no damage is determined, the hoses must be replaced after 6 years of operating time at the very latest, including a storage time of a maximum of 2 years.

Identification of the hydraulic hoses: (Z 30 193) The hydraulic hoses are marked with the following details: − (1) manufacturer − (2) hose type (classification) − (3) nominal width − (4) DIN standard drawing − (5) date of manufacture (quarter and year of construction) The date of manufacture on the hydraulic hose forms the basis of calculating the operating and storage time.

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12

RKF

RKL

1

Z 54 614

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Hydraulic System 12

12.11

Hydraulic System - Handling the Hose Couplings Pipe couplings Legend: (Z 54 614) 1.

Knurled nut

Pipe couplings are hose couplings which can be closed on both sides. The valves in the fixed and loose halves open and close automatically during the coupling process. To make sure they work perfectly, the two halves must be screwed as far as possible onto the connection threads.

Coupling Screw them together by turning the knurled nut (1) as far as possible.

Decoupling The hydraulic system must be depressurised before disconnecting the hose coupling.

Stopping the drive motors (ignition off) Danger of scalding Let the hydraulic oil cool down before opening the hydraulic system.

Depressurise the hydraulic system by opening a mini pressure gauge coupling.

Disconnect the hose coupling by turning the knurled nut (1).

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12

3

1

2

2

Z 30 194

SP1

18/45

SP2

SP3

Z 55 956

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Hydraulic System 12

12.12

Hydraulic System Checking the Accumulator Initial Gas Pressure (Z 30 194, Z 55 956) The accumulators used in the hydraulic system of the crane are diaphragm--type pressure or bubble reservoir accumulators with nitrogen filling.

They are fitted in the slew gear control equipment of the crane.

The corresponding components will only function perfectly if the accumulator fitted is charged with the initial gas pressure specified.

This initial gas pressure must be checked at regular intervals.

In order to check the initial gas pressure a filling and testing device is required for the bubble reservoir.

This inspection may only be performed by a specialist trained in the use of this filling and testing device.

Proceed as follows to test the accumulator and/or fill if necessary: 1.

Switch off the drive engine on the superstructure and put the ignition switch into position “0”.

2.

Depressurise the hydraulic system.

The accumulator (2) must be completely emptied of hydraulic oil.

Check this on a pressure gauge if a test nipple is available or gently loosen the union nut on the hydraulic line on the oil connection for the accumulator.

The system is depressurised when no pressure is shown on the pressure gauge or when no hydraulic oil escapes from the loosened union nut.

3.

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Remove the safety guard (1) on the gas valve of the accumulator (2) and screw on the filling and testing device (3).

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12

3

2 5

4

Z 40 155

SP1

20/45

Z 40 157

SP2

SP3

Z 55 956

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Hydraulic System 12

(Z 55 956, Z 40 155, Z 40 157) 4.

Open the gas valve via the filling and testing device which is screwed on and read off the boost pressure on the pressure gauge of the testing device.

Preload pressure of the accumulator: − Accumulator (SP 1) 20 bar (290 psi) − Accumulator (SP 2) 30 bar (435 psi) − Accumulator (SP 3) 10 bar (145 psi)

5.

If the preload pressure is insufficient, the accumulator must be filled with nitrogen to the corresponding preload pressure via the filling device (3).

Following the initial filling, wait approx. two to three minutes, check the preload pressure again and top up if necessary.

Check the pressure gauge at the test nipple “X” when topping up the initial gas pressure on the accumulator.

The pressure in the corresponding hydraulic circuit must not increase.

If this is the case, the diaphragm in the accumulator is defective.

The accumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

If a considerable fall in pressure (approx. 60%) in the preload pressure is observed during the initial check, the accumulator must be checked again after approx. 3 to 4 weeks.

If another fall in pressure is then observed, the accumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

A pressure reducer (5) must be fitted on the nitrogen bottle.

Accumulators may only be repaired by the manufacturer or in approved workshops.

The accumulator must be officially accepted by an approved specialist following completion of repairs.

A new test certificate must be drawn up for the accumulator.

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21/45

12

Filling connection

Z 63 360

E

E1

E1

Z 63 361

22/45

Z 63 362

059--2120--090a_en

Hydraulic System 12

12.13

Lower Luffing Mast Back Stops

12.13.1 Lower Luffing Mast Back Stops - Checking the Oil Level (Z 63 360, Z 63 361, Z 63 362) The oil level must be checked before erecting the boom system.

It is expedient to have this take place while the derricking supports are being mounted.

The main boom and the fly jib assembled and lie on the ground in front of the crane.

The lower and upper derricking supports are both set down to the front on the jib foot.

H1 or H2 are connected below with the lower luffing mast in order for it to be raised.

W1 is reeved in the lower and upper luffing mast and the upper luffing mast is secured to the fly jib with a ratchet lashing strap in accordance with the assembly instructions. −

Use the upper receiving bore on the tank side to bolt the outrigger cylinder to the lower luffing mast. The piston rod must be retracted completely and the transport safety lock (chains or cable) must be fitted.

−

Use the auxiliary crane to move the outrigger cylinder into horizontal position.

−

Unscrew the oil inspection plug (K).

−

Check oil level. The oil level must be 2--3 cm (0.78 -- 1.2 inches) below the upper edge of the cylinder pipe when the cylinder is in horizontal position and the piston rod is completely retracted.

Top up oil as required. See Section 2, “Oils, Lubricants and Capacities”, for type of oil.

Lubricate the back stop cylinder pins before each erection procedure.

059--2120--090a_en

23/45

12

Filling connection

Z 63 360

E

E1

E1

Z 63 361

24/45

Z 63 362

059--2120--090a_en

Hydraulic System 12

12.13.2 Bleeding Outrigger Cylinder Lower Luffing Mast Cylinder (Z 63 360, Z 63 361, Z 63 362) The outrigger cylinder of the lower luffing mast must be inspected for trapped air in the cylinder before every erection of the boom system.

This check must take place during the erection of the derricking supports The main boom and the fly jib assembled and lie on the ground in front of the crane.

The outrigger cylinder is bolted not only to the lower luffing mast but also with the reducer.

H1 or H2 are connected below with the lower luffing mast.

W1 is reeved in the lower and upper luffing mast and the upper luffing mast is secured to the fly jib with a ratchet lashing strap in accordance with the assembly instructions.

The piston rod of the outrigger cylinder is completely retracted.

The transport safety lock between cylinder pipe and piston rod is removed. −

Loosen flanged nut (X1) and unscrew screws (X2) to the distance of 25 mm (0.984 inch). Secure screws (X2) with flanged nut (X1).

−

Reel in luffing rope W1 sufficiently until the piston rod of the outrigger cylinder has extended approximately 500 mm (19.685 inches). Reel out the hoist rope H1 or H2 accordingly.

−

Use a metric ruler to measure the length the piston rod has extended.

−

Reel out luffing rope W1 and reel in H1 and/or H2 accordingly, so that the weight of the lower derricking support comes to rest on the outrigger cylinder.

−

Measure the amount the piston rod have extended once again and compare with the value that was previously measured.

If the measured now length is less than the previously measured value by more than 5 mm (0.2 inch), then the cylinder must be bled, because otherwise air would be trapped in the cylinder.

To accomplish this, proceed as follows:

059--2120--090a_en

−

Reel in luffing rope W1 somewhat, so that the piston rod of the outrigger cylinder is relieved of load.

−

Unscrew the blind plug at connection E1 of the valve block and screw in a GE 6--PLM screw--in threaded connector.

25/45

12

Filling connection

Z 63 360

E

E1

E1

Z 63 361

26/45

Z 63 362

059--2120--090a_en

Hydraulic System 12

(Z 63 360, Z 630361, Z 63 362) −

Screw a measurement connector VKA 3/06LA3C and a miniature measurement line onto the screw--in threaded connector.

−

Slowly reel out luffing rope W1, thereby retracting the outrigger cylinder while doing so, until the air escapes from the cylinder and oil emerges.

−

Remove the miniature measurement line at once when oil emerges.

−

Undo the flanged nut (X1) and screw the screw (X2) in until it stops.

−

Reel out luffing rope W1 further until the piston rod is completely retracted.

−

Unscrew the set bolt (X2) to 25 mm (0.984 inch) and secure with flanged nut (X1).

−

Now repeat the procedure described above in order to ensure that there is no more air in the cylinder

After completely the bleeding procedure, do not fail to screw out the screw (X2) back to the distance of 25 mm (0.984 inch) and to secure it with the flanged nut (X1).

Filling the cylinder following repairs: The activity described below may only be carried out by a professional hydraulics fitter.

059--2120--090a_en

−

Place cylinders in horizontal position with the connections (E) and (K) facing upwards on a workbench or similar.

−

Open connections (E) and (K).

−

Connect the pressure line of a hydraulic power pack to the connecting port (E).

−

Connect the return line to the connection (K) in order to channel the escaping oil into an empty container or similar.

−

Undo the flanged nut (X1) and screw the screw (X2) in until it stops. The non--return valve is now unblocked and the oil can flow through the cylinder into the tank during the filling procedure.

27/45

12

Filling connection

22

Z 63 655

E

E1

E1

Z 63 361

28/45

Z 63 362

059--2120--090a_en

Hydraulic System 12

−

For approximately 5--7 minutes, pump hydraulic oil at low pressure and low speed at connecting port (E) through the cylinder and collect it at connecting port K.

−

Unscrew the pressure pipe of the hydraulic power pack at connecting port (E) and screw in sealing plug without allowing air to enter the cylinder.

−

Place the cylinder in a vertical position and unscrew the return line at connecting port (K). The oil in the tank of the cylinder must now be at the lower edge of the inspection opening (K). Screw in sealing plug.

−

Unscrew the cylinder screw (X2) to 25 mm (0.984 inch) and secure with flanged nut (X1).

The non--return valve in the valve block is now functioning again.

12.13.3 Checking the Lower Luffing Mast Back Stops for Leaks (Z 63 360, Z 63 361, Z 63 362) Check the valves, lines and cylinder seals for leaks.

Replace any parts which leak.

Operation is not permitted when the back stops are defective or when they leak.

12.13.4 Lower Luffing Gear Back Stops Checking the Screw Connections (Z 63 655) Check that the screws (22) are tightly fitted and retighten if necessary.

Lubricate the screw head and thread with KP2K; Tightening torque Ma = 210 Nm (154.88 lbf--ft).

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29/45

K

12

Level

K

Z 63 357

Z 63 358

K

Z 63 359

30/45

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Hydraulic System 12

12.14

Outrigger Cylinder for Outrigger Strut LF (Z 63 357, Z 63 358, Z63 359)

12.14.1 Support Cylinder for Support LF – Check Oil Level, Deaerate Cylinder The oil level must be checked before fitting the outrigger cylinder to the outrigger strut LF and before each erection procedure.

Bolt the cylinder with the upper fixing point (tank side) to the luffing mast in such a way that it hangs perpendicularly downward.

Undo the transport safety lock at the piston rod and pull rod out by approximately 400 mm (15.75 inches).

Open inspection plug (K) and stop valve (H).

The stop valve is open when the lever is perpendicular to the pipeline.

Undo the flanged nut (X1) and screw the screw (X2) all the way in.

Press the piston rod of the cylinder all the way in.

The cylinder has now been bled and the oil level must be at the lower edge of the inspection bore hole (K).

If required, top up the oil to the lower edge of the inspection bore hole (for oil type, see Sect. 2) Close stop valve (H), unscrew set bolt (X2) out 25 mm (0.984 inch) and retighten with flanged nut (X1).

Screw the inspection plug (K) back in.

With the stop valve closed (H) and the set bolt (X2) screwed out 25 mm (0.984 inch), the piston rod can be pulled out by hand in order to pin it, for example.

If the piston rod is to be pushed in manually, then the stop valve (H) must always be open and the set bolt (X2) must be screwed all the way in.

When sliding the piston rod in or pulling it out, the cylinder must always be in vertical position – with the piston rod pointing downwards -- in order to ensure that no air can make its way into the cylinder.

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31/45

K

12

Level

K

Z 63 357

Z 63 358

K

Z 63 359

32/45

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Hydraulic System 12

12.14.2 Outrigger Cylinder for Outrigger Strut LF - Filling With Oil (After Repairs) (Z 63 357, Z 63 358, Z63 359) The activity described below may only be carried out by a professional hydraulics fitter.

The fly jib must be lying on the ground for filling with oil.

Outrigger cylinder in horizontal position, filling bore hole (E) and inspection bore hole (K) facing upwards and piston rod slid in completely To slide in the piston rod, undo flanged nuts (X1) and screw in cylinder screw (X2), open stop valve (H). The non--return valve in the valve block is now opened.

The piston rod can now be slid in and the stop valve (H) can be closed again Unscrew the inspection plug (K) and connect a return line to the collecting vessel (drum) at the inspection opening (K).

Screw out the screw plug (E) and connect a hydraulic power pack to this opening.

The transport safety lock is still fitted, the stop valve (H) is closed and the set bolt (X2) is screwed in until it stops and secured with a flanged nut (X1).

Now allow oil to be pumped through the filler neck (E) through the cylinder for approximately 5--7 minutes, until the oil flows bubble-free into the drum.

Remove the line from the filler neck and screw in the screw plug without allowing air to enter.

It must be ensured that there is no air trapped in the cylinder.

Place the cylinder in vertical position (tank facing upwards), remove hose from the inspection opening and make sure that the oil level is at the lower edge of the inspection bore hole.

Screw in the inspection plug.

Unscrew the set bolt (X2) to 25 mm (0.984 inch) and secure with flanged nut (X1).

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12

12 27

X N

860

7.8

11

9.1

7.9 A

Einzelheit “X” Detail “X”

E

Z 60 940

34/45

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Hydraulic System 12

12.15 Outrigger Cylinder Fly Jib 12.15.1 Outrigger Cylinder Fly Jib - Checking for Leaks (Z 60 940) Before fitting the outrigger cylinder (27) to the foot section of the fly jib (9.1) and before each erecting procedure, each outrigger cylinder must be checked for leakage and for any damage.

12.15.2 Outrigger Cylinder Fly Jib - Checking the Oil Pressure (Z 60 940) The oil pressure check must be carried out with the outrigger cylinder fully extended (L = 860 mm / 33.86 inches).

1.

Remove the steel protective cap from the vent connection “E”.

2.

Screw the pressure gauge onto the test nipple connecting thread M16x2.

3.

Read the pressure and compare with the value in the “Table for pressure test”, column “Oil pressure p1 at temperature T”.

4.

Unscrew the pressure gauge.

5.

Screw on the steel protective cap on the vent connection “E”.

12.15.3 Outrigger Cylinder Fly Jib - Checking the Gas Pressure (Z 60 940) This check may only be carried out by trained personnel using the gas filling and inspection device.

This gas pressure check must be carried out with the outrigger cylinder fully extended (L = 860 mm / 33.86 inches).

A gas filling and inspection device is required for checking the gas pressure (for example from the company HYDAC, type: FP K 100).

1.

Remove the screw cap (36) from the gas filling connection “N”

2.

Slightly loosen the cylinder screw (10) with hexagon socket screw key SW 6 (approx. 1/2 turn).

Cylinder is under preliminary tension! No gas should be permitted to escape!

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12

12 27

X N

860

7.8

11

9.1

7.9 A

Einzelheit “X” Detail “X”

E

Z 60 940

36/45

059--2120--090a_en

Hydraulic System 12

Continued: Check the gas pressure 3.

Insert the spindle of the gas filling and inspection device into the hexagon socket screw key SW 6.

4.

Screw on the union nut M28x1.5 and tighten manually.

5.

Close the stop valve of the gas filling and inspection device.

6.

Unscrew the spindle slowly and read the gas pressure on the pressure gauge. Compare the read value with the value in the “Table for pressure test”, column “Gas pressure p1 for temperature T”.

7.

Screw on the spindle again and tighten manually.

8.

Briefly open the stop valve of the gas filling and inspection device in order to release pressure.

9.

Screw off union nut M28x1.5.

10. Tighten the cylinder screw (10) again (Ma = 25 Nm / 18.4 lbf--ft).

11. Check the gas filling connection “N” for leaks using seal spray or soapy water.

12. Screw on the screw cap (36) again.

12.15.4 Correcting the Oil and/or Gas Pressure and Filling the Outrigger Cylinder (Z 59 744) Before any corrective measures are undertaken with relation to the oil or gas pressure −

the outrigger cylinder must be fully extended (1690 mm / 66.54 inch).

−

the oil compartment must be without pressure.

Depressurising the oil compartment Danger of injury! due to oil gushing out under high pressure.

Depressurise the oil compartment by screwing a hose with a test nipple onto the vent connection “E” and draining the leaking oil into a container.

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12

12 27

X N

860

7.8

11

9.1

7.9 A

Einzelheit “X” Detail “X”

E

Z 60 940

38/45

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Hydraulic System 12

Reducing the gas pressure The reduction of the gas pressure must be carried out while the oil compartment is depressurised.

1.

Remove the cap of the gas filling connection “N”.

2.

Carefully unscrew cylinder screw (10) approx. 1 turn using the hexagon socket screw key SW 6.

3.

Let nitrogen escape slowly.

4.

Set the gas pressure p 0.

Refer to the “Table for pressure test”, column “Gas pressure p 0” to find the gas pressure value required for the respective temperature.

Increasing the gas pressure The gas pressure must be increased while the oil compartment is depressurised.

A gas filling and inspection device is required for increasing the gas pressure (e.g. from the company HYDAC, type: FP K 100).

Only NITROGEN (N2, purity 99.8 %) may be used for filling. !! Risk of explosions!!

Under no circumstances may oxygen be used!

If the pressure in the gas container is higher than the permitted operating pressure of the outrigger cylinder, a gas pressure limit valve must be used.

059--2120--090a_en

1.

Connect the gas filling and testing device to the gas filling connection “N”.

2.

Connect the gas container with the hose to the gas filling and inspection device.

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12

12 27

X N

860

7.8

11

9.1

7.9 A

Einzelheit “X” Detail “X”

E

Z 60 940

40/45

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Hydraulic System 12

3.

Slowly open the gas container valve, constantly checking the pressure at the pressure gauge.

Interrupt the filling procedure several times by closing the stop valve and check the gas pressure after an approximate waiting time of 5 minutes.

Refer to the “Table for pressure test”, column “Gas pressure p 0” to find the gas pressure value required for the respective temperature.

The Usit ring (26) can become damaged when filling is done too quickly.

4.

After completing the filling procedure, close the gas container and remove the gas filling and inspection device from the outrigger cylinder.

5.

Tighten the cylinder screw (10) again (Ma = 25 Nm / 18.4 lbf--ft).

6.

Check the gas filling connection “N” for leaks using seal spray or soapy water.

7.

Screw on the screw cap (36) again.

Filling the oil compartment --Only filtered hydraulic oil HLP 46 may be used.

--A hydraulic hose with union 8 S (union nut M16x1.5) as well as a pump unit with pressure filter must be used.

--The oil compartment must be filled with the outrigger cylinder fully extended (L = 1690 mm / 66.54 inches).

--The vent connection “E” must be at the highest point during filling.

After the gas pressure setting has been completed, the oil compartment of the outrigger cylinder can be filled with filtered hydraulic oil HLP 46 as described in the following.

059--2120--090a_en

1.

Remove the protective cap from the oil filling connection “A” and from the vent fitting “E”.

2.

Connect the hydraulic hose to the oil filling connection “A”.

3.

Screw on the hose with the test nipple to the vent fitting “E”.

4.

Prepare a container for collecting the rinsing oil.

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12

12 27

X N

860

7.8

11

9.1

7.9 A

Einzelheit “X” Detail “X”

E

Z 60 940

42/45

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Hydraulic System 12

Continued: Filling the oil compartment 5.

Rinse the oil compartment using filtered hydraulic oil via the oil filling connection “A” and the vent fitting “E”.

6.

Unscrew hose with test nipple from the vent fitting “E”. The vent fitting is now closed.

7.

Slowly fill the outrigger cylinder with hydraulic oil up pressure p1 (see table for gas checks).

8.

After a waiting period of 5 minutes, release the pressure by connecting the hose with a miniature test port in the vent fitting “E” again.

Repeat this procedure (but at least three times) until air bubbles no longer escape from the vent fitting “E”.

9.

Set the pressure in relation to the temperature (See “Table for pressure test”, column “Oil pressure p1”)

The pressure setting must be carried out precisely (setting tolerance +/-- 2 bar I +/-- 29 psi).

10. Pressure correction measures: --Pressure reduction by draining the hydraulic oil at the vent fitting “E”.

--Pressure increase by topping up with hydraulic oil via the oil filling connection “A”.

11. Remove the hoses from the oil filling and vent fitting connections.

12. Screw the protective caps back on.

059--2120--090a_en

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44/45

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Hydraulic System 12

Table for gas checks Temperature T

Gas pressure p1 +/-- 2 at temperature T

Oil pressure p1 +/-- 2 at temperature T

degree C

degree F

bar

50

+122.0

98.1

1422.82

98.1

1422.82

95.9

1390.91

45

+113.0

96.6

1401.07

96.6

1401.07

94.4

1369.16

40

+104.0

95.1

1379.31

95.1

1379.31

92.9

1347.40

35

+95.0

93.6

1357.55

93.6

1357.55

91.5

1327.10

30

+86.0

92.0

1334.35

92.0

1334.35

90.0

1305.34

25

+77.0

90.5

1312.59

90.5

1312.59

88.5

1283.58

20

+68.0

89.0

1290.84

89.0

1290.84

87.0

1261.83

15

+59.0

87.5

1269.08

87.5

1269.8

85.5

1240.07

10

+50.0

86.0

1247.33

0

0

84.0

1218.37

5

+41.0

84.4

1224.20

0

0

82.5

1196.57

0

+32

82.9

1202.36

0

0

81.1

1176.26

--5

+23.0

81.4

1180.61

0

0

79.6

1154.5

--10

+14.0

79.9

1158.85

0

0

78.1

1132.75

--15

+5.0

78.4

1137.10

0

0

76.6

1110.99

--20

--4.0

76.8

1113.89

0

0

75.1

1089.23

--25

--13.0

75.3

1092.13

0

0

73.6

1067.48

059--2120--090a_en

psi

bar

Gas pressure p0 +/-- 2 at temperature T

psi

bar

psi

45/45

Heating and air-- conditioning 13

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1/33

13

Z 53 921

6

1

2 3 4 5

B

A

Z 39 292

2/33

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Heating and air-- conditioning 13

13

Heating and Air conditioning

13.1

Checking the System is Functioning Correctly The manufacturer’s operating instructions for the hot water heater D 5WS must be followed.

Switch on the heating briefly (for approx. 10 minutes) approximately once a month, even outside of regular heating periods.

This prevents the water pump and the burner motor from seizing up.

Do not operate the heating in enclosed spaces.

If the heater assembly does not start after switching on, proceed as follows:

059--2130--057a_en

1.

Check the components for mechanical damage.

2.

When switching to winter operation, check to see if there is any summer diesel remaining in the fuel line.

3.

Check the exhaust and combustion air lines.

4.

Check the fuses in the fuse panel (Z 53 921).

Replace blown fuses if necessary. (see Section 13.1.1 “Checking the Fuses”.)

5.

Switch the heating off and on again. Not more than twice. If the heating still fails to start, have the error repaired in a workshop.

6.

Check to see if an error code is indicated in the display (6, Z 39 292) of the heater (error code table see from page 11).

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13

A

93

97

95

Z 42 602

6

5 4 3 2 1 Z 39 294

4/33

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Heating and air-- conditioning 13

13.1.1

Checking the Fuses The fuses inserted in the fuse panel (11) are allocated as follows: (Z 42 602) Item 93

-- Fuse F 10 A: Main fuse for heater assembly

Item 97

-- Fuse F 10 A: Control (e.g. heater timer)

Item 95

-- Fuse F 10 A: for cab fan

If the 10 A fuse has blown, the heater assembly will start but no warm air will be circulated.

The blown fuse must be replaced by a new one after the inspection.

13.1.2

Error Diagnosis with the Heating Timer (Z 39 294) If the control unit recognises an error when the heater is switched on or during operation of the heater, the error is displayed within 15 seconds by the heating timer with a letter F and 2--digit number.

Indication in the display: eg

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F 64 (current error) and flashing heater symbol

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13

6

5 4 3 2 1 Z 39 294

6/33

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Heating and air-- conditioning 13

(Z 39 294) Calling up the error memory in the control unit with the heater timer The electronic control unit can save up to 5 errors which are then read off and displayed using the heater timer.

The current error is always written in memory position F1.

Previous errors are stored in positions F2 -- F5, the content of memory position F5 is overwritten as required.

Calling up the error memory Condition: The heater is switched off.

Press button 3 -- the heater is switched on -- then press button 1, hold pressed down and press button 2 within 2 seconds.

The heater flashes and the current error is displayed.

Using buttons 4 and 5, the errors stored in memory positions F1 and F5 can be called up.

Error code, error description, comments are described on page 11.

Please note!

Not only the defective component, but also a defective current path leads to an error display.

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6

5 4 3 2 1 Z 39 294

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Heating and air-- conditioning 13

(Z 39 294) Disabling the control unit

Overheating If the heater overheats 10 x in sequence -- error F12 -- F15 is indicated in the display, ie the control unit is disabled.

Too many start attempts If the heater attempts 10 starts without success -- error F50 -- F50 is indicated in the display, ie the control unit is disabled.

Reverse the disabling of the control unit by deleting the error memory -- after the cause of the error has been rectified Condition: There is an electrical connection from the 12--pin plug, terminal 10 of the heater timer to terminal 15 (ignition).

Press button 3 -- the current error F15 or F50 is displayed -- then press button 1, keep pressed down and press button 2 within 2 seconds.

The heater timer is now in the program “call up error memory”.

Continue operation: Switch off ignition (terminal 15).

Press buttons 1 and 2 at the same time, keep pressed down, in addition switch on the ignition (terminal 15) and wait until the following is shown in the display.

Display on screen after ignition “ON”

Screen flashing, heater symbol not flashing

After 3 seconds the control unit is enabled, the heater then starts up.

Display on screen after heater has started

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Screen flashing, heater symbol not flashing

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Heating and air-- conditioning 13

Error code table

Error code 010

Error description

Comment

Overvoltage -- shut--off

Overvoltage for at least 20 sec. uninterrupted on the control unit ----> heater without function.

011

Low voltage -- shut--off

Voltage too low for at least 20 sec. uninterrupted on the control unit ----> heater without function.

012

Overheating (software -- threshold value)

014

Possible overheating recognised (evaluation of difference)

Temperature at the overheating sensor >125°C (+257°F).

Difference in the temperature levels of the overheating sensor and the temperature sensor > 25K. Condition for this error code display is that the heater is in operation and the water temperature on the overheating sensor has reached at least 80°C (+176°F).

015

Operation disabled -- system has overheated more than the permitted 10 times Overheating detected -- EMERGENCY OFF (hardware threshold value) Glow plug interruption

017 020 021 030

Glow plug failure -- short circuit, overload or short circuit to ground Speed of the combustion air fan motor outside the permitted range

031

Combustion air fan motor interruption

032

Combustion air fan motor -- short circuit, overload or short circuit to ground

038

Relay control of the vehicle fan -- interruption Relay control of the vehicle fan -- short circuit, overload or short circuit to ground

039

059--2130--057a_en

The control unit is disabled.

Temperature at the overheating sensor >130°C (+266°F).

Fan wheel or combustion air fan motor blocked (frozen, clogged, restricted, cable strand brushing against end of shaft ...).

Fan wheel or combustion air fan motor blocked (frozen, clogged, restricted, cable strand brushing against end of shaft ...).

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12/33

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Heating and air-- conditioning 13

Error code 041

Error description

042

Water pump -- short circuit, overload or short circuit to ground

047

Metering pump -- short circuit, overload or short circuit to ground Metering pump -- interruption

048

Comment

Water pump -- interruption

050

Operation disabled as too many start attempts have been made (10 start attempts, in addition to a start repeat for each start attempt)

Too many start attempts, the control device is disabled.

051

Time out -- cold blowing

During the start the flame probe detects a temperature >70°C (+158°F) for longer than 240 seconds.

052

Safety time exceeded

053 056

Flame shut--off at control level “high” Flame shut--off at control level “low”

060

Temperature sensor -- interruption

061

Temperature sensor -- short circuit, overload or short circuit to ground Flame probe -- interruption

064

059--2130--057a_en

Warning If the flame is shut off from the “high” or “low” setting and more start attempts are permitted, the heater automatically attempts a new start, if necessary with a start repeat.

If the new start or the start repeat was successful, the error code display is deleted.

Error (because a further start attempt is not permitted).

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13

14/33

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Heating and air-- conditioning 13

Error code 065 071 072 090 / 092 -103 091

Error description

Comment

Flame probe -- short circuit, overload or short circuit to ground Overheating sensor -- interruption Overheating sensor -- short circuit, overload or short circuit to ground Control unit defective

External interference voltage

059--2130--057a_en

Replace control unit

Malfunction of the control unit as a result of interference voltages from the onboard power supply, possible causes: Poor batteries, charging set, other error sources; remedy interference voltages.

15/33

13

4.1 4

Z 53 923

16/33

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Heating and air-- conditioning 13

13.2

Checking the Water Level 1.

Unscrew the cover (4.1, Z 53 923).

Depending on the design, the heater system is correctly filled when the water comes up to the edge of the filler neck or the marking on the filler neck.

2.

Add water as required.

3.

Determine the cause of any loss of water and remedy.

--

To protect against corrosion, the water should contain at least 10 % antifreeze all year round.

--

In cold weather conditions, the water must contain sufficient antifreeze.

Operation of the heater with frozen water is prohibited.

After any work carried out on the heating system (repairs, change of water) the heater unit must subsequently be ventilated.

13.3

Replacing the Heat Exchanger The heat exchanger is designed for a service life of 10 years and must be replaced after this period of time with an original spare part by the manufacturer or a workshop appointed by the manufacturer. The heater must then be fitted with a plate which carries the date of sale for the heat exchanger and the words “original spare part”.

059--2130--057a_en

17/33

13

5

1

2,3

7

6

7

Z 56 831

2 6

1 2

5

5 4

3 1

Z 56 832

18/33

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Heating and air-- conditioning 13

13.4

Air Conditioning Legend: (Z 56 831, Z 56 832):

13.4.1

1.

Collector dryer (fluid container)

2.

Compressor

3.

Compressor holding device

4.

V--belts

5.

Condenser

6.

Evaporator

7.

Cab

Switching on the Air Conditioning Equipment The air--conditioning equipment must be switched on once per month for at least 10 minutes to prevent the shaft sealing in the compressor from drying and becoming brittle. Otherwise, there is a danger that refrigerant escapes from it. Furthermore, the compressor components will thereby be regularly greased.

13.4.2

Servicing the Air Conditioning Equipment (Z 56 832) Maintenance and repairs at the refrigeration circuit of the air--conditioning equipment may only be carried out by experts.

Safety Instructions

059--2130--057a_en

1.

Danger of burning!

Do not come into contact with the condenser and its connections. Lines and tubes for refrigerant may get hot and be under pressure.

2.

Risk of explosions!

Do not carry out any soldering and welding directly at those parts within the closed cooling circuit or in their near vicinity.

The pressure in the air--conditioning rises due to the increased heat and this may result in explosions.

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13

5

1

2,3

7

6

7

Z 56 831

2 6

1 2

5

5 4

3 1

Z 56 832

20/33

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Heating and air-- conditioning 13

Visual checks (Z 56 831, Z 56 832) The following visual checks should be carried out monthly by the crane operator: 1.

Check the tension of the v--belts (4) and the fixture of the compressor (2).

2.

Check the coolant fill--up (1).

The refrigerant must thereby flow bubble--free through the inspection glass of the collector dryer (1) with running motor and at the highest rate of power of the air--conditioning (set control knob in the crane cab for temperature selection and blower level to the max. position).

If there are bubbles in the inspection glass then there is not enough refrigerant in the air--conditioning. The air--conditioning must be checked by an authorised service company for leaks and then re--filled.

After switching off, the fluid level in the reservoir should sink again. This is the only way to ensure that the reservoir is not over-filled.

The air conditioning equipment may only be filled by a specialist workshop.

3.

Check the condition of the refrigerant and heating lines.

Check the fixture, tightness and wiring path of the tubes and wiring.

4.

Check electrical connection lines and plug connections for perfect condition and tight connection.

5.

Clean clogged evaporator.

Cleaning is performed by blowing out or spray washing (do not use high--pressure water blasting) Lamellas that have been pushed in by outside influences can once more be straightened out.

Check drainage for perfect condition.

The condensation water created must not be used as drinking water.

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Heating and air-- conditioning 13

13.4.3

Having the Air Conditioning Equipment Checked To ensure the perfect function of the air--conditioning,

13.4.4 Result

--

the following must be checked every six months by a specia-list workshop: The refrigeration circuit for the level of refrigerant The condition of the collector dryer The perfect functioning of the compressor and the magnetic coupling.

--

Every 2 years of after any action or work on the refrigeration circuit, the collector dryer must be replaced by a specialist workshop.

Error Diagnosis for Condenser Cause

Insufficient air flow at conden- Dirt at the lamellas of the ser condenser

Loss of refrigerant

Clean the lamellas with a water spray.

Note: do not use high--pressure cleaner.

Clogged pump inlet

Cleanpump inlet

Clogged or saturated collector dryer.

Replace the collector dryer. A clogged dryer can be checked during operation by measuring the temperature of the refrigerant at the inlet and outlet of the dryer. A temperature difference of 2--3° indicates that the collector dryer is clogged.

Break in the refrigerant cir- Check all lines for a break caused cuit by outside influences or galling Leak in the system

059--2130--057a_en

Measure

Evacuate, fill, check for leak and carry out repairs

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Heating and air-- conditioning 13

13.4.5

Error Diagnosis for Heat Conditioning Unit

Malfunction

Cause

Remedy:

Blower not functioning

Loose or defective fuse

Check seating of fuse and insert correctly if required. Replace defective fuse. If a defect once more occurs within a short period after replacing the fuse then this indicates that there is a short--circuit or a blockage. Check the blower for a blockage or another defect and remedy the cause.

Break in power

Check lines for loose contacts or breaks Replace the blower

Defective blower motor Defective blower switch Blower can not be switched off Short--circuit in the cable or in the blower switch Blower works at reduced power

Blower does not run in all levels

Contacts are dirty

Clean the plug contacts. Be careful in order to avoid short-circuits.

Electrical lines are not thick enough The micro--temperature fuse (MTS) has triggered.

Lay lines with the recommended cable cross--section Replace the resistor and check the blower motor for causes of the functional impairment.

Defective blower switch

Replace switch with original spare part of the manufacturer.

Loose connection plug

Check plug connection for firm seating and mount correctly if required

Defective resistor

059--2130--057a_en

Check and replace switch if required Remedy the short--circuit and mount new cable and/or switch if required.

Check connection at blower switch Mount new resistor

25/33

13

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Heating and air-- conditioning 13

Continued: Error diagnosis for heat conditioning unit

Malfunction

Cause

Remedy:

No or insufficient heating power

Inlet temperature is too low Defective vehicle thermostat

Wait until the vehicle motor is warm Replace the thermostat

Clogged heat exchanger lamellas

Check the heat exchanger and clean if required

Clogged filter

Clean or replace filter

Bent or crushed lines

Remedy the cause of the error or re--lay the tubes The coolant is not flowing through the heat exchanger.

Mount an additional pump, or a more powerful one.

Water pump pressure is too low

Coolant leakage at the unit

Tube connection has become loose

Check the seating of the tube lines and tighten the tube clamps

Damaged tube

Lay down and connect a new tube Install an original spare part and connect it (attention! observe safety instructions)

Heat exchanger is damaged

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13

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Heating and air-- conditioning 13

Cooling power:

Malfunction

Cause

Remedy:

Compressor is not working

Break in the solenoid coil of the compressor V--belts are loose or torn

Check current flow to the coupling Set correct V--belt tension or renew V--belts Check the compressor and replace if required

V--belt pulley does not rotate although the magnetic coupling is applied The compressor coupling slides Defective controls The evaporator is flooded The evaporator is frozen

The evaporator is clogged Loss of refrigerant

Insufficient cooling power

059--2130--057a_en

The expansion valve is stuck when open or is frozen The thermostat sensor is at an incorrect position The expansion valve or the thermostat is defective The lamellas are clogged or dirty Break in the refrigerant circuit

Repair the coupling or replace the compressor Check the controls and replace if required Replace the expansion valve Re--position the sensor Replace the expansion valve or the thermostat Clean the evaporator Check all lines for a break caused by outside influences or galling

Leak in the system

Evacuate, fill, check for leak and carry out repairs

Blower throughput is hindered

Check the air inlet or outlet for impairments. Remedy the error

The fill level of the refrigerant is too low Damp in the system

Top up the refrigerant (service mechanic) Empty the air--conditioning, replace the collector dryer, evacuate and fill (service mechanic)

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13

30/33

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Heating and air-- conditioning 13

Continuation of cooling power:

Malfunction

Cause

Remedy:

Insufficient cooling power

The collector dryer is saturated or blocked Dirt in the lamellas of the condenser

Replace the collector dryer.

The system cools with breaks

Line break Check the lines, repair or reLoose contacts in the solenoid place coil of the compressor Defective blower motor

059--2130--057a_en

Clean the lamellas Note: do not use high--pressure cleaner.

Replace the blower

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13

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Heating and air-- conditioning 13

The system is very loud:

Malfunction

Cause

Remedy:

The system is very loud

Loose V--belts or excessively worn The coupling is loud

Re--tighten or replace the V-belts Repair the coupling

The holding device of the Repair the holding device; Recompressor is loose or internal place the compressor parts of the compressor have been knocked out

059--2130--057a_en

The blower motor is excessively worn The system is overfilled

Replace the blower

Not enough refrigerant in the system

Make a leak check; Top up the system

Suck off refrigerant until the display of high--pressure returns to normal

33/33

Electrical System 14

059--2140--083_en

1/13

14

Z 39 297

2/13

059--2140--083_en

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 39 297) (Example: Aircraft warning rotaflare light)

14.2

Checking the Limit Switches.

14.2.1

Lower Limit Switch - Check Function It is best to carry out this inspection of the lower limit switches when one large number of strands is reeved and one large boom length is fitted.

Then lower the hook block with the hoist until the lower limit switch switches off this movement for the respective hoist. Then check to make sure that there are at least three turns of the rope remaining on the rope drum.

Carry out this check at regular intervals whenever the crane is in the suitable configuration.

14.2.2

Hoist Limit Switch - Checking Functionality Retract the hoist limit switch on a daily basis and check functionality.

For this, raise the hook block with the hoist to such an extent that the shift weight is relieved of load. The “Raise hoist” movement must then be switched off.

14.3

Checking the Slip Ring Contacts on the Rope Winches and on the Rotary Joint to the Undercarriage Condensation in the housing can lead to clogging and corrosion of the contacts.

059--2140--083_en

1.

Unscrew the housing cover.

2.

Check the slip ring contacts and clean if necessary. Spray the contacts with contact spray (Parts No. 174 427 40).

3.

Remove any condensation water.

4.

Screw on the housing cover and carry out a test run of the functions involved.

3/13

14

4/13

059--2140--083_en

Electrical System 14

14.4

Precautionary Measures Against Cable Fires Cable fires in electrical components and systems do not result from technical errors but from carelessness or manipulation of the components and/or the circuit. Moreover, the use of original parts is absolutely essential when replacing parts in the case of repairs.

The use of non--original parts with their subsequent effects on the electrical system can only be overlooked with great difficulty.

They can lead to malfunctions in the individual electrical circuits.

The electrical current is recognised only by its effects.

One of these is the heat effect Every live conductor normally heats up slightly. As a result of high currents which are not permitted, high temperatures and thus fires may occur.

In order to prevent this happening, fuses must be fitted in the individual electrical circuits. These fuses break the electrical flow of current if this rises above the maximum permitted value.

Fuses protect the cables of the electrical system in the case of short circuits.

They must not be bridged, even very briefly.

Under no circumstances may larger fuses (higher ampere value) be used.

Faulty fuses are consequently one of the main causes of cable fires.

059--2140--083_en

5/13

14

6/13

059--2140--083_en

Electrical System 14

Other causes may be: −

impermissible and/or defective cables or cable connectors (cable section not sufficient)

−

impermissible and/or defective consumers or operating elements (relays, motors, switches, lights, etc.),

−

connecting up additional consumers to one fuse (overloading of cables and fuse),

−

fitting a battery which is too large in size or of a different design (fitting dimensions of the battery box are exceeded, danger of short circuiting through ground contact at positive pole),

−

moisture penetrating into components of the electrical system after cleaning with water or a steam jet device,

−

the electrical system being in bad condition due to insufficient maintenance and inspections.

All of the points cited above may lead, either individually or together with several other points, to a scorching or open cable fire.

Effective protection against this can be achieved if the following measures are observed.

Precautionary measures: −

The electrical equipment of the crane must be inspected / checked regularly.

Deficiencies such as loose connections and burned cables must be rectified immediately. Likewise their causes must also be found and eliminated.

−

Check all electrical lines, connectors and terminals for loose fittings and damage (recognised by oxide formation at terminals or at battery poles).

Rectify any damage found immediately.

Work on electrical systems or equipment must only be undertaken by a qualified electrician or by instructed persons under the direction and supervision of a qualified electrician in accordance with the electric--technical regulations.

059--2140--083_en

7/13

14

8/13

059--2140--083_en

Electrical System 14

−

Only use original spare parts and original fuses of the prescribed strength. (see spare parts catalogue or electrical circuit diagram).

Switch off the crane immediately if the electrical power supply malfunctions.

−

Do not make any changes and/or additions and modifications to the electrical system without approval from the manufacturer.

−

Have the electrical system checked by a specialist in accordance with the operating conditions and the applications for which it is used where required but at least once a year.

For example:

Components: Generator,

Fitting, condition,

Starter, diesel engine auxiliary start pilot, Lighting, lines, collectors, slip rings,

Functioning, insulation, Protection against dimust be checked for: rect contact of active parts

Heating, switches, relays, fuses,

Protection in the case of indirect contact of active parts

Batteries

059--2140--083_en

9/13

14

10/13

059--2140--083_en

Electrical System 14

14.5

Fuse Overview (Circuit diagram no.: 280 271 12)

Code F0301

Value / A 50

Fitting location Battery

F0302

50

Battery

F0311

15

Cab

24.8

Power supply: central

F0312

25

Cab

25.2

Power supply: PLD

F0313

10

Cab

25.5

Power supply: ADM

F0314

15

Cab

44.2

Rotaflare lighting

F0315

5

Cab

44.7

Hazard light (aircraft warning light)

F0316

10

Cab

44.11

Horn

F0317

5

Cab

36.6

Diagnosis IFM / J1939

F0318

10

Cab

48.2

Radio system

F0319

10

Cab

96.8

Heater: ventilator motor

F0320

10

Cab

96.11

Heater timer

F0321

10

Cab

97.3

Air conditioning: Motor -- ventilator

F0322

10

Cab

97.9

Air conditioning: compressor relay

F0323

10

Cab

29.7

Power supply: computer battery

F0324

10

Cab

25.7

Monitoring: engine/hydraulics

F0325

10

Cab

25.8

Power supply: IFM

F0326

10

Cab

31.6

Lubrication system track frame

F0327

10

Cab

40.3

F0328

10

Cab

43.2

START/STOP + speed adjustment of diesel engine Interior / control panel lighting

F0329

15

Cab

43.5

Cab exterior lighting

F0330

15

Cab

43.8

Exterior lighting of winches

F0331

10

Cab

48.11

Central lubricating system superstructure (Option)

F0332

10

Cab

45.2

Instrument / switch lighting

F0333

10

Cab

47.4

Windscreen wiper system front window

F0334

10

Cab

47.10

Windscreen wiper system roof window

F0335

10

Cab

47.13

Windscreen washer front window

F0336

5

Cab

88.2

Power supply of monitoring system

F0337

10

Cab

96.2

Heater: servo valve

F0338

10

Cab

97.5

Air conditioning: engine ventilator

F0339

10

Cab

97.11

Air conditioning: engine ventilation

059--2140--083_en

Page path Description Main fuse: basis electric Main fuse: Control

11/13

14

12/13

059--2140--083_en

Electrical System 14

Continuation: Fuse Overview

F0340

Value / A 10

Fitting location Cab

F0341

10

F0342

Code

Page path Description 26.2

Power supply MCM 1: primary card

Cab

26.8

Power supply MCM 1: secondary card

10

Cab

27.2

Power supply MCM 2: primary card

F0343

10

Cab

27.8

Power supply MCM 2: secondary card

F0344

10

Cab

28.2

Power supply MCM 3: primary card

F0345

10

Cab

28.8

Power supply MCM 3: secondary card

F0346

10

Cab

29.2

Power supply: MCM 1--3, System

F0347

10

Cab

29.8

Power supply: Computer, ignition

F0348

10

Cab

30.2

Power supply: Limit switch: Superstructure

F0349

10

Cab

30.5

Power supply: Limit switch + boom sensor

F0350

10

Cab

30.8

Superstructure sensor

F0351

10

Cab

30.11

SL crossbar sensor, SLGW

F0352

10

Cab

30.13

F0353

10

Cab

87.3

Power supply: Limit switch + sensor for winches HA Power supply: Radio Remote Control

F0354

10

Cab

31.2

Power supply: Carrier, reserve (CC)

F0355

5

Cab

37.1

Power supply: CAN BUS system

F0356

10

Cab

49.2

LLD: bridging, warning

F0357

10

Cab

50.6

Cab control lever: signal transmitter + and controls

F0358

10

Cab

54.2

Cab pedal: slew gear brake

F0359

10

Cab

55.2

Cabin adjustment, seat heating

F0360

10

Cab

55.11

Intercom (optional)

F0361

10

Cab

31.9

***free***

F0362

10

Cab

89.2

***free***

F0363

10

Cab

89.4

***free***

F0364

10

Cab

89.6

Emergency control system: pump adjustment

F0365

10

Cab

90.4

Emergency control system: power supply

F0366

10

Cab

90.13

Emergency control system: power supply for relay outputs

059--2140--083_en

13/13

Fuel System 15

059--2150--093

1/11

15

2

3

16

17

1

18 Z 63 393

2/11

059--2150--093

Fuel System 15

15

Fuel System Legend (Z 63 393): 1.

Fuel tank with strainer

2.

Fuel water separator integrated in fuel filter 5

3.

Telligent engine control unit -- cooled by fuel --

4.

Fuel pump

5.

Fuel filter

6.

Plug pumps

7.

High pressure leads

8.

Injection nozzles

9.

Pressure regulating valve

10. Return to the tank via throttle hole 11. Leak fuel of the injection nozzles 12. Flushing quantity of the plug pumps 13. Funnelling for return (including filter idling line) 14. Return to the tank 15. Throttle check valve 0.1 bar (1.45 psi) 16. Fuel drain valve in filter idling line 17. Fuel drain valve in tank 18. Screw plug for fuel drain

059--2150--093

3/11

15

5 3 10

6 7

8

Z 55 958

4/11

059--2150--093

Fuel System 15

15.1

Fuel Filter - Emptying the Inspection Glass (Z 55 958) Water is heavier than diesel fuel, it collects as a different coloured fluid at the bottom of the inspection glass (7). The inspection glass (7) must be emptied before clogging reaches the bottom of the filter element (6). Drain off the water that has collected in the inspection opening (7) daily.

1.

15.2

Open the drain valve (8) and actuate the supply pump (3).

Then close the drain valve again.

Fuel Filter - Changing the Filter Element Prefilter (Z 55 958) The intervals for changing the filter element depend on the contamination level of the fuel. Clogging of the filter leads to a reduced fuel supply and as a result a loss in power and starting difficulties.

The filter element must be replaced where there is a considerable and noticeable loss of power.

It is recommended that you always have a spare filter element to hand, as even one tank filling of heavily contaminated fuel can clog the filter.

Before the filter element can be replaced, the fuel filter (7) must be drained by opening the shutoff lever (17).

Once all the fuel has been drained off, carefully close the shutoff lever (17). Pull the lever off the shutoff valve and place in the toolbox.

059--2150--093

1.

Unscrew the filter element (6) with the inspection glass (7) from the filter head (10). Remove the filter element (6) and clean the sealing surfaces of the O--ring.

2.

Coat the O--ring and the filter sealing ring with fresh fuel or some grease. Screw on the inspection glass (7) onto the new filter element (6) and then screw both hand--tight onto the filter head (10). Do not use any tools to tighten.

5/11

15

5 3 10

6 7 8 Z 54 306

23

Z 54 308

14

14

15 6/11

Z 56 847

059--2150--093

Fuel System 15

3.

Activate the supply pump (3, Z 54 306) with the vent screw (5) opened until the fuel flows out of the vent screw. Close the vent screw, start the engine and watch out for leaks. If necessary, carry out any corrections when the engine is switched off.

Fuel filter in the diesel engine Before the filter element can be replaced, the fuel filter (23, Z 54 308) must be drained by opening the shutoff lever (15, Z 56 847).

Once all the fuel has been drained off, carefully close the shutoff lever (15). Pull the lever off the shutoff valve and place in the toolbox.

Please see the instructions and notes on maintaining the fuel filter given in the operating instructions from the engine manufacturer.

The operating instructions for the engine and a maintenance log-book are enclosed in Part 4 of this service literature.

Fuel filter of the heating

059--2150--093

1.

Clamp fuel hose between the tank and the fuel filter.

2.

Release both hose clips from the fuel filter (14, Z 56 847).

3.

Remove hoses from the fuel filter.

4.

Fit new filter.

7/11

15

18 Z 62 074

18 Z 63 233

8/11

059--2150--093

Fuel System 15

15.3

Draining Off Water and Residue From the Fuel Tank Fuel tank in the superstructure (Z 62 074) fuel tank in the carrier (Z 63 233) The plug (18) must be released and at least 1 l (0.26 gallons) of fuel drained off to remove water and residue.

Clean the seal and screw the plug (18) back in.

This should only be done when the fuel tank is almost empty.

15.4

Fuel System, Checking the Lines In addition to the visual inspections (e.g. checking the oil level), the fuel system in the engine compartment should be inspected once a year. The following points must then be checked: --

The unions must not leak and must be sufficiently secured.

--

In the case of reusable fittings, the hose connection to the hose nipple must be checked to ensure it is fitted tightly. If in doubt, secure the hose additionally with a hose clip or replace the hose completely.

Lines and/or hoses damaged due to mechanical, thermal or other effects must be replaced Ensure that all lines and hoses are at an adequate distance from hot engine parts (e.g. turbocharger) and are laid so that they do not chafe.

059--2150--093

9/11

15

1 Z 58 049

1

2 3 1 Z 57 320

10/11

Z 63 372

059--2150--093

Fuel System 15

15.5

Refuelling With a Fuel Tank Filling System (Optional) (Z 58 049) When refuelling, observe the safety instructions in part 2 chapter 1 “Fire prevention”.

Only fill up when the diesel engine is switched off and no-one is in the crane operator’s cab.

Only fill up where there is good ventilation.

The auxiliary heating must be switched off.

Naked flame, easily flammable materials, work causing fire or flying sparks must be kept at a safe distance when filling up.

No smoking!

Fill the fuel tank only through the filler neck.

Only use the refueling pump -- with the supplied suction hose with fuel sieve -- to pump diesel fuel.

Do not let the refueling pump run empty. When the fuel tank is empty, switch off the refueling pump immediately.

Filling up procedure (Z 57 320) 1.

Switch off the diesel engine.

2.

Switch the ignition on again.

3.

Keep fuel tank at the ready.

4.

Connect the suction hose to the refueling pump (1, Z 58 049) (3, Z 57 320 “SOG”) and completely submerge the other end of the hose into the diesel fuel.

5.

Connect the filling hose to the refueling pump (1) (2, Z 57 320 “DRUCK” [“PRESSURE”]) and place the other end of the hose into the filler neck of the fuel tank.

6.

Switch on the fuel tank filling system (1, Z 58 049) with the switch (1, Z 63 372).

After filling up, remove hoses and put the cover on the refueling pump.

Wipe up any spilt diesel fuel!

059--2150--093

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Cooling, Intake and Exhaust System 16

059--2160--073_en

1/15

16

1

Z 42 607

2/15

059--2160--073_en

Cooling, Intake and Exhaust System 16

16

Cooling, Intake and Exhaust System Danger of burning and scalding!

Allow a cooling time of 60 minutes before carrying out the work on the cooling system described here!

16.1

Check the Coolant and Top up as Necessary (Z 42 607) ACCIDENTS MAY OCCUR! Only open the sealing cap of the motor cooling system when it has cooled down. Otherwise the system will be under pressure.

1.

As a precaution, turn the sealing cap (1) on the expansion tank as far as the first detent, thus allowing any overpressure present to be released.

2.

Then turn as far as the second detent and remove the sealing cap.

Depending on the design, the cooling system is correctly filled when the coolant comes up to the edge of the filler neck or the marking on the filler neck.

Check the coolant for its antifreeze properties every year before the cold season begins.

Also consult the operating instructions of the engine manufacturer

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16

Z 42 608

4/15

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Cooling, Intake and Exhaust System 16

16.2

Cleaning the Cooling System (Z 42 608) Danger of burning and scalding!

Allow a cooling time of 60 minutes before carrying out the work on the cooling system described here!

Using gentle pressure so as not to damage the cooler fins, blow out the cooler with compressed air in a counter--air--flow direction -- or else do the same with a water spray -- until the cooler fins are thoroughly free of foreign matter (e.g., dust, insects).

An extreme temperature increase of the cooling water at normal ambient temperatures may indicate that the interior of the cooler is clogged if the exterior has been cleaned and no other malfunctions exist.

In this case, the cooling system should be cleaned thoroughly, and the complete cooling cycle should be degreased, decalcified and derusted.

Please see the operating instructions of the respective engine manufacturer for details!

The cooler guard must be removed for cleaning the cooler ribs.

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16

Z 39 452

Z 42 609

6/15

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Cooling, Intake and Exhaust System 16

16.3

Change Cooling Fluid (Z 42 609) Add corrosion/antifreeze agent to your cooling fluid year--round (refer to the operating instructions for the respective engine).

The antifreeze does not have any negative impact on the refined cooling fluid.

The coolant must be changed as soon as this is necessary e.g. in the case of repair. The coolant must, however, be changed at least every two years.

1. Turn off the engine.

ACCIDENTS MAY OCCUR! Only open the sealing cap of the motor cooling system when it has cooled down. Otherwise the system will be under pressure.

2. Slowly rotate the sealing cap of the equalising tank until it reaches the first detent to allow any excess pressure to be released. Only then turn the cap to the second detent and remove it from the tank.

3. Draining engine and cooling system. − In order to empty the engine, the drain plug on the crankcase (Z 39 452) and the drain plug on the oil cooler must be opened. − In order to empty the cooler, the drain plug on the cooler must be opened (Z 42 609).

4. Screw all drain screws back in after the cooling system has been drained.

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16

1

Z 42 607

8/15

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Cooling, Intake and Exhaust System 16

(Z 42 607) 5.

Fill the cooling system with new coolant.

When filling the cooling system with coolant, care must be exercised to prevent air pockets from entering the cooling system. Enclosed air can damage the engine.

Only use water that is free from scale forming minerals. Do not use softened water.

Interrupt the filling several times and allow the coolant level to settle and stabilise. Any trapped air can also escape.

Add coolant until the equalising tank is filled completely.

6.

Start the engine and let it run for a minute in idle while the equalising tank is open. If necessary, shut down the engine and add more coolant to the equalising tank until the max. level is reached.

7.

Start the engine again and let it run for a minute in idle while the equalising tank is open. Check the coolant level and top up, if necessary.

Replace the cover (1) on the expansion tank.

Monitor the engine temperature during the warm--up period.

After the operating temperature has been reached, check the coolant level and top up, if necessary.

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16

2 1 Z 42 610

4

Z 4965

10/15

Z 42 611

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Cooling, Intake and Exhaust System 16

16.4

Change or Replace the Filter Element of the Air Filters (Z 42 610) --Only replace the filter element when the maintenance display (2) is activated.

--The filter element should only be cleaned in exceptional cases.

Never service the air filter (1) with the engine running.

16.4.1

Replacing the Filter Element Clean the filter element if the maintenance display (2) is activated.

1.

Turn off the engine. Remove the cap from the housing by loosening the retaining clips.

2.

Lift the clogged filter element (4) out of the housing (Z 4965).

The filter element must be replaced after five cleaning cycles or when contaminated with carbon--particulate matter, and after two years the latest.

059--2160--073_en

3.

Before inserting a new filter element, the gaskets and the sealing coating in the housing must be cleaned again thoroughly.

4.

Insert the new filter element into the housing.

5.

After completing the maintenance work, the maintenance indicator (arrow) must be moved to its initial position by pulling the knob (Z 42 611).

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16

Z 59 750

Z 0130

12/15

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Cooling, Intake and Exhaust System 16

16.4.2

Cleaning the Filter Element --Do not wash out filter elements.

--Do not clean filter elements by shaking or hammering.

-- Never reuse filter elements with damaged folds or gaskets.

Dry cleaning using compressed air Wear protective glasses and safety garments when cleaning the filter element using compressed air. Maximum air pressure should not exceed 5 bar (72.52 psi).

For cleaning purposes, put a tube that has a bend of about 90 degrees at the end onto the compressed air gun (Z 59 750). The tube must be long enough to reach the bottom of the filter element.

Blow the filter element carefully clean starting from inside and moving to the outside, i.e. from the clean side towards the dirty side, until no more dust forms.

The tip of the tube must not touch the filter element whilst the filter element is being cleaned.

After cleaning, check the filter element carefully for possible damage.

Inspecting the element To check the filter element, insert a bulb into the cleaned filter element (Z 0130). If damage is found, throw the filter element away.

It is recommended to hold replacement filter elements ready which can be used while the used filter elements are being cleaned.

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16

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Cooling, Intake and Exhaust System 16

16.5

Exhaust System Visual Inspection Inspecting the exhaust system for leaks.

Do not lay any wires or cables in the radiant heat danger area around the exhaust system.

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Piston Rods 17

17

Piston Rods

17.1

Exposed Chrome Surfaces - Applying Protective Grease Despite being of the highest quality, surfaces may be susceptible to corrosion in an aggressive environment. If the device is out of operation for more than one day, exposed surfaces must be protected against corrosion by applying acid--free protective grease, see Sect. 2.

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Crane Operator’s Cab 18

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18

Z 54 311

2/5

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Crane Operator’s Cab 18

18

Crane Operator’s Cab

18.1

Checking the Windscreen Washing Assembly Check at least once a week that the windscreen washing assembly is functioning properly.

18.2

Filling Up the Supply Tank of the Windscreen Washing Assembly The supply tank of the windscreen washing assembly must always be filled with water and if necessary with a little cleaning agent (Z 54 311).

Before the onset of winter, a suitable amount of antifreeze (depending on the temperature) must be added to the water.

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18

Z 63 959

4/5

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Crane Operator’s Cab 18

18.3

Lubricating the Cab Tilt Cylinder (Z 63 959) Lubricate the cab tilt cylinder at least once a year with multipurpose grease on both lubricating nipples of the swivel heads.

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Undercarriage 19

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19

1

2

Z 42 614

2/25

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Undercarriage 19

19

Undercarriage Danger due to the crawler and slewing of the superstructure.

Particular care is required in this area when carrying out maintenance, inspection and erection work.

Work on the undercarriage may only be carried out with the drive motor switched off.

19.1

Checking the Final Drive Oil Level (Z 42 614) Turn the final drive in such a way that the drain screw (2) is located at the lowest point.

Unscrew the filler and check plug (1).

The oil must come up to the bore.

Top up the oil, see Section 19.3, “Changing the Oil”.

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

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19

1

2

Z 42 614

4/25

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Undercarriage 19

19.2

Changing the Oil in the Final Drive (Z 42 614) When changing the oil, it must be drained off while still warm, i.e. after a longer period of operation.

1.

Turn the final drive in such a way that the drain screw 2 is located at the lowest point.

2.

Unscrew drain plug (2) and check and filler plug (1) and drain off the oil into a suitable container.

Dispose of used oil in an environmentally friendly manner.

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3.

Before filling with new oil, rinse the gear with flushing oil (warmed, clean oil) to remove abraded material and impurities.

4.

Screw in cleaned drain plug (2) and fill with new oil. The oil is at the correct level if it comes up to the inspection opening (1).

5.

Clean check and filler plug (1) and screw back in.

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19

1

3

1

2

4 Z 55 959

6/25

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Undercarriage 19

19.3

Lubricating Front Idlers, Track and Carrier Rollers (Z 55 959) The front idlers (4), track rollers (2) and carrier rollers (3) are automatically lubricated by the centralised lubrication pump (1) mounted on the track carrier (see sect. 19.9).

19.4

Lubricating the Connecting Pins All connecting pins must be sufficiently greased before every erection procedure.

19.5

Maintaining the Hydraulic Cylinders on the Undercarriage When operating the crane in an aggressive environment (near the ocean, in chemical factories or in steel works) or if it has standstill times of more than one day. the exposed chrome surfaces of the piston rods must be protected against corrosion by applying an acid--free protective grease (see section 2).

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19

1 3

2 Z 54 312

6 8

4

4 Z 57 542

4

8/25

4

8

7

9

Z 57 543

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Undercarriage 19

19.6

Tensioning the Crawler Track (Z 54 312, Z 57 542, Z 57 543) You should always check or tension the track group before fitting the crane equipment and the counterweight.

Before checking the crawler track tension, the track must be cleaned.

Checking the crawler track tension: The slack of the track group is a measure for the correct track group tension (Z 54 312).

If the track is clean and correctly tensioned, the slack must be 250 mm +/--20 mm (98.43 inches +/--7.87 inches). If the slack is greater or smaller, the track group must be relieved or tensioned.

Legend: (Z 54 312) 1.

2.

3.

Bottom edge track roller Slack Tread of the track shoes

Tensioning procedure: 1.

Open the cover for the tensioner chamber.

--

Make sure the tensioner (4) is in the correct position to the track frame.

--

To achieve the maximum tension travel, the tensioner (4) must be displaced using suitable spacer blocks.

2.

3.

Connect the hydraulic manual pump (LUCAS).

Using the hydraulics hand pump, make sure the slack is 250 mm (9.84 inch).

Remove locking bolt (7).

Fill up the space between the track carrier frame and the sliding carrier (1) by fitting additional locking bolts (7).

4.

5.

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19

1 3

2 Z 54 312

6 8

4

4 Z 57 542

4

10/25

4

8

7

9

Z 57 543

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Undercarriage 19

Continuation: Tensioning Procedure (Z 54 312, Z 57 542, Z 57 543) 6.

Fit locking bolt (7) again.

7.

Relax tensioner (4).

8.

Remove hydraulic manual pump from the tensioner.

9.

Drive the crane a few metres forwards.

10. Check slack again.

11. Remove tensioner.

12. Close the cover for the tensioner chamber.

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19

“B”

“A”

Z 55 960

12/25

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Undercarriage 19

19.7

Lubricating the Track Pins on the Track Type Undercarriage and Checking the Track Tension in the Case of Running Noises (Z 55 960) Insufficiently lubricated track pins or an incorrect chain tension of the track group are, as a rule, the causes of running noises and premature wear.

Soiling of the crawler can also lead to such occurrences.

Therefore check the following regularly, at least once a month or before every operation, and if the crane is driven over longer distances: −

the track group (1) (wear, lubrication of track pins and chain tension)

−

the track rollers (2) or support rollers (3) (wear, lubrication of rollers, functioning)

−

the track drive (5) (wear, lubrication of final drive)

−

the crawler for soiling

Cleaning of the crawler is absolutely essential if it is soiled.

A soiled crawler demands a greater expenditure of energy to move the crane. Wear on the movable parts of the crawler is thus considerably higher.

Lubricating the track pins In the upper part of the track, spray the track pins at the joints with lubricant (“Gleitmo 805” SP no. 420 213 00, 1 kg /2.20 lb spray can).

Lubricate the track pins after cleaning the crawler and before tensioning the track group.

Move the crane forwards until the lower part of the track is on the carrier rollers and spray here too with “Gleitmo 805”.

Ensure that the lubricant penetrates into the bearings between track pins “A” and track shoes “B” (arrow, see figure).

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19

2

3

2

3

Z 55 961

2

Z 55 962

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Undercarriage 19

19.8

Checking the Screw Connections and Retightening if Necessary (Z 55 961, Z 55 962) As all fixing bolts of the drive are secured using Loctite, retightening is not required as a rule. A visual inspection is adequate.

Loose, broken off or defective screws must be removed and replaced with new ones where necessary.

For all bolts, that are not secured using Loctite, thread and head support must be greased for tightening using KP2K. Torques of the gear housing screws: Size

Quality

Torque Ma (Nm)

(lbf--ft)

M 10

8.8

42

30.98

M 12

8.8

74

54.58

m20

8.8

358

264.05

with Loctite type

638

Torques of the fixing bolts for the hydraulic motor and gear mount: No.

059--2190--098_en

Size

Quality

Torque Ma (Nm)

(lbf--ft)

with KP2k

1

M 20 x 45

10.9

510

376.16

x

2

M 30 x 2 x 250

10.9

1960 1445.62

x

3

M 36 x 3 x 90

10.9

3250

x

2397.1

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19

1 3 2 4 6

5

7

Z 37 335

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Undercarriage 19

19.9

Central Lubricating System

19.9.1

Component Parts (Z 37 335) The components for the central lubrication system are listed below.

19.9.2

(1)

Case

(2)

Pump element

(3)

Safety valve

(4)

Re--filling nipple

(5)

Plug

(6)

Return connector

(7)

Lube distributor

Function The central lubrication system automatically supplies all connected lubricating points with grease via a lube distributor.

The lubrication procedure begins with the driving movement and continues as long as the crane is in motion.

The duration of a lubrication cycle, in other words the length of break time and working time, depends on the amount of lubricant needed by the system.

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19

18/25

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Undercarriage 19

19.9.3

Servicing Central Lubrication System Servicing consists mainly in filling with clean lubricant when necessary. Nonetheless, all lubrication points must be checked for lubricant leakage at regular intervals. −

check lubrication points for grease leakage

−

Check tubes and pipes for damage. Damaged tubes and pipes must be replaced in their entirety.

When working on the central lubrication system, always observe the utmost cleanliness. Dirt in the system causes malfunctions.

Use kerosene or petroleum ether to clean the system. Solvents may not be used.

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19

1

2

Z 37 184

20/25

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Undercarriage 19

19.9.4

Filling the Tank of the Central Lubrication System (Z 37 184) Fill the tank (1) of the central lubrication system to a level which must always be beyond the filling nipple (2) using a standard commercial grease pump or a manual lever press.

Never exceed the maximum level. The grease must be free of impurities, and may not change consistency over time.

The lubrication tank is filled with high pressure grease (see Sect. 2 of these Lubrication and Maintenance Instructions).

After complete drainage, the pump can require up to 10 minutes running time to reach maximum delivery rate.

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19

22/25

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Undercarriage 19

19.9.5

Troubleshooting

Malfunction: Engine of pump not running Cause:

Remedy:

Power supply interrupted.

Check power supply and fuses. If necessary, eliminate defective or replace fuses.

Check line from the fuses to the plug of the pump.

Electric motor

Check power supply for the electric motor. If necessary, replace electric motor.

Malfunction: Pump not delivering Cause:

Remedy:

Case empty.

Fill case with clean grease, allow pump to run (additional lubrication) until lubricant emerges from all lubricating points.

NOTE: Depending on ambient temperature and/or lubricant, pump elements may require up to 10 minutes to run before they reach full delivery.

Air trapped in lubricant.

Release additional lubrication. Unscrew outlet union on safety valve. Lubricant must emerge without bubbles.

Unsuitable lubricant used.

Replace lubricant, see lubricant table (see Lubrication and Maintenance Instructions).

Intake bore of pump element clogged.

Remove pump element and examine intake bore for foreign bodies and remove if necessary.

Pump piston worn.

Replace pump element.

Non--return valve in the pump element defective or clogged.

Replace pump element.

Malfunction: Pump not delivering Cause:

Remedy:

Corresponding valve body is fitted without clamping ring.

Remove valve body and check whether clamping ring is fitted. If not, fit clamping ring.

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19

Z 29 549

24/25

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Undercarriage 19

Malfunction: Blockage in secondary progressive system (Z 29 549) Cause:

Remedy:

Bearing, lines or distributor clogged.

The malfunction can be recognised by the following: a) Grease emerges from safety valve. b) The check pins (if fitted) located on the distributor pistons, do not move.

Determine and eliminate the cause of the blockage as described in the example below.

1. Allow the pump to run (see additional lubrication).

2. Release all the main leads (G) to the sub--distributors on the main distributor (B) individually and in succession. If, for example, grease emerges from outlet (1) of the main distributor (B), under pressure, the cause of the blockage is in the lubricating circuit of the sub--distributor (D).

3. Allow the pump to continue to run.

4. Loosen all lubricant leads (E) of the sub--distributor (D) individually. If, for example, grease emerges from outlet (3) of the distributor (D), under pressure, the cause of the blockage is in the lead of the outlet (3) or in the bearing connected to it.

5. Exchange safety valve A. NOTE: In order to check each individual outlet, leave each outlet released for a prolonged period as only one piston strike is effected per pump rotation. Several strokes are, however, required for flow through of all the distributors.

c) If a distributor is blocked, luPump through the blocked lead or bearing using a hand--opbricant does not emerge from erated pump. any outlet.

Replace the distributor or clean it as described below: 1. Remove all pipe connection unions.

2. Unscrew the piston plugs.

3. Push pistons out, if possible using a small thorn (smaller than ø 6 mm /ø 0.236 inch).

Caution: the pistons are fitted in the distributor bores.

Following removal, mark the pistons according to fitting position and direction for re--fitting subsequently. They may not be exchanged during fitting.

4. Thoroughly clean the distributor body in grease solvent cleaning agent and pass over with compressed air.

5. Push through the oblique channels (ø 1.5 mm / ø 0.59 inch) on the thread ends of the piston bores using a pin.

6. Clean distributor again and blow air through it.

7. Assemble distributor.

8 Replace the copper discs.

9. Before screwing in the pipe connection unions, pump oil through the distributor several times using a hand--operated pump if possible. The pressure in the distributor must not exceed 25 bar (362.8 psi).

If this happens, replace the distributor.

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Counterweight Dolly 20

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20

1 Z 62 829

Z 62 517

2/29

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Counterweight Dolly 20

20

Counterweight Dolly

20.1

Lubricate Ball Bearing Slewing Rim (Z 62 829) Lubricate the grease nipples (1) on the inside of the frame.

The grease nipples can only be reached if there is no superlift counterweight stacked on the counterweight carriage.

Always relubricate adequately so that a collar of grease forms around the entire extent of the gaps in the bearings.

This lubricating procedure must be carried out: -----

20.2

Each time before the superlift counterweight is stacked on After each use of steam jets Before and after a long break in operation At least every three months.

Lubricating the Ring Gear (Z 62 517) Regularly lubricate the ring gear with special adhesive grease; at the latest, however, when there are exposed areas in the tooth flanks. See section 2, “Oils, Lubricants and Capacities”.

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20

1

Z 62 830

4/29

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Counterweight Dolly 20

20.3

Checking the Screws of the Slewing Rim (Z 62 830) The preliminary tension of the screws (1) must be ensured by regularly retightening to the prescribed torque of 510 Nm (376.15 lbf--ft).

Lubricate the heads and threads of all screws (1) with roller bearing grease “KP2K” before screwing them in.

If the slewing rim is to be replaced, all the screws must also be replaced.

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20

1

2

3

Z 55 981

6/29

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Counterweight Dolly 20

20.4

Slew Gear When maintenance work is being carried out, there is a risk of being dragged in at the slew gear pinion (Z 55 981) -- in spite of the protective covering.

Observe the warning sign which is attached there!

20.4.1

Slew Gear Mechanism - Checking the Oil Level (Z 55 981) −

Oil level check.

The oil must right come up to the outlet of the oil level control opening (2).

−

Top up the oil if necessary.

Top up the oil, see Section 20.4.2, “Changing the Oil”!

If a continual loss of oil is determined when checking the oil level, operation must be suspended and dismantling performed.

20.4.2

Slew Gear Mechanism - Changing the Oil (Z 55 981)

059--2200--087b

1.

Unscrew the filler screw (1) with breather filter.

2.

Unscrew the drain screw (3) and drain oil.

3.

Clean the gear mechanism with flushing oil before adding new oil.

4.

Clean drain screw (3) and screw back in firmly.

5.

Fill in new oil until it comes up to the outlet of the oil level control opening.

6.

Screw the filler screw (1) with breather filter firmly in.

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20

8/29

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Counterweight Dolly 20

20.4.3

Slew Gear Mechanism - Checking the Disc Brake Check the slew gear brake to make sure it is not leaking and that it is functioning perfectly.

In order to ensure a perfect braking effect, the disc brake on the slew gear must be checked at regular intervals.

If operation is not perfect, the defective parts must always be replaced and the brake cleaned before taking up work again.

Proceed as follows to check the slew gear brake: −

Set the operating mode “RG0” on the LLD screen and activate the assembly remote control using the “counterweight vehicle” function, see sections 8 and 9 in part 1 of the crane documentation

−

Stabilise the counterweight dolly.

−

On the hydraulic block of the counterweight vehicle, pull out the electrical plugs for valves Y9843 and Y9844. The slew gear brakes will then not be opened when the swivelling bolsters are adjusted.

−

Activate assembly remote control, see section 14 in part 1 of the crane documentation and operate swivelling bolsters 1 and 2 one after the other for about 10 seconds.

As the slew gear brake do not work, the swivelling bolsters ought not turn. If they should turn, check the slew gear brakes.

−

After checking, plug the electrical plugs on the aforementioned valves.

This work may only be undertaken by a trained specialist.

In the case of work with insufficient braking effect,

RISK

OF

A C C I D E N T S!

Releasing the disc brake without the tension arrangement can lead to serious injury.

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20

35

34

Z 55 982

10/29

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Counterweight Dolly 20

20.4.4

Checking the Slew Gear Mechanism Screw Connections (Z 55 982) The preliminary tension of the screws (34 and 35) must be ensured by regularly retightening to the prescribed torque.

Lubricate the heads and threads of all screws (1) with roller bearing grease “KP2K” before screwing them in.

Torques of the fixing bolts for the hydraulic motor and gear housing mount:

20.4.5

Item

Size

Quality

34

M 16 x 70

10.9

265

195.45

35

M 12 x 35

10.9

108

79.66

Torque Ma (Nm) (lbf--ft)

Slew Gear Mechanism Visual Inspection (Z 55 982) Check the gear housing, lines and neck bearings for leaks.

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20

A--A

1A

1V 2V 1A

B--B 2A 1P

1V

2P Ansicht A View A Z 62 830

12/29

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Counterweight Dolly 20

20.5

Final Drive - Checking Oil Level

20.5.1

Drive Axle (Z 62 830) −

Use outriggers to support the counterweight carriage until the wheels can turn freely.

Wheel planetary gear −

Turn the wheel until the oil filling and inspection plug (1P) is horizontal, somewhat lower than the centre. Open the oil filling and inspection plug. The oil level must come up to the lower edge of the opening; if it does not, top up oil.

−

Screw the oil filling and inspection plug (1P) back in.

Axle housing and countershaft To check the oil level of the axle housing, a wheel must be removed.

059--2200--087b

−

Open the oil inspection plug (2V). The oil level must come up to the lower edge of the opening; if it does not, top up oil.

−

Screw oil inspection plug (2V) back in.

13/29

20

Ansicht X View X

1P 2P

Z 62 831

14/29

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Counterweight Dolly 20

20.5.2

Rigid Axle (Z 62 831) Wheel planetary gear

059--2200--087b

−

Turn the wheel until the oil filling and inspection plug (1P) is horizontal, somewhat lower than the centre. Open the oil filling and inspection plug. The oil level must come up to the lower edge of the opening; if it does not, top up oil.

−

Screw the oil filling and inspection plug (1P) back in.

15/29

20

A--A

1A

1V 2V 1A

B--B 2A 1P

1V

2P Ansicht A View A Z 62 830

16/29

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Counterweight Dolly 20

20.6

Travel Drive - Replace Oil

20.6.1

Drive Axle (Z 62 830) The travel drive is lifetime--lubricated. An oil change is only needed after repairs −

Use outriggers to support the counterweight carriage until the wheels can turn freely.

Wheel planetary gear −

Turn the wheel until the oil drain plug (2P) is at the lowest point. Open the oil drain plug and allow the oil to discharge.

Collect the oil and dispose of it in an environmentally--friendly manner. −

Replace the old seal with a new one and clean the oil drain plug (1P) before screwing it in.

−

Unscrew the oil filling and inspection plug (1P).

−

Add new oil up to the lower edge of the inspection hole, replace the seal and screw the oil filling and inspection plug (1P) back in.

Axle housing and countershaft To change the oil in the axle housing, a wheel pair must be removed. −

Open the oil drain plug (2A) and allow the oil to discharge.

Collect the oil and dispose of it in an environmentally--friendly manner.

059--2200--087b

−

Replace the old seal with a new one and clean the oil drain plug (2A) before screwing it in.

−

Unscrew the oil filling and inspection plug (1A).

−

Add new oil up to the lower edge of the inspection hole, replace the seal and screw the oil filling and inspection plug (1A) back in.

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20

A--A

1A

1V 2V 1A

B--B 2A 1P

2P

1V Ansicht X View X

18/29

Z 62 830

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Counterweight Dolly 20

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−

Unscrew the oil filling and inspection plug (1V and 2V).

−

Fill up with new oil until it comes out of the oil level inspection hole.

−

Screw in oil filling and oil level check plugs (1V and 2V) with new gaskets.

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20

Ansicht X View X

1P 2P

Z 62 831

20/29

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Counterweight Dolly 20

20.6.2

Rigid Axle (Z 62 831) The travel drive is lifetime--lubricated. An oil change is only needed after repairs −

Use outriggers to support the counterweight carriage until the wheels can turn freely.

Wheel planetary gear −

Turn the wheel until the oil drain plug (2P) is at the lowest point. Open the oil drain plug and allow the oil to discharge.

Collect the oil and dispose of it in an environmentally--friendly manner.

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−

Replace the old seal with a new one and clean the oil drain plug (1P) before screwing it in.

−

Unscrew the oil filling and inspection plug (1P).

−

Add new oil up to the lower edge of the inspection hole, replace the seal and screw the oil filling and inspection plug (1P) back in.

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20

1

Z 64 205

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Counterweight Dolly 20

20.7

Lubricating the Axles All axles must be lubricated regularly at the grease nipple (1, Z 64 205) with multipurpose grease KP2K.

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20

4

Z 55 986

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Counterweight Dolly 20

20.8

Check Tyre Air Pressure, Tread and Rims (Z 55 986)

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−

Check the air pressure at valve (4). − The cold tyre air pressure should be 10 bar (145 PSI) for all wheels.

−

Check the tread.

−

Check the tyres for visible damage.

−

Check the rims for visible damage.

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20

3

Z 55 987

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Counterweight Dolly 20

20.9

Checking Tyre Wheel Nuts, Tightening if Required (Z 55 987) −

Check all wheel nuts (3) and tighten them with a torque wrench.

The torque is 350 Nm (265.52 lbf--ft).

After a tyre change, the wheel nuts must be retightened after 10 hours of operation and after 20 hours of operation.

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20

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Counterweight Dolly 20

20.10

Checking Welds for Cracks −

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Check all frame parts for damage and weld cracks.

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Visual Checks 21

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21

B

B

B

K

B

G

H

2/5

A

D

C

E

I

F

M

N Z 39 465

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Visual Checks 21

21

Visual Checks The following visual checks must be carried out daily before putting the unit into operation:

21.1

Visual Check - Superstructure and Crawler Chassis (Z 39 465) A B C D

E F G H I

21.2

= Slewing ring -- check that lubricant film on external teeth is intact. = Check that lubricant film on rope is intact and check for damage to rope. = Check hydraulic system for leaks and damage, and check oil level. = Check the cap and protective covers to see if any are missing, damaged, loose or have missing screws.

Safety signage must be visible and complete. = Check the engine for oil and fuel leaks and for dirt and contamination. = Check the cooling system for leaks, damage and contamination. = Check instruments and indicators for proper functioning and any damage. = Check the track travel gear for dirt and contamination, damage and correct track tension. = Check the travel drive for leaks.

Visual Checks on the Superlift Counterweight Supporting Frame (Z 39 465) The following visual checks must be carried out daily before putting the unit into operation: K M

N

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= Check for any damage to the stay rope and its connecting pins with safety devices. = Check for any damage to the retaining rope of the counterweight supporting frame and its connecting pins with safety devices. = Check the main frame for damage.

Check that the counterweights are in a secure position.

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21

D

D

P

L

P

0

0 Z 39 466

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Visual Checks 21

21.3

Visual Check - Equipment (Z 39 466) The following visual checks must be carried out daily before putting the unit into operation: K O

P

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= Check for any damage to the boom sections and their connecting pins with safety devices for any damage. = Check the hydraulic cylinders of the boom sections: − Check the outrigger cylinders on the main boom and superlift mast foot section, − and outrigger cylinders of the luffing masts, for proper functioning and any damage. = Check rods for correct fastening and any damage.

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Examinations of the Crane 22

22

Examinations of the Crane The operator must take adequate precautions to maintain the crane in a safe operating status. For this, regular inspections are extremely important. Only expert employees (ISO 9927--1), e.g. “specialists” or “experts”, should be entrusted with these inspection activities.

A specialist is someone who, due to his professional training and experience, has adequate knowledge concerning cranes and who is sufficiently acquainted with the appropriate government industrial safety regulations, accident prevention regulations and generally recognised rules of technology to be able to judge the operational safety of cranes. (BGG 905, section 3.2) An expert is someone who is authorised by an employer’s liability insurance association or an expert of Technical Surveillance. (BGG 905, section 3.1)

22.1

Recurring Crane Inspections It is the responsibility of the crane operator to have the crane inspected according to the applicable international and national regulations at regular intervals. This responsibility is described in several national regulations regarding the prevention of accidents (in Germany: BGV D6 and BGV D8) and in international standards (for example, ISO 9927, ISO 12480, BS 7121, CSA Z150, ASME B30.5 or others).

The following applies for Germany: Inspections to be performed yearly by a technical specialist, and at least every four years by an expert (yearly, after 12 years of operation).

The remaining theoretical service life of winches (in conformity with BGV D8, ISO 12482--1 Annex A) must be determined within the scope of this inspection. In this respect, observe the following section 22.1.3.1

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The following information is based upon the regulations of the accident prevention regulations “Cranes” (BGV D6) with regard to regular routine crane inspections.

The section 22.1.7 contains a check list for the repeated inspections of TEREX--Demag vehicle and crawler--mounted cranes to help the inspector.

Inspections in accordance with BGV D6 do not replace the appropriate national regulations.

Carrying out the inspection The routine inspection is primarily a visual and functional check, mainly comprising: −

checking the identity of the crane with the information in the inspection book (crane log book).

−

checking the condition of components and equipment for damage, wear, corrosion or other changes.

−

checking the completeness and effectiveness of safety equipment and brakes.

−

checking the condition of carrying equipment for damage, wear, corrosion or other changes.

−

checking the availability, completeness and legibility of signs.

The results of the inspections must be entered in the inspection book and certified by the inspector.

Experts and specialists inspect the crane as matter of their own responsibility.

After significant modifications in a crane or after repairing load--bearing parts, the operator must ask a specialist to inspect the crane before re--commissioning.

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The following must be checked: 1. Frameworks 1.1 Superstructure and Undercarriage Components:

Check:

Frame, outriggers/supports, slewing rim crawler track shoes

cracks, deformation, wear, safe and secure attachment of loose components, corrosion and corrosion protection, warning paint.

Installation of cables and tubings

1.2 Crane Equipment Components: main boom, fly jib, luffing masts, A--frame stay bars bracing rods

Check: Cracks, deformations, wear, mountings and locks of mobile components, easy movement of bearings and guides, assembly and rope reeving, corrosion and corrosion protection, elongation Plastic deformation Paint Laying of cables and hoses

1.3 Counterweight Components: Weights, base plate,

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Check: That all parts are complete and properly attached.

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Examinations of the Crane 22

2. Engines 2.1 Drives Components: Final drive, slew gear drive, winch drive

Check: Safe and secure attachment of loose components, condition, function and noises, smooth starting and stopping, idle running, Wear of couplings and brakes, effectiveness of return locks.

Wear of the spline shaft connection Laying of cables and hoses

2.2 Rope Drives Components: Rope drums, Rope sheaves, Rope guide rollers

Check: State and bearings of the sheaves, rope guide rollers and rope drums (rope grooves, flanged wheels, wear).

2.3 Hydraulic Equipment Components: Hydraulic pumps, hydraulic motors, cylinders, valves, cases, hydraulic accumulator, leads, filters,

Check: Attachment, condition, function, noises, leaks, hydraulic oil condition and quantity filling pressures

2.4 Pneumatic Equipment Components: Compressors, engines, cylinders, valves, pressure tanks, leads, filters,

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Check: Attachment, condition, function, noises, leaks.

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Examinations of the Crane 22

2.5 Electric Equipment Components:

Check:

Alternators, motor, resistors, brake vents, lighting equipment, heating, leads, collector, switches, protectors, fuses, batteries, lines warning devices

Attachment, condition, function, insulation, guard against direct contact with active components, guard against indirect contact installation

2.6 Control Equipment Final Drive Components: Circuitry, engine control, brakes,

Check: Condition, function, shutdown, smooth running, lost motion of linkage and cords (end play), display of control functions, lamps and signals, designation, brake tests

2.7 Controls for the Crane Drive Components: hoists, luffing gear, derricking gear, slew gear, brakes,

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Check: condition, function, switching off, free movement, play of linkage and movements (dead gear), display of the monitors, lamps and signals, markings, brake checks with load (test load in the range of the lifting capacity).

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Examinations of the Crane 22

2.8 Other Controls Components: Outriggers, additional equipment,

Check: condition, function.

3. Lubrication 3.1 Oil Baths Components: transmission,

Check: adequately filled, oil loss.

3.2 Lubricating Points

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Components:

Check:

lubricating nipples,

accessibility, recognisibility, markings.

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Examinations of the Crane 22

4. Ladders, Safety Guards, Safety Equipment;, Signs 4.1 Ladders Components: Ladders

Check: Attachment and condition.

4.2 Safety guards Components: panels, covers, guides,

Check: Attachment and condition completeness, effectiveness.

4.3 Safety Devices Components: Load limit device, emergency limit switch equipment, warning devices, locking devices, radius indicator, tilt indicator, air speed indicator, wind safeguard,

Check: Attachment and condition completeness, function.

4.4 Signs Components: Plates

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Check: Completeness and legibility.

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22.1.1

Inspection of Load-- Bearing Steel Constructions The load--bearing steel constructions must also be carefully checked at least during the prescribed recurrent crane inspection (min. 1x annually).

It is important to especially observe the welded seams.

The principle depictions listed in the following are exemplary figures of load--bearing welded constructions. Connections / zones must be checked all--round at the areas marked with arrows / welded seams.

The content and extent of the inspection is the direct responsibility of the inspector. The following principle depictions only serve as examples and additional aids for the inspector. They make no claim to completeness.

On the one hand, the service life of load--bearing steel constructions is determined by the number of load cycles pursuant to DIN 15018, part 3, and on the other hand by the loads (load collective) that arise during periods of operation.

TEREX--Demag cranes are dimensioned for assembly operation with the following calculative values of dimensioning as the basis (DIN 15018 part 3).

Load collective: So (light) Number of load cycles: 25 000

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Z 54 332

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If the crane has been subjected to prohibited loads during operational periods (e. g. overloading, shock loads, duty cycle loading, etc.), an immediate inspection of the entire crane must be carried out.

If damage, for example cracks, is found anywhere on the steel construction, the extent of the damage must be determined by suitable specialist personnel using material examination methods, for example a magnetic powder examination, or ultrasound or x--ray inspections.

The welds of the retaining and bracing rods (Z 54 332) must be checked with an ultrasound inspection. The person performing the check must have Qualification Level 2 pursuant to DIN EN 473 or Level 2 pursuant to the ASNT Directive SNT-TC--1A. Additionally, a complete inspection of cranes at the latest within a general overhaul is recommended, when the crane is used as intended.

The intervals for general overhauls depend on the how intensively the crane is used. For the designated one shift operation, 8 -- 10 years are appropriate. The stay bars used on the crane for this must be inspected with an ultrasound inspection.

For instructions on how to carry out and evaluate the inspection results, consult the ultrasound inspection recommendations 014 and 015, which you can obtain from Terex--Demag GmbH customer services if required.

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Z 56 823

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Chassis -- centre section (Z 56 823)

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Z 56 826

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Chassis -- track frame (CC 8800) (Z 56 826)

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View Z

Z

Y

View Y

Z 56 827

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Chassis -- track frame (Duo) (Z 56 827)

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Z 56 828

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Chassis -- track frame (Quattro) (Z 56 828)

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A

B A

A

A--A

Z 56 829

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Examinations of the Crane 22

Chassis -- sliding frame (Z 56 829) Legend: A = right B = left

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Z 56 830

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Chassis -- sliding frame (idler side) (Z 56 830)

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A--A

A View Z A Z

Z 54 328

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Frame superstructure 1 (Z 54 328)

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C--C

C B C B--B B

Z 56 814

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Frame superstructure 2 (Z 56 814)

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Z 56 821

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A--frame (Z 56 821)

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Z 56 822

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Base plate counterweight (Z 56 822)

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Z 54 329

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Main boom (foot section, intermediate section) (Z 54 329)

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Z 56 816

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Reducer (main boom) (Z 56 816)

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A

B

Z 56 815

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Examinations of the Crane 22

Fly jib (foot section) (Z 56 815) Legend: A = top piece B = foot section

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Z 56 817

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Fly jib LF (Z 56 817)

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Z 56 818

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Mast basic boom mast point (Z 56 818)

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Z 54 330

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Connection head (Z 54 330)

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Z 56 819

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Roller set (Z 56 819)

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Z 56 820

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Runner (Z 56 820)

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A

B

B

Z 54 331

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Luffing masts (Z 54 331)

Legend: A = top B = bottom

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Z 54 332

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Bracing rods (general) (Z 54 332)

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Z 51 910

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22.1.2

Inspection of the Disc Wheels (Rims) The rim of a wheel is an important component of the mobile crane which is relevant to safety.

In addition to the annually prescribed inspection of the crane, there must be a crack inspection of the rims. If it is determined that cracks are starting to form or if cracks are discovered, the affected rims must be replaced immediately.

After a running stretch of max. 40 000 km (24854.85 mi), the crane operator must carry out a running observation.

In particular, the rims must be checked for incipient cracks in the base material and in the zones marked with arrows (Z 51 910).

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22.1.3

Inspection of the Winches An external visual inspection is not sufficient. The service life of the winches can be reduced by bad servicing, defective seals, unprofessional operation or overloading. For this reason a specialist must carry out inspections in accordance with the following regulation.

Inspections −

Inspections interval -- every 1000 operating hours, at least once a year

−

Check the oil level

−

Check for colouring of oil

−

Check for solid foreign materials -- this check must be carried out by a qualified lab

−

Visual inspection

−

Check of the brakes on the transmission of the winches

−

Check of the spline fitting “engine/brake/transmission”

During the annual crane inspection, the used portion of the theoretical period of use of the winches must also be determined. If required, the operator of the crane must assign this work to a specialist.

Where accident prevention regulations of the German employer’s liability insurance association apply, this is required by law.

Outside of the validity period, the crane manufacturer recommends that the procedures listed also be observed.

Not complying with these standard settings for determining the remaining period of use of the winch may result in unnoticed expiration of the winch and sudden, unexpected winch failure. This could result in property damage accidents and fatalities!

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22.1.3.1 Theoretical Service Life When calculating and dimensioning the winches of your crane, the designer has assumed certain operating conditions.

The winches of your crane are graded as follows (ISO 4301/1, FEM 1.001, DIN calculation parameters for drives): Power unit group: M........

Load collective: Q....... (L.......)

Factor of the load collective: Km = ..........

This results in a theoretical service life D. The valid values can be taken from the table “Monitoring the Winches” in the crane log book.

The theoretical period of use may not be equated with the real (actual) period of use of a winch!

The real period of use of a winch is additionally influenced by many external conditions, for example: -- overloading as a result of improper use of the crane.

-- insufficient maintenance: oil change not carried out in good time.

-- incorrect operation as a result of extreme acceleration or dragging or falling of the load into the ropes.

-- maintenance errors, for example using the wrong oil, incorrect capacities or contamination during oil changes.

-- assembly errors during repair and maintenance.

-- unattended leaks.

-- incorrectly adjusted safety equipment.

-- hidden damage from accidents.

-- extreme environmental conditions such as low and high temperatures, aggressive atmosphere or dust and dirt.

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Z 29 551

Z 29 552

Z 29 553

Z 29 554

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Examinations of the Crane 22

22.1.3.2 Actual Operating Conditions To calculate what proportion of the theoretical service life has already been utilised for the winches, the actual operating conditions (load collective) and the operating hours of the hoists per inspection interval must be determined.

22.1.3.3 Calculating the Operating Conditions (Load Collective) The load collective of the crane is divided into groups (see also ISO 4301/1, FEM 1.001).

From the knowledge of the actual operating conditions one of the following listed load collectives must be selected and entered in the examination log book for the crane for the corresponding inspection interval.

Load collective class

Term definition

Running time sections

light Q1 L1

Engines or parts thereof which are only placed under high load as an exception, but which are normally run at very low load

10 % of the run time with highest load (dead load + 1/1 payload) 40 % of the run time with dead load + 1/3 payload 50 % of the run time only with dead load see graphic Z 29 551

0.125

Engines or parts thereof, which are operated fairly frequently under high load, but are also run primarily at low load

1/6 of the run time with the highest load (dead load + 1/1 payload) 1/6 of the run time with dead load + 2/3 payload 1/6 of the run time with dead load + 1/3 payload 50 % of the run time only with dead load see graphic Z 29 552

0.25

medium Q2 L2

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Factor of the load collective (Km)

heavy Q3 L3

Engines or parts thereof, which are regularly operated at the highest load and/or medium loads

50 % of the run time with the highest load (dead load + 1/1 payload) 50 % of the run time only with dead load see graphic Z 29 553

0.5

very heavy Q4 L4

Engines or parts thereof which are 90 % of the run time with the regularly operated at high or mehighest load (dead load + 1/1 paydium/high loads load) 10 % of the run time only with dead load see graphic Z 29 554

1

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22.1.3.4 Operating Hours of the Hoists per Inspection Interval Calculate the effective operating hours per inspection interval (Ti). These must be entered for the individual inspection interval in the examination log book for the crane.

For mobile cranes in assembly operation, the proportion of the hoist winches to the overall operating hours of the superstructure is generally 20 %.

If hoist rope reevings are correspondingly reduced for loads beneath the maximum loads of the selected load table, and the permitted rope load therefore almost completely used, this must be taken into consideration when calculating the winch load.

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22.1.3.5 Calculating the Used Proportion of the Theoretical Service Life of the Winches For the inspection interval i (max. 1 year in accordance with ISO 9927--1 or BGV D8), the used percentage of the theoretical service life of the winches is calculated using the formula:

Km Si =

i

x Ti

km Si

= used proportion of the theoretical service life

Kmi = factor of the load collective in the inspection interval “i” in accordance with section 22.1.3.3 km = factor of the load collective, used as a basis for calculating the winches (here: Km = 0.125) Ti

= effective operating hours in the inspection interval “i” in accordance with section 22.1.3.4

This used proportion is deducted after each inspection interval from the remaining theoretical service life (see example in section 22.1.3.6). Observe the following: −

If a theoretical service life remains which is insufficient for the next operating period, a general overhaul of the winches must be carried out.

−

If the theoretical service life D is reached, the winch may only be operated further once a general overhaul has taken place.

In each case a general overhaul is required at the latest 10 years after the crane is placed in operation.

The general overhaul must be arranged by the operator and carried out by the manufacturer (or persons authorised by the manufacturer) and must be entered in the crane book.

Following the general overhaul, a new theoretical service life is specified by the manufacturer or the persons authorised by the manufacturer.

The max. time period until the next general overhaul is, however, at the most 10 years.

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Z 60 292

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22.1.3.6 Documentation (Z 60 292) The operator is responsible for documenting the calculation of the used percentage of the theoretical service life of the winches.

The required formulae for this are contained in the examination log book for the crane: −

Sample tables (Z 35 995)

−

Tables for each winch.

With the help of these tables the remaining theoretical period of use of each winch is to be documented.

How the example table is collated is shown using the following example: Inspection no. 1 (1st year) The crane has been used in the previous year for assembly work: Load collective L 1, i.e. Km1 = 0.125 The superstructure operating hour meter reads 800 h. Of these, the winch was in operation approx. 20 % of the time, i.e. T1 = 160 h.

The used percentage S1 of the theoretical service life for the 1st inspection.

S1 =

km1 x T1 km

=

0.125 0.125

x 160 h = 160 h

The values for the factor of the load collective (here: Km= 0.125) and the theoretical service life (here: D = 3200 h) are specified at the head of the corresponding table.

Remaining theoretical service life after the first year: D1 = D -- S1 = 3200 h -- 160 h = 3040 h

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Z 60 292

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(Z 60 292) Inspection no. 2 (2nd year) The crane has been used for unloading operations at the harbour: Load collective L 3, i.e. Km2 = 0.5.

The superstructure operating hour meter reads 2000 h, i.e. during this period: 2000 h -- 800 h (used in the first operating year) = 1200 h.

Of these, the winch was in operation approx. 40 % of the time, i.e.

T2 = 480 h.

The percentage S2 of the theoretical service life used in the 2nd inspection interval therefore equals: S2 =

km2 x T2 km

=

0.5 0.125

x 480 h = 1920 h

Remaining theoretical service life after the second year: D2 = D1 -- S2 = 3040 h -- 1920 h = 1120 h Inspection no. 3 (3rd year) The crane was used for assembly work and occasionally for unloading work in the harbour: Load collective L 2, i.e. Km3 = 0.25.

The superstructure operating hour counter reads 3000 h, i.e. during this period: 3000 h -- 2000 h (used in the first two operating years) = 1000 h.

Of these, the winch was in operation approx. 30 % of the time, i.e.

T3 = 300 h.

The percentage S2 of the theoretical service life used in the 3rd inspection interval therefore equals: S3 =

km3 x T3 km

=

0.25 0.125

x 300 h = 600 h

Remaining theoretical service life after the third year: D3 = D2 -- S3 = 1120 h -- 600 h = 520 h Calculations must now be carried out to determine whether the remaining theoretical service life is sufficient for the next operating period. If this is not the case, a general overhaul must be carried out (see section 22.1.3.5).

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”Y”

”y1” + ”y2”

Z 54 325

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22.1.4

Hook (Z 54 325) The hooks must be checked by a specialist once a year. This should prevent accidents because errors will be determined early on. Any errors that are discovered must be documented as well as their rectification. Then you must check whether the determined errors have been rectified.

22.1.4.1 Inspection and Surveillance Measures Deformation, local cold deformation and crushing in the jaw, cracks, wear, rust.

Lock fitting of the hook nuts.

Deformation If the hook jaw expands more than 10 % compared to the starting dimension “y” or “y1”+“y2”, the hook must be replaced.

The starting dimension “y” or “y1”+“y2” is recorded on the hook.

It is measured from grain to grain.

Corrosion Threads and the operated shaft smut be checked for corrosion and wear. To do so, the hook nut must be unscrewed from the shaft.

If after--treatment is needed to remove the corrosion, the thread core diameter may not be exceeded by more than 5 % by this process. Otherwise, the hook must be replaced.

With older hooks the main dimensions must be compared with the data in DIN 687, 689, 699, newer hooks with the data in DIN 15401 and 15402 with regard to jaw width, main bending cross--section, thread core diameter.

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“Y”

“Y”

“X”

Z 33 646

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Examinations of the Crane 22

22.1.5

Inspection of the Sheaves (Z 33 646) Check all rope sheaves for damage as for example notches or similar damage, and check if the bearings are properly seated (running smoothly).

Sheaves with such damage must be replaced immediately.

Check all plastic sheaves for wear: −

Bottom tread “X” max. 3 mm (0.118 inch) Measure “X” = difference between ∅ new bottom tread and ∅ bottom tread is !

−

Side tread “Y” max. 5 mm (0.197 inch) Measure “Y” measured between rope (S) and tread of the sheave.

If the sheave is worn up to the wear limit, it must be replaced.

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22.1.6

Inspection of the Ropes General A cable is a basic consumer item with a limited life span. Many characteristics of a cable change throughout its period of use. For example, at first, its breaking force increases slightly as run time increases, to then fall rapidly once a maximum has been reached.

This breaking force decrease is due to an increased loss of the metal percentage caused by wear and corrosion which occur with wire breakage and structure changes of the cable.

In the cable, the load--bearing elements are connected in parallel. This is why a cable can still be safe for operation even if a large number of wires have broken.

One of the goals of a cable inspection is to monitor the increased number of cable breaks so that the cable can be removed before it is in a state that is not safe for operation.

Another goal is to recognise unusual rope damage which is generally caused by external influences.

On one hand, this means that it becomes possible to remove the cables in good time, on the other hand it helps to recognise weak points in rope operation so that measures to prevent such damage recurring can be taken.

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Intervals Standard ISO 4309 recommends the following: −

daily visual inspection of cables and rope end fittings for possible damage

−

regular inspection of the cables for operational safety by trained personnel

−

Special inspections: − after exceptional loads or assumed, invisible damage − after longer standstill periods − when lifting devices are removed to change location, every time before starting operation at a new operating location − after any accident or case of damage occurring in connection with rope operation.

Scope of the inspection Wear due to friction, corrosion pits, rust, pinch points, loosening of outer wire layers, bulges, loop formation of cords or wire, twist movement, corkscrews, kinks, number of visible broken wires, groups of broken wires, cord / wire breakage.

Determine the rope diameter in relation to the condition of the sheaves on the drums and sheaves.

Safeguarding of the rope to prevent it jumping out of place.

Condition of the rope end attachment.

Shielding against the effect of heat in fire operations.

It might become necessary to remove components to safely judge carrying equipment. During the inspection, ropes must be checked in their entire length, even the hidden parts, for example, support surfaces for balancing sheaves, pressure points under rope clamps and rope end mountings.

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Criteria for removal A rope must be removed when one or several of the following points are fulfilled. See also the relevant DIN standards. a) Wire breakage A cable must be removed when the permitted wire breakage number is in accordance with DIN 15 020 or exceeds it.

The cable must be removed if there are wire breakage clusters or if a cord breaks. b) Rope wear If the rope diameter in cables is decreased by 15 % or more during longer journeys compared to the nominal value, the cable must be removed. c) Corrosion You can determine corrosion of the outer rope wires with a visual inspection. However, it is difficult to determine corrosion on wires that cannot be seen externally.

Corrosion can lead to a decrease of the static breaking force of the cable due to reduction of the metallic rope average as well as a decrease of the operational stability due to corrosion pits. d) Abrasion Abrasion of the rope wires can be “interior abrasion” which is caused by movements of the cords and wire against each other when bending the cable up and down or “external abrasion” which is caused by movements between the cable and the sheave or by dragging the cable on the ground or over the material to be conveyed.

Abrasion is encouraged if lubrication is insufficient or lacking or by the existence of dust. If the rope diameter is decreased by 10 % or more compared to the nominal value, the cable must be removed even if no wire breakage was discovered.

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X

Z 1367

Z 1368

Z 1369

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e) Rope deformation Deformation of the cable is visible change to the rope structure.

Deformation generally also causes the rope configuration to loosen in the area of the deformation. Depending on the appearance, there is the following differentiation of the most important deformations: − − − − − − − − −

corkscrew--type deformation “basketwork” formation (deformation) loop formation of the wires loosening of individual wires or cords knots contraction flattening curl--type deformation Kinks and bends

Corkscrew--type deformation (Z 1367) With the corkscrew--type deformation, the axle of the unloaded cable becomes a corkscrew.

Remove cable, if the deformation X has become 1/3 d larger or more (d = rope nominal diameter).

“Basketwork” formation (deformation) (Z 1368) “Basketwork” formation (deformation) can occur in cables with steel inserts if the outboard bearing of the wires is loosened or the external cords are longer than the internal ones.

If the external wire or cord positions slip in comparison to the interior ones, the excessive length share is shifted in one place.

If there is “basketwork” formation (deformation), the cable must be removed.

Loop formation of wires (Z 1369) If there is loop formation of the wires, individual wires or wire groups poke out of the rope structure like little hairs on the rope side facing the sheave.

If there is a significant change to the rope structure due to wire loop formation, the cable must be removed.

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Z 1370

Z 1371

Z1372

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Examinations of the Crane 22

Loosening of individual wires or cords (Z 1370) If individual wires or cords loosen, the exterior wires of the loaded cable or individual cords can be shifted.

This means that they do not assume the share of then tension force assigned to them, which overloads the other wires or cords.

If the cable runs over sheaves, it can cause increased bending tension which causes premature wire breakage.

If the wires become loose due to rust and abrasion, the cable must be removed. If there is another cause for the loosening, the wire breakage occurring as a consequence determine the aptitude for removal.

Knots (Z 1371) A knot is defined as a thickening of the wires which repeatedly occur over longer periods. Often the inlay pokes out of the cable at the point of thickening.

At the thinner points in the cable, the cords push against each other, forming arches, which causes wire breakage.

Cables with several knots must be removed.

Contraction (Z 1372) Contraction is when the cable’s diameter is decreased on short stretches.

Cable components immediately in front of end fastenings must be carefully checked for contraction, which can be difficult to see at these points.

Cable with a lot of contraction must be removed.

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Z 1373

Z 1374

Z 1375

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Examinations of the Crane 22

Flattening (Z 1373) Flattening is defined as permanent deformation of the cable, which is caused by crushing.

Flattening causes increased wire breakage.

Curl--type deformation Curl--type deformation is caused when a loaded cable is pulled over an edge.

Cables with curl--type deformation must be removed.

Kinks (Z 1374) A kink is a deformation of the cable caused by pulling an eyelet-shaped rope loop straight without the cable being able to balance out the deformation by rotating around its axle.

Cables with one or more kinks must be removed.

Bends (Z 1375) A bend is a deformation of the cable which is caused by forceful external influences.

Cables with bends must be removed.

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Heat influences Cables subjected to exceptional heat (can be recognised by annealing colours) must be removed.

Period of use If operating conditions are sufficiently known, the time for changing the cables can be estimated beforehand within the frame of preventative maintenance with operating conditions and number of cables remaining the same.

However, the previously mentioned criteria are decisive for determining the time for removal.

In case of doubt, the cables should be removed.

The listed removal criteria are only guidelines for the daily visual inspections.

The description of the regular inspections exceeds the context of the lubricating and maintenance instructions.

It is determined in the corresponding national regulations.

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22.1.7

Documentation Instructions for repeated inspections on TEREX crawler-mounted and mobile cranes in accordance with § 26 sections 1 and 2 of the accident prevention regulations “Cranes” (BVG D6)

Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

1st inspection group: Crane document test component

A

B

C

D

E

Remarks

A

B

C

D

E

Remarks

A

B

C

D

E

Remarks

Inspection log book for the crane Operation / assembly instructions Load tables 2nd inspection group: notices / markings test component Factory sign Load / stress details Notice of operating regulations Prohibition and regulation notices Other safety markings 3. inspection group

travel gear 1)

test component: Axles Wheels Tyres Bearing Distributor gear Cardan shaft Leaf springs / springs Shock dampers Brakes A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

4th inspection group: chassis 1) test component

A

B

C

D

E

Remarks

D

E

Remarks

Frame Axle suspension Axle interlock Back stop Covering Steeping surfaces Steps Counterweight holding devices Holding device for block Boom support Attachment device 5th inspection group: chassis / crane operator’s cab test component

A

B

C

Doors Windows / glass Wipers Mirrors Seat Heater Ventilation Noise absorption Tachograph First--aid kit Substitute lamp Hazard warning triangle Warning jacket A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

6th inspection group: chassis / drive test component

A

B

C

D

E

Remarks

A

B

C

D

E

Remarks

B

C

D

E

Remarks

Combustion engine Exhaust system / combustion protection Fuel tank Fuel lines Filter Engine suspension Oil / coolant levels 7th inspection group: chassis / hydraulics test component Oil tank Filter Pumps Engines Valves Lines Hoses Cylinders 8th inspection group: chassis / air pressure system test component

A

Compressor Filter Air tank Valves Lines Hoses Cylinders A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

9th inspection group: chassis / electrical system test component

A

B

C

D

E

Remarks

Engines Alternators Battery Switch Lines Fuses Resistors Lighting equipment Braking lights Indicators Tail lights Flood lights Signalling devices Indicator lights Battery switch Limit switch transmission, steering, drive Support pressure gauge

A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

10th inspection group: chassis/control devices 1) test component

A

B

C

D

E

Remarks

A

B

C

D

E

Remarks

Engine control Transmissions Clutches Circuits Steering Control displays Engine stop pull Control of the outriggers 2) Axle suspension Crane levelling Rear--axle steering 11th inspection group: Superstructure test component Frame Coverings Steeping surfaces Bearing Counterweights Back--stroke safety device Slewing rim: fastening screw Slewing rim: toothing Slew gear: fastening screws Slew gear: toothing Slew gear: Drive Slew gear: lock Slew gear: Covering A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

12th inspection group: superstructure / cab test component

A

B

C

D

E

Remarks

Doors Windows / glass Wipers Mirrors Seat Heating / air conditioning equipment Ventilation Mufflers Control lever for operating functions Transmission switches Safety device: points of crushing / shearing 13th inspection group: superstructure / retaining devices and safety guards test component

A

B

C

D

E

Remarks

A

B

C

D

E

Remarks

Handles and ladders Coverings Covers Flaps 14th inspection group: superstructure / drive test component Combustion engine Exhaust system / combustion protection Fuel tank Filter Engine suspension Noise absorption Oil / coolant levels A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

15th inspection group: superstructure / hydraulic system test component

A

B

C

D

E

Remarks

D

E

Remarks

Oil tank Filter Pumps Engines Valves Lines Hoses Cylinders Pressure relief valves Lowering brake valves 16th inspection group: superstructure / electric system test component

A

B

C

Engines Alternators Battery Switch Lines Fuses Resistors Lighting equipment Switch cabinet Indicator lights

A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

17th inspection group: superstructure / control devices test component

A

B

C

D

E

Remarks

C

D

E

Remarks

Engine control Transmissions Elastic clutches Circuits Engine stop Control displays Slewing brake 18th inspection group: superstructure / rope drives test component

A

B

Winch H1 Winch H2 Winch W1/H3 Winch W2 Winch E Winch R Rope end fixture Ropes for winch H1 Ropes for winch H2 Ropes for winch W1/H3 Ropes for winch W2 Ropes for winch E Ropes for winch R Bracing ropes

A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

19th inspection group: superstructure / hooks / hook blocks test component

A

B

C

D

E

Remarks

E

Remarks

Sheaves Protecting clamps on the sheaves Axle stirrups Hook Hook fastenings Lock--on hook 20th inspection group: superstructure / safety and switching devices test component

A

B

C

D

Hoist emergency limit switch H1 Hoist emergency limit switch H2 Lowering emergency limit switch H1 Lowering emergency limit switch H2 Boom emergency limit switch E Boom emergency limit switch E Boom emergency limit switch W1 Boom emergency limit switch W2 Load limit device Length display: working radius, boom length Angle display: boom Angle display: top section Angle display: Slew gear Safety device: Control Operating range limits Tilt display Support pressure gauge Emergency off A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Company:

Inspector:

Date:

Crane manufacturer: TEREX Demag

Crane type:

Construction number:

Construction year:

Inventory no.:

Signature

20th inspection group: boom test component

A

B

C

D

E

Remarks

Welded construction: Foot section Welded construction: Intermediate sections Welded construction: boom head Welded construction: Luffing masts Sheaves Boom support Boom pinning Bracing rods / ropes Retaining cylinders Welded construction Luffing cylinders Telescoping cylinders Extension ropes Pull ropes A: existing / complete

B: state / servicing

C: Function

D: repair / replacement

E: subsequent inspection required not fulfilled = --

not required = 0

fulfilled = x

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Remarks

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1)

It is considered that an inspection of the traffic safety status of the mobile crane has been carried out if there is a error-free result of expert inspection in accordance with the road traffic licensing regulations. The expert must carry out an inspection of the traffic safety status on mobile cranes which are not authorised for travel on public roads (see also accident prevention regulations “Vehicles” BGV D29).

2)

The expert must still carry out these inspections even if there is a error--free result from an expert inspection in accordance with the road traffic licensing regulations.

3)

Inspection of the winches with regard to the used portion of the theoretical period of use

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Central Lubricating System Superstructure 23

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1/19

23

3

8.1 6

1

29

2

16

30

3

7

30

1

16

29

Z 61 154

10

11

3 2 12

9 4 5

6 8 13 Z 63 396

2/19

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Central Lubricating System Superstructure 23

23

Central Lubricating System Component Parts (Z 61 154) The components for the central lubrication system are listed below.

(1)

Central lubricating pump

(2)

Distributor SSV 6

(3)

Distributor SSV 8

(6)

A--frame foot bearing

(7)

Slew ring connection

(8.1) SL mast foot bearing (16) Roller set in the superstructure (29) Boom outrigger cylinder (30) SL mast outrigger cylinder Central lubricating pump (Z 63 396) (1)

Case

(2)

Pump element

(3)

Safety valve

(4)

Refilling nipple

(5)

Plug

(6)

Return connector

(7) (8) Sealing screw Control board (is revealed after removing the screw plug “8”) (9)

Light--emitting diode for “battery voltage on”

(10) Rotary switch for “setting the interval” (11) Rotary switch for “setting the operating period” (12) Light--emitting diode for “display of greasing procedure” (13) Button for additional lubrication

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23

1 3 2 4 6

5

10

11

12

9

13

4/19

Z 39 461

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Central Lubricating System Superstructure 23

23.1

Function (Z 39 461) The central lubrication system automatically supplies all connected lubricating points with grease via a lube distributor.

It operates according to certain lubrication cycles, i.e. there are interval and operating periods. These begin to run as soon as the ignition is switched on.

Interval period: -- period in which there is no automatic lubricating procedure.

Operating period: -- period in which the lubrication takes place.

A detailed description of the interval and operating periods are given in section 23.1.1.

If there is a malfunction in the system, lubricant will come out of the pump safety valve (3).

A detailed description of the instructions to follow in the event of malfunctions is given in section 23.3.

A test run is possible for a functions check of system and controls.

059--2230--090_en

1.

Switch on the ignition: Light--emitting diode (9) must light up.

2.

Actuate button (13) for additional lubrication for approx. 2 seconds.

The interval period is then shortened and a normal lubrication procedure follows. Light--emitting diode (12) and luminous touch contact (3) in the driver’s cab light up.

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23

10 11

9

12

13

Z 38 092

6/19

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Central Lubricating System Superstructure 23

23.1.1

Setting the Interval and Operating Times (Z 38 092)

23.1.1.1 General The ratio between the interval and operating periods is determined by an electronic control device.

As soon as the ignition is switched on, the interval period starts to run.

After the interval period has elapsed, the operating period, i.e. the actual lubrication procedure, starts.

If, for example, an interval period of 6 hours has been set, the interval period already elapsed when the ignition is switched off will be stored (e.g. 4 hrs.). Just 2 hours of interval period then remain once the ignition is switched back on.

If the battery voltage is interrupted -- for more than 4 days-- a complete interval time (6 hours) will first elapse.

Once started, an operating period lasts for the time the ignition remains switched on. If the operating period is interrupted by switching off the ignition, it will -- when the ignition is switched on again -- continue at the same point where it stopped.

The corresponding time periods are stored by the electronic system.

Example: Operating time elapsed 3 minutes -Remaining operating time 3 minutes.

The duration of a lubrication cycle, in other words the lengths of break time and working time, depend on the amount of lubricant needed by the system.

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23

10 11

9

12

13

Z 38 092

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Central Lubricating System Superstructure 23

23.1.1.2 Jumper Setting The jumper setting is factory set for interval time = 1 -- 1 h operating time = 7 -- 56 sec

23.1.1.3 Setting the Interval Time (Z 38 092) The interval time can be set to 15 levels using the blue rotary switch (10).

Switch position Hours

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

8

Switch position Hours

A

B

C

D

E

F

10

11

12

13

14

15

23.1.1.4 Setting the Operating Time (Z 38 092)

059--2230--090_en

Switch position Seconds

1

2

3

4

5

6

7

8

9

8

16

24

32

40

48

56

64

72

Switch position Seconds

A

B

C

D

E

F

80

88

96

104

112

120

9/19

23

93

92

102 112 115 116

111 114 118

109

108

107

106

103

104

117

101

96

110

105 97 100 95 99

94

91 98 Z 59 541

10/19

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Central Lubricating System Superstructure 23

23.1.2

Initiation of an Additional Lubrication Impulse (Z 59 541) Independent of the automatic lubrication procedure, which is triggered in accordance with the number of operating hours, the crane operator can initiate a lubrication procedure.

This can be accomplished either using the pushbutton on the pump (for description, see page 5/19) or by means of the pushbutton on the side desk to the right in the crane cab.

Press pushbutton (118, Z 59 541) for 2 seconds.

The pause time will now be skipped over and one lubrication procedure will be carried out.

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Central Lubricating System Superstructure 23

23.2

Servicing Central Lubrication System Servicing consists mainly in filling with clean lubricant when necessary. Nonetheless, all lubrication points must be checked for lubricant leakage at regular intervals. −

check lubrication points for grease leakage

−

Check tubes and pipes for damage. Damaged tubes and pipes must be replaced in their entirety.

When working on the central lubrication system, always observe the utmost cleanliness. Dirt in the system causes malfunctions.

Use kerosene or petroleum ether to clean the system. Solvents may not be used.

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23

1

2

Z 37 184

14/19

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Central Lubricating System Superstructure 23

23.2.1

Filling the Tank of the Central Lubrication System (Z 37 184) Fill the tank (1) of the central lubrication system to a level which must always be beyond the filling nipple (2) using a standard commercial grease pump or a manual lever press.

Never exceed the maximum level. The grease must be free of impurities, and may not change consistency over time.

The lubrication tank is filled with high pressure grease (see section 2 of these Lubrication and Maintenance Instructions).

After complete drainage, the pump can require up to 10 minutes running time to reach maximum delivery rate.

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Central Lubricating System Superstructure 23

23.3

Troubleshooting

Malfunction: Pump motor not running Cause:

Remedy:

Power supply interrupted.

Check power supply and fuses. If necessary, eliminate defective or replace fuses.

Check line from the fuses to the plug of the pump.

Electric motor

Check power supply for the electric motor. If necessary, replace electric motor.

Malfunction: Pump not delivering Cause:

Remedy:

Case empty.

Fill case with clean grease, allow pump to run (additional lubrication) until lubricant emerges from all lubricating points.

NOTE: Depending on ambient temperature and/or lubricant, pump elements may require up to 10 minutes to run before they reach full delivery.

Air trapped in lubricant.

Release additional lubrication. Unscrew outlet union on safety valve. Lubricant must emerge without bubbles.

Unsuitable lubricant used.

Intake bore of pump element clogged.

Replace lubricant, see lubricant table (see Lubrication and Maintenance Instructions).

Remove pump element and examine intake bore for foreign bodies and remove if necessary.

Pump piston worn.

Replace pump element.

Non--return valve in the pump element defective or clogged.

Replace pump element.

Malfunction: Pump not delivering Cause

Remedy:

Corresponding valve body is fitted without clamping ring.

Remove valve body and check whether clamping ring is fitted. If not, fit clamping ring.

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Z 29 549

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059--2230--090_en

Central Lubricating System Superstructure 23

Malfunction: Blockage in secondary progressive system (Z 29 549) Cause

Remedy:

Bearing, lines or distributor clogged.

The malfunction can be recognised by the following: a) Grease emerges from safety valve. b) The check pins (if fitted) located on the distributor pistons, do not move.

Determine and eliminate the cause of the blockage as described in the example below.

1. Allow the pump to run (see additional lubrication).

2. Release all the main leads (G) to the sub--distributors on the main distributor (B) individually and in succession. If, for example, grease leaks from outlet (1) of the main distributor (B) when under pressure, the cause for the blockage is in the lubricating circuit of the sub--distributor (D).

3. Allow the pump to continue to run.

4. Loosen all lubricant leads (E) of the sub--distributor (D) individually. If, for example, grease emerges from outlet (3) of the distributor (D), under pressure, the cause of the blockage is in the lead of the outlet (3) or in the bearing connected to it.

5. Exchange safety valve A. NOTE: In order to check each individual outlet, leave each outlet released for a prolonged period as only one piston strike is effected per pump rotation. Several strokes are, however, required for flow through of all the distributors.

c) If a distributor is blocked, luPump through blocked line/bearing using a hand pump. bricant does not emerge from Replace the distributor or clean it as described below: any outlet.

1. Remove all pipe connection unions.

2. Unscrew the piston plugs.

3. Push pistons out, if possible using a small thorn (smaller than 6 mm / 0.236 inch).

Caution: the pistons are fitted in the distributor bores.

Following removal, mark the pistons according to fitting position and direction for refitting subsequently. They may not be exchanged during fitting.

4. Thoroughly clean the distributor body in grease solvent cleaning agent and pass over with compressed air.

5. Push through the oblique channels (ø 1.5 mm/ 0.06 in) on the thread ends of the piston bores using a pin.

6. Clean distributor again and blow air through it.

7. Assemble distributor.

8 Replace the copper discs.

9. Before screwing in the pipe connection unions, pump oil through the distributor several times using a hand-operated pump if possible. The pressure in the distributor must not exceed 25 bar (362.8 psi).

If this happens, replace the distributor.

059--2230--090_en

19/19