Hydraulic System 12

12 Hydraulic System

Ensure that all lines and hoses are at

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

If lines and hoses are found damaged due

to mechanical, thermal or other effects,
they must be replaced.
(Z 163 700)
Z 163 700
Check all hoses regulary for damages.
If any damages - even if they are minor - are
detected when performing this visual check the
damaged hoses have to be replaced
immediately.

Even if no damages are detected the

hoses have to be replaced at the latest after
4 years.
Date: 15.CW/00

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12.1 Hydraulic Tank - Checking and

Topping Up the Oil Level

The hydraulic tank contains the general oil

supply for all hydraulic components.

When checking the oil level:

- Position the crane on level, flat ground.

- Crane in the travel position.
- Suspension cylinders retracted.
- Switch off the engine.
(Z 160 113)
Z 160 113

Read off the oil level at the oil inspection

window.
(Z 163 660)

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

topped up.

Find the cause of the oil loss and rectify

immediately.

Z 163 660
Date: 15.CW/00

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 Hydraulic System 12

12.2 Hydraulic Tank - Filter

1 - Return oil filter

(Z 163 661)

Z 163 661

2 - HP filter
(Z 163 662)

Z 163 662

For replacement intervals see Section 4

"Lubrication and Maintenance Schedule".

If one of the filters needs to be cleaned or

replaced between the specified intervals, this
will be indicated by the indicator light on the
dashboard.
(Z 163 803)
Date: 15.CW/00

Z 163 803

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In order to find out which filter needs

to be changed or cleaned, you must remove the
plugs on the pressure switches of the
filters one after the other and watch the indicator
light on the dashboard.
(Z 163 664, Z 163 665)

Z 163 664

Z 163 665
- Clean the housing of return oil filters
and replace the filters elements.
(Z 163 661)

To clean the filter barrel and to replace the

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

DANGER OF INJURY
Date: 15.CW/00

from high hydraulic oil pressure.

Therefore switch off the engine before
Z 163 661 working on the hydraulic system.

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 Hydraulic System 12

- Return oil filter

Loosen the hexagon nuts (1) with wrench SW

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

Then remove the filter cover (2) while paying

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

Z 160 250

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

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

It is advisable to set the filter unit down on

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

Z 160 251

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

the handle (5) downwards and return it
approximately 60o to the left or the right.
Remove the handle (5) with the attached valve,
clean the latter in diesel oil or petroleum ether
and place it on a clean base.
(Z 160 252)
Date: 15.CW/00

Z 160 252

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Remove paper elements which are marked with

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

The element number of the replacement

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

Z 160 253

Pour the residual oil out of the filter tube into a

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

In filters which have a magnet system, the

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

The return oil filter 2 is assembled in the

reverse seqence.
Before assembly, seals (3) and (6) must
be checked to ensure that they are in perfect
condition and positioned correctly. Replace
damaged parts. Fit new paper elements in the
filter tube. Press the handle between the
locking plates fastened at the top of the filter
tube downwards and turn it until it has locked in
position in the slots in the cams.
(Z 160 251)
Date: 15.CW/00

Z 160 251 Beim Probelauf Filter auf Dichtheit prüfen.

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 Hydraulic System 12

- Cleaning the High Pressure Filter and

Replacing the Element

- Switch off the engine

- Place a suitable container beneath the filter

to catch any oil that might run off.
(Z 163 662)

Oils that are drained off must be stored in

suitable containers and disposed of
Z 163 662 correctly.

- Unscrew the socket housing.

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

- Drain off the remaining oil from the bottom of

the socket housing and dispose of it.

- Wash out the socket housing with diesel oil

or petrol of a suitable grade for washing
purposes.

Z 160 176

- Remove and dispose of the dirtied paper

element (2) from the outlet pipe (3) by
moving it gently from side to side and pulling
it downwards.
(Z 160 177)
Date: 15.CW/00

Z 160 177

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

(Z 160 178)

Z 160 178

- Apply new paper element (2) on the outlet

pipe (3).
(Z 160 179)

Z 160 179

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

with clean hydraulic oil.
Carefully place the filter barrel over the
filter element (2) and...
(Z 160 193)
Date: 15.CW/00

Z 160 193

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 Hydraulic System 12

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

with a wrench.
(Z 160 194)

Carry out a test run to ensure that the

filter is fitted correctly.

Z 160 194
Date: 15.CW/00

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12.3 Hydraulic Tank - Replace the

Aeration Filter

The aeration filter must be changed

more regularly in especially harsh operating
conditions.
(Z 163 666)

Z 163 666

- Unscrew the filter and dispose of

appropriately.
(Z 160 188)

Z 160 188

- Screw on the new filter.

(Z 160 189)
Date: 15.CW/00

Z 160 189

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 Hydraulic System 12

12.4 Changing the Hydraulic Oil

The vehicle should be level and the

engine switched off.

Oils that are drained off must be stored in

suitable containers and disposed of
2 correctly.

- Unscrew the screw connections (1) on the

1
drain cock (2) on the underside of the
Z 163 806 hydraulic tank.
(Z 163 806)
- Screw the drain hoses onto the drain cocks.
(Z 163 684)

Z 163 684

- Open the drain cocks and drain the oil into

suitable containers and dispose of it.
(Z 163 686)
Date: 15.CW/00

Z 163 686

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- Clean the hydraulic oil container.

(Z 163 668)

Z 163 668

- Close the drain cocks again.

Loosen the screw connections and remove
the drain hoses.
- Screw the screw connections (1) back on.
(Z 163 690)

This seals the hydraulic tank again.

Z 163 690
- Fill in new hydraulic oil
(also see section 12.1).
(Z 163 669)

When oil is filled into the hydraulic

system there is a danger of dirt particles
contaminating the hydraulic oil circuit.
In order to prevent malfunctions in the
system caused by impurities, ensure that
the initial fill up and subsequent fill ups
are carried out under extremely clean
Date: 15.CW/00

conditions.
If necessary, first pass the hydraulic oil
Z 163 669 through a filter.

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 Hydraulic System 12

12.5 Bleeding the Hydraulic System

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

i.e. - boom lowered

(Z 160 008)
Z 160 008

While the engine is running the hydraulic

system is bled through the vent ports
provided...

...hydraulic pump
(Z 163 595)

While bleeding the system, with the

engine running at idle speed, the vent fittings
should be kept open until oil which is free from
air bubbles escapes from the fittings.

Z 163 595

At points where there are no bleeder

connections, a union (union nut) situated at a
high level is loosened by a small amount.
(Z 160 197)
Date: 15.CW/00

Z 160 197

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At high engine speeds or with a high

suction current, smaller air pockets are sucked
back into the pump where they are broken up
into tiny bubbles; this can lead to foaming and
can cause venting of the system to take much
longer.
(Z 163 670)

Z 163 670

12.6 Hydraulic System -

Pressure Accumulator, Checking
the Preliminary Gas Tension

The pressure accumulators fitted in the

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

They are fitted in the following components:

- Pilot control circuit of the superstructure
hydraulics

The corresponding components can only

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

The preliminary gas tension must be checked

at regular intervals.

To check the preliminary gas tension,

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

This inspection may only be carried out

Date: 15.CW/00

by specialist personnel who are trained in

the use of the filling and test equipment.

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 Hydraulic System 12

To check and fill the pressure accumulator,

1 proceed as follows:
2
Switch off the drive motor on the
superstructure and switch the ignition key to
the "0" position.

Depressurize the hydraulic system.

The pressure accumulator (2) must be
completely emptied of hydraulic fluid.
(Z 30 640)

Check this on the mini-gauge connection "X"

"X" at the pilot control circuit using a manometer.
Z 30 640 (0 bis 10 bar)

If the pressure gauge does not indicate a

pressure level, the system is not under
3 pressure.

- Remove the protective device (1) on the gas

1 valve of the pressure accumulator (2) and
screw on the filling and test device (3).
2
- Open the gas valve over the screwed-on
filling and test device and read off the charge
2 pressure on the pressure gauge of the
testing device.

Z 30 194 - If there is insufficient initial pressure, the

pressure accumulator must be filled up with
nitrogen via the filling device (3) up to the
corresponding initial pressure.
(Z 30 194)

After the initial fill-up, wait approximately two to

three minutes.
Check the preliminary pressure again and top
up as necessary.
Date: 15.CW/00

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When filling up the preliminary gas tension

1 on the pressure accumulator observe the
2 pressure gauge on the mini-gauge connection
"X".
The pressure in the corresponding hydraulic
circuit must not be allowed to rise.
If this is the case, the diaphragm in the
pressure accumulator is defective.
The pressure accumulator must be replaced.
(Z 30 640)

"X" Z 30 640

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

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

3 Only NITROGEN may be used to fill the

pressure accumulator.
A pressure reducer (5) must be fitted to
5 the nitrogen link.
Pressure accumulators may only be
repaired by the manufacturer or by
approved workshops.
The pressure accumulator must be
approved by an expert following repair
4 2 work.
Date: 15.CW/00

A new test certificate must be produced

for the pressure accumulator.
Z 30 641 (Z 30 641)

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