AC250-5 AC220-5-82640-Part3 538653 1 en

Lubrication and maintenance
instructions Entire crane

AC 220-5 / AC250-5
This document is a translation of the original operating instructions which are sent with this
specific machine and are designated as belonging to this machine. It is not intended as a basis
for further translations.
Please use only the original operating instructions as a reference. They are labelled accordingly.
82640
Disclaimer
Disclaimer
The only warranty applicable to our products is the corresponding

standard written warranty. Tadano shall neither explicitly nor implicitly
provide any warranty beyond this. The named products and services may
be trademarks, service marks or trade names of Tadano Ltd. and/or its
subsidiaries in the USA or other countries. All rights reserved.
82640 2021-04-22 3
Disclaimer
4 82640 2021-04-22
Table of contents
Table of contents
1 Safety Instructions ....................................................................... 15

1.1 General ...........................................................................................15
1.2 Warning Information ....................................................................... 15
1.2.1 General ...........................................................................................15
1.2.2 Structure ......................................................................................... 16
1.2.3 Types ..............................................................................................17
1.2.4 Warning symbols ............................................................................ 17
1.3 Personnel Selection and Qualifications .......................................... 20
1.4 Fire prevention ................................................................................20
1.5 Cleaning the crane ......................................................................... 21
1.5.1 After cleaning the crane ..................................................................23
1.6 Basic safety instructions ................................................................. 23
1.7 Before Commencing Lubrication and Maintenance Work .............. 23
1.8 Carrying out Lubrication and Maintenance Work ........................... 24
1.9 Repair work .................................................................................... 25
2 Consumables and capacities ...................................................... 27

2.1 Initial fill-up ......................................................................................27
2.2 General ...........................................................................................28
2.2.1 Permitted consumables .................................................................. 28
2.2.2 Changing consumables .................................................................. 29
2.2.3 Measures for low temperatures ...................................................... 29
2.2.4 Ambient temperature / operating temperature ................................30
2.2.5 Filling capacities ............................................................................. 30
2.3 Engine oil ........................................................................................31
2.4 Engine oil ........................................................................................31
2.5 Coolant ........................................................................................... 32
2.6 Diesel fuel .......................................................................................33
2.7 Diesel fuel .......................................................................................34
2.8 AdBlue® / DEF ............................................................................... 35
2.9 Hydraulic oil .................................................................................... 36
2.10 Transmission oil ..............................................................................37
2.13 Grease ............................................................................................38
2.14 Adhesive lubricant .......................................................................... 39
2.15 Adhesive lubricant .......................................................................... 40
2.16 Adhesive lubricant (special grease) ................................................40
2.17 Adhesive lubricant (special grease) ................................................40
2.18 Anti-corrosive spray ........................................................................41
2.19 Windscreen wiper fluid ................................................................... 41
2.20 Refrigerant ......................................................................................41
2.21 Refrigerator oil ................................................................................ 41
2.22 contact ............................................................................................ 42
2.23 Full assembly paste ........................................................................42
3 Lubrication and Maintenance Schedule .....................................43

3.1 Initial Lubrication and Maintenance ................................................ 43
3.2 Regular lubrication and maintenance work .................................... 43
3.3 Targets of crane maintenance ........................................................43
3.4 Measures for maintaining the crane ............................................... 44
3.4.1 Inspections of the condition ............................................................ 44
3.4.2 Preventative Maintenance .............................................................. 44
3.5 Maintenance list by kilometres driven .............................................46
3.6 Maintenance List by operational hours ...........................................52
82640 2021-04-22 5
Table of contents
3.7 Maintenance list - daily checks .......................................................63

3.8 Maintenance list - weekly checks ................................................... 65
3.9 Maintenance list - monthly checks ..................................................66
4 Visual inspections ........................................................................ 69

4.1 Visual inspections of the chassis ....................................................69
4.2 Visual inspections of the superstructure .........................................70
5 Engine ............................................................................................71
5.1 Engine components ........................................................................71
5.2 Servicing the engine ....................................................................... 74
5.2.1 Cleaning the engine – High pressure cleaning ...............................74
5.2.2 Checking the engine oil level ..........................................................74
5.2.2.1 Checking the engine oil level in the cab using the electronic oil
level detection system .................................................................... 74
5.2.2.2 Checking the engine oil level with the dipstick ............................... 75
5.2.3 Changing the engine oil ..................................................................76
5.2.3.1 Changing the engine oil – Version with oil drain cock .................... 77
5.2.3.2 Changing the engine oil – Version with oil drain valve ................... 79
5.2.4 Changing the oil filter ......................................................................81
5.2.5 Cleaning the oil centrifuge .............................................................. 81
5.3 Start engines with exhaust gas after-treatment (SCR system)
regularly ..........................................................................................83
5.4 Quick stop button - checking the function .......................................83
6 Transmission ................................................................................ 87
6.1 Check the drive gearbox and the distributor gear for leaks ............ 87
6.2 Drive gearbox ZF Traxon with intarder ........................................... 87
6.2.1 Serial Plates ................................................................................... 87
6.2.2 Drive gearbox – Carry out visual check ..........................................88
6.2.3 Drive gearbox - check the oil level ..................................................89
6.2.4 Drive gearbox - change oil ..............................................................90
6.2.4.1 Draining transmission oil ................................................................ 90
6.2.4.2 Change the filter element of the oil filter ......................................... 92
6.2.4.3 Filling with transmission oil ............................................................. 94
6.2.4.4 Performing test drive ...................................................................... 95
6.2.5 Drive gearbox – Fill with oil after repair work ..................................96
6.3 Distributor gear ............................................................................... 97
6.3.1 Distributor gear – checking the oil level, topping up if required ...... 97
6.3.2 Distributor gear – change oil ...........................................................99
6.3.3 Distributor gear – Carry out visual check ......................................101
6.3.4 Checking the Distributor Gear Shift .............................................. 103
7 Joint shafts ................................................................................. 105

7.1 Safety instructions (joint shafts) ....................................................105
7.2 Check the flange connections for proper fitting ............................ 105
7.2.1 Design with bolts / screws with zinc flake coating ........................ 106
7.2.2 Design with black bolts / screws or bolts / screws with A3C
coating .......................................................................................... 107
8 Axles and suspension ................................................................109

8.1 Conditions for Carrying out Work ................................................. 109
8.2 Axles .............................................................................................110
8.2.1 Check the axle fixing bolts ............................................................110
8.2.2 Replacing the axle fixing bolts ...................................................... 111
8.2.3 Lubricating the Steered Axles .......................................................111
8.2.4 Driven axles - checking the oil level ............................................. 112
8.2.4.1 Axles without drive shaft differentials ........................................... 113
6 82640 2021-04-22
Table of contents
8.2.4.2 Axles with Drive Shaft Differentials ...............................................114

8.2.4.2.1 Axle 3 ............................................................................................114
8.2.4.2.2 Axle 4 ............................................................................................115
8.2.5 Driven axles - change oil .............................................................. 115
8.2.5.1 Axles without drive shaft differentials ........................................... 116
8.2.5.2 Axles with Drive Shaft Differentials ...............................................117
8.2.5.2.1 Axle 3 ............................................................................................118
8.2.5.2.2 Axle 4 ............................................................................................119
8.2.6 Wheel hub drive - check the oil level ............................................ 120
8.2.7 Wheel hub drive - change oil ........................................................ 121
8.2.8 Wheel hub bearing – Changing the grease .................................. 122
8.2.9 Checking the wheel bearing ......................................................... 123
8.2.9.1 Checking the Axial Play of the Wheel Bearing ............................. 123
8.2.9.2 Checking the Lock Fitting of the Wheel Locking Nut .................... 124
8.3 Suspension ...................................................................................125
8.3.1 Suspension Cylinders - Lubricating the Pivot Bearings ................125
8.3.2 Check hoses of the suspension ....................................................126
8.3.3 Replace hoses of the suspension .................................................127
9 Steering ....................................................................................... 129

9.1 Safety instructions (steering) ........................................................ 129
9.2 Overview: Steering components ...................................................130
9.3 Visually check the steering components ...................................... 131
9.4 Check that the steering transmission components are fitted
firmly ............................................................................................. 131
9.4.1 Check the axial play in the steering lever bearing and adjusting
as necessary ................................................................................ 132
9.5 Lubricate the steering transmission components ......................... 133
9.5.1 Lubricating the steering lever ....................................................... 133
9.5.2 Lubricating the steering cylinders ................................................. 133
9.6 Check steering cylinder for leak-tightness ....................................134
9.7 Check the steering angle sensor .................................................. 134
9.8 Check hoses .................................................................................135
9.9 Replace hoses of the steering system ..........................................135
9.10 Fault search path (steering) ..........................................................135
10 Brake and compressed air system ........................................... 137

10.1 Safety instructions (Brake and compressed air system) .............. 137
10.2 Disc brakes ...................................................................................138
10.2.1 Checking the disc brakes ............................................................. 138
10.2.2 Check the brake disc .................................................................... 140
10.2.2.1 Checking the lining thickness of the brake linings ........................ 141
10.2.2.2 Checking the wear limit of the brake disc ..................................... 141
10.2.2.3 Checking the state of the brake discs ...........................................142
10.2.2.4 Checking the brake disc run-out ...................................................143
10.3 Checking the leak-tightness of the compressed air system ......... 143
10.4 Drain the compressed air tanks ....................................................144
10.5 Air dryer - replace the granulate cartridge .................................... 146
10.6 Compressed air lines ....................................................................148
10.6.1 Check compressed air lines ......................................................... 148
10.6.2 Markings of Compressed Air Lines ...............................................149
11 Wheels and tyres ........................................................................ 151

11.1 Check the wheel nuts ................................................................... 151
11.2 Tightening wheel nuts (standard rims) ......................................... 151
11.3 Tightening wheel nuts (aluminium rims) ....................................... 152
11.4 Check tyres ...................................................................................153
11.4.1 Checking tyre pressure .................................................................153
82640 2021-04-22 7
Table of contents
11.4.2 Checking the Tread Depth ............................................................154

11.4.3 Checking Visible Damage ............................................................ 154
11.4.4 Checking Age ............................................................................... 155
11.5 Check disc wheels (rims) ..............................................................155
11.6 Clean tyres ................................................................................... 156
12 Hydraulic System ....................................................................... 157

12.1 Safety Instructions ........................................................................ 157
12.2 Checking the hydraulic oil level .................................................... 157
12.3 Check hydraulic oil ....................................................................... 158
12.3.1 Analysis and lab report ................................................................. 161
12.4 Change the hydraulic oil ............................................................... 161
12.4.1 Drain off hydraulic oil .................................................................... 162
12.4.2 Add hydraulic oil ........................................................................... 163
12.5 Replacing the hydraulic filter ........................................................ 164
12.5.1 Overview: Hydraulic tank ..............................................................164
12.5.2 Replacing return line filter 1 ..........................................................165
12.5.3 Replacing return line filter 2 ..........................................................166
12.5.4 Replacing the aeration filter ..........................................................167
12.5.5 Replacing high-pressure filter element ......................................... 168
12.5.6 High-pressure Line Filter - Cleaning or Replacing the Filter Ele-
ment ..............................................................................................171
12.5.7 Replacing the high-pressure return line filter ................................174
12.6 Fault message - hydraulic filter .....................................................175
12.7 Check the hydraulic system ..........................................................176
12.8 Bleeding the Hydraulic System .....................................................176
12.9 Check the preliminary gas tension of the pressure accumula-
tors ................................................................................................177
12.10 Hose assemblies on mobile cranes ..............................................178
12.10.1 General .........................................................................................178
12.10.2 Markings of hydraulic hoses ......................................................... 179
12.10.3 Replace hoses ..............................................................................179
12.11 Servicing the hydraulic emergency unit (optional) ........................180
12.11.1 Checking the combustion air intake area ..................................... 180
12.11.2 Checking the cooling air area ....................................................... 180
12.11.3 Filling the fuel tank ........................................................................181
12.11.4 Checking the engine oil level ........................................................182
12.11.5 Changing the engine oil ................................................................185
12.11.6 Checking the water separator .......................................................188
12.11.7 Checking the poly-V-belt .............................................................. 190
12.11.8 Cleaning the cooling air blower, the cooling fins and the oil
cooler ............................................................................................192
12.11.9 Checking screw joints ...................................................................194
12.11.10 Checking the preliminary fuel filter for dirt .................................... 195
12.11.11 Changing the preliminary fuel filter ............................................... 195
12.11.12 Servicing the dry air filter .............................................................. 198
12.11.12.1 Removing the air filter cartridge ....................................................198
12.11.12.2 Checking and cleaning the air filter cartridge ............................... 200
12.11.12.3 Replacing the air filter cartridge ....................................................201
12.11.13 Checking and adjusting the valve clearance ................................ 202
12.11.14 Changing the oil filter ....................................................................205
12.11.15 Checking the fuel vaporizer .......................................................... 207
12.11.16 Checking the exhaust backpressure sensor .................................211
12.11.17 Replacing the main fuel filter ........................................................ 213
12.11.18 Replacing the sealing rings in the belt tensioner or the com-
plete belt tensioner ....................................................................... 216
8 82640 2021-04-22
Table of contents
12.11.19 Replacing the poly-V-belt and checking the shut-off device

function ......................................................................................... 216
12.11.20 Cleaning the EGR valve, the EGR housing and the intake
area .............................................................................................. 220
12.11.21 Regenerating the diesel particle filter ........................................... 220
12.11.22 Changing the diesel particle filter ................................................. 222
12.11.23 Resetting the maintenance interval display .................................. 223
12.12 Fault diagnosis of hydraulic emergency unit (optional) ................ 225
13 Supports ......................................................................................231
13.1 Check lubrication of the support strut and lubricate if needed ......231
13.2 Lubricate the support rollers of the struts ..................................... 232
13.3 Checking the State of the Outrigger Plates and for Wear and
Evenness ......................................................................................232
13.4 Check hoses .................................................................................233
13.5 Outrigger length transducer – carry out a visual check ................ 233
14 Electrical system ........................................................................ 235

14.1 Check the lighting system .............................................................235
14.2 Lighting equipment: Replacing bulbs ............................................235
14.3 Batteries ....................................................................................... 236
14.3.1 Service battery ..............................................................................236
14.3.2 Charging batteries ........................................................................ 236
14.3.3 Removing / fitting batteries ........................................................... 236
14.4 Checking the fuses ....................................................................... 237
14.4.1 Fuse overview (main fuses) ..........................................................240
14.4.2 Fuse Overview Stage V ................................................................240
14.4.2.1 Fuse overview (superstructure) .................................................... 240
14.4.2.2 Fuse Overview (Chassis) ............................................................. 243
14.4.3 Fuse overview EM3a / EM4 / Tier4f ............................................. 249
14.4.3.1 Fuse overview (superstructure) .................................................... 249
14.4.3.2 Fuse Overview (Chassis) ............................................................. 252
14.5 Service the slip rings .................................................................... 258
14.5.1 Servicing the slip rings: Housing .................................................. 258
14.5.2 Servicing the slip rings: Slip rings .................................................258
14.5.3 Servicing the slip rings: Brush Holder ...........................................258
14.5.4 Servicing the slip rings: Carbon Contacts .....................................259
14.6 Check the electrical system ..........................................................259
15 Fuel system .................................................................................263

15.1 Fuel system diagram, exhaust emission class EM4 / Tier4f,
Stage V .........................................................................................263
15.2 Diagram of the fuel system, exhaust emission standard EM3a ....264
15.3 Filling up ....................................................................................... 265
15.3.1 Safety instructions on filling up ..................................................... 265
15.3.2 Fuel Tank ......................................................................................267
15.3.3 Filling the additional tank .............................................................. 268
15.4 Fuel tank – draining water and deposits .......................................268
15.5 Fuel tank – Check the air bleed filter ............................................ 269
15.6 Check the fuel system .................................................................. 270
15.7 Preliminary fuel filter (EM3a) ........................................................ 270
15.7.1 Preliminary fuel filter - emptying the water collection container ....270
15.7.2 Preliminary fuel filter - change the filter element .......................... 272
15.8 Fuel filter in the diesel engine .......................................................274
16 Cooling system ...........................................................................277

16.1 Cooling system – overview ...........................................................277
16.2 Cooling System - Carry out a Visual Inspection ........................... 280
82640 2021-04-22 9
Table of contents
16.3 Cleaning the cooling system .........................................................280

16.4 Checking the coolant level, topping up if required ........................281
16.5 Changing the Cooling Fluid .......................................................... 283
16.6 Bleeding the Cooling System ....................................................... 287
17 Intake System ............................................................................. 289

17.1 Intake System - Carrying out a Visual Inspection .........................289
17.2 Replace the main element of the air filter ..................................... 290
17.3 Cleaning the main element of the air filter .................................... 292
17.4 Air Filter - Checking the Preseparator (Optional) ......................... 293
18 Exhaust system .......................................................................... 295

18.1 Exhaust System – Carrying out a Visual Check ........................... 295
18.2 SCR system (Stage V) ................................................................. 298
18.2.1 SCR System - Carrying out a Visual Inspection ........................... 299
18.2.2 Filling up AdBlue® / DEF ..............................................................299
18.2.2.1 Safety instructions for handling AdBlue® / DEF ........................... 299
18.2.2.2 Filling up AdBlue® / DEF ..............................................................301
18.2.3 Pump module - replace the filter element .....................................302
18.2.4 Replacing diesel particle filters ..................................................... 305
18.2.5 Service SCR catalytic converter ................................................... 309
18.3 SCR System (EM4 / Tier4f) .......................................................... 310
18.3.1 SCR System - Carrying out a Visual Inspection ........................... 310
18.3.2 Filling up AdBlue® / DEF ..............................................................311
18.3.2.1 Safety instructions for handling AdBlue® / DEF ........................... 311
18.3.2.2 Filling up AdBlue® / DEF ..............................................................312
18.3.3 Pump module - replace the filter element .....................................313
18.3.4 Servicing the SCR catalytic converter .......................................... 315
19 Piston rods ..................................................................................319

19.1 Exposed chrome surfaces - apply protective grease ....................319
20 Special Equipment ..................................................................... 321

20.1 Dolly coupling ............................................................................... 321
20.1.1 Lubricate dolly coupling ................................................................ 321
20.1.1.1 Lubricating the dolly coupling: Rockinger ..................................... 321
20.1.1.2 Lubricating the dolly coupling: Ringfeder ......................................321
20.1.1.3 Lubricating the dolly coupling: VBG ..............................................321
20.1.2 Service dolly coupling ...................................................................322
20.1.2.1 Servicing the dolly coupling: Rockinger ........................................323
20.1.2.2 Servicing the dolly coupling: Ringfeder ........................................ 324
20.1.2.3 Servicing the dolly coupling: VBG ................................................ 324
20.2 Central lubricating system ............................................................ 324
20.2.1 Central lubricating system - check level ....................................... 325
20.2.2 Central lubricating system - fill lubricant container ....................... 325
20.2.3 Clean the central lubricating system .............................................326
20.2.4 Check the central lubricating system ............................................326
20.3 Anti-fall protection via safety mast ................................................327
21 Slewing rim ................................................................................. 329

21.1 Safety Instructions ........................................................................ 329
21.2 Lubricate the bearing ....................................................................330
21.3 Lubricating the Ring Gear .............................................................331
21.4 Checking Screwed Connections for Firm Fitting .......................... 331
22 Slew gear .....................................................................................333

22.1 Overview: Slew gear .....................................................................333
22.2 Perform visual and noise checks ..................................................333
10 82640 2021-04-22
Table of contents
22.3 Lubricate the slew gear pinion ......................................................334

22.4 Check the involute spline connections ......................................... 335
22.5 Slew gearbox – check oil level, top up if required ........................ 335
22.6 Slew gearbox - change oil ............................................................ 336
22.7 Inspection of the drained oil ..........................................................339
22.8 Checking the brakes .....................................................................339
22.9 Check the bolted connections and tighten as required .................341
23 Hoists ...........................................................................................343
23.1 Hoist gears – checking the oil level, topping up if required .......... 343
23.2 Hoist gear – change oil .................................................................344
23.2.1 Inspection of the drained oil ..........................................................346
23.3 Exterior bolted connections - check and tighten if required ..........346
23.4 Lubricating the Rope Drum Bearing ............................................. 349
23.5 Checking the lower limit switch .....................................................349
23.6 Checking hoist limit switch ............................................................350
23.7 Hoists - Checking the Brakes ....................................................... 350
23.8 Calculation of the Spent Share of the Theoretical Service Life .... 352
23.9 General overhaul of the hoist winches ......................................... 352
24 Luffing gear .................................................................................355

24.1 Luffing cylinders - lubricating the foot and piston rod bearings .... 355
24.2 Check the bolted connections and tighten as required .................356
25 Main Boom, Rope Equipment, Devices .................................... 357

25.1 Main boom ....................................................................................357
25.1.1 Main boom – lubricate the sliding surfaces .................................. 357
25.1.1.1 Sample "Length code selection (LC) for lubrication of the main
boom" screen ................................................................................358
25.1.1.2 Preparing the lubricating procedure ............................................. 359
25.1.1.3 Telescoping out the lubrication length for lubrication (descrip-
tion as example) ........................................................................... 360
25.1.2 Main Boom- Checking the Rope of the Length Transducer ......... 362
25.1.3 Main boom – lubricate the foot bearing ........................................ 362
25.1.4 Main Boom - Lubricating Head Axles ........................................... 364
25.1.5 Check the main boom for cracks in the welding seams ............... 364
25.1.6 Main boom - check the rope track rollers ..................................... 365
25.2 Service the locking and pinning unit (LPU) ...................................365
25.2.1 Lubricate the locking and pinning unit .......................................... 366
25.2.2 Locking and pinning unit – carry out a visual inspection .............. 370
25.2.3 Locking and pinning unit - check the proximity switches and
sliding contacts ............................................................................. 370
25.2.4 Locking and pinning unit - check the preliminary gas tension of
the accumulators .......................................................................... 371
25.3 MBE - design with fixed operating angles .................................... 371
25.3.1 Checking the pins for cracks ........................................................ 371
25.3.2 Pins – Lubricating Moving Parts ................................................... 371
25.3.3 Checking the tension plates ......................................................... 372
25.3.4 Lubricating the tension plates .......................................................374
25.4 MBE - design with hydraulically smooth angle adjustment ...........375
25.4.1 Checking the pins for cracks ........................................................ 375
25.4.2 Pins – Lubricating Moving Parts ................................................... 375
25.4.3 Replace hoses ..............................................................................375
25.5 Assembly jib – checking the draw bars ........................................ 376
25.6 Service wind measuring device on adjustable bracket .................377
25.7 Sheaves on the boom system ...................................................... 377
25.7.1 Sheaves – carry out a visual inspection ....................................... 378
25.7.2 Plastic rope sheaves – carrying out a check for wear .................. 379
82640 2021-04-22 11
Table of contents
25.7.3 Steel rope sheaves – carrying out a check for wear .....................379
25.7.4 Check the rope sheave bearings ..................................................380
25.7.5 Lubricating the sheave bearing of the steel sheave ..................... 380
25.7.6 Replacing plastic rope sheaves ....................................................381
25.8 Ropes ........................................................................................... 381
25.8.1 General notes on handling and assembly .................................... 382
25.8.1.1 Transport ...................................................................................... 382
25.8.1.2 Storage ......................................................................................... 383
25.8.1.3 Assembly ...................................................................................... 383
25.8.1.3.1 Assembly procedure .....................................................................384
25.8.1.3.2 Re-reeling ..................................................................................... 385
25.8.1.3.3 Drawing the cable by means of an auxiliary reeving rope ............ 385
25.8.1.3.4 Winding on the rope under load ................................................... 387
25.8.1.3.5 Retracting ..................................................................................... 389
25.8.1.3.6 Cutting into sections and shortening ............................................ 389
25.8.1.3.7 Moving ropes ................................................................................ 391
25.8.2 Clean ropes .................................................................................. 392
25.8.3 Lubricate ropes .............................................................................392
25.8.4 Visual inspection of the ropes, rope end connections, etc. .......... 394
25.8.5 Check entire ropes, replace if required .........................................394
25.9 Lubricate hook block .....................................................................394
26 Heating ........................................................................................ 397

26.1 Crane chassis ...............................................................................397
26.1.1 Engine-independent auxiliary heating "Hydronic M-II D 10 W"
(optional) .......................................................................................397
26.1.1.1 Check the system is functioning correctly .................................... 397
26.1.1.2 Auxiliary Heating - Error Diagnosis ...............................................398
26.1.1.3 Replacing fuel filter ....................................................................... 398
26.2 Superstructure .............................................................................. 399
26.2.1 Engine-independent heating system (Hydronic) ...........................399
26.2.1.1 Check the system is functioning correctly .................................... 399
26.2.1.2 Heating system – fault diagnosis ..................................................400
26.2.1.3 Checking the Water Level ............................................................ 401
26.2.1.4 Filling the fuel tank of the superstructure heating .........................403
26.2.1.5 Replacing fuel filter ....................................................................... 404
26.2.1.6 Replace the heat exchanger .........................................................405
26.2.2 Flameless auxiliary heating (engine-dependent), optional ........... 406
26.2.2.1 Check the hydraulic system ..........................................................406
26.2.2.2 Hydraulic tank – checking the oil level, topping up if necessa-
ry ...................................................................................................406
26.2.2.3 Hydraulic tank (auxiliary heating) – changing the oil .................... 407
26.2.2.4 Hydraulic filter – checking the filter ...............................................409
26.2.2.5 Replacing the hydraulic filter ........................................................ 409
26.2.2.5.1 Replacing the return line filter .......................................................410
26.2.2.5.2 Replacing the aeration filter ..........................................................411
26.3 Petrol gas heating (optional) .........................................................411
26.3.1 Petrol gas heating - Overview ...................................................... 411
26.3.2 Petrol gas heating - checking the system is functioning proper-
ly ................................................................................................... 412
26.3.3 Liquid petrol gas heating - carrying out a visual inspection .......... 413
26.3.4 Petrol gas heating - replacing the heat exchanger ....................... 414
26.3.5 Petrol gas heating - having the system checked .......................... 415
26.3.6 Petrol gas heating - replacing the fuse ......................................... 416
26.3.7 Petrol gas heating - changing the gas cylinder .............................418
12 82640 2021-04-22
Table of contents
27 Air Conditioning ......................................................................... 423

27.1 Components of the air conditioning on the crane chassis ............ 423
27.1.1 Standard air conditioning on the crane chassis ............................423
27.1.2 Auxiliary air conditioning on the crane chassis .............................425
27.2 Components of the superstructure's air conditioning ....................427
27.2.1 Standard air conditioning on the superstructure ...........................427
27.2.2 Auxiliary air conditioning on the superstructure ............................429
27.3 Switching on the Air-Conditioning (Damage Prevention) ............. 430
27.4 Servicing the Air Conditioning Equipment - Operator ...................431
27.4.1 Service standard air conditioning ................................................. 431
27.4.2 Service auxiliary air conditioning .................................................. 435
27.5 Servicing the Air Conditioning - Specialist Workshop ...................440
27.5.1 Components of the standard air conditioning ............................... 440
27.5.2 Components of the auxiliary air conditioning ................................442
27.5.3 Checking the air conditioning in its entirety .................................. 444
27.5.4 Checking the refrigeration circuit .................................................. 444
27.5.5 Replacing the collector dryer ........................................................ 445
27.5.6 Changing refrigerator oil ............................................................... 445
27.5.7 Top up refrigerant ......................................................................... 446
27.6 Fault diagnosis air conditioning unit ............................................. 446
27.7 Fault Diagnosis Cooling Performance .......................................... 448
27.8 Fault Diagnosis Noise Development ............................................ 449
28 Cabs .............................................................................................451
28.1 Driver's Cab .................................................................................. 451
28.1.1 Checking the windscreen washer system for proper function-
ing .................................................................................................451
28.1.2 Fill up the supply tank of the windscreen washer system .............451
28.1.3 Emergency call equipment (Glonass - FORT 112 EC, option) -
Check function ..............................................................................451
28.1.3.1 Test mode .....................................................................................452
28.1.3.1.1 Select test mode ...........................................................................452
28.1.3.1.2 Perform tests ................................................................................ 453
28.1.3.2 Elimination of malfunctions ...........................................................454
28.2 Crane operator's cab .................................................................... 455
28.2.1 Lubricate tilt cylinder (option) ........................................................455
28.2.2 Checking the windscreen washer system for proper function-
ing .................................................................................................456
28.2.3 Fill up the supply tank of the windscreen washer system .............456
29 Inspections of the Crane ............................................................457

29.1 General .........................................................................................457
29.2 Recurrent Inspections of the Crane ..............................................457
29.2.1 General .........................................................................................457
29.2.2 Inspection of lashing points with wear markings .......................... 458
29.2.3 Checking the components ............................................................ 460
29.2.4 Inspection of Load-bearing Steel Constructions ...........................464
29.2.4.1 General .........................................................................................464
29.2.4.2 Schematic diagrams - mobile cranes ........................................... 464
29.2.4.3 Schematic diagram - lattice-mast cranes ..................................... 476
29.2.5 Checking the adjusting cylinders .................................................. 487
29.2.6 Inspection of the Winches ............................................................ 488
29.2.6.1 General .........................................................................................488
29.2.6.2 Theoretical Service Life ................................................................ 489
29.2.6.3 Actual Operating Conditions .........................................................489
29.2.6.4 Determining the Operating Conditions (Load Spectrum) ..............490
29.2.6.5 Operating Hours of the Hoists per Inspection Interval ..................491
82640 2021-04-22 13
Table of contents
29.2.6.6 Determining the Spent Share of the Theoretical Service Life of

the Winches ..................................................................................492
29.2.6.7 Documentation ............................................................................. 493
29.2.6.7.1 Documentation - example (creating the sample table) ................. 494
29.2.7 Load hook .....................................................................................495
29.2.8 Inspection of the Sheaves ............................................................ 497
29.2.8.1 Perform a visual check ................................................................. 497
29.2.8.2 Checking plastic rope sheaves for wear .......................................498
29.2.8.3 Checking steel rope sheaves for wear ......................................... 499
29.2.9 Inspection of the Ropes ................................................................500
29.2.9.1 General .........................................................................................500
29.2.9.2 Criteria for removal ....................................................................... 501
29.2.10 Checking the hose assemblies .....................................................507
29.2.10.1 Documenting the inspection ......................................................... 507
29.2.10.2 Check hoses .................................................................................507
29.2.10.3 Inspection criteria ......................................................................... 508
29.2.10.4 Possible causes for damage ........................................................ 508
29.2.10.5 Specifications on replacing hose assemblies ............................... 509
29.2.11 Test specifications for the recurrent crane inspection .................. 510
29.3 Inspection of Cranes with a Load Test ......................................... 518
29.3.1 General .........................................................................................518
29.3.2 Load and Overload Test ............................................................... 519
29.3.3 Recommendations of the crane manufacturer with regard to
the load test .................................................................................. 520
29.3.3.1 Checking the assembly ................................................................ 520
29.3.3.2 Load Test Factors .........................................................................521
29.3.3.3 Load Test Configurations ............................................................. 521
Index of figures .......................................................................... 523
Index of tables ........................................................................... 531
14 82640 2021-04-22
1 Safety Instructions
1.1 General
This section provides a concentrated and general overview of risks
that can occur when carrying out lubrication and maintenance work
on the crane.
1.2 Warning Information
1.2.1 General
During some lubrication and maintenance work, you must work in pla-
ces where risks are prevented during operation due to safety clearan-
ces or covers. Warning information is given within the description of
the work in question in the lubrication and maintenance instructions
so that you can detect and avoid these risks.
Particular types of risks (e. g. crushing, snagging, etc.) are indicated
by a corresponding warning symbol (for an overview of the warning
symbols, see 1.2.4 Warning symbols, side 17).
82640 2021-04-22 15
1.2.2 Structure
The structure is explained using the example of the depicted warning
information.
Fig. 1: Safety note (z82353)
1 Pictogram 2 Sign for danger / risk

3 Signal word 4 Type and source of the danger
5 Possible consequences 6 Measures for prevention / bans
Item Function
1 Pictogram, optional: symbolises consequences, measures or
bans concerning a concrete type of risk; alternatively, the
general sign for danger/risk (such as item "2") appears in
large.
2 Sign for danger/risk, general: indicates the risk of injury to
persons
3 Signal word: indicates the extent of the risk and severity of
possible injury to persons
4 Type and source of the danger
5 Possible consequences
6 Measures for prevention / bans
Points "4" and "5" can also be combined.
16 82640 2021-04-22
1.2.3 Types
The following types of warning information are used in these instruc-
tions:
DANGER
Hazardous situation with a high level of risk, result-
ing in death or serious injury if not avoided.
WARNING
Hazardous situation with a moderate level of risk,
which could result in death or serious injury if not
avoided.
CAUTION
Hazardous situation with a low level of risk, which
could result in moderate or minor injuries if not avoi-
ded.
NOTE
Hazardous situation which could result in damage to goods or
property.
Particularly important or further information is indicated without a sig-

nal word in the following manner:
This is an example for an indication of particularly important or fur-

ther information.
1.2.4 Warning symbols

Symbol Meaning
General warning sign
Warning, explosive substances
82640 2021-04-22 17
Symbol Meaning
Warning, radioactive substances or ionising radiation
Warning, laser radiation
Warning, non-ionising radiation
Warning, magnetic field
Warning, obstacles at ground level
Warning, risk of falling
Warning, biohazard
Warning, low temperature/frost
Warning, risk of slipping
Warning, electrical voltage
Warning, forklift trucks
Warning, hanging load
18 82640 2021-04-22
Symbol Meaning
Warning, toxic substances
Warning, hot surface
Warning, automatic start-up
Warning, risk of crushing
Warning, obstacles at head height
Warning, flammable substances
Warning, sharp object(s)
Warning, corrosive substances
Warning, hand injuries
Warning, counter-rotating rollers
Warning of hazards associated with charging batteries
Warning, optical radiation
82640 2021-04-22 19
Symbol Meaning
Warning, oxidising substances
Warning, gas cylinders
Table 1: Warning symbols
1.3 Personnel Selection and Qualifications

Have any maintenance and setting work carried out only by specialist
personnel. This especially applies to work on the electrics, hydraulics,
travel gear and brake and steering systems.
Only assign experienced personnel to attach loads and act as banks-
men for crane operators. The banksman must be within view of the
operator or must be in audio contact with him (see the operating in-
structions in the section "Safety instructions").
1.4 Fire prevention

Keep the crane clean, particularly of flammable materials (observe
Cleaning the crane).
Following maintenance work on the hydraulic system, engine and fuel
system, clean the crane thoroughly.
Remove any residue of oil, fuel or cleaning agents.
Oily rags and highly flammable materials must be stored away to pre-
vent the risk of fire or disposed of properly.
After cleaning the engine compartment, check all

- fuel lines
- engine oil lines
- hydraulic oil lines
for leaks, loose connections, shear points and damage.
Rectify identified faults immediately.
20 82640 2021-04-22
Check all electrical lines, plug connections and connecting terminals

for loose fastenings and damage.
Check the turbocharger mounting.

Check the exhaust and air inlet lines as well as lubricant feed and re-
turn lines for leaks.
Hand-held fire extinguishers must be filled and ready for use.
1.5 Cleaning the crane

Ensure that the crane is always clean, i.e. free of flammable materi-
als. To do so, wash the crane with an ample amount of water and re-
move dirt or salt residue.
82640 2021-04-22 21
NOTE
Damage to delicate components due to water jets.
Before cleaning the crane with water or a steam cleaner (high-
pressure cleaner) or other cleaners, cover/tape together all
openings that must remain free of water, steam or cleaning
agents for safety or functional reasons (e.g. switch cabinets).
To avoid damage, do not point the water jet directly at door
gaps, hoses, electric components (control devices, starters, al-
ternators, spotlights) and electric leads (socket connections, ca-
ble lead-ins or fuses).
During cleaning, always keep the water jet moving.
Apply the steam or water jet across a wide surface area.
Observe the operating instructions of the steam jet (or high-
pressure cleaner).
When commencing maintenance, clean the crane, in particular the

connections and screw connections, to remove oil, fuel or mainte-
nance agents. After maintenance work on the hydraulic system, the
engine and the fuel system, clean the crane thoroughly, best of all us-
ing a pressure washer.
- Clean the electrical connections with particular care.
- Do not use any aggressive cleaning agents (e. g. abrasive agents).
- Use non-fibrous cleaning cloths.
Minimum clearance between high-pressure nozzle and object to be
cleaned for all cleaning work:
- circular spray nozzles: approx. 700 mm (27.6 inch)
- 25° flat spray nozzles and dirt blasters: approx. 300 mm
(11.8 inch)
- steam sprays: 800 mm (31.5 inch)
- maximum temperature 60 °C (140 °F)
NOTE
Damage to rubber components due to unsuitable cleaning.
Clean rubber parts, such as tyres, etc. (see 11.6 Clean tyres,
side 156).
If air-cooled components (e. g. retarder) are fitted on the crane,

clean them regularly in winter or in dusty operating conditions. The
equipment must be cleaned when it is cold and without adding sol-
vents.
Do not clean sound absorption mats with high-pressure cleaners.
You must replace any sound absorption mats contaminated with fuel
or oil, as they are flammable and combustible.
22 82640 2021-04-22
Only clean the cab interiors using warm water with washing up liquid
added to it. Only wipe down all surfaces with a damp cloth, particular-
ly the surfaces with fittings or switches installed.
1.5.1 After cleaning the crane
Lubricate the crane after cleaning, particularly the slewing rim and
universal joints, especially if steam jets were used.
Remove the covers/any tape completely and carry out a visual check
to ensure that no water has penetrated.
Check all fuel, engine oil and hydraulic oil lines for leaks, loose screw
connections, shearing points and damage. Rectify any damage de-
tected immediately.
Lubricate all lubricating points.
1.6 Basic safety instructions

Wear safety clothing (safety gloves, safety shoes, safety helmet),
goggles, face mask and other safety equipment when required by the
working conditions.
Keep all handles, steps, rails, platforms, stages and ladders free of
dirt, snow and ice.
Use only the catwalks and steps described. They have sufficient
means of holding on and are designed to be slip-resistant (e. g. sand-
ing, corrugated metal plates or similar).
Do not allow any unauthorised persons on the crane during lubrica-
tion and maintenance work.
Spare parts must satisfy the technical requirements prescribed by
the manufacturer. Therefore only use our original spare parts. A new
examination and authorisation may be required.
Observe the listed safety instructions for lubrication, maintenance

and setting work for all overhaul / repair work as well.
1.7 Before Commencing Lubrication and Maintenance Work

Inform the operating personnel and appoint a supervisor.
Never carry out any lubrication and maintenance work with a load at-
tached.
Shut the engine down. The component group on which mainte-
nance work is to be carried out must be switched off and free of load.
The only exception to this requirement is for parts that do not need
to be powered up for lubrication and maintenance work to be carried
out.
82640 2021-04-22 23
Take measures to ensure there are no accidental crane move-

ments.
- Set the crane equipment on the ground
- Support the crane on outriggers (observe the capacity of the
ground)
Before carrying out any lubrication and maintenance work on the
electrical system, remove the ignition key and disconnect the battery
from the crane's electrical system with the battery isolating switch
(optional).
Ensure that the crane cannot be started up by an unauthorised per-
son (e. g. lock the cab doors, actuate the battery isolating switch or
remove the ignition key) and fix corresponding warning signs in place.
Cordon off the required area, leaving sufficient safety clearance as
necessary.
As oil can be emitted during maintenance and assembly work, keep
suitable collecting containers and binding agents ready.
1.8 Carrying out Lubrication and Maintenance Work
DANGER
Risk to life and limb due to falling or flung tools or
parts.
Make sure no tools are left on the crane after com-
pleting lubrication and maintenance work or after re-
pairs.
Refit all parts (trims, etc.) in accordance with regula-
tions.
Always tighten loose bolted / screwed connections
during maintenance work.
General
Comply with all regulations and specifications.
Adhere to all deadlines in the lubrication and maintenance schedule.
Thoroughly clean all nipples, caps and plugs before lubrication.
Replace the seals of drain, filling and check plugs as well as filters
with new ones before screwing plugs and filters back in place again.
If safety equipment must be dismantled during maintenance, refit it
immediately after completing maintenance work and check the func-
tion.
Consumables
Ensure that all consumables, auxiliary materials and used parts are
disposed of properly and in an environmentally friendly manner.
24 82640 2021-04-22
When handling oil, grease and other chemical substances, observe

the relevant safety regulations for the product.
Load-handling devices
Attach and secure individual components and larger component
groups to lifting devices during the replacement procedure to ensure
that all risks are avoided.
Use only suitable and technically faultless lifting devices and load-
handling devices with sufficient capacity.
Do not stand or work underneath suspended loads.
Working at height
When carrying out maintenance work above head height, use the
step-up equipment and work platforms specified or other such equip-
ment which is designed with safety in mind.
Do not use machine components as climbing aids or as step-up
equipment.
Wear anti-fall protection when carrying out maintenance work at
height.
1.9 Repair work
NOTE
There is a risk of accidents if changes are made to the crane
and not checked.
After any major changes to the crane or after repair work on car-
rying parts, the operator must authorise an inspection by a tech-
nical expert before resuming operation.
General repair work is not included in the scope of these lubrication

and maintenance instructions. If required, please contact our custom-
er service department.
Nevertheless, some relevant general safety instructions are included
below:
- Only carry out welding, torch cutting and grinding work on the
crane if express permission has been given to do this (e.g. there
may be a risk of fire and explosion).
- Never carry out any repair welding work without first discussing it
with our customer service team. Incorrect repair welding can cause
serious damage which in turn causes complicated repairs at a high
cost.
- Before welding, torch cutting and grinding, clean the crane and the
surrounding area of dust and combustible materials and provide
sufficient ventilation (risk of explosion).
- When working on the hydraulics system, depressurise any sec-
tions of the system that must be opened before work is com-
menced.
82640 2021-04-22 25
- Do not carry out any changes, fit additional parts or make modifi-
cations to the crane that could affect its safety without first obtain-
ing permission from the manufacturer. This also applies to fitting
and adjustment of safety equipment and valves and welding load-
bearing components.
26 82640 2021-04-22
2 Consumables and capacities
2.1 Initial fill-up

The initial filling is generally for the normal temperature range (from
0°C to +45°C / +32°F to +113°F). If the crane is to be used at lower
temperatures, replace the consumables according to the consuma-
bles lists and observe the specifications in 2.2.3 Measures for low
temperatures, side 29.
For topping up, use precisely the consumables listed in the table be-
low. When adding other permissible consumables, you must always
observe the compatibility of the different consumables and any pos-
sibly changed properties of the consumables which are no longer
"pure".
NOTE
Consequential damage due to mixing transmission or hydraul-
ic oils.
Oil types with different chemical bases are not compatible.
Do not mix different types of transmission oils or different types
of hydraulic oils, even if they are the same brand.
If a permitted oil type is used which is different from the one al-
ready used, replace the oil entirely.
Temperature range
Filling point Consumable Classification (ambient temperature)
°C °F
Engine (EM5) Shell RIMULA ULTRA SAE 5W-30 -40 +30 -40 +86
Engine (EM3a,
Mobil Delvac XHP EXTRA SAE 10W-40 -20 +45 -4 +113
EM4 / Tier4f)
50 % distilled water + 50 % anti-
Cooling system SCANIA DC 13 -40 +45 -40 +113
freeze Glysantin G48 (green)
Diesel, low in sulphur < 15 ppm,
Fuel tank temperature suitability in accord- DIN EN 590 - - - -
ance with the season
AdBlue® / DEF
AdBlue® / DEF ISO 22241
67.5 % water -10 +45 +14 +113
tank DIN 70070
32.5 % carbamide
82640 2021-04-22 27
Temperature range
Filling point Consumable Classification (ambient temperature)
°C °F
Standard (up to -20°C / -4°F)
Fuchs Renolin Xtreme Temp 46 HVLPD -16 +35 +3 +95
Plus
ATF (up to -25°C / -13°F) ATF Dexron III
-28 +35 -18 +95
Shell Spirax S4 ATF HDX G -3407 7
Hydraulic tank Low temperature
(up to -30°C / -22°F) -36 +10 -33 +50
Shell Tellus S4 VX32
High temperatures (from 0°C
+32°F to +50°C / +122°F) HVLPD -11 +45 +12 +113
Shell Tellus S3 V68
Drive gearbox ZF-ECO Fluid M ZF TE-ML02E -30 +45 -22 +113
Distributor gear
Driven axles Mobil Mobilube HD-A SAE 85W-90 -19 +50 -2 +122
Wheel hub drive
Slew gear
Mobilgear 600 XP 220 -20 +45 -4 +113
Hoists
Air Conditioning R134a DIN 8960 - - - -
Air Conditioning Reniso PAG 46 DIN 51 503-1 - - - -
2.2 General
2.2.1 Permitted consumables

All permitted consumables are listed in the consumables tables. We
recommend using the consumables for initial fill-up when topping up
(see section "Initial fill-up").
Only consumables corresponding with the columns "Permitted con-
sumables" or "Regulation" may be used. Adding additives can change
the consumable in a way which cannot be calculated or foreseen. We
shall not fulfil any warranty even within the guarantee period for con-
sequential damage due to the use of consumables which do not com-
ply with regulations or to which additives - no matter which type -
have subsequently been added.
If consumables are used which are not listed by name but are inclu-
ded in the regulations, the maintenance intervals could change, which
means the specifications in the lubrication and maintenance schedule
are no longer valid. In this case, please consult our customer service
department.
Special regulations and safety measures apply to biodegradable con-
sumables. Please consult our customer service department when us-
ing biodegradable consumables.
28 82640 2021-04-22
2.2.2 Changing consumables

If the lubrication and maintenance schedule prescribes a change in
consumables, replace the consumable according to the respective
consumables table. The same applies if the ambient temperatures
change and the consumables used are no longer suitable for the ex-
isting operating temperatures.
There is a risk of the function of safety-relevant components becom-
ing affected or of them being damaged if the consumables are not
changed within the ambient temperature range indicated in the tables
or if the crane is has not been brought to the correct temperature
throughout.
When changing liquid consumables, rinse system components which
have no through-flow (for example, cylinders). This is particularly im-
portant if another consumable is used than the one which has already
been filled.
Mixed operation (e. g. a permitted lower ambient temperature of the
hydraulic oil of -36°C (-33°F) and a permitted lower ambient tempera-
ture of the other consumables of -20°C (-4°F)) is prohibited. The
technically possible operating temperature of the crane would be re-
stricted at the upper end by the hydraulic oil used for the cold temper-
ature range and it would be restricted at the lower end by the con-
sumables used for warm temperatures.
2.2.3 Measures for low temperatures

Engine / fuel system
The engine can be started without additional starter equipment at
temperatures up to −20 °C (-4 °F); if corresponding measures are tak-
en for the engine, it can be started at even lower temperatures
(-40 °C / -40 °F). If temperatures are lower, the engine block must be
warmed up using suitable warming-up measures to a temperature
higher than −20 °C (-4 °F). After engine start, a warm-up phase must
be adhered to. The cooling water must be warmed up to at least
+70 °C (+158 °F) if the engine is placed under full load.
SCR system / AdBlue®
The start and operating temperatures of the engine are not affected
by AdBlue® / DEF. AdBlue® / DEF is controlled by the engine man-
agement system.
At temperatures below -11 °C (+12 °F), the AdBlue® / DEF starts to
freeze. At low temperatures, the AdBlue® / DEF is heated using cool-
ing water at a sufficient coolant temperature (limit temperature ap-
prox. +8 °C / +46 °F).
Hydraulic System
The following rules apply when starting operation at temperatures be-
low 0 °C (+32 °F):
- The hydraulic system must warm up at least 10 minutes at
1200 rpm. To do so, increase the engine speed slowly from idling.
82640 2021-04-22 29
- The hydraulic pumps may only be operated when the oil viscosity
is below 1000 cSt.
- Shut the crane down immediately if there are any unusual noises.
Drive gearbox
When starting operation at −25 °C to −30 °C (-13 °F to -22 °F), the
transmission must warm up at least 10 minutes at 1500 rpm.
When starting operation at temperatures from −30 °C to −40 °C
(-22 °F to -40 °F), the transmission must be preheated with hot air.
Axles and distributor gear
When starting operation at temperatures below −25 °C (-13 °F), axles
and distributor gear must warm up in the supported state for at least
10 minutes at 10 km/h (6 mph).
2.2.4 Ambient temperature / operating temperature

The temperature specifications in the tables below are subdivided into
ambient temperature and operating temperature.
- Lower ambient temperature :
The lowest ambient temperature at which it is permitted to start the
crane (the engine) under certain conditions. The consumable can
be cooled down to this temperature.
- Upper ambient temperature :
Upper ambient temperature at which the crane (engine, pumps)
can be operated while adhering to the upper operating tempera-
ture. The upper ambient temperature may rise above the specified
maximum value if this does not exceed the upper operating tem-
perature.
- Temperature range (operating temperature):
Lower and upper temperature of the consumable from which the
vehicle (engine, pump) may be placed under load.
- No specification:
The value is not relevant or cannot be measured.
2.2.5 Filling capacities

The specified capacities are approximate values.
NOTE
Damage due to insufficient filling level.
After filling up with liquid consumables, check at the designated
check plugs, dipsticks and inspection windows whether the fill-
ing level indicated in the corresponding section has been
reached.
30 82640 2021-04-22
2.3 Engine oil

Temperature range (am- Temperature range (op-
Permitted consuma- Regula- Classi- bient temperature) erating temperature)
bles tion fication
°C °F °C °F
Scania
LDF-4
ACEA
Shell RIMULA ULTRA SAE
E6 -40 +30 -40 +86 - +120 - +248
(EM 5) 5W-30
ACEA
E9
API CJ4
Scania
Mobil Delvac XHP Extra
LDF-3 SAE
(EM 3a, EM3b / Tier4i, -20 +45 -4 +113 - +120 - +248
ACEA- 10W-40
EM 4 / Tier 4f)
E7
Scania
Shell Rimula R6 M (EM
LDF-3 SAE
3a, EM3b / Tier4i, EM -20 +45 -4 +113 - +120 - +248
ACEA- 10W-40
4 / Tier 4f)
E7
Scania
Mobil Delvac 1 (EM 3a,
LDF-3 SAE
EM3b / Tier4i, EM 4 / -25 +45 -13 +113 - +120 - +248
ACEA- 5W-40
Tier 4f)
E5
Filling/application points
section Work to be carried out Filling quantities
5.2.3 Changing the engine oil 40 Litres 10.6 US gal
2.4 Engine oil
NOTE
Engine damage due to unsuitable engine oil.
Unsuitable engine oil will reduce the engine's service life significant-
ly.
Only use engine oil that meets the specifications given below.
NOTE
Damage to the particle filter due to unsuitable engine oil.
Unsuitable engine oil will impair operation and reduce the service
life of the particle filter.
Only use engine oil that meets the specifications given below
and that also has the designation: Low SAPS.
82640 2021-04-22 31
Oil quality
A diesel particle filter is used to reduce the number of soot particles in
the exhaust gas. To ensure the function of the particle filter, the use
of special engine oil is prescribed. Engine oil with the designation
Low SAPS is suitable that at least meets one of the following specifi-
cations:
- ACEA E6 (to be preferred, as it is "Low SAPS")
- ACEA E9
- ACEA C3 / C4 (HTHS ≥ 3.5 mPas)
- API CJ-4
Oil viscosity
Select the recommended viscosity according to the ambient tempera-
ture at which the engine is operated.
12.11.4 Checking the engine oil level - -
12.11.5 Changing the engine oil 13 Litres 3.4 US gal
2.5 Coolant
NOTE
Risk of engine damage.
Antifreeze Glysantin G48 (green) is not compatible with Glysantin
G40 (red). They may not be mixed together.
Only use Glysantin G48 (green).
Check the cooling system for suitability in case of temperatures

above +40 °C (+104 °F).

bles tion fication
°C °F °C °F
50 % distilled water
+ 50 % antifreeze Gly- Scania DC 13 -40 +45 -40 +113 -40 +100 -40 +212
santin G48 (green)
16.4 Checking the coolant level, topping up if required - -
16.5 Changing the Cooling Fluid 80 Litres 21.1 US gal
26.2.1.3 Checking the Water Level 6 Litres 1.6 US gal
32 82640 2021-04-22
2.6 Diesel fuel
NOTE
Damage to the engine when prohibited diesel fuel is used!
It is extremely important to use sulphur-free or particularly low-sul-
phur diesel fuel in engines with SCR systems which are certified in
accordance with stage EM 3b / EPA Tier 4i or later in order for the
engines to function correctly. Using diesel fuel with an excessively
high amount of sulphur in the fuel can cause damage to the engine
and SCR system.
Use the correct diesel fuel in accordance with regulations.
In the case of diesel fuel for engines with exhaust emission class
stage V and EM 4 / Tier4f, the share of sulphur must be < 15 ppm
(diesel fuel in accordance with DIN EN 590 or ASTM D975).
In the case of diesel fuel for engines in accordance with EM 3a / Tier
3, the sulphur share can be up to 2000 ppm. The oil change inter-
vals must be cut in half in the case of 2000 to 4000 ppm of sulphur.
We shall not fulfil any warranty - even within the warranty period - if
diesel fuel is used or added which does not comply with the require-
ment. It can cause damage to the drive unit and the exhaust gas sys-
tem. In addition, the following points must be observed:
- Do not add any petrol, petroleum or special additives, (e.g. drag
reducer, cleaning agents, antifreeze, etc.).
- Do not use biodiesel (FAME), heating oil, marine diesel oil, or air-
craft turbine diesel.
Winter diesel must satisfy the CFPP specification in accordance with

DIN EN 116. The Cold Filter Plugging Point must be lower than the
operating temperature.
Temperature range (am-

Permitted consuma- bient temperature)
Regulation Note
bles
°C °F
Engines in accordance
with Exhaust gas emis-
sions class Stage V: DIN EN 590 0 +45 +32 +113
Summer diesel, low in
sulphur, < 15 ppm
with EM4 / EPA Tier 4f: DIN EN 590
0 +45 +32 +113
Summer diesel, low in ASTM D975
sulphur, < 15 ppm
82640 2021-04-22 33

Regulation Note
bles
°C °F
From a sulphur content of
with EM3a / EPA Tier 3: DIN EN 590
2000 ppm, the oil change 0 +45 +32 +113
Summer diesel up to ASTM D975
intervals are cut by half.
2000 ppm
DIN EN 590
with Exhaust gas emis-
CFPP in accord-
sions class Stage V: -22 +15 -8 +59
ance with
Winter diesel, low-sul-
DIN EN 116
phur, < 15 ppm
DIN EN 590
CFPP in accord-
with EM4 / EPA Tier 4f:
ance with -22 +15 -8 +59
Winter diesel, low-sul-
DIN EN 116
phur, < 15 ppm
ASTM D975
DIN EN 590
CFPP in accord- From a sulphur content of
with EM3a / EPA Tier 3:
ance with 2000 ppm, the oil change -22 +15 -8 +59
Winter diesel up to
DIN EN 116 intervals are cut by half.
2000 ppm
ASTM D975
500 Li- 132.1 US
15.3.2 Fuel Tank
tres gal
196 Li-
15.3.3 Filling the additional tank 51.8 US gal
tres
26.2.1.4 Filling the fuel tank of the superstructure heating 22 Litres 5.8 US gal
2.7 Diesel fuel
NOTE
Damage to the engine when prohibited diesel fuel is used!
It is extremely important to use sulphur-free or particularly low-sul-
phur diesel fuel in engines with SCR systems which are certified in
accordance with stage EM 3b / EPA Tier 4i or later in order for the
engines to function correctly. Using diesel fuel with an excessively
high amount of sulphur in the fuel can cause damage to the engine
and SCR system.
Use the correct diesel fuel in accordance with regulations.
No warranty shall be fulfilled – even within the warranty period – if

diesel fuel is used or added which does not comply with the require-
34 82640 2021-04-22
ments of DIN EN 590. It can cause damage to the drive unit and the
exhaust gas system.
- For engines complying with emission class EM 3b, the sulphur
level must be < 50 ppm.
- For engines in accordance with the emission standard classifica-
tion EM 4f, the proportion of sulphur must be < 15 ppm.
- Do not add any petrol, petroleum or special additives.
- Do not use biodiesel (FAME), heating oil, marine diesel oil, or air-
craft turbine diesel.

Regulation Classification
bles
°C °F
Summer diesel, low in
DIN EN 590
sulphur, < 50ppm or 0 +45 +32 +113
ASTM D975
< 15ppm
DIN EN 590
Winter diesel, low in sul- ASTM D975
phur, < 50ppm or CFPP in accord- -22 +15 -8 +59
< 15ppm ance with DIN EN
116
12.11.3 Filling the fuel tank 21 Litres 5.5 US gal
2.8 AdBlue® / DEF

At temperatures above +80 °C (+176 °F), the AdBlue® / DEF breaks
down so quickly that there can be a risk of overpressure in the con-
tainer.
It is permitted to store the AdBlue® / DEF at -5°C (+23°F) up to max.
+30°C (+86°F) for a maximum of 12 months.

bles tion fication
°C °F °C °F
AdBlue® / DEF ISO 22241
67.5 % water DIN 70070 -10 +45 +14 +113 -10 +45 +14 +113
32.5 % carbamide AUS32 (CEFIC)
18.2.2 Filling up AdBlue® / DEF 60 Litres 15.9 US gal
18.3.2 Filling up AdBlue® / DEF 60 Litres 15.9 US gal
82640 2021-04-22 35
2.9 Hydraulic oil
NOTE
Consequential damage due to mixing hydraulic oils!
Do not mix different types of hydraulic oils even if they are the
same brand.
Permitted consum- Temperature range (ambient temperature)

ables °C °F
Fuchs Renolin
Xtreme Temp 46 HVLPD -16 +35 +3 +95
Plus
Fuchs Renolin
Xtreme Temp 32 HVLPD -23 +30 -9 +86
Plus
Shell Tellus S3 V 46 HVLPD -18 +30 0 +86
Shell Tellus S3 V 32 HVLPD -24 +20 -11 +68
Shell Tellus S3 V 68 HVLPD -11 +45 +12 +113
Shell Spirax S1 ATF ZF TE−ML ATF Type A Suf-
-20 +35 -4 +95
TASA 09 fix A
Shell Spirax S2 ATF ZF TE−ML ATF Dexron II D
-25 +35 -13 +95
AX 09 −2166 6
Shell Spirax S4 ATF ZF TE−ML ATF Dexron III
-28 +35 -18 +95
HDX 09 G -3407 7
Shell Tellus S4 -36 +10 -33 +50

VX 32 max. oil temperature, less than 70°C (+158° F)
-60 -10 -76 +14
Aeroshell Fluid 41
max. oil temperature, less than 50°C (+122° F)
12.2 Checking the hydraulic oil level - -
1115 Li- 294.6 US
12.4 Change the hydraulic oil
tres gal
26.2.2.2 Hydraulic tank – checking the oil level, topping up if necessary - -
26.2.2.3 Hydraulic tank (auxiliary heating) – changing the oil 10 Litres 2.6 US gal
36 82640 2021-04-22
2.10 Transmission oil

When starting operation at −25 °C to −30 °C (-13 °F to -22 °F), the
transmission must warm up at least 10 minutes at 1500 rpm.
When starting operation at temperatures from −30 °C to −40 °C
(-22 °F to -40 °F), the transmission must be preheated with hot air.

bles tion fication
°C °F °C °F
ZF TE SAE
ZF−ECO Fluid M −ML 75W -30 +45 -22 +113 -20 +110 -4 +230
02E −80
ZF TE SAE
Castrol Syntrans Z Long
−ML 75W -30 +45 -22 +113 -20 +110 -4 +230
Life
02E −80
6.2.4 Drive gearbox - change oil 19 Litres 5 US gal
22.5 Li-
6.2.5 Drive gearbox – Fill with oil after repair work 5.9 US gal
tres
NOTE
Consequential damage due to mixing transmission oils.
Do not mix different types of transmission oils even if they are
the same brand.

bles tion fication
°C °F °C °F
API- SAE
Mobil Mobilube HD-A -19 +50 -2 +122 -19 +110 -2 +230
GL-5 85W-90
API- SAE
GL-5 75W-85
API- SAE
GL-5 75W-90
82640 2021-04-22 37
6.3.1 Distributor gear – checking the oil level, topping up if required - -
6.3.2 Distributor gear – change oil 17 Litres 4.5 US gal
8.2.4 Driven axles - checking the oil level - -
8.2.5 Driven axles - change oil 19 Litres 5 US gal
8.2.6 Wheel hub drive - check the oil level - -
1.5 Li-
8.2.7 Wheel hub drive - change oil 0.4 US gal
tres
Permitted consuma- Temperature range (ambient temperature)

bles °C °F
Mobilgear 600 DIN 51517.3 XP 220 -15 +45 +5 +113
22.5 Slew gearbox – check oil level, top up if required - -
5.5 Li-
22.6 Slew gearbox - change oil 1.5 US gal
tres
23.1 Hoist gears – checking the oil level, topping up if required - -
23.2 Hoist gear – change oil 5 Litres 1.3 US gal
2.13 Grease
bles
°C °F
KP2K-20 NLGI
Shell Gadus S2 V 220 -15 +45 +5 +113
class 2 Lithium complex
KP2N-40 NLGI
Shell Gadus S5 V 220 -30 +45 -22 +113
class 2 Lithium complex
Klüber Isoflex Topas L NLGI grade 2
-40 +45 -40 +113
152 synthetic
NLGI grade 1
Fuchs Renolit JP 1619 -40 +25 -40 +77
Lithium complex
38 82640 2021-04-22
Design with black bolts / screws or bolts / screws with A3C coat-
7.2.2 - -
ing
8.2.3 Lubricating the Steered Axles - -
8.2.8 Wheel hub bearing – Changing the grease - -
8.3.1 Suspension Cylinders - Lubricating the Pivot Bearings - -
9.5 Lubricate the steering transmission components - -
13.1 Check lubrication of the support strut and lubricate if needed - -
13.2 Lubricate the support rollers of the struts - -
20.1.1 Lubricate dolly coupling - -
20.1.2 Service dolly coupling - -
20.2.2 Central lubricating system - fill lubricant container - -
21.2 Lubricate the bearing - -
23.4 Lubricating the Rope Drum Bearing - -
24.1 Luffing cylinders - lubricating the foot and piston rod bearings - -
25.1.3 Main boom – lubricate the foot bearing - -
25.1.4 Main Boom - Lubricating Head Axles - -
25.3.2 Pins – Lubricating Moving Parts - -
25.4.2 Pins – Lubricating Moving Parts - -
25.6 Service wind measuring device on adjustable bracket - -
25.7.5 Lubricating the sheave bearing of the steel sheave - -
25.9 Lubricate hook block - -
28.2.1 Lubricate tilt cylinder (option) - -
2.14 Adhesive lubricant

bles
°C °F
DIN 51 502, MLE
Bechem: Berulub PAL 1 NLGI class 2 -20 +45 -4 +113
2N −40
25.1.1 Main boom – lubricate the sliding surfaces - -
82640 2021-04-22 39
2.15 Adhesive lubricant

bles
°C °F
Fuchs Lubritech: Gleit-
NLGI class 2 -20 +45 -4 +113
mo 805−1
25.2.1 Lubricate the locking and pinning unit - -
25.3.4 Lubricating the tension plates - -
2.16 Adhesive lubricant (special grease)

bles
°C °F
Fuchs:CEPLATTYN ECO S -20 +80 -4 +176
Interflon: Fin Grease OG -10 +50 +14 +122
Interflon: Grease LS1/2 -20 +50 -4 +122
21.3 Lubricating the Ring Gear - -
22.3 Lubricate the slew gear pinion - -
2.17 Adhesive lubricant (special grease)

bles
°C °F
ELASKON 30 -20 +45 -4 +113
25.8.3 Lubricate ropes - -
40 82640 2021-04-22
2.18 Anti-corrosive spray

bles
°C °F
Fuchs: Decordyn 350 - - - -
19.1 Exposed chrome surfaces - apply protective grease - -
2.19 Windscreen wiper fluid

bles
°C °F
with antifreeze for −xx° -xx +45 -xx +113
28.1.2 Fill up the supply tank of the windscreen washer system 12 Litres 3.2 US gal
28.2.3 Fill up the supply tank of the windscreen washer system 3 Litres 0.8 US gal
2.20 Refrigerant
bles
°C °F
R134a DIN 8960 - - - -
27.5.7 Top up refrigerant - -
2.21 Refrigerator oil

bles
°C °F
Reniso PAG 46 DIN 51 503-1 - - - -
82640 2021-04-22 41
27.5.6 Changing refrigerator oil - -
2.22 contact
Permitted consumables Filling / emptying point
Contact spray K 61 Slip ring contacts, rope drum
2.23 Full assembly paste

Permitted consumables Filling / application point
Manke: VOLER−AC exposed screws, mobile parts
42 82640 2021-04-22
3 Lubrication and Maintenance Schedule
3.1 Initial Lubrication and Maintenance

Lubrication and maintenance tasks that are to be carried out before
the regularly recurring tasks are marked with "1." in the maintenance
list.
The work must be undertaken once at the time specified.
3.2 Regular lubrication and maintenance work

Depending on the crane type, maintenance lists are specified accord-
ing to operating hours or kilometres drive.
Regularly recurring lubrication and maintenance tasks are marked
with "X" in the maintenance list. The work must be undertaken for the
first time at the interval specified and then regularly repeated at this
interval. An "X" in the column entitled 250 operating hours means
therefore that the corresponding work must be undertaken every 250
operating hours, i.e. after 250, 500, 750 operating hours, etc.
If the corresponding entry is listed in the maintenance list with further
instructions (e.g. "at least once a year"), the corresponding lubricating
and maintenance task - in the above example - must be carried out
after 250 operating hours, but at least once a year. This depends on
whichever occurs first.
For larger maintenance tasks, e.g. "Every 1000 operating hours", all
those maintenance tasks which are required at shorter intervals and
which coincide with this time must also be carried out.
Entries in the maintenance list according to kilometres driven apply
accordingly.
The following details on maintenance intervals are applicable to

cranes which are subject to normal operating and environmental in-
fluences. For special operating conditions, the maintenance sched-
ules must be adapted (see Operating instructions in section "Safety
instruction" under "Ambient conditions to be observed").
The maintenance intervals for the winch gears and slew gearbox ap-
ply under the condition that their on-time is maximum 40 % of the
on-time of the crane engine. If the on-time of these gears/slew gear-
box exceeds this value, the specified maintenance intervals are re-
duced accordingly.
3.3 Targets of crane maintenance

- safeguard operational reliability
- maintain efficiency
- prevent downtimes
- maintain the value of the machine
- reduce repair costs
82640 2021-04-22 43
3.4 Measures for maintaining the crane

A log is created concerning the following inspections of the condition.
This inspection log then forms the basis for any repair measures
which may be required.
Important for the success of any such measures is their professio-
nal implementation, their regular repetition and documentation of
the inspections.
Our customer service department in Zweibrücken is there to help with
any information regarding this matter.
3.4.1 Inspections of the condition

Inspections of the condition are visual inspections undertaken by the
crane operator at regular intervals in accordance with the lubrication
and maintenance schedule.
For example:
- Checking oil levels and oil quality
- Checking display and monitoring equipment
- Checking the tank and filter systems to ensure they are functioning
properly and for contamination
- Checking the hoses and lines for leaks and damage
- Checking bearings for adequate lubrication and abnormal bearing
clearance
- Checking the drive mountings (transmission, engine, valves)
- Checking the ropes for lubrication, contamination and wear
As a result of these regular visual inspections, damage can often be
recognised and eliminated in good time. This means downtimes are
prevented during crane operation.
3.4.2 Preventative Maintenance

Preventative maintenance describes measures which can be carried
out during an "Inspection of the condition of the crane". The in-
spection of the condition thus serves to recognise and eliminate any
wear, damage or defects in good time. In this way, operational
downtimes and repairs can be prevented during crane operation.
The tasks involved in the inspection of the condition include visual
and function inspections of the component groups of the superstruc-
ture and chassis and a comparison of the desired and actual values
of measurable quantities. These tasks must be carried out by a suffi-
ciently trained specialist.
Various measures are required for this.
For example:
- Checking the safety equipment
- Comparing the desired/actual values in the hydraulic and electrical
system
44 82640 2021-04-22
- Checking the hydraulic and electrical system is functioning correct-

ly
- Checking the nitrogen boost pressure of the accumulator fitted
- Quality analysis of the hydraulic and transmission oil
- Checking the individual drives for noises and vibrations
- Checking the bearings for damage and wear
- Checking the crane equipment for damage and wear
- Checking the ropes for damage and wear.
The exact visual and function inspections with the corresponding re-
sults are listed in the "Crane inspection log".
82640 2021-04-22 45
3.5 Maintenance list by kilometres driven
46
Con- Inspections Interval (kilometres driven)
Minimum
suma-
daily week- mont 50 500 1 5 10 20 30 40 as mainte-
ble ac-
section Work to be carried out ly hly neces- nance
cord- x 1000
sary (maximum
ing to
interval)
section
5 Engine
5.2 Servicing the engine
5.2.1 Cleaning the engine – High pressure cleaning x
6 Transmission
Check the drive gearbox and the distributor gear for
6.1 x
leaks
6.2 Drive gearbox ZF Traxon with intarder
6.2.2 Drive gearbox – Carry out visual check x
6.2.3 Drive gearbox - check the oil level x

6.2.4 Drive gearbox - change oil 2.10 3 Years
6.2.4.2 Change the filter element of the oil filter 3 Years
6.2.5 Drive gearbox – Fill with oil after repair work 2.10 x
6.3 Distributor gear
Distributor gear – checking the oil level, topping up if re-
6.3.1 2.11 x
quired
6.3.2 Distributor gear – change oil 2.11 1. x 1 Year
6.3.3 Distributor gear – Carry out visual check x
6.3.4 Checking the Distributor Gear Shift 1 Year
7 Joint shafts
7.2 Check the flange connections for proper fitting x 1 Year
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
8 Axles and suspension
8.2 Axles
8.2.1 Check the axle fixing bolts x
8.2.3 Lubricating the Steered Axles 2.13 x 1. x 1 Year
8.2.4 Driven axles - checking the oil level 2.11 x
8.2.5 Driven axles - change oil 2.11 x 1 Year
8.2.6 Wheel hub drive - check the oil level 2.11 x
8.2.7 Wheel hub drive - change oil 2.11 1. x 1 Year
8.2.8 Wheel hub bearing – Changing the grease 2.13 x 1 Year
8.2.9 Checking the wheel bearing x 1 Year
8.3 Suspension
8.3.1 Suspension Cylinders - Lubricating the Pivot Bearings 2.13 x
8.3.2 Check hoses of the suspension x x 1 Year
8.3.3 Replace hoses of the suspension 2 Years
9 Steering
9.3 Visually check the steering components 1. 1. x 1 Year
Check that the steering transmission components are
9.4 x 1 Year
fitted firmly
9.5 Lubricate the steering transmission components 2.13 x 1 Year
9.6 Check steering cylinder for leak-tightness x
9.7 Check the steering angle sensor x
9.9 Replace hoses of the steering system 2 Years
47
Minimum
suma-
48
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
10 Brake and compressed air system
10.2 Disc brakes
10.2.1 Checking the disc brakes x
10.2.2 Check the brake disc 1 Year
10.2.2.1 Checking the lining thickness of the brake linings 1 Year
Checking the leak-tightness of the compressed air sys-
10.3 x 1 Year
tem
10.4 Drain the compressed air tanks daily in winter
10.5 Air dryer - replace the granulate cartridge x 2 Years
10.6 Compressed air lines

10.6.1 Check compressed air lines x 1 Year
11 Wheels and tyres
11.1 Check the wheel nuts x
11.2 Tightening wheel nuts (standard rims) 1. x
11.3 Tightening wheel nuts (aluminium rims) 1. x
11.4 Check tyres x
11.5 Check disc wheels (rims) x
11.6 Clean tyres x
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
15 Fuel system
15.3 Filling up
15.3.2 Fuel Tank 2.6 x
15.3.3 Filling the additional tank 2.6 x
15.4 Fuel tank – draining water and deposits x 6 Months
15.5 Fuel tank – Check the air bleed filter x 2 Years
15.6 Check the fuel system x 1 Year
15.7 Preliminary fuel filter (EM3a)
Preliminary fuel filter - emptying the water collection
15.7.1 x
container
15.7.2 Preliminary fuel filter - change the filter element x 1 Year
15.8 Fuel filter in the diesel engine x 5 Years
16 Cooling system
16.2 Cooling System - Carry out a Visual Inspection x 1 Year
16.3 Cleaning the cooling system x 1 Year
16.4 Checking the coolant level, topping up if required 2.5 x
16.5 Changing the Cooling Fluid 2.5 x 5 Years
16.6 Bleeding the Cooling System x
17 Intake System
17.1 Intake System - Carrying out a Visual Inspection x 1 Year
17.2 Replace the main element of the air filter x 5 Years
17.4 Air Filter - Checking the Preseparator (Optional) x 1 Year
49
Minimum
suma-
50
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
18 Exhaust system
18.1 Exhaust System – Carrying out a Visual Check x 1 Year
18.2 SCR system (Stage V)
18.2.1 SCR System - Carrying out a Visual Inspection x
18.2.2 Filling up AdBlue® / DEF 2.8 x
18.2.2.2 Filling up AdBlue® / DEF x
18.2.3 Pump module - replace the filter element x 1 Year
18.2.4 Replacing diesel particle filters Every 4500 h when using Scania LDF4 motor oil 5 Years
18.2.5 Service SCR catalytic converter 1 Year

18.3 SCR System (EM4 / Tier4f)
18.3.1 SCR System - Carrying out a Visual Inspection x
18.3.2 Filling up AdBlue® / DEF 2.8 x
18.3.2.2 Filling up AdBlue® / DEF x
18.3.3 Pump module - replace the filter element x 1 Year
18.3.4 Servicing the SCR catalytic converter 1 Year
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
20 Special Equipment
20.1 Dolly coupling
20.1.1 Lubricate dolly coupling 2.13 x 1 Year
20.1.2 Service dolly coupling 2.13 x 1 Year
20.2 Central lubricating system
20.2.1 Central lubricating system - check level x
20.2.2 Central lubricating system - fill lubricant container 2.13 x
20.2.3 Clean the central lubricating system x
20.2.4 Check the central lubricating system x
51
3.6 Maintenance List by operational hours
52
Con- Inspections Interval (operating hours)
Minimum
suma-
daily week- mont 50 100 150 250 500 1 1.5 3 5 10 as mainte-
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
4 Visual inspections
4.1 Visual inspections of the chassis x
4.2 Visual inspections of the superstructure x
5 Engine
5.2 Servicing the engine See the engine manufacturer's instructions
5.2.2 Checking the engine oil level
Checking the engine oil level in the cab using
5.2.2.1 x
the electronic oil level detection system
5.2.2.2 Checking the engine oil level with the dipstick x

5.2.3 Changing the engine oil 2.3 x 1 Year
5.2.4 Changing the oil filter x 1 Year
5.2.5 Cleaning the oil centrifuge x 1 Year
Start engines with exhaust gas after-treatment
5.3 x
(SCR system) regularly
5.4 Quick stop button - checking the function 1 Year
9 Steering
9.8 Check hoses x x 1 Year
11 Wheels and tyres
11.4 Check tyres x
11.4.4 Checking Age 10 Years
12 Hydraulic System
12.2 Checking the hydraulic oil level 2.9 x
12.3 Check hydraulic oil x 1 Year
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
12.4 Change the hydraulic oil 2.9 1,5 Years
12.5 Replacing the hydraulic filter
12.5.2 Replacing return line filter 1 in case of an error message
12.5.3 Replacing return line filter 2 in case of an error message
12.5.4 Replacing the aeration filter when exchanging return line filter
12.5.5 Replacing high-pressure filter element in case of an error message
High-pressure Line Filter - Cleaning or Re-
12.5.6 in case of an error message
placing the Filter Element
12.5.7 Replacing the high-pressure return line filter in case of an error message
12.7 Check the hydraulic system 1 Year
12.8 Bleeding the Hydraulic System After every oil change x
Check the preliminary gas tension of the pres-
12.9 x 1 Year
sure accumulators
12.10 Hose assemblies on mobile cranes
12.10.3 Replace hoses x 6 Years
Servicing the hydraulic emergency unit (op-
12.11
tional)
12.11.1 Checking the combustion air intake area x
12.11.2 Checking the cooling air area x
12.11.3 Filling the fuel tank 2.7 x
12.11.4 Checking the engine oil level 2.4 If the oil pressure gauge lights up
12.11.5 Changing the engine oil 2.4 1. x 1 Year
12.11.6 Checking the water separator x x
12.11.7 Checking the poly-V-belt x
53
Minimum
suma-
54
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
Cleaning the cooling air blower, the cooling
12.11.8 x
fins and the oil cooler
12.11.9 Checking screw joints x
12.11.10 Checking the preliminary fuel filter for dirt x
12.11.11 Changing the preliminary fuel filter x
12.11.12 Servicing the dry air filter
12.11.12.
Checking and cleaning the air filter cartridge in case of an error message
2
12.11.12.
Replacing the air filter cartridge x
3
12.11.13 Checking and adjusting the valve clearance 1. x
12.11.14 Changing the oil filter x
12.11.15 Checking the fuel vaporizer x
12.11.16 Checking the exhaust backpressure sensor x
12.11.17 Replacing the main fuel filter x
Replacing the sealing rings in the belt tension-
12.11.18 - every 2000 operating hours
er or the complete belt tensioner
Replacing the poly-V-belt and checking the
12.11.19 every 2000 operating hours
shut-off device function
Cleaning the EGR valve, the EGR housing
12.11.20 x
and the intake area
12.11.21 Regenerating the diesel particle filter in case of an error message
12.11.22 Changing the diesel particle filter in case of an error message
12.11.23 Resetting the maintenance interval display x
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
13 Supports
Check lubrication of the support strut and lu-
13.1 2.13 x x
bricate if needed
13.2 Lubricate the support rollers of the struts 2.13 6 Months
Checking the State of the Outrigger Plates
13.3 1 Year
and for Wear and Evenness
13.4 Check hoses x x 1 Year
Outrigger length transducer – carry out a visu-
13.5 x
al check
14 Electrical system
14.1 Check the lighting system x
14.2 Lighting equipment: Replacing bulbs x
14.3 Batteries
14.3.1 Service battery x 1 Year
14.3.2 Charging batteries x
14.4 Checking the fuses x
14.5 Service the slip rings x 1 Year
14.6 Check the electrical system x 1 Year
19 Piston rods
Exposed chrome surfaces - apply protective
19.1 2.18 1 Year
grease
20.3 Anti-fall protection via safety mast see manufacturer's documents
55
Minimum
suma-
56
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
21 Slewing rim
21.2 Lubricate the bearing 2.13 x x
21.3 Lubricating the Ring Gear 2.16 x 1 Year
Checking Screwed Connections for Firm Fit-
21.4 x 1 Year
ting
22 Slew gear
22.2 Perform visual and noise checks x
22.3 Lubricate the slew gear pinion 2.16 x x 1 Year
22.4 Check the involute spline connections 1 Year
Slew gearbox – check oil level, top up if re-

22.5 2.12 x
quired
22.6 Slew gearbox - change oil 2.12 1. x 2 Years
22.8 Checking the brakes 1 Year
Check the bolted connections and tighten as
22.9 x 1 Year
required
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
23 Hoists
Hoist gears – checking the oil level, topping up
23.1 2.12 x
if required
23.2 Hoist gear – change oil 2.12 1. x 1 Year
Exterior bolted connections - check and tight-
23.3 x 1 Year
en if required
23.4 Lubricating the Rope Drum Bearing 2.13 x 6 Months
23.5 Checking the lower limit switch x
23.6 Checking hoist limit switch x 1 Year
23.7 Hoists - Checking the Brakes At regular intervals 1 Year
Calculation of the Spent Share of the Theoreti-
23.8 1 Year
cal Service Life
23.9 General overhaul of the hoist winches 10 Years
24 Luffing gear
Luffing cylinders - lubricating the foot and pis-
24.1 2.13 x 6 Months
ton rod bearings
25 Main Boom, Rope Equipment, Devices
25.1 Main boom
25.1.1 Main boom – lubricate the sliding surfaces 2.14 x
Main Boom- Checking the Rope of the Length
25.1.2 1 Year
Transducer
25.1.3 Main boom – lubricate the foot bearing 2.13 x 1 Year
25.1.4 Main Boom - Lubricating Head Axles 2.13 x 1 Year
Check the main boom for cracks in the weld-
25.1.5 x 1 Year
ing seams
57
Minimum
suma-
58
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
25.1.6 Main boom - check the rope track rollers 1 Year
25.2 Service the locking and pinning unit (LPU)
25.2.1 Lubricate the locking and pinning unit 2.15 6 Months
Locking and pinning unit – carry out a visual
25.2.2 6 Months
inspection
Locking and pinning unit - check the proximity
25.2.3 6 Months
switches and sliding contacts
Locking and pinning unit - check the prelimina-
25.2.4 x 1 Year
ry gas tension of the accumulators
25.3 MBE - design with fixed operating angles

25.3.1 Checking the pins for cracks 1 Year
25.3.2 Pins – Lubricating Moving Parts 2.13 x 1 Year
25.3.3 Checking the tension plates 1 Year
25.3.4 Lubricating the tension plates 2.15 1 Year
MBE - design with hydraulically smooth angle
25.4
adjustment
25.4.1 Checking the pins for cracks 1 Year
25.4.2 Pins – Lubricating Moving Parts 2.13 x 1 Year
25.4.3 Replace hoses x 6 Years
25.5 Assembly jib – checking the draw bars 1 Year
Service wind measuring device on adjustable
25.6 2.13 x 1 Year
bracket
25.7 Sheaves on the boom system
25.7.1 Sheaves – carry out a visual inspection x
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
Plastic rope sheaves – carrying out a check
25.7.2 x 6 Months
for wear
Steel rope sheaves – carrying out a check for
25.7.3 x 1 Year
wear
25.7.4 Check the rope sheave bearings x 6 Months
Lubricating the sheave bearing of the steel
25.7.5 2.13 x 1 Year
sheave
25.7.6 Replacing plastic rope sheaves x 5 Years
25.8 Ropes
25.8.2 Clean ropes x 1 Year
25.8.3 Lubricate ropes 2.17 1 Year
Visual inspection of the ropes, rope end con-
25.8.4 x
nections, etc.
25.8.5 Check entire ropes, replace if required 1 Year
25.9 Lubricate hook block 2.13 x 1 Month
26 Heating
26.1 Crane chassis
Engine-independent auxiliary heating "Hy-
26.1.1
dronic M-II D 10 W" (optional)
26.1.1.1 Check the system is functioning correctly x
26.1.1.2 Auxiliary Heating - Error Diagnosis x
26.1.1.3 Replacing fuel filter 1 Year
26.2 Superstructure
Engine-independent heating system (Hydron-
26.2.1
ic)
59
Minimum
suma-
60
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
26.2.1.1 Check the system is functioning correctly x
26.2.1.2 Heating system – fault diagnosis x
26.2.1.3 Checking the Water Level 2.5 daily during the heating period
Filling the fuel tank of the superstructure heat-
26.2.1.4 2.6 daily during the heating period x
ing
26.2.1.5 Replacing fuel filter 1 Year
26.2.1.6 Replace the heat exchanger 10 Years
Flameless auxiliary heating (engine-depend-
26.2.2
ent), optional
26.2.2.1 Check the hydraulic system after every use 1 Month

Hydraulic tank – checking the oil level, topping
26.2.2.2 2.9 x
up if necessary
Hydraulic tank (auxiliary heating) – changing
26.2.2.3 2.9 1,5 Years
the oil
26.2.2.4 Hydraulic filter – checking the filter daily in the first week x
26.2.2.5 Replacing the hydraulic filter with every oil change x
26.3 Petrol gas heating (optional)
Petrol gas heating - checking the system is
26.3.2 x
functioning properly
Liquid petrol gas heating - carrying out a visu-
26.3.3 x
al inspection
Petrol gas heating - replacing the heat ex-
26.3.4 10 Years
changer
Petrol gas heating - having the system
26.3.5 2 Years
checked
26.3.6 Petrol gas heating - replacing the fuse x
82640 2021-04-22
Minimum
suma-
ble ac-
cord- x 1000
82640 2021-04-22
sary (maximum
ing to
interval)
section
26.3.7 Petrol gas heating - changing the gas cylinder x
27 Air Conditioning
Switching on the Air-Conditioning (Damage
27.3 x
Prevention)
Servicing the Air Conditioning Equipment -
27.4 x 1 Month
Operator
Servicing the Air Conditioning - Specialist
27.5 6 Months
Workshop
27.5.4 Checking the refrigeration circuit 6 Months
27.5.5 Replacing the collector dryer after any intervention in the refrigeration circuit 2 Years
27.5.6 Changing refrigerator oil 2.21 x 2 Years
28 Cabs
28.1 Driver's Cab
Checking the windscreen washer system for
28.1.1 x
proper functioning
Fill up the supply tank of the windscreen
28.1.2 2.19 x
washer system
Emergency call equipment (Glonass - FORT
28.1.3 x
112 EC, option) - Check function
28.2 Crane operator's cab
28.2.1 Lubricate tilt cylinder (option) 2.13 x 1 Year
28.2.2 x
proper functioning
Fill up the supply tank of the windscreen
28.2.3 2.19 x
washer system
61
Minimum
suma-
62
ble ac-
cord- x 1000
sary (maximum
ing to
interval)
section
29 Inspections of the Crane
29.2 Recurrent Inspections of the Crane 1 Year
82640 2021-04-22
3.7 Maintenance list - daily checks

Consuma-
ble accord-
section Work to be carried out Remarks
ing to sec-
tion
4.1 Visual inspections of the chassis
4.2 Visual inspections of the superstructure
5 Engine
Checking the engine oil level in the cab using
5.2.2.1
the electronic oil level detection system
8.2 Axles
8.2.3 Lubricating the Steered Axles 2.13
8.3 Suspension
8.3.2 Check hoses of the suspension
9 Steering
9.6 Check steering cylinder for leak-tightness
9.7 Check the steering angle sensor
9.8 Check hoses
11 Wheels and tyres
11.1 Check the wheel nuts
11.4 Check tyres
11.5 Check disc wheels (rims)
12 Hydraulic System
12.2 Checking the hydraulic oil level 2.9
12.11
tional)
12.11.1 Checking the combustion air intake area
12.11.2 Checking the cooling air area
12.11.4 Checking the engine oil level 2.4
82640 2021-04-22 63
Consuma-
ble accord-
ing to sec-
tion
13 Supports
Check lubrication of the support strut and lubri-
13.1 2.13
cate if needed
13.4 Check hoses
Outrigger length transducer – carry out a visu-
13.5
al check
14.1 Check the lighting system
14.2 Lighting equipment: Replacing bulbs
15 Fuel system
Preliminary fuel filter - emptying the water col-
15.7.1
lection container
16 Cooling system
Checking the coolant level, topping up if re-
16.4 2.5
quired
18 Exhaust system
18.2.1 SCR System - Carrying out a Visual Inspection
23 Hoists
23.6 Checking hoist limit switch
25.7.1 Sheaves – carry out a visual inspection
25.8 Ropes
Visual inspection of the ropes, rope end con-
25.8.4
nections, etc.
26 Heating
26.2 Superstructure
26.2.1
ic)
26.2.1.3 Checking the Water Level 2.5
64 82640 2021-04-22
3.8 Maintenance list - weekly checks

Consuma-
ble accord-
ing to sec-
tion
6 Transmission
6.2.2 Drive gearbox – Carry out visual check
6.2.3 Drive gearbox - check the oil level
Distributor gear – checking the oil level, top-
6.3.1 2.11
ping up if required
10.4 Drain the compressed air tanks
12 Hydraulic System
12.11
tional)
12.11.6 Checking the water separator
22 Slew gear
22.2 Perform visual and noise checks
Slew gearbox – check oil level, top up if re-
22.5 2.12
quired
23 Hoists
Hoist gears – checking the oil level, topping up
23.1 2.12
if required
26 Heating
26.2 Superstructure
Flameless auxiliary heating (engine-depend-
26.2.2
ent), optional
Hydraulic tank – checking the oil level, topping
26.2.2.2 2.9
up if necessary
82640 2021-04-22 65
Consuma-
ble accord-
ing to sec-
tion
28 Cabs
28.1 Driver's Cab
28.1.1
proper functioning
Fill up the supply tank of the windscreen wash-
28.1.2 2.19
er system
28.2.2
proper functioning
Fill up the supply tank of the windscreen wash-
28.2.3 2.19
er system
3.9 Maintenance list - monthly checks

Consuma-
ble accord-
ing to sec-
tion
5 Engine
Start engines with exhaust gas after-treatment
5.3
(SCR system) regularly
6 Transmission
Check the drive gearbox and the distributor
6.1
gear for leaks
6.3.3 Distributor gear – Carry out visual check
8.2 Axles
8.2.4 Driven axles - checking the oil level 2.11
8.2.6 Wheel hub drive - check the oil level 2.11
20.2.1 Central lubricating system - check level
20.2.3 Clean the central lubricating system
20.2.4 Check the central lubricating system
21 Slewing rim
21.2 Lubricate the bearing 2.13
66 82640 2021-04-22
Consuma-
ble accord-
ing to sec-
tion
23 Hoists
23.5 Checking the lower limit switch
26 Heating
26.1 Crane chassis
Engine-independent auxiliary heating "Hydron-
26.1.1
ic M-II D 10 W" (optional)
26.1.1.1 Check the system is functioning correctly
26.2 Superstructure
26.2.1
ic)
Petrol gas heating - checking the system is
26.3.2
functioning properly
Liquid petrol gas heating - carrying out a visual
26.3.3
inspection
27 Air Conditioning
Switching on the Air-Conditioning (Damage
27.3
Prevention)
Servicing the Air Conditioning Equipment - Op-
27.4
erator
82640 2021-04-22 67
68 82640 2021-04-22
4.1 Visual inspections of the chassis

Maintenance list, side 52
1. Check all covers and trims for damage, loose or missing screws.
Fig. 2: Visual inspections of the chassis
1 Instruments and displays 2 Batteries

3 Hydraulic system AC 250-5, 4 Lighting system
AC 220-5 (Explorer 5800)
5 Hydraulic system AC 130-5 (Ex- 6 Motor, cooling unit
plorer 5500), AC 160-5 (Explor-
er 5600)
7 Windscreen washer system
2. Check the hydraulic system (3; 5) for leaks and damage and
check the oil level.
3. Check the engine (6) for oil and fuel leaks and contamination;
check the cooling unit for contamination.
4. Check instruments and displays (1) for damage.
5. Check batteries (2) to ensure they are clean and dry and that the
clips are fitted firmly.
6. Check the lighting system (4) for damage.
7. Check the function of the windscreen washer system (7) at least
once a week. The supply tank must always be filled with water
together with a cleaning agent as necessary.
Before the onset of winter, a suitable amount of antifreeze (depend-

ing on the temperature) must be added to the water.
82640 2021-04-22 69
4.2 Visual inspections of the superstructure

1. Check all covers and trims for damage, loose or missing screws.
Fig. 3: Visual inspections of the superstructure
1 Ropes, rope end connections, 2 Instruments and displays

rope sheaves
3 Lighting system 4 Windscreen washer system
5 Hydraulic System 6 Slew ring - external toothing
2. Slew ring − check the external toothing (6) for intact lubricating
film.
3. Check instruments and displays (2) for damage.
4. Check the hydraulic system (5) for leaks and damage.
5. Checks ropes (1) for intact lubrication; check ropes, rope end
connections, rope sheaves and winches for damage.
6. Check the lighting system (3) for damage.
7. Check the function of the windscreen washer system (4) at least
once a week. The supply tank must always be filled with water
together with a cleaning agent as necessary.

70 82640 2021-04-22
5 Engine
5 Engine
5.1 Engine components
The description of the engine and the engine number can be found
on the engine type plate. Please find the assignment of the engine
type plate in the manufacturer's instructions. They can be found in
the "Various" part of these instructions.
Depending on the version, the crane engine is equipped with either

an oil drain cock or an oil drain valve.
Fig. 4: Engine components Scania DC 13 XPI - Exhaust emissions class Stage V
1 Oil filter 2 Oil drain valve

3 Engine control unit 4 Dipstick
5 Preliminary fuel filter 6 Fuel filter
7 Oil fill hole
82640 2021-04-22 71
5 Engine
Fig. 5: Engine components Scania DC 13 XPI - Exhaust emissions class EM4 / Tier4f
1 Oil filter 2 Oil fill hole

3 Oil drain valve 4 Dipstick
7 Engine control unit 8 Equalising tank
Fig. 6: Engine components Scania DC 13 XPI - Exhaust emissions class EM4 / Tier4f
1 Oil filter 2 Dipstick

3 Oil fill hole 4 Oil drain valve
5 Engine control unit 6 Equalising tank
72 82640 2021-04-22
5 Engine
Fig. 7: Engine components Scania DC 13 PDE - Exhaust emissions class EM3a

3 Oil drain valve 4 Dipstick
6 Fuel filter 7 Engine control unit
8 Equalising tank
Fig. 8: Engine components Scania DC 13 PDE - Exhaust emissions class EM3a

3 Oil drain valve 4 Engine control unit
5 Equalising tank 6 Dipstick
7 Fuel filter
82640 2021-04-22 73
5 Engine

5.2.1 Cleaning the engine – High pressure cleaning

CAUTION
Risk of injury due to hot water jets!
Wear suitable protective clothing and protective
gloves as well as goggles.
During cleaning work, ensure that the water jet is not directed at the
components listed below:
- electric components (e.g. the engine control unit)
- plugged connections
- seals
- Hoses
5.2.2.1 Checking the engine oil level in the cab using the electronic oil level detec-
tion system
1. Check the engine oil quantity in the driver information system in

the crane chassis driver's cab or in the additional display of the
superstructure crane operator's cab.
The oil level is sufficient if the display is within the green

range.
The measurement is only valid if the coolant temperature is 20°C

(+68 °F) and the engine has not been in operation for 40 minutes.
74 82640 2021-04-22
5 Engine
WARNING
Risk of accidents in the event of non-compliance.
If warnings or alarms occur, the operating safety of the
crane is at risk.
Observe warnings/alarms.
Rectify the fault as soon as possible.
2. The engine oil level is too low or too high when the display is in
the red range. The figure on the left shows a level that is too low.
If the engine oil level is too high or too low, check the engine
oil level using the dipstick (see 5.2.2.2 Checking the engine
oil level with the dipstick, side 75).
5.2.2.2 Checking the engine oil level with the dipstick

Additional instructions and notes on checking the engine oil level

can be found in the manufacturer's instructions. They can be found
in the "Various" part of these instructions.
Requirements:
- Crane is parked on level ground
- Main boom is luffed up slightly
- Engine is switched off
- Drive gearbox is in neutral position
- Parking brake is applied
- Crane is secured with wheel chocks against rolling away
DANGER
Risk of accidents due to starting the engine!
The work may only be carried out if the engine is
switched off.
No one may be in the cabs and they must be locked.
WARNING
Risk of injury on crane components!
Maintain a safe distance to hot, rotating and moving

components.
82640 2021-04-22 75
5 Engine
CAUTION
Risk of burning and scalding!
If the engine is hot, the handles and the engine covering
get hot.
Maintain a sufficient cooling down period.
Wear protective gloves.
1. Reach through the grip hole in the marked cover and pull out the
dipstick
Or
open the maintenance flap and pull out the dipstick (depending
on the design).
2. Check the oil level on the dipstick.

3. Top up the oil if low.
NOTE
Engine damage due to continuous oil loss!
If continuous oil loss is detected, stop operation, rectify the
cause of the leak and proceed as specified by the engine manu-
facturer (see manufacturer's instructions in the "Various" part).
5.2.3 Changing the engine oil

Consumables: 2.3 Engine oil, side 31
From a sulphur content of 2000 to 4000 ppm in the diesel fuel

(Em3a / Tier 3 engines), the oil change interval is cut in half and is
maximum 250 hours or every 6 months.
76 82640 2021-04-22
5 Engine
5.2.3.1 Changing the engine oil – Version with oil drain cock
Requirements:
- Crane is secured against rolling away with wheel chocks
- Suitable collecting container is ready
DANGER
switched off.
WARNING

components.
82640 2021-04-22 77
5 Engine
Fig. 9: Engine - Version with oil drain cock
3 Oil drain cock 3.1 Lever
WARNING
Risk of injury due to hot engine oil!
Hot engine oil squirting out can scald skin and eyes.
Before carrying out the work, ensure that the pres-
sure has been released.
1. Open lever (3.1).

2. Let the oil drain into the collecting container.
Dispose of the old oil in accordance with the legal regulations appli-
cable at the operating site.
3. After draining the oil, close lever (3.1) again.
78 82640 2021-04-22
5 Engine
Fig. 10: Access to dipstick - schematic di- Fig. 11: Access to dipstick - schematic di-
agram for AC 130-5 (Explorer 5500), agram for AC 250-5, AC 220-5 (Explor-
AC 160-5 (Explorer 5600) er 5800)
4. Depending on the design, reach through the grip hole in the

marked cover or open the maintenance flap.
5. Open the cover of the oil fill hole and fill up with new oil.
5.2.3.2 Changing the engine oil – Version with oil drain valve
Requirements:
DANGER
switched off.
WARNING

components.
82640 2021-04-22 79
5 Engine
1. Unscrew the protective cap.
WARNING
Risk of injury due to hot engine oil!
Hot engine oil squirting out can scald skin and eyes.
2. Screw the hose onto the oil drain valve (from the toolbox on the
crane).
The drain valve opens.
3. Let the oil drain into the collecting container.
4. Once the oil has drained, unscrew the hose again.

The oil drain valve closes again.
5. Screw the protection cap back on.
6. Reach through the grip hole in the marked cover
Or
80 82640 2021-04-22
5 Engine
open the maintenance flap (depending on the design).
7. Open the cover of the oil fill hole and fill up with new oil.
5.2.4 Changing the oil filter

For instructions and notes on changing the oil filter, please consult
the engine manufacturer's instructions. They can be found in the
"Various" part of these instructions.
5.2.5 Cleaning the oil centrifuge

CAUTION
Risk of burns!
The engine and the exhaust system may still be very hot.
Wear corresponding protective clothing.
1. Open the maintenance flap; alternatively, completely dismantle

the engine covering.
82640 2021-04-22 81
5 Engine
Fig. 12: Position of the oil centrifuge, Fig. 13: Position of the oil centrifuge,
Scania DC 13 EM5 Scania DC 13 EM4 / Tier4f
Fig. 14: Position of the oil centrifuge,

Scania DC 13 EM3a
Additional instructions and notes on cleaning the oil centrifuge can

be found in the operating instructions of the engine manufacturer.
They can be found in the "Various" part of these instructions.
82 82640 2021-04-22
5 Engine
5.3 Start engines with exhaust gas after-treatment (SCR system) regularly
If the engine is to be shut down from time to time (up to 6 months)
and if there is diesel fuel with a share of biodiesel in the tank before
the engine is switched off which has not been replaced with biodiesel-
free fuel, start the engine regularly in addition to the measures descri-
bed in the operating instructions.
1. Before starting the engine, check:
- Engine oil level
- Coolant level
2. For engines with a water separator in the fuel system, drain the
water separator.
3. Start the engine. When starting or while running the engine, ob-
serve the engine oil pressure, coolant and engine oil tempera-
ture.
NOTE
There is a risk of damage if the engine is operated while the
engine oil pressure is too low or the coolant and engine oil
temperature is too high.
Switch the engine off immediately.

Have the fault identified and rectified immediately.
4. Let the engine run approx. 10 minutes at max. 900 min-1

(900 rpm) with the air conditioning and heating switched on and if
present, the auxiliary heating switched on.
If, before switch-off, there is diesel fuel with a share of biodiesel (e. g.
diesel in accordance with DIN EN 590) in the tank, it is sufficient to
drain the remaining fuel in the tank and to fill the tank with at least 50 l
(13.2 gal) of biodiesel-free diesel fuel. Let the engine run at least
30 minutes before switching it off, so that the fuel-conducting compo-
nents are rinsed through.
5.4 Quick stop button - checking the function

In case of an emergency, the engine can be switched off by pressing
the quick stop button in the crane operator's cab
or
82640 2021-04-22 83
5 Engine
by pressing the quick stop button (optional) on the crane chassis in

the area of the outrigger controls at the left and right of the vehicle
side.
These keys latch into place when they are actuated. For specifica-
tions, see the "Engine" section in the operating instructions of the
crane.
1. Check whether the engine can be switched off using any of the
quick stop buttons.
2. If the engine is equipped with an optional air shut-off valve,
check whether it has closed.
NOTE
Engine damage due to closed shut-off valve!
If the air shut-off valve is closed, the engine cannot be started. Re-
peated starting attempts lead to engine damage.
Unlock the air shut-off valve manually to start the engine again.
Before restarting, check all air-conducting hoses - including the
charge air hoses between the engine and aftercooler - to ensure
that they are fitted firmly and are completely free of any block-
ages.
3. Reset the perforated lever on the air shut-off valve in the position
"Open".
The air suction channel is open again.
Optionally, the air shut-off valve can be unlocked with a cable pull
system:
84 82640 2021-04-22
5 Engine
Fig. 15: Cable pull system for unlocking the air shut-off valve
1 Cable pull system for unlocking 2 Air filter

the air shut-off valve
3 Engine 4 Exhaust system step plate (de-
pending on design)
5 Actuation ring
4. Pull on the actuation ring (5) up to the stop.

The perforated lever on the air shut-off valve is reset from the
"closed" position to the "open" position.
The air suction channel is open again.
82640 2021-04-22 85
5 Engine
86 82640 2021-04-22
6 Transmission
6 Transmission
6.1 Check the drive gearbox and the distributor gear for leaks
Requirements:
- Crane parked on level ground
- Engine switched off
- Drive gearbox in neutral position
- Parking brake applied
- Crane secured with wheel chocks against rolling away
Fig. 16: Position of drive gearbox and distributor gear on drive 10 x 8 x 10
1 Motor 2 Drive gearbox

3 Joint shaft 4 Joint shaft
5 Distributor gear 6 Joint shaft
1. Check drive gearbox (2) and distributor gear (5) for leaks (so-
called sweating or oil leak points).
6.2.1 Serial Plates

The serial plates contain the most important data. They are on the
left-hand side (with respect to the direction of travel) of the fitted drive
gearbox and intarder (if present).
82640 2021-04-22 87
6 Transmission
The following positions must be specified at the time of inquiries, or-

ders or repairs:
Fig. 17: Drive gearbox - serial plate
1 Parts list no. of the transmission 2 Type of transmission

3 Serial no. of transmission
Fig. 18: Intarder serial plate (if intarder is present)
1 Parts list no. of the intarder 2 Serial no. of the intarder
6.2.2 Drive gearbox – Carry out visual check

DANGER
switched off.
CAUTION
Risk of burns!
The gearbox and the associated components may still be
very hot.
Observe a sufficient cooling down period.
Wear suitable protective clothing and gloves.
88 82640 2021-04-22
6 Transmission
Requirements:
- Drive gearbox is in the neutral position (position "N").
Check the following components for possible leaks:
- Drive gearbox
- Intarder
- Oil/water heat exchanger
- Associated cooling water pipes
6.2.3 Drive gearbox - check the oil level

DANGER
switched off.
NOTE
Damage to the transmission due to too little oil!
Ensure that there is always sufficient oil in the transmission.
Do not activate the intarder immediately before the crane is
switched off. This ensures that the correct oil quantity is in the
transmission.
Do not carry out an oil level check immediately after driving.
Check the level only after the transmission oil has cooled down
(< 40 °C / +104 °F).
Requirements:
- Crane switched off without intarder activation
- Transmission oil has cooled down (< 40 °C / +104 °F)
82640 2021-04-22 89
6 Transmission
CAUTION
Risk of burns!
The transmission including the oil fill plug could still be
very hot.
Wear suitable protective clothing and gloves.
1. Remove the oil fill and inspection plug.
2. Check oil level.

The oil level must be up to the oil fill hole.
3. If the oil level has dropped below the oil filling hole, top up the
transmission oil (see 6.2.4.3 Filling with transmission oil,
side 94).
4. Screw in a new sealing ring onto the oil filler and inspection plug
and tighten it.
- Tightening torque: 60 Nm (44.25 lbf-ft)
6.2.4 Drive gearbox - change oil

Consumables: 2.10 Transmission oil, side 37
6.2.4.1 Draining transmission oil
DANGER
switched off.
NOTE
Gearbox damage due to incorrect oil change quantity!
Do not activate the intarder immediately before the crane is
switched off. This ensures that the correct oil quantity is in the
transmission.
90 82640 2021-04-22
6 Transmission
Requirements:
- Crane switched off without intarder activation
- Transmission oil is at operating temperature and of low viscosity
Fig. 19: Drive gearbox - overview
1 Oil drain plug 2 Oil fill and inspection plug
CAUTION
Risk of injury due to hot transmission oil!
Hot transmission oil can scald skin and burn eyes.
1. Remove the oil drain plug (1) and the oil fill and inspection
plug (2) from the transmission.
2. Let the oil drain into a suitable collecting container.
3. Clean the magnet at the oil drain plug (1) and replace the sealing
ring.
4. Screw in the oil drain plug (1) and the oil fill and inspection
plug (2) with a tightening torque of 60 Nm (45 lbf ft).
5. Change the filter element of the oil filter (see 6.2.4.2 Change
the filter element of the oil filter, side 92).
82640 2021-04-22 91
6 Transmission
6.2.4.2 Change the filter element of the oil filter

Requirements:
- Transmission oil is drained
Use a new oil filter for every oil change.
CAUTION
Risk of injury due to hot transmission oil and hot
surfaces!
Hot transmission oil can scald skin and burn eyes.
Fig. 20: Bolts on the oil filter
1. Unscrew the bolts (2 pcs.) on the oil filter housing cover.
There is residual oil in the oil filter housing.
2. Pull the filter out of the intarder housing.
92 82640 2021-04-22
6 Transmission
Fig. 21: O-rings on the new filter housing

1 filters
2 O-rings
3. Check the O-rings on the new filter for damage and grease them.
4. Insert a new filter into the intarder housing.
Fig. 22: Screws on the oil filter housing

cover
5. Fasten the filter with screws (2 pcs) with a tightening torque of

23 Nm (17 lbf ft).
82640 2021-04-22 93
6 Transmission
6.2.4.3 Filling with transmission oil
Two different oil filling positions are used with TraXon transmissions
with INTARDER. One is for the oil change and the other is for filling
transmission oil after a gearbox repair. The oil filling process for the
oil change is described in the following. For information about filling
after a repair, see 6.2.5 Drive gearbox – Fill with oil after repair
work, side 96.
Requirements:
DANGER
switched off.
CAUTION
Risk of injury due to hot surfaces!
Parts of the gearbox could be hot.
1. Remove the oil fill and inspection plug.
2. Fill the transmission oil through the oil filling opening until oil has
reached the lower edge of the oil overflow point or until oil is al-
ready emerging from the overflow point.
94 82640 2021-04-22
6 Transmission
3. Screw in the oil fill and inspection plug with a tightening torque of
60 Nm (45 lbf ft).
4. Carry out a test drive (see 6.2.4.4 Performing test drive,

side 95).
6.2.4.4 Performing test drive

1. Start the engine of the crane chassis and let it run at idle speed
for approx. 2 to 3 minutes.
2. Shut down the engine and check the oil level (see 6.2.3 Drive
gearbox - check the oil level, side 89).
3. Check the transmission for leaks (see 6.2.2 Drive gearbox –
Carry out visual check, side 88).
4. Test drive:
- journey of 2 – 5 km (1 – 3 mi).
- Minimum duration 1 minute at minimum speed 10 km/h (6
mph).
- Switch off the activation of the intarder by the foot brake dur-
ing the trial run. Do not actuate the intarder during the test
drive.
5. At the end of the test drive, bring the crane to a standstill without
the aid of the intarder.
6. Switch off the engine.
DANGER
Danger when the engine is started!
switched off.
No one may be in the driver's cab and it must be
locked.
7. After a pause, check the oil level once more (see 6.2.3 Drive
gearbox - check the oil level, side 89) and if necessary, refill the
oil until it overflows.
82640 2021-04-22 95
6 Transmission
6.2.5 Drive gearbox – Fill with oil after repair work

Requirements:
DANGER
switched off.
CAUTION
Risk of injury due to hot surfaces!
Parts of the gearbox could be hot.
Fig. 23: Oil fill and inspection plug in the drive gearbox
1. Remove screw plugs at the oil filling point (1) and the oil overflow
point (2).
2. Fill the transmission through the oil filling opening (1) until oil has
reached the lower edge of the oil overflow point (2) or until oil is
already emerging from the overflow point (2).
3. Screw in oil fill plugs at the oil filling point (1) and the oil overflow
point (2) with a new sealing ring and a tightening torque of
60 Nm (45 lbf ft).
96 82640 2021-04-22
6 Transmission
4. Start the engine of the crane chassis and let it run at idle speed
for approx. 2 to 3 minutes.
5. Shut down the engine and check the oil level (see 6.2.3 Drive
gearbox - check the oil level, side 89).
6. Check the transmission for leaks (see 6.2.2 Drive gearbox –
Carry out visual check, side 88).
7. Perform trial run: Distance 2 – 5 km (1 – 3 mi), Minimum duration
1 minute at minimum speed 10 km/h (6 mph).
7.1. Switch off the activation of the intarder by the foot brake
during the trial run.
7.2. At the beginning of the drive, actuate the intarder (Stage 6)
once briefly and switch it off again. This means that the
oil distributes itself evenly.
7.3. At the end of the test drive, bring the crane to a standstill
without the aid of the intarder.
7.4. Switch off the engine.
DANGER
switched off.
locked.
8. After a pause, check the oil level once more (see 6.2.3 Drive
gearbox - check the oil level, side 89) and if necessary, refill the
oil until it overflows.
6.3.1 Distributor gear – checking the oil level, topping up if required

Requirements:
82640 2021-04-22 97
6 Transmission
Fig. 24: Distributor gear
1 Distributor gear 2 Screw plug of the filler and in-

spection opening
DANGER
Danger when the engine is started.
switched off.
locked.
1. Unscrew screw plug from the filler and inspection hole (2).
2. Oil must be topped up if the oil level does not reach the bottom
edge of the filler and inspection hole (2) or, if the oil lever is high-
er, oil must be drained off.
3. Screw screw plug with a new seal into the filler and inspection
hole (2).
98 82640 2021-04-22
6 Transmission
6.3.2 Distributor gear – change oil

Requirements:
- Gearbox oil at operating temperature
Fig. 25: Distributor gear
1 Distributor gear 2 Screw plug of the filler and in-

spection opening
3 Oil drain opening
WARNING
Risk of injury due to hot gear oil!
Hot gear oil can scald skin and burn eyes.
Wear protective clothing and gloves as well as gog-
gles.
1. Unscrew screw plug of oil drain opening (3) and screw plug of oil
fill hole (2).
2. Let the oil drain into a suitable collecting container.
82640 2021-04-22 99
6 Transmission
3. Clean the magnet on the screw plug of oil drain openings (3)
from any abrasion that has become attached to it.
The transmission oil of the distributor gear is cooled by a tube cool-

ing coil (1).
Fig. 26: Connecting hoses to the tube cooling coil on the two-stage distributor
gear
1 Tube cooling coil 2 Connecting hose to tube cooling

coil, return line
3 Screw connection on the exteri- 4 Screw connection on the exteri-
or, return line or, feed line
5 Connecting hose to tube cooling
coil, feed line
4. Drain oil from the tube cooling coil:

4.1. Release connecting hoses (2) and (5) to the tube cooling
coil (1) on the distributor gear and let the oil (approx. 4 l /
1 US gal) drain into the collecting container. Alternatively,
open screw connections (3), (4).
4.2. After draining the oil: Screw connecting hoses (2) and (5)
back on the distributor gear and/or close screw connec-
tions (3), (4).
Dispose of the old oil in accordance with the legal regulations valid
at the operating site.
5. Fit the screw plug on oil drain opening (3) with a new seal.
100 82640 2021-04-22

6 Transmission
6. Fill up with new oil:

6.1. Top up transmission oil via the filler and inspection hole
until it starts to flow over.
6.2. Screw in screw plug of the filler and inspection hole using
a new seal.
7. Test drive the vehicle for about 5 km (3 mi).
During driving, the oil is pumped from the distributor gear into the
tube cooling coil.
8. Check oil level at the filler and inspection hole (2) again, see
6.3.1 Distributor gear – checking the oil level, topping up if re-
quired, side 97.
6.3.3 Distributor gear – Carry out visual check

CAUTION
Danger due to faults not being rectified.
Rectify any determined faults immediately.
Rectify any faults which impair the operating safety of
the vehicle before renewed operation.
Requirements:
- Drive gearbox is in the neutral position (position "N")
82640 2021-04-22 101

6 Transmission
Fig. 27: Connections on the distributor gear (schematic diagram)
1 pneumatic connections - distrib- 2 pneumatic connections - distribu-

utor gear shift tor gear shift
3 pneumatic connections - distrib- 4 compressed air connection – dif-
utor gear shift ferential lock
5 electric connection – on-road 6 electric connection – off-road
gear (2nd gear) gear (1st gear)
7 electric connection – differential 8 shift cylinder (road, off-road, neu-
lock tral)
DANGER
switched off.
locked.
1. Check the bolted connections to ensure they are fitted tightly.

2. Check the leak-tightness of housing screws and shafts.
3. Check stability of attachment elements.
4. Check transmission ventilation for contamination.
5. Check state of the hydraulic lines to the tube cooling coil, the air
lines and electrical cables as well as their connections.
6. Check function of the switches and indicator lights
102 82640 2021-04-22

6 Transmission
6.3.4 Checking the Distributor Gear Shift

Requirements:
Fig. 28: Air pressure display in the supply tank
1 Air pressure brake circuit 1 2 Air pressure brake circuit 2
1. Ensure there is sufficient air pressure in the supply tank.
82640 2021-04-22 103

6 Transmission
Fig. 29: pneumatic connections on the distributor gear (schematic diagram)
1 pneumatic connections – distrib- 2 pneumatic connections – distrib-

utor gear shift utor gear shift
3 pneumatic connections – distrib- 4 compressed air connection – dif-
utor gear shift ferential lock
8 shift cylinder (road, off-road,
neutral)
CAUTION
Danger due to faults not being rectified.
Rectify any faults which impair the operating safety of
the vehicle before renewed operation.
2. Check the on-road and off-road gear shifts for leak-tightness of

the shift cylinder (8) and of the pressure lines (1), (2), (3), (4).
3. Check the pressure lines generally for chafing points.
4. Check the solenoid valve for quick venting (clean if required).
104 82640 2021-04-22

7 Joint shafts
7 Joint shafts
7.1 Safety instructions (joint shafts)
DANGER
switched off.
DANGER
Danger due to rotating drive shafts!
The crane operator and / or operating company must
take the necessary safety precautions wherever peo-
ple or equipment are at risk due to rotating joint
shafts.
Maintain a safe distance to rotating and moving com-
ponents.
NOTE
Prevention of damage due to professional maintenance and re-
pairs!
Only have the joint shafts fitted by specialist personnel.
7.2 Check the flange connections for proper fitting

WARNING
Danger due to missing or loose screws / bolts.
Replace missing or defective bolts.
Only bolts may be used which correspond in size and
strength with the ones listed in the tables below.
82640 2021-04-22 105

7 Joint shafts
7.2.1 Design with bolts / screws with zinc flake coating
NOTE
Danger due to overloading the bolts!
Do not use any grease.
Only screw the screws/bolts in when dry.
Screw-in thread and head support surface must be dry and
clean.
The screw-in thread must be free of corrosion and protective
wax.
1. Check the nuts and bolts of the flange connections for signs of
damage and to make sure that they are fitted properly, and re-
tighten as necessary.
The following values apply for the tightening torque of the

bolts / screws with zinc flake coating of the flange connections
on the joint shafts and intermediate shafts:
Torque
Size Quality
(Nm) (lbf ft)
M 12 x 1.5 10.9 102 ± 8 75.2 ± 5.9
M 14 x 1,5 10.9 166 ± 12 122.4 ± 8.85
Table 2: Torque of the flange connections - bolts / screws with zinc flake coating
106 82640 2021-04-22

7 Joint shafts
7.2.2 Design with black bolts / screws or bolts / screws with A3C coating
Consumables: 2.13 Grease, side 38
NOTE
The screw-in thread must be cleaned and free of corrosion and
protective wax.
The thread and head support surface must be lubricated with
grease.
1. Check the nuts and bolts of the flange connections for signs of
damage and to make sure that they are fitted properly, and re-
tighten as necessary.
The following values apply for the tightening torque of the

black bolts / screws or A3C-coated bolts / screws of the flange
connections on the joint shafts and intermediate shafts:
Torque
Size Quality
(Nm) (lbf ft)
M 12 x 1.5 10.9 119 88
M 14 x 1,5 10.9 187 138
Table 3: Torque of the flange connections - black or A3C-coated bolts / screws
82640 2021-04-22 107

7 Joint shafts
108 82640 2021-04-22

8.1 Conditions for Carrying out Work

The conditions listed below must be satisfied for all work described in
this section:
82640 2021-04-22 109

8.2 Axles
8.2.1 Check the axle fixing bolts

Fig. 30: Axle fixing bolts
1 Gripper clam screws 2 Fastening screws
Requirements:
- Observe the conditions listed in 8.1 Conditions for Carrying out
Work, side 109.
DANGER
switched off.
locked.
1. Check screws (1) on the collars of the axle braces and tighten
with the prescribed torque if required. (Tightening torque: 70 -
80 Nm (52 - 59 lbf ft)
2. Tighten fixing screws (2) on the axle braces using a torque
wrench. The tightening torque is as follows:
- Bolts M 18: 390 Nm (288 lbf ft)
- Bolts M 20: 560 Nm (413 lbf ft)
110 82640 2021-04-22

8.2.2 Replacing the axle fixing bolts
WARNING
Do not use any striking tools.
Fit screws dry and without grease and oil.
8.2.3 Lubricating the Steered Axles

Requirements:
Work, side 109.
DANGER
switched off.
locked.
82640 2021-04-22 111

Fig. 31: Steering swivel pin bearing, upper lubricating nipple Fig. 32: Steering swivel pin bearing, lower lubricating nipple
(schematic diagram) (schematic diagram)
1. If a lubricating nipple is available, lubricate the steering swivel pin

bearing at the top and bottom.
If the crane is fitted with a central lubricating system (optional) the

lubricating points of the steering swivel pin bearing are supplied with
grease from the central lubricating pump.
8.2.4 Driven axles - checking the oil level

- For drive variant 10 x 6 x 10: axles 3, 4 and 5
- For drive variant 10 x 8 x 10: axles 2, 3, 4 and 5
DANGER
switched off.
locked.
112 82640 2021-04-22

WARNING
Risk of injury due to hot transmission oil.
Wear protective clothing and gloves as well as gog-
gles.
NOTE
Adhere to the maintenance interval.
Carry out an oil level check after a week, even if a mileage of
500 km (300 mi) has not been reached within a week.
8.2.4.1 Axles without drive shaft differentials

- For drive variant 10 x 6 x 10: Axle 5
- For drive variant 10 x 8 x 10: Axle 2 and 5
Requirements:
- Observe the conditions listed in section 8.1 Conditions for Carry-
ing out Work, side 109.
- Observe the safety instructions in section 8.2.4 Driven axles -
checking the oil level, side 112.
1
Fig. 33: Axle without drive shaft differential (schematic diagram, Z 104 330)
1 Oil drain plug 2 Screw plug of the filler and in-

spection opening
1. Unscrew the screw plug (2) out of the filler and inspection hole.
2. The oil level must be up to the bottom edge of the filler and in-
spection hole. If this is not the case, oil must be topped up (see
section 8.2.5.1 Axles without drive shaft differentials,
side 116).
3. Screw in screw plug (2).
82640 2021-04-22 113

8.2.4.2 Axles with Drive Shaft Differentials

- Axle 3 and 4
8.2.4.2.1 Axle 3
Requirements:
- Observe the conditions in the section 8.1 Conditions for Carrying
out Work, side 109.
- Observe the safety instructions in the section 8.2.4 Driven axles
- checking the oil level, side 112.
Fig. 34: Axle with drive shaft differential and distributor gear (schematic diagram,
Z 104 332)

spection opening
1. Unscrew screw (2) out of the filler and inspection opening.

section 8.2.5.2 Axles with Drive Shaft Differentials, side 117).
114 82640 2021-04-22

8.2.4.2.2 Axle 4
Requirements:
out Work, side 109.
- checking the oil level, side 112.
3
1
Fig. 35: Axle with drive shaft differential (schematic diagram, Z 104 331)

spection opening
3 Oil drain plug 4 Screw plug of the filler neck

section 8.2.5.2 Axles with Drive Shaft Differentials, side 117).
When topping up axles with drive differentials, it is useful to first top

up oil in the drive differentials (idler shaft). If there is any excess top-
ped-up oil there, it will run into the axle housing.
8.2.5 Driven axles - change oil

- For drive variant 10 x 6 x 10: axles 3, 4 and 5
82640 2021-04-22 115

- For drive variant 10 x 8 x 10: axles 2, 3, 4 and 5
DANGER
switched off.
locked.
WARNING
Risk of injury due to hot transmission oil.
NOTE
Damage to the environment due to the oil draining.
Clean any oil puddles immediately using an oil absorbent.
NOTE
Adhere to the maintenance interval.
Carry out an oil level check after a week, even if a mileage of
500 km (300 mi) has not been reached within a week.
Always change the oil at the end of a longer journey while the trans-
mission oil is still warm from operation and has low viscosity.
8.2.5.1 Axles without drive shaft differentials

- For drive variant 10 x 6 x 10: Axle 5
116 82640 2021-04-22

- For drive variant 10 x 8 x 10: Axle 2 and 5

Requirements:
- Observe the conditions listed in section 8.1 Conditions for Carry-
ing out Work, side 109.
- Observe the safety instructions in section 8.2.5 Driven axles -
change oil, side 115.
1
Fig. 36: Axle without drive shaft differential (Z 104 330)
1 Oil drain plug 2 Screw plug / filler and inspection

plug
1. Unscrew the oil drain plug (1) and the filler and inspection
plug (2).
2. Let the oil drain into a collecting container and dispose of it in an
environmentally friendly manner in accordance with the legal reg-
ulations valid at the location of operation.
3. Clean the oil drain plug (1), fit a new seal and screw in place.
4. Add new oil into the axle housing until it runs out of the filler and
inspection opening (2).
5. Clean the filler and inspection plug (2) and screw back in place
with a new seal.
8.2.5.2 Axles with Drive Shaft Differentials

- Axle 3 and 4
82640 2021-04-22 117

8.2.5.2.1 Axle 3
Requirements:
out Work, side 109.
- change oil, side 115.
Fig. 37: Axle with drive shaft differential and distributor gear (schematic diagram,
Z 104 332)

spection opening

3. Clean oil drain plug (1), fit a new seal and screw in place.
4. Add new oil into the axle housing until it runs out of the filler and
inspection opening (2).
5. Clean the filler and inspection plug (2) and screw back in place
with a new seal.
118 82640 2021-04-22

8.2.5.2.2 Axle 4
Requirements:
out Work, side 109.
- change oil, side 115.
3
1
Fig. 38: Axle with drive shaft differential (Z 104 331)
1 Oil drain plug 2 Filler and inspection plug

3 Oil drain plug 4 Filler and inspection plug
1. Unscrew oil drain plugs (1) and (3) as well as filler and inspection
plugs (2) and (4).
3. Clean oil drain plugs (1) and (3), fit new seals and screw in
place.
4. When filling up the new transmission oil, first fill up approx. 1.5 l
(0.4 gal) transmission oil into the filler neck (4) of the reduction
gear. Then fill up the remaining transmission oil into the filler and
inspection opening (2) until the oil level is at the bottom edge of
this hole.
5. Clean filler and inspection plugs (2) and (4) and fit new seals.
82640 2021-04-22 119

8.2.6 Wheel hub drive - check the oil level

Requirements:
Work, side 109.
Fig. 40: Position of the filler and inspec-

Fig. 39: Screws on the wheel hub drive tion hole for the oil level check (schematic
diagram)
1 Filler and inspection plug 1 Filler and inspection plug
2 Oil drain plug 2 Bottom edge of the filler and in-
spection hole (oil level)
1. Drive the crane forwards or backwards on level ground until the

oil drain plug (2) is at the lowest point and the bottom edge of the
filler and inspection hole (1) 20mm (0.79 in) is below the axle
centre.
DANGER
switched off.
locked.
3. Unscrew the screw from the filler and inspection opening.
120 82640 2021-04-22

4. Check the oil level. The oil level must be up to the bottom edge
of the filler and inspection hole.
5. Top up oil if the oil level is not correct (see 8.2.7 Wheel hub
drive - change oil, side 121).
6. Screw in and clean the plug of the filler and inspection opening.
8.2.7 Wheel hub drive - change oil

Requirements:
Work, side 109.
- Suitable collecting container is ready.
Carry out an oil change when the oil and warm and therefore thin.
Fig. 42: Position of the filler and inspec-

Fig. 41: Screws on the wheel hub drive tion hole for the oil level check (schematic
diagram)
1 Filler and inspection plug 1 Filler and inspection plug
2 Oil drain plug 2 Bottom edge of the filler and in-
spection hole (oil level)
1. Drive the crane forwards or backwards on level ground until the

oil drain plug (2) is at the lowest point and the bottom edge of the
filler and inspection hole (1) 20mm (0.79 in) is below the axle
centre.
DANGER
switched off.
locked.
82640 2021-04-22 121


3. Clean the wheel side.
4. Let the oil drain into the collecting container. To do so:
4.1. Open the oil drain plug (2).
4.2. Open the filler and inspection plug (1).
5. Clean oil drain plug (2), fit a new seal and screw in place.
6. Checking the wheel bearing (see 8.2.9 Checking the wheel
bearing, side 123).
7. Fill the wheel side with new oil. To do so:
7.1. Fill with new oil until it flows out of the filler and inspection
opening.
7.2. After a few minutes, check the oil level at the filler and in-
spection opening.
7.3. Fill the wheel side with oil until the oil level remains con-
stant.
7.4. Clean the hole and filler and inspection plug and screw
back in place with a new seal.
8.2.8 Wheel hub bearing – Changing the grease

Requirements:
Work, side 109.
DANGER
switched off.
locked.
122 82640 2021-04-22

Fig. 44: Wheel hub caps for steering

Fig. 43: Position of the wheel hub caps
axles and / or rigid axles, interior view
1. Remove the wheel hub cap.

2. Clean the wheel hub on the inside and outside thoroughly. Re-
move all the old grease, place in a suitable container and dis-
pose of the grease in accordance with local statutory regulations.
3. Clean the roller bearing and check to see if it can be used again.
4. Check wheel bearing (see 8.2.9 Checking the wheel bearing,
side 123).
5. Fill the wheel hub cap up to ¾ with grease and fit in place.
8.2.9 Checking the wheel bearing

Check the axial play of the wheel bearing and the lock of the wheel
lock nut when changing oil in the wheel hub drive or changing the
grease in the wheel hub bearing.
8.2.9.1 Checking the Axial Play of the Wheel Bearing

Resetting is necessary if there is noticeable axial play in the wheel
bearing. To do so, contact our customer services department.
82640 2021-04-22 123

8.2.9.2 Checking the Lock Fitting of the Wheel Locking Nut

Requirements:
Fig. 45: Planetary gear of the driven Fig. 46: Wheel hub caps for steering
wheel hub axles and / or rigid axles
- For drive axles:

- Oil drained (see section "Wheel hub drive - changing oil"),
- Planetary housing unscrewed.
- For steering or rigid axles:
- Wheel hub cap unscrewed.
NOTE
Damage due to check using a wrench.
The cylinder screw is secured using Loctite 270.
Do not use a wrench to check it.
124 82640 2021-04-22

Fig. 47: Variants of the wheel lock nut
2 Planetary housing 4 Wheel lock nut as shaft nut

5 Cylinder screw 6a Lock nut
6b Wheel lock nut as groove nut 7 Locking plate
1. Check the lock of the wheel lock nut to ensure it is fitted firmly
and for damage.
If the wheel lock nut is designed as a shaft nut (4), check the
cylinder screw (5) to ensure it is firmly fitted.
If the wheel lock nut is designed as a groove nut (6b):

- check the locking plate (7) for damage,
- replace the locking plate if the locking tongue has been
sheared off,
- finally, secure the lock nut (6a) with Loctite 242.
8.3 Suspension
8.3.1 Suspension Cylinders - Lubricating the Pivot Bearings

Requirements:
Work, side 109
82640 2021-04-22 125

DANGER
switched off.
locked.
1. Lubricate the pivot bearing of the suspension cylinders via the lu-
bricating nipples.
Fig. 48: Lubricating nipple on the pivot bearing of the suspension cylinder
If the crane is equipped with a central lubrication system (optional

equipment), the lubricating points of the suspension cylinders are
supplied with grease from the central lubricating pump.
8.3.2 Check hoses of the suspension

CAUTION
Danger due to damaged lines and hoses!
Replace lines and hoses damaged by mechanical,
thermal or other effects immediately.
Lines and hoses must have sufficient clearance to hot
engine components (e.g. turbocharger) and must be
laid so that they do not chafe.
126 82640 2021-04-22

1. Check all hose lines daily for damage (see 12.10 Hose assem-
blies on mobile cranes, side 178).
8.3.3 Replace hoses of the suspension

Even if there is no sign of damage, the hose lines must be replaced at
the latest after 2 years operating time.
The date of manufacture which is stamped on the part is decisive for
calculating the operating and storage time.
The markings of the hydraulic hoses are described in the section:
12.10.2 Markings of hydraulic hoses, side 179.
82640 2021-04-22 127

128 82640 2021-04-22

9 Steering
9 Steering
9.1 Safety instructions (steering)
DANGER
Risk of accidents when work is not carried out prop-
erly.
The steering system is a safety component of the highest
order; any incorrect work performed on it could lead to
steering failure.
Service and repair work require specialised knowl-
edge and must only be carried out by trained person-
nel.
We recommend consulting an authorised specialist
workshop.
In some countries, a safety check is prescribed by law.
82640 2021-04-22 129

9 Steering
9.2 Overview: Steering components
Fig. 49: Parts of the steering system
1 Angular gear 2 Telescopic shaft

3 Steering gear (SERVOCOM) 4 Steering cylinder with fastening elements
5 Steering lever 6 Steering rod
Fig. 50: Steering cylinder with fastening elements
4 Steering cylinder 5 Steering lever

8 Hydraulic steering hoses 9 Axle stop
130 82640 2021-04-22

9 Steering
9.3 Visually check the steering components

1. Check the screws of the entire steering system (steering column
strand, angular gear, steering gear, push rods and operating cyl-
inders) and their fastenings.
2. Check the metal and splint pin locks.
3. Check whether the strut rod is still firmly fitted to the sector shaft
by alternatively steering and straining the steering wheel.
4. Check axle stops, push rods and cross ties for damage and
cracks.
5. When the engine is running, check the outer leak-tightness of the
entire steering system (steering gear and protective caps,
pumps, valves and operating cylinders).
9.4 Check that the steering transmission components are fitted firmly
1. Check all screws / bolts of the steering transmission components
to ensure they are firmly fitted and particularly for corrosion.
Tighten any loose bolted connections as required.
Tightening torques
Tightening torque
Fastening element
Nm lbf ft
Bolt M10 45−55 33.2−40.6
Bolt M12 60 44.3
Castle nut M24 x 1.5 270 199
Castle nut M30 x 1.5 330 243
Table 4: Tightening torques of the steering cylinder mounting parts
82640 2021-04-22 131

9 Steering
9.4.1 Check the axial play in the steering lever bearing and adjusting as necessary
If axial play is noticeable in the steering lever, make adjustments.
Fig. 51: Steering arm bearing – schematic diagram
1 Groove nut 2 Threaded pins

3 Steering rods
Adjustment procedure:
1. Remove steering rods (3).
2. Loosen threaded pins (2) (2 x per bearing).
3. Tighten groove nut (1) until the steering lever cannot be moved
any further by hand.
4. Loosen the groove nut (1) again until the steering arm can just
be moved (Ma = 960 Nm / 708 lbf-ft).
5. Secure the groove nut with threaded pins (2) (Ma = 4 Nm / 3 lbf-
ft).
6. Attach steering rods (3) again.
132 82640 2021-04-22

9 Steering
9.5 Lubricate the steering transmission components

9.5.1 Lubricating the steering lever
Fig. 52: Lubricating nipple on the steering lever - schematic diagram
1. Clean the lubricating nipple.

2. Inject fresh grease into the lubricating nipple until all the old
grease is completely replaced by the new.
If the crane is equipped with a central lubrication system (optional),

the steering arm lubrication points are supplied with grease from the
central lubricating pump.
9.5.2 Lubricating the steering cylinders

If a lubricating nipple is available, lubricate the pivot bearing.
82640 2021-04-22 133

9 Steering
9.6 Check steering cylinder for leak-tightness

1. Check the steering cylinders for leaks.
The piston rods of the cylinders can be coated with a thin film of oil.
However, no beads of oil must be allowed to form.
9.7 Check the steering angle sensor

Fig. 53: Steering angle sensors
1. Check the steering angle sensors of axles 1, 3 and 4 (right side)

for correct fitting, mechanical damage, corrosion and wear or
play.
134 82640 2021-04-22

9 Steering
9.8 Check hoses

CAUTION
Leads and hoses must be laid so that they are at a
sufficient distance to hot engine parts (e.g. turbo-
charger) and so they do not chafe.
Regularly check all hose lines for damage (see 12.10 Hose assem-
9.9 Replace hoses of the steering system

Even if there is no sign of damage, the hose lines must be replaced at
the latest after 2 years operating time.
The date of manufacture which is stamped on the part is decisive for
calculating the operating and storage time.
The markings of the hydraulic hoses are described in the section:
9.10 Fault search path (steering)

Error Cause Remedy
Have repaired / replaced by cus-
Noises Pump defective
tomer service team
Pressure relief valve defec- Have repaired / replaced by cus-
sluggish on both sides
tive / contaminated tomer service team
Steering system drawing / pass-
Rectify leaks
ing air (suction area)
Universal joints / steering col- have checked and possibly re-
umn sluggish placed by customer services
Have repaired by customer serv-
Steering defective
ice team
Have repaired by customer serv-
Pump defective
ice team
Have adjusted by customer serv-
sluggish on one side Steering limit set incorrectly
ice team
Steering defective
tomer service team
82640 2021-04-22 135

9 Steering
Error Cause Remedy

Steering system drawing / pass-
sluggish when steered quickly Rectify leaks
ing air (suction area)
pump defective or incorrect ver- Have pump replaced by custom-
sion er service team
Axle / axle guide components Have repaired by expert person-
retardant return
sluggish nel
Steering / steering column fitting have tension removed by spe-
distorted cialist personnel
have sluggishness rectified by
Steering column sluggish
specialist personnel
Steering defective
tomer service team
Axle / axle guide compo- Have checked by specialist per-
precise straight-ahead driving is
nents / steering column not free sonnel, replace components if
not possible
of play required
Have checked by specialist per-
steering not free of play sonnel, replace components if
required
136 82640 2021-04-22

10.1 Safety instructions (Brake and compressed air system)
DANGER
erly.
The brake is a safety component of the first degree. The
brake system may fail if work has not been carried out
properly.
edge and must only be carried out by personnel
trained for this type of brake.
We recommend that an authorised specialist work-
shop be used in such cases (for example, brake re-
pair service).
Vehicles requiring authorisation

Observe the road traffic regulations of the country in question for ve-
hicles which are authorised for use on public roads. Carry out an in-
spection of the individual components during the special brake in-
spection.
Vehicles not requiring authorisation
Have vehicles not subject to license requirements inspected at least
once a year by a technical expert in accordance with the correspond-
ing accident prevention regulations.
Repairs
NOTE
Do not use components which do not correspond with the
technical requirements.
Only use original spare parts from the crane manufacturer (see
the spare parts catalogue).
Wearing in brake linings

Each new brake lining must be worn in to achieve the optimum brak-
ing effect. This is best done by braking at intervals in the lower to mid-
dle speed range.
When wearing in new linings, avoid continuous braking over longer
periods of time or forceful braking from maximum speeds.
82640 2021-04-22 137

10.2 Disc brakes
WARNING
Risk of crushing between the brake saddle and brake
supports!
When working on the brake or moving the brake sad-
dle, only grip on the outside with your hands.
NOTE
Damage to brakes.
Do not use power tools.
10.2.1 Checking the disc brakes

DANGER
erly.
Service and repair work on brakes require specialised
expertise and may only be carried out by personnel
trained for this type of brake. Please consult an au-
thorised specialist workshop (e. g. brake service) in
this regard.
Observe the Wabco repair and maintenance instruc-
tions.
Always replace the brake linings axle by axle.
138 82640 2021-04-22

Fig. 55: Wear indicator of the brake lin-

Fig. 54: Brake lining thickness
ings
A Remaining lining thickness 25 Indicator light
1. Replace brake linings if:

- Burned, vitrified or oily brake linings
- The wear limit of the brake linings has been reached
- Indicator light (25) in the instrument panel is illuminated
- Remaining lining thickness (A) is less than 2 mm (0.08 in) (see
section 10.2.2.1 Checking the lining thickness of the brake lin-
ings, side 141)
82640 2021-04-22 139

2. Check the wear contacts (arrow) for damage.
Replace the wear contacts if damaged.
CAUTION
Monitoring of the wear limit disrupted.
The brake can lock.
Only drive with undamaged wear contacts.
10.2.2 Check the brake disc

DANGER
switched off.
locked.
Requirements:
140 82640 2021-04-22

10.2.2.1 Checking the lining thickness of the brake linings

1. Check the brake lining thickness (A) regularly depending on vehi-

cle operation.
NOTE
Damage to the brake disc.
Replace brake linings at the latest when a remaining lining thick-
ness (A) of 2 mm (0.08 in) is measured over the brake lining
support plate at the weakest point.
10.2.2.2 Checking the wear limit of the brake disc
Always replace the brake linings axle by axle.
1. When the wear limit (SV) of 33 mm (1.3 in) has been reached, re-
place the brake disc. The total strength (SN) of a new brake disc
is 41 mm (1.6 in).
82640 2021-04-22 141

10.2.2.3 Checking the state of the brake discs
DANGER
Risk of accidents due to damaged brake discs!
Replace the brake disc immediately if there are faults
specified as "not permitted".
In this case, do not move the crane any longer.
Check the brake disc for cracks and maximum wear as well as the
surface quality.
1. Network-type cracks are permitted.
2. Cracks running to the hub centre with a width of max. 0.5 mm

(0.02 in) are permissible as long as they are no longer than 0.75
x a mm (in). The length is measured from the edge of the brake
disc inwards. Example: If a disc has a dimension a = 100 mm (a
= 3.9 in), then a crack is permitted that is maximum 0.5 mm (0.02
in) wide, but no longer than 0.75 x 100 mm = 75 mm (0.75 x 3.9
in = 2.9 in), measured from the edge of the brake disc.
3. Unevenness of the disc surface less than 1.5 mm (0.06 in) is per-
mitted.
4. It is not permitted for cracks to run through.
5. Radially running cracks are not permitted.
142 82640 2021-04-22

10.2.2.4 Checking the brake disc run-out

1. Fasten a measuring gauge onto a brake support.
Fig. 56: Checking the brake disc run-out

with measuring gauge
2. With the brake disc fitted, check the brake disc run-out by turning
the wheel hub. Limit value: 0.15 mm (0.006 in)
10.3 Checking the leak-tightness of the compressed air system

1. Start the engine of the crane vehicle.
2. Call up menu point "Brake system" in the "Driver information"
screen (see the operating instructions of the crane chassis, sec-
tion "Driver's cab").
3. Let the engine run until a supply pressure of max. 8.5 bar
(123 psi) is displayed in the "Driver information" screen.

The system is properly sealed when the decrease in pressure
within 3 minutes is no more than 0.4 bar (6 psi).
DANGER
Risk of accidents if the compressed air system is not
leak-tight.
A compressed air system which is not leak-tight endan-
gers the operating and traffic safety of the vehicle.
Have the compressed air system checked in a spe-
cialist workshop.
5. If there is a loss in pressure, find the cause and have it rectified.
82640 2021-04-22 143

6. To check the system for leaks in the supply tanks, valves and
brake cylinders, press the brake pedal down to brake partially
(3 bar / 43.5 psi).
The bar displays may not go back visibly within 3 minutes with
the brake pedal position remaining the same.
10.4 Drain the compressed air tanks

CAUTION
Malfunction due to ice!
The brake system can fail.
Drain the compressed air tanks daily if there is a risk
of frost.
Fig. 57: Position of the compressed air tanks
1 Compressed air tanks 2 Compressed air tanks

The drain valves are on the bottom of the compressed air tanks.
144 82640 2021-04-22

Container volume Brake

Item Position
L US gal circuit
behind axle 1, central in the
1 20 5.3 2
frame
2 40 10.6 2 on axle console 2/3, right
on the lower chord at axle 3,
3 20 5.3 4
right
on the lower chord in front of
4 20 5.3 3
axle 4, right
5 20 5.3 1 on axle console 4/5, right
behind axle 5, central in the
6 40 10.6 1
frame
7 30 7.9 1 on axle console 4/5, left
on the lower chord in front of
8 20 5.3 3
axle 4, left
on the lower chord behind
9 40 10.6 4
axle 3, left
10 30 7.9 2 on axle console 2/3, left
Table 5: Overview of the compressed air tanks
Requirements:
82640 2021-04-22 145

Fig. 58: Pins for opening the drain valves Fig. 59: Pins for opening the drain valves
at the compressed air tank, schematic di- at the compressed air tank, schematic di-
agram agram
1. Pull or press the drain valve pin (arrow) to the side.

The tilt valve is opened and the condensation water can es-
cape from the container.
10.5 Air dryer - replace the granulate cartridge

Fig. 60: Position of the air dryer
1 Air dryer 2 Cover plate
The air dryers are mounted on the right-hand side of the crane chas-
sis between axles 3 and 4 in the direction of travel.
146 82640 2021-04-22

Requirements:
- Drive gearbox in the neutral position (rotary switch turned to posi-
tion "N").
DANGER
Danger when the engine is left on.
switched off.
locked.
WARNING
Risk of accidents due to the drying agent cartridges
being under pressure.
The air dryer must be placed in a pressure-free state
before beginning maintenance work.
1. Remove cover plate (2) (see Fig. 60, side 146).
2. Unscrew the cartridge by turning it to the left (if necessary, use

strap wrench ø 160 mm / 6.3 in).
3. Grease the ring seal slightly.

Replace damaged seal.
4. Tighten new cartridge with specified torque.

- Tightening torque: 15 Nm (11 lbf ft)
In addition, also observe the specifications on the cartridge itself.
82640 2021-04-22 147

10.6 Compressed air lines
10.6.1 Check compressed air lines

NOTE
Damage to the compressed air lines.
The compressed air lines are partially made of plastic. Welding,
soldering, sanding or other types of processing will damage
them.
CAUTION
Replace lines and hoses which have been damaged
by mechanical, thermal or other effects immediately.
1. Check all compressed air lines for damage (see 12.10 Hose
assemblies on mobile cranes, side 178).
148 82640 2021-04-22

10.6.2 Markings of Compressed Air Lines

The compressed air lines are marked as follows:
Fig. 61: Markings of compressed air lines (Z 68 529)
1 Standard marking 2 Nominal size

3 Material 4 Manufacturer
5 Date of manufacture (year/
month)
The connection fittings are marked with the identification number of

the compressed air line, e. g. 511 797 12.
82640 2021-04-22 149

150 82640 2021-04-22

11 Wheels and tyres
11 Wheels and tyres
11.1 Check the wheel nuts

WARNING
Risk of accidents due to loosened wheel nuts.
If you suspect that any wheel nuts have come loose,
retighten all the wheel nuts.
Do not drive with loose wheel nuts.
Before beginning driving, the wheel nuts must be checked to ensure

that they are fitted firmly and tightly.
Wheel nut indicators (optional)
So-called wheel nut indicators are fitted onto the wheel nuts. The
points of the wheel nut indicators point towards each other in pairs.
If the points of a pair of wheel nut indicators are no longer pointing to-
wards each other, this means that a nut or several nuts have come
loose.
1. Remove the wheel nut indicators if the wheel nuts are loose.
2. First loosen each wheel nut completely before tightening it.
3. Tighten all the wheel nuts. Observe the tightening torque (see
11.2 Tightening wheel nuts (standard rims), side 151).
4. Refit and realign the removed wheel nut indicators.
The load capacity of the rim screw connection depends on the

screw preliminary tension. A loss in preliminary tension cannot be
detected using the wheel nut indicators. Wheel nut indicators can
only help detect completely loose nuts.
11.2 Tightening wheel nuts (standard rims)

WARNING
Risk of accidents due to wheels nuts being fitted im-
properly.
If threads or support surfaces (nuts / pressure discs) are
lubricated or greased, it causes the wheel nuts to be
overtightened with the tightening torque.
Fit the thread and support surface of the wheel nut in
a clean and dry state and free or oils and greases.
82640 2021-04-22 151

11 Wheels and tyres
WARNING
After a wheel change, tighten the wheel nuts accord-
ing to regulations.
1. Tighten the wheel nut. The tightening torque of the wheel nuts
with pressure discs (M 22x1.5) is 550 Nm (406 lbf ft) to 600 Nm
(422.5 Ibf ft).
11.3 Tightening wheel nuts (aluminium rims)

WARNING
Risk of accidents due to wheels nuts being fitted im-
properly.
If threads or support surfaces (nuts / pressure discs) are
lubricated or greased, it causes the wheel nuts to be
overtightened with the tightening torque.
Fit the thread and support surface of the wheel nut in
a clean and dry state and free or oils and greases.
WARNING
After a wheel change, tighten the wheel nuts accord-
ing to regulations.
Wheel nuts L22 with long shaft and pressure plate (DIN 74361-
L22-10) are required for mounting the aluminium rims. Aluminium
rims must not be fitted with wheel nuts without shafts. The shaft is
necessary to bridge the missing wheel bolt length.
1. Tighten the wheel nuts crossways. The tightening torque of the

wheel nuts with long shaft and pressure plate (M 22x1.5) is 600
Nm (422.5 lbf ft) to 650 Nm (479.4 lbf ft).
152 82640 2021-04-22

11 Wheels and tyres
11.4 Check tyres

11.4.1 Checking tyre pressure
If the tyres are filled with nitrogen, fill the tyres with nitrogen using a
nitrogen filling system.
1. Check the tyre pressure regularly (for required tyre pressure, see
table).
Design with tyre pressure monitoring (optional)
2. Correct the tyre pressure as soon as the indicator light in the

driver information system in the driver's cab is illuminated.
Version with tyre pressure gauge (optional)

Tyre pressure gauges are fitted to the tyre valves instead of valve
caps.
3. Correct the tyre pressure as soon as the displayed tyre pressure

falls below the required tyre pressure (see table).
CAUTION
Danger due to tyre pressure loss.
Damage to the tyre pressure gauge can result in slow or
rapid tyre pressure loss.
Regularly check the condition of the tyre pressure
gauge.
Michelin tyres
385/95 R 25 445/95 R 25 525/80 R 25
Tyre size
(14.00 R 25) (16.00 R 25) (20.50 R 25)
Identification 170F 174F 176F
X − Crane AT X − Crane AT
Tread X − Crane +
X − Crane + X − Crane +
9.0 bar 9.0 bar 7.0 bar
Tyre pressure
(131 psi) (131 psi) (102 psi)
82640 2021-04-22 153

11 Wheels and tyres
Bridgestone tyres
385/95 R 25 445/95 R 25 525/80 R 25
Tyre size
(14.00 R 25) (16.00 R 25) (20.50 R 25)
VHS
Tread VHS VHS
VHS2
9.0 bar 7.0 bar
Tyre pressure
(131 psi) (102 psi)
Magna tyres
385/95 R 25 445/95 R 25
Tyre size
(14.00 R 25) (16.00 R 25)
Identification 170F 174F
Tread MA03 MA03
10.0 bar 9.0 bar
Tyre pressure
(145 psi) (131 psi)
TechKing tyres
385/95 R 25 445/95 R 25 525/80 R 25
Tyre size
(14.00 R 25) (16.00 R 25) (20.50 R 25)
ETGC ETGC
Tread ETGC
ETCrane ETCrane
9.0 bar 9.0 bar 7.0 bar
Tyre pressure
(131 psi) (131 psi) (102 psi)
Table 6: Tyre pressure in relation to tyre size
11.4.2 Checking the Tread Depth

The minimum tread depth is prescribed by law. In Germany, the tyres'
main grooves must have a tread depth of at least 1.6 mm (0.06 in).
1. Measure the tread depth in the grooves or notches.
If tyres have indications of wear (TWI=Tread Wear Indicator), meas-

ure the grooves where these tread wear indicators can be found.
11.4.3 Checking Visible Damage

1. When checking the tyres' filling pressure, check the tyres for
damage ( for example, nails driven in).
Replace damaged tyres.
Replace missing valve caps and leaky valves immediately.
154 82640 2021-04-22

11 Wheels and tyres
11.4.4 Checking Age

1. At the latest, replace tyres 10 years after manufacture.
11.5 Check disc wheels (rims)

1. Check the rims for damage and cracking in the base material
and the areas marked with arrows.
If damage is detected, a check for cracks must be carried out.
2. Check the rim for cracks.
82640 2021-04-22 155

11 Wheels and tyres
11.6 Clean tyres

1. Clean soiled tyres with a brush and / or with a water jet.
NOTE
Damage to the tyres by high-pressure cleaners.
Cleaning the wheels using high-pressure cleaners may cause tyre
damage. This does not depend on the water temperature.
The sides of the tyres are particularly prone to such damage.
The pulsating jet of water causes tyre vibration at the effected point.
The ensuing frictional heat cannot be dissipated quickly enough, re-
sulting in localised overheating and melting.
Do not use round spray jet nozzles as they can damage the
tyres even after less than one second and when sprayed at a
distance of less than 700 mm (27 in).
When using 25° fan nozzles and cleaning tools, you must main-
tain a minimum distance of 300 mm (12 in). The water jet should
be moved continually to and fro and not be concentrated on a
single point for any length of time or directly on tyre surfaces.
Replace damaged tyres.
Fig. 62: Damage to tyres
156 82640 2021-04-22

12 Hydraulic System
12 Hydraulic System
12.1 Safety Instructions
DANGER
switched off.
WARNING
Risk of injury due to hot hydraulic oil and higher tem-
peratures in parts of the hydraulic system.
Hot hydraulic oil can scald skin and eyes and causes
higher temperatures in parts of the hydraulic system.
WARNING
Risk of injury due to high hydraulic oil pressure.
Before starting maintenance work, you must ensure
that the hydraulic system is depressurised.
Switch off the engine.
NOTE
Possible malfunction due to components which do not comply
with the technical requirements.
Only use original spare parts from the crane manufacturer.
12.2 Checking the hydraulic oil level

Consumables: 2.9 Hydraulic oil, side 36
Requirements:
- Crane in the transport position.
82640 2021-04-22 157

12 Hydraulic System
1. Check the filling level of the hydraulic system in the driver infor-
mation system in the driver's cab.
The filling level for the AC 250-5 and AC 220-5 (Explor-

er 5800) must be over 96 %.
The filling level for the AC 160-5 (Explorer 5600) and
AC 130-5 (Explorer 5500) must be over 93 %.
2. Crane operation is not possible if the filling level is too low. Inves-
tigate the cause of the oil loss and rectify immediately.
NOTE
Consequential damage due to mixing hydraulic oils.
Do not mix different types of hydraulic oils.

Fill up using the same oil as the oil already in the hydraulic oil
tank.
3. Top up hydraulic oil, see section 12.4.2 Add hydraulic oil,

side 163.
12.3 Check hydraulic oil

Oil samples must be taken and sent for analysis to safely detect pos-
sible contamination of the hydraulic oil. This can also be carried out
as a precautionary measure to prevent failures in the hydraulic sys-
tem.
Only use an analysis set and test pump from a competent analysis in-
stitute to take the oil sample.
We recommend using the analysis set offered by the crane manu-

facturer and the test pump from our tool catalogue to take the oil
samples.
158 82640 2021-04-22

12 Hydraulic System
Fig. 63: Analysis set
1 Test vessel 2 Lid for test vessel

3 Sample submission form with 4 Pre-addressed envelope
peelable lab number
Fig. 64: Test pump
1 Test pump 2 Clothes

3 Operating instructions 4 Hose, 3 m
5 Cutter 6 Pen
1. Warm up and mix the hydraulic oil before taking an oil sample.
1.1. Carry out several functions for approx. 10 minutes with a
high volume of oil throughput (e.g. for telescopic cranes,
luffing gear and telescoping system and for lattice mast
cranes, derricking gear and crawler running gear).
1.2. Retract any extended cylinders again.
82640 2021-04-22 159

12 Hydraulic System
When taking the oil sample, observe the general safety instructions
on the hydraulic system in the lubrication and maintenance instruc-
tions.
NOTE
Note manufacturer's information!
Observe the enclosed operating instructions (3) and other in-
structions from OELCHECK GmbH.
Fig. 65: Schematic diagram, taking an oil sample
1 Hydraulic tank (example: 2 Test pump

CC3800-1)
3 Test vessel
2. Clean the area around the point where the sample was taken.
3. Unscrew the aeration filter (or other access options) from the hy-
draulic tank (1).
4. Guide the chamfered hose end of the test pump (2) through this
hole in the hydraulic tank.
Ensure that the test pump hose does not fall down to the bottom of
the tank; take a hydraulic oil sample from the centre of the tank.
5. Pump the hydraulic oil evenly into the test vessel (3).
Always hold the sample container (3) upright.
160 82640 2021-04-22

12 Hydraulic System
6. Fill out the sample submission form completely.

- In particular, make precise notes on the hydraulic oil used up
to now.
- Hydraulic oil manufacturer
- Manufacturer designation
- Oil quantity of the hydraulic system
- Any quantity specification in case of topped up hydraulic oil
- Operating hours - hydraulic oil
- Operating hours - crane.
7. Place the oil sample and sample submission form in the corre-
sponding envelope and post it to the address indicated (OEL-
CHECK GmbH in 83098 Brannenburg, Germany).
12.3.1 Analysis and lab report

You will receive the lab report directly from OELCHECK GmbH after
analysis.
Note the following:
- The lab report is to be understood as a recommendation for further
usability and provides a statement concerning contamination and
specifications on ageing of the hydraulic oil.
- No warranty claims, warranty extensions or acceptance of liabili-
ties can be derived from the lab report or compliance with the
specified measures.
- A positive lab report does not mean that the service and mainte-
nance intervals and areas of application (e.g. with regard to the
ambient temperature) specified in the lubrication and maintenance
instructions can be changed. The change intervals for hydraulic oil
and hydraulic oil filters must still be adhered to.
12.4 Change the hydraulic oil

Requirements:
- Crane in the transport position.
- Hydraulic oil at operating temperature
82640 2021-04-22 161

12 Hydraulic System
12.4.1 Drain off hydraulic oil
1. Unscrew the protective caps from every hose coupling on the

bottom of the hydraulic tank.
2. Screw drain hoses onto every hose coupling.

This releases the cross-sectional through-flow, hydraulic oil is
drained.
3. Drain old hydraulic oil into the collecting container.
4. Check the hydraulic tank for contamination.

4.1. Clean any visible deposits using suitable agents (e.g.
flushing oil).
4.2. Ensure that no dirt gets into the hydraulic system. This
could damage the hydraulic system.
4.3. If there is a high level of contamination, commission a spe-
cialist workshop with the cleaning.
WARNING
Risk of accidents due to incorrect hydraulic fluid!
Water in the hydraulic system causes serious damage,
even to the point of complete failure.
Never clean the hydraulic oil reservoir with water.
Water may never get into the hydraulic system.
5. Loosen all hose couplings and remove the drain hoses.

The hydraulic oil reservoir is now sealed tight again.
6. Screw all protective caps back on.

The hose couplings are protected from contamination.
When changing the oil, do not change only the reservoir contents,
but also the contents of the system and cylinders. Otherwise, a sig-
nificant amount of used oil will remain in the machine.
162 82640 2021-04-22

12 Hydraulic System
12.4.2 Add hydraulic oil
NOTE
Subsequent damage due to mixing hydraulic oils.
Do not mix different types of hydraulic oils.

When changing the oil, do not change only the reservoir con-
tents, but also the contents of the system and cylinders.
NOTE
Damage due to unfiltered hydraulic oil.
When supplied, hydraulic oil can contain larger particles than is per-
mitted for the hydraulic system of the crane.
The new hydraulic oil may only be added when it has been fil-
tered.
1. Pour in fresh hydraulic oil. To do this, fill pre-filtered hydraulic oil

(filter fineness of the pre-filter system at least 15 μm) directly
through one of the filter openings, e. g. with an aeration filter re-
moved
Or
fill unfiltered hydraulic oil through the return line filter with an
open cover but using the filter element, and taking the time nec-
essary.
Fig. 66: Oil level display on the hydraulic tank
1 Hydraulic tank – AC 250-5 and 2 Hydraulic tank – AC 160-5 (Ex-

AC 220-5 (Explorer 5800) plorer 5600) and AC 130-5 (Ex-
plorer 5500)
2. Check the filling level of the hydraulic system in the oil level dis-
play of the hydraulic tank (1; 2).
The filling level must be between the "min" marking and
the "max" marking in the oil level display.
82640 2021-04-22 163

12 Hydraulic System
Each time hydraulic oil is filled up or changed, it is to be checked that

the hydraulic filters do not become clogged within a very short period
of time (e. g. due to contaminated oil).
3. Check the return line filter for contamination and mechanical
damage, check the sealing surfaces and threads.
4. Close all filter covers.
5. Carry out a test run.
6. Check the oil level.
12.5 Replacing the hydraulic filter
12.5.1 Overview: Hydraulic tank
Fig. 67: Components of the hydraulic tank
1 Hydraulic tank 2 Tank sensor, dip tube

3 Return line filter 2 (R 2) 4 Aeration filter
5 Return line filter1 (R1 )
164 82640 2021-04-22

12 Hydraulic System
12.5.2 Replacing return line filter 1

Requirements:
- Attached load has been set down on the ground
- Telescopic sections retracted
- Hydraulic system depressurised
1. Unscrew the filter cover. Take care with the O-ring while doing
so.
2. Pull the filter element out slowly, pulling at the bracket, and let oil
drain into the tank.
3. Check the return line filter, clean it if necessary.

3.1. Check the surface of the filter element for dirt residue and
larger particles. This could indicate damage to the hydraul-
ic components.
3.2. Check the O-ring. Replace if required.
3.3. If required, spray clean operating liquid over the sealing
surfaces on the filter housing and cover as well as the O-
rings.
Dispose of the used filter element in an environmentally friendly

manner.
4. Carefully fit a new filter element onto the element centring pivot
in the filter housing.
5. Screw the filter cover in place.
5.1. Ensure that O-ring is fitted correctly in the groove of the fil-
ter cover.
5.2. Tighten the fixing bolts with a tightening torque of 30 Nm
(22 lb ft).
6. Check the filter for leak-tightness during a system trial run.
82640 2021-04-22 165

12 Hydraulic System
12.5.3 Replacing return line filter 2

Requirements:
1. Unscrew the filter cover. Take care with the O-ring while doing
so.
2. Pull the filter element out slowly, pulling at the bracket, and let oil
drain into the tank.
3. Check the return line filter, clean it if necessary.

ic components.
3.2. Check the O-ring. Replace if required.
surfaces on the filter housing and cover as well as the O-
rings.

manner.
4. Carefully fit a new filter element onto the element centring pivot
in the filter housing.
5. Screw the cover lid on by hand. Ensure that O-ring is fitted cor-
rectly in the groove of the filter cover.
166 82640 2021-04-22

12 Hydraulic System
12.5.4 Replacing the aeration filter

Requirements:
- Telescopic sections are retracted
- Hydraulic system is depressurised
DANGER
switched off.
No one may be in the cab and it must be locked.
WARNING
Risk of injury due to high hydraulic oil pressure!
Before beginning maintenance work, ensure that the
system and therefore the corresponding pressure
area (for example, filter housing) is depressurised.
1. Unscrew the aeration filter.
Dispose of the used aeration filter in an environmentally friendly

manner.
2. Screw on the new aeration filter with a new O-ring.
82640 2021-04-22 167

12 Hydraulic System
12.5.5 Replacing high-pressure filter element

Requirements:
WARNING
Risk of overturning when slewing with a crane that is
not supported on outriggers in accordance with reg-
ulations!
Support crane on outriggers before slewing.

Read and observe the safety notes in the section
"Slewing the superstructure" in the operating instruc-
tions of the superstructure.
- Crane supported on outriggers

WARNING
Before starting maintenance work, ensure that the
area (e.g. filter housing) is depressurised.
DANGER
switched off.
- Superstructure engine switched off

1. Rotate superstructure by 90°.
It is possible to access the hydraulic reservoir from the crane
chassis.
168 82640 2021-04-22

12 Hydraulic System
2. Open the hydraulic reservoir.
3. Unscrew the filter housing of the high-pressure filter.
4. Collect the remaining oil from the filter barrel and clean it or dis-
pose of it in an environmentally friendly manner.
5. Pull the filter element from the element's centering pivot.

manner.
NOTE
Damage to the thread from contaminants!
Dirt or incomplete pressure release during removal can cause cor-
rosion of the screw-in thread of the filter housing.
Clean the filter housing including the thread.
6. Check the high-pressure filter, clean if necessary.

6.1. Check the filter element for dirt residue and larger parti-
cles. This could indicate damage to the hydraulic compo-
nents.
6.2. Check the filter for mechanical damage, check sealing sur-
faces and the thread in particular. In case of damage,
completely replace the high-pressure filter.
6.3. Check the O-rings and the support rings. If required, re-
place the components.
6.4. Spray the thread and sealing surfaces on the filter housing
and head as well as the O-ring on the filter housing and el-
ement with clean operating fluid if necessary.
82640 2021-04-22 169

12 Hydraulic System
NOTE
Damage due to use of incorrect spare parts!
Check whether the description of the new filter element corre-
sponds with the one that has been removed.
7. Fit the high-pressure filter.

7.1. Carefully fit the filter element onto the element's centering
pivot.
7.2. Screw in the filter barrel up to the stop, then turn back a
quarter of a turn.
A sensor is screwed into the head of the filter housing to register the
filter's state of contamination. The torque of this contamination indica-
tor is 33 Nm ( (24.3 lbf-ft) (wrench SW 30).
170 82640 2021-04-22

12 Hydraulic System
12.5.6 High-pressure Line Filter - Cleaning or Replacing the Filter Element

Requirements:
WARNING
ulations!

WARNING
DANGER
switched off.

chassis.
82640 2021-04-22 171

12 Hydraulic System
Fig. 68: Structure of the high-pressure line filter HD 150-01 (schematic diagram)
1 Screw-in strut 2 O-ring

3 Holding-down clamp 4 Filter element
5 Filter housing
3. Unscrew the screw-in strut (1) using an AF 55 wrench from the

filter housing (5). Unscrew the filter element (4) with an AF 36
wrench.
4. Place a collecting container ready to collect any oil that flows off.
Dispose of used oil in an environmentally friendly manner.
5. Remove the filter element (4) and then clean or replace it.
If, when the filter element is being dismantled, larger more coarse
contaminants are found, for example, metal shavings, it may be that
excessive wear is occurring on the pumps.
6. Collect the residual oil from filter housing (5) and clean it with
diesel oil or cleaning solvent or, if need be, dispose of it in an en-
vironmentally friendly manner.

manner.
7. Check that the O-ring (2) on the screw-in strut (1) with filter ele-
ment (3) is in perfect condition. Replace the O-ring if damaged.
172 82640 2021-04-22

12 Hydraulic System
NOTE
Damage due to use of incorrect spare parts!
Check whether the description of the new filter element matches
that of the removed one.
8. Carefully push the cleaned or new filter element (4) into the filter
housing (5).
9. Carefully push the screw-in strut (1) with the holding-down
clamp (3) into the filter housing (5) as far as it will go and tighten
(AF 36 / AF 55 wrench, torque 180±20 Nm (132.8±14.8 lbf-ft)).
10. Start the superstructure engine and check the filter for leak-tight-
ness during a system trial run.
82640 2021-04-22 173

12 Hydraulic System
12.5.7 Replacing the high-pressure return line filter

Requirements:
WARNING
ulations!


WARNING
DANGER
switched off.

chassis.
174 82640 2021-04-22

12 Hydraulic System
3. Unscrew the filter cartridge using a strap wrench.
4. Let the residual oil drain into a suitable collecting container.
Dispose of the filter cartridge and the old oil in accordance with the
legal regulations valid at the operating location.
5. Lubricate the seal with oil and insert in the new filter cartridge.
NOTE
Risk of damage due to overwinding the thread!
Do not tighten the filter cartridge excessively.
6. Screw the filter cartridge onto the filter head by hand until there is
contact with the sealing surface. Then, using the strap wrench,
tighten by an additional half to full turn.
12.6 Fault message - hydraulic filter

Error Cause Remedy
If the message appears in the
display of the driver information
system while the hydraulic oil is Replace the filter element of re-
warm from operation, the filter turn line filter 1
element of the return line filter 1
is contaminated.
If the message appears in the
display of the driver information
system while the hydraulic oil is Replace the filter element of re-
warm from operation, the filter turn line 2
element of the return line return
line filter 2 is contaminated.
82640 2021-04-22 175

12 Hydraulic System
12.7 Check the hydraulic system

1. Carry out a visual inspection of the equipment:
1.1. Check the hydraulic hoses thoroughly for traces of hy-
draulic oil.
1.2. Check whether the screw connections are leak-tight and
are fastened tightly enough.
2. Check the entire mobile crane and the ground under the parked
mobile crane for traces of hydraulic oil.
CAUTION
Danger due to damaged lines and hoses.
engine components (e. g. turbocharger) and must be
3. Initiate further inspections immediately if irregularities and/or

leaks in the hydraulic system are detected.
12.8 Bleeding the Hydraulic System

NOTE
Trapped air can damage the hydraulic pumps.
Bleed the hydraulic system carefully.
1. Open the cover over the hydraulic pump.
The test union is now visible.
176 82640 2021-04-22

12 Hydraulic System
2. Bleed the hydraulic system.

2.1. Remove the test union.
2.2. Keep the screw connection open until the trapped air has
completely escaped.
2.3. For the AC 160-5 (Explorer 5600) and AC 130-5 (Explor-
er 5500), bleed the system for at least 5 minutes using a
suction pump. Actuate the pump for an additional minute
each until air bubbles can no longer be observed in the
vent hose.
3. Fit the screw connection, fasten the cover.

For the AC 160-5 (Explorer 5600) and AC 130-5 (Explorer 5500),
bleed the system at the steering pumps as well. To do so:
4. Open the cover over the steering pumps.
The screw connections are now visible.
5. Connect the suction pump, one after the other, to each screw
connection and pump for at least 5 min. Actuate the pump for an
additional minute each until air bubbles can no longer be ob-
served in the vent hose.
6. Fasten all screw connections and the cover.
12.9 Check the preliminary gas tension of the pressure accumulators

NOTE
Damage due to inadequate inspection!
A filling and testing device for diaphragm-type and bubble accu-
mulators is required for checking the preliminary gas tension.
This check may only be carried out by a specialist who knows
how to work with a filling and inspection device of this type.
Please contact our customer service if a suitable technician
and/or the required filling and testing device is not available.
82640 2021-04-22 177

12 Hydraulic System
The pressure accumulators used in the hydraulic system of the crane

are diaphragm-type pressure or bubble reservoir accumulators with
nitrogen filling. The corresponding components will only function
properly if the pressure accumulators fitted are charged with the pre-
liminary gas pressure specified.
1. Check the preliminary gas tension at regular intervals.
12.10 Hose assemblies on mobile cranes
12.10.1 General
Hose assemblies are manufactured from rubber hose material whose
physical characteristics naturally change throughout the years, which
means it only has a limited service life. The material's manufacturer
guarantees a shelf life of at least 10 years from the date of manufac-
ture. The specifications on the service life are based on the condition
that the hoses are stored, fitted and used appropriately.
The material's date of manufacture is usually indicated by a marking

on the rubber hose. See the example in the section 12.10.2 Mark-
ings of hydraulic hoses, side 179. The hose assembly's date of
manufacture is generally indicated by a marking on the fitting.
The working life of a hose used in a mobile crane can differentiate

greatly from the service life indicated on the hose. The working life
depends on several factors, for example, environmental influences
(temperature, humidity, corrosive air, etc.), use, working cycles, bend-
ing cycles, abrasion and corresponding fluids. External unfavourable
factors such as heat or frequent bending under pressure, etc. can de-
crease the service life considerably, while other circumstances can
facilitate an actual working life which even exceeds the estimated
working life.
NOTE
Danger due to exceeding the service life of the hydraulic ho-
ses.
Maintain the hose guide specified by the manufacturer.
Avoid abrasion and / or bending / turning the hydraulic hoses
excessively.
Check the hydraulic hoses regularly.
178 82640 2021-04-22

12 Hydraulic System
12.10.2 Markings of hydraulic hoses

The hydraulic hoses are marked as follows:
Fig. 69: Markings of hydraulic hoses (Z 68 531)
1 Manufacturer of the material 2 Hose type (classification)

3 Rated width 4 Standard
5 Date of manufacture of the ma-
terial (quarter and year)
12.10.3 Replace hoses

NOTE
Only use original spare parts of the crane manufacturer or hose
assemblies which comply with the specifications of the crane
manufacturer.
Also use original spare parts for fittings, hose materials and manu-
facturing procedures.
Even if no damage can be detected, replace hose assemblies after a

limited operating time, including a storage period of maximum
2 years.
The date of manufacture stamped on the component is decisive for
calculating the operating and / or storage time, see the section
When replacing the hose assemblies, observe the 29.2.10.5 Speci-
fications on replacing hose assemblies, side 509.
82640 2021-04-22 179

12 Hydraulic System
12.11 Servicing the hydraulic emergency unit (optional)

Servicing work must be carried out depending on the operating hours
of the emergency unit.
DANGER
switched off.
Protect the starter key or starting crank from unau-
thorised access.
Disconnect the battery's negative terminal.
12.11.1 Checking the combustion air intake area

CAUTION
Risk of burns!
There is a risk of burns during work on the hot engine.
Allow the engine to cool down.
Check the intake opening for any coarse contamination, such as

leaves, severe accumulation of dust etc. and clean it, if necessary.
12.11.2 Checking the cooling air area

CAUTION
Risk of burns!
Allow the engine to cool down prior to maintenance
work.
180 82640 2021-04-22

12 Hydraulic System
CAUTION
Risk of injury!
When working with compressed air, foreign matter can
hit the eye.
Wear protective goggles.
Never direct the compressed air jet at persons or
yourself.
NOTE
Risk of engine damage due to overheating.
The engine temperature display (optional) lights up as soon as the
engine get unacceptably hot.
Switch off the engine immediately and eliminate the cause.
1. Check the supply air and exhaust air area for any coarse con-
tamination, such as leaves, severe accumulation of dust etc.
2. If necessary, clean the supply air and exhaust air area (see
12.11.8 Cleaning the cooling air blower, the cooling fins and the
oil cooler, side 192).
12.11.3 Filling the fuel tank

Consumables: 2.7 Diesel fuel, side 34
DANGER
Risk of fire due to fuel.
Leaking or spilt fuel can ignite on hot engine parts and
cause serious burns.
Never fill the tank when the engine is running.
Never fill the tank in the vicinity of naked flames or ig-
nitable sparks.
Do not smoke.
Do not spill fuel.
CAUTION
Risk of injury!
Repeated contact with diesel fuel can lead to brittle and
chapped skin.
82640 2021-04-22 181

12 Hydraulic System
1. Open the cover.
2. Unscrew the cover from the filler neck.
CAUTION
Danger of environmental contamination through spilt
fuel!
Do not overfill the fuel tank and do not spill any fuel.
Catch any fuel that escapes and dispose of it in ac-
cordance with the local environmental rules.
3. Fill the fuel tank with fuel via the filler neck.
4. Screw the cover back on to the filler neck.
5. Close the cover.

CAUTION
Risk of injury!
Prolonged contact with engine oil can cause skin irrita-
tion.
In the case of skin contact, wash the affected areas
thoroughly with soap and water.
182 82640 2021-04-22

12 Hydraulic System
NOTE
If you continue to operate the engine after the oil pressure gauge
lights up, that can result in damage to the engine.
If the oil pressure gauge lights up, switch off the engine immedi-
ately.
If the oil pressure gauge lights up at the ttCAN control panel, switch
off the engine immediately and check the oil level.
If the oil pressure gauge lights up at the MC714 control panel, switch
off the engine immediately and check the oil level.
Requirements:
- The hydraulic power pack is stored in a horizontal position
- The engine oil has cooled down
1. After switching off the engine, wait a few minutes for engine oil to
accumulate in the crankcase.
CAUTION
Risk of burns!
2. Remove any contaminants from the engine in the vicinity of the

dipstick.
3. Pull out the dipstick and clean it.
82640 2021-04-22 183

12 Hydraulic System
4. Re-insert the dipstick.
5. Pull out the dipstick and read off the oil level.
The oil level is correct if it is between the min. and max. mark-
ings.
NOTE
Engine operation with an oil level below the min. marking or above
the max. marking can result in engine damage.
Make sure that the engine always has the correct oil quantity.
6. If the oil level is near the min. marking, top up engine oil up to the
max. marking.
If the oil level is correct and the indicator light lights up, contact the
HATZ service station.
184 82640 2021-04-22

12 Hydraulic System
12.11.5 Changing the engine oil

Requirements:
- The engine oil is still warm
82640 2021-04-22 185

12 Hydraulic System
CAUTION
Risk of burns!
There is a risk of burns by hot oil during work on the hot
engine.
Fig. 70: Draining the engine oil
1 Drain pipe 2 Oil drain plug
1. Drain the engine oil:

1.1. Unscrew the oil drain plug (2).
1.1.1. When unscrewing the oil drain plug (2), take care
not to loosen the drain pipe (1).
1.1.2. Hold it in position with an open-end wrench.
1.2. Allow the entire engine oil to drain completely into the col-
lecting container.
1.3. Insert the cleaned oil drain plug (2) with a new sealing ring
and tighten it.
186 82640 2021-04-22

12 Hydraulic System
CAUTION
Risk of injury!
tion.
2. Pull out the dipstick.
3. Fill up engine oil via the oil fill hole.
5. Pull out the dipstick again and check if engine oil is filled up to
the max. marking of the dipstick. If necessary, top up with more
engine oil.
82640 2021-04-22 187

12 Hydraulic System
7. After a short test run, check the engine oil level again and correct
it, if necessary (see 12.11.4 Checking the engine oil level,
side 182).
12.11.6 Checking the water separator

Requirements:
Water in the fuel accumulates at the lowest point of the fuel filter in
the water separator.
Fig. 71: Water separator
1 Vent screw 2 Drain screw
1. Place a collecting container under the drain plug (2).
If access is difficult, an extension hose can be plugged on to the

drain screw (2).
188 82640 2021-04-22

12 Hydraulic System
CAUTION
fuel!
If the water is drained from the water separator, a small
amount of fuel is also drained with it.
Catch the escaping water-fuel mixture and dispose of
it in an environmentally friendly way.
2. Open the drain screw (2) and drain the water into the collecting
container.
3. If sufficient fluid does not come out, also undo the vent screw (1).
4. As soon as fuel escapes, close the drain screw (2) and the vent
screw (1).
Fig. 72: Manual fuel pump
1 Vent screw 2 Filter

3 Rubber ball
5. If there are any starting difficulties, bleed the injection system

with the manual fuel pump:
5.1. Place a suitable container under the filter (2) to catch any
fuel that escapes.
5.2. Open the vent screw (1) about one rotation.
5.3. Continue to press the rubber ball (3) together and let it go
again until fuel emerges at the vent screw (1)
5.4. Close the vent screw (1) and then press the rubber ball
twice.
82640 2021-04-22 189

12 Hydraulic System
12.11.7 Checking the poly-V-belt

CAUTION
Risk of burns!
work.
NOTE
Risk of engine damage due to insufficient engine cooling.
Operate the engine only if all covers are fitted.
1. Unscrew the cover for the air duct housing.
2. Check the belt tensioner for leak-tightness.
If the belt tensioner is fouled with oil, contact the HATZ serv-
ice station.
190 82640 2021-04-22

12 Hydraulic System
Fig. 73: Damage to the poly-V-belt
1 Transverse cracks on the back 2 Fraying at the side

3 Broken-out fins 4 Transverse cracks in several fins
3. Check poly-V-belt for the following damage:

- Transverse cracks on the back of the belt (1)
- Fraying at the side (2)
- Dirt deposits between the fins
- Contamination with oil
- Transverse cracks in several fins (4)
- Broken-out fins (3)
If there are one or more of these damage symptoms, replace

the poly-V-belt (see 12.11.19 Replacing the poly-V-belt and
checking the shut-off device function, side 216).
4. Refit the cover on the air duct housing.
82640 2021-04-22 191

12 Hydraulic System
12.11.8 Cleaning the cooling air blower, the cooling fins and the oil cooler
NOTE
Risk of engine damage due to overheating.
The engine temperature display (optional) lights up as soon as the
engine get unacceptably hot.
Switch off the engine immediately and eliminate the cause.
NOTE
CAUTION
Risk of burns!
work.
1. Unscrew the following at the engine:

- Cover
- Side wall
- Cover plate on operating side
- Exhaust duct for cooling air
- Cover plate on exhaust side
2. Unscrew the baffle plate.
192 82640 2021-04-22

12 Hydraulic System
DANGER
Risk of explosion due to flammable cleaning agents.
There is a risk of explosion if petroleum ether is used for
cleaning. It is highly flammable, electrostatically chargea-
ble and can produce an explosive gas-air mixture.
Use halogen-free cold cleaner with a high flash point
for cleaning.
Observe the manufacturer's regulations.
CAUTION
Risk of injury!
hit the eye.
yourself.
Fig. 74: Cooling air area Fig. 75: Cooling air area
3. Remove any dry dirt:

3.1. Clean the cooling air blower, the cylinder head and the cyl-
inder with a suitable brush.
3.2. Blow the entire cooling air area clear using compressed
air.
3.3. Blow the oil cooler clear using compressed air only. Do not
apply the compressed air gun to the sensitive cooling ele-
ments.
3.4. Clean the area between the base plate and the crankcase.
82640 2021-04-22 193

12 Hydraulic System
NOTE
Risk of damage to the device due to incorrect cleaning.
Allow the engine to cool down completely prior to cleaning.
Do not spray components of the electrical system with a water
jet or high-pressure jet when cleaning the engine.
Do not use petrol or acidic cleaning agents.
4. Remove any damp or oily dirt:

4.1. Disconnect the battery's negative terminal.
4.2. Clean the alternator and controller by hand.
4.3. Cover the alternator with the installed controller, do not
spray it directly.
4.4. Spray the entire area with a suitable cleaning solution ac-
cording to the manufacturer's instructions and then spray it
with a water jet.
4.5. Dry-clean the engine with compressed air.
4.6. Determine the cause of the oil pollution and have the leak
repaired by HATZ service station.
5. Refit the capsule or air-ducting parts.
6. Warm up the engine to avoid any formation of rust.
12.11.9 Checking screw joints

NOTE
Risk of damage!
Do not re-tighten the cylinder head attachment.
The adjustment screws on the speed controller and on the injec-
tion system have been treated with locking paint and must not
be re-tightened or adjusted.
Only re-tighten loose screw joints. Screw joints can be secured
with locking adhesive or tightened to a defined torque. Re-tight-
ening tight screw joints can result in damage.
1. Check all screw joints for their condition and that they are firmly
fitted (for exceptions, see note).
2. R-tighten loose screw joints.
194 82640 2021-04-22

12 Hydraulic System
12.11.10 Checking the preliminary fuel filter for dirt

Check the preliminary fuel filter for dirt and replace it, if necessary
(see 12.11.11 Changing the preliminary fuel filter, side 195).
12.11.11 Changing the preliminary fuel filter

DANGER
Never fill the tank in the vicinity of naked flames or ig-
nitable sparks.
Do not smoke.
Do not spill fuel.
CAUTION
Risk of injury!
chapped skin.
82640 2021-04-22 195

12 Hydraulic System
CAUTION
fuel!
When the filter is removed, a small amount of fuel is also
drained.
Collect the fuel that escapes and dispose of it in an
environmentally sound manner.
NOTE
Risk of damage to the injection system.
Dirt particles can damage the injection system.
Pay attention to cleanliness in order that no dirt enters the fuel
line.
Requirements:
1. Place a collecting container under the filter to catch any fuel that
escapes.
2. Shut off the fuel supply line.
196 82640 2021-04-22

12 Hydraulic System
Fig. 76: Preliminary fuel filter
1 Preliminary fuel filter 2 Fuel lines
3. Disconnect fuel lines (2) on both sides from the preliminary fuel
filter (1).
Dispose of the old filter in accordance with the legal regulations valid
4. Insert a new preliminary fuel filter. In doing so, note the following:
- Arrow for direction of flow, depending on the arrangement of
the fuel tank: HIGH or LOW
- Fitting position/flow direction vertical if possible
5. Enable the fuel supply line.
6. Carry out a test run. In doing so, check the filter and lines for
leak-tightness.
82640 2021-04-22 197

12 Hydraulic System

3 Rubber ball
7. If there are any starting difficulties, bleed the injection system

with the manual fuel pump:
fuel that escapes.
twice.
12.11.12 Servicing the dry air filter
12.11.12.1 Removing the air filter cartridge
1. Remove the cover from the capsule.
198 82640 2021-04-22

12 Hydraulic System
Fig. 78: Overview of air filter cartridge
1 Cover 2 Screws
3 Bush 4 Spacer
5 Air filter housing 6 Filter cartridge
2. Remove any adhering dirt from the area of the air filter hous-
ing (5).
3. Only undo the screws (2) until the complete air filter housing (5)
can be lifted off.
4. Cover the opening in the intake pipe to avoid any ingress of dirt
or other foreign matter.
5. Open the air filter housing (5).
6. Remove the filter cartridge (6).
7. Clean the air filter housing (5) and the cover (1).
8. If the spacer (4) is loose, replace the bush (3).
The spacer (4) is connected by the flexible bush (3) with the
screw (2) in order that it cannot fall into the intake pipe during dis-
mantling and assembly work.
82640 2021-04-22 199

12 Hydraulic System
12.11.12.2 Checking and cleaning the air filter cartridge

The engine has two filter cartridges.
If this display lights up, clean or replace the filter cartridges.
If, at maximum speed, the combination display on the instrument pan-

el flashes 14 times, clean or replace the filter cartridges.
1. Remove the air filter cartridge (See 12.11.12.1 Removing the
air filter cartridge, side 198).
CAUTION
Risk of injury!
hit the eye.
yourself.
NOTE
Risk of damage to the filter cartridge due to incorrect cleaning
with compressed air.
The pressure must not exceed 5 bar (72.5 psi).
Maintain a distance of about 150 mm (6 in) between the filter
cartridge and the compressed air gun.
Do not wash out or knock out the filter cartridge.
Even the slightest damage to the sealing surface, filter paper
and filter cartridge areas will rule out any reuse of the filter car-
tridge.
2. Blow the filter cartridge clear with dry compressed air from the in-
side to the outside until there no dust comes out any more.
200 82640 2021-04-22

12 Hydraulic System
3. Check the sealing surfaces of the filter cartridge for damage.
4. Check the filter cartridge for cracks or other damage to the filter
paper by holding it at an angle against the light or shining it
through with the lamp.
In the event of damp or oily dirt or of the slightest damage to
the sealing surface, filter paper or filter cartridge, replace the
filter cartridge (see 12.11.12.3 Replacing the air filter car-
tridge, side 201).
5. Refit an undamaged and clean filter cartridge in the reverse re-

moval order.
- Install all parts individually in succession to ensure their tight
fitting and reliable sealing.
12.11.12.3 Replacing the air filter cartridge

The engine has two filter cartridges.
1. Remove the air filter cartridge (See 12.11.12.1 Removing the

air filter cartridge, side 198).
Dispose of the old air filter cartridge in accordance with the legal
regulations valid at the operating site.
2. Install the new filter cartridge in the opposite removal order.

- Install all parts individually in succession to ensure their tight
fitting and reliable sealing.
82640 2021-04-22 201

12 Hydraulic System
12.11.13 Checking and adjusting the valve clearance

CAUTION
Risk of burns!
work.
Only make adjustments with a cold engine (10°C to
30°C / +50°F to +86°F).
1. Lift the cover off the capsule.
Fig. 79: Engine cylinder head
1 Hexagon nut 2 Cover for cylinder head
2. Remove the hexagon nut (1) and take the cover off the cylinder
head (2).
202 82640 2021-04-22

12 Hydraulic System
3. Remove the cover for the air duct housing.
4. Insert a ratchet or 1/2" T-piece with the required extension into

the square opening.
5. Turn the engine in the direction of rotation.
In both cases - flywheel end or control end - anti-clockwise.
82640 2021-04-22 203

12 Hydraulic System
Fig. 80: Numbering of the valves and cylinders, seen from the blower end
1 Valves of the cylinders 2 Cylinders
Valve no. … fully open Check valves of the … cylinder

1 3rd cylinder
5 4th cylinder
7 2nd cylinder
3 1st cylinder
Table 7: Adjustment method for four-cylinder engines
6. Check valve clearance with a feeler gauge. Valve clearance set-

ting value at (10°C to 30°C / +50°F to +86°F) inlet/outlet:
0.10 mm (0.004 in)
204 82640 2021-04-22

12 Hydraulic System
Fig. 81: Adjusting the valve clearance
1 Hexagon nut 2 Adjustment screw
7. If a valve clearance correction is required:

7.1. Undo the hexagon nut (1).
7.2. Turn the adjustment screw (2) in such a way that after re-
tightening the hexagon nut (1), the feeler gauge (3) can
only be pulled through with hardly noticeable resistance.
8. Repeat the above procedure over the entire valve area, paying
special attention to the previously mentioned adjustment method.
9. Refit the cover for the cylinder head:
- Always replace the sealing rings.
- Use the fastening nuts for the cover for the cylinder head a
maximum of twice, then replace them.
- Torque: 10 Nm (7.37 lbft-ft).
NOTE
10. Fit all covers.

11. After a short test run, check the cover for the cylinder head for
leak-tightness.
12.11.14 Changing the oil filter

Change the oil filter together with the engine oil.
82640 2021-04-22 205

12 Hydraulic System
CAUTION
Risk of burns!
There is a risk of burns by hot oil during work on the hot
engine.
Catch the used oil and dispose of it in accordance
with the local environmental rules.
Requirements:
- The engine oil is still warm
1. Release the oil filter with a strap wrench and quickly unscrew it
or pull it out.
2. Wipe any engine oil that escapes out of the oil drip pan.
3. Lubricate the sealing lip of the new oil filter slightly with oil.
4. Insert the oil filter and tighten it by hand.
206 82640 2021-04-22

12 Hydraulic System
CAUTION
Risk of injury!
tion.
5. Fill up with engine oil (see 12.11.5 Changing the engine oil,
side 185).
6. After a short test run, check the engine oil level again and correct
it, if necessary (see 12.11.4 Checking the engine oil level,
side 182)
7. Check the oil filter for leak-tightness, and re-tighten it by hand, if
necessary.
12.11.15 Checking the fuel vaporizer

DANGER
Risk of explosion due to fuel mist.
There is an explosion hazard due to the fuel-air mixture.
Do not clean fuel vaporizer in the proximity of naked
flames or hot surfaces.
Do not smoke when cleaning the fuel vaporizer.
CAUTION
Risk of burns!
During the regeneration process, the diesel particle filter
and the exhaust system get very hot. There is a risk of
burns during work on the hot exhaust system.
Allow the diesel particle filter and the exhaust system
to cool down.
82640 2021-04-22 207

12 Hydraulic System
Fig. 82: Fuel vaporizer - overview
1 Electrical connection cable 2 Fixing bolts for vaporizer unit

3 Seal 4 Hexagonal bolt
5 Coiled filament 6 Vaporizer housing
7 Copper ring 8 Exhaust pipe
9 Fuel hose
1. Remove the fuel vaporizer:

1.1. Disconnect the electric connection cable (1). To do this,
release the plug locks.
1.2. Release the clamp of the fuel hose (9) and pull off the fuel
hose.
1.3. Undo the fixing bolts (2) for the vaporizer unit.
1.4. Carefully loosen the vaporizer unit. The seal (3) should not
be damaged. If the seal remains undamaged, it can be
reused.
1.5. Remove the complete vaporizer unit from the exhaust pipe
(8).
1.6. Use the hexagon bolt (4) to unscrew the coiled filament (5)
from the vaporizer housing (6), and remove the copper
ring (7).
208 82640 2021-04-22

12 Hydraulic System
NOTE
Risk of damage to the coiled filament by the wire brush.
Only use a soft copper or brass wire brush to clean the coiled
filament.
Do not use a hard steel wire brush.
2. Brush soot deposits off the flow filament (5) using a copper or
brass wire brush.
3. Check the coiled filament (5) visually for damage.

If there is visible damage, replace the coiled filament (5).
82640 2021-04-22 209

12 Hydraulic System
CAUTION
Risk of injury!
hit the eye.
yourself.
Fig. 83: Cleaning the fuel vaporizer
1 Fuel connection 2 Fuel bores
4. Blow the fuel connection (1) clear with compressed air. Before
doing so, cover fuel bores (2) in the vaporizer housing with a rag,
to catch deposits and splashes of fuel.
If the fuel bores (2) are clogged, clean the vaporizer housing.
5. Carefully remove stubborn soot or carbon deposits from the fuel

bores (2) with some wire. Then, blow the fuel connection clear
again.
210 82640 2021-04-22

12 Hydraulic System
Fig. 84: Fuel vaporizer - overview
1 Electrical connection cable 2 Fixing bolts for vaporizer unit

3 Seal 4 Hexagonal bolt
5 Coiled filament 6 Vaporizer housing
7 Copper ring 8 Exhaust pipe
9 Fuel hose
6. Re-install the fuel vaporizer:

6.1. Replace the copper ring (7), screw the coiled filament (5)
back into the vaporizer housing (6), tightening torque
55 Nm (40.5 lbf-ft).
6.2. Screw the vaporizer unit firmly on to the exhaust pipe (8).
Undamaged seals can be reused. If there is visible dam-
age, replace the seal (3).
6.3. Connect the fuel hose (9) and secure it with a clamp.
6.4. Re-insert the electric connection cable (1).
12.11.16 Checking the exhaust backpressure sensor

CAUTION
Risk of burns!
work.
82640 2021-04-22 211

12 Hydraulic System
NOTE
Risk of damage to the exhaust backpressure sensor by clean-
ing.
The exhaust backpressure sensor will be damaged irreparably by
cleaning in most cases. The correct function of the sensor cannot
easily be checked.
Always replace an exhaust backpressure sensor that is clogged
with soot.
Fig. 85:
1 Signal line with plug 2 Exhaust pressure sensor

3 Line connection
1. Disconnect the signal line (1) at the exhaust backpressure sen-

sor (2). Release the plug lock for this purpose.
2. Unscrew the line connection (3) and remove the exhaust back-
pressure sensor.
3. Check the hole of the exhaust backpressure sensor. If the hole is
clogged with soot, the exhaust backpressure sensor will need to
be replaced.
4. Refit the exhaust backpressure sensor and plug the signal line
back in place.
212 82640 2021-04-22

12 Hydraulic System
12.11.17 Replacing the main fuel filter

DANGER
There must be no naked flames when working on the
fuel system.
Do not smoke.
Do not spill fuel.
CAUTION
Risk of injury!
chapped skin.
CAUTION
fuel!
When the filter is removed, a small amount of fuel is also
drained.
Collect the fuel that escapes and dispose of it in an
environmentally sound manner.
NOTE
Risk of damage to the injection system by dirt particles.
Dirt particles can damage the injection system.
Pay attention to cleanliness in order that no dirt enters the fuel
line.
Only install the fuel filter in dry condition and do not pre-fill it, to
avoid any ingress of dirt.
Requirements:
82640 2021-04-22 213

12 Hydraulic System
1. Shut off the fuel lines at the filter housing.
2. Place a collecting container under the filter to catch any fuel that
escapes.
3. Undo the drain screw and drain fuel.
Dispose of drained fuel in an environmentally friendly manner and in

accordance with the legal regulations valid at the operating location.
4. Push on the strap wrench and unscrew the fuel filter anti-clock-
wise.
214 82640 2021-04-22

12 Hydraulic System
5. Lubricate the seal of the new fuel filter slightly.
6. Fit the fuel filter and tighten it by hand.

7. Enable the fuel supply line.

3 Rubber ball
8. Bleed the injection system using the manual fuel pump:

fuel that escapes.
twice.
82640 2021-04-22 215

12 Hydraulic System
9. Carry out a test run. In doing so, check the fuel filter and lines for
leak-tightness. If necessary, re-tighten them by hand.
12.11.18 Replacing the sealing rings in the belt tensioner or the complete belt ten-
sioner
NOTE
Risk of damage due to incorrectly performed maintenance!
Only trained and qualified personnel may replace the sealing
rings in the belt tensioner or the complete belt tensioner.
12.11.19 Replacing the poly-V-belt and checking the shut-off device function
NOTE
Risk of damage!
Check general functioning of shut-off device. The shut-off pin
must protrude due to spring force, otherwise the automatic shut-
off function will not work in the event of a torn belt.
In the case of broken or bent running grooves, the damaged belt
pulley should always be replaced.
216 82640 2021-04-22

12 Hydraulic System
Fig. 87: Removing the poly V-belt
1 Cylinder screw 2 Belt pulley

3 Idler
1. Remove the poly V-belt:

1.1. Unscrew one cylinder screw (1) from the belt pulley (3).
1.2. Push the idler (2) back and lock it using the cylinder screw
(1).
1.3. Unscrew the belt pulley (3).
1.4. Check the belt pulley (3) for broken or bent running
grooves.
1.5. Remove the poly V-belt.
82640 2021-04-22 217

12 Hydraulic System
Fig. 88: Shut-off device of belt monitoring unit
1 Angle lever 2 Shut-off pin

3 Idler
2. Check functioning of shut-off device of the belt monitoring unit.

To do this, release the piston with idler (3) by removing the cylin-
der screw.
The piston with idler (3) is pushed out of the housing by spring
force. The angle lever (1) turns down, releasing the shut-off
pin (2). The shut-off pin (2) must protrude due to spring force,
otherwise the automatic shut-off function will not work in the
event of a torn belt.
If there is no reaction, please contact the next HATZ service station.
218 82640 2021-04-22

12 Hydraulic System
Fig. 89: Putting on the poly-V-belt
1 Shut-off pin 2 Housing

3 Idler
3. Push in the shut-off pin (1).

4. Push the piston with idler (3) into the housing (2) and lock it us-
ing the cylinder screw.
5. Fit the poly-V-belt in a centred position on the belt pulley of the

fan wheel, fit the idler (3) and the belt pulley at the bottom.
6. Centre the belt pulley. To do this, fasten the belt pulley slightly
with a cylinder screw, without fully fitting the pulley on the cen-
tring mechanism.
82640 2021-04-22 219

12 Hydraulic System
7. Insert a ratchet or 1/2" T-piece with the required extension into

the square opening.
8. Turn the belt pulley, until another cylinder screw can be fitted.
9. Insert and tighten the remaining cylinder screws.
12.11.20 Cleaning the EGR valve, the EGR housing and the intake area
NOTE
Risk of damage due to incorrect cleaning.
Only trained and qualified personnel may clean the EGR valve,
the EGR housing and the intake area.
12.11.21 Regenerating the diesel particle filter

The engine has an automatic regeneration process for cleaning the
diesel particle filter (DPF). The diesel particle filter filters soot particles
out of the exhaust gas. During regular regeneration, the accumulated
soot particles are burned at high temperatures.
The regeneration process starts automatically and takes about 15 mi-
nutes. It can be suppressed in special situations using a switch on the
instrument panel (see operating instructions for the superstructure in
section "Emergency operation (optional)" under "Suppressing the re-
generation of the diesel particle filter").
220 82640 2021-04-22

12 Hydraulic System
DANGER
Risk of fire due to hot exhaust system!
The exhaust system and in particular the diesel particle
filter can get very hot. Flammable materials can ignite on
the exhaust system, even if the engine has already been
switched off.
Keep flammable materials away from the exhaust
system.
Do not operate or position the engine in the direct
proximity of flammable materials.
NOTE
Risk of damaging the diesel particle filter!
If the regeneration of the diesel particle filter is suppressed for a
long time, a large amount of particles will build up in the filter. This
can damage or destroy the diesel particle filter.
Only suppress regeneration as required and re-activate it again
as soon as possible.
The full regeneration process of the diesel particle filter takes about
15 minutes.
If the regeneration process is interrupted (e. g. by pressing the
push-button or by switching off the engine), then its is automatically
continued after the next engine start until regeneration is complete.
1. The regeneration process starts automatically and runs during

engine operation without being noticed. The "DPF regeneration
active" display lights up.
2. If the "Regeneration of the diesel particle filter not possible" dis-

play lights up, the exhaust gas temperature is too low. The re-
generation process cannot be started. Increase the engine load
in such a case.
How to increase the engine load depends on the respective use of

the engine. Do not reduce the engine load during the regeneration
process.
82640 2021-04-22 221

12 Hydraulic System
12.11.22 Changing the diesel particle filter

CAUTION
Risk of burns!
During the regeneration process, the diesel particle filter
and the exhaust system get very hot. There is a risk of
burns during work on the hot exhaust system.
Allow the diesel particle filter and the exhaust system
to cool down.
NOTE
Risk of damage to the diesel particle filter due to incorrect
cleaning.
Do not spray-wash the filter fabric of the diesel particle filter with
a water jet or high-pressure jet.
Do not use petrol or chemical cleaning agents.
Do not burn the filter fabric of the diesel particle filter free.
The diesel particle filter must be reconditioned / replaced if the indica-

tor light for a "fault in the exhaust gas aftertreatment system" flashes
twice for a lengthy period. For more information, refer to the operating
instructions for the superstructure in section "Emergency operation
(optional)" under "Faults in the exhaust gas aftertreatment system".
Reconditioning of the diesel particle filter must be carried out by a

specialised company. To ensure downtimes are as short as possi-
ble, we recommend the "Hatz EasyClean" replacement program.
222 82640 2021-04-22

12 Hydraulic System
Fig. 90: Diesel particle filter - overview
1 Diesel particle filter 2 Differential pressure line

3 Swivel nut 4 Discharge funnel
5 V-band clamp (discharge funnel) 6 Retaining foot clamp
7 V-band clamp (diesel particle fil- 8 Sealing cap
ter)
9 Cord seal
1. Undo the swivel nut (3) on the differential pressure line. Carefully
pull off the differential pressure line (2), while paying attention to
the sealing cap (8).
2. Release the V-band clamp (5) of the discharge funnel, and re-
move the discharge funnel (4) from the diesel particle filter.
3. Release the V-band clamp (7) of the diesel particle filter.
4. Release the retaining foot clamp (6) and take off the diesel parti-
cle filter (1).
5. Remove the cord seals (9) from the diesel particle filter.
6. Fit new cord seals on the new / reconditioned diesel particle fil-
ter.
7. Refit the diesel particle filter (1), discharge funnel (4) and differ-
ential pressure line (2) in the reverse order.
The diesel particle filter's direction of installation results from its de-
sign. Only fully tighten the retaining foot clamp (6) at the very end.
12.11.23 Resetting the maintenance interval display

When a maintenance interval is due, the maintenance interval display
flashes on the instrument panel. The following table shows the possi-
ble flashing signals and their significance.
82640 2021-04-22 223

12 Hydraulic System
Flashing signal Maintenance interval / operating hours (h)

flashing pause 250 500 1000
1 -1 x
2 -1 x
3 -1 x x
4 -1 x
5 -1 x x
6 -1 x x
7 -1 x x x
Table 8: Flashing code table for maintenance intervals
Requirements:
- The starter key is in position "0"
After completing maintenance work, reset the maintenance interval
display. The counter restarts at zero and indicates when the next
maintenance is due.
1. Press the push-button and keep it pressed.
2. Turn starter key from position "0" to position "1".
3. Let go of the push-button after waiting for at least 5 seconds, but

no longer than 10 seconds.
The maintenance interval display is now reset.
224 82640 2021-04-22

12 Hydraulic System
12.12 Fault diagnosis of hydraulic emergency unit (optional)
If fault cases listed below were processed and the fault still persists,
please contact the next HATZ service station.
Error Cause Remedy

The engine does not start or
Top up fuel (see 12.11.3 Filling
does not start immediately, but No fuel in the injection pump
the fuel tank, side 181).
can be turned using the starter
No fuel in the injection pump Operate the manual fuel pump.
Check the entire fuel supply sys-
tematically: If that does not pro-
duce results: Check the feed line
to the engine, check the prelimi-
nary fuel filter (see 12.11.10
No fuel in the injection pump Checking the preliminary fuel fil-
ter for dirt, side 195), check the
main fuel filter (see 12.11.17
Replacing the main fuel filter,
side 213), check the function of
the delivery pump
Check valve clearance and ad-
Insufficient compression: Valve just it, if necessary (see
clearance incorrect. 12.11.13 Checking and adjusting
the valve clearance, side 202).
Insufficient compression: Cylin- Contact the HATZ service sta-
der and / or piston ring wear tion.
Injection nozzle not fully func- Contact the HATZ service sta-
tional tion.
Replace the poly-V-belt (see
12.11.19 Replacing the poly-V-
Poly-V-belt torn
belt and checking the shut-off
device function, side 216).
82640 2021-04-22 225

12 Hydraulic System
Error Cause Remedy

The engine does not start at low Contact the HATZ service sta-
Preheating system defective
temperatures tion.
Check directly at the injection
pump where the fuel supply line
was disconnected whether clear,
i.e. unclouded fuel emerges. If
Fuel gelling due to insufficient
the fuel gels, either warm up the
resistance to low temperatures
engine again or drain the entire
fuel supply system. Fill up with a
temperature-resistant fuel mix-
ture.
Change the engine oil and fill up
Oil too viscous and therefore with oil of the correct viscosity
starting speed too low category (see 12.11.5 Chang-
ing the engine oil, side 185).
Check the battery, if required,
Insufficiently charged battery
contact a specialist workshop.
Disconnect the engine – if possi-
Device not decoupled ble – by decoupling it from the
device.
Irregularity in the electrical sys-
tem: Battery and / or other cable
connections incorrect, cable
Check electrical system and its
The starter is not switched on / connections loose and oxidised,
components. Contact HATZ
the engine does not turn battery defective and/or not
service station.
charged, starter defective, de-
fective relay or monitoring ele-
ments etc.
226 82640 2021-04-22

12 Hydraulic System
Error Cause Remedy

The engine is ignited, but does Disconnect the engine – if possi-
not continue to run as soon as Device not decoupled ble – by decoupling it from the
the starter is switched off device.
Replace the preliminary fuel filter
Preliminary fuel filter clogged (see 12.11.11 Changing the
preliminary fuel filter, side 195).
Replace the main fuel filter (see
Main fuel filter clogged 12.11.17 Replacing the main
fuel filter, side 213).
Check the entire fuel supply sys-
Fuel supply interrupted
tematically.
Stop signal of monitoring units
Check the engine oil level (see
in combination with the auto-
12.11.4 Checking the engine oil
matic shut-off unit (additional
level, side 182).
equipment): No oil pressure
Stop signal of monitoring units Check degree of clogging of the
in combination with the auto- air filter, clean or replace it, if
matic shut-off unit (additional necessary (See 12.11.12
equipment): Clogged air filter Servicing the dry air filter,
system side 198).
Stop signal of monitoring units
in combination with the auto-
matic shut-off unit (additional Contact HATZ service station.
equipment): Defective three-
phase alternator
The engine is automatically cut Top up fuel (see 12.11.3 Filling
Tank run empty
off during operation the fuel tank, side 181).
Replace the poly-V-belt (see
12.11.19 Replacing the poly-V-
Poly-V-belt torn
belt and checking the shut-off
device function, side 216).
Contact the HATZ service sta-
Mechanical defects
tion.
82640 2021-04-22 227

12 Hydraulic System
Error Cause Remedy

Stop signal from monitoring ele- Check the engine oil level (see
With electrical shut-off unit (ad-
ments for: oil pressure that is 12.11.4 Checking the engine oil
ditional equipment)
too low level, side 182).
Check engine for contamination
of the cooling air ducts or any
Stop signal from monitoring ele- other impairment of the cooling
ments for: engine temperature system (see 12.11.8 Cleaning
that is too high the cooling air blower, the cool-
ing fins and the oil cooler,
side 192).
Any irregularity in the electrical
system, such as loose contacts Check electrical system and its
on cable connections, defective components, contact a specialist
three-phase alternator, defec- workshop if required.
tive relay
The engine is losing power and Top up fuel (see 12.11.3 Filling
Tank run empty
speed the fuel tank, side 181).
Ensure sufficient ventilation of
Tank ventilation insufficient
the tank.
Check line screw joints for leak-
Line connections not tight
tightness.
Check degree of clogging of the
air filter, clean or replace it, if
Clogged air filter system necessary (See 12.11.12
Servicing the dry air filter,
side 198).
Check valve clearance and ad-
just it, if necessary (see
Valve clearance not OK
12.11.13 Checking and adjusting
the valve clearance, side 202).
Injection nozzle not fully func- Contact the HATZ service sta-
tional tion.
Observe flashing signal and rec-
tify the fault in accordance with
the flashing code table (see op-
Fault in the exhaust gas after-
erating instructions for the super-
treatment system
structure in section "Emergency
operation (optional)" under
"Faults and troubleshooting").
228 82640 2021-04-22

12 Hydraulic System
Error Cause Remedy

The engine gets very hot; The
indicator light for the cylinder Too much engine oil in the en- Drain engine oil up to the upper
head temperature (additional gine marking on the dipstick.
equipment) lights up
Clean the cooling air area (see
Cooling insufficient: Contamina-
12.11.8 Cleaning the cooling air
tion in the complete cooling air
blower, the cooling fins and the
ducting area
oil cooler, side 192).
Cooling insufficient: Incomplete- Check air-ducting parts or ducts
ly closed air ducting parts or for completeness and good seal-
capsule parts ing.
82640 2021-04-22 229

12 Hydraulic System
230 82640 2021-04-22

13 Supports
13 Supports
13.1 Check lubrication of the support strut and lubricate if needed

DANGER
Risk of crushing and reeving!
When retracting and extending the support struts, ob-
serve the procedure described in the operating in-
structions of the crane chassis, section "Outriggers".
Make sure that no-one is in the hazardous area.
1. Check the lubrication of the sliding surfaces on the outrigger sup-

ports.
2. If required, lubricate the upper guide bracket and the underside

of the outrigger supports.
3. Check the lubrication of the top side of the outrigger cylinders

and grease if necessary.
On a small outrigger support area the top side is a function surface

that will corrode without lubrication.
4. Check lubrication of the slide rails on the support plates.
5. If required, lubricate the support plate slide rails on the support

plate holders with grease.
This makes pushing the support plates into operating or trans-
port position easier.
82640 2021-04-22 231

13 Supports
13.2 Lubricate the support rollers of the struts

1. Lubricate the bearing of the support rollers with a grease gun on

both sides of the support strut.
13.3 Checking the State of the Outrigger Plates and for Wear and Evenness
DANGER
Risk of tilting due to damages outrigger plates!
If you work with damaged support plates, the support
plate breaking abruptly can cause the crane to tilt.
Check the support plates regularly and replace if re-
quired.
In case of doubt, consult the crane manufacturer's customer service

team.
1. Check the support plate regularly for cracks and damage (e.g.
flaking and wear). Checking the marked zone for wear is espe-
cially important.
If cracks and damage are discovered, replace the polyamide

component of the support plate immediately.
232 82640 2021-04-22

13 Supports
2. Before using, check the flatness of the support surface.
The maximum permitted flatness deviation of the support sur-

face is 18 mm (0.71 in) for a polyamide support plate.
The maximum permitted flatness deviation of the support sur-

face is 6 mm (0.24 in) for a steel support plate.
3. If the flatness deviation is greater than permitted, the support

plate must be replaced immediately.
13.4 Check hoses

CAUTION
Leads and hoses must be laid so that they are at a
sufficient distance to hot engine parts (e.g. turbo-
charger) and so they do not chafe.
Regularly check all hose lines for damage (see 12.10 Hose assem-
13.5 Outrigger length transducer – carry out a visual check

1. Check the length transducer for damage or ice.
82640 2021-04-22 233

13 Supports
234 82640 2021-04-22

14.1 Check the lighting system

1. Determine functionality (Example: hazard light, rotaflare light, po-
sition light).
2. Rectify any damage immediately.
14.2 Lighting equipment: Replacing bulbs

Fig. 91: Lighting equipment components
1 Headlights 2 Rotaflare light

3 Spotlights 4 Interior lighting of driver's cab
with LED
5 Rear lamps 6 Indicators
7 Side marker lights with LED 8 Spotlights
9 Clearance lamp 10 Front indicator light (on the side)
1. Remove the appropriate glass and/or diffusing glass.

2. Remove the defective bulb by turning and/or pulling it from the
lamp bracket.
3. Fit new bulb and push on glass.
Avoid touching the glass of the bulb.
82640 2021-04-22 235

14.3 Batteries
14.3.1 Service battery

The crane is supplied with maintenance-free batteries. Maintenance-
free batteries require no servicing in the form of adding water, there-
fore please do not force open the sealed plug.
We recommend that you only use maintenance-free batteries.
1. Keep the batteries' surfaces clean.
2. Clean the contacts and grease with terminal lubricant.
3. Checking the Battery Cable for Sheared Points
4. Check the connecting terminals are fitted firmly.
5. Only for "maintenance-free" batteries: Check fluid level regularly
and add distilled water if necessary.
Loose connection terminals could lead to leakage current, which
could in turn lead to a discharging of the batteries, starting problems,
failures of parts in the electrical system and fires.
14.3.2 Charging batteries

Requirements:
- Ignition switched off
- All electricity consumers switched off
- Battery undamaged
- Battery not frozen
Recharge discharged battery (see operating instructions of the crane
chassis in the section "Engine" under "Battery charging device").
Alternatively, recharge using a suitable charging device.
Read the operating instructions of the charging device used before

the charging procedure.
14.3.3 Removing / fitting batteries
When replacing batteries, observe the connection diagram that is

shown by the decals in the battery case.
1. When removing, disconnect the negative terminal first, then the

positive terminal of the battery.
236 82640 2021-04-22

2. When connecting, connect the positive terminal first, then the

negative terminal on the battery.
NOTE
Damage due to incorrect connection of the batteries!
Incorrect connection of the batteries can lead to a loss of perform-
ance or destruction of the batteries or components of the electrical
system.
When removing and replacing the batteries, take care with the
connection of the individual battery terminals.
14.4 Checking the fuses

NOTE
Risk of damage due to incorrect fuse amperage!
Always replace a defective fuse (as stated on this fuse label)
with a fuse with the same amperage.
Requirements:
- Before replacing a fuse, first determine the cause of the fault and
rectify it.
The fuse numbers are indicated on the fuse boxes.
The main fuses are:

- in the fuse box behind axle 1.
Fig. 92: Position of the fuse box and overview for the main fuses
1 F1001A 2 F1001B
3 F1001C 4 F1001D
82640 2021-04-22 237

- on the bottom plate between the driver and passenger seats, be-
low the central electrical unit of the chassis.
The fuse boxes are located:
- In the central electrical unit of the chassis in the driver's cab on the
back wall between the driver and the passenger seats.
Fig. 93: Position of the fuse box in the central electrical unit of the crane chassis
- in the central electrical unit of the superstructure behind the crane

operator’s cab.
Fig. 94: Position of the fuse box in the central electrical unit of the superstructure
WARNING
ulations!

It is possible to access the fuse box from the crane chassis.
2. Open the flap of the hydraulic reservoir.

3. Open the fuse box.
238 82640 2021-04-22

Alternatively, access is also possible from the ground. To do so, at-

tach a ladder onto the frame of the hydraulic reservoir and use the
safety eyelets for the personal protective equipment.
82640 2021-04-22 239

14.4.1 Fuse overview (main fuses)

Plug-in posi-
Mounting place Value (A) Function
tion
F1001A 80 Cab electrical system, main circuit 130
Battery case, generator, circuit to bat-
F1001B 150
tery
Fuse box behind axle 1
Battery case, main fuses, superstruc-
F1001C 100
ture
F1001D 80 Cab electrical system, main circuit 230
below chassis central electri- F1002A 60 Cab electrical system, main circuit 130
cal unit F1002B 60 Cab electrical system, main circuit 230
Table 9: Fuse overview of the main fuses for the crane chassis (UW) and superstructure (OW)
14.4.2 Fuse Overview Stage V
14.4.2.1 Fuse overview (superstructure)

Location Plug-in position Value (A) Function
F101 2 ignition
F102 25 auxiliary heating
F103 10 Retract / extract cabin platform
F104 5 Central locking
F105 5 24 V CAN cockpit
CEU SS F106 10 Rotaflare lights, counterweight

XF1 F107 10 Optional Trumatic gas auxiliary heating - cab
F108 10 Hazard light
F109 5 Wiper front
F110 10 Pendant light
F111 15 Blower, air-conditioning
F112 15 Supply, Japan (option)
Table 10: Fuse overview - fitting location: central electrical unit of the superstructure (ZE OW XF1)
240 82640 2021-04-22


F201 25 Oil air cooler
F202 25 Optional additional oil cooler
F203 Reserve
F204 Reserve
F205 15 Supply A0701
CEU SS F206 15 Supply A0701

XF2 F207 15 Supply A0701
F209 5 Supply A0701
F210 5 Supply A0701
F211 5 Supply A0701
F212 5 Cab instrument lighting

F301 5 Supply DLOG MPC
F302 15 Cigarette lighter, socket, horn
F303 10 1st work light, adjustable
F304 10 2nd adjustable work light (optional)
Operating console, oil supply of main boom extension (op-
F305 5
tional)
CEU SS F306 10 Camera system (optional)
XF3
F307 10 Front wipers, washing pump
F308 15 Work lights
F309 5 Switch
F310 10 Locking and pinning unit (LPU), emergency control system
F311 2 Counterweight sensors
F312 10 Tilt cab, seat heating, radio remote control
82640 2021-04-22 241


F401 2 Supply bus sensor system CAN 1
F403 2 Supply bus sensor system CAN 2+ 3
F404 5 Auxiliary illumination
F405 15 Fan - auxiliary heating
CEU SS F406 5 Air conditioning, defrost

XF4 F407 25 Capacitor fan - air conditioning
F410 5 Air conditioning, defrost
F412 2 Supply A0702

F501 10 Supply of main boom
F502 15 Supply VBA TD2 A0701
F503 5 Flameless heating system
Supply, lowering limit switch, pressure transmitter, locking
F504 5
and pinning unit (LPU), telecylinder
F505 15 Reserve
XF5
F507 5 Supply A0702
F508 2 Hoist Limit Switches
F512 Reserve
242 82640 2021-04-22


F601 5 Supply A0702
F602 5 Supply A0702
F603 5 Supply A0702
F604 15 Supply, seat functions
CEU SS F605 2 Air conditioning control unit, auxiliary heating control unit
XF6 F606 15 Reserve
F607 5 Reserve
F608 5 Reserve
F609 5 Reserve
F610 Reserve
14.4.2.2 Fuse Overview (Chassis)

Plug-in posi-
Location Value (A) Function
tion
F101
F102 10 Power heating R4007A
Power supply, steering computer, master auxiliary steering
F103 10
circuit
F104 10 Power supply for Retarder, diagnostic interface Retarder
F105 10 Rotating beacon, superstructure
CEU-CR F106 15 ABS trailer socket

XF1 F107 10 Rotaflare light
F108 20 Power supply, ABS controller
F109 10 Power supply control A0622 VBATP
F110 15 Power supply control A0622 VBATD1
Power supply control ZF Traxon transmission control unit
F111 30
(ECU)
F112 Reserve
Table 16: Fuse overview of the central electrical unit of the chassis (ZE UW XF1)
82640 2021-04-22 243

Plug-in posi-
tion
F201 15 Operating unit, control unit, heating and air conditioning
F202 10 Voltage converter 24 V / 12 V, radio, sockets
F203 10 Sockets
F204 10 Power heating R4007B
Power supply, ZF E-module, transmission ECU, driving
F205 10
switch transmission diagnostics, transmission interface
CEU-CR F206 15 Power supply, auxiliary heating
XF2
F207 10 Steering computer, slave main steering circuit
F208 10 Power supply control Multic II
F209 10 Power supply control A0623 VBA TP
F211 Reserve
F212 Reserve
Plug-in posi-
tion
Diagnostics plug, battery isolating switch, tyre pressure moni-
F301 5
tor, immobiliser system, ignition switch
F302 20 Power supply, control unit, electrical engine control (EMS)
F303 20 Power supply, control unit, electrical engine control (EMS)
F304 10 Cab lighting, ambient light, door opener outside, lock / release
F305 5 Lighting system
CEU-CR F306 5 Brake light, trailer

XF3 F307 Reserve
F308 Reserve
Speedometer, datalogger, central locking, auxiliary heating
F309 10
radio receiver, battery isolating switch
F311 15 Power supply control A0621 VAB TD1
F312 Reserve
244 82640 2021-04-22

Plug-in Value
Location Function
position (A)
F401 10 Window opener, right
F402 10 Window opener, left
Outrigger control box, ACTIA programming plug, support pressure
F403 5 measurement, diagnostics plug CAN open, length transducer sup-
ports
Parking brake pressure transmitter, brake system pressure trans-
mitter, diagnostics plug ABS, OBD (On Board Diagnostics) diag-
F404 5
nostics plug, unloading limitation lighting equipment, return line fil-
ter steering circuit, water in fuel sensor, length transmitter level
F405 15 Washing pump, wiper, horn
Heating system fan, operating unit, control unit, heating and air
CEU-CR F406 5 conditioning, seat heating, additional lighting, rotaflare light, fog
XF4 light, blinker, lighting equipment, horn
F407 5 Datalogger, speedometer
Control independent rear axle steering (IRAS), mirror adjustment,
F408 5
mirror heater
F409 Reserve
Emergency operation switch, hydraulic power pack, starting aid
button, Longitudinal differential lock preparation, transverse differ-
F410 5
ential lock, road travel gear, terrain driving, level adjustment, block
spring accumulator
F411 Reserve
F412 Reserve
82640 2021-04-22 245

Plug-in posi-
tion
F501 10
circuit
F502 20 Crane ABS control unit (ECU), ABS trailer, ABS warning light
F503 10 Retarder control unit (ECU)
ZF E-module, transmission control unit (ECU), transmission
F504 10
driving switch, display diagnostics
F505 10 Steering computer power supply, slave main steering circuit
CEU-CR F506 10 Ignition motor control unit (ECU) ACM2 + MCM2
XF5
F507 20 Engine power supply, control unit (ECU) SCR
Ignition motor, control unit (ECU) CPC4, engine / Retarder
F508 10
brake
F509 10 ABS trailer socket
F510 Reserve
F511 Reserve
F512 Reserve

CEU-CR F606 15 Power supply control A0621 VBATD7

XF6 F607 15 Power supply control A0621 VBATF1
F608 15 Power supply control A0621 VBATF2
F611 15 Power supply control A0624 + VBAT
F612 15 Power supply control A0624 + VAMS
246 82640 2021-04-22



F711 15 Power supply control A0625 +VBAT


F812 Reserve
82640 2021-04-22 247

Plug-in posi-
tion
F901 5
circuit
Operating unit, control unit, heating system and air condi-
F902 2
tioning
F903 2 Air conditioning, optional auxiliary fan, Scania engine
F904 Reserve
F905 10 Steering computer power supply, slave main steering circuit
CEU-CR F906 10 Air dryer
XF9
F907 10
circuit
F908 Reserve
F909 Reserve
F910 Reserve
F911 Reserve
F912 Reserve

Power supply, control unit (ECU), Scania VGT_SCR en-
F1001 20
gine
F1002 20 Power supply, control unit (ECU), Scania SCR engine
F1003 Reserve
F1004 Reserve
F1005 Reserve
CEU-CR F1006 Reserve
XF10
F1007 Reserve
F1008 Reserve
F1009 Reserve
F1010 Reserve
F1011 Reserve
F1012 Reserve
248 82640 2021-04-22

14.4.3 Fuse overview EM3a / EM4 / Tier4f
14.4.3.1 Fuse overview (superstructure)

F101 2 ignition
F102 25 auxiliary heating
F103 10 Retract / extract cabin platform
F104 5 Central locking
F105 5 24 V CAN cockpit
CEU SS F106 10 Rotaflare lights, counterweight

XF1 F107 10 Optional Trumatic gas auxiliary heating - cab
F108 10 Hazard light
F109 5 Wiper front
F110 10 Pendant light
F111 15 Blower, air-conditioning
F112 15 Supply, Japan (option)

F201 25 Oil air cooler
F202 25 Optional additional oil cooler
F203 15 Evaporator fan - auxiliary air conditioning
F204 25 Capacitor fan - auxiliary air conditioning

XF2 F207 15 Supply A0701
F209 5 Supply A0701
F210 5 Supply A0701
F211 5 Supply A0701
F212 5 Cab instrument lighting
82640 2021-04-22 249


F301 5 Supply DLOG
F302 15 Cigarette lighter, socket, horn
F303 10 1st spot light (main boom), adjustable
F304 10 2nd work light (main boom), adjustable (optional)
Operating console, oil supply of main boom extension (op-
F305 5
tional)
CEU SS F306 10 Camera system - hoists (optional)
XF3
F307 10 Front wipers, washing pump
F308 15 Work lights
F309 5 Switch
F310 10 Emergency operation, locking and pinning unit (LPU)
F311 2 Counterweight sensors
F312 10 Tilt cab, seat heating, radio remote control

F403 2 Supply bus sensor system CAN 2+ 3
F404 5 Outrigger lighting
F405 15 Fan - auxiliary heating
CEU SS F406 5 Air conditioning, defrost flap

XF4 F407 25 Capacitor fan - air conditioning
F410 5 Air conditioning, defrost flap
F412 2 Supply A0702
250 82640 2021-04-22


F501 10 Supply of main boom
F502 15 Supply VBA TD2 A0701
F503 5 Flameless heating system
Supply, lowering limit switch, pressure transmitter, locking
F504 5
and pinning unit (LPU), telecylinder
F505 15 Reserve
XF5
F507 5 Supply A0702
F508 2 Hoist Limit Switches
F512 Reserve

F601 5 Supply A0702
F602 5 Supply A0702
F603 5 Supply A0702
F604 15 Supply, seat functions
F605 2 Air conditioning control unit, auxiliary heating control unit
CEU SS
F606 15 Reserve
XF6
F607 5 Reserve
F608 5 Reserve
F609 5 Reserve
F610 - Reserve
F611 - Reserve
82640 2021-04-22 251

14.4.3.2 Fuse Overview (Chassis)

Plug-in posi-
tion
F101 - -
F102 10 Line heating R4007A
F103 10
circuit
F104 10 Power supply for Retarder, diagnostic interface Retarder
F105 10 Rotating beacon, superstructure
CEU-CR F106 15 ABS trailer socket
XF1
F107 10 Rotaflare light
F108 20 Power supply, ABS controller
F109 10 Power supply control A0622 VBATP
F111 30 Power supply control ZF Traxon transmission (ECU)
F112 25 Capacitor fan - auxiliary air conditioning
Plug-in posi-
tion
Operating unit, control unit, heating system and air condition-
F201 15
ing
F202 10 Voltage converter 24 V / 12 V, radio, sockets
F203 10 Sockets
F204 10 Line heating R4007B
CEU-CR Power supply, ZF E-module, transmission ECU, driving switch

F205 10
XF2 transmission diagnostics, transmission interface
F206 15 Power supply, auxiliary heating
F207 10 Steering computer, slave main steering circuit
252 82640 2021-04-22

Plug-in po-
sition
Diagnostics plug, battery isolating switch, tyre pressure moni-
F301 5
tor, immobiliser system, ignition switch
Power supply, control unit, electrical engine control (EMS)
F302 20
Scania
Power supply, control unit, electrical engine control (EMS)
F303 20
Scania
F304 10 Cab lighting, ambient light, door opener outside, lock / release
CEU-CR F305 5 Lighting system
XF3
F306 5 Brake light, trailer
F307 20 Heating system for preliminary fuel filter
F308 - Reserve
Speedometer, datalogger, central locking, auxiliary heating ra-
F309 10
dio receiver, battery isolating switch
F311 15 Power supply control A0621 VAB TD1
82640 2021-04-22 253

Plug-in Value
Location Function
position (A)
F401 10 Window opener, right
F402 10 Window opener, left
Outrigger control box, ACTIA programming plug, support pressure
F403 5 measurement, diagnostics plug CAN open, length transducer sup-
ports
Parking brake pressure transmitter, brake system pressure trans-
mitter, diagnostics plug ABS, OBD (On Board Diagnostics) diag-
F404 5
nostics plug, unloading limitation lighting equipment, return line fil-
ter steering circuit, water in fuel sensor, length transmitter level
F405 15 Washing pump, wiper, horn
CEU-CR
XF4 Heating system fan, operating unit, control unit, heating and air
F406 5 conditioning, seat heating, additional lighting, rotaflare light, fog
light, blinker, lighting equipment, horn
F407 5 Datalogger, speedometer
Control independent rear axle steering (IRAS), mirror adjustment,
F408 5
mirror heater
F409 - Reserve
Emergency operation switch, hydraulic power pack, starting aid
button, Longitudinal differential lock preparation, transverse differ-
F410 5
ential lock, road travel gear, terrain driving, level adjustment, block
spring accumulator
Plug-in po-
sition
Power supply, steering computer, master auxiliary steering cir-
F501 10
cuit
F502 20 Crane ABS control unit (ECU), ABS trailer, ABS warning light
F503 10 Retarder control unit (ECU)
ZF E-module, transmission control unit (ECU), transmission
F504 10
driving switch, display diagnostics
CEU-CR
XF5 F505 10 Steering computer power supply, slave main steering circuit
F506 10 Ignition motor control unit (ECU) ACM2 + MCM2
F507 20 Power supply, control unit (ECU), Scania engine SCR
Ignition motor, control unit (ECU) CPC4, engine / Retarder
F508 10
brake
F509 10 ABS trailer socket
254 82640 2021-04-22



F611 15 Power supply control A0624 + VBAT


F711 15 Power supply control A0625 +VBAT
82640 2021-04-22 255


CEU-CR
XF8
Plug-in posi-
tion
F901 5
circuit
Operating unit, control unit, heating system and air condition-
F902 2
ing
F903 2 Air conditioning, optional auxiliary fan, Scania engine
F904 - Reserve
CEU-CR
XF9 F905 10 Steering computer power supply, slave main steering circuit
F906 10 Air dryer
F907 10
circuit
F908 - -
F909 15 Evaporator fan - auxiliary air conditioning
256 82640 2021-04-22


Power supply, control unit (ECU), Scania VGT_SCR en-
F1001 20
gine
F1002 20 Power supply, control unit (ECU), Scania SCR engine
F1003 - -
F1004 - -
F1005 2 Reserve
CEU-CR F1006 5 Reserve
XF10
F1007 10 Reserve
F1008 15 Reserve
F1009 20 Reserve
F1010 25 Reserve
F1011 10 Reserve
F1012 15 Reserve
82640 2021-04-22 257

14.5 Service the slip rings

The work listed below must be carried out on the existing slip rings
(e. g. on the spring cable drum of the main boom, hoist(s), rotary
transmission).
14.5.1 Servicing the slip rings: Housing

Requirements:
- Housing cover is unscrewed
1. All screws and nuts must be checked for a firm fit.
2. Check all rubber seals and PG screw connections for leak-tight-
ness and that they are not damaged, replace if required.
14.5.2 Servicing the slip rings: Slip rings

Requirements:
1. The entire slip ring including the brush holder and insulation ma-
terial must be dry and free of dust and grease.
2. Carefully remove any grit from the carbon contacts.
3. Rub down oxidised points of the treads with a sanding cloth.
4. Check that the connecting cable is fitted firmly to the ring and to
the brush holders, tighten screws if required.
14.5.3 Servicing the slip rings: Brush Holder
NOTE
Danger due to greasing and lubricating with oil!
Under no circumstances may the brush holder's joints and the
ring surface be lubricated or oiled.
Requirements:
1. Check the pressing force of the brush holder's joint arms by rais-
ing them.
Replace sluggish joint arms as well as ones with too little
pressing force .
2. Checked whether all brush holders are aligned central to the slip
rings.
258 82640 2021-04-22

14.5.4 Servicing the slip rings: Carbon Contacts
NOTE
Carbon contacts replacement!
If new carbon contacts required, as a rule both brush holder car-
bons should be exchanged.
Use carbon contacts of the same make.
Requirements:
1. Check the carbon contacts.
The carbon contacts may only be used up to a maximum of
1/3 of their original length.
Carbon contacts that have been used a great deal and car-
bons with fire marks must be replaced in good time.
14.6 Check the electrical system

WARNING
Risk of accidents!
Switch the crane off immediately if there are faults in
the electric power supply.
Preventative measures against cable fires

Cable fires in electric components and systems do not occur due to
technical faults but due to carelessness or manipulation of the com-
ponents or the circuit.
Electric currents can only be detected by the effects. One is the

heat effect.
Usually, each lead with currents only heats up minimally. Prohibitively

high currents may cause high temperatures and fires. In order to pre-
vent this, fuses have been fitted in the individual circuits. These fuses
interrupt the electric current flow if it rises above the maximum permit-
ted value.
82640 2021-04-22 259

DANGER
Danger if fuses are too large!
Fuses protect the cables of the electric equipment if
there is a short circuit.
Never bridge fuses, not even for a short period of
time.
Never use larger fuses (with a higher Ampere value).
Faulty fuses are one of the main reasons for cable fires. Other causes
could be:
- prohibited or defective cables or cable connectors (insufficient ca-
ble cross sections)
- prohibited or defective consumers or operating elements (relays,
engines, switches, lamps, etc.),
- connecting additional consumers to a fuse (cable and fuse over-
loaded),
- installation of a larger-sized or differently constructed battery (fit-
ting measurements of the battery box are exceeded, risk of a short
circuit due to ground contact at the +-pole),
- penetration of moisture into components of the electric equipment
after cleaning with water or a steam jet,
- bad state of the electric equipment due to faulty maintenance and
inspections.
All these points mentioned - either individually or several points to-
gether - can cause scorching or an open cable fire. Effective protec-
tive is achieved by keeping to the preventative measures listed below.
Precautionary measures :
DANGER
Danger due to working on the electric systems!
Only electric specialists or trained persons under the
supervision and guidance of an electric specialist
may work on electric systems or operating equipment
and only in accordance with the electronic technical
regulations.
1. Inspect / check the crane's electrical equipment regularly.

Rectify faults such as loose connections or burned cables im-
mediately.
Look for causes of malfunctions and rectify them.
260 82640 2021-04-22

2. Adapt the inspection intervals of the electric equipment according

to the conditions of use and operation. Adhere to the mainte-
nance interval.
3. Check all electrical lines, plug connections and connecting termi-
nals for loose fastenings and damage.
Such damage is detected by oxidation on the clamps or battery ter-

minals.
WARNING
Danger due to fitting of non-original parts!
If non-original parts are used, it is very difficult to foresee
the effect this has on the electric equipment. This can
cause malfunctions in the individual circuit.
When replacing parts during repairs, only use original
spare parts.
4. Only original spare parts and original fuses with the specified
amperage must be used (see the "Spare parts catalogue" or
"Electrical circuit diagram").
5. Have modifications and / or additions and conversions to the
electric equipment authorised by the manufacturer in advance.
Components Check for:

Generator,
Generator
Starter,
Jump Start,
Diesel engine - State of fittings
lighting, - Function, insulation
leads, - Protection against direct contact of active parts
collectors,
slip rings, - Protection for indirect contact of active parts
heating, switches,
relays,
Fuses
Batteries
82640 2021-04-22 261

262 82640 2021-04-22

15 Fuel system
15 Fuel system
15.1 Fuel system diagram, exhaust emission class EM4 / Tier4f, Stage V
Fig. 95: Fuel system - position of the components EM4 / Tier4f, Stage V
1 Additional tank (optional) 2 Filler necks for diesel fuel

3 Fuel tank
Fig. 96: Fuel system diagram, exhaust emission standard EM4/Tier4f, Stage V
1 Filler necks for diesel fuel 2 Fuel tank

3 Feed line - engine 4 Scania Motor, incl. fuel filter
5 Return line - engine 6 Additional tank (optional)
82640 2021-04-22 263

15 Fuel system
15.2 Diagram of the fuel system, exhaust emission standard EM3a
Fig. 97: Diagram of the fuel system EM3a
1 Filler neck for diesel fuel 2 Fuel Tank

4 Return line engine 5 Scania Motor, incl. fuel filter
6 Feed line engine 7 Additional tank (optional)
10 Preliminary fuel filter with man-
ual fuel pump and water separa-
tor
264 82640 2021-04-22

15 Fuel system
Fig. 98: Fuel system - position of the components, exhaust emission standard
EM3a
1 Preliminary fuel filter with man- 2 Fuel Tank

ual fuel pump and water separa-
tor
3 Filler neck for diesel fuel 4 Additional tank (optional)
Depending on the design, the preliminary fuel filter is fitted near the
engine or between axles 3 and 4.
15.3 Filling up
15.3.1 Safety instructions on filling up
WARNING
Risk of explosions!
Switch off the diesel engine.
Leave the crane operator’s cab unoccupied.
Switch off the auxiliary heating.
Naked flame, easily flammable materials, work caus-
ing fire or flying sparks must be kept at a safe dis-
tance when filling up.
Do not smoke.
82640 2021-04-22 265

15 Fuel system
CAUTION
Harmful materials!
Contact with the skin or breathing in can cause health
problems.
Wear protective equipment.
Only fill up where there is good ventilation.
Do not breathe in any fumes.
NOTE
Damage to the catalytic converter by diesel fuel with high sul-
phur content.
Only fill up with diesel fuel permitted for the respective emis-
sions class (see section "Consumables and capacities" under
"Diesel fuel").
NOTE
Serious engine damage due to filling up with prohibited con-
sumables.
Only fill up with permitted diesel fuel (see section "Consumables
and capacities" under "Diesel fuel").
Under no circumstances may the following be used:
- no biodiesel (FAME)
- no heating oil
- no marine diesel
- no aircraft turbine diesel
- no addition of petrol or petroleum
- no other additives
NOTE
Serious damage to the engine due to filling up with AdBlue® /
DEF.
Do not fill the fuel tank with AdBlue® / DEF under any circum-
stances.
Wipe up any spilt diesel fuel!
266 82640 2021-04-22

15 Fuel system
15.3.2 Fuel Tank

Fig. 99: Fuel gauge in the instrument panel
1. Check the tank contents in the fuel gauge (42) in the instrument
panel.
82640 2021-04-22 267

15 Fuel system
Fig. 100: Position of the fuel tank
1 Filler neck for diesel fuel 2 Fuel Tank

7 Additional tank (optional)
2. If required, fill the fuel tank (2) after removing the filler cap of the
filler necks (1).
The procedure for filling the AdBlue® / DEF tank can be found in
these operating instructions in the following section: 18.2.2 18.3.2
Filling up AdBlue® / DEF Filling up AdBlue® / DEF, side 299.
15.3.3 Filling the additional tank

1. The additional tank (7, Fig. 100, side 268) is filled using the
same filler necks (1, Fig. 100, side 268) as the main tank.
Drainage of the contents of the additional tank into the main tank is
controlled automatically.
15.4 Fuel tank – draining water and deposits

Requirements:
This should only be done when the fuel tank is almost empty.
268 82640 2021-04-22

15 Fuel system
Fig. 101: Fuel tank (Z 81 854)
1 Fuel tank 1.2 Drain bolt
1. Loosen the drain screw (1.2).

2. Drain water and deposits as well as the remaining fuel (at least
1 l / 0.26 gal fuel).
3. Clean the seal and screw drain screw (1.2) back in place.
4. Fill up (see section "Filling up").
15.5 Fuel tank – Check the air bleed filter

Fig. 102: Air bleed filter on the fuel tank
1. Check the air bleed filter for contamination; replace when neces-
sary, or every two years at least.
82640 2021-04-22 269

15 Fuel system
15.6 Check the fuel system

CAUTION
engine components (e. g. turbocharger) and must be
1. In addition to visual checks (e.g. when checking the oil level), the
fuel system in the engine compartment must be regularly inspec-
ted.
- All system fittings must be free of leaks and sufficiently tight-
ened.
- With reusable fittings, the hose on the connection to the hose
nipple must be a tight fit. If in doubt, secure the hose addition-
ally with a hose clip or replace the hose completely.
The preliminary fuel filter is fitted in the fuel supply system of the en-
gine EM3a.
WARNING
Risk of fire due to easily flammable fuels.
Avoid fire, naked flame, smoking and spark formation
when handling fuels.
Dispose of used filter elements, seals and fuel remnants in accord-

ance with the regulations valid at the location of operation and in an
environmentally-friendly manner.
15.7.1 Preliminary fuel filter - emptying the water collection container

Water is heavier than diesel fuel, it collects as a differently coloured
fluid at the bottom of the water collection container (7). The water col-
lection container must be emptied before any contamination can
reach the bottom of the filter element (5). Drain the water collected in
the water collection container daily.
270 82640 2021-04-22

15 Fuel system
Fig. 103: Preliminary fuel filter components (Z 81 855)
1 Filter head 2 Vent screw

3 Manual fuel pump 4 Filter seal ring
5 Filter element 6 O-ring
7 Water collection container 8 Drain valve
Requirements:
DANGER
switched off.
locked.
1. Open drain valve (8) and vent screw (2).

2. Collect the water-fuel mixture from the filter element using the
collection container.
82640 2021-04-22 271

15 Fuel system
3. Close the drain valve (8) again with the specified torque. Tighten-
ing torque 1.6 Nm ± 0.3 Nm (1.18 lbf ft ± 0.2 lbf ft).
4. Fill the preliminary filter using the manual fuel pump (3).
5. Close vent screw (2).
15.7.2 Preliminary fuel filter - change the filter element

Requirements:
Change the filter element of the preliminary fuel filter only when the
fuel tank has been either fully or partially drained.
The intervals for changing the filter element depend on the contami-
nation level of the fuel. Clogging of the preliminary fuel filter results in
a reduced quantity of fuel being fed through, which in turn causes
performance loss and start-up difficulties. Replace the filter element if
there is a noticeable loss in output.
We recommend always having a replacement filter element along as

even one tank filling of heavily contaminated fuel can clog the pre-
liminary fuel filter.
272 82640 2021-04-22

15 Fuel system
DANGER
switched off.
locked.
Fig. 104: Preliminary fuel filter components
1 Filter head 2 Vent screw

3 Manual fuel pump 4 Filter seal ring
5 Filter element 6 O-ring
7 Water collection container 8 Drain valve
1. Open the drain valve (8) on the preliminary fuel filter and drain
some fuel into the collecting container.
2. Twist the filter element (5) with the water collection container (7)
off the filter head (1).
3. Unscrew water collection container (7) from the filter housing and
clean it. Replace if required.
4. Remove the filter element (5) and clean sealing surfaces of the
O-ring (6). Replace if required.
5. Coat O-ring (6) and filter sealing ring (4) with some fresh fuel or a
little grease.
82640 2021-04-22 273

15 Fuel system
6. Screw the water collection container (7) onto the new filter ele-
ment (5) and then screw both onto the filter head (1) hand-tight.
NOTE
Damage due to tools being used when screwing in place!
Do not use any tools to screw it on.
7. Activate the manual fuel pump (3) with vent screw (2) opened
until fuel flows out of the vent screw.
8. Close the vent screw (2), start the engine and check for leaks.
9. If required, make corrections with the engine switched off.
15.8 Fuel filter in the diesel engine

Fig. 105: Position of the fuel filter
Requirements:
274 82640 2021-04-22

15 Fuel system
DANGER
switched off.
locked.
For instructions and specifications on servicing the fuel filter, please

consult the operating instructions of the engine manufacturer.
The operating instructions from the engine manufacturer is included
in the section "Various" in these operating instructions.
1. Let the fuel drain into a suitable collection container.
Dispose of fuel in an environmentally friendly manner and in accord-

ance with the legal regulations valid at the operating location.
82640 2021-04-22 275

15 Fuel system
276 82640 2021-04-22

16 Cooling system
16 Cooling system
16.1 Cooling system – overview
Fig. 106: Diagram of cooling system exhaust emission class Stage V
1 Equalising tank 2 External thermostat

3 Retarder 4 Drive gearbox
5 Diesel engine 6 Water pump with thermostat
7 Heating control valve 8 Vehicle heating
9 Water cooler
Fig. 107: Diagram of cooling system EM3a, EM4 / Tier4f
1 Equalising tank 2 External thermostat

3 Retarder 4 Drive gearbox
5 Diesel engine 6 Water pump with thermostat
7 Vehicle heating 8 Water cooler
82640 2021-04-22 277

16 Cooling system
Fig. 108: Water cooler
1 Equalising tank 1.1 Expansion tank cover lid

8 Water cooler 8.1 Drain plug - coolant
9 Charge cooler
Cooling system for engines in accordance with Exhaust gas

emissions class Stage V
Fig. 109: Position of the cooling system (Exhaust gas emissions class Stage V)
1 Equalising tank 2 Drive gearbox

3 Diesel engine 4 Water cooler
278 82640 2021-04-22

16 Cooling system

emissions class EM4 / Tier4f
Fig. 110: Position of the cooling system (Exhaust gas emissions class EM4 / Tier
4f)
1 Equalising tank 4 Transmission

5 Diesel engine

emissions class EM3a
Fig. 111: Position of the cooling system (Exhaust gas emissions class EM3a)
1 Equalising tank 4 Transmission

5 Diesel engine 8 Water cooler
82640 2021-04-22 279

16 Cooling system
16.2 Cooling System - Carry out a Visual Inspection

1. The following components must be checked to ensure they are
fitted firmly and for damage and leaks:
- Radiator, expansion tank
- Hoses
- Retaining clips
- Plugs
- Sensors and cables
16.3 Cleaning the cooling system

WARNING
Risk of burning and scalding!
Before carrying out the described work on the cooling
system, observe a cooling down period of 60 mi-
nutes.
1. Using gentle pressure so as not to damage the cooler fins, blow

out the cooler with compressed air against the air flow - or do the
same with a water spray - until the cooler fins are completely free
of foreign matter (dust, insects, etc.).
If the coolant rises to unusually high temperatures at normal ambient

temperatures, although the cooler exterior has been cleaned and
there are no other malfunctions, the cooling system interior may be
contaminated.
In this case:
2. Clean the cooling system thoroughly and while doing so de-
grease, descale and derust the entire cooling circuit.
For details on this, please refer to the manufacturer's instructions in

the section "Various".
280 82640 2021-04-22

16 Cooling system
16.4 Checking the coolant level, topping up if required

Consumables: 2.5 Coolant, side 32
DANGER
switched off.
locked.
Requirements:
- Main boom erected
- Engine cooled down (< 40 °C / +104 °F)
Fig. 112: Access to coolant container (schematic diagram)
There is a finger hole in the cover (arrow) through which the coolant
container can be accessed.
82640 2021-04-22 281

16 Cooling system
Fig. 113: Checking the coolant level
1 Expansion tanks 1.1 Cover lid
1. As a precaution, turn the cover lid (1.1) on the expansion tank (1)
up to the 1st stop and release any overpressure.
WARNING
Risk of burning due to squirting coolant!
The cooling system is under overpressure.
Only open the cover of the engine cooling system
when it has cooled down.
Wear protective clothing and goggles.
2. Continue to turn cover lid (1.1) up to the 2nd stop, remove the
cover lid.
The cooling system is filled correctly when the coolant, de-
pending on the design, is level with the rim of the filler neck or
with the marker on the filler neck.
3. If required, top up coolant (see the operating instructions of the

engine manufacturer in the part "Various" of these operating in-
structions).
Before the onset of winter, check the coolant for antifreeze. See op-
erating instructions of the engine manufacturer in section "Various".
282 82640 2021-04-22

16 Cooling system
16.5 Changing the Cooling Fluid

The coolant must be changed as soon as required, for example, in

the case of repair. The coolant must, however, be changed at least
at the intervals indicated in the lubrication and maintenance sched-
ule.
DANGER
switched off.
locked.
WARNING
Risk of burning due to squirting coolant!
The cooling system is under overpressure.
Only open the cover of the engine cooling system
when it has cooled down.
NOTE
Risk of short circuiting on electric components!
Cover leads and other electrical components before draining the
coolant.
Requirements:
- Secure the crane against rolling away using chocks.
- Engine cooled down (< 40 °C / +104 °F)
82640 2021-04-22 283

16 Cooling system
Fig. 114: Checking the coolant level
1 Equalising tank 1.1 Cover lid
1. As a precaution, turn the cover lid (1.1) on the expansion tank (1)
up to the 1st stop and release any overpressure.
2. Continue to turn cover lid (1.1) up to the 2nd stop and remove it.
3. Drain the engine. To do this, open drain plug at the crankcase.
The position of the drain plugs on the engine is shown in the sup-
plied operating instructions of the engine manufacturer.
284 82640 2021-04-22

16 Cooling system
Fig. 115: Changing the Cooling Fluid
1 Equalising tank 1.1 Expansion tank cover lid

8 Water cooler 8.1 Drain plug - coolant
9 Charge cooler
4. Drain the cooler (8).

4.1. Open drain screw (8.1).
4.2. Drain the coolant into a collecting vessel.
Dispose of old coolant in an environmentally friendly manner and in

accordance with the regulations valid at the operating location.
5. When the cooling system has been drained, screw in all drain
plugs again.
82640 2021-04-22 285

16 Cooling system
NOTE
Damage to the engine due to trapped air!
When filling the cooling system make sure that you do not cre-
ate any air pockets.
6. Fill the cooling system with fresh coolant.
- Only use water that is free from scale forming minerals.

- Do not use softened water.
- Mix a corrosion antifreeze into the coolant all year round (see the
operating instructions of the engine manufacturer in the part "Var-
ious" of these operating instructions). The antifreeze does not
have any adverse effect on the refined coolant.
- Interrupt the filling several times and allow the coolant level to
settle and stabilise.
- This also enables enclosed air to escape.
- Add coolant until the expansion tank (1) is filled completely.
7. Bleed the cooling system, see section 16.6 Bleeding the Cool-
ing System, side 287.
286 82640 2021-04-22

16 Cooling system
16.6 Bleeding the Cooling System

The entire cooling system, including the heater assembly, must be
bled to ensure that no air bubbles remain following any servicing of
the system (repairs, changing the coolant).
All water fittings (clamps) must be screwed on properly and leak-tight
and must be tightened again after approx. 100 km (60 mi) driving.
Fig. 116: Checking the coolant level (Z 71 739)
1 Expansion tanks 1.1 Cover lid
1. Start the engine and let it run at idle speed for one minute with
the expansion tank (1) open.
2. Check the coolant level and, if required, switch off the engine
and top coolant up to the max. position in the expansion tank (1).
3. Start the engine again and let it run for one minute at idle speed
with the expansion tank (1) open.
4. Check the coolant level.
The cooling system is filled correctly when the coolant, de-
pending on the design, is level with the rim of the filler neck or
with the marker on the filler neck.
5. If required, switch the engine off and top up coolant.

6. Fit cover lid (1.1) on the expansion tank (1).
Observe the engine temperature during the warm-up phase. If the

operating temperature is reached, check the coolant level and top
up if necessary.
82640 2021-04-22 287

16 Cooling system
288 82640 2021-04-22

17 Intake System
17 Intake System
17.1 Intake System - Carrying out a Visual Inspection

DANGER
switched off.
locked.
Fig. 117: Position of the air filter, exhaust emission standard Fig. 118: Position of the air filter, exhaust emission standard
Stage V EM4 / Tier 4f
Fig. 119: Position of the air filter, exhaust emission standard

EM3a
82640 2021-04-22 289

17 Intake System
1. Check the following components to ensure they are fitted firmly

and for damage and leaks:
- Air filter
- Hoses
- Retaining clips
- Plug
- for the quick stop button option with shut-off flap: shut-off flap
17.2 Replace the main element of the air filter

NOTE
Damage due to starting the engine with the filter element re-
moved.
Do not start the engine if the filter element has been removed.
NOTE
Safety is put at risk with components which do not correspond
to the technical requirements.
Only use original spare parts from the crane manufacturer. See
the relevant spare parts catalogue.
Under no circumstances may elements with a metal exterior be
fitted.
As slight damage is often difficult or impossible to see, so always

use new elements in order to protect the engine.
There is no warranty for cleaned elements.
In exceptional cases, the main element can be cleaned as described
in 17.3 Cleaning the main element of the air filter, side 292.
Change the filter element as soon as:

- the filter indicator light in the driver information system in the driv-
er's cab is illuminated or
- a fault message is displayed in crane control.
290 82640 2021-04-22

17 Intake System
Requirements:
DANGER
switched off.
locked.
1. Remove the main element. To do so, unlock the tension locks

and remove the bottom part of the housing.
2. With slight rotating movements, completely pull the main element

down from the inner support tube.
3. Carefully wipe the inside of the housing with a damp cloth. When
doing so, make sure that no dust or dirt gets into the filter's clean
air side.
82640 2021-04-22 291

17 Intake System
4. Fit a new main element. To do so, proceed as described under

points 1. and 2., but in the opposite sequence.
Ensure that the dust discharge valve points downwards. A deviation

of +/− 15° is permitted.
5. Check the plastic housing and bracket for damage and cracks,
replace if required.
17.3 Cleaning the main element of the air filter
NOTE
Damage to the filter elements!
Filter elements must not be rinsed.
Do not clean filter elements by banging or hitting them.
1. Fit a tube with an end which is bent by approx. 90 onto a com-

pressed air pistol. The tube must be long enough to reach the
floor of the main element.
CAUTION
Risk of injury due to dust being stirred up!
Wear goggles and protective clothing when using
compressed air to clean the filter element.
2. Carefully blow through the main element from the inside out with
dry compressed air (maximum 5 bar / 72.5 psi) by moving the
tube in the main element up and down until there is no longer
any dust formation.
No dust may get into the main element's interior when blowing
through the element.
292 82640 2021-04-22

17 Intake System
3. Before refitting it, check the cleaned main element carefully for
damage on the paper diaphragm and on the rubber seals:
3.1. Using a suitable penlight, check each fold of the paper dia-
phragm for cracks and holes.
3.2. In order for even slight damage to be recognisable, this
check should not take place under direct sunlight, but e. g.
in a darkened room.
3.3. Filter elements with damaged folds or seals must not be
used again.
17.4 Air Filter - Checking the Preseparator (Optional)

The air filter preseparator prevents dirt from getting into the air filter
and the engine with the intake air. The contamination is discarded
through the side ejection hole.
1. If required, clean the ejection hole.
82640 2021-04-22 293

17 Intake System
294 82640 2021-04-22

18 Exhaust system
18 Exhaust system
18.1 Exhaust System – Carrying out a Visual Check

CAUTION
CAUTION
Risk of burns!
The exhaust system may still be very hot.
Wear corresponding protective clothing.
Fig. 120: Exhaust system step plate – schematic diagram
1 Step plate 2 Lock
1. Depending on the design, there is a step plate above the exhaust

system. Fold it up and secure with the lock.
82640 2021-04-22 295

18 Exhaust system
Exhaust system for engines in accordance with Exhaust gas

emissions class Stage V
Fig. 121: Visual check of the exhaust system – schematic diagram, exhaust emis-
sions class standard Stage V

emissions class EM4 / Tier 4f
sion standard EM4 / Tier 4f
296 82640 2021-04-22

18 Exhaust system

emissions class EM3a
sion standard EM3a
2. Check the exhaust system for any leaks.

- Do not lay any wires or cables in the radiant heat danger area
around the exhaust system.
82640 2021-04-22 297

18 Exhaust system
Fig. 124: SCR system diagram
1 Cooling water valve 2 Return line AdBlue® / DEF

3 Electrical interface SCR system 4 AdBlue® / DEF tank
5 Cabling between engine and SCR control unit 6 Cooling water return line from tank and pump heat-
ing
7 Engine 8 Customer interface of the SCR system
9 Temperature sensor cable 10 Electrical cable Dosing unit
11 Cooling water hose for tank and pump heating 12 Temperature sensor
13 SCR Catalytic Converter 14 NOx-sensor system with control unit
15 Evaporator with dosing unit 16 NOx-Sensor cable
17 Feed line AdBlue® / DEF
298 82640 2021-04-22

18 Exhaust system

- All components:
- SCR catalytic converter
- Diesel particle filter
- pump module
- AdBlue® / DEF tank
- Dosage apparatus
- AdBlue® / DEF injection nozzle
- Solenoid valve tank preheater SCR on the engine
- Hoses
- Retaining clips
- Plug
18.2.2 Filling up AdBlue® / DEF

Consumables: 2.8 AdBlue® / DEF, side 35
18.2.2.1 Safety instructions for handling AdBlue® / DEF
CAUTION
Risk to health by swallowing AdBlue® / DEF.
Do not swallow AdBlue® / DEF.
If AdBlue® / DEF has been swallowed, immediately
drink plenty of water and consult a doctor.
CAUTION
Risk of injury to skin and eyes!
Wear protective goggles and gloves when handling
AdBlue® / DEF.
If it comes into contact with your eyes, immediately
wash them out with plenty of water.
If the eyes are irritated, consult a doctor.
If it comes into contact with skin, immediately wash
the skin with soap and plenty of water.
If you experience pain or you feel unwell, consult a
doctor.
82640 2021-04-22 299

18 Exhaust system
NOTE
Damage due to spilling AdBlue® / DEF.
AdBlue® / DEF can affect concrete and brickwork.
AdBlue® / DEF lines to corrosion of electric and electronic compo-
nents.
Do not spill AdBlue® / DEF.
If spilt, clean the affected objects, surfaces and the affected
ground using water.
Do not pour AdBlue® / DEF into the canalisation system. AdBlue® /

DEF and AdBlue® / DEF containers must be disposed of correctly as
rubbish in accordance with regulations. Observe and comply with the
corresponding local and national regulations.
You must ensure that AdBlue® / DEF is kept completely separate
from other consumables, fuels and lubricants, and that the same con-
tainers and collecting containers are not used. Even the smallest
amounts of AdBlue® / DEF in the cooling circuit suffice to damage
thermostats and temperature sensors. Do not continue to use con-
sumables which contain AdBlue® / DEF.
When handling AdBlue® / DEF, only use clean containers which are
specifically designated for that purpose. Do not continue to use AdBl-
ue® / DEF which is contaminated.
Clean all tools which have come into contact with AdBlue® / DEF im-
mediately and thoroughly with water.
300 82640 2021-04-22

18 Exhaust system
18.2.2.2 Filling up AdBlue® / DEF

NOTE
Damage due to filling up incorrectly!
Under no circumstance must you fill the AdBlue® / DEF tank
with diesel.
Only use pure AdBlue® / DEF. Do not use AdBlue® / DEF if it
has been mixed with water or diesel. The pump modules and
AdBlue® / DEF hoses are not resistant to diesel, petrol or min-
eral oil residue.
Fig. 125: Position of the AdBlue® / DEF tank
The AdBlue® / DEF tank is located on the right-hand side of the vehi-
cle chassis between axle 3 and axle 4.
1. If required, fill the AdBlue® / DEF tank after removing the filler
cap. When filling up, ensure the highest level of cleanliness so
that no dust or dirt particles can get into the storage tank.
82640 2021-04-22 301

18 Exhaust system
2. Clean the pump nozzle after filling up. To do so, dip it into a con-
tainer with clean tap water to remove any white dried AdBlue® /
DEF deposits.
3. If drops of AdBlue® / DEF drip onto the AdBlue® / DEF tank, re-
move the resulting carbamide crystals with water and a clean
cleaning cloth.
There may not be any added cleaning agents in the rinsing water.
Adding cleaning agents could damage the emission control system.
NOTE
Damage to the pump module and dosage unit!
Cleaning agent residue can damage the pump module and the dos-
age unit.
Do not clean components under any circumstances.
Incorrect filling
If the AdBlue® / DEF tank has been filled up incorrectly, the following
parts must be replaced to prevent the pump module failing again:
- all AdBlue® / DEF hose assembly
- pump module
18.2.3 Pump module - replace the filter element

Requirements:
- AdBlue® / DEF system depressurised
CAUTION
Risk burning and scalding!
Maintain a cooling period of 60 minutes before carry-
ing out the work described.
Wear protective goggles, protective clothing and
gloves when handling AdBlue® / DEF.
Open line connections and system components plugs
slowly. Cover the disconnecting point with a cloth
when opening.
302 82640 2021-04-22

18 Exhaust system
In addition to the descriptions listed here, please find further instruc-

tions and specifications in the manufacturer's instructions of the en-
gine manufacturer in the part "Various".
Fig. 126: Position of the filter element in the AdBlue® / DEF tank
1 AdBlue® / DEF tank 2 Cover

3 Filter cover
1. Remove cover (2) from the back of the AdBlue® / DEF tank (1).
2. Place a suitable collecting vessel under the pump filter unit for
emerging AdBlue® / DEF.
82640 2021-04-22 303

18 Exhaust system
Fig. 127: Pump filter unit

3 Filter cover
4 Pump
5 Filter element
6 Antifreeze device
7 O-ring
3. Remove filter element.

3.1. Unscrew filter cover (3) and remove it together with the O-
ring(7).
3.2. Wipe the pump (4) clean.
3.3. Ensure that the antifreeze device and valve ring are fitted
correctly in the new cover.
4. Fit new filter element (5).
5. Fit new antifreeze device (6).
6. Lubricate thread with grease spray.
7. Fit new O-ring (7) in the new filter element (5).
8. Fit new filter cover (3) and tighten with 80 Nm (59 lb ft).
9. Fasten cover (2) on the back of the AdBlue® / DEF tank (1).
304 82640 2021-04-22

18 Exhaust system
18.2.4 Replacing diesel particle filters

WARNING
Danger from fine dust particles!
Wear P3-breathing device/filter mask, protective gog-
gle and protective gloves for all tasks where there is a
risk of exposure to particle filter dust. The protective
equipment must be worn from the exposure of the fil-
ter unit to the completion of the cleaning work. For
unprotected individuals, the safety distance is 3 m
(9.84 ft).
Do not eat, drink or smoke while performing the
tasks.
Remove dust from particle filters with the aid of a vac-
uum cleaner with an HEPA filter which is able to filter
out particles up to 0.3 μm in size, in order to minimise
the load.
Wash your hands carefully after performing work on
particle filters.
CAUTION
Observe a sufficient cooling period before carrying
out the work described.

Requirements:
82640 2021-04-22 305

18 Exhaust system
Fig. 128: Diesel particle filter components

1 Temperature sensor
2 Particle filter
3 differential pressure sensor
4 Bracket
1. Remove the temperature sensor (1) and disconnect the plug (ca-
ble harness on the component) of the differential pressure sen-
sor (3).
1.1. Dismantle the connections of the differential pressure sen-
sor to the particle filter (2).
1.2. Dismantle the bracket (4) with the differential pressure
sensor.
Fig. 129: End plate on the diesel particle

filter
1 V-clip outlet on the particle filter
2 V-clip end plate
3 End plate
2. Dismantling V-clips.
2.1. Dismantle the V-clip at the outlet of the particle filter (1).
2.2. Dismantle the V-clip with which the end plate (2) is fas-
tened and remove the end plate (3).
306 82640 2021-04-22

18 Exhaust system
Fig. 130: V-clips on the diesel particle fil-

ter
1 V-clip
2 Restraining strap
3. Support the particle filter with a car jack and dismantle the V-
clip (2) and tension band around the particle filter (1).
4. Replacing particle filters:
4.1. Carefully lift out the old particle filter.
4.2. Insert the new particle filter. Support the particle filter with
a car jack.
Fig. 131: V-clips on the diesel particle fil-

ter
1 V-clip
2 Restraining strap
5. Attach V-clip (2) and tension band around the particle filter (1).
82640 2021-04-22 307

18 Exhaust system
Fig. 132: End plate on the diesel particle

filter
1 V-clip outlet on the particle filter
2 V-clip end plate
3 End plate
6. Install the end plate (3).

6.1. Attach V-clip to the end plate (2).
6.2. Attach the V-clip at the outlet of the particle filter (1).
Fig. 133: Diesel particle filter components

1 Temperature sensor
2 Particle filter
3 differential pressure sensor
4 Bracket
7. Install the bracket (4) with the differential pressure sensor.

7.1. Attach the connections of the differential pressure sensor
to the particle filter (2).
7.2. Install the temperature sensor (1) and disconnect the plug
(cable harness on the component) of the differential pres-
sure sensor (3).
308 82640 2021-04-22

18 Exhaust system
18.2.5 Service SCR catalytic converter

CAUTION
Risk of burning and scalding when working on the
catalytic converter and parts connected to it!
Only start work on the exhaust gas aftertreatment
system once the catalytic converter has cooled down.
In addition to the descriptions listed here, please read the instruc-

tions and specifications on servicing the catalytic converter in the
operating instructions of the engine manufacturer. The engine oper-
ating instructions are included in the section "Various" in these oper-
ating instructions.
Fig. 134: Position of SCR catalytic converter (Exhaust gas emission class Stage
V)
The SCR catalytic converter is located on the right-hand side of the

crane chassis.
1. Check the exhaust gas pipe once a year for deposits of AdBl-
ue® / DEF. To do so, remove the exhaust pipe of the catalytic
converter at the disconnecting point:
1.1. Release connecting clamps.
1.2. Remove the exhaust pipes.
1.3. Check to see if AdBlue® / DEF deposits have formed in
the exhaust pipe. If required, rinse out the exhaust pipe
thoroughly with hot water.
Before applying the assembly paste, make sure that the exhaust
pipe slides easily and without resistance into the catalytic converter
connecting piece. The exhaust pipe must be fitted without delay
once the assembly paste has been applied.
2. Apply an approx. 5 cm (2 in) wide line of assembly paste "FIRE

GUM" to the inside of the catalytic converter connecting piece.
82640 2021-04-22 309

18 Exhaust system
3. Fit the exhaust pipes. Use new clips at the connecting points.
Fig. 135: SCR system diagram (Z 71 741)
1 Engine 2 Tank by AdBlue® / DEF and pump module

3 Cooling water valve 4 SCR catalytic converter
5 Temperature sensor 6 NOx sensor with control unit
7 Evaporator with dosing unit A Feed line AdBlue® / DEF
B Return line AdBlue® / DEF C Cooling water line for tank and pump heating
D Cooling water return line from tank and pump heat-
ing

- All components:
- SCR catalytic converter
- Pump module
- Dosage apparatus
- AdBlue® / DEF injection nozzle
- Solenoid valve tank preheater SCR on the engine
- Hoses
- Retaining clips
- Plugs
310 82640 2021-04-22

18 Exhaust system
18.3.2 Filling up AdBlue® / DEF

Consumables: 2.8 AdBlue® / DEF, side 35
18.3.2.1 Safety instructions for handling AdBlue® / DEF
CAUTION
Risk to health by swallowing AdBlue® / DEF.
Do not swallow AdBlue® / DEF.
If AdBlue® / DEF has been swallowed, immediately
drink plenty of water and consult a doctor.
CAUTION
Risk of injury to skin and eyes!
Wear protective goggles and gloves when handling
AdBlue® / DEF.
If it comes into contact with your eyes, immediately
wash them out with plenty of water.
If the eyes are irritated, consult a doctor.
If it comes into contact with skin, immediately wash
the skin with soap and plenty of water.
If you experience pain or you feel unwell, consult a
doctor.
NOTE
Damage due to spilling AdBlue® / DEF.
AdBlue® / DEF can affect concrete and brickwork.
AdBlue® / DEF lines to corrosion of electric and electronic compo-
nents.
Do not spill AdBlue® / DEF.
If spilt, clean the affected objects, surfaces and the affected
ground using water.
Do not pour AdBlue® / DEF into the canalisation system. AdBlue® /

DEF and AdBlue® / DEF containers must be disposed of correctly as
rubbish in accordance with regulations. Observe and comply with the
corresponding local and national regulations.
82640 2021-04-22 311

18 Exhaust system
You must ensure that AdBlue® / DEF is kept completely separate

from other consumables, fuels and lubricants, and that the same con-
tainers and collecting containers are not used. Even the smallest
amounts of AdBlue® / DEF in the cooling circuit suffice to damage
thermostats and temperature sensors. Do not continue to use con-
sumables which contain AdBlue® / DEF.
When handling AdBlue® / DEF, only use clean containers which are
specifically designated for that purpose. Do not continue to use AdBl-
ue® / DEF which is contaminated.
Clean all tools which have come into contact with AdBlue® / DEF im-
mediately and thoroughly with water.
18.3.2.2 Filling up AdBlue® / DEF

NOTE
Damage due to filling up incorrectly!
Under no circumstance must you fill the AdBlue® / DEF tank
with diesel.
Only use pure AdBlue® / DEF. Do not use AdBlue® / DEF if it
has been mixed with water or diesel. The pump modules and
AdBlue® / DEF hoses are not resistant to diesel, petrol or min-
eral oil residue.
Fig. 136: Position of the AdBlue® / DEF tank
The AdBlue® / DEF tank is located on the right-hand side of the vehi-
cle chassis between axle 3 and axle 4.
312 82640 2021-04-22

18 Exhaust system
1. If required, fill the AdBlue® / DEF tank after removing the filler
cap. When filling up, ensure the highest level of cleanliness so
that no dust or dirt particles can get into the storage tank.
2. Clean the pump nozzle after filling up. To do so, dip it into a con-
tainer with clean tap water to remove any white dried AdBlue® /
DEF deposits.
3. If drops of AdBlue® / DEF drip onto the AdBlue® / DEF tank, re-
move the resulting carbamide crystals with water and a clean
cleaning cloth.
There may not be any added cleaning agents in the rinsing water.
Adding cleaning agents could damage the emission control system.
NOTE
Damage to the pump module and dosage unit!
Cleaning agent residue can damage the pump module and the dos-
age unit.
Do not clean components under any circumstances.
Incorrect filling
If the AdBlue® / DEF tank has been filled up incorrectly, the following
parts must be replaced to prevent the pump module failing again:
- all AdBlue® / DEF hose assembly
- pump module
18.3.3 Pump module - replace the filter element

Requirements:
82640 2021-04-22 313

18 Exhaust system
CAUTION
Maintain a cooling period of 60 minutes before carry-
ing out the work described.
Wear protective goggles, protective clothing and
gloves when handling AdBlue® / DEF.
Open line connections and system components plugs
slowly. Cover the disconnecting point with a cloth
when opening.

Fig. 137: Position of the filter element in the AdBlue® / DEF tank
1 AdBlue® / DEF tank 2 Cover

3 Filter cover
1. Remove cover (2) from the back of the AdBlue® / DEF tank (1).
2. Place a suitable collecting vessel under the pump filter unit for
emerging AdBlue® / DEF.
314 82640 2021-04-22

18 Exhaust system
Fig. 138: Pump filter unit

3 Filter cover
4 Pump
5 Filter element
6 Antifreeze device
7 O-ring
3. Remove filter element.

3.1. Unscrew filter cover (3) and remove it together with the O-
ring(7).
3.2. Wipe the pump (4) clean.
3.3. Ensure that the antifreeze device and valve ring are fitted
correctly in the new cover.
4. Fit new filter element (5).
5. Fit new antifreeze device (6).
6. Lubricate thread with grease spray.
7. Fit new O-ring (7) in the new filter element (5).
8. Fit new filter cover (3) and tighten with 80 Nm (59 lb ft).
9. Fasten cover (2) on the back of the AdBlue® / DEF tank (1).
18.3.4 Servicing the SCR catalytic converter

CAUTION
Risk of burning and scalding when working on the
catalytic converter and parts connected to it.
Only start work on the exhaust gas after treatment
system once the catalytic converter has cooled down.
82640 2021-04-22 315

18 Exhaust system
In addition to the descriptions listed here, please read the instruc-

tions and specifications on servicing the catalytic converter in the
operating instructions of the engine manufacturer. The engine oper-
ating instructions are included in the "Various" part of these operat-
ing instructions.
The SCR catalytic converter (1) is on the right-hand side of the crane
chassis.
Fig. 139: Position of the SCR catalytic converter
1 SCR catalytic converter 2 Connecting clamps

3 Exhaust pipe 4 Exhaust pipe
316 82640 2021-04-22

18 Exhaust system
1. Check the exhaust pipe (4) once a year for AdBlue® / DEF de-
posits. To do so, remove the exhaust pipe of the catalytic con-
verter at the disconnecting point:
1.1. Release connecting clamps (2).
1.2. Remove exhaust pipes (3) and (4).
1.3. Check to see if AdBlue® / DEF deposits have formed in
the exhaust pipe. If required, rinse out the exhaust pipe
thoroughly with hot water.
Before applying the assembly paste, make sure that the exhaust
pipe slides easily and without resistance into the catalytic converter
connecting piece. The exhaust pipe must be fitted without delay
once the assembly paste has been applied.
2. Apply an approx. 5 cm (2 in) wide line of assembly paste "FIRE

GUM" to the inside of the catalytic converter connecting piece.
3. Fit exhaust pipes (3) and (4). Use new clips 2) on the connecting
points.
82640 2021-04-22 317

18 Exhaust system
318 82640 2021-04-22

19 Piston rods
19 Piston rods
19.1 Exposed chrome surfaces - apply protective grease

Consumables: 2.18 Anti-corrosive spray, side 41
Despite being of the highest quality, surfaces may be susceptible to
corrosion in an aggressive environment.
1. If the crane is not in operation for longer than one day, the ex-
posed surfaces must be protected against corrosion by applying
acid-free protective greases.
82640 2021-04-22 319

19 Piston rods
320 82640 2021-04-22

20.1 Dolly coupling
20.1.1 Lubricate dolly coupling

CAUTION
Risk of crushing due to the coupling pin closing ac-
cidentally.
Do not reach or grasp into the jaw.
20.1.1.1 Lubricating the dolly coupling: Rockinger
1. Lubricate the lubricating nipples when uncoupled (coupling pins

upward) to avoid the pins being over-lubricated.
20.1.1.2 Lubricating the dolly coupling: Ringfeder
1. Lubricate the lubricating nipple on the lock when uncoupled.
20.1.1.3 Lubricating the dolly coupling: VBG

1. If the coupling is equipped with a pneumatic servo, interrupt the
air flow for the valve box.
82640 2021-04-22 321

2. Lubricate the lubricating nipple when uncoupled.
20.1.2 Service dolly coupling

CAUTION
Risk of crushing due to the coupling pin closing ac-
cidentally.
Do not reach or grasp into the jaw.
NOTE
Prevention of damage due to professional repairs.
Service and repair work require specialist expertise. We recom-
mend consulting an authorised specialist workshop for this.
1. Check the coupling for visible damage or faults such as:

- Wear
- Rust
- Cracks
- Deformation
2. Clean the coupling.
3. Open / close the coupling manually.
The check pin may not protrude in the closed state.
322 82640 2021-04-22

20.1.2.1 Servicing the dolly coupling: Rockinger
Fig. 140: Underside of Rockinger cou-

pling
1 Fastening screws
1. If the latch release cannot engage in the coupling jaw automati-

cally when decoupling into the second lock position, adjust the
coupling jaw to its central position.
1.1. Unscrew three screws (1) from the bottom.
1.2. Using the latch release, reach into the lock of the jaw and
tighten the three screws (1) again.
2. Check whether the preliminary tension of the rubber springs is
sufficient to ensure the coupling is firmly seated. To do this, take
hold of the complete coupling head (not just the jaw) and shake
hard. If required, you can fit the coupling firmly again by replac-
ing the two rubber springs and the two taper adapters.
3. Grease the castle nut well to protect it against rust.
4. Check the cotter pin of the castle nut. The ends must be com-
pletely flush.
82640 2021-04-22 323

20.1.2.2 Servicing the dolly coupling: Ringfeder
Fig. 141: Coupling pins and coupling ring, Ringfeder dolly coupling
1 Coupling pins 2 Coupling ring
1. Always keep coupling pin (1) and coupling ring (2) clean and well
greased.
The bearing of the towing bar is maintenance-free.
20.1.2.3 Servicing the dolly coupling: VBG

1. Always keep the coupling pin clean and well greased to minimise
wear.
NOTE
System faults due to contamination.
Ensure absolute cleanliness for all work on the central lubricat-
ing system.
Use petroleum ether or petroleum to clean the system.
Do not use solvents.
There can be a central lubricating system on the chassis and also on

the superstructure.
The fitting location of the respective lubricant pump is described in

the operating instructions of the superstructure and/or of the crane
chassis in the corresponding section "Central lubricating system" in
"Structure of the system / supplied lubricating points".
324 82640 2021-04-22

20.2.1 Central lubricating system - check level

1. Check the filling level of the lubricant container.
2. If required, fill the lubricant container (see 20.2.2 Central lubri-

cating system - fill lubricant container, side 325).
20.2.2 Central lubricating system - fill lubricant container

NOTE
System faults due to contamination.
The grease must be free of impurities and may not change its
consistency over a period of time.
NOTE
Risk of bursting when overfilled.
Never exceed the maximum filling level.
1. Fill the lubricant container of the corresponding pump using a

commercial grease pump or hand lever press, always using the
filling nipple (directly on the housing).
Once completely emptied, the pump might need up to 10 minutes

run time to achieve full capacity.
82640 2021-04-22 325

20.2.3 Clean the central lubricating system

NOTE
Damage to the lubricant container by cleaning it with aggres-
sive substances.
The plastic material of the lubricant container can become dam-
aged if it comes into contact with trichloroethylene, acetone or other
similar cleaning and thinning agents.
Do not clean the lubricant container with aggressive substan-
ces.
1. Clean the lubricant pump of the central lubricating system using

petroleum ether or petroleum.
20.2.4 Check the central lubricating system

The structure of the system and the supplied lubricating points are
described in the operating instructions of the superstructure and/or of
the crane chassis in the corresponding section "Central lubricating
system" in the corresponding section "Structure of the system / sup-
plied lubricating points".
1. Initiate one or several additional lubrication impulses (see the op-
erating instructions of the superstructure and/or of the crane
chassis in the corresponding section "Central lubricating system"
in "Additional lubrication impulse".
2. Then check the following:
- the lines for leak-tightness
- lubricant leakage at all lubricating points
- time setting of control (see the operating instructions of the
superstructure and/or of the crane chassis in the correspond-
ing section "Central lubricating system" in "Setting the pause
and work times").
- hoses and tubes for damage
Replace damaged hoses and tubes immediately (see
29.2.10.5 Specifications on replacing hose assemblies,
side 509).
326 82640 2021-04-22

20.3 Anti-fall protection via safety mast

Observe the corresponding manufacturers' documents on the follow-
ing subjects in the part "Various":
- Safety regulations
- Maintenance and care
- Repairs
- Inspections
82640 2021-04-22 327

328 82640 2021-04-22

21 Slewing rim
21 Slewing rim
21.1 Safety Instructions
DANGER
Danger of crushing / danger due to shearing.
When carrying out the tasks described below, ensure
that no maintenance personnel, with the exception of
the crane operator (in the cab), is in the danger areas
between the main boom, superstructure and crane
chassis or between the superstructure and chassis
once the engine has been started to carry out the
necessary slewing or luffing movements.
DANGER
Risk of snagging and being dragged in at the slew
gear pinion.
When maintenance work is carried out, there is a risk of
snagging and being dragged in at the slew gear pinion −
despite the protective covering.
Ensure that no limbs or body parts and no clothes are
in the danger zone.
Fig. 142: Slew gear pinion entanglement zone
82640 2021-04-22 329

21 Slewing rim
21.2 Lubricate the bearing

NOTE
Damage due to insufficient lubrication!
Carry out this lubricating procedure:
at maintenance intervals in accordance with the maintenance
list (see section 3 Lubrication and Maintenance Schedule,
side 43)
following any use of steam jets
before and after a longer operating break/standstill time
Fig. 143: Central lubricating nipple
1. Luff up the main boom slightly out of the transport position.

2. Lubricate the central lubricating nipple.
3. Lubricate the lubricating nipple of the slewing rim.
WARNING
ulations.
4. Slew the superstructure by 360° two times.
330 82640 2021-04-22

21 Slewing rim
5. Lubricate the lubricating nipple again.

Following the second lubricating procedure, lubricant must be
emitted along the whole circumference of the slewing rim
forming a collar of grease.
Optionally, this lubricating point can also be connected to the central

lubricating system (see section 20.2 Central lubricating system,
side 324).
21.3 Lubricating the Ring Gear

Consumables: 2.16 Adhesive lubricant (special grease), side 40
1. Lubricate the ring gear regularly and after cleaning with a high-
pressure cleaner as well as at the latest when exposed areas
appear on the tooth flanks, using adhesive lubricant.
21.4 Checking Screwed Connections for Firm Fitting

WARNING
Danger due to loose bolts.
If screws turn, the customer service team of the crane
manufacturer must be informed. The required meas-
ures for achieving operating safety again must be dis-
cussed with them.
It is never sufficient to simply tighten the loose screws
with the nominal torque again.
82640 2021-04-22 331

21 Slewing rim
Fig. 144: Slew ring bolt
1. Check the screwed connection for firm fitting. To do so, apply the
prescribed torque to several screws of the rotating assembly (1),
distributed in the machine.
NOTE
Risk of breaking due to torque being too high.
Maintain the prescribed tightening torque.
The screwed connection is firm when the screws do not do

not turn when the torque is applied.
Torque
Item Quantity Size Quality
(Nm) (lbf ft)
min. 1300 min. 958.8
1 86 M 27 x 145 10.9
max. 2000 max. 1475
Table 42: Torque of the bolts on the slew ring
332 82640 2021-04-22

22 Slew gear
22 Slew gear
22.1 Overview: Slew gear
Fig. 145: Overview slew gear
1 Vent screw 2 Expansion tanks

3 Oil level indicator 4 Screw on slew gear brake
5 Screw plug (4 pieces) 6 Slew gear pinion
22.2 Perform visual and noise checks

1. Check the leak-tightness of the following components:
- of the transmission
- of the engine
- of the hydraulic connections
2. Listen for unusual noises.
82640 2021-04-22 333

22 Slew gear
22.3 Lubricate the slew gear pinion

Fig. 146: Slew gear pinion entanglement zone
DANGER
Risk of snagging and being dragged in at the slew
gear pinion!
When maintenance work is carried out, there is a risk of
snagging and being dragged in at the slew gear pinion −
despite the protective covering.
Ensure that no limbs or body parts or clothing are in
the danger zone.
Fig. 147: Protective guard of the slew gear pinion
1 Protective guard 2 Slew gear pinion
2. Remove protective covering (1).

3. Lubricate slew gear pinion (2).
4. Refit the protective cover (1).
334 82640 2021-04-22

22 Slew gear
22.4 Check the involute spline connections

CAUTION
Danger due to inadequate inspection.
The necessary work must be carried out safely and the
result must be interpreted correctly to ensure future oper-
ating safety of the crane.
This work may only be carried out by especially
trained personnel.
In case of doubt, the work must be carried out by the
customer service team of the crane manufacturer.
1. Check the involute spline connection (drive-side) between the

hydraulic motor, slew gear brake and transmission:
- In the case of normal wear, the teeth flanks have a smooth,
bright, shiny surface after the run-in period.
- The involute spline connections may not display any plastic
deformation or wear due to abrasion, e. g. if tooth flanks are
worn down or partially worn down, degrees of wear are found
in the tooth flanks in the base of the gear teeth).
- The tooth flanks must show no signs of abrasive wear, scor-
ing, scuffing, pit marks, flaking, blistering or cracks.
CAUTION
Danger due to worn involute spline connections.
Replace the affected parts immediately if any dam-
age to the involute spline connections is detected.
22.5 Slew gearbox – check oil level, top up if required

Requirements:
- Transmission is at a standstill
- Oil has cooled down
1. Open the maintenance flap on the slew gear trim.
82640 2021-04-22 335

22 Slew gear
2. Read off the oil level on the oil level indicator. When the oil level
is correct, the oil must be in the middle of the white area.
NOTE
Only top up using the oil that is already in the system.
3. If the oil level is too low, fill the transmission oil from above via
the expansion tank. Observe the oil level in the oil level indicator.
NOTE
Damage to the transmission due to continuous oil loss.
If a continuous oil loss is determined, operation must be stop-
ped and the cause of the leak must be rectified.
22.6 Slew gearbox - change oil

Requirements:
- Transmission is still warm
WARNING
Both the surfaces of the transmission and the oil that is
coming out can be very hot.
Wear goggles, protective gloves and protective cloth-
ing.
336 82640 2021-04-22

22 Slew gear
Fig. 148: Overview slew gear
1 Vent screw 2 Oil drain hose
1. Drain transmission oil:

1.1. Place a collecting container under the oil drain hose (2).
1.2. Unscrew the vent screw (1) on the expansion tank.
1.3. Open the valve on the oil drain hose (2) and drain the
transmission oil into the collecting container.
2. Clean the vent screw (1) and then screw it firmly in place.
82640 2021-04-22 337

22 Slew gear
Fig. 149: Filling the slew gear with a pump (schematic diagram)
1 Screw on slew gear brake 2 Oil drain hose

3 Pump 4 Oil tank
3. Fill up new transmission oil:

3.1. Remove one of the four screws (1) on the slew gear brake.
3.2. Connect pump (3) to oil drain hose (2) and fill from below
until oil comes out of the screw hole of the slew gear
brake (1).
3.3. Quickly unscrew screw (1) on the slew gear brake.
3.4. Remove pump (3) from oil drain hose (2).
Handle the magnetic screw plugs with particular care as they are
very sensitive. Before assembly, remove any metallic swarf that
might have accumulated there. This swarf is not an indication of
damage to the transmission.
4. Unscrew the vent screw on the expansion tank.
5. Fill in the remaining transmission oil from above via the expan-
sion tank until the transmission oil is in at the middle of the white
area the oil level indicator.
338 82640 2021-04-22

22 Slew gear
6. Clean the vent screw and then screw it firmly in place.
NOTE
Incorrect oil level display after oil change.
During operation, a considerable amount of oil is distributed in the
interior of the gearbox housing.
Immediately after starting operation of the system, check the oil
level again with the transmission at a standstill and correct if
necessary.
22.7 Inspection of the drained oil

Systematic oil inspections at regular intervals are one of the meas-
ures of "preventative maintenance". They make it possible to diag-
nose reliable trends with regard to wear development and the onset
of damage.
If damage is diagnosed early enough it means lower repair and down-
time costs and can save large partial or complete dismantling proce-
dures.
A reliable diagnosis can only be made by a competent lab.
To give a representative cross-section for the whole transmission,
drain off the oil while at operating temperature.
22.8 Checking the brakes

Requirements:
- No load on the crane
- No wind (windless/calm)
- Main boom fully retracted and raised so that it cannot become en-
tangled with other parts of the crane
- Main boom extension (if existing) completely removed from the
crane
82640 2021-04-22 339

22 Slew gear
WARNING
erly.
The brake is a safety component of the first degree; the
properly.
Service and repair work require specialised expertise
and may only be carried out by personnel trained for
this type of brake.
We recommend consulting our customer service
team or an authorised specialist workshop if braking
performance is insufficient.
WARNING
Risk of injury when opening the disc brake.
Releasing the disc brake without the clamping device
can lead to serious injury.
Do not open the disc brake.
This work may only be undertaken by a trained spe-
cialist.
The brake might have to be serviced after an emergency stop.
1. Check the disc brake on the slew gear for leaks. Have defective
components replaced immediately.
2. Proceed as described below to check the disc brakes on the
slew gear to ensure they function faultlessly:
3. Start the engine and set to approx. 1200 m.-1 (1200 rpm).
4. Select the highest pressure level if the crane has different pres-
sure levels (see the operating instructions in "Slewing the super-
structure").
5. Do not actuate the depicted switch to open the disc brake. The
indicator light in the switch may not light up.
340 82640 2021-04-22

22 Slew gear
Fig. 150: Control levers
6. Slowly (not jerkily) start the slewing movement in the right- or

left-hand slewing direction by actuating one of the "Release
switch system" buttons.
7. Hold the control lever for approx. 10 seconds in the fully exten-
ded position and then release the control lever. The crane must
not however slew into the steered direction.
Crane remains in the starting position = disc brake is OK
Or
Crane does not remain in the starting position = disc brake is

defective, have the disc brake repaired.
22.9 Check the bolted connections and tighten as required

NOTE
clean.
wax.
Requirements:
- Slew gear trim (if present) is dismantled
82640 2021-04-22 341

22 Slew gear
Fig. 151: Bolted connections on the slew gear
1 Engine fixing bolt 2 Fixing bolt
1. Check the tightening torque of the bolted connections regularly.
For safety reasons, this should also be done before or after longer
continuous operation and if a maximum load is often involved.
2. If required, tighten bolts in accordance with the table below.
Torque
Nm lbf ft
1 4 M 10 x 30 10.9 57 ± 7 42 ± 5
2 24 M 16 x 140 10.9 240 ± 18 177 ± 13.6
Table 43: Torque of the bolted connections on the slew gear
342 82640 2021-04-22

23 Hoists
23 Hoists
23.1 Hoist gears – checking the oil level, topping up if required

WARNING
Danger due to becoming entangled!
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.
NOTE
Damage due to continuous oil loss!
If continuous oil loss is detected during the regular oil level
checks, stop operation and remove the winch.
The oil is semi-liquid. The oil level can therefore only be reliably
checked two hours after the last movement.
21
22
Fig. 152: Schematic diagram: Hoists 1 and 2
21 Hoist 1 22 Hoist 2
Requirements:
- Oil has cooled down
82640 2021-04-22 343

23 Hoists
1. Check the oil level in the inspection glass of the oil level indica-
tor. The oil level must be between the"min" marking and
the"max" marking in the inspection glass on the oil level display.
NOTE
Only top up using the oil that is already in the system.
2. If the oil level does not reach the "min" marking, top up oil until
the oil level reaches the "max." marking (see section "Hoist gears
- changing oil").
23.2 Hoist gear – change oil

WARNING
Danger due to becoming entangled!
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.
WARNING
Risk of burns and scalding!
Both the surface of the transmission and the oil that is
being drained off can be very hot.
Avoid contact with hot transmission components and
the emerging transmission oil.
Wear suitable protective clothing.
344 82640 2021-04-22

23 Hoists
WARNING
Skin damage and eye irritation due to contact with
oil.
Prolonged contact with the oil can irritate or damage your
skin and eyes.
Wear goggles, protective gloves and protective cloth-
ing.
Requirements:
- Transmission is still warm
Fig. 153: Hoist
1 Oil fill plug 2 Oil level display

3 "Max" oil level 4 "Min" oil level
5 Oil drain plug
1. Unscrew oil fill plug (1) from the top end of the oil level indicator
(2).
2. Remove the oil drain plug (5) from the bottom end of the oil level
indicator (2) and drain oil into the collecting container.
82640 2021-04-22 345

23 Hoists
3. Clean the transmission with flushing oil before filling with fresh oil
so that any possible abraded material or contaminants can drain.
At a low ambient temperature, you should carry out flushing with

some heated fresh oil.
4. Screw in the oil drain plug (5) again with max. 30 Nm.
5. Top up oil using a funnel or hose until the oil level reaches the
"max" marking (3) in the inspection glass of the oil level indicator.
NOTE
Incorrect oil level display after oil change.
During operation, a considerable amount of oil is distributed in the
interior of the gearbox housing. Depending on the position of the
transmission, more or less remnant oil can remain in the transmis-
sion. This is why it might not be possible to fill up the entire oil
quantity. The display in the inspection glass of the oil level indicator
(2) is decisive.
Immediately after starting operation of the system, check the oil
level again with the transmission at a standstill and correct if
necessary.
6. Screw in the oil fill plug (1) again with max. 30 Nm.
23.2.1 Inspection of the drained oil

Systematic oil inspections at regular intervals are one of the meas-
ures of "preventative maintenance". They make it possible to diag-
nose reliable trends with regard to wear development and the onset
of damage.
If damage is diagnosed early enough it means lower repair and down-
time costs and can save large partial or complete dismantling proce-
dures.
A reliable diagnosis can only be made by a competent lab.
To give a representative cross-section for the whole transmission,
drain off the oil while at operating temperature.
23.3 Exterior bolted connections - check and tighten if required

The description below applies to all hoists on the crane.
346 82640 2021-04-22

23 Hoists
NOTE
clean.
wax.
1. Using a torque key, regularly check the tightening torque of the

exterior bolted connections of the hoists.
82640 2021-04-22 347

23 Hoists
2. Tighten any loose screws, remove broken off or defective screws

and replace them with new ones.
Fig. 154: Bolted connections on the hoist (schematic diagram)
1 Bolt M10 2 Bolt M20

3 Bolt M16
Tightening torque
Nm lbf ft
1 6 M 10 x 35 10.9 57 ± 4 42 ± 3
2 18 M 20 x 50 10.9 470 ± 35 347 ± 26
3 4 M 16 x 50 10.9 240 ± 18 177 ± 13
Table 44: Tightening torque of the exterior bolted connections - hoist (Siebenhaar)
Fig. 155: Bolted connections on the hoist (schematic diagram)
1 Bolt M12 2 Bolt M16

3 Bolt M16
Tightening torque
Nm lbf ft
1 6 M 12 x 35 10.9 98 ± 7 72 ± 5
2 22 M 16 x 45 10.9 240 ± 18 177 ± 13
3 4 M 16 x 50 10.9 240 ± 18 177 ± 13
Table 45: Tightening torque of the exterior bolted connections - hoist (Zollern)
348 82640 2021-04-22

23 Hoists
23.4 Lubricating the Rope Drum Bearing

Fig. 156: Lubricating nipples - rope drum bearing
1. Lubricate the rope drum bearing of hoist 1 (H1) via the lubricating
nipple on the front side.
2. Prepare auxiliary equipment (for example, ladder) for access
from the ground.
3. Lubricate the rope drum bearing of hoist gear 2 (H2) via the lubri-
cating nipple on the front side.
Optionally, this lubricating point can also be connected to the central

lubricating system (see section Central lubricating system).
23.5 Checking the lower limit switch

WARNING
Risk of accidents when checking the function of the
lower limit switches under load.
If the lower limit switch does not work, the rope can rip
out of the rope drum's rope clamp and a hanging load
could fall.
Only check the limit switches without a load attached.
Requirements:
- High number of falls is reeved
- Main boom is in the high position
Always carry out this check when the crane is in the configuration
required for it.
1. Telescope the main boom out and lower the hook block using the
hoist until the lower limit switch switches off this movement for
the respective hoist.
82640 2021-04-22 349

23 Hoists
2. Then check that there are at least 3 turns of rope on the rope
drum.
23.6 Checking hoist limit switch

DANGER
Risk of accidents!
Only check the limit switches without a load attached.
1. Activate the hoist limit switch daily and check that it functions
properly.
1.1. Raise the hook block using the corresponding hoist until
the shift weight is relieved of load.
The movement "Raise hoist" must then be switched off.
23.7 Hoists - Checking the Brakes

Requirements:
For mobile cranes:
- Crane is supported on outriggers
350 82640 2021-04-22

23 Hoists
WARNING
erly.
The brake is a safety component of the first degree; the
properly.
edge and must only be carried out by personnel
trained for this type of brake.
We recommend consulting our customer service
team or an authorised specialist workshop if braking
performance is insufficient.
WARNING
Risk of injury when opening the disc brake.
Releasing the disc brake without the clamping device
can lead to serious injury.
Do not open the disc brake.
This work may only be undertaken by a trained spe-
cialist.
The brake might have to be serviced after an emergency stop.
1. Check the disc brakes on the corresponding hoist for leaks. Have
defective components replaced immediately.
2. Proceed as described below to check the disc brakes on the cor-
responding hoist to ensure they function faultlessly:
3. Start the engine and let it run at slightly higher idle speeds.
4. Load the corresponding hoist with the maximum permitted rope
load at the highest possible layer.
While doing so, observe the rope reeled on under preliminary ten-
sion so that the rope is not damaged.
5. Move the control lever of the corresponding hoist in the "Raise

hoist" direction and raise the load off the ground.
6. When the load is suspended freely on the hook, release the con-
trol lever for the corresponding hoist in the middle position.
82640 2021-04-22 351

23 Hoists
7. Make marks on the rope drum and on the frame of the hoist.
Let the load hang freely for approx. 2 to 3 minutes with the engine
running. During this time the hoist rope drum may not move.
8. Check the marks on the rope drum and on the frame of the cor-
responding hoist:
- If the marks have not changed, then the brake is OK
Or
- If the marks have changed (winch is creeping), then the brake
is defective; have the brake repaired
23.8 Calculation of the Spent Share of the Theoretical Service Life

DANGER
Danger if the winch service life expires!
If the specifications for calculating the winch's remaining
service life are not observed, the service life of the winch
could run out undetected and the winch could fail sud-
denly and unexpectedly. This can cause serious acci-
dents resulting in death and major damage.
Observe - without fail - the specifications on deter-
mining the remaining service life of the winch (see
29.2.6 Inspection of the Winches, side 488).
23.9 General overhaul of the hoist winches

DANGER
Risk of accidents due to lack of general overhaul!
In any case, a general overhaul must be carried out
at the latest 10 years after the crane was commis-
sioned.
The maximum time period between two general over-
hauls may not exceed 10 years.
352 82640 2021-04-22

23 Hoists
1. Depending on the remaining service life or when service life D

has been reached (see the explanation in 29.2.6 Inspection of
the Winches, side 488), carry out a general overhaul of the
winches.
82640 2021-04-22 353

23 Hoists
354 82640 2021-04-22

24 Luffing gear
24 Luffing gear
24.1 Luffing cylinders - lubricating the foot and piston rod bearings
DANGER
Danger of crushing / danger due to shearing.
When carrying out the tasks described below, ensure
that no maintenance personnel, with the exception of
the crane operator (in the cab), is in the danger zones
between the main boom, superstructure and crane
chassis or between the superstructure and crane
chassis once the engine has been started to carry out
the necessary slewing and luffing movements.
2. Lubrication of the lubricating nipples on the foot bearing.
3. Lubrication of the lubricating nipples on the piston rod bearing.
Optionally, these lubricating points can also be connected to the

central lubricating system (see 20.2 Central lubricating system,
side 324).
82640 2021-04-22 355

24 Luffing gear
24.2 Check the bolted connections and tighten as required
NOTE
Caution!
Only screw the screws / bolts in when dry.
clean.
wax.
Fig. 157: Exterior bolted connections - – luffing gear
1 Cylinder screw M 20 x 45
1. The torque of the exterior bolted connections must be checked

regularly with a torque key.
For safety reasons, this should also be done before or after longer
continuous operation and if a maximum load is often involved.
2. If necessary tighten the screws (1) according to the following ta-

ble.
Torque
(Nm) (lbf ft)
1 2 M 20 x 45 10.9 470 ± 35 39 ± 4
Table 46: The torque of the exterior bolted connections - luffing gear
356 82640 2021-04-22

25.1 Main boom
25.1.1 Main boom – lubricate the sliding surfaces

Consumables: 2.14 Adhesive lubricant, side 39
For machines with the main boom extension (MBE) fitted in the trans-
port position, the lubricating point for lubricating the inner sliding sur-
faces of the basic boom section is covered by the MBE on the right-
hand side. Thus, to lubricate the inner sliding surfaces of the basic
section, remove the main boom extension (MBE) completely.
In order to completely remove the main boom extension from the
crane, it must be folded in front of the crane and removed with an
auxiliary crane. See the operating instructions of the superstructure
under section “Main boom extension".
Using a paintbrush, apply grease to the inner sliding surfaces of the
basic case and of the telescopic sections and to the outer sliding sur-
faces of the telescopic sections. To do so, extend the telescopic sec-
tions of the main boom in the horizontal to specified extension se-
quences. Take all required specifications on the outrigger support
area, counterweight and space requirements from the "Length code
selection (LC) for lubrication of the main boom" screen.
The basic procedure is described below using a boom with six tele-
scopic sections as an example. The values that are shown on the
crane control are always decisive.
82640 2021-04-22 357

25.1.1.1 Sample "Length code selection (LC) for lubrication of the main boom"
screen
Fig. 158: Example of a "Length code selection (LC) for lubrication of the main
boom" screen
1 Number of the length code 2 Main boom length

3 Extension state of the telescopic 4 Minimum counterweight configu-
sections ration
5 Minimum outrigger support area
Item Symbol Explanation

1 selected length code and number of the length
code (LC no.), here: 100 to 105
The desired length code is selected and receives
a coloured background when pressed (the entire
line is touch-sensitive).
2 Main boom length
3 Extension state of the telescopic sections (from
left to right)
0% extended
45% extended
90 % extended
100 % extended
The number of bars represents the number of

telescopic sections. In the example, the
screen is shown for a main boom extension
with 6 telescopic sections.
4 Minimum counterweight configuration, here 18.7t
(41.2 kip)
5 Minimum outrigger support area, here 8.4 m
(27.6 ft)
358 82640 2021-04-22

25.1.1.2 Preparing the lubricating procedure

Requirements:
- Crane in transport condition
- Main boom extension (if existing) completely removed from the
crane
- Main boom positioned horizontally
1. Select crane configuration "Main boom operation (HA)" on the
crane control.
For navigating in the crane control, observe the section "Safety

equipment": for subsequent telescoping, observe the section "Tele-
scoping", and there particularly the sections "Telescoping proce-
dure" and "Length code" in the operating instructions of the super-
structure.
2. Call up the "Length code (LC) selection" screen.
3. Confirm the "Lubricate" button.
The "Selection of length code (LC) for lubricating the main

boom" screen appears with the selection list of the length co-
des for lubricating the main boom.
DANGER
Risk of overturning!
If the configuration of the crane that is currently stored in
the control system does not satisfy the specified mini-
mum requirements for the counterweight and outrigger
support area, the corresponding value is displayed in
red. In this case, the screen cannot be exited by pressing
the "Save" button.
Do not carry out the telescoping procedure.
Ensure that the required crane configuration is selec-
ted with regard to counterweight combination and
outrigger support area.
4. Support the crane on outriggers as specified and align.

5. Start the engine and fit the prescribed counterweight.
82640 2021-04-22 359

25.1.1.3 Telescoping out the lubrication length for lubrication (description as exam-
ple)
1. Press on the length code to select the lubrication length (in the
example: LC 100). The selected line has a colour background.
2. Exit the "Length code (LC) selection for lubricating the main
boom" screen by pressing the "Save" key.
The "Telescoping display" screen appears, in the example:

"LC 100".
3. With the selected length code, telescope the main boom out to
the extension state.
DANGER
switched off.
locked.
4. Switch off the drive motor once the telescoping procedure has
been completed.
WARNING
Risk of crushing!
It must be ensured that the main boom cannot be tel-
escoped during the following lubricating procedures
on the main boom.
5. Exit and lock the crane operator’s cab.
360 82640 2021-04-22

WARNING
Risk of crushing!
As the basic boom section is always accessible from the
outside, all holes are closed with covers to prevent risk of
crushing.
Fit the cover over the pinning hole immediately after
completing the lubrication procedure.
6. Lubricate the inner top and bottom sliding surfaces through the
side maintenance holes in the front. Apply a thick coat of grease
behind the sliding elements:
6.1. On both sides, remove cover over the 90 % pinning hole.
6.2. Lubricate the inner sliding surfaces. To do so, insert a suit-
able paintbrush through the 90 % pinning hole and thickly
coat the opposite sliding surfaces which can then be
reached. Carry out this procedure in sequence from both
sides..
6.3. On both sides, fit cover over the 90 % pinning hole.
The sliding elements then automatically distribute the applied grease

during subsequent telescoping.
For the inner sliding surfaces, the top sliding surfaces are most
heavily loaded.
7. Coat the outer top and bottom sliding surfaces of the extended
telescopic section with grease.
For the outer sliding surfaces, the bottom sliding surfaces are most
heavily loaded.
8. In sequence, move to the other lubrication length codes and lu-

bricate the remaining telescopic sections / sliding surfaces inside
and out. To do so, proceed as described previously in detail for
the length code "LC 100".
82640 2021-04-22 361

25.1.2 Main Boom- Checking the Rope of the Length Transducer

Fig. 159: Schematic diagram - Length transducer on main boom
1 Rope of the length transducer
1. Check that rope (1) is undamaged.
25.1.3 Main boom – lubricate the foot bearing

Requirements:
- Main boom slightly luffed up out of the transport position
362 82640 2021-04-22

Fig. 160: Main boom foot section bearing lubricating nipple
1 Lubricating nipple 2 Valve
The valve (2) is not present on all crane types.
1. On the right-hand side of the main boom foot section bearing, lu-
bricate the nipples (1).
The bearing is sufficiently lubricated when grease escapes out
of the valve (2).
2. Prepare auxiliary equipment (for example, lifting platform) for ac-

cess from the ground.
3. On the left-hand side of the main boom foot section bearing, lu-
bricate the nipples (1).
The bearing is sufficiently lubricated when grease escapes out
of the valve (2).
Optionally, these lubricating points can also be connected to the

central lubricating system (see section "Central lubricating system").
82640 2021-04-22 363

25.1.4 Main Boom - Lubricating Head Axles

Fig. 161: Lubricating nipples - main boom head axles
1. Prepare auxiliary equipment (e. g. lifting platform) for access

from the ground.
2. Lubricate the lubricating nipples on both sides of the lower main
boom head axles.
25.1.5 Check the main boom for cracks in the welding seams
WARNING
Risk of breaking due to improper maintenance and
repair work.
Only have suitably qualified welders carry out repair
welding work.
1. Check the weld seams on the main boom once a year during
crane inspections for weld seam cracks to prevent breakage.
If cracks are found, request repair instructions from the cus-
tomer service team of the crane manufacturer for welding re-
pairs. An exact description of the course of the crack should
be given (relevant page from the spares catalogue, photos,
sketches , etc.).
364 82640 2021-04-22

25.1.6 Main boom - check the rope track rollers

WARNING
Danger due to worn rope sheaves.
Rope track rollers which are split by hoist ropes pose the
danger of crane parts falling from a great height.
If clear wear grooves made by the hoist ropes are
visible on the sheaves, the rope sheaves must be re-
placed.
Fig. 162: Check the main boom rope sheaves
1. Check all main boom and main boom extension (MBE) rope
sheaves regularly for wear and to ensure they move easily when
turned.
25.2 Service the locking and pinning unit (LPU)
WARNING
Risk of crushing in the interior of the main boom!
Do not reach into the opened assembly opening
while the telescoping cylinder and/or locking and pin-
ning unit are/is moving.
switched off.
locked.
Attach a warning plate to the latch of the crane cab.
82640 2021-04-22 365

CAUTION
Risk of falling!
To carry out this work, you must step onto the top of the
main boom which has been set down.
Take additional safety measures against falling (e.g.
using a lift stage).
25.2.1 Lubricate the locking and pinning unit

Requirements:
- Crane is supported on outriggers
- Main boom is positioned horizontally
- Counterweight fitted so that it is possible to telescope out with LC
2 (telescopic 1: 45% extended) in the following procedure
For the required extension sequence, take the corresponding speci-

fications, such as outrigger support area, counterweight, etc. from a
valid capacity table.
Fig. 163: Cover lid on the top of the basic case (schematic diagram)
1 Cover lid
1. Remove cover lid (1) over the assembly opening on the top of
the basic case.
2. Leave the hazardous area (assembly opening or basic case inte-
rior).
366 82640 2021-04-22

WARNING
Do not reach into the opened assembly opening
while the locking and pinning unit is moving.
3. Telescope the main boom out with selected LC 2.
Main boom with 6 telescopic sections LC 2 (45/0/0/0/0/0)
4. Pull the locking and pinning unit (LPU) back until it is just in front
of the assembly opening.
- To do so, switch over to "Manual telescoping".
Important! Observe the corresponding section "Manual telescoping"

and the subsequent section "Teaching..." in the section "Telescop-
ing" of the operating instructions of the superstructure.
5. Switch off the drive engine.
WARNING
switched off.
locked.
Ensure that under no circumstances the LPU can be
actuated when lubrication procedures are being car-
ried out in the interior of the basic case on the LPU.
82640 2021-04-22 367

Fig. 164: Sliding surfaces and lubricating nipples that need to be lubricated on the
locking and pinning unit (LPU)
1 Locking pin 2 Clamshell
6. Lubricate all moving parts with adhesive lubricating grease.

While doing this, pay particular attention to the sliding surfaces
and lubricating nipples indicated by arrows.
The LPU state is "unlocked / pinned". This means that locking bolts
(1) are retracted and clamshells (2) are extended.
7. Leave the hazardous area (assembly opening or basic case inte-

rior).
WARNING
Risk of crushing in the interior of the basic case!
Before actuating the LPU in the following procedure,
ensure that no-one nor any body parts are in the LPU
area or in the basic case interior.
368 82640 2021-04-22

8. Re-enter the crane operator’s cab and place the LPU in the
"locked / unpinned" state.
In this case, the locking bolts (1) are extended and the clam-
shells (2) are retracted.
WARNING
switched off.
locked.
10. Lubricate the LPU in the area of the locking bolts (1) which are
now extended.
11. Leave the hazardous area.
WARNING
Risk of crushing in the interior of the basic case!
Before actuating the LPU in the following procedure,
ensure that no-one nor any body parts are in the LPU
area or in the basic case interior.
12. Re-enter the crane operator’s cab and place the LPU in the state
"lock/unlock" or "pin/unpin" several times.
The grease is distributed evenly.
WARNING
switched off.
locked.
82640 2021-04-22 369

14. Check the LPU for sufficient lubrication. Repeat the lubrication
procedure if necessary.
Fig. 165: Cover lid on the top of the basic case (schematic diagram)
1 Cover lid
15. Close the assembly hole using the cover.

16. Fasten cover lid using screws and washers.
25.2.2 Locking and pinning unit – carry out a visual inspection

1. Check the following components to ensure they are fitted firmly,
are undamaged and for any leaks:
- Plugs (in particular on the solenoid valves)
- Solenoid valves
- Hoses and cables
25.2.3 Locking and pinning unit - check the proximity switches and sliding contacts
1. Check the proximity switches and sliding contacts:
- to ensure they are fitted firmly
- under no circumstances may they be loose
- they must not be able to move in the housing
- to make sure that they are undamaged;
- to make sure they can move easily, i.e. that the spring reset
functions properly
370 82640 2021-04-22

25.2.4 Locking and pinning unit - check the preliminary gas tension of the accumula-
tors
The accumulators are in front of the locking and pinning unit on the
telescopic drive in the main boom interior.
For further specifications on checking the preliminary gas tension,

see section "Hydraulic system" under "Checking the preliminary gas
tension of the pressure accumulators".
25.3 MBE - design with fixed operating angles
25.3.1 Checking the pins for cracks

1. Check all pins regularly for cracks, e.g. during assembly or dis-
mantling.
25.3.2 Pins – Lubricating Moving Parts

1. Check all pins, i.e. fixing pins, locking bolts (figure left) etc. and
other moving parts of the fly jib for free movement and lubricate if
required.
2. Lubricate the lubricating nipples on both sides of the intermediate

section.
82640 2021-04-22 371

25.3.3 Checking the tension plates

Have the tension plates checked at least once a year by an expert −
in accordance with the accident prevention regulations "Cranes"
(BGV D6).
Furthermore, have them checked by an expert when necessary if re-
quired by the site and operating conditions. Since the inspection inter-
vals are normally based on the operating conditions, they should be
correspondingly shortened if the crane is operated more frequently.
Make a record of this inspection (e.g. in the examination log book for
the crane).
Dismantling might be required so that it is possible to inspect the ten-
sion plates safely and correctly.
The tension plates must be inspected in their entirety, i.e. all hidden
surfaces and bores must also be inspected.
WARNING
Danger due to lack of stability.
Replace damaged tension plates immediately.
Carry out the following checks:

1. Check for cracks:
- Check the tension plates regularly for cracks.
- If there are visible cracks, carry out a surface crack test (e.g.
magnetic particle inspection).
If cracks are found when inspecting a tension plate, replace
the tension plate.
372 82640 2021-04-22

Fig. 166: Initial length - tension plates
1 Version with cylinder on the inside 2 Version with cylinder positioned in between
Length Permitted length change

Item
mm in mm in
1 2615 103 in 1,3 0.51
2 2614 102.9 in 1,3 0.51
Table 47: Permitted length change of the tension plates of the main boom extension
2. Depending on the design, unpin interior cylinder or cylinder posi-

tioned in between and pull the tension plates to the maximum
length.
3. Check the length:
- The draw bars are dimensioned so that, even under test load,
there can be no permanent expansion.
- Remeasure the length of the tension plates to check that they
have not been overloaded and damaged.
- The limit value for serviceability is a length change of 0.05 %.
Replace the tension plates if a change in length of > 0.05 % is
measured.
82640 2021-04-22 373

4. Check for wear:

- Check pin locks, pins and bores for wear.
It must be ensured that the pin locking mechanism is function-
ing correctly.
5. Check for plastic deformation:

Do not use the tension plates any longer if there has been
plastic deformation (e.g. bending).
6. Check the paintwork:

- Check the paintwork regularly for corrosion.
- Repair / touch up damaged areas.
- Do not store tension plates in aggressive media (e.g. seawa-
ter).
25.3.4 Lubricating the tension plates

1. Check the tension plates to make sure they can be moved easily.
2. Lubricate the upper and lower guides of the cylinder in the ver-
sion with the cylinder on the inside.
3. For the version with the cylinder positioned in between, pull the
tension plate to maximum length and lubricate the interior sliding
surfaces.
374 82640 2021-04-22

25.4 MBE - design with hydraulically smooth angle adjustment
25.4.1 Checking the pins for cracks

1. Check all pins regularly for cracks, e.g. during assembly or dis-
mantling.
25.4.2 Pins – Lubricating Moving Parts

1. Check all pins, i.e. fixing pins, locking bolts (figure left) etc. and
other moving parts of the fly jib for free movement and lubricate if
required.
2. Lubricate the lubricating nipples on both sides of the intermediate

section.
25.4.3 Replace hoses

NOTE
Only use original spare parts of the crane manufacturer or hose
assemblies which comply with the specifications of the crane
manufacturer.
Also use original spare parts for fittings, hose materials and manu-
facturing procedures.
82640 2021-04-22 375

Even if no damage can be detected, replace hose assemblies after a

limited operating time, including a storage period of maximum
2 years.
The date of manufacture stamped on the component is decisive for
calculating the operating and / or storage time, see the section
When replacing the hose assemblies, observe the 29.2.10.5 Speci-
fications on replacing hose assemblies, side 509.
25.5 Assembly jib – checking the draw bars

Fig. 167: Draw bar of the assembly jib
1. Check the draw bars. To do so, proceed as shown in the descrip-

tion 25.3.3 Checking the tension plates, side 372.
The maximum boom length (L) of the draw bars of the assembly jib
is 874.8 mm (34.4 in).
376 82640 2021-04-22

25.6 Service wind measuring device on adjustable bracket

Fig. 168: Wind measuring device with ad-

justable bracket
1 Stay bar
2 Locking bolts
1. Check locking bolts (2) for free movement and grease them if
necessary.
2. Grease stay bar (1). To do this, apply a thin layer of grease with
a brush.
3. Check the wind measuring device for damage and have it re-
paired if necessary.
DANGER
Danger due to becoming entangled.
There is a risk of snagging and entanglement between
rope sheaves and ropes.
Particular care is required in this area when carrying
out maintenance, inspection and assembly work.
Check the rope sheaves of the main boom, the fly jib and the hook
blocks.
82640 2021-04-22 377

25.7.1 Sheaves – carry out a visual inspection

DANGER
Danger due to damaged rope sheaves.
Replace rope sheaves with damage, e.g. cracks or
notches, immediately.
CAUTION
Danger due to corrosion of the plastic rope sheaves.
Plastic sheaves are not completely resistant to chemi-
cals and paints. It is particularly important to remem-
ber this when working in aggressive environments or
for cleaning purposes.
1. Check rope sheaves for damage such as e.g. cracks, notches or

similar damage and check the bearings are seated properly (free
movement).
2. Check the tread:
- The tread must be smooth.
- The bottom tread must be concentric to the shaft or to the
bore in the rope sheave.
- The centre line of the groove must be vertical to the shaft axle
or to the hole in the rope sheave at one level.
378 82640 2021-04-22

25.7.2 Plastic rope sheaves – carrying out a check for wear

Fig. 169: Check for wear - plastic rope sheaves
d Diameter of the rope X Wear on the lower tread

Y Wear to the lateral tread
1. Check all rope sheaves for wear:

- Bottom tread "X" max. 3 mm (0.12 inch).
Dimension "X" is the half a diameter difference from the diam-
eter of the lower tread of a new rope sheave (Dnew) to the di-
ameter of the lower tread of the rope sheave to be inspected
(Dactual):
X = (Dactual - Dnew)/2
- Side tread "Y" max. 5 mm (0.2 inch).
Dimension "Y" measured between the rope and the tread of
the rope sheave.
2. Replace the rope sheave when it is worn up to the wear limit.
25.7.3 Steel rope sheaves – carrying out a check for wear

Fig. 170: Check for wear - steel rope sheaves
d Nominal diameter of the rope R Tread radius, actual state
82640 2021-04-22 379

1. Checking the rope sheaves for wear:

- For the minimum values, see 29.2.8.3 Checking steel rope
sheaves for wear, side 499.
2. Replace the rope sheave when it is worn up to the wear limit.
25.7.4 Check the rope sheave bearings

1. Check all sheave bearings for:
- Leakage of grease
- correct seating of bearing seals
- correct fitting of circlips
- noisy bearings, rolling resistance
- Bearing play
- Signs of wear
CAUTION
Danger due to incorrect assembly of the rope
sheaves.
Special skills and production facilities are required to
assemble the individual components of the rope
sheaves.
For safety reasons, rope sheaves may only be re-
placed as complete components.
2. If faults are detected in the rope sheaves, replace them entirely.

In this case, please contact our customer service department.
25.7.5 Lubricating the sheave bearing of the steel sheave

1. Regrease each sheave bearing. To do so, proceed as follows:

1.1. Remove the threaded pin from the tapped hole.
1.2. Screw the lubrication adapter - to which a lubricating nip-
ple is attached - into the tapped hole.
The lubrication adapter can be found in the toolbox.
380 82640 2021-04-22

25.7.6 Replacing plastic rope sheaves

We recommend replacing all plastic rope sheaves in accordance with
specifications in the lubrication and maintenance schedule.
In this case, please contact our customer service department.
25.8 Ropes
DANGER
When carrying out maintenance, inspection and assem-
bly tasks, there is a risk of becoming entangled and drag-
ged in the following areas:
− rope to rope winches
− rope to rope sheaves of the main boom or additional
boom components
− rope to rope sheaves of the hook block
− rope to rope sheaves on fixed bridle / flying bridle
Proceed with particular care in these areas.
CAUTION
Danger due to protruding rope wires !
When ropes are handled, protruding wires can cause in-
jury.
Always wear gloves for your protection.
Fig. 171: Danger due to protruding wires
82640 2021-04-22 381

CAUTION
Danger due to friction and scraping.
There is a risk of injury when handling ropes due to fric-
tion and scraping.
Always wear gloves for your protection.
25.8.1 General notes on handling and assembly
25.8.1.1 Transport
When working with cables, problems can be encountered even at the
delivery stage: the fork of the forklift truck moves beneath the reel or
into the rope bundle thereby damaging the cable surface.
Wherever possible, the cable, which is delivered in bundles or on
reels, should not come into direct contact with a hook or with the forks
of a forklift truck. Rather, it should be raised by means of wide textile
lifting slings.
Fig. 172: Raising the cable with flat lifting slings (Z 29 084)
A reel is best raised by means of a rod placed through its central axis.
Fig. 173: Raising the reel with a rod (Z 29 085)
382 82640 2021-04-22

25.8.1.2 Storage
Cables should be stored in a cool, clean, dry and covered environ-
ment. The cables should not be stored directly on the ground but, for
example, on pallets.
If it is not possible to store the cables indoors, they must at least be
covered so that they do not become damp.
A plastic film may provide protection against rain, but will not, howev-
er, prevent condensation from forming beneath it - which in turn can-
not escape and will possibly damage the cables permanently. In this
instance a solution may, for example, be provided by using an inter-
mediate 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 in-
stance of a cable first being used after several years in storage.
25.8.1.3 Assembly
When cables are assembled, always ensure that they are wound from
the reel or bundle and onto the system without the cables becoming
twisted or damaged.
Cable which is supplied on a reel is either unwound by means of a
swivel plate or rolled out on the ground.In the 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 be-
tween 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.
The cable must, however, under no circumstances be pulled side-
ways from the bundle or reel, as with this method a torsion is created
in each turn of the rope as it is unwound. Every rope torsion alters the
length of lay of the strands and cable and thereby the ratios of the
rope element lengths and ultimately the load distribution in the cable.
82640 2021-04-22 383

Cable that is pulled sideways from the bundle or reel resists the tor-
sion which acts on it and forms loops. When such a cable is placed
under load, the loops are drawn together and form a kink, an irrepara-
ble deformation. Cables with kinks are no longer safe to be used and
must be replaced.
Fig. 174: Loop (Z 29 086)
25.8.1.3.1 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
work 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.
384 82640 2021-04-22

25.8.1.3.2 Re-reeling
Fig. 175: 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 direc-
tion. It is then supplied to the customer bent in this direction.When re-
reeling from the reel onto the rope drum, ensure that the cable is
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.
If the cable is re-reeled against the directional tendency, the cable will
either tend to turn between the lifting winch and the rope drum or will
turn later on when in operation in order to bend to the preferred direc-
tion.
In both instances, this can result in structural changes in the cable.
25.8.1.3.3 Drawing the cable by means of an auxiliary reeving rope

If the new cable is to be drawn through by cable which is to be re-
moved 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 be-
ing drawn.
Whenever a new cable is drawn through using the old cable, the two
cable ends are often welded end to end. Such a connection can
cause the torsion of the old cable, built up during operation, to be
transferred to the new rope causing extensive damage even at the
assembly stage. This procedure is, however, also problematic for oth-
er 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.
82640 2021-04-22 385

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 pos-
sesses 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 assembly will
show to what degree the old cable on the equipment was twisted.
Fig. 176: Ring / piece of chain at the end of the rope (Z 29 088)
386 82640 2021-04-22

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.
Fig. 177: Rope stocking (Z 29 089)
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 adhe-
sive tape round the cable surfaces which are to be held by the rope
stockings.
25.8.1.3.4 Winding on the rope under load

To wind the cable onto the drum smoothly 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 ten-
sion.
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 be-
ing reeled off may even become stuck at this point, the winding direc-
tion of the drum may be reversed suddenly when the cable is being
unreeled, causing the downward moving load to be raised jerkily.
82640 2021-04-22 387

The preliminary tension must be approximately 1 to 2 % of the cables'

minimum 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 assembly stage.
This can be achieved, for example, 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 manu-
facturer.
Fig. 178: Braking the reel flange Fig. 179: Braking the reel flange using a
(Z 29 090) plank (Z 29 091)
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.
Fig. 180: Jamming the cable between two wooden planks is prohibited (Z 29 092)
388 82640 2021-04-22

25.8.1.3.5 Retracting
Before a cable is placed in operation following its assembly, a certain
number of load cycles with small partial loads should first be carried
out. The cable should be "run in" so that the cable elements can set-
tle and adapt to their new environment.
Unfortunately, the opposite normally proves to be the case in prac-
tice: following assembly of the cable, overload checks are normally
carried out with loads which are above the permissible load-bearing
capacity of the system.
25.8.1.3.6 Cutting into sections and shortening
NOTE
Synchronous control of the hoists 1 (H1) and 2 (H2) of CC
cranes not possible when hoist ropes are shortened to differ-
ent lengths!
If one of the two hoist ropes H1 or H2 is shortened, then the oth-
er rope will also need to be shortened by the same length.
It is possible to use a cast fitting if a rope must be shortened at the

end which has the fitting for hanging the rope pocket. Please contact
our customer service team with any questions in this regard.
Often cables have to be cut into sections or shortened by the user.

The cables can be cut in various ways. Cable cutters can be used up
to a diameter of approx. 8 mm (0.31 in); mechanical or hydraulic cut-
ters are also available for larger diameters. If, however, a power
source is available, it is recommended that a pneumatic or electric
right-angle grinder be used.
In all cases, the cables must be carefully bound at the disconnecting
point to prevent fraying of the rope ends or changes in the cable and
strand laying lengths. This especially applies when sectioning off non-
rotating or non-twisting cables, the strands of which are often pur-
posefully 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.
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 the wire
and the cable are bound together starting at the separating point.
82640 2021-04-22 389

The cable is now bound tightly around along a length of approx.

3 times the cable diameter.
The length of wire which has been bound is then pulled tight using
pincers and is twisted together with the second wire end.
The length of the entwined wire ends is shortened to approx. the di-
ameter 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, to prevent the risk of an accident. Following corresponding
preparation of the other side of the separating point, the cable can
now be cut through.
Instead of one long winding, three windings approximately one cable

diameter wide can be placed on either side of the cutting point.
390 82640 2021-04-22

25.8.1.3.7 Moving ropes
Fig. 181: Rope deflection
When winding ropes in several positions, cables often have to be re-

moved since short rope areas are already heavily damaged (flatten-
ing, cable displacement, initial cable breakage) while the remaining
length of rope is still in flawless condition. Provided this damage is
caused by high levels of stress when crossing or raising the number
of windings on the drum, you can increase the service life of cables
by shifting (moving) them along and shortening them at the fixing
point , which moves the most heavily used rope section out of the
area of the highest stress. After this procedure, the neighbouring area
is subjected to the heavy demands.
82640 2021-04-22 391

Fig. 182: Rope crossing area
A Crossing area B Drum core

C Drum flange
For shifting purposes, the length of the most heavily damaged cross-
ing area (A) is measured. To do this, 10% of the crossing length is
added both at the start and end. This shifting is achieved by pulling
out and shortening at the drum fixing point. To shorten the ropes see
in this section under "Shortening and cutting into sections".
25.8.2 Clean ropes

1. Cables which are very dirty should be cleaned externally from
time to time.
- This applies especially to cables which are used in a particu-
larly abrasive environment and/or in the vicinity of chemically
active materials.
25.8.3 Lubricate ropes

When manufactured, a cable receives intensive lubrication which pro-
vides protection against corrosion as well as improving the friction co-
efficient of the rope elements internally and between the cable and
sheave or cable and drum. This initial lubrication lasts only for a limi-
ted period of time and must be supplemented regularly.
392 82640 2021-04-22

Cables must be relubricated at regular intervals depending on the op-

erating environment, especially in the areas where the cable bends.
If, for operational reasons, it is not possible to relubricate the rope, a
shorter service life is to be expected and the ropes must be monitored
accordingly. The effects of lubrication and relubrication on the service
life of the rope can be seen in the following figure:
Fig. 183: Effect of lubrication and relubrication on the cable's service life
(Z 29 094)
x Number of alternate bends (%) y Tensile stress (N/mm²)

a greased and re-greased b greased
c degreased
Before relubricating the ropes, they must be cleaned (see section

25.8.2 Clean ropes, side 392).
To increase their life expectancy and to protect against rust, the ropes
should be liberally coated with grease. It is not sufficient to lightly coat
the ropes; the grease must penetrate through.
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:
- using a brush or glove
- applying in the area of a sheave
- running the cable through a lubricant bath
- using a pressure collar
82640 2021-04-22 393

It is important that cables are lubricated regularly from the very start
and not only when the first signs of damage are discovered.
Furthermore, the existing standards (e. g. DIN 15 020) or national
regulations must be observed.
25.8.4 Visual inspection of the ropes, rope end connections, etc.

1. Check the state of all accessible ropes, winches and rope
sheaves before reeving and before starting crane work (including
end connections).
The responsible person in charge must be notified of any ir-
regularities found during the visual inspection.
In addition, ropes, rope end connections, etc. must undergo a more

detailed inspection (in accordance with the section 25.8.5 Check
entire ropes, replace if required, side 394). Depending on the dam-
age, the rope can be "moved along" (see section 25.8.1.3.7 Moving
ropes, side 391) or must be replaced.
25.8.5 Check entire ropes, replace if required

The inspection of the ropes in their entirety is described in detail in
the following section: 29.2.9 Inspection of the Ropes, side 500.
25.9 Lubricate hook block

DANGER
Particular care must be taken in this area during
maintenance, inspection and assembly work.
Use the hand grips located on the hook blocks.
394 82640 2021-04-22

1. Lubricate all lubricating nipples at the hook blocks or hook sus-

pension gear.
82640 2021-04-22 395

396 82640 2021-04-22

26 Heating
26 Heating
26.1 Crane chassis
26.1.1 Engine-independent auxiliary heating "Hydronic M-II D 10 W" (optional)
NOTE
Prevention of damage caused by operating errors!
In addition to the descriptions listed here, observe the manufac-
turer's instructions for the auxiliary heating in the part "Various".

WARNING
Risk of injury, fire and poisoning!
Switch the heating system off when filling up.
Never operate heating in enclosed spaces.
1. Switch the heating system on about once a month for about 10

minutes, even outside of regular heating periods.
This prevents the water pump and the burner motor from seiz-
ing up.
2. Carry out a safety check before the heating period:

2.1. Check all components to ensure they are fitted firmly,
tighten screws/bolts if required.
2.2. Check the fuel system for leak-tightness with a visual in-
spection.
3. Carry out a test run with the heater assembly before the heating
period.
NOTE
Danger due to incorrect operation or handling!
If the device starts to smoke heavily for a long period of time or
if unusual burning noises occur and/or a strong smell of fuel or
overheated electric/electronic components, switch off the heater
assembly and put it out of operation by removing the fuse (see
section "Electrical system" under "Checking the fuses"). Only re-
sume operation after it has been checked by trained qualified
personnel.
82640 2021-04-22 397

26 Heating
26.1.1.2 Auxiliary Heating - Error Diagnosis

NOTE
Repairs by non-authorised third parties and / or with non-original
spare parts are dangerous and are therefore prohibited. This results
in expiry of the type approval of the heater assembly; consequently,
it can cause expiry of the vehicle operating licence.
The heater assembly may only be repaired by authorised and
trained personnel using original spare parts.
Proceed as described below if the heater assembly does not start af-
ter switching on:
1. Switch the heater assembly off and on again.
If the heating does not start after the second attempt, proceed as fol-
lows:
2. Check the fuel supply in the fuel tank (see the section "Fuel sys-
tem").
3. If transitioning to winter operation, check whether there is still
summer diesel in the fuel line.
4. Check the components of the auxiliary heating for mechanical
damage.
5. Check the exhaust and combustion air ducts.
6. Check the fuses for the heating device in the central electrical
unit of the crane chassis.
7. Check whether a fault code is displayed in the remote control op-

eration screen (see the operating instructions of the manufactur-
er in the part "Various").
If the heater assembly is still malfunctioning even after checking

these points, please consult a specialist workshop.
26.1.1.3 Replacing fuel filter

Requirements:
If the fuel tank is full, the hose between the fuel filter and the tanks
must be disconnected before releasing the hose clips.
398 82640 2021-04-22

26 Heating
2
2
Fig. 184: Hose clips fuel filter
1 Fuel filter 2 Hose clip
1. Release both hose clips on the fuel filter.

2. Remove hoses from fuel filter.
3. Fit new fuel filter.
4. Reopen the hose between the fuel filter and fuel tank.
26.2 Superstructure
26.2.1 Engine-independent heating system (Hydronic)

WARNING
Risk of injury, fire and poisoning!
1. Switch the heating system on about once a month for about 10

minutes, even outside of regular heating periods.
This prevents the water pump and the burner motor from seiz-
ing up.
2. Carry out a safety check before the heating period:

2.1. Check all components to ensure they are fitted firmly,
tighten screws/bolts if required.
2.2. Check the fuel system for leak-tightness with a visual in-
spection.
82640 2021-04-22 399

26 Heating
3. Carry out a test run with the heater assembly before the heating
period.
NOTE
Danger due to incorrect operation or handling!
If the device starts to smoke heavily for a long period of time or
if unusual burning noises occur and/or a strong smell of fuel or
overheated electric/electronic components, switch off the heater
assembly and put it out of operation by removing the fuse (see
section "Electrical system" under "Checking the fuses"). Only re-
sume operation after it has been checked by trained qualified
personnel.
26.2.1.2 Heating system – fault diagnosis

NOTE
Only have the heater assembly repaired by authorised and
trained personnel using original spare parts.
Proceed as described below if the heater assembly does not start af-
ter switching on:
1. Switch the heater assembly off and on again.
If the heating does not start after the second attempt, proceed
as follows.
2. Check the fuel supply at the fuel tank of the superstructure heat-
ing system.
3. If transitioning to winter operation, check whether there is still
summer diesel in the fuel line.
4. Check the components of the heating system for mechanical
damage.
5. Check the exhaust and combustion air ducts.
6. Check the fuses for the heater assembly (see section "Check
fuses" under "Electrical system").
400 82640 2021-04-22

26 Heating
Fig. 185: Operating element of the heater timer (schematic diagram)
7. Check whether a fault message is shown in the timer display

(see operating instructions for the superstructure in the section
"Heating system and ventilation").
If the heater assembly is still malfunctioning even after checking

these points, please consult a specialist workshop.
26.2.1.3 Checking the Water Level

WARNING
Risk of burning due to squirting hot water!
The heating system is under overpressure.
Only open the cover lid of the expansion tank when it
has cooled down.
Fig. 186: Engine-independent heating: position of the expansion tank
1 Plastic expansion tank 2 Metal expansion tank
1. Screw off expansion tank cover lid.
82640 2021-04-22 401

26 Heating
2. Check the water level. The heating system is properly filled when
the water level is up to 20 mm (0.8 in) below the upper edge or
up to the "max" marking, depending on the model.
Check the water level when the heating system is bled.
NOTE
Danger of freezing in cold weather!
Operation with the water frozen damages the heater assembly.
Add sufficient antifreeze to the water. Use only the coolant listed
in 2 Consumables and capacities, side 27. For further coolant
approvals, please contact the heater manufacturer directly.
3. Add water as required.

4. Determine the cause of the water loss and rectify.
After any work carried out on the heating system (repairs, change of
water) bleed the heater unit including the heater assembly so that is
bubble-free.
402 82640 2021-04-22

26 Heating
26.2.1.4 Filling the fuel tank of the superstructure heating

Fig. 187: Position of fuel tank on AC 250-5 / AC 220-5
Fig. 188: Position of fuel tank on AC 160-5 / AC 130-5 / AC 150/5J
The engine-independent heating system is connected to its own fuel

tank. Depending on the crane type, it is located on the superstructure
frame on the right (AC250-5 / AC220-5) or left (AC 160-5 / AC 130-5 /
AC 150/5J).
WARNING
Risk of fire, explosion, poisoning and injury!
Switch off the auxiliary heating and switch off the die-
sel engine.
Leave the crane operator’s cab unoccupied.
Naked flame, easily flammable materials, work caus-
ing fire or flying sparks must be kept at a safe dis-
tance when filling up.
Do not smoke.
82640 2021-04-22 403

26 Heating
CAUTION
Harmful materials!
Contact with the skin or breathing in can cause health
problems.
Wear protective equipment.
Only fill up where there is good ventilation.
Do not breathe in any fumes.
NOTE
Serious heating system damage due to filling up with prohibi-
ted consumables.
Only fill up with permissible diesel fuel (see 2.6 Diesel fuel,
side 33).
1. Open the cover lid of the fuel tank.
If the maximum filling capacity is exceeded (see 2.6 Diesel fuel,

side 33), the aeration/vent valve will become immersed in the fuel
and close. The fuel tank can no longer be aerated/vented properly.
2. Fill the fuel up to the maximum fill level marking on the tank.
3. Close the cover lid of the fuel tank.
26.2.1.5 Replacing fuel filter

Requirements:
If the fuel tank is full, the hose between the fuel filter and the tanks
must be disconnected before releasing the hose clips.
404 82640 2021-04-22

26 Heating
2
2
Fig. 189: Hose clips fuel filter
1 Fuel filter 2 Hose clip
1. Release both hose clips on the fuel filter.

2. Remove hoses from fuel filter.
3. Fit new fuel filter.
4. Reopen the hose between the fuel filter and fuel tank.
26.2.1.6 Replace the heat exchanger

NOTE
Only have the heat exchanger replaced by the manufacturer or
one of his authorised workshops using an original part.
1. Have the heat exchanger replaced with an original part.

2. Have the heater assembly labelled with the purchase date of the
heat exchanger and the words "original spare part".
82640 2021-04-22 405

26 Heating
26.2.2 Flameless auxiliary heating (engine-dependent), optional
26.2.2.1 Check the hydraulic system

1. Carry out a visual inspection of the equipment:
1.1. Check the hydraulic hoses thoroughly for traces of hy-
draulic oil and damage.
1.2. Check whether the screw connections are leak-tight and
are fastened tightly enough.
2. Check the entire area under the hydraulic power pack for traces
of hydraulic oil.
CAUTION
Danger due to damaged lines and hoses.
See also the specifications in 12.10 Hose assemblies on mobile

cranes, side 178.
3. Initiate further inspections immediately if irregularities and / or

leaks in the hydraulic system are detected.
26.2.2.2 Hydraulic tank – checking the oil level, topping up if necessary

Requirements:
NOTE
Damage to the hydraulic pump when the heating system is op-
erated with too little oil.
Only operate the heating system when there is sufficient oil in
the hydraulic tank.
406 82640 2021-04-22

26 Heating
1. Check the filling level in the oil level display.
The oil level is correct if the hydraulic oil in the oil level display
is at ¾ full with an ambient temperature of 20 °C (68 °F).
2. If the filling level is too low, investigate the cause of the oil loss
and rectify immediately.
Fig. 190: Filter in the hydraulic tank
1 Aeration filter 2 Return line filter
3. Top up hydraulic oil. To do so, fill pre-filtered hydraulic oil (filter

fineness of the pre-filter system at least 15 μm) directly through
one of the filter openings, e. g. with the aeration filter removed.
Or
fill unfiltered hydraulic oil through the return line filter with an
essary.
4. Check the filter element for contamination, replace if required.
26.2.2.3 Hydraulic tank (auxiliary heating) – changing the oil

Requirements:
82640 2021-04-22 407

26 Heating
WARNING
switched off.
Ensure the system is depressurised before starting
maintenance work.
No one may be in the cab and it must be locked.
WARNING
Risk of injury due to hot hydraulic oil!
Hot hydraulic oil can scald skin and eyes and causes
higher temperatures in parts of the hydraulic system.
Fig. 191: Heat exchanger of the flameless auxiliary heating
1 Hydraulic carrier 2 Heat exchanger

3 Return hose on the heat ex-
changer

2. Release return hose (3) on the heat exchanger (2). Drain emerg-
ing oil into the collecting container.
3. Fasten the return hose (3) to the heat exchanger (2).
408 82640 2021-04-22

26 Heating
Fig. 192: Filter in the hydraulic tank

1 Aeration filter
2 Return line filter
4. Pour in fresh hydraulic oil. To do so, fill pre-filtered hydraulic oil

(filter fineness of the pre-filter system at least 15 μm) directly
through one of the filter openings on the hydraulic tank, e.g. with
the aeration filter (1) removed.
Or
Fill unfiltered hydraulic oil through the return line filter (2) with an
essary.
The oil level is correct if the hydraulic oil is at ¾ full in the oil
level display.
5. Carry out a test run.

6. Check the oil level, see 26.2.2.2 Hydraulic tank – checking the
oil level, topping up if necessary, side 406.
26.2.2.4 Hydraulic filter – checking the filter

1. Check the filter element of the return line filter in the hydraulic
tank to ensure it is not becoming clogged within a very short peri-
od of time (e. g. due to contaminated oil).
26.2.2.5 Replacing the hydraulic filter

Requirements:
82640 2021-04-22 409

26 Heating
CAUTION
Before starting maintenance work, you must ensure

that the hydraulic system is depressurised.
Switch off the engine.
NOTE
Danger of malfunction if unsuitable spare parts are used.
Only use original spare parts from the crane manufacturer.
26.2.2.5.1 Replacing the return line filter
1. Unscrew the filter cover. Take care with the sealing ring.
2. Pull the filter hood with cover and filter element from above to re-
move it.
3. Remove the filter element by moving it slightly back and forth.
4. Check the filter element, clean it if necessary.
ic components.
4.2. Check seals. Replace if required.
surfaces on the filter housing and cover as well as the
seals.
Dispose of the filter element in an environmentally friendly manner.
5. Fit the filter element in the reverse sequence.
410 82640 2021-04-22

26 Heating
6. Screw the filter cover in place. Ensure that the seal is fitted cor-
rectly in the groove of the filter cover.
26.2.2.5.2 Replacing the aeration filter

1. Completely unscrew the aeration filter from the hydraulic tank
and dispose of it in accordance with the regulations valid at the
location of operation.
2. Screw on the new aeration filter with a new O-ring.
If environmental conditions are particularly unfavourable, change the

aeration filter more frequently than specified in the lubrication and
maintenance schedule.
NOTE
Prevent damage with correct maintenance.
In addition to the descriptions listed here, observe the manufac-
turer's instructions for the auxiliary heating in the part "Various".
26.3.1 Petrol gas heating - Overview

Depending on the version, the petrol gas heating is installed in the su-
perstructure or in the crane chassis as auxiliary heating.
Petrol gas heating components in the superstructure
Fig. 193: Petrol gas heating components in the superstructure
1 Gas cylinder 2 Heat exchanger
82640 2021-04-22 411

26 Heating
Item Designation Mounting place

1 Gas cylinder behind the cab
2 Heat exchanger beneath the cab
- Electronic control unit fuse in the cab behind the seat
Petrol gas heating components in the crane chassis
Fig. 194: Petrol gas heating components Fig. 195: Position of the central electrical
in the crane chassis unit in the driver's cab
1 Gas cylinder
2 Heat exchanger
Item Designation Mounting place

1 Gas cylinder behind the cab
2 Heat exchanger beneath the cab
Electronic control unit in the central electrical unit in the
-
fuse rear panel of the driver's cab
26.3.2 Petrol gas heating - checking the system is functioning properly

WARNING
Risk of injury, fire and suffocation!
1. Even outside of the heating period, switch the heating system on

regularly to the "half" and "full" stages for approx. 10 minutes
(see the section "Heating and ventilation" in the operating in-
structions of the superstructure and/or the section "Heating, ven-
tilation and air conditioning" in the operating instructions of the
crane chassis).
412 82640 2021-04-22

26 Heating
26.3.3 Liquid petrol gas heating - carrying out a visual inspection

Fig. 196: Liquid petrol gas heating heat exchanger
1 Heat exchanger 2 Air pipes

3 Double exhaust pipe
1. Check the heat exchanger for correct mounting.

2. Check flexible air pipes for damage.
DANGER
Risk of asphyxiation due to exhaust fumes.
Exhaust fumes can get into the crane operator's cab due
to a damaged pipe or damaged seals.
Replace damaged pipes.
Fit new O-rings after every dismantling of the flue gas
evacuation system.
3. Check double exhaust pipe between the heat exchanger and the
wall flue to ensure it is intact and is connected firmly.
4. If exhaust pipes run through the cab, they must be replaced with
original parts after ten years.
82640 2021-04-22 413

26 Heating
Fig. 197: Position of the gas cylinder

1 Gas cylinder
2 Connecting line
5. Check the connecting line between gas cylinder and heater as-
sembly for damage. Replace the lead if required.
6. Check the wall flue of the flue gas evacuation system for contam-
ination due to snow slush, leaves, etc. Clean the outlet if re-
quired.
7. Check the gas cylinder to ensure it is fitted tightly.
26.3.4 Petrol gas heating - replacing the heat exchanger

NOTE
Only have the heat exchanger replaced by the manufacturer or
one of his authorised workshops using an original part.
The crane operator is responsible for instigating this replacement.
414 82640 2021-04-22

26 Heating
Fig. 198: Heat exchanger with pipes
1 Heat exchanger
1. Have the heat exchanger (1) replaced with an original part.

2. Have the heater assembly labelled with the purchase date of the
heat exchanger and the words "original spare part".
26.3.5 Petrol gas heating - having the system checked

The crane operator is responsible for instigating this inspection.
1. Have the gas system checked by a qualified person within the

specified intervals.
2. The inspection of the gas system must be confirmed on the in-
spection document in accordance with the DVGW (German
Technical and Scientific Association for Gas and Water) work-
sheet G607.
82640 2021-04-22 415

26 Heating
26.3.6 Petrol gas heating - replacing the fuse

Fig. 199: Operating element with combination gas heating rotary switch
1 Rotary switch – thermostat 2 Rotary switch - heating setting /

ventilation
3 Indicator lights under rotary A Heating setting
switch
B OFF setting C Ventilation setting
Fig. 200: Operating element with gas heating sliding switch
1 Red indicator light 2 Sliding switch - output control

3 Sliding switch - heating setting / 4 Green indicator light
ventilation
5 Rotary switch – thermostat A Heating setting
B OFF setting C Ventilation setting
The indicator lamp must be illuminated if the switch of the control unit
is switched to "Heating" or "Ventilation".
416 82640 2021-04-22

26 Heating
Proceed as follows if the indicator lamp does not light up:

1. Check the fuse in the central electrical unit (see the section
"Electrical system" under "Check fuses").
CAUTION
Electrical voltage!
The heating system must be current-less before starting
work on electric / electronic parts of the heating system.
Remove the fuse in the central electrical unit.
Switching off the heating system at the operating
panel is not enough.
Fig. 201: Fuse (F1) in the fuse box
2. Check the fuse (F1) of the electronic control unit:

2.1. Unscrew the cover of the electronic control unit.
2.2. Remove fuse (F1) and check it.
2.3. Replace defective fuses.
NOTE
Damage due to using incorrect fuses.
Only replace the microfuse (F1) on the circuit plate with an iden-
tical one: F1 = 3.15 AT (time-delay) EN 60127-2-3.
3. Screw the cover back on.
If the microfuse (F1) is damaged, it is an indication of damage to a

component in the gas heating. In this case, we recommend consult-
ing the customer service team.
82640 2021-04-22 417

26 Heating
NOTE
The heater assembly may only be repaired by authorised and
trained personal using original spare parts.
26.3.7 Petrol gas heating - changing the gas cylinder

A 5 kg gas cylinder or a 11 kg gas cylinder can be connected to op-

erate the petrol gas heating system.
Use the enclosed screw aid to screw the high-pressure lines on and
off. It ensures the required torque and prevents damage to the
screw connection caused by using the incorrect tool.
1. Remove the cover hood, if present, and close the cylinder valve
of the empty gas cylinder.
2. Unscrew the high pressure hose from the gas cylinder.
418 82640 2021-04-22

26 Heating
Fig. 202: 5 kg gas cylinder attachment Fig. 203: 11 kg gas cylinder attachment
1 Belt strap 1 Belt strap
2 Turnbuckle 2 Turnbuckle
3 Safety chain 3 Safety chain
3. Loosen the safety chain (3) and belt strap (1) using the turnbuck-
le (2).
4. Remove the empty gas cylinder from the bracket and insert a full
gas cylinder.
Fig. 204: 5 kg gas cylinder attachment Fig. 205: 11 kg gas cylinder attachment
1 Belt strap 1 Belt strap
2 Turnbuckle 2 Turnbuckle
3 Safety chain 3 Safety chain
5. The belt strap (1) is pretensioned for the 5 kg gas cylinder. After
a tension test with turnbuckle (2), pay out the strap or tighten it
as required.
Or
82640 2021-04-22 419

26 Heating
When using a 11 kg gas cylinder, the end of the belt strap and
the belt buckle must be moved almost up to the turnbuckle (2).
After a tension test with the turnbuckle, pay out the belt or tighten
it as required. If there is not enough room to tension the buckle,
the entire belt strap (1) is pulled around so that the turnbuckle
can be closed without any problems.
6. After fastening the gas cylinder, feed safety chain (3) around the
cylinder handle, tension it and attach it.
7. Screw the high pressure line into the full gas cylinder using the
screw aid.
8. Open the cylinder valve and check the leak tightness of the
screw connection using a leak-detecting spray.
9. Hold the line break protection on the high-pressure line for ap-
prox. 5 seconds.
420 82640 2021-04-22

26 Heating
Fig. 206: Hood
4 Hood 5 Gas pressure regulator

6 Reset button
10. Open the cover hood (4) and, if required, press and hold the
green reset button (6) on the gas pressure regulator (5) for ap-
prox. 5 seconds
Fig. 207: Hood
4 Hood
11. Pull cover hood (4) over the gas pressure regulator and cylinder
valve.
The regulator must be protected against contamination.
Observe the instructions for the gas pressure regulator in the sec-
tion "Various".
82640 2021-04-22 421

26 Heating
422 82640 2021-04-22

27 Air Conditioning
27 Air Conditioning
27.1 Components of the air conditioning on the crane chassis
27.1.1 Standard air conditioning on the crane chassis
Fig. 208: Diagram of standard air conditioning on the crane chassis
1 Capacitor (condenser) 3 Air conditioning compressor

5 Evaporator 8 Collector dryer
9 Filling connections 10 Vehicle engine
14 Pressure measurement 15 Ambient temperature measure-
ment
82640 2021-04-22 423

27 Air Conditioning
Fig. 209: Components of the standard air conditioning on the crane chassis
1 Capacitor (condenser), depending on design moun- 2 Air conditioning compressor

ted on the vehicle engine
3 Vehicle engine 4 Capacitor (condenser), depending on design moun-
ted on the hydraulic tank
5 Collector dryer 6 Filters
7 Evaporator 8 Heat exchanger
9 Air conditioner: Filter (6), evaporator (7), heat ex- 10 Fan
changer (8) and fan (10) are installed in this.
11 V-belts
424 82640 2021-04-22

27 Air Conditioning
27.1.2 Auxiliary air conditioning on the crane chassis
Fig. 210: Diagram of the auxiliary air conditioning on the crane chassis
1 Components of the air condition- 2 Evaporator

ing in the crane operator’s cab
3 Ambient temperature measure- 4 Filling connection
ment
5 Air conditioning compressor with 6 Components of the condenser
hydraulic motor unit
7 Capacitor (condenser) 8 Pressure measurement
9 Collector dryer
82640 2021-04-22 425

27 Air Conditioning
Fig. 211: Components of the auxiliary air conditioning in the driver's cab (sche-
matic diagram)
1 Driver's Cab 2 Filters

5 Air conditioner: Filter (5), evapo- 6 Fan
rator (6), heat exchanger (7) and
fan (9) are installed in this.
Fig. 212: Components of the auxiliary air conditioning on the crane chassis
1 Capacitor (condenser) 2 Collector dryer

3 Air conditioning compressor with
hydraulic motor
426 82640 2021-04-22

27 Air Conditioning
27.2 Components of the superstructure's air conditioning
27.2.1 Standard air conditioning on the superstructure
Fig. 213: Diagram of the standard air conditioning on the superstructure
1 Components of the standard air conditioning in the 2 Evaporator

crane operator’s cab
3 Ambient temperature measurement 4 Components of the condenser unit on the hydraulic
reservoir
5 Collector dryer 6 Pressure measurement
7 Capacitor (condenser) 8 Rotary transmission
9 Filling connection 10 Air conditioning compressor, fitted on the hydraulic
pump
11 Liquid separator
82640 2021-04-22 427

27 Air Conditioning
Fig. 214: Components of the standard air conditioning in the crane operator’s cab
1 Fan 2 Air conditioner: Fan (1), heat ex-

changer (3) filter (4) and evapo-
rator (6) are installed in this.
3 Heat exchanger 4 Filters
5 Air flap 6 Evaporator
Fig. 215: Capacitor (condenser) of the standard air conditioning for the crane op-
erator’s cab on the superstructure
1 Capacitor (condenser)
428 82640 2021-04-22

27 Air Conditioning
Fig. 216: Components of the standard air conditioning for the crane operator's cab
on the crane chassis
10 Air conditioning compressor, fit- 11 Liquid separator, fitted at axle 3

ted on the hydraulic pump be-
tween axles 2 and 3
17 V-belts
27.2.2 Auxiliary air conditioning on the superstructure
Fig. 217: Diagram of the auxiliary air conditioning on the superstructure
1 Components of the auxiliary air 2 Evaporator

conditioning in the crane opera-
tor’s cab
3 Ambient temperature measure- 4 Filling connection
ment
5 Air conditioning compressor with 6 Components of the condenser
hydraulic motor unit
7 Capacitor (condenser) 8 Pressure measurement
9 Collector dryer
82640 2021-04-22 429

27 Air Conditioning
Fig. 218: Components of the auxiliary air conditioning in the crane operator's cab
(schematic diagram)
1 Crane operator's cab 2 Fan

3 Air conditioner: Fan (2), heat ex- 4 Heat exchanger
changer (4), evaporator (5) and
filter (6) are installed in this.
5 Evaporator 6 Filters
Fig. 219: Components of the auxiliary air-conditioning on the superstructure

hydraulic motor
27.3 Switching on the Air-Conditioning (Damage Prevention)

1. Switch the air conditioning on at least once a month for ap-
prox. 10 minutes.
This prevents the shaft seal in the air conditioning compressor
becoming dry and brittle. Otherwise there is a risk of cooling
agent leaking.
The components of the air conditioning compressor are lubri-

cated regularly.
430 82640 2021-04-22

27 Air Conditioning
27.4 Servicing the Air Conditioning Equipment - Operator

27.4.1 Service standard air conditioning
DANGER
Risk of explosions due to heating up!
Soldering and welding work on parts of the air condition-
ing cause the cooling circuit to heat up a great deal. This
increases the pressure in the air conditioning system and
can cause explosions.
Do not carry out any soldering or welding directly on
components in the closed refrigeration circuit or in its
close proximity.
Carry out visual inspections even when the air conditioning equip-
ment is not being used.
Carry out visual inspections:
Fig. 220: Components of the standard air Fig. 221: Components of the standard air
conditioning for the driver's cab on the conditioning for the crane operator's cab
crane chassis on the crane chassis
1 V-belts
2 Air conditioning compressor
1. Check the function of the air conditioning compressors (2):

1.1. Check the tension of the V-belt (1).
1.2. Check the mounting of the air conditioning compres-
sors (2).
82640 2021-04-22 431

27 Air Conditioning
2. Check the refrigerant level:

2.1. To do so, operate the air conditioning at the highest level
with the engine running (control knob for temperature se-
lection and fan settings in the crane operator's cab and
driver's cab to max. position).
Fig. 222: Collector dryer of the standard air conditioning on the crane chassis
Fig. 223: Collector dryer of the standard air conditioning on the superstructure
2.2. Observe the inspection glass of the collector dryer. The re-
frigerant must flow through it without any bubbles.
NOTE
pairs!
Maintenance and repair work on the air conditioning refrigera-
tion circuit may only be carried out by expert personnel.
The air conditioning equipment may only be filled by a specialist
workshop.
If there are bubbles in the inspection glass, there is not enough refrig-
erant in the air conditioning system. The air conditioning must be
checked by an authorised workshop for any leaks and refilled.
After switching off, the fluid level must go back down in the respective
collector dryer. This is the only way to ensure that the reservoir is not
over-filled.
432 82640 2021-04-22

27 Air Conditioning
WARNING
Risk of fire at components of the air conditioning!
Tubes and hoses containing coolant can be hot and they
can be under pressure.
Do not come into contact with the capacitor, the air
conditioning compressor or their leads.
3. Check the leads and their mountings:

3.1. Check the state of the refrigerant and heating lines:
3.1.1. Check the mountings, leak-tightness and laying of
the hoses and screw connections.
3.1.2. Check the hoses are working faultlessly when
there is obvious material fatigue.
3.1.3. Tighten the hose clips if required.
3.2. Check the electrical connecting lines and plug connections
to ensure they are in faultless condition and are fitted firm-
ly.
82640 2021-04-22 433

27 Air Conditioning
Fig. 225: Capacitor on the standard air

Fig. 224: Components of the standard air
conditioning of the superstructure on the
conditioning on the crane chassis
hydraulic reservoir
NOTE
Risk of damage!
Do not use a high pressure washer.
4. Check the state of the capacitors (1) on the crane chassis and
superstructure:
4.1. Clean the contaminated capacitors on the chassis and su-
perstructure by blowing through them or spray washing.
4.2. Discs which are pressed inwards by external influences
can be straightened again.
4.3. Check water drainage to ensure it is fault-free.
CAUTION
Risk to health due to condensed water!
The air conditioning's condensed water can carry an in-
creased amount of dirt and germs.
Under no circumstances may the resulting condensed
water be used for drinking water.
434 82640 2021-04-22

27 Air Conditioning
Fig. 226: Air conditioning unit of the standard air conditioning in the driver's cab
and crane operator's cab (schematic diagram)
1 Fan 2 Evaporator/heat exchange com-

bination
3 Filters
5. Check the state of the evaporator / heat exchanger combination:

5.1. Clean the contaminated evaporator/heat exchanger com-
bination (2) and fan (1) in the driver's cab and in the crane
operator's cab regularly.
5.2. Check the insulation on the air conditioning unit for dam-
age and replace if required.
5.3. Check the probe of the thermostat on the evaporator. It
may not be positioned in the unit so that it is bent or cau-
ses leaks.
6. Check the filter (3) in the driver's cab and in the crane operator’s
cab for contamination. If required, clean it by blowing through it,
tapping it or changing the filter.
Do not wash out the filter using water.
27.4.2 Service auxiliary air conditioning
DANGER
Risk of explosions due to heating up!
Soldering and welding work on parts of the air condition-
ing cause the cooling circuit to heat up a great deal. This
increases the pressure in the air conditioning system and
can cause explosions.
Do not carry out any soldering or welding directly on
components in the closed refrigeration circuit or in its
close proximity.
Carry out visual inspections even when the air conditioning equip-
ment is not being used.
82640 2021-04-22 435

27 Air Conditioning
Carry out visual inspections:
Fig. 227: Components of the auxiliary air conditioning on the Fig. 228: Components of the superstructure's auxiliary air
crane chassis conditioning
2 Collector dryer
3 Air conditioning compressor with hydraulic motor
1. Check the function of the air conditioning compressors (3):

1.1. Check the mounting of the air conditioning compres-
sors (3).
2. Check the refrigerant level:
2.1. To do so, operate the air conditioning at the highest level
with the engine running (control knob for temperature se-
lection and fan settings in the driver's cab and crane oper-
ator's cab to max. position).
2.2. Observe the inspection glass of the collector dryer (2). The
refrigerant must flow through it without any bubbles.
NOTE
pairs!
Maintenance and repair work on the air conditioning refrigera-
tion circuit may only be carried out by expert personnel.
The air conditioning equipment may only be filled by a specialist
workshop.
436 82640 2021-04-22

27 Air Conditioning
If there are bubbles in the inspection glass, there is not enough refrig-
erant in the air conditioning system. The air conditioning must be
checked by an authorised workshop for any leaks and refilled.
After switching off, the fluid level must go back down in the respective
collector dryer. This is the only way to ensure that the reservoir is not
over-filled.
WARNING
Risk of fire at components of the air conditioning!
Tubes and hoses containing coolant can be hot and they
can be under pressure.
Do not come into contact with the capacitor, the air
conditioning compressor or their leads.
3. Check the leads and their mountings:

3.1. Check the state of the refrigerant and heating lines:
3.1.1. Check the mountings, leak-tightness and laying of
the hoses and screw connections.
3.1.2. Check the hoses are working faultlessly when
there is obvious material fatigue.
3.1.3. Tighten the hose clips if required.
3.2. Check the electrical connecting lines and plug connections
to ensure they are in faultless condition and are fitted firm-
ly.
82640 2021-04-22 437

27 Air Conditioning
Fig. 229: Components of the auxiliary air conditioning on the Fig. 230: Components of the superstructure's auxiliary air
crane chassis conditioning
2 Collector dryer
3 Air conditioning compressor with hydraulic motor
NOTE
Risk of damage!
do not use a high pressure washer.
4. Check the state of the capacitors (1) on the crane chassis and
superstructure:
4.1. Clean the contaminated capacitors on the chassis and su-
perstructure by blowing through them or spray washing.
4.2. Discs which are pressed inwards by external influences
can be straightened again.
4.3. Check water drainage to ensure it is fault-free.
CAUTION
Risk to health due to condensed water!
The air conditioning's condensed water can carry an in-
creased amount of dirt and germs.
Under no circumstances may the resulting condensed
water be used for drinking water.
438 82640 2021-04-22

27 Air Conditioning
Fig. 231: Air conditioning unit of the auxiliary air conditioning in the driver's cab
and crane operator's cab (schematic diagram)
1 Fan 2 Evaporator/heat exchange com-

bination
3 Filters
5. Check the state of the evaporator / heat exchanger combination:

5.1. Clean the contaminated evaporator/heat exchanger com-
bination (2) and fan (1) in the driver's cab and in the crane
operator's cab regularly.
5.2. Check the insulation on the air conditioning unit for dam-
age and replace if required.
5.3. Check the probe of the thermostat on the evaporator. It
may not be positioned in the unit so that it is bent or cau-
ses leaks.
6. Check filter (3) for contamination. If required, clean it by blowing
through it, tapping it or changing the filter.
Do not wash out the filter using water.
82640 2021-04-22 439

27 Air Conditioning
27.5 Servicing the Air Conditioning - Specialist Workshop

27.5.1 Components of the standard air conditioning
Fig. 232: Components of the standard air conditioning for the driver’s cab
1 Capacitor (liquefier) 2 V-belts

3 Air conditioning compressor 4 Filters
7 Fan 8 Collector dryer
10 Vehicle engine 16 Air conditioner: Filter (4), evaporator (5), heat ex-
changer (6) and fan (7) are installed in this.
440 82640 2021-04-22

27 Air Conditioning
Fig. 233: Components of the standard air conditioning in the crane operator’s cab
1 Fan 2 Air conditioner: Fan (1), heat ex-

changer (3) filter (4) and evapo-
rator (6) are installed in this.
3 Heat exchanger 4 Filters
5 Air flap 6 Evaporator
Fig. 234: Capacitor (condenser) of the standard air conditioning for the crane op-
erator’s cab on the superstructure
82640 2021-04-22 441

27 Air Conditioning
Fig. 235: Components of the standard air conditioning for the crane operator's cab
on the crane chassis
10 Air conditioning compressor, fit- 11 Liquid separator, fitted at axle 3

ted on the hydraulic pump be-
tween axles 2 and 3
17 V-belts
27.5.2 Components of the auxiliary air conditioning
Fig. 236: Components of the auxiliary air conditioning in the driver's cab (sche-
matic diagram)
1 Driver's Cab 2 Filters

5 Air conditioner: Filter (5), evapo- 6 Fan
rator (6), heat exchanger (7) and
fan (9) are installed in this.
442 82640 2021-04-22

27 Air Conditioning
Fig. 237: Components of the auxiliary air conditioning for the driver's cab on the
crane chassis

hydraulic motor
Fig. 238: Components of the auxiliary air conditioning in the crane operator's cab
(schematic diagram)
1 Crane operator's cab 2 Fan

3 Air conditioner: Fan (2), heat ex- 4 Heat exchanger
changer (4), evaporator (5) and
filter (6) are installed in this.
5 Evaporator 6 Filters
82640 2021-04-22 443

27 Air Conditioning
Fig. 239: Components of the auxiliary air conditioning for the crane operator's cab
on the superstructure

hydraulic motor
27.5.3 Checking the air conditioning in its entirety

A specialist workshop must service the air conditioning to ensure it
functions faultlessly.
1. Check the electrical connecting lines to ensure they are in fault-
less condition and are firmly fitted.
2. Check that the air conditioning functions faultlessly.
27.5.4 Checking the refrigeration circuit

NOTE
Risk of damage due to incorrect refrigerant!
Only use authorised refrigerant (see 2.20 Refrigerant,

side 41).
Observe the safety data sheet of the refrigerant.
1. Check the refrigeration circuit for the refrigerant filling level and
for contamination.
Replace contaminated refrigerant.
2. Check the state of collector dryer on the crane chassis and su-
perstructure.
Replace the collector dryer if there are signs of rust or con-
densation in the inspection glass (see 27.5.5 Replacing the
collector dryer, side 445).
444 82640 2021-04-22

27 Air Conditioning
3. Check the state of the refrigerant and heating lines:

3.1. Check the mountings, leak-tightness and laying of the ho-
ses and screw connections.
3.2. Replace the hoses if there is obvious material fatigue.
3.3. Tighten the hose clips if required.
4. Check the air conditioning compressors to ensure they operate
faultlessly:
- Noise-free running
- Oil level
- Safe attachment of the air condition compressor
27.5.5 Replacing the collector dryer

NOTE
Risk of environmental pollution.
Carefully evacuate the air conditioning before any intervention in

the refrigeration circuit.
Do not release refrigerant into the atmosphere.
1. Ensure that dirt and moisture cannot get into the refrigeration cir-
cuit.
2. Carefully undo connections to relieve any residual pressure.
3. Replace the collector dryer on the crane chassis and superstruc-
ture.
Replace the collector dryer after any intervention in the cooling cir-
cuit.
27.5.6 Changing refrigerator oil

Consumables: 2.21 Refrigerator oil, side 41
1. Extract refrigerator oil together with the refrigerant.
2. Seal the connections correctly for filling the system. To do so, al-
ways use new sealing rings.
3. Determine filling quantity. Only add as much refrigerator oil as
was previously drained.
4. Through the filling connections on the air conditioning hoses, fill
new refrigerator oil together with the refrigerant into the pressure
side of the refrigeration circuit.
82640 2021-04-22 445

27 Air Conditioning
We recommend that you change the refrigerator oil during regular

replacement of the collector dryer.
27.5.7 Top up refrigerant

Consumables: 2.20 Refrigerant, side 41
CAUTION
Danger due to contact with refrigerant.
Liquid refrigerant may not come into direct contact
with skin.
Wear protective goggles when handling refrigerant.
1. Switch off the air conditioning in the driver's cab and in the crane
operator’s cab.
2. Top up refrigerant through filling connections.
27.6 Fault diagnosis air conditioning unit

Error Cause Remedy
Check the fitting of the fuse, fit
correctly if required. Replace de-
fective fuses. If another fault oc-
curs within the shortest possible
Blower not functioning Loose or defective fuse
time, it indicates a short circuit or
a blockage. Check the fan for
blockages or other defects and
rectify the problem.
Check lines for loose contacts or
Line interruption
breaks.
Defective blower motor Replace the fan.
Check switch, replace if re-
Defective blower switch
quired.
Rectify the short circuiting, if re-
Short circuiting in the cable or in
Fan cannot be switched off quired fit (a) new cable(s) and /
the blower switch
or switch(es).
Clean the plug contacts. Pro-
Fan working at reduced per-
Contact contaminated ceed carefully to prevent short
formance
circuiting.
Electrical lines under-dimen- Install cables with recommended
sioned cross-sections
Clean it carefully and avoid dam-
Heat exchanger heavily conta- age which could lead to leaks.
minated Caution! Observe the safety in-
structions.
446 82640 2021-04-22

27 Air Conditioning
Error Cause Remedy

Replace the resistor and check
Micro temperature fuse (MTS) is
Fan not running at all settings the blower motor for causes for
activated
diminished function.
Replace the switch with an origi-
Defective blower switch nal spare part from the manufac-
turer.
Check the coupling for firm fitting
and fit correctly if required.
Connector plug is loose
Check the connection on the fan
switch.
Resistor faulty Fit a new resistor.
Wait until the vehicle engine is
No or insufficient heating Inlet temperature is too low
warm.
Check the water valve and wire
Water valve cannot be opened
pull and replace if required.
Vehicle thermostat is faulty Replace the thermostat.
Heat exchanger fins are conta- Check the heat exchanger, clean
minated if required.
Filter is clogged Clean or replace filter.
Rectify cause of the fault or lay
Water leads bent or squashed
new hoses.
Cooling agent not flowing
Water pump pressure is too low through the heat exchanger. Fit
additional or stronger pumps.
The heating system cannot be Bowden cable for water valve
Adjust the Bowden cable.
switched off set incorrectly
Check the Bowden cable and re-
Bowden cable defective
place if necessary.
Fit water valve correctly, observe
Water valve not fitted correctly
direction of the forward motion!
Check the fitting of the hoses
Cooling agent leaking from unit Hose coupling is loose
and tighten hose clips.
Damaged tube Lay a new hose and connect it.
Fit an original spare and connect
Heat exchanger is damaged it. Caution! Observe the safety
instructions.
82640 2021-04-22 447

27 Air Conditioning
Error Cause Remedy

Foreign object is blocking the Check the flap and remove any
Flap cannot be adjusted
flap foreign bodies.
Check the flap bearing and re-
Flap bearing defective
place if required.
Check the wire pull and replace
Wire pull corroded
if required.
Bowden cable control defective Replace the control.
27.7 Fault Diagnosis Cooling Performance

Error Cause Remedy
Interruption in the solenoid coil Check the power supply to the
Condenser does not work
of the condenser coupling.
V-belt loose or torn Set V-belt tension, replace V-belt
V-belt pulley not turning even
Check the condenser, replace if
though magnetic coupling is ap-
required
plied
Repair coupling or replace com-
Condenser coupling is slipping
pressor.
Check control and replace if re-
Control defective
quired.
Expansion valve is in the open
Evaporator is flooded Replace expansion valve.
position or is stuck
Thermostat probe in incorrect
Evaporator is iced over Reposition probe.
position
Expansion valve or thermostat Replace expansion valve or ther-
defective mostat.
Evaporator is clogged Cooling fins clogged Clean evaporator.
Check all leads for beaks due to
Interference of the refrigerant
Loss of refrigerant external circumstances or to
lead
chafing.
Evacuate, fill, check for leaks
Leak in the system
and repair.
448 82640 2021-04-22

27 Air Conditioning
Error Cause Remedy

Check air inlet and outlet for ob-
Cooling power is insufficient Fan flow hindered
stacles. Rectify fault.
Fill up with refrigerant (service
Filling level of refrigerant too low
engineer).
Empty the air conditioning equip-
ment, replace the collector dryer,
Damp in the system
empty and fill up (service engi-
neer)
Collector dryer saturated or
Replace collector dryer.
clogged
Condenser fins are contamina- Clean the fins. Note: Do not use
ted a high-pressure cleaner!
Interruption in lead; Loose con-
Check the leads, repair or re-
System cools with interruptions tacts in the field coil of the com-
place.
pressor
Fan motor defective Replace fan.
27.8 Fault Diagnosis Noise Development

Error Cause Remedy
System very loud V-belt loose or excessively worn Retension or replace V-belt.
Coupling is loud Repair the coupling.
Condenser holding device is
Repair holding device; replace
loose or inner condenser com-
compressor.
ponents have been knocked out
Excessive wear of the fan motor Replace fan.
Vacuum cooling agent until high
System overfilled
pressure display is normal again.
Too little refrigerant in the sys-
Check for leaks; fill up system.
tem
82640 2021-04-22 449

27 Air Conditioning
450 82640 2021-04-22

28 Cabs
28 Cabs
28.1 Driver's Cab
28.1.1 Checking the windscreen washer system for proper functioning

1. Check the windscreen washer system regularly for proper func-
tioning.
28.1.2 Fill up the supply tank of the windscreen washer system

Consumables: 2.19 Windscreen wiper fluid, side 41
The filling opening of the supply tank is located on the passenger's
side.
1. Fill the supply tank of the windscreen washer system with water
and some cleaning agent if required.

28.1.3 Emergency call equipment (Glonass - FORT 112 EC, option) - Check function
The function of the emergency call device is checked by means of
self-diagnostic tests. The device performs a self-diagnostic test every
time the ignition is switched on.
NOTE
It is prohibited to press the emergency call button to check the
functioning of the device. In this case, the device does not use
the verification number, but the emergency call number.
82640 2021-04-22 451

28 Cabs
28.1.3.1 Test mode
28.1.3.1.1 Select test mode

Some of the tests require the participation of one person sitting in the
vehicle (they must follow instructions and perform certain actions), the
other part of the tests does not require the participation of persons.
The results of all tests can be heard over the loudspeaker in Russian
and English. Upon completion of the tests, the device will exit the test
mode and send the minimum data record of the test result to the
ERA-GLONASS test number.
Requirements:
- Do not move the crane vehicle for (at least) 1 minute
1. Switch on test mode.
1.1. Switch on the ignition.
1.2. Press the "Additional functions" key briefly (not longer than
1.5 seconds).
The following message sounds: "Please confirm the switch to
test mode by pressing the" Additional functions" button for 1
second."
If the device does not switch to test mode, this message does
not sound and the status indicator flashes red.
The device can not switch to test mode when:

- the ignition is off,
- the vehicle was moved during the last minute,
- the device waits for a callback of the ERA-GLONASS operator (the
waiting time depends on the configuration of the device, but does
not exceed 2 hours).
The number of flashing signals can help to find the possible reason
why the device can not switch to test mode.
- 5 flashing signals: the vehicle was moved.
- 10 flashing signals: other reasons (for example: the ignition is
switched off).
- 15 flashing signals: the vehicle waits for a callback from the ERA-
GLONASS operator (the waiting time depends on the configura-
tion of the device, but does not exceed 2 hours).
452 82640 2021-04-22

28 Cabs
2. Press the "Additional functions" button to confirm the activation

of the test mode.
If the "Additional functions" button is not pressed, the device
will switch to basic mode within 10 seconds.
If the test mode is activated, the status display of the control

device alternately flashes red and green.
The test is interrupted if:

- the ignition or the external power supply is switched off (except
during the ignition test),
- the crane vehicle is moved more than 300 m (0.186 mi).
28.1.3.1.2 Perform tests

Description of
Test # Measures Expected result
the test
The device checks the loudspeaker cir- The loudspeaker is connected to
cuits. If there are no malfunctions, the the TCU. The "Additional func-
Loudspeaker
1 following message sounds: "Press the tions" button was pressed 10
test
"Additional functions" button when you seconds after the audio mes-
hear this message". sage.
The device checks the microphone cir-
cuits. If there are no malfunctions, the
following message sounds: "Please
The microphone is connected to
speak the text within 5 seconds of the
the TCU. The "Additional func-
signal". This text will be re-encoded.
2 Microphone test tions" button was pressed 10
The following message sounds: "Press
seconds after the audio mes-
the "Additional functions" button when
sage.
you hear your voice". The following
messages sound: "Switch off the igni-
tion" and then "Switch on the ignition".
The following messages sound: The ignition was switched off
3 Ignition test "Switch off the ignition" and then and switched on 20 seconds af-
"Switch on the ignition". ter the audio message.
Two messages sound: "Press the "Ad-
ditional functions" button when the dis- The "Additional functions" button
Display (status
4 play is green" and then "Press the" Ad- was pressed 10 seconds after
display) test
ditional functions"button when the dis- each audio message.
play is red.
Test of the The emergency call button was
5 emergency call pressed for 10 seconds after the
the emergency call button".
button audio message.
Checking the The "Additional functions" button
6 "Additional func- was pressed 10 seconds after
the "Additional functions" button".
tions" button the audio message.
82640 2021-04-22 453

28 Cabs
Description of
Test # Measures Expected result
the test
Measurement of the voltage state of
Test the backup The voltage state is constant
7 the backup battery and its power sta-
batteries and lies within the target range.
bility.
Response from the acceleration
Acceleration Start the acceleration sensor self-diag- sensor that the acceleration sen-
8
sensor test nostic function. sor test has been successfully
completed.
GSM module Send the test command to the GSM Received the correct answer
9
test module. from the GSM module.
GLONASS /
Validation of received data (NMEA
10 GPS module The received data are correct.
communication protocol)
test
Check of the ex-
The device checks if there is an exter- The external power supply is
11 ternal power
nal power supply or not. available.
supply
Test of the
Calculation of the checksum of the The calculated checksum is cor-
12 checksum of the
software image. rect.
software image
Test of the flash Writing of random data to the FLASH The written and the read data
13
memory memory and reading this data. match.
The GSM antenna is connected
Test of the GSM The device checks the circuits of the
14 to the TCU and there is no short
antenna GSM antenna.
to ground or current.
The GLONASS / GPS antenna
Test of the GLO- is connected to the TCU and the
The device checks the circuits of the
15 NASS / GPS an- current consumption of the an-
GLONASS / GPS antenna.
tenna tenna amplifier is within the tar-
get range.
Table 48: Tests of the emergency call device
28.1.3.2 Elimination of malfunctions
The test numbers listed below refer to the tests in the table "Tests of
the emergency call system" (see 28.1.3.1.2 Perform tests,
side 453).
If malfunctions of external circuits have been detected (Test # 1-6,

11, 14, 15 failed), make sure that the circuits of the corresponding
parts are working properly and connected to the TCU. Then switch
the device back to test mode. If there are still malfunctions, replace
the corresponding part of the device.
454 82640 2021-04-22

28 Cabs
Failure of the backup battery test (test # 7) may result in low backup
battery charge because the external power supply was interrupted for
a long time (while the backup battery was connected). There is no ex-
ternal power supply to the device if the crane vehicle battery is dis-
connected or has a low charge, especially if the crane vehicle has not
been used for a long time.
Make sure that the backup battery has been charged for at least 10
hours after connecting to the external power supply (total) and that
during this time the ignition has been turned on and the ambient air
temperature has exceeded 0 °C (+32 °F). If after charging the backup
battery, the backup battery fails again, replace the backup battery.
If some of the tests for internal components (test # 8, 9, 10, 13) fail,
exit test mode and then put the device back into test mode. If the mal-
functions are confirmed after new tests, replace the TCU.
If the test of the checksum of the software image (test # 12) has
failed, it is possible that there is no information about the crane vehi-
cle in the TCU: VIN code, vehicle type, type of energy storage (if the
control input parameter function was activated during configuration).
In this case, use the VIN-Loader software to read out parameters
from the TCU and to verify that all parameters have been written. If
this is not the case, write the parameters of the crane vehicle.
28.2.1 Lubricate tilt cylinder (option)

Fig. 240: Lubricating nipple of the tilt cylinder
1 Tilt cylinder
1. Lubricate the tilt cylinder of the crane operator's cab via a lubri-
cating nipple on both the foot bearing and the piston rod bearing.
82640 2021-04-22 455

28 Cabs
28.2.2 Checking the windscreen washer system for proper functioning

1. Check the windscreen washer system regularly for proper func-
tioning.
28.2.3 Fill up the supply tank of the windscreen washer system

Consumables: 2.19 Windscreen wiper fluid, side 41
WARNING
ulations.

It is possible to access the supply tank of the windscreen
washer system from the crane chassis.
The supply tank is behind the crane operator's cab.
3. Fill the supply tank of the windscreen washer system with water
and some cleaning agent if required.

456 82640 2021-04-22

29.1 General
In order to keep the crane in a safe operating condition, the operator
must take the relevant precautions. An important tool is regular in-
spections. These inspections may only be carried out by specialised
employees (ISO 9927−1), i. e. "technical experts" or "appraiser".
A technical expert is someone who, due to his/her professional train-
ing and experience, has sufficient knowledge of cranes and is familiar
enough with the appropriate governmental health and safety regula-
tions, accident prevention regulations and the generally recognised
regulations of the technology to ascertain the operational safety of
cranes (BGG 905, section 3.2).
An appraiser is someone authorised by the employer's liability insur-
ance association or an authorised expert of the technical surveillance
(BGG 905, section 3.1).
Assembly of the crane must be part of the inspection before first rais-
ing of loads. The inspection is carried out while the boom/equipment
is on the ground.
In addition to an extensive inspection, we recommend carrying out a
function test under actual conditions but without load. This test, car-
ried out at the construction site before a load is raised for the first
time, makes it possible to check the kinematics of the crane (e.g. op-
erating range, length of ropes/cables) and to confirm the operating
conditions for all functions and the operating elements required for
raising.
If the crane has been subjected to an exceptional situation, for exam-
ple, overloading or a collision with external obstacles, we recommend
carrying out a thorough inspection to ensure the integrity of the con-
struction. This inspection may consist of a visual inspection, non-de-
structive examinations and function tests.
29.2 Recurrent Inspections of the Crane

29.2.1 General
It is the responsibility of the crane operator to have the crane inspec-
ted 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).
82640 2021-04-22 457

The following applies for Germany: Crane inspection to be carried out

at least once annually by a technical expert, and at least every four
years by an authorised expert (however, they must be carried out an-
nually after the 12th year of operation). The minimum requirement of
the German regulations applies for the inspection intervals; for stricter
regulations over and above this, they should be observed.
As part of this inspection, the remaining theoretical service life of the

winches (in accordance with BGV D8, ISO 12482−1, Annex A) must
be calculated, see 29.2.6.2 Theoretical Service Life, side 489.
The following information is based upon the regulations of the acci-

dent prevention regulations "Cranes" (BGV D6) with regard to regular
routine crane inspections.
Inspections according BGV D6 do not replace the applicable nation-

al regulations.
The recurrent crane inspection is basically a visual and function in-

spection which essentially includes:
- checking the identity of the crane against the details in the inspec-
tion book (crane log book).
- checking the condition of the components and equipment with re-
gard to damage, wear, corrosion or other changes.
- checking the completeness and effectiveness of safety equipment
and brakes.
- checking the state of the carrying equipment with regard to dam-
age, wear, corrosion or other changes.
- checking to ensure there are decals and that they are complete
and legible.
The test specifications for the recurrent crane inspection can serve
as an aid, see 29.2.11 Test specifications for the recurrent crane
inspection, side 510
Technical experts / qualified personnel inspect the crane as a matter
of their own responsibility. The results of the inspections must be re-
corded in the log book and must be certified.
29.2.2 Inspection of lashing points with wear markings
CAUTION
Danger due to damaged welding points and improper
use!
Incorrectly installed or damaged welding points as well
as improper use can lead to injuries to persons and dam-
age to objects during a fall.
Check all welding points carefully before each use.
458 82640 2021-04-22

The continued suitability of the attachment point must be checked at

least once a year by a technical expert. The inspection is also neces-
sary when damage has occurred and any special incidents.
1. Check the entire welding point:
- for completeness of the attachment point
- for complete, legible capacity specification and existing manu-
facturer's designation
- for any deformation on load-bearing parts such as base bod-
ies
- for mechanical damage such as strong notches, especially in
areas subject to tensile stress
- for heavy corrosion (pitting)
- for cracks in load-bearing parts
- for cracks or other damage to the weld seam
Fig. 241: wear markings - use permitted Fig. 242: wear markings - use prohibited
2. Carefully check the wear markings of the welding point for cross-
sectional changes.
If the material has been rubbed down to the wear lenses, the
use of the corresponding lashing point is prohibited.
82640 2021-04-22 459

29.2.3 Checking the components
The inspector is personally responsible for carrying out the inspec-

tion, as well as for content and extent. The following tables only
serve as examples and additional aids to the inspector. They make
no claim to completeness.
Crawler-mounted vehicle, crane chassis and superstructure

Components Check for
- Frame
- Cracks
- Supports
- Deformation
- Slewing rim
- Wear
- Axles
- Mounting and locks of detachable parts
- Axle suspension
- Corrosion and corrosion protection
- Wheels
- Warning paint
- Crawlers
- Laying of cables and hoses
- Base plates
Crane equipment
- Main boom - Cracks
- Fly jib - Deformation
- Luffing masts - Wear
- A-frame - Mounting and locks of detachable parts
- Boom support - Free movement of bearings and guides
- Erecting supports - Assembly and rope reeving
- Guides - Corrosion and corrosion protection
- Expanders - Elongation
- Overextension lock - Plastic distortion
- Stay bars - Paintwork
- Bracing rods - Laying of cables and hoses
Counterweight
- Counterweight sections
- to make sure all parts are complete and properly attached.
- base plate
460 82640 2021-04-22

Drives
- Mounting and locks of detachable parts
- Condition
- Function
- Final drive - Noises
- Slew gear drive - Smooth starting and stopping
- Crane drive - Idling
- Winch drive - Wear of couplings and brakes
- Effectiveness of return locks
- Wear of involute spline connection
- Laying of cables and hoses
Rope drives
- Rope drums
- Configuration and storage of rope sheaves, rope guide rollers
- Sheaves
and rope drums (sheave grooves, flanged wheels, wear).
- Rope guide rollers
Hydraulic equipment
- Hydraulic pumps
- Mounting
- Hydraulic motors
- Condition
- Cylinders
- Function
- Valves
- Noises
- Container
- Leaks
- Hydraulic accumulators
- State of the hydraulic oil and quantity
- Lines
- Filling pressures
- Filter
Pneumatic equipment
- Compressors
- Engines - Mounting
- Cylinders - Condition
- Valves - Function
- Pressure tanks - Noises
- Lines - Leak-tightness
- Filter
82640 2021-04-22 461

Electric equipment
- Alternators
- Engine
- Resistors
- Brake vents
- Mounting
- Lighting equipment
- Condition
- Heating
- Function
- Lines
- Insulation
- Collectors
- Protection against direct contact of active parts
- Switch
- Protection against indirect contact
- Contactors
- Installation
- Fuses
- Batteries
- Lines
- Warning devices
Control equipment final drive

- Condition
- Function
- Coupling - Idling
- Shift mechanism - Shutdown
- Engine control - Free movement
- Steering - Play of linkage and tie-rods (dead gear)
- Brakes - Display of monitors, lamps and signals
- Marking
- Brake tests
Controls for the crane drive

- Condition
- Function
- Idling
- Slew gear
- Shutdown
- Hoists
- Free movement
- Boom derricking gears
- Play of linkage and tie-rods (dead gear)
- Brakes
- Display of monitors, lamps and signals
- Marking
- brake test with load (test load in the load capacity range)
462 82640 2021-04-22

Other control equipment

- Outriggers
- Condition
- Additional equipment
- Function
- axle blocks
Lubrication
- Sufficient filling
- Transmission
- Oil loss
- Accessibility
- Lubricating nipple - Recognisability
- Marking
Steps and safety guards

- Mounting and state
- Ladders
- Mounting
- Trims
- Condition
- Coverings
- Completeness
- Rope guides
- Effectiveness
Safety Equipment
- Load limit device
- Emergency limit switch equip-
ment
- Mounting
- Warning devices
- Condition
- Locking devices
- Completeness
- Radius indicator
- Function
- Tilt indicator
- Wind meter
- Wind safeguard
Signs
- Plates - Completeness and legibility
82640 2021-04-22 463

29.2.4 Inspection of Load-bearing Steel Constructions
29.2.4.1 General
The load-bearing steel constructions must also be carefully inspected
during the specified recurrent crane inspections.
It is important to check the welded seams in particular.
The schematic diagrams listed below are examples for load-bearing
welded constructions. Inspections must be carried out at the connec-
tions / zones around the points / welded seams marked by arrows.
The inspector is personally responsible for carrying out the inspec-

tion, as well as for content and extent. The following schematic dia-
grams only serve as examples and additional aids for the inspector.
They make no claim to completeness.
The crane is designed for assembly operation in accordance with

ISO 4301−1 and EN 13000.
If the crane was subjected to excessive stress during operation, e. g.
due to an exceptional hit or blow, there must be an immediate inspec-
tion of the load-bearing components.
If damage, e. g. cracks, are found anywhere in the steel construction,
the extent of the damage must be determined by suitable specialists
using recognised material examination methods (e. g. magnetic pow-
der, ultrasound or x-ray inspections) - with a subsequent decision on
the possibility and type of repair work.
29.2.4.2 Schematic diagrams - mobile cranes
Fig. 243: Frame of the crane chassis
464 82640 2021-04-22

Fig. 244: Front frame of the crane chassis
Fig. 245: Supports
82640 2021-04-22 465

Fig. 246: Superstructure frame
Fig. 247: Superstructure frame
466 82640 2021-04-22

Fig. 248: Main boom
Fig. 249: Basic boom of the main boom extension
82640 2021-04-22 467

Fig. 250: Box top piece of the main boom extension
Fig. 251: Intermediate section of the main boom extension
468 82640 2021-04-22

Fig. 252: Intermediate section of the main boom extension
Fig. 253: Foot section of the fly jib
82640 2021-04-22 469

Fig. 254: Reducer of the fly jib
Fig. 255: Intermediate section of the fly jib
470 82640 2021-04-22

Fig. 256: Intermediate section of the fly jib
Fig. 257: Top section of the fly jib
82640 2021-04-22 471

Fig. 258: Head connecting piece of the fly jib
Fig. 259: Luffing mast connection piece of the fly jib
Fig. 260: Luffing mast of the fly jib
472 82640 2021-04-22

Fig. 261: Luffing mast of the fly jib
Fig. 262: Flying bridle of the fly jib Fig. 263: Bracing rod of the fly jib
Fig. 264: Head sheave
82640 2021-04-22 473

Fig. 265: Runner
Fig. 266: Superlift
474 82640 2021-04-22

Fig. 267: Lateral Superlift
Fig. 268: Anti-fall protection Fig. 269: Disc wheel
82640 2021-04-22 475

29.2.4.3 Schematic diagram - lattice-mast cranes
Fig. 270: Intermediate section of the chassis
Fig. 271: Crawler track carrier (CC 8800)
476 82640 2021-04-22

Fig. 272: Crawler track carrier (Duo)
Fig. 273: Crawler track carrier (Quadro)
82640 2021-04-22 477

Fig. 274: Sliding girder of the chassis Fig. 275: Sliding girder of the chassis (idler side)
Fig. 276: Superstructure frame 1
478 82640 2021-04-22

Fig. 277: Superstructure frame 2
Fig. 278: A-frame
82640 2021-04-22 479

Fig. 279: Counterweight base plate
Fig. 280: Foot section of the main boom
480 82640 2021-04-22

Fig. 281: Intermediate section of the main boom
Fig. 282: Reducer of the main boom
82640 2021-04-22 481

Fig. 283: Top piece of the fly jib
Fig. 284: Foot section of the fly jib
482 82640 2021-04-22

Fig. 285: Fly jib LF
82640 2021-04-22 483

Fig. 286: SL mast foot section and SL mast point
Fig. 287: Head adapter Fig. 288: Sheave head
484 82640 2021-04-22

Fig. 289: Runner
Fig. 290: Upper luffing mast
82640 2021-04-22 485

Fig. 291: Lower luffing mast
Fig. 292: Bracing rods of the fly jib
486 82640 2021-04-22

Fig. 293: Anti-fall protection Fig. 294: Disc wheel
29.2.5 Checking the adjusting cylinders

Have adjusting cylinders checked at least once a year by a technical
expert. Depending on the country in which the work is being per-
formed, this may be regulated by country-specific regulations, e.g. ac-
cording to the accident prevention regulations "Cranes" (BGV D6). If
there are no corresponding regulations in the country in which the
work is being performed, perform the test anyway in order to maintain
the operating safety of the crane. Make a record of this inspection
(e. g. in the examination log book for the crane).
Since the inspection intervals are normally based on the operating

conditions, shorten them correspondingly if the crane is operated
more frequently.
1. Check the following points by visual inspection:

- Leak tightness of the cylinders
- Cracks in the piston rod, piston rod housing and attachment
points
- Chromium plating of the piston rod
- Damage
- Paintwork
- Plastic deformation
If defects are found, inform the crane manufacturer's custom-
er service department.
82640 2021-04-22 487

29.2.6 Inspection of the Winches
29.2.6.1 General
DANGER
Danger if the winch service life expires!
Not complying with these specifications for calculating
the remaining service life of the winch may result in un-
noticed expiration of the winch and sudden, unexpected
winch failure. This could result in serious accidents with
extensive property damage and fatalities.
Observe the regulations on calculating the remaining
service life of the winch.
An external visual inspection is not sufficient. The service life of the

winches can be reduced by bad servicing, defective seals, unprofes-
sional operation or overloading. For this reason a specialist must car-
ry out inspections in accordance with the following regulation.
Inspections
- Inspection interval:
- every 1000 operating hours
- at least 1 x annually
- Check the oil level
- Check for colouring of oil
- Check for solid foreign matter (this inspection must be carried out
by a qualified lab)
- Visual inspection
- Check the brakes on the transmission of the winches
- Check the involute spline connection "Engine-brake-transmission"
During the annual crane inspection, the spent share of the theoreti-
cal service life of the winches must also be calculated. The crane
operator must employ a specialist for the purpose if necessary.
Where accident prevention regulations of the German employer's li-

ability insurance association apply, this is required by law.
Outside of the scope of application, the crane manufacturer recom-
mends that the procedure listed is also observed.
488 82640 2021-04-22

29.2.6.2 Theoretical Service Life
WARNING
Risk of accidents due to incorrect period of use.
The theoretical period of use may not be equated with
the real (actual) period of use of a winch!
In addition, the real service life of a winch is affected by a
number of external influences, for example:
Overloading due to not using the crane in accordance
with regulations.
Insufficient maintenance: the oil is not changed in
good time.
Maloperation such as extreme acceleration or decel-
eration of the load or the load falling into the ropes.
Maintenance errors such as using the wrong oil, in-
correct filling quantity or contamination when chang-
ing the oil.
Assembly errors during repair and maintenance.
Leaks that have been neglected.
Incorrectly set safety equipment.
Concealed damage caused by accidents.
Extreme ambient conditions such as low or high tem-
peratures, aggressive atmosphere or dust and dirt.
The design engineer has assumed certain operating conditions in cal-

culating and dimensioning the winches on your crane.
The winches of your crane are classified as follows (ISO 4301/1,
FEM 1.001, DIN Calculation parameters for power units):
Power unit group: M........

Load collective: Q....... (L.......)
Factor of the load collective: km = ..........
This results in a theoretical service life D.
The individual values can be taken from the table "Monitoring the
winches" in the crane log book.
29.2.6.3 Actual Operating Conditions

To calculate the spent share of the theoretical service life of the
winches, the actual operating conditions (load spectrum) and the
operating hours of the hoists per inspection interval must be de-
termined.
82640 2021-04-22 489

29.2.6.4 Determining the Operating Conditions (Load Spectrum)

The load spectrum of the crane is divided into groups (see also
ISO 4301/1, FEM 1.001).
1. From knowledge of the actual operating conditions, select one of
the load spectrums listed below.
2. Enter the selected load spectrum in the crane examination log
book for the respective inspection interval.
Load spectrum class: light Q 1 L 1: Power units or parts thereof
subject to highest load only as an exception but which are routinely
subject to very low operational demands
Shares of operating time:
- 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
Load spectrum factor (Km): 0,125
Load spectrum class: medium Q 2 L 2: Power units or parts thereof

subject to highest load quite often but routinely only subject to low op-
erational demands
- 1/6 of the run time with 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
Load spectrum class: heavy Q 3 L 3: Power units or parts thereof

often subject to highest load and routinely subject to medium opera-
tional demands
490 82640 2021-04-22

Load spectrum class: very heavy Q 4 L 4: Power units or parts

thereof regularly subject to high load in the realm of highest opera-
tional demands
Load spectrum factor (Km): 1
29.2.6.5 Operating Hours of the Hoists per Inspection Interval

1. Calculate the effective operating hours per inspection interval
(Ti).
2. Record these effective operating hours for the respective inspec-
tion interval in the crane examination log book.
As a rule, the hoist winch share of the total operating hours for the su-
perstructure is 20 % for mobile cranes used for assembly operation.
If hoist rope reevings are correspondingly reduced for loads below

the maximum capacities of the selected capacity table, and the per-
mitted rope load is therefore almost completely utilised, this must be
taken into consideration when calculating the winch load.
82640 2021-04-22 491

29.2.6.6 Determining the Spent Share 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 spent share of the theoretical service
life of the winches is calculated from the formula:
Si = spent share of theoretical service life

factor of the load spectrum in the inspection interval "i" in ac-
kmi = cordance with section 29.2.6.4 Determining the Operating
Conditions (Load Spectrum), side 490
factor of the load spectrum which formed the basis of calcula-
km =
tion of the winch (here: km = 0.125)
effective operating hours in the inspection interval "i" in ac-
Ti = cordance with section 29.2.6.5 Operating Hours of the
Hoists per Inspection Interval, side 491
CAUTION
Risk of accidents due to worn parts.
In any case, a general overhaul is required at the lat-
est 10 years after the crane is placed in operation.
The general overhaul must be arranged by the opera-
tor and carried out by the manufacturer (or persons
authorised by the manufacturer) and must be entered
in the crane log book.
A new theoretical service life is then specified by the
manufacturer or persons authorised by the manufac-
turer following the general overhaul.
The max. time period to the next general overhaul is,
however, 10 years at the most.
This spent share is subtracted from the remaining theoretical service

life after each inspection interval (see the example in 29.2.6.7.1
Documentation - example (creating the sample table), side 494). Ob-
serve the following:
- If the theoretical service life remaining is presumably insuffi-
cient for the next operating period, a general overhaul of the
winch must be carried out.
- If the theoretical service life D is reached, the winch may only be
operated further after a general overhaul has been carried out.
492 82640 2021-04-22

29.2.6.7 Documentation
Fig. 295: Example of a sample table (theoretical service life of the winches)
82640 2021-04-22 493
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
- Tables for each winch.
With the help of these tables the remaining theoretical period of
use of each winch is to be documented.
The crane operator is liable for the correctness of the specifications

in the corresponding tables!
29.2.6.7.1 Documentation - example (creating the sample table)

Inspection no. 1 (year 1)
The crane has been used for assembly work in the past year:
Load spectrum L1, i. e. km1 = 0.125
The superstructure operating hour meter reads 800 h. The winch
was in operation for approx. 20 % of this time i. e. T1 = 160 h.
The used share S1 of the theoretical service life is therefore during
1st inspection:
The values for the load spectrum factor (here: km = 0.125) and the
theoretical service life (here: D = 3200 h) are specified in the head
of the respective table.
Remaining theoretical service life after the first year:
494 82640 2021-04-22


The crane has been used for unloading operations at the harbour:
load spectrum L3, 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 year of operation) =
1200 h. The winch was in operation for approx. 40 % of this time i. e.
T2 = 480 h.
The used share S2 of the theoretical service life is therefore in the
2nd inspection interval:
Remaining theoretical service life after the second year:

The crane has been used for assembly work and occasionally for un-
loading work in the harbour:
load spectrum L2, i. e. km3 = 0.25.
The superstructure operating hour meter reads 3000 h, i. e. during
this period: 3000 h − 2000 h (used in the first two years of operation)
= 1000 h. The winch was in operation for approx. 30 % of this time
i. e. T3 = 300 h.
The used share S3 of the theoretical service life is therefore in the
3rd inspection interval:
Remaining theoretical service life after the third year:
Calculations must now be carried out to determine whether the re-

maining theoretical service life is sufficient for the next operating peri-
od. If this is not the case, a general overhaul must be carried out (
29.2.6.6 Determining the Spent Share of the Theoretical Service Life
of the Winches, side 492).
29.2.7 Load hook

1. The hooks must be checked by a specialist once a year.
This should prevent accidents because faults will be deter-
mined early on.
2. Any faults that are discovered must be documented as well as

their rectification.
82640 2021-04-22 495

3. Then you must check whether the determined faults have been
rectified.
Inspection and surveillance measures:
Check for deformation, localised cold forming and compression in the
pincer mouth, cracks, wear, rusting.
Lock fitting of the hook nuts.
Deformation
If the hook jaw expands more than 10 % compared to the starting di-
mension "y" or "y1"+ "y2", the hook must be replaced.
Fig. 296: Graining on the hook for measuring the deformation (Z 54 325)
The starting measurement "y" or "y1" + "y2" is marked on the hook.

It is measured from grain to grain.
Corrosion
Threads and the treated shaft must be checked for corrosion and
wear. To do so, the hook nut must be unscrewed from the shaft.
If aftertreatment is needed to remove the corrosion, the thread core

diameter may not be undercut by more than 5 % by this process.
Otherwise, the hook must be replaced.
For older hooks, the main dimensions must be compared with the
specifications in DIN 687, 689, 699, for newer hooks, the main di-
mensions must be compared with the specifications in DIN 15401
and 15402 with regard to the jaw width, main bending cross-section,
thread core diameter.
496 82640 2021-04-22

29.2.8 Inspection of the Sheaves
29.2.8.1 Perform a visual check
DANGER
Danger due to damaged rope sheaves.
Replace rope sheaves with damage such as e. g.
cracks or notches immediately.
DANGER
Particular care must be taken in this area during
maintenance, inspection and assembly work.
1. Check rope sheaves for damage such as e. g. cracks, notches or

similar damage and check the bearings are seated properly (free
movement).
2. Check the tread:
- The tread must be smooth.
- The bottom tread must be concentric to the shaft or to the
bore in the rope sheave.
- The centre line of the groove must be vertical to the shaft axle
or to the hole in the rope sheave at one level.
82640 2021-04-22 497

29.2.8.2 Checking plastic rope sheaves for wear
Fig. 297: Plastic rope sheave
d Diameter of the rope X Wear on the lower tread

Y Wear to the lateral tread
1. Checking the rope sheaves for wear:

- Bottom tread "X" max. 3 mm (0.12 inch).
Dimension "X" is the half a diameter difference from the diam-
eter of the lower tread of a new rope sheave (Dnew) to the di-
ameter of the lower tread of the rope sheave to be inspected
(Dactual):
X = (Dactual - Dnew)/2
- Side tread "Y" max. 5 mm (0.2 inch).
Dimension "Y" measured between the rope and the tread of
the rope sheave.
CAUTION
sheaves.
assemble the individual components of the sheaves.
For safety reasons, sheaves may only be replaced as
complete components.
2. Replace rope sheaves when the wear limit has been reached.
498 82640 2021-04-22

29.2.8.3 Checking steel rope sheaves for wear
Fig. 298: Steel rope sheave
d Nominal diameter of the rope R Tread radius, actual state
1. Check the rope sheaves for wear.

The tread radius must not undercut the values in the table.
Nominal diameter of the rope min. tread radius

mm in mm in
21 0.827 10.7 0.42
23 0.906 11.8 0.46
24 0.945 12.3 0.48
26 1.000 13.3 0.51
28 1.102 14.3 0.56
30 1.181 15.3 0.60
32 1.250 16.3 0.64
40 1.575 20.5 0.80
Table 49: Wear limit of the steel rope sheaves
CAUTION
sheaves.
assemble the individual components of the sheaves.
For safety reasons, sheaves may only be replaced as
complete components.
2. Replace rope sheaves when the wear limit has been reached.
82640 2021-04-22 499

29.2.9 Inspection of the Ropes
29.2.9.1 General
In addition, observe national standards such as DIN 15 020, Part 2,

for example, and international standards, such as ISO 4309, for ex-
ample.
A cable is a basic consumer item with a limited life span. Many char-
acteristics of a cable change throughout its period of use. For exam-
ple, its breaking force initially increases slightly with continued use
before falling rapidly once a maximum value has been reached.
This fall in breaking force is explained by the increasing loss in the
metal cross-section due to abrasion and corrosion, wire breakage and
structural changes in 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 purposes of a cable inspection is to monitor the continu-
ous increase in the amount of wire breakage, so that the cable can be
removed in good time, before an unsafe operating state is achieved.
A further purpose of the rope inspection is to spot abnormal cable
damage, which as a rule is normally caused by external influences.
On the one hand, this makes it possible to remove cables in good
time; on the other hand, identifying weak points in the rope drive ena-
bles one to take measures which help prevent such damage occur-
ring repeatedly.
Generally, the visual appraisal must be of the entire cable; critical
points must of course be given increased scrutiny.
Critical points are:
- Cable sections which carry out the highest number of flexing cy-
cles. Increased abrasion and wire breakage must be anticipated
here.
- Load pick-up points. If a lifting device favours a certain point for
picking up or setting down a load, all cable sections which are on
rope sheaves in this position or that reel onto or from the drum in
this position, are subjected to exceptional demands.
- Cable end mountings
- Cable sections on balancing sheaves
- Cable sections on cable drums
- Cable pulleys
- Cable sections subjected to aggressive media or heat.
It may be necessary to dismantle components before an accurate as-
sessment of the carrying equipment can be made.
500 82640 2021-04-22

Intervals
The ISO 4309 standard recommends:
- daily visual check of the cables and rope end fastenings for any
possible damage
- regular inspection of the cables by trained specialists to ensure an
operationally safe condition
- Special inspections:
- after exceptional loading or supposed invisible damage
- after longer standstill times
- when lifting devices have been removed for a change in loca-
tion, before beginning operation at the new operating location
- after any accident or cases of damage in connection with the
rope drive
Scope of the inspection
Wear from friction, rust markings, rusting, crushing points, loosening
of outer wire layers, clustering of ropes, formation of loops from cords
or wires, twisting, corkscrew formation, kinks, number of visible wire
breakages, clusters of broken wires, cord breakage. Determine the
rope diameter in relation to the condition of the sheaves on the drums
and rollers. Fasten to ensure the rope does not spring out. Check the
condition of the fastening of the ends of the rope. Protect against the
effects of heat from fire operations.
29.2.9.2 Criteria for removal

Cables must be removed in good time with safety in lifting equipment
operation in mind. Using the listed criteria, the following is an indica-
tion of when a cable must be removed in relation to the extent of the
damage. If use is continued, operation of the lifting device can be-
come dangerous. See also DIN 15 020, sheet 2 and ISO 4309.
The criteria stated previously do, however, determine the replace-
ment schedule. In borderline cases, or if in doubt, always replace the
ropes.
82640 2021-04-22 501

The criteria for replacing the ropes which have been listed are
meant to act merely as a reference point for the daily visual inspec-
tion. The description of the regular inspections exceeds the context
of the lubrication and maintenance instructions. It is contained in the
corresponding national regulations.
- Type and quantity of wire breaks

Rope / cable drives are designed so that the cables are not fatigue
endurable. This is why wire breakage occurs during operation. A
cable must be removed at the latest when a certain number of visi-
ble wire breaks is determined at any point. For the precise number
of max. permissible wire breaks for a fixed length - depending on
the cable used - observe the corresponding details in the national
standards (DIN 15 020, Part 2) or international standards
(ISO 4309).
- Position of wire breakages
If there are wire breakage clusters, the cable must be removed. If
a cord is broken, the cable must be removed immediately.
- Time sequence of wire breakage
In important cases we recommend determining the number of wire
breaks in relation to time. This helps to predict the further increase
of wire breakage and to forecast when the cable will have to be re-
moved. You must remember that wire breakage only occurs after a
certain period of operation and then advances increasingly quickly.
- Reduction of cable diameter
The cable must be removed if, due to structural changes, the di-
ameter of a longer section of the rope has decreased by more than
15 % of the specified size.
- 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 reduction
of the static breaking strength of the cable, as the metal rope
cross-section is reduced, and can lead to a reduction in operation-
al stability due to corrosion pits. If the rope diameter is decreased
by 10 % or more compared to the specified size, the cable must
be removed even if no wire breakage has been discovered.
- 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 con-
veyed. Abrasion is encouraged if lubrication is insufficient or lack-
ing or by the effect of dust. Due to abrasion, the cable's static ten-
sile strength can be reduced due to a decrease in the metallic rope
cross section and the fatigue strength can be reduced due to wear
grooves. If the rope diameter is decreased by 10 % or more com-
pared to the specified size, the cable must be removed even if no
wire breakage has been discovered.
502 82640 2021-04-22

- Rope deformations
Cable deformations are visible in the rope structure. Deformation
generally also causes the rope structure to loosen in the area of
the deformation. Depending on the appearance, there is the follow-
ing differentiation of the most important deformations:
Fig. 299: Corkscrew type deformation
Fig. 300: Corkscrew type deformation
d Cable nominal diameter g Distance
- Corkscrew type deformation

The cable must be removed if any of the following occurs:
- on a straight cable section which never runs through or
around a rope pulley or reels onto a drum, the gap between
a level surface and the bottom of the helix is 1/3 × d or more;
- on a straight cable section which runs through a rope pulley
or reels onto a drum, the gap between a level surface and
the bottom of the helix is 1/10 × d or more.
Fig. 301: "Basketwork" formation (deformation)
- "Basketwork" formation (deformation)

Cables with basket formation must be removed immediately; or
the relevant section must be removed if the remainder of the
cable is in a serviceable state.
82640 2021-04-22 503

Fig. 302: Emerging inlay - single-layer cable
Fig. 303: Emerging or deformed cords
- Emerging or deformed inlay and/or cords

If individual wires or cords loosen, the exterior wires of the loa-
ded cable or individual cords can be shifted.
They do not then take on the tensile force as intended and
which overloads the other wires or cords.
If the cable runs over sheaves, it can cause increased bending
tension which causes premature wire breakage.
Fig. 304: Emerging wire
- Loop formation
Cables with emerging wires must be removed immediately. Of-
ten these occur in groups on the side which is opposite to the
side in contact with a rope pulley groove.
504 82640 2021-04-22

Fig. 305: Local cable diameter increase due to deformation of the inlay
- Local increase of the rope diameter

If the rope diameter is increased during operation by 5 % or
more in a cable with a steel core or by 10 % or more in a cable
with a fibre core, the reason for this must be determined and re-
moval of the cable must be taken into consideration.
Fig. 306: Flattening
Fig. 307: Flattening
- Flattening
Flattened cable sections which run through a rope pulley tend
to wear more quickly and have wire breakage. In such cases,
removal of the cable must be taken into consideration depend-
ing on the extent of flattening.
Flattened cable sections in standing rigging can corrode more
than other, non-affected sections, particularly if the outer cords
open up, enabling penetration of damp. If these cables remain
in operation, they must be inspected more often; otherwise re-
moval of the cable must be taken into consideration.
82640 2021-04-22 505

Fig. 308: Kink (positive, in the rope-closing sense)
Fig. 309: Kink (negative, in the rope-opening sense)
Fig. 310: Kink
- Kink or tightened rope loop

Cables or ropes with a kink or tightened rope loop must be re-
moved immediately.
A kink or tightened rope loop is a deformation caused by a loop
in the rope or cable which has been tightened around its axis
without twisting. This creates an uneven length of lay which
causes excessive wear; in serious cases the rope or cable is so
deformed so that there is only a small share of its strength left.
- Bends in the cable
Cable sections with a pronounced bend which run through a
rope pulley tend to wear more quickly and have wire breakage.
In such cases, the cable must be removed immediately.
If the degree of deformation is not regarded as serious, and if
the cable remains in operation, it must be inspected more regu-
larly; Otherwise its removal must be taken into consideration.
The decision on whether the bend is serious or not is a subjec-
tive one. It must be viewed as serious if there is a fold on the
bottom of the bend, regardless of whether the cable runs over a
rope pulley or not.
506 82640 2021-04-22

- Damage due to heat or electric arcs

Cables must be removed immediately which are not normally oper-
ated under the effects of heat but have been subjected to excep-
tionally high thermal impact; this can be detected on the exterior by
the corresponding heat discolouration of the steel wires and/or a
significant loss of lubricant from the cable.
The cable must be removed if two or more wires are locally affec-
ted by electric arcs due to e.g. welding lines being earthed incor-
rectly. This can occur at the current entry point or the current exit
point.
29.2.10 Checking the hose assemblies
29.2.10.1 Documenting the inspection

1. When the hose assemblies are inspected, keep a record of any
notable observations made by the authorised inspector; Recom-
mendation:
1.1. Location and state of the hose assembly in question
1.2. Corresponding details on date and time
1.3. Date of the next inspection of the hose assemblies in
question
2. A record must be kept of this decision if the authorised expert de-
cides not to replace a hose assembly which has exceeded its
normal service life or is slightly damaged.
3. Keep any observations and decisions by the authorised expert
with the documents of the respective crane.
29.2.10.2 Check hoses
CAUTION
Danger due to damaged hose assemblies.
Replace hose assemblies which show signs of exter-
nal damage or abrasion immediately.
1. Check the hose assemblies using the inspection criteria, see

29.2.10.3 Inspection criteria, side 508.
2. Disassemble hose assemblies which are not completely accessi-
ble for inspection.
3. If hose assemblies are encased by protecting hoses (e. g. corru-
gated hoses), the protecting hoses must also be checked.
Contact points between the hydraulic and protecting hoses
can indicate abrasion on the hose assembly.
82640 2021-04-22 507

29.2.10.3 Inspection criteria

Replace the hose assemblies when at least one of the following
points applies:
- Damage to the external surface of the hose material, e. g. cracks,
cuts, abrasion.
- Brittle external surfaces due to the material ageing (cracks).
- Deformation which does not correspond with the original guide and
shape of the hose assemblies.
Check this criterion both when the hose assemblies are under
pressure and when they are not under pressure and/or are bent.
Example:
- Separation of hose layers
- Formation of hollow spaces
- Crushing
- Bending
- Twisting
- Leaks
- Damage or deformation to the hose fittings (sealing function im-
paired).
- Movement between hose material and hose assembly, hose is
coming out of the fitting.
- Corrosion on the fittings which could impair the fittings' solidity and
function.
29.2.10.4 Possible causes for damage

Hose assemblies may show no signs of external damage or abrasion.
If this is the case, the reasons listed below could be the cause:
- Due to improper hose guide or the hose assembly vibrating/
moving during operation, there is contact with other components.
- There is contact with external particles in hose assemblies which
are fitted at unprotected points and during driving, are therefore
exposed to:
- stones
- water
- salt, etc.
- There is an aggressive environment (corrosive air, etc.).
508 82640 2021-04-22

29.2.10.5 Specifications on replacing hose assemblies

- During assembly or replacement, maintain the specified hose
bending radii.
- The values of the hose bending radii selected by the crane
manufacturer are based on international or hose manufacturer
specifications and have been confirmed by testing the hose as-
semblies. If a hose is bent below the minimum value of the pos-
sible bending radii specified by the crane manufacturer, it cau-
ses a loss of mechanical force and can cause the hose to mal-
function.
- During assembly or replacement, ensure that the hose assembly is
laid in accordance with the crane manufacturer's specifications.
- Lay the hose assembly according to the specifications of the
crane manufacturer to prevent possible damage to the hose, for
example by stretching, compressing, bending or abrasion at
sharp edges, therefore ensuring a maximum period of use and
safety.
- After replacement, ensure that the hose assembly has been laid
correctly.
- This applies to when the line is under pressure as well as to
when it is not under pressure.
- If required, check the direct vicinity of the hose assembly for mo-
bile parts.
- Prevent any contact between the hose assembly and mobile
parts.
- Fit hose assemblies in a straight position, ensure they are not taut.
- This allows for changes in length.
Changes to length occur when pressure is applied to the hose
assembly. For example, a hose line is shortened if it is under
pressure. If a hose line is too short, it could be ripped out of the
fitting or place too heavy demands on it, which causes prema-
ture wear to the metal or the seal.
It is important that the hose line maintains its function as a "flexible

tube" and that it is not impaired by changes to length when under
pressure.
- Do not twist the hose assembly during fitting.

- Mechanical demands are prevented.
- Clamp, hold or support the hose assembly in accordance with the
specifications of the crane manufacturer.
- The hose assembly is laid safely.
- Contact with damaging surfaces is prevented.
82640 2021-04-22 509

- Do not cross or clamp together hoses assemblies for high-pres-

sure lines and hose assemblies for low-pressure lines with direct
contact.
- The different length changes could cause wear to the hose
sleeves.
- Keep hose assemblies from warm components.
- High ambient temperatures decrease the hose assemblies' peri-
od of use. Protective hose assembly insulation in accordance
with the specifications of the crane manufacturer could be re-
quired in environments with high temperatures and must be re-
fitted after any repairs.
29.2.11 Test specifications for the recurrent crane inspection

Test specifications for recurrent crane inspections in accordance with
§ 26 Seg. 1 and 2 of the accident prevention regulations"Cranes"
(BGV D6).
These test specifications are only a general guide. They are not
type-related and do not cover the complete range of all possible de-
signs.
Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
Construction year: Inventory no.: Signature:
Inspection group: crane document

test component A B C D E Remarks
Inspection log book for the crane
Operation / assembly instructions
Capacity tables
Inspection group: notices/markings

Crane designation sign
Load / stress details
Notice of operating regulations
Prohibition and regulation signs
Other safety markings
510 82640 2021-04-22

Inspection group: counterwight dolly 1)

Axles
wheels
Tyres
storage
Connecting components Superlift -
counterweight dolly
Inspection group: crawler chassis 1)

Drive gearbox
Idlers
Sheaves
Support rollers
covering
Steps
Crawler track
travel gear
Central lubricating system
Inspection group: crance chassis 1)

Frame 2)
Axle suspension
Axle interlock
Outriggers 2)
covering
Steeping surfaces
Steps
Counterweight holding devices 2)
Holding device for block 2)
Boom support 2)
Attachment device
82640 2021-04-22 511

Inspection group: travel gear 1)

Axles
wheels
Tyres
storage
Distributor gear
Cardan shaft
Leaf springs / springs
Shock dampers
Brakes
Hydraulic axle suspension
Inspection group: driver's cab 1)

Doors
Windows / glass
Wipers
Mirrors
Seat
Heating
Ventilation
Noise absorption
Tachograph
First-aid box
Replacement lamps
Hazard warning triangle
Warning jacket
512 82640 2021-04-22

Inspection group: drive 1)

Combustion engine
Exhaust system / combustion protec-
tion
Fuel tank
fuel lines
filters
Engine suspension
Oil / coolant levels
Inspection group: hydraulics 1)

Oil tank
filters
Pumps
Engines
Valves
Lines
Hoses
Cylinders
Pressure relief valves
Lowering brake valves
Inspection group: compressed air system 1)

Compressor
filters
Air tank
Valves
Lines
Hoses
Cylinders
82640 2021-04-22 513

Inspection group: electrical system 1)

Engines
Alternators
Batteries
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 Display 2)
Inspection group: control devices 1)

Engine control
Transmission
Clutches
Circuits
Steering
Control displays
Engine stop
Control of the outriggers 2)
Axle suspension
Crane levelling
rear-axle steering
Slew brake
514 82640 2021-04-22

Inspection group: superstructure

Frame
Coverings
Steeping surfaces
storage
Counterweights
Backstroke safety device
Slewing rim: fixing screw
Slewing rim: toothing
Slew gear: fixing screw
Slew gear: toothing
Slew gear: drive
Slew gear: lock
Slew gear: trim
Inspection group: crane operator's cab

Doors
Windows / glass
Wipers
Mirrors
Seat
Heating / air conditioning equipment
Ventilation
Mufflers
Control lever for operating functions
gear shifts
Safety devices: points of crushing/
shearing
Inspection group: retaining devices and safety guards

Handles and ladders
Coverings
Covers
Flaps
82640 2021-04-22 515

Inspection group: rope drive

Winch H13)
Winch H23)
Winde W1/H33)
Winch W2 3)
Winch E3)
Winch R3)
Rope sheaves
Rope end fixture
Rope for winch H1
Rope for winch H2
Rope for winch W1/H3
Rope for winch W2
Rope for winch E
Rope for winch R
Bracing ropes
Inspection group: hook/hook blocks

Sheaves
Protecting clamps on the sheaves
Axle stirrups
Hooks
Hook fastenings
Lock-on hook
516 82640 2021-04-22

Inspection group: safety and switching devices

Hoist limit switch H1
Hoist limit switch H2
Lower limit switch H1
Lower limit switch H2
Boom limit switch E1
Boom limit switch E2
Top section:
Boom limit switch W1
Top section:
Boom limit switch W2
load limit device
Length display: working radius, boom
length
Angle indicator: boom
Angle indicator: luffing fly jib
Angle indicator: slew gear
Safety equipment: control system
Operating Range Limits
Tilt Indicator
Support Pressure Display
EMERGENCY OFF
Inspection group: boom

Welded construction
Rope sheaves
Boom support
Boom pinning
Bracing rods / ropes
Retaining cylinders
Back stroke cylinder
Luffing cylinder
Telescoping cylinders
Extension ropes
Pull ropes
82640 2021-04-22 517

Inspection group: special equipment

Test criteria:
A: existing / complete
B: state / servicing
C: Function
D: repair / replacement
E: subsequent inspection required
Evaluation:
x= satisfied
-= not satisfied
0= not required
Remarks:
1) It is considered that an inspection of the traffic safety status of the mobile crane has been car-
ried out if there is a fault-free result of expert inspection in accordance with the road traffic li-
censing regulations. The expert must carry out an inspection of the traffic safety status on mo-
bile cranes which are not authorised for travel on public roads (see also UVV “Vehicles"
BGV D29).
2) The expert must still carry out these inspections even if there is a fault-free result from an ex-
pert 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
29.3 Inspection of Cranes with a Load Test
29.3.1 General
The crane manufacturer does not recommend carrying out a regular
overload test on cranes / mobile cranes.
An overload test after every change of location or crane reconfigura-
tion is not a reliable and safe inspection method and can cause pre-
mature material fatigue.
518 82640 2021-04-22

In some countries, national laws require overload tests, e.g. in ac-

cordance with information from the crane manufacturer.
Every crane / mobile crane is subjected to a load test by the manufac-
turer within a final acceptance procedure before delivery. These tests
are carried out with test loads in different configurations in accord-
ance with the scenarios with the lowest safety reserves in relation to
mechanical strength and stability of the crane. This includes an over-
load test with defined conditions and standards which can be applied
accordingly.
Further acceptance tests with overloads during the crane's service life
must only be carried out after modifications or repairs of load-bearing
components or within a general overhaul. In some countries, national
regulations may require tests with overload and/or overload tests be-
fore carrying out hoist work after any change to the crane configura-
tion.
The calculation of the load-bearing structure of cranes / mobile
cranes satisfies all applicable international standards (EN, ISO, FEM,
etc.) and does not provide for handling operation. The cranes there-
fore have a service life which is defined by the permitted number of
working cycles. Any overloading of the crane can have a negative ef-
fect and leads to a reduction in the crane's service life. This can be-
come a critical problem if the crane is tested with overload before ev-
ery hoist operation (e.g. when building a wind farm with 80 to 100
wind turbines at one location within a few weeks).
It is legally prohibited to raise overloads with cranes. Safety equip-
ment such as a load limit device prevent overloads being raised; the
corresponding bridging switch is only provided for emergency situa-
tions or for when the load limiter fails (as determined in the operating
instructions and the product standard EN 13000 as well as further na-
tional and international standards).
29.3.2 Load and Overload Test

The crane manufacturer does not recommend using the bridging
switch regularly for overload tests and generally advises against regu-
lar overload tests - even including tests during which the test load is
attached via external equipment without activating the bridging
switch.
NOTE
Decreased service life due to regular overload tests.
The crane manufacturer aims to avoid overload tests, as such
tests decrease the service life of the cranes.
The following aspects must also be taken into consideration from the
viewpoint of the operator / customer:
82640 2021-04-22 519

- Operational planning:
- higher floor loading than provided for;
- difficult handling of the additional test load;
- Ban on carrying out any overload tests on-site in some fields of
industry (e.g. petrochemical plants).
- Operational safety:
- Anyone in the vicinity of the crane must be warned of the test
procedure and
- must leave the area during the test.
WARNING
Risk of accidents due to damage to load-bearing
parts.
After an overload test, carry out extensive investiga-
tions to ensure the intactness of the load-bearing
components.
Damage to load-bearing parts can occur due to cracks caused by

overload and/or fatigue; such defects are not covered by an overload
test. For this reason, an overload test can give owners and operators
a false sense of security.
To ensure the intactness of load-bearing components, extensive in-
vestigations are recommended after an overload test and before car-
rying out hoist work. Such an investigation consists of a visual inspec-
tion combined with function tests (including the safety equipment) and
can necessitate non-destructive inspections such as magnetic particle
or ultrasonic inspections.
Any malfunction or irregularity discovered during the inspection must
be evaluated by an expert. This person must determine whether the
movement can be carried out safely or whether immediate repair/
modification is required.
29.3.3 Recommendations of the crane manufacturer with regard to the load test
29.3.3.1 Checking the assembly

Checking the correct crane assembly (e. g. after reconfiguration)
must include:
- a visual inspection of all assembled parts on the ground before
erecting the boom;
- a function check of the crane without or with limited load including
- any movements important for the crane operation and
- an inspection of all limit switches (among others, the hoist limit
switches);
- an inspection to ensure the assembly has been carried out in ac-
cordance with the assembly instructions.
520 82640 2021-04-22

29.3.3.2 Load Test Factors

If load tests are required due to national laws for checking the crane
assembly, 100% of the permitted capacity of the crane must not be
exceeded in the given configuration.
Load tests due to national laws can be e.g. required
- after assembling the crane or
- after changes to location.
This applies to all mobile cranes of the manufacturer for the static and
dynamic load test. A period of 5 minutes is sufficient for the static test.
The conditions listed above do not apply after substantial changes

or repairs to load-bearing crane components. In this case, the load
test factor can be higher (in accordance with e.g. the safety factors
from the product standards). It is recommended to involve the crane
manufacturer in such tests.
29.3.3.3 Load Test Configurations

If a load test is required due to national laws, the test conditions must
correspond with the conditions during the scheduled lift. It is accepta-
ble for the crane manufacturer to carry out a load test for a given
crane configuration with reduced loads (below the maximum capaci-
ty), but at a greater radius up to the maximum radius e.g. maximum
load moment.
Reason: In the case of lattice-mast cranes, erecting the boom is one
of the most critical load cases of a crane configuration with regard to
the load; erecting must therefore be regarded as a load test for the
tension-carrying structures such as the lattice mast sections (with re-
gard to pressure and bending stress), the bracing rods (tensile load),
the boom adjustment winch, the Superlift mast, etc.
82640 2021-04-22 521

522 82640 2021-04-22

Index of figures and tables
Index of figures
Fig. 1: Safety note (z82353)............................................................................................................................. 16

Fig. 2: Visual inspections of the chassis.......................................................................................................... 69
Fig. 3: Visual inspections of the superstructure............................................................................................... 70
Fig. 4: Engine components Scania DC 13 XPI - Exhaust emissions class Stage V........................................ 71
Fig. 5: Engine components Scania DC 13 XPI - Exhaust emissions class EM4 / Tier4f ................................ 72
Fig. 6: Engine components Scania DC 13 XPI - Exhaust emissions class EM4 / Tier4f ................................ 72
Fig. 7: Engine components Scania DC 13 PDE - Exhaust emissions class EM3a.......................................... 73
Fig. 8: Engine components Scania DC 13 PDE - Exhaust emissions class EM3a.......................................... 73
Fig. 9: Engine - Version with oil drain cock...................................................................................................... 78
Fig. 10: Access to dipstick - schematic diagram for AC 130-5 (Explorer 5500), AC 160-5 (Explorer 5600) ... 79
Fig. 11: Access to dipstick - schematic diagram for AC 250-5, AC 220-5 (Explorer 5800).............................. 79
Fig. 12: Position of the oil centrifuge, Scania DC 13 EM5............................................................................... 82
Fig. 13: Position of the oil centrifuge, Scania DC 13 EM4 / Tier4f................................................................... 82
Fig. 14: Position of the oil centrifuge, Scania DC 13 EM3a............................................................................. 82
Fig. 15: Cable pull system for unlocking the air shut-off valve......................................................................... 85
Fig. 16: Position of drive gearbox and distributor gear on drive 10 x 8 x 10.................................................... 87
Fig. 17: Drive gearbox - serial plate................................................................................................................. 88
Fig. 18: Intarder serial plate (if intarder is present).......................................................................................... 88
Fig. 19: Drive gearbox - overview.................................................................................................................... 91
Fig. 20: Bolts on the oil filter............................................................................................................................. 92
Fig. 21: O-rings on the new filter housing........................................................................................................ 93
Fig. 22: Screws on the oil filter housing cover................................................................................................. 93
Fig. 23: Oil fill and inspection plug in the drive gearbox................................................................................... 96
Fig. 24: Distributor gear................................................................................................................................... 98
Fig. 25: Distributor gear................................................................................................................................... 99
Fig. 26: Connecting hoses to the tube cooling coil on the two-stage distributor gear.................................... 100
Fig. 27: Connections on the distributor gear (schematic diagram)................................................................ 102
Fig. 28: Air pressure display in the supply tank............................................................................................. 103
Fig. 29: pneumatic connections on the distributor gear (schematic diagram)................................................ 104
Fig. 30: Axle fixing bolts................................................................................................................................. 110
Fig. 31: Steering swivel pin bearing, upper lubricating nipple (schematic diagram)...................................... 112
Fig. 32: Steering swivel pin bearing, lower lubricating nipple (schematic diagram)....................................... 112
Fig. 33: Axle without drive shaft differential (schematic diagram, Z 104 330)................................................ 113
Fig. 34: Axle with drive shaft differential and distributor gear (schematic diagram, Z 104 332)..................... 114
Fig. 35: Axle with drive shaft differential (schematic diagram, Z 104 331)..................................................... 115
Fig. 36: Axle without drive shaft differential (Z 104 330)................................................................................ 117
Fig. 37: Axle with drive shaft differential and distributor gear (schematic diagram, Z 104 332)..................... 118
82640 2021-04-22 523

Fig. 38: Axle with drive shaft differential (Z 104 331)..................................................................................... 119
Fig. 39: Screws on the wheel hub drive......................................................................................................... 120
Fig. 40: Position of the filler and inspection hole for the oil level check (schematic diagram)....................... 120
Fig. 41: Screws on the wheel hub drive......................................................................................................... 121
Fig. 42: Position of the filler and inspection hole for the oil level check (schematic diagram)....................... 121
Fig. 43: Position of the wheel hub caps......................................................................................................... 123
Fig. 44: Wheel hub caps for steering axles and / or rigid axles, interior view................................................ 123
Fig. 45: Planetary gear of the driven wheel hub............................................................................................ 124
Fig. 46: Wheel hub caps for steering axles and / or rigid axles..................................................................... 124
Fig. 47: Variants of the wheel lock nut........................................................................................................... 125
Fig. 48: Lubricating nipple on the pivot bearing of the suspension cylinder.................................................. 126
Fig. 49: Parts of the steering system............................................................................................................. 130
Fig. 50: Steering cylinder with fastening elements......................................................................................... 130
Fig. 51: Steering arm bearing – schematic diagram...................................................................................... 132
Fig. 52: Lubricating nipple on the steering lever - schematic diagram........................................................... 133
Fig. 53: Steering angle sensors .................................................................................................................... 134
Fig. 54: Brake lining thickness....................................................................................................................... 139
Fig. 55: Wear indicator of the brake linings.................................................................................................... 139
Fig. 56: Checking the brake disc run-out with measuring gauge .................................................................. 143
Fig. 57: Position of the compressed air tanks................................................................................................ 144
Fig. 58: Pins for opening the drain valves at the compressed air tank, schematic diagram ......................... 146
Fig. 59: Pins for opening the drain valves at the compressed air tank, schematic diagram.......................... 146
Fig. 60: Position of the air dryer..................................................................................................................... 146
Fig. 61: Markings of compressed air lines (Z 68 529).................................................................................... 149
Fig. 62: Damage to tyres................................................................................................................................ 156
Fig. 63: Analysis set....................................................................................................................................... 159
Fig. 64: Test pump......................................................................................................................................... 159
Fig. 65: Schematic diagram, taking an oil sample......................................................................................... 160
Fig. 66: Oil level display on the hydraulic tank............................................................................................... 163
Fig. 67: Components of the hydraulic tank.................................................................................................... 164
Fig. 68: Structure of the high-pressure line filter HD 150-01 (schematic diagram)........................................ 172
Fig. 69: Markings of hydraulic hoses (Z 68 531)............................................................................................ 179
Fig. 70: Draining the engine oil...................................................................................................................... 186
Fig. 71: Water separator................................................................................................................................ 188
Fig. 72: Manual fuel pump............................................................................................................................. 189
Fig. 73: Damage to the poly-V-belt................................................................................................................ 191
Fig. 74: Cooling air area................................................................................................................................. 193
Fig. 75: Cooling air area................................................................................................................................. 193
524 82640 2021-04-22

Fig. 76: Preliminary fuel filter......................................................................................................................... 197

Fig. 78: Overview of air filter cartridge........................................................................................................... 199
Fig. 79: Engine cylinder head........................................................................................................................ 202
Fig. 80: Numbering of the valves and cylinders, seen from the blower end.................................................. 204
Fig. 81: Adjusting the valve clearance........................................................................................................... 205
Fig. 82: Fuel vaporizer - overview.................................................................................................................. 208
Fig. 83: Cleaning the fuel vaporizer............................................................................................................... 210
Fig. 84: Fuel vaporizer - overview.................................................................................................................. 211
Fig. 85: .......................................................................................................................................................... 212
Fig. 87: Removing the poly V-belt.................................................................................................................. 217
Fig. 88: Shut-off device of belt monitoring unit............................................................................................... 218
Fig. 89: Putting on the poly-V-belt.................................................................................................................. 219
Fig. 90: Diesel particle filter - overview.......................................................................................................... 223
Fig. 91: Lighting equipment components....................................................................................................... 235
Fig. 92: Position of the fuse box and overview for the main fuses................................................................. 237
Fig. 93: Position of the fuse box in the central electrical unit of the crane chassis........................................ 238
Fig. 94: Position of the fuse box in the central electrical unit of the superstructure....................................... 238
Fig. 95: Fuel system - position of the components EM4 / Tier4f, Stage V..................................................... 263
Fig. 96: Fuel system diagram, exhaust emission standard EM4/Tier4f, Stage V.......................................... 263
Fig. 97: Diagram of the fuel system EM3a..................................................................................................... 264
Fig. 98: Fuel system - position of the components, exhaust emission standard EM3a................................. 265
Fig. 99: Fuel gauge in the instrument panel .................................................................................................. 267
Fig. 100: Position of the fuel tank................................................................................................................... 268
Fig. 101: Fuel tank (Z 81 854)........................................................................................................................ 269
Fig. 102: Air bleed filter on the fuel tank........................................................................................................ 269
Fig. 103: Preliminary fuel filter components (Z 81 855)................................................................................. 271
Fig. 104: Preliminary fuel filter components................................................................................................... 273
Fig. 105: Position of the fuel filter................................................................................................................... 274
Fig. 106: Diagram of cooling system exhaust emission class Stage V.......................................................... 277
Fig. 107: Diagram of cooling system EM3a, EM4 / Tier4f.............................................................................. 277
Fig. 108: Water cooler.................................................................................................................................... 278
Fig. 109: Position of the cooling system (Exhaust gas emissions class Stage V)......................................... 278
Fig. 110: Position of the cooling system (Exhaust gas emissions class EM4 / Tier 4f)................................. 279
Fig. 111: Position of the cooling system (Exhaust gas emissions class EM3a) ............................................ 279
Fig. 112: Access to coolant container (schematic diagram).......................................................................... 281
Fig. 113: Checking the coolant level.............................................................................................................. 282
82640 2021-04-22 525

Fig. 114: Checking the coolant level.............................................................................................................. 284

Fig. 115: Changing the Cooling Fluid............................................................................................................. 285
Fig. 116: Checking the coolant level (Z 71 739)............................................................................................ 287
Fig. 117: Position of the air filter, exhaust emission standard Stage V.......................................................... 289
Fig. 118: Position of the air filter, exhaust emission standard EM4 / Tier 4f.................................................. 289
Fig. 119: Position of the air filter, exhaust emission standard EM3a............................................................. 289
Fig. 120: Exhaust system step plate – schematic diagram............................................................................ 295
Fig. 121: Visual check of the exhaust system – schematic diagram, exhaust emissions class standard
Stage V........................................................................................................................................... 296
Fig. 122: Visual check of the exhaust system – schematic diagram, exhaust emission standard EM4 /
Tier 4f.............................................................................................................................................. 296
Fig. 123: Visual check of the exhaust system – schematic diagram, exhaust emission standard EM3a...... 297
Fig. 124: SCR system diagram ..................................................................................................................... 298
Fig. 125: Position of the AdBlue® / DEF tank................................................................................................ 301
Fig. 126: Position of the filter element in the AdBlue® / DEF tank................................................................ 303
Fig. 127: Pump filter unit................................................................................................................................ 304
Fig. 128: Diesel particle filter components..................................................................................................... 306
Fig. 129: End plate on the diesel particle filter............................................................................................... 306
Fig. 130: V-clips on the diesel particle filter................................................................................................... 307
Fig. 131: V-clips on the diesel particle filter................................................................................................... 307
Fig. 132: End plate on the diesel particle filter............................................................................................... 308
Fig. 133: Diesel particle filter components..................................................................................................... 308
Fig. 134: Position of SCR catalytic converter (Exhaust gas emission class Stage V)................................... 309
Fig. 135: SCR system diagram (Z 71 741).................................................................................................... 310
Fig. 136: Position of the AdBlue® / DEF tank................................................................................................ 312
Fig. 137: Position of the filter element in the AdBlue® / DEF tank................................................................ 314
Fig. 138: Pump filter unit................................................................................................................................ 315
Fig. 139: Position of the SCR catalytic converter........................................................................................... 316
Fig. 140: Underside of Rockinger coupling.................................................................................................... 323
Fig. 141: Coupling pins and coupling ring, Ringfeder dolly coupling............................................................. 324
Fig. 142: Slew gear pinion entanglement zone.............................................................................................. 329
Fig. 143: Central lubricating nipple................................................................................................................ 330
Fig. 144: Slew ring bolt.................................................................................................................................. 332
Fig. 145: Overview slew gear......................................................................................................................... 333
Fig. 146: Slew gear pinion entanglement zone.............................................................................................. 334
Fig. 147: Protective guard of the slew gear pinion......................................................................................... 334
Fig. 148: Overview slew gear......................................................................................................................... 337
Fig. 149: Filling the slew gear with a pump (schematic diagram).................................................................. 338
Fig. 150: Control levers.................................................................................................................................. 341
526 82640 2021-04-22

Fig. 151: Bolted connections on the slew gear.............................................................................................. 342

Fig. 152: Schematic diagram: Hoists 1 and 2................................................................................................ 343
Fig. 153: Hoist ............................................................................................................................................... 345
Fig. 154: Bolted connections on the hoist (schematic diagram).................................................................... 348
Fig. 155: Bolted connections on the hoist (schematic diagram).................................................................... 348
Fig. 156: Lubricating nipples - rope drum bearing......................................................................................... 349
Fig. 157: Exterior bolted connections - – luffing gear..................................................................................... 356
Fig. 158: Example of a "Length code selection (LC) for lubrication of the main boom" screen..................... 358
Fig. 159: Schematic diagram - Length transducer on main boom................................................................. 362
Fig. 160: Main boom foot section bearing lubricating nipple.......................................................................... 363
Fig. 161: Lubricating nipples - main boom head axles................................................................................... 364
Fig. 162: Check the main boom rope sheaves.............................................................................................. 365
Fig. 163: Cover lid on the top of the basic case (schematic diagram)........................................................... 366
Fig. 164: Sliding surfaces and lubricating nipples that need to be lubricated on the locking and pinning
unit (LPU)........................................................................................................................................ 368
Fig. 165: Cover lid on the top of the basic case (schematic diagram)........................................................... 370
Fig. 166: Initial length - tension plates........................................................................................................... 373
Fig. 167: Draw bar of the assembly jib........................................................................................................... 376
Fig. 168: Wind measuring device with adjustable bracket ............................................................................ 377
Fig. 169: Check for wear - plastic rope sheaves............................................................................................ 379
Fig. 170: Check for wear - steel rope sheaves.............................................................................................. 379
Fig. 171: Danger due to protruding wires....................................................................................................... 381
Fig. 172: Raising the cable with flat lifting slings (Z 29 084).......................................................................... 382
Fig. 173: Raising the reel with a rod (Z 29 085)............................................................................................. 382
Fig. 174: Loop (Z 29 086).............................................................................................................................. 384
Fig. 175: Re-reeling (Z 29 087)...................................................................................................................... 385
Fig. 176: Ring / piece of chain at the end of the rope (Z 29 088).................................................................. 386
Fig. 177: Rope stocking (Z 29 089)................................................................................................................ 387
Fig. 178: Braking the reel flange (Z 29 090).................................................................................................. 388
Fig. 179: Braking the reel flange using a plank (Z 29 091)............................................................................ 388
Fig. 180: Jamming the cable between two wooden planks is prohibited (Z 29 092)..................................... 388
Fig. 181: Rope deflection............................................................................................................................... 391
Fig. 182: Rope crossing area......................................................................................................................... 392
Fig. 183: Effect of lubrication and relubrication on the cable's service life (Z 29 094)................................... 393
Fig. 184: Hose clips fuel filter......................................................................................................................... 399
Fig. 185: Operating element of the heater timer (schematic diagram)........................................................... 401
Fig. 186: Engine-independent heating: position of the expansion tank......................................................... 401
Fig. 187: Position of fuel tank on AC 250-5 / AC 220-5................................................................................. 403
82640 2021-04-22 527

Fig. 188: Position of fuel tank on AC 160-5 / AC 130-5 / AC 150/5J............................................................. 403

Fig. 189: Hose clips fuel filter......................................................................................................................... 405
Fig. 190: Filter in the hydraulic tank............................................................................................................... 407
Fig. 191: Heat exchanger of the flameless auxiliary heating......................................................................... 408
Fig. 192: Filter in the hydraulic tank............................................................................................................... 409
Fig. 193: Petrol gas heating components in the superstructure..................................................................... 411
Fig. 194: Petrol gas heating components in the crane chassis...................................................................... 412
Fig. 195: Position of the central electrical unit in the driver's cab.................................................................. 412
Fig. 196: Liquid petrol gas heating heat exchanger....................................................................................... 413
Fig. 197: Position of the gas cylinder............................................................................................................. 414
Fig. 198: Heat exchanger with pipes.............................................................................................................. 415
Fig. 199: Operating element with combination gas heating rotary switch...................................................... 416
Fig. 200: Operating element with gas heating sliding switch......................................................................... 416
Fig. 201: Fuse (F1) in the fuse box................................................................................................................ 417
Fig. 202: 5 kg gas cylinder attachment.......................................................................................................... 419
Fig. 203: 11 kg gas cylinder attachment........................................................................................................ 419
Fig. 204: 5 kg gas cylinder attachment.......................................................................................................... 419
Fig. 205: 11 kg gas cylinder attachment........................................................................................................ 419
Fig. 206: Hood............................................................................................................................................... 421
Fig. 207: Hood............................................................................................................................................... 421
Fig. 208: Diagram of standard air conditioning on the crane chassis............................................................ 423
Fig. 209: Components of the standard air conditioning on the crane chassis............................................... 424
Fig. 210: Diagram of the auxiliary air conditioning on the crane chassis....................................................... 425
Fig. 211: Components of the auxiliary air conditioning in the driver's cab (schematic diagram)................... 426
Fig. 212: Components of the auxiliary air conditioning on the crane chassis................................................ 426
Fig. 213: Diagram of the standard air conditioning on the superstructure..................................................... 427
Fig. 214: Components of the standard air conditioning in the crane operator’s cab...................................... 428
Fig. 215: Capacitor (condenser) of the standard air conditioning for the crane operator’s cab on the su-
perstructure..................................................................................................................................... 428
Fig. 216: Components of the standard air conditioning for the crane operator's cab on the crane chassis.. 429
Fig. 217: Diagram of the auxiliary air conditioning on the superstructure...................................................... 429
Fig. 218: Components of the auxiliary air conditioning in the crane operator's cab (schematic diagram)..... 430
Fig. 219: Components of the auxiliary air-conditioning on the superstructure............................................... 430
Fig. 220: Components of the standard air conditioning for the driver's cab on the crane chassis................. 431
Fig. 222: Collector dryer of the standard air conditioning on the crane chassis............................................ 432
Fig. 223: Collector dryer of the standard air conditioning on the superstructure........................................... 432
Fig. 224: Components of the standard air conditioning on the crane chassis............................................... 434
528 82640 2021-04-22

Fig. 225: Capacitor on the standard air conditioning of the superstructure on the hydraulic reservoir.......... 434
Fig. 226: Air conditioning unit of the standard air conditioning in the driver's cab and crane operator's cab
(schematic diagram)....................................................................................................................... 435
Fig. 228: Components of the superstructure's auxiliary air conditioning........................................................ 436
Fig. 230: Components of the superstructure's auxiliary air conditioning........................................................ 438
Fig. 231: Air conditioning unit of the auxiliary air conditioning in the driver's cab and crane operator's cab
(schematic diagram)....................................................................................................................... 439
Fig. 232: Components of the standard air conditioning for the driver’s cab................................................... 440
Fig. 233: Components of the standard air conditioning in the crane operator’s cab...................................... 441
Fig. 234: Capacitor (condenser) of the standard air conditioning for the crane operator’s cab on the su-
perstructure..................................................................................................................................... 441
Fig. 236: Components of the auxiliary air conditioning in the driver's cab (schematic diagram)................... 442
Fig. 237: Components of the auxiliary air conditioning for the driver's cab on the crane chassis.................. 443
Fig. 238: Components of the auxiliary air conditioning in the crane operator's cab (schematic diagram)..... 443
Fig. 239: Components of the auxiliary air conditioning for the crane operator's cab on the superstructure.. 444
Fig. 240: Lubricating nipple of the tilt cylinder................................................................................................ 455
Fig. 241: wear markings - use permitted........................................................................................................ 459
Fig. 242: wear markings - use prohibited....................................................................................................... 459
Fig. 243: Frame of the crane chassis............................................................................................................. 464
Fig. 244: Front frame of the crane chassis.................................................................................................... 465
Fig. 245: Supports.......................................................................................................................................... 465
Fig. 246: Superstructure frame...................................................................................................................... 466
Fig. 247: Superstructure frame...................................................................................................................... 466
Fig. 248: Main boom...................................................................................................................................... 467
Fig. 249: Basic boom of the main boom extension........................................................................................ 467
Fig. 250: Box top piece of the main boom extension..................................................................................... 468
Fig. 251: Intermediate section of the main boom extension.......................................................................... 468
Fig. 252: Intermediate section of the main boom extension.......................................................................... 469
Fig. 253: Foot section of the fly jib................................................................................................................. 469
Fig. 254: Reducer of the fly jib....................................................................................................................... 470
Fig. 255: Intermediate section of the fly jib.................................................................................................... 470
Fig. 256: Intermediate section of the fly jib.................................................................................................... 471
Fig. 257: Top section of the fly jib.................................................................................................................. 471
Fig. 258: Head connecting piece of the fly jib................................................................................................ 472
Fig. 259: Luffing mast connection piece of the fly jib..................................................................................... 472
Fig. 260: Luffing mast of the fly jib................................................................................................................. 472
82640 2021-04-22 529

Fig. 261: Luffing mast of the fly jib................................................................................................................. 473

Fig. 262: Flying bridle of the fly jib................................................................................................................. 473
Fig. 263: Bracing rod of the fly jib.................................................................................................................. 473
Fig. 264: Head sheave................................................................................................................................... 473
Fig. 265: Runner............................................................................................................................................ 474
Fig. 266: Superlift........................................................................................................................................... 474
Fig. 267: Lateral Superlift............................................................................................................................... 475
Fig. 268: Anti-fall protection........................................................................................................................... 475
Fig. 269: Disc wheel....................................................................................................................................... 475
Fig. 270: Intermediate section of the chassis................................................................................................. 476
Fig. 271: Crawler track carrier (CC 8800)...................................................................................................... 476
Fig. 272: Crawler track carrier (Duo).............................................................................................................. 477
Fig. 273: Crawler track carrier (Quadro)........................................................................................................ 477
Fig. 274: Sliding girder of the chassis............................................................................................................ 478
Fig. 275: Sliding girder of the chassis (idler side).......................................................................................... 478
Fig. 276: Superstructure frame 1................................................................................................................... 478
Fig. 277: Superstructure frame 2................................................................................................................... 479
Fig. 278: A-frame........................................................................................................................................... 479
Fig. 279: Counterweight base plate............................................................................................................... 480
Fig. 280: Foot section of the main boom........................................................................................................ 480
Fig. 281: Intermediate section of the main boom........................................................................................... 481
Fig. 282: Reducer of the main boom.............................................................................................................. 481
Fig. 283: Top piece of the fly jib..................................................................................................................... 482
Fig. 284: Foot section of the fly jib................................................................................................................. 482
Fig. 285: Fly jib LF......................................................................................................................................... 483
Fig. 286: SL mast foot section and SL mast point......................................................................................... 484
Fig. 287: Head adapter.................................................................................................................................. 484
Fig. 288: Sheave head................................................................................................................................... 484
Fig. 289: Runner............................................................................................................................................ 485
Fig. 290: Upper luffing mast........................................................................................................................... 485
Fig. 291: Lower luffing mast........................................................................................................................... 486
Fig. 292: Bracing rods of the fly jib................................................................................................................. 486
Fig. 293: Anti-fall protection........................................................................................................................... 487
Fig. 294: Disc wheel....................................................................................................................................... 487
Fig. 295: Example of a sample table (theoretical service life of the winches)................................................ 493
Fig. 296: Graining on the hook for measuring the deformation (Z 54 325).................................................... 496
Fig. 297: Plastic rope sheave......................................................................................................................... 498
Fig. 298: Steel rope sheave........................................................................................................................... 499
530 82640 2021-04-22

Fig. 299: Corkscrew type deformation........................................................................................................... 503

Fig. 300: Corkscrew type deformation........................................................................................................... 503
Fig. 301: "Basketwork" formation (deformation)............................................................................................ 503
Fig. 302: Emerging inlay - single-layer cable................................................................................................. 504
Fig. 303: Emerging or deformed cords.......................................................................................................... 504
Fig. 304: Emerging wire................................................................................................................................. 504
Fig. 305: Local cable diameter increase due to deformation of the inlay....................................................... 505
Fig. 306: Flattening........................................................................................................................................ 505
Fig. 307: Flattening........................................................................................................................................ 505
Fig. 308: Kink (positive, in the rope-closing sense)....................................................................................... 506
Fig. 309: Kink (negative, in the rope-opening sense).................................................................................... 506
Fig. 310: Kink................................................................................................................................................. 506
Index of tables
Table 1: Warning symbols............................................................................................................................... 20

Table 2: Torque of the flange connections - bolts / screws with zinc flake coating........................................ 106
Table 3: Torque of the flange connections - black or A3C-coated bolts / screws.......................................... 107
Table 4: Tightening torques of the steering cylinder mounting parts............................................................. 131
Table 5: Overview of the compressed air tanks............................................................................................. 145
Table 6: Tyre pressure in relation to tyre size................................................................................................ 154
Table 7: Adjustment method for four-cylinder engines.................................................................................. 204
Table 8: Flashing code table for maintenance intervals................................................................................. 224
Table 9: Fuse overview of the main fuses for the crane chassis (UW) and superstructure (OW)................. 240
Table 10: Fuse overview - fitting location: central electrical unit of the superstructure (ZE OW XF1)........... 240
Table 16: Fuse overview of the central electrical unit of the chassis (ZE UW XF1)...................................... 243
82640 2021-04-22 531

Table 25: Fuse overview of the central electrical unit of the chassis (ZE UW XF10).................................... 248
Table 41: Fuse overview of the central electrical unit of the chassis (ZE UW XF10).................................... 257
Table 42: Torque of the bolts on the slew ring............................................................................................... 332
Table 43: Torque of the bolted connections on the slew gear....................................................................... 342
Table 44: Tightening torque of the exterior bolted connections - hoist (Siebenhaar).................................... 348
Table 45: Tightening torque of the exterior bolted connections - hoist (Zollern)............................................ 348
Table 46: The torque of the exterior bolted connections - luffing gear.......................................................... 356
Table 47: Permitted length change of the tension plates of the main boom extension................................. 373
Table 48: Tests of the emergency call device................................................................................................ 454
Table 49: Wear limit of the steel rope sheaves.............................................................................................. 499
532 82640 2021-04-22

Technical Documentation
c/o Tadano Demag GmbH

Europaallee 2
66482 Zweibrücken
Germany
Tel. +49 (0) 6332 830
info.demag@tadano.com
www.tadano.com

AC250-5 AC220-5-82640-Part3 538653 1 en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AC250-5 AC220-5-82640-Part3 538653 1 en

Uploaded by

Copyright:

Available Formats

Lubrication and maintenance

instructions Entire crane

The only warranty applicable to our products is the corresponding

1 Safety Instructions ....................................................................... 15

2 Consumables and capacities ...................................................... 27

3 Lubrication and Maintenance Schedule .....................................43

3.7 Maintenance list - daily checks .......................................................63

4 Visual inspections ........................................................................ 69

7 Joint shafts ................................................................................. 105

8 Axles and suspension ................................................................109

8.2.4.2 Axles with Drive Shaft Differentials ...............................................114

9 Steering ....................................................................................... 129

10 Brake and compressed air system ........................................... 137

11 Wheels and tyres ........................................................................ 151

11.4.2 Checking the Tread Depth ............................................................154

12 Hydraulic System ....................................................................... 157

12.11.19 Replacing the poly-V-belt and checking the shut-off device

14 Electrical system ........................................................................ 235

15 Fuel system .................................................................................263

16 Cooling system ...........................................................................277

16.3 Cleaning the cooling system .........................................................280

17 Intake System ............................................................................. 289

18 Exhaust system .......................................................................... 295

19 Piston rods ..................................................................................319

20 Special Equipment ..................................................................... 321

21 Slewing rim ................................................................................. 329

22 Slew gear .....................................................................................333

22.3 Lubricate the slew gear pinion ......................................................334

24 Luffing gear .................................................................................355

25 Main Boom, Rope Equipment, Devices .................................... 357

26 Heating ........................................................................................ 397

27 Air Conditioning ......................................................................... 423

29 Inspections of the Crane ............................................................457

29.2.6.6 Determining the Spent Share of the Theoretical Service Life of

Index of figures .......................................................................... 523

Index of tables ........................................................................... 531

1.2 Warning Information

Fig. 1: Safety note (z82353)

1 Pictogram 2 Sign for danger / risk

Points "4" and "5" can also be combined.

Particularly important or further information is indicated without a sig-

This is an example for an indication of particularly important or fur-

1.2.4 Warning symbols

General warning sign

Warning, explosive substances

Warning, radioactive substances or ionising radiation

Warning, laser radiation

Warning, non-ionising radiation

Warning, magnetic field

Warning, obstacles at ground level

Warning, risk of falling

Warning, low temperature/frost

Warning, risk of slipping

Warning, electrical voltage

Warning, forklift trucks

Warning, hanging load

Warning, toxic substances

Warning, hot surface

Warning, automatic start-up

Warning, risk of crushing

Warning, obstacles at head height

Warning, flammable substances

Warning, sharp object(s)