Hoists 22

22 Hoists

Hazards caused by dragging!

When carrying out maintenance,
inspection and assembly work in this field
particular care must be paid, as there is a
danger of becoming tangied between the
winches and hoist ropes and being
dragged into the equipment.

The same maintenance work applies for

hoist 2 as for hoist 1.

22.1 Hoist Gear - Checking and Topping

Up the Oil Level

Check the oil level through the inspection

glass.

The oil level should be checked

immediately after commencing operations,
while the gear is at a standstill, as a
considerable quantity of the oil is distributed
throughout the inner parts of the housing during
operation.
Z 163 710
The correct oil level is reached when, with the
crane in a level, horizontal position, the oil is
level with the "max." marking on the inspection
glass.
(Z 163 710)

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

hoist gear must be drained off and new oil
filled in.
Date: 11.CW/04

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If the level is below the minimum marking

proceed as follows:

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

of the inspection glass.
(Z 163 711)

- Using a funnel or hose, fill in oil up to the

"max." marking on the inspection glass.
(Z 163 710)

See section 22.2 and section 2 "Fuels and

Lubricants" for the correct oil types.
Z 163 711
- Screw the filler plug (1) back in.

If a continual loss of oil is discovered

when checking the oil level, operation
must be stopped and the winch gear
checked.

Z 163 710

22.2 Hoist Gear - Changing the Oil

Use the oil grade given in section 2 "Fuels and

Lubricants" or on the serial plate. It is
preferable to use an oil of a higher viscosity
rather than using a thinner oil.
Different oil types should not be mixed, even if
they come from the same manufacturer.
Date: 11.CW/04

It is prohibited to mix mineral and

synthetic oils.

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 Hoists 22

Fully synthetic oils may only be used

with acidproof 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:

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

the inspection glass.
- Remove the drain plug (2) at the lower end
of the inspection glass (Z 163 711)
and drain off the oil into a suitable container.
Z 163 712 (Z 163 712)

Z 163 713
Date: 11.CW/04

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22.3 Checking the gear oil

The gear oil which is drained off should be

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

Date: 11.CW/04

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 Hoists 22

22.4 Lubricating the Rope Drum Bearing

Grease lubricating nipple.

(Z 163 316)

Lubricat until lubricant is emitted evenly

at the seal.

Z 163 316

22.5 Checking and Tightening the

Screw Connections

(Z 163 317, Z 163 414)

The torque for the screws is as follows:

Item Dimension Material Torque

Pos. 1 M 10 x 40 10.9 46 Nm
Pos. 2 M 20 x 70 10.9 558 Nm
Pos. 3 M 16 x 50 10.9 265 Nm

Z 163 317

The same values apply for hoist 2 as for

hoist 1.

When new screws are fitted, the thread

and head should be smeared with KP2K roller
bearing grease.
Date: 11.CW/04

Z 163 414

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22.6 Lubricating the Hook Block

Risk of snagging!
When carrying out maintenance,
inspection and assembly work, special
care must be taken in this area as there
is a danger of becoming entangled and
dragged into the equipment between the
hook block pulleys and ropes.
Use the hand grips located on the hook
Z 160 318 blocks!

The lubricating nipples on the hook block should

be smeared before the crane is put into operation
and thereafter every 50 operating hours.

(Z 160 318)

22.7 Determination of the spent share

of the theoretical service life

A detailled description is given in chap. 1

"Notes on safety", point 1.4.4.
Date: 11.CW/04

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