Contents

Contents (Part 3)

Foreword (Part 3)

Notes for the Operator

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

2 Fuels and Lubricants

3 Capacities

4 Lubrication and Maintenance Schedule

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

5 Drive
5 Drive ........................................................................................ 3
5.1 Engine OM 926 LA .................................................................. 3

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

7 Joint Shafts
7 Joint Shafts .............................................................................. 1
7.1 Flange Connections ................................................................. 1
Date: 08.CW/05

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 Contents

8 Axles
8 Axles ........................................................................................ 1
8.1 Checking and Tightening the Axle Fixings ............................... 1
8.2 Lubricating the Axles ............................................................... 2
8.3 Steering and Track Arm ........................................................... 3
8.4 Axle Drive - Checking and Topping Up the Oil Level ............... 3
8.5 Wheel Hub Drive - Checking and Topping Up the Oil Level .... 4
8.6 Axle Drive - Changing the Oil .................................................. 5
8.7 Wheel Hub Drive - Changing the Oil ........................................ 7
8.8 Wheel Hub Bearing - Changing the Grease ............................ 7
8.9 Suspension Cylinders .............................................................. 8

9 Steering
9 Steering ................................................................................... 1
9.1 Steering Components .............................................................. 1
9.2 Lubricating the Steering Components ..................................... 1
9.3 Replacing the Hoses................................................................ 2
9.4 Lubricating Independent Rear Axle Steering ........................... 2
9.5 Electric-hydraulic Steering ....................................................... 3

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

11 Wheels and Tyres

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

12 Hydraulic System
12 Hydraulic System ..................................................................... 1
12.1 Hydraulic Tank - Checking and Topping Up the Oil Level ....... 2
12.2 Hydraulic Tank - Filter .............................................................. 3
12.3 Hydraulic Tank - Replacing the Aeration Filter ...................... 12
12.4 Changing the Hydraulic Oil .................................................... 13
12.5 Bleeding the Hydraulic System .............................................. 15
Date: 08.CW/05

12.6 Hydraulic System - Pressure Accumulator, Checking the

Preliminary Gas Tension ....................................................... 17

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 Contents

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

14 Electrical System
14 Electrical System .................................................................... 1
14.1 Checking the Lighting System ................................................. 1
14.2 Replacing the Headlamp Bulbs ............................................... 1
14.3 Battery maintenance ................................................................ 1
14.4 Fuses ....................................................................................... 2
14.4.1 Superstructure Fuses .............................................................. 2
14.4.2 Carrier Fuses ........................................................................... 2

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

16 Air Intake and Cooling System

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

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

18 Optional Equipment
18 Optional Equipment ................................................................. 1
18.1 Auxiliary Heating ...................................................................... 1
18.2 Auxiliary Heating System - Checking System is
Functioning Correctly ............................................................... 1
18.3 Replacing the Heat Exchanger ................................................ 2
18.4 Switching on the Hot Water Heating ........................................ 2
18.5 Checking and Replacing the Fuel Filter ................................... 2
18.6 Lubricating the Dolly Coupling ................................................. 3
18.7 Servicing the Dolly Coupling .................................................... 3
18.8 Refilling the Central Lubrication System .................................. 4

19 Visual Inspections
19 Visual Inspections .................................................................... 1
19.1 Visual Inspection of the Chassis .............................................. 1
19.2 Visual Inspection of the Superstructure ................................... 3

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

21 Slew Gear
21 Slew Gear ................................................................................ 1
Date: 08.CW/05

21.1 Slew Gear Mechanism - Checking and Topping Up the Oil Level ... 1
21.2 Slew Gear Mechanism - Changing the Oil ............................... 1
21.3 Checking and Tightening the Screw Connections ................... 2

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22 Hoists
22 Hoists ....................................................................................... 1
22.1 Hoist Gear - Checking and Topping Up the Oil Level .............. 1
22.2 Hoist Gear - Changing the Oil .................................................. 3
22.3 Checking the gear oil ............................................................... 4
22.4 Lubricating the Rope Drum Bearing ........................................ 5
22.5 Checking and Tightening the Screw Connections ................... 5
22.6 Lubricating the Hook Block ...................................................... 6
22.7 Determination of the spent share of the theoretical service life .... 6

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

24 Equipment
24 Equipment ............................................................................... 1
24.1 Main Boom - Lubricating the Linings ....................................... 1
24.2 Main Boom - Lubricating the Sliding Surfaces ......................... 2
24.3 Lubricating the Basic Bolts on the Main Boom ........................ 3
24.4 Ropes ...................................................................................... 3
24.4.1 General Notes on Handling and Assembly .............................. 4
24.4.1.1 Transport ................................................................................. 4
24.4.1.2 Storage .................................................................................... 4
24.4.1.3 Assembly ................................................................................. 5
24.4.2 Lubricating the Ropes ............................................................ 13
24.4.3 Cleaning the Ropes ............................................................... 14
24.4.4 Checking the Cables and Replacing as Necessary ............... 14
24.5 Checking the Main Boom for Weld Cracks ............................ 21
24.6 Main Boom - Adjusting Retracting Ropes ES 1 and ES 2 ..... 22
24.7 Main Boom - Visual Inspection of the Extending and
Retracking Ropes .................................................................. 23
24.8 Inspect Rope Track Rollers ................................................... 25
24.9 Checking the Sheaves ........................................................... 25
24.10 Sheaves - Checking the Roller Bearing ................................. 26
24.11 Sheaves - Lubricating the Roller Bearings............................. 27
24.12 Checking the Pins for Cracks ................................................ 27
24.13 Checking the Draw Bars ........................................................ 28
24.14 Telescopic Main Boom Extension (Optional) -
Greasing Sliding Surfaces ..................................................... 31
24.15 Telescopic Main Boom Extension (Optional) -
Greasing the Foot Bearing ..................................................... 31
24.16 Telescopic Main Boom Extension (Optional) -
Greasing the Luffing Cylinder ................................................ 31
24.17 Checking the welding on the Telescopic Main Boom Extension
for cracks (Optinal) ................................................................ 32
Date: 08.CW/05

25 Heating
25 Heating .................................................................................... 1
25.1 Checking and Filling Up the Fuel Tank .................................... 1
25.2 Checking and Replacing the Glow Plug .................................. 1
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 Foreword

Part 3: Lubrication and Maintenance Instructions for the Crane

For you,

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

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

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

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

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

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

NOTE:
"Note" is used to indicate an important operation or mounting pro cedure or
to draw attention to further information.
Date: 11.CW/04

ENVIRONMENT:
This symbol is used when an action serves to protect the
environment or avoid unnecessary pollution.
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2/3
e50_1-3002
Date: 11.CW/04
 Foreword

General Recommendations Regarding Lubrication and Maintenance

Tasks

- Thoroughly clean all nipples, caps and plugs before grea sing.

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

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

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

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

- After cleaning the crane, grease all lubricating points.

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

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

Please contact the Customer Service Department immediately if you

discover cracks in the steelwork of your crane.
Describe the course of the crack as closely as possible (enclose
photograph, page from spare parts catalogue etc.).
Date: 11.CW/04

e50_1-3002 3/3
 Notes for the Operator

The safety instructions for the lubrication and maintenance

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

The specifications for the quality of the lubricant can be found

in Section 2.

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

All the service points, ordered according to service intervals,

are listed in section 4.

Service points without fixed service intervals are listed under

"as required".

Service intervals should be determined by the kilometres

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

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

detail in Section 5 - 25.

Definitions:

Service Point = Unit or point on which the maintenance

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

Service Interval = Number of kilometres after which the

stipulated service task is to be
repeated (e.g."every 1000 km": at
1000, 2000, 3000, 4000, 5000
kilometres driven, etc.; "every 5000
km": at 5000, 10000, 15000, 20000
kilometres driven, etc.).
Date: 11.CW/04

e50_1-3004 1/1
 Notes on Safety 1

1 Notes on Safety

1.1 General Recommendations for the

Lubrication and Maintenance Tasks

Undertake the prescribed adjustment and

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

Ensure that all handles, steps, rails, platforms,

stages and laders remain free from dirt, snow and
ice at all times.
(Z160 366)
Z 160 366

Ensure that the crane is kept clean at all

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

Z 160 002

- Thoroughly clean all nipples, caps and plugs

before greasing.
(Z 160 001)
Date: 07.CW/95

Z 160 001

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1

- Refill the fuel tank at the end of each

working day.
(Z 160 017)

Sufficient ventilation has to be ensured

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

Z 160 017

- Renew the sealing rings for drain, filler,

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

The oil can be drained more easily from

individual units if it is drained at operating
temperature.

When the operating temperature is reached,

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

After cleaning the engine bay, check all

- fuel lines
- engine oil lines
- hydraulic oil lines

for leaks, loose connections, worn patches

and damage.

Repair any damage immediately.

(Z 160 003)
Date: 07.CW/95

Z 160 003

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 Notes on Safety 1

After cleaning the crane, grease all grease

points.

When dry, spray the slew gear teeth with the

recommended grease.
(Z 160 010)

Z 160 010

Check all electrical lines, push-on connections

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

Repair any damage immediately.

(Z 160 504)

Z 160 504

Check the turbocharger mounting.

Check the exhaust and air inlet lines and the

lubricant supply and return lines for leaks.

Repair any damage immediately.

Date: 07.CW/95

bs_e908-3010d /b 3/16
a / 06/97
1

Fire extinguishers must be full and ready for use.

(Z 160 009)

Z 160 009

Never carry out welding repairs without first

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

Z 160 005

- Please contact the Customer Service

Department immediately if you discover cracks
in the steelwork of your crane. Describe the
course of the crack as closely as possible
(enclose photograph, page from spare parts
catalogue, etc.).
(Z 160 006)
Date: 07.CW/95

Z 160 006

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 Notes on Safety 1

1.2 Notes on Safety

The diesel engine must always be switched off

before lubrication and maintenance tasks are
carried out, with the exception of tasks which
must be carried out with the engine running.
(Z 160 113)

Z 160 113

Before carrying out any lubrication or

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

The residual energy or stored energy wich

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

Check that the crane is free of faults.

(Z 160 415)

Z 160 415

Lubrication and maintenance tasks may only be

carried out if the working equipment has been
made secure by placing it on the ground, by
extending the outriggers or by any other
appropriate means.
(Z 160 008)
Date: 07.CW/95

Z 160 008

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a / 06/97
1

Before carrying out any lubrication or

maintenance tasks, place a warning sign in the
driver's cab and ensure that no unauthorized
persons can set the crane in operation (e.g.
lock the cab doors and remove the contact
keys).
(Z 160 014)

Z 160 014

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

i.e. - boom lowered

- vehicle supported on outriggers
- axles lowered

(Z 160 018)
Z 160 018

Wear safety clothing, protective goggles,

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

Do not allow unauthorized persons near

the equipment whilst carrying out maintenance
or lubrication tasks.

Work which could affect the operational

Date: 07.CW/95

and road safety of the crane must only be

carried out by trained personnel.
Z 160 011

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 Notes on Safety 1

If it is necessary for one or more persons to be

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

Z 160 023

DANGER OF INJURY
Always wear protective gloves when handling
and guiding the ropes.
Only use a wooden rod to guide moving
ropes.
(Z 160 024)

Z 160 024

Store oil-impregnated rags and flammable

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

Oils that are drained off must be stored in

suitable containers and disposed of
correctly.

These safety instructions are to be

Date: 07.CW/95

observed whenever the crane is operated or

repaired.
Z 160 016

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1

After service and maintenance work has

been carried out, check that all safety devices
have been replaced and are in full working
order.
(Z 160 366)

Z 160 366

After service and maintenance work has

been carried out, check that there are no tools or
loose components on the crane.
(Z 160 027)

Z 160 027

If you vuse electrical equipment for

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

(Z 160 083)
Date: 07.CW/95

Z 160 083

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 Notes on Safety 1

1.3 Recurrent Inspections of the Crane Carrying out the inspection

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

Within the framework of this inspection, - Checking the sfety equipment and the brakes
the theoretical remaining service life of for completeness and effectiveness.
the winches must be determined.
Observe Section 1.4.

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

The VBG 9 inspections do not affect the

national and international regulations
applicable.

Inspection interval

Cranes must be checked by a "Sachkundiger"

where necessary according to the applications
of use and the operating conditions, but must
be checked at least once a year.
An inspection must be carried out at least once
every 4 years by a "Sachverständiger".
Date: 07.CW/95

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a / 24/95
1

1.4 Measures to Ensure Safe

Operating Periods

1.4.1 General 1.4.2 Theoretical Service Life

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

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

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

Date: 07.CW/95

10/16 bs_e908-3010d /b
 Notes on Safety 1

1.4.3 Actual Operating Conditions

Before the spent share of the theoretical service

The theoretical service life must not be life of the winches can be determined, the actual
equated with the real (actual) service life of operating conditions (load spectrum) and the
a winch. operating hours of the hoists per inspection
In addition, the real service life of a winch interval must be determined.
is affected by a number of external
influences, for example:
1.4.3.1 Determining the Operating
- Overloading through not using the crane Conditions (Load Spectrum)
as intended.
The load spectrum of the crane is divided into
- Insufficient maintenance: the oil is not groups (also see ISO 4301/1, FEM 1.001).
changed in good time. From knowledge of the actual operating
conditions, one of the load spectrums listed
- Maloperation such as extreme below must be selected and recorded in the
acceleration or deceleration of the load crane log-book for the relevant inspection
or the load falling into the ropes. interval.

- Maintenance mistakes such as using the 1.4.3.2 Operating Hours of the Hoists
wrong oil, incorrect oil fill or contamination per Inspection Interval
when changing the oil.
Determine the effective number of operating
- Mounting mistakes when undertaking hours per inspection interval (Ti). This must be
repairs or maintenance. recorded in the crane log-book for the relevant
inspection interval.
- Leaks not taken into consideration.
For mobile cranes used for erection operation,
- Incorrectly adjusted safety equipment. the share of the hoist winches is generally
20 % of the total operating hours for the
- Concealed damage caused by accidents. superstructure and 12 % of the total operating
hours for the entire crane.
- Extreme ambient conditions such as low
or high temperatures, aggressive
atmosphere, dust and dirt.
Date: 07.CW/95

bs_e908-3010d /b 11/16
 1
Load Load
spectrum spectrum

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

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

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

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

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

Laufzeit
%
Operating time

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

Laufzeit
%
Operating time

bs_e908-3010d /b
Date: 07.CW/95
 Notes on Safety 1

1.4.4 Determining the Spent Share of

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

Ti = effective operating hours for inspection

interval "i" as per Section 1.4.3.2

After each inspection interval, the spent share

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

- If the theoretical service life remaining is

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

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

the winch must only be continued to be
operated following a general overhaul.
Date: 07.CW/95

bs_e908-3010d /b 13/16
 1

14/16
Monitoring the Winches

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

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

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

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

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

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

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

Z 29 555

bs_e908-3010d /b
Date: 07.CW/95
 Notes on Safety 1

1.4.5 Documentation
(Z 29 555)

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

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

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

The specimen table is clarified by the following Km1 0.125

S1 = x T1 = x 160 h = 160 h
exemple: Km 0.125

The value for the load spectrum factor

(here: Km = 0.125) and the theoretical service
life (here: D = 3200 h) are recorded at the top
of the relevant table.

Theoretical remaining service life after the

first year:

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

Date: 07.CW/95

bs_e908-3010d /b 15/16
1

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

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

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

Theoretical remaining service life after the

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

It must now be assessed whether the

theoretical remaining service life is expected
to be sufficient for the next period of operation.
If this is not the case, a general overhaul must
be undertaken (see Section 1.4.4).
Date: 07.CW/95

16/16 bs_e908-3010d /b
 Date: 07.CW/95

Monitoring the Winches

bs_e908-3010d /b
Table for determining the theoretical remaining service life for winch ......................................
Crane type: ....................................
Construction number: ....................................
Initial commissioning: ....................................
Serial number of winchgear as per serial plate: ....................................
Design specifications of winch (see crane certification log):
Power unit group: M ............................................
Load spectrum: Q ..........................(L...............)
Load spectrum factor: Km = ............................................
Theoretical service life: D = ............................................

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

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

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

17/16
For further notes, see Section 1 in the Lubrication and Maintenance Instructions for the Superstructure
 Fuels and Lubricants 2

Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards
2.1 Engine Engine Oil See regulations SAE 10W 40 MB - Regulations for
Multigrade Oil for fuels and fuels and lubricants
lubricants page 225. 6 or
contained in page 228. 5
the instructions ACEA E4-98
for operation
of the engine

2.2 Cooling Water / Protection See regulations for fuels 50 % Water

System Anti-Corrosive and lubricants contained in 50 % Antifreeze
Antifreeze the instructions for operation
mixture of the engine

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

System or DEXRON II

0 to +60 68 HLP (D) acc.

DIN 51524 additionally
with detergend quality

2.4 Fuel Tank Premium See DIN 51 601

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

2.5 Drive Gear Engine Oil -20 to +15 SAE 10 W API: CD / CE / CF

-10 to +25 SAE 20 W 20 API: CD / CE / CF

-15 to +35 SAE 15 W 40 API: CD / CE / CF

2.6 Slew Gear Hypoid -20 to +40 SAE 80W - 90 API - GL 4 or 5

Mechanism Gear Oil or SAE 90

2.7 Hoist Gear Gear Oil -15 to +35 SAE 90 API- GL -5

Date: 20.CW/04

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

e50_1-3020_b 1/2
2

Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards

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

with Intermediate Gear Oil
Transmission

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

2.10 Slew Ring Spray Grease - Special Adhesive Demag

Teeth Grease Order No.:
006 058 98

2.11 Ropes Spray Grease - Special Adhesive Demag

Grease Order No.:
083 371

2.12 Main Boom Grease, -40 to +140 Demag

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

2.13 Piston Rods GLEITMO 350 Spray Grease Demag

Order No.:
604 106 40

2.14 Independent Voler Demag

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

For ambient temperatures below those given in the table, please refer to the figures given in
the operating instructions of the original manufacturer.
Date: 20.CW/04

2/2 e50_1-3020_b
 Capacities 3

Housing or System Metric Capa- US Capacity Initial Fill Up

city (Litres) (Gallons)

Engine OM 926 LA 32.00 8.45 Shell RIMULA Ultra

with Filter Change (10 W 40)

Hydraulic System 880.00 232.50 ATF...:Shell Donax TM

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

Fuel Tank 300.00 79.25 Diesel Fuel

Auxiliary Tank

Fuel Tank for Heating 10.00 2.60 Diesel Fuel

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

Slew Gear 3.50 0.90 Shell Gear Oil 90 LS

Slew Gear Brake 1.00 0.25 Shell Donax TM

Hoist Gear Hoist 1 2.00 0.50 TOTAL

Hoist 2 2.00 0.50 API GL 5 - 90

Axle 1 Axle Drive 20.00 5.30 TOTAL

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

Axle 2 Axle Drive 30.00 7.90 TOTAL

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

Axle 3 Axle Drive 20.00 5.30 TOTAL

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

Radiator Expansion Tank 40.00 10.60 50 % Water

and Pipe 50 % Glysantin

The capacities given are approximate. For more exact measurements, checks should be
carried out at the specified inspection points, such as the inspection plugs, dipsticks and screens.
Date: 20.CW/04

e50_1-3030_b 1/1
 Lubrication and Maintenance Schedule 4
Date: 38.CW/05

e50_1-3040_c 1/12
4

4 Lubrication and Maintenance

Schedule

The lubrication and maintenance intervals

are divided into two types of interval.

The sections concerned with driving

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

1x

The sections concerned with crane

operations are given in operating hours.

Interval / Operating hours

Daily 50 100 250 500 1.000 1.500 3.000 we

1x

4.1 Initial Lubrication and Maintenance

Lubrication and maintenance work which is due

after the first operation and before regular work,
is marked with “1X” on the maintenance list.
It must be carried out once at the stated time.

Fuel / Interval / Kilometres driven

Lubricants Daily 50 500 1.000 5.000 10.000 20.000

1x
Date: 38.CW/05

2/12 e50_1-3040_c
 Lubrication and Maintenance Schedule 4

4.2 Regular Routine Lubrication and

Maintenance

The following service intervals apply to cranes

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

Regular routine lubrication and maintenance

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

- When carrying out more comprehensive

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

- In the above example, maintenance work for

x x "at 1,000 km" should also be carried out at
the same time.
Date: 38.CW/05

e50_1-3040_c 3/12
 4
4.3 Maintenance List

4/12
Fuel/ Interval / Kilometres driven
No.: Work to be carried out Lubricants Daily 50 500 1.000 5.000 10.000 20.000 40.000 as necessary

5 Drive
5.1 Engine: MERCEDES-BENZ (OM 926 LA) see the Operating Instructions of the Manufacturer
Engine: check / replenish oil level Sec. 2.1 x
Engine: change oil and oil filter for oil quality: in accordance with Mercedes-Benz Frequency 50.000 km
fuel regulations 228.5 at least 1x annually

for differing oil quality: see Operating instructions of the engine

manufacturer
other maintenance works see the Operating Instructions of the Manufacturer

6 Transmission
6.1 Drive Gear - check the oil level / top up as nec. Sec. 2.5 at least once a month
6.2 Drive Gear - change the oil / replace the intake filter Sec. 2.5 1x x every 18 months

7 Joint Shafts
7.1 Check and tighten the flange connections 1x 1x x

e50_1-3040_c
Date: 38.CW/05
 Date: 38.CW/05

Fuel/ Interval / Kilometres driven

No.: Work to be carried out Lubricants Daily 50 500 1.000 5.000 10.000 20.000 40.000 as necessary

e50_1-3040_c
8 Axles
8.1 Check and tighten the axle retaining bolts 1x 1x x
8.2 Lubricate the axles, steering knuckle bearing Sec. 2.9 1x 1x x
8.3 Steering and track arm 1x x
8.4 Axle drive - check the oil / top up as necessary Sec. 2.8 at least once a week
8.5 Wheel hub drive - check the oil / top up as nec. Sec. 2.8 at least once a week
8.6 Axle drive - change the oil Sec. 2.8 1x x
8.7 Wheel hub drive - change the oil Sec. 2.8 1x x
8.8 Wheel hub bearing - change the grease Sec. 2.9 at least once a year
8.9 Suspension cylinder - lubricate the swing bering Sec. 2.9 x
Lubrication and Maintenance Schedule 4

5/12
 4
Fuel/ Interval / Kilometres driven

6/12
No.: Work to be carried out Lubricants Daily 50 500 1.000 5.000 10.000 20.000 40.000 as necessary

9 Steering
9.1 Steering componets 1x x
9.2 Lubricate the steering componets Sec. 2.9 1x x
9.3 Replacing the hoses every 4 years
9.4 Lubricating Independent Rear Axle Steering Sec. 2.14 every 3 months
9.5 Check the steering angle sensors x

10 Braking system
10.1 Check brake lining for wear 1x x at least once a week
10.2 Renew brake linings x
10.3 Replace brake drums x
10.4 Perform brake funcion check x
10.5 Check expanding cylinder x min. once every 2 years
10.6 Replace other brake parts x x min. once every 2 years
10.7 Air drier - replace granulate cartridge min. once every 2 years
10.8 Drain water from the air tank x at least once a year

11 Wheels and Tyres

11.1 Tighten the wheel nuts (after a wheel change) 1x 1x x
11.2 Check the tyres x

e50_1-3040_c
Date: 38.CW/05
 Date: 38.CW/05

Fuel/ Interval / Operating hours

No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

e50_1-3040_c
12 Hydraulic system
12. Replace the hoses every 4 years
12.1 Hydraulic tank - check oil level & top up as nec. Sec. 2.3 x
12.2 Hydraulic tank - Return oil filter 1 1x 1x 1x x x
12.2 Hydraulic tank - Return oil filter 2 1x 1x x x
12.2 Hydraulic tank - High pressure filter 1x x x
12.3 Hydraulic tank - replace the aeration filter 1x 1x x
12.4 hange hydraulic oil Sec. 2.3 x
12.5 Bleed the hydraulic system x
12.6 Pressure accu., check the preliminary gas tension x

13 Outriggers
13.1 Lubricate sliding surface on outrigger struts Sec. 2.12 x

14 Electrical system
14.1 Check the lighting system x
14.2 Replace bulbs, e.g. of headlamps x
14.3 Service the battery x
14.4.1 Superstructure Fuses x
14.4.2 Carrier Fuses x
Lubrication and Maintenance Schedule 4

7/12
 4
Fuel/ Interval / Operating hours

8/12
No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

15 Fuel system
15. Fuel tank, drain off sediment and water x

16 Air intake and cooling system

16. Clean or replace the air filter element x
16. Clean the cooling system x
16. Check the coolant & top up as necessary x

17 Piston rods
17. Lubricate piston rods Sec. 2.13 x

e50_1-3040_c
Date: 38.CW/05
 Date: 38.CW/05

Fuel/ Interval / Operating hours

No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

e50_1-3040_c
18 Optional equpment
18.1 Auxiliary Heating see the Operating Instructions of the Manufacturer
18.2 Auxiliary Heating - check system is functioning correctly x
18.3 Replace the heat exchanger x
18.4 Switch on the hot water heating x
18.5 Check the fuel filter and replace as necessary x
18.6 Lubricate the dolly coupling Sec. 2.9 x
18.7 Service the dolly coupling x
18.8 Fill central lubrication system Sec.2.9 x

19 Visual inspections - chassis

19.1 Covers and panels x
19.1 Hydraulic system x
19.1 Engine x
19.1 Transmission x
19.1 Radiator x
19.1 Instruments and displays x
19.1 Lighting system x
19.1 Windscreen washing assembly - check for correct function & top up wash solution at least once a week
Lubrication and Maintenance Schedule 4

9/12
 4
Fuel/ Interval / Operating hours
No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

10/12
19 Visual inspections - superstructure
19.2 Covers and panels x
19.2 Instruments and displays x
19.2 Lighting system x
19.2 Windscreen washing assembly - check for correct function & top up wash solution at least once a week

20 Slew ring
20.1 Lubricate the bearing Sec. 2.9 x
20.2 Lubricate the gear ring Sec. 2.10 x
20.3 Slew ring - check at least once a year

21 Slew gear
21.1 Slew gear mechanism - check oil & top up as nec. Sec. 2.6 x
21.2 Slew gear mechanism - change oil Sec. 2.6 1x x
21.3 Check screw connections and tighten as nec. x

e50_1-3040_c
Date: 38.CW/05
 Date: 38.CW/05

Fuel/ Interval / Operating hours

No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

e50_1-3040_c
22 Hoists
22.1 Hoist gear - check oil level & top up as nec. Sec. 2.7 x
22.2 Hoist gear - change oil Sec. 2.7 1x x
22.3 Check the gear oil x
22.4 Lubricate the rope drum bearing Sec. 2.9 x
22.5 Check screw connections and tighten as nec. x
22.6 Lubricate hook block Sec. 2.9 x
22.7 Determining the spent share of the theoretical service life at least once a year

23 Luffing gear
23.1 Luffing cylinders - lubricate foot & piston bearing Sec. 2.9 x
Lubrication and Maintenance Schedule 4

11/12
 4
Fuel/ Interval / Operating hours
No.: Work to be carried out Lubricants Daily 50 100 250 500 1.000 1.500 3.000 as necessary

12/12
24 Equipment
24.1 Main boom - lubricate the linings Sec. 2.9 x
24.2 Main boom - lubricate the sliding surfaces Sec. 2.12 x
24.3 Main boom - lubricate the basic bolts Sec. 2.9 x
24.4 Ropes
24.4.1 General Notes on Handling and Assembly see section 24.4.1
24.4.2 Lubricating the Ropes Sec. 2.11 x
24.4.3 Cleaning the Ropes x
24.4.4 Checking the Cables and Replacing as Necessary 1 x year
24.5 Check the main boom for weld cracks x
24.6 Main boom - set the retracting rope x
24.7 Main boom - visual inspection of all extending and retracting ropes x At least every four years
24.8 Inspect main boom rope track rollers At least every three months
24.8 Inspect main boom extension rope track rollers During every folding procedure
24.9 Checking the sheaves x
24.10 Sheaves - check the roller bearings x
24.11 Sheaves - lubricate the roller bearings Sec. 2.9 x
24.12 Check the pins for cracks x
24.13 Check the pull rod x
24.14 Telescopic main boom ext. - lubricate sliding surfaces Sec. 2.12 x
24.15 Telescopic main boom ext. - lubricate the foot bearings Sec. 2.9 x
24.16 Telescopic main boom ext. - lubricate the luffing cylinder Sec. 2.9 x
24.17 Check for weld cracks on the telescopic main boom extension x

25 Heating
25.1 Check fuel tank and fill up as necessary x
25.2 Check the glow plug and replace as necessary x

e50_1-3040_c
Date: 38.CW/05
 Drive 5

50−1−3050a_en 1/3
5

Z 501 300

2/3 50−1−3050a_en
 Drive 5

5 Drive

5.1 Engine OM 926 LA

(Z 501 300)

Risk of injury!
Maintain safety distance to hot, rotating and moving
components.

Danger of burning or scalding.

Before carrying out maintenance work in the engine area,
allow a cooling period of 60 minutes.

Please follow the notes and instructions concerning mainte-

nance of the engine in the operating instructions of the engine
manufacturer.
(see section 4 of this documentation)

The description of the engine is on the bearing plate. The location

of the bearing plate can also be found in the operating instruc-
tions of the engine manufacturer.

50−1−3050a_en 3/3
 Transmission 6

6 Transmission

To make the oil check easier,

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

(Z 501 310)

Z 501 310

6.1 Drive Gear - Checking and Topping

Up the Oil Level

With this transmission, an oil check can

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

Ensure that the vehicle is in the horizontal

position and apply the parking brake.

When checking the oil level, the

Z 160 077 prescribed safety regulations must be
observed.
The vehicle must be safeguarded with
chocks to prevent it from rolling.

(Z 160 077)

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

The cold check is made to determine

wether the transmission is sufficiently filled with
oil to be able to carry out a warm oil check.
Date: 47.CW/00

bs_e50_1-3060 1/6
6

Carry out the oil checks as follows:

Clean the edge of the filler pipe before

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

- Unscrew the oil dipstick from the oil level

tube in the anticlockwise direction and wipe
off with a non-fibrous cloth.
Then reinsert the oil dipstick in the oil level
tube up to the stop and remove again.

Z 160 029
(Z 160 029)

- When the gear oil is cold (approx. 40o C),

the oil dipstick must be covered up to the
"MIN" marking.
If the oil is below this marking, oil must be
added.

(Z 501 311)

Z 501 311

Date: 47.C W/00

2/6 bs_e50_1-3060
 Transmission 6

Warm check
(When the gear oil is at operating temperature
is 80o C)

The oil level should be checked when the

gear oil is at operating temperature and the
engine at idle speed. It is best if this check is
carried out at the end of an operating period
(or journey).

Ensure that the vehicle is in the horizontal

position and apply the parking brake.

Carry out the oil checks as follows:

- Shift the gear lever into neutral "N" and

leave the engine running at idle speed
(approx. 1000 rpm).

- Unscrew the oil dipstick from the oil level

tube in the anticlockwise direction and wipe
off with a non-fibrous cloth.
Then reinsert the oil dipstick in the oil level
tube up to the stop and remove again.
(at least x2).

Z 501 311

If the oil level is not in the warm range

"A-B", oil must be added as the
transmission could otherwise be
damaged.
The oil level must not be above the upper
marking "A".
(Z 501 311)

- Insert the oil dipstick again and turn

clockwise to secure in place.

The oil dipstick and the oil filler pipe may

Date: 47.CW/00

have different lengths and shapes depending

on the type of transmission.

bs_e50_1-3060 3/6
6

6.2 Changing the Oil in the Drive

Gearbox and Replacing the Filter

For replacement intervals see section 4

"Lubrication and Maintenance schedule"

Depending on operating conditions an

earlier oil or filter change may be necessary.
The oil must be changed if there are any signs
of contamination or high temperatures-
conditions indicated by discolouring, strong
smells or oil inspections.

Z 501 312 Replace the filter each time the oil is changed.
(Z 501 312)

The oil should be drained when the drive

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

Change the oil as follows:

- Ensure that the vehicle is in the horizontal

position and engage the parking brake.
(Z 501 313)

- Engine switched off

Z 501 313

- Secure the vehicle with blocks to prevent

any rolling movement.
(Z 160 077)
Date: 47.C W/00

Z 160 077

4/6 bs_e50_1-3060
 Transmission 6

- Unscrew the oil drain plug and drain off the oil.
(Z 501 314)

Oils that are drained off must be stored in

suitable containers and disposed of
correctly.

- Clean the oil drain plug with magnetic insert

and the sealing surface on the housing and
refit with a new O-ring.

Z 501 314

- Replace the filter element.

(Z 501 312)

When changing the filter you must make

sure that no dirt or oil sludge enters the
system. In addition, the parking brake
must be covered and protected to prevent
it from coming into contact with oil.

Z 501 312
Date: 47.CW/00

bs_e50_1-3060 5/6
6

- Fill in oil.
(Z 501 311)

Utmost cleanliness must be observed at

all times.

- Place the gearshift lever in neutral "N".

- Start the engine and leave running at idle

speed (1000 rpm).

- Add oil up to the upper marking of the range

Z 501 311 "A-B".
For temperatures of approx. 40 oC the lower
marking "MIN" on the oil dipstick is used as
an indicator level for the starting procedure.

- Apply the parking brake on the vehicle

- Shift through all gearshift positions.

- Check the oil level again and top up again if

required.

- The upper marking "A" on the oil dipstick is

for temperatures of approx. 80 degrees C
and must not be exceeded.

- The oil level at 80 oC is binding.

Date: 47.C W/00

6/6 bs_e50_1-3060
 Joint Shafts 7

7 Joint Shafts

Suitable safety measures must be

implemented by the crane operator
and / or user wherever people or
machinery may be endangered by
rotating drive shafts.
Drive shafts may only be fitted by
suitably trained personnel.

7.1 Flange Connections

Check and, if necessary, tighten the screws and

nuts on the flange connections.

Tightening torque:

- screws M12 x 1.5 : 112 Nm

(Z 160 103)

Z 160 103
Stand: 47.KW/00

bs_e50_1- 3070 1/1

 Axles 8

8 Axles

8.1 Checking and Tightening the Axle

Fixings

- Check and, if necessary, tighten the screws

on the axle brace collars.

The correct torque is 70 to 80 Nm.

(Z 160 105)

Z 160 105

- Tighten the fixing screws on the axle braces

using a torque spanner.

The correct torque is as follows:

- Screw M18 (outer axle brace): 410 Nm

- Screw M 20 (inner axle brace): 580 Nm

(Z 160 106)

Z 160 106

Before replacing the screws:

* Clean the threaded hole and surface areas.

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

Do not use MoS2 !

Date: 47.CW/00

Z 160 107

bs_e50_1-3080 1/8
8

8.2 Lubricating the Axles

- Steering knuckle bearing

- Grease the upper part of the steering knuckle

bearing.
(Z 160 108)

Z 160 108

- Grease the lower part of the steering knuckle

bearing.
(Z 160 109)

Z 160 109

- Lubricating the Rigid Axle

- Axle 2 (only for 6 x 4)

- Lubricate the rigid axle via the available

lubricating nipple (1) until grease is emitted
on the opposite of the breather (2)or the
groove.
(Z 163 326)
Date: 47.CW/00

1
2
Z 163 326

2/8 bs_e50_1-3080
 Axles 8

8.3 Steering and Track Arm

- Check the screws and tighten as necessary.

(Z 160 110)

Z 160 110

8.4 Axle Drive - Checking and Topping

Up the Oil Level

- Axle 1 and Axle 3

(Single Axle Drive with Integrated Lock)

Check the oil level as follows:

- The vehicle must be in the horizontal position

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

- Remove screw (2) from the inspection/filler

Z 075 363 opening.
(Z 160 125)

The axle gear is filled correctly when the

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

- If the oil level is too low, unscrew the

filler plug and fill in oil.

If the oil check is carried out when the gear

is warm, ensure that oil does not spill over
Date: 47.CW/00

when the inspection plug is opened.

Z 160 125

bs_e50_1-3080 3/8
8

- Axle 2 (for drive variant 6 x 6)

The vehicle must be in the horizontal

position before the oil check is carried out.

- Remove screw (2) from the inspection/filler

opening.
(Z 163 100)

The distributor gear is filled correctly when

the oil level comes up to the sill on the
inspection opening.
Z 163 100
- If the oil level is too low, unscrew the filler plug
and fill in oil.

If the oil check is carried out when the gear

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

8.5 Wheel Hub Drive - Checking and

Topping Up the Oil Level

- Drive the vehicle forwards or backwards until

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

- Remove the oil inspection plug (2).

The oil level must come up to the sill of the
inspection opening. Top up if necessary.
(Z 160 117)
Date: 47.CW/00

Z 160 117

4/8 bs_e50_1-3080
 Axles 8

8.6 Axle Drive - Changing the Oil

- Axle 1 and Axle 3

(Single Axle Drive with Integrated Lock)

Oil should be changed after operation

because warm oil drains better.

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

must be unscrewed when an oil change is to
be carried out.
(Z 160 121)

Z 160 121 - Drain off the old oil.

Oils which are drained off should be caught

in suitable containers and disposed off
appropriately.

- Clean the screw and fit a new sealing ring.

(Z 160 007)

Z 160 007

- Fill new oil into the axle housing until it

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

- Then screw filler plug back in.

Date: 47.CW/00

Z 160 124

bs_e50_1-3080 5/8
8

- Axle 2 (for drive variant 6 x 6)

- Park the machine on an even surface.

Oil should be changed after operation

because warm oil drains better.

- To change the oil, oil filler plug (2) and

oil drain plugs (1) must be removed.
(Z 163 101)

- Drain off the old oil.

Z 163 101

Oils which are drained off should be caught

in suitable containers and disposed off
appropriately.

- Clean the plug, replace the old seal and

screw the plug back in.

- Fill new oil into the axle housing until it

overflows from the filler/inspection opening.
(Z 163 102)

Oils which are drained off should be caught

in suitable containers and disposed off
appropriately.

- Then screw filler plug back in.

Date: 47.CW/00

Z 163 102

6/8 bs_e50_1-3080
 Axles 8

8.7 Wheel Hub Drive - Changing the Oil

- Drive the vehicle forwards or backwards until

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

- Unscrew the drain plug (1) and the oil

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

Oils which are drained off should be caught

in suitable containers and disposed off
Z 160 117 appropriately.

- Clean the plug, replace the old seal and

screw the plug back in.

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

opening.
(Z 160 118)

- Next clean the filler plug or inspection plug,

replace the sealing rings and screw back in.

Z 160 118

8.8 Wheel Hub Bearing - Changing the

Grease

- Axle 2 (only 6x4)

- Dismantle the wheel hub.

(Z 160 128)
Date: 47.CW/00

Z 160 128

bs_e50_1-3080 7/8
8

- Thoroughly clean the inside and outside of

the wheel hub, removing any traces of old
grease.

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

(Z 160 131)

- Screw on the hub cap.

Z 160 131

8.9 Suspension Cylinders

- Lubricate the swing bearing.

(Z 160 127)

Z 160 127
Date: 47.CW/00

8/8 bs_e50_1-3080
 Steering 9

9 Steering

9.1 Steering Components

- Check the steering components are

sufficiently tightened

- Check that all the screws on the steering

components are sufficiently tightened and
tighten any loose screws as required.
(Z 162 133)

Z 162 133

9.2 Lubricating the Steering Components

- Lubricating and Checking the

Steering Cylinder

- Lubricate the swing supports if nipples are

provided.
(Z 160 132)

- If the working cylinder has been fitted at a

later stage (e.g. after repair work), it should be
inspected after the first 1 000 km.
(Z 160 136)
Z 160 132
Check that all screws and hydraulic lines are
tightly fitted.
Date: 27.CW/02

Z 160 136

bs_e50_1- 3090 /a 1/3

9

9.3 Replacing the Hoses

Even if there is no sign of damage, the

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

Z 160 136

9.4 Lubricating Independent Rear Axle

Steering

To ensure faultless operation while releasing

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

(Z 501 320)
Z 501 320

Before resuming road travel, switch off

independent rear axle steering and lock.
The indicator lights (143, H 344 and
144, H 345) may not light up.
Date: 27.CW/02

2/3 bs_e50_1-3090 /a
 Steering 9

9.5 Electric-hydraulic Steering

Check the steering angle sensors of axles 1, 2

and 3 (right-hand side) daily to check that they
are fitted correctly and free of damage.

(Z 501 321)

Z 501 321
Date: 27.CW/02

bs_e50_1- 3090 /a 3/3

 Braking System 10

10 Braking System

Safety instructions

The brakes are a paramount safety

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

Service and repair work require

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

Vehicles requiring authorisation

The traffic regulations of the land in question

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

Vehicles not requiring authorisation

are to be inspected at least once a year by a

specialist in accordance with the appropriate
accident prevention regulations.

Repair sets

Various repair sets are available for

maintenance purposes.
Only original parts may used.
Stand: 06.KW/06

e908-3100_d 1/4
10

Wear in brake linings

Each new brake lining must be worn in so that

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

10.1 Check brake linings for wear

Drum brakes

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

10.2 Renew brake linings

d

For worn or oiled brake linings always replace

both brakes on an axle and always use a
consistent quality of lining per axle.
Ensure that only linings cleared for release are
Stand: 06.KW/06

used.

Z 36 581

2/4 e908-3100_d
 Braking System 10

10.3 Replace brake drums

Brake drums

They may only be worn down to the minimum

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

10.4 Perform brake function check

Press brake pedal slowly and check if brake

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

10.5 Check expanding cylinder

Clean all parts with spirit or a suitable cleaning

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

10.6 Replace other brake parts

Compression springs, draw springs and sealing

rings, protective caps and bellows must be
replaced at least every two years.
Stand: 06.KW/06

e908-3100_d 3/4
10

10.7 Air Drier with Integrated Pressure

Regulator

Replacing the granulate cartridge (1)

The air drier must be depressurized.

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

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

Before screwing in a new cartridge, lightly

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

Read the instructions on the cartridge.

The tightening torque for the cartridge is 15 Nm.

Z 160 168

10.8 Draining Water from the Air Tanks

Air tanks with a manual drain valve are to

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

- When the drain valve pin is pressed or

pulled sideways the rocker valve opens and
the condensation can escape from the tank.
Stand: 06.KW/06

(Z 160 145)

Z 160 145

4/4 e908-3100_d
 Wheels and Tyres 11

11 Wheels and Tyres

11.1 Tightening the Wheel Nuts

The wheel nuts should be tightened every 10,000 km.

The wheel nuts must be tightened 50 km

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

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

When fitting new wheel nuts, ensure that

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

(Z 161 132)
Z 161 132

11.2 Tyres - Checking Pressure and Tread

Depth and Checking for Damage

Type Tyre pressure

14.00 R 25 10 bar

16.00 R 25 9 bar

20.50 R 25 7 bar
Date: 47.CW/00

bs_e50_1-3110 1/1
 Hydraulic System 12

12 Hydraulic System

Ensure that all lines and hoses are at

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

If lines and hoses are found damaged due

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

Check all hoses regulary for damages.

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

Even if no damages are detected the

hoses have to be replaced at the latest after 4
years.
Date: 47.CW/00

bs_e501-3120 1/19
12

12.1 Hydraulic Tank - Checking and

Topping Up the Oil Level

The hydraulic tank contains the general oil

supply for all hydraulic components.

When checking the oil level:

- Position the crane on level, flat ground.

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

- Read the oil level off the dipstick.

(Z 162 152)

Z 162 152

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

topped up.
(Z 160 153)

Find the cause of the oil loss and rectify

immediately.

If there are three markings on the dipstick,

the centre marking indicates the max. level.
Date: 47.CW/00

Z 160 153

2/19 bs_e501-3120
 Hydraulic System 12

12.2 Hydraulic Tank - Filter

1 - Return oil filter 1

2 - Return oil filter 2
3 - HP filter
(Z 501 325)

Z 501 325

For replacement intervals see Section 4

"Lubrication and Maintenance Schedule".

If one of the filters needs to be cleaned or

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

(Z 501 326)

Z 501 326
Date: 47.CW/00

bs_e501-3120 3/19
12

In order to find out which filter needs to be

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

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

Z 501 327

Z 501 328

- Clean the housing of return oil filters 1

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

To clean the filter barrel and to replace the

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

DANGER OF INJURY
from high hydraulic oil pressure.
Date: 47.CW/00

Therefore switch off the engine before

working on the hydraulic system.
Z 075 250

4/19 bs_e501-3120
 Hydraulic System 12

- Return oil filter 1

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

release the cover (1) by means of an
appropriate tool and then unscrew the cover.
(Z 160 170)

Z 160 170

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

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

- Remove and dispose of the paper

element (8) in the barrel (2).
(Z 160 257)

Z 160 257

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

petrol of a suitable grade for cleaning
purposes.
(Z 160 160)
Date: 47.CW/00

Z 160 160

bs_e501-3120 5/19
12

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

in reverse order.

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

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

Z 160 161

Before a new paper element is fitted in the

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

Z 160 162

When screwing on the filter cover (1),

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

Carry out a test run to ensure that the filter

is fitted correctly.
Date: 47.CW/00

Z 160 170

6/19 bs_e501-3120
 Hydraulic System 12

- Return oil filter 2

- Loosen the hexagon nuts (1) with wrench

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

- Then remove the filter cover (2) while paying

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

Z 160 250

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

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

It is advisable to set the filter unit down on

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

Z 160 251

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

the handle (5) downwards and return it
approximately 60o to the left or the right.

- Remove the handle (5) with the attached

valve, clean the latter in diesel oil or
petroleum ether and place it on a clean base.
(Z 160 252)
Date: 47.CW/00

Z 160 252

bs_e501-3120 7/19
12

- Remove paper elements which are marked

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

The element number of the replacement

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

Z 160 253
- Pour the residual oil out of the filter tube into
a container for used oil and rinse out the
filter tube with diesel oil or petroleum ether.

In filters which have a magnet system, the

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

- The return oil filter 2 is assembled in the

reverse seqence.

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

be checked to ensure that they are in perfect
condition and positioned correctly. Replace
damaged parts. Fit new paper elements in the
filter tube. Press the handle between the
locking plates fastened at the top of the filter
tube downwards and turn it until it has locked in
position in the slots in the cams.
(Z 160 251)
Date: 47.CW/00

On the test run, check that the filter is not

Z 160 251 leaking.

8/19 bs_e501-3120
 Hydraulic System 12

- Cleaning the High Pressure Filter and

Replacing the Element

- Switch off the engine

- Place a suitable container beneath the filter (3)

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

Z 075 251

- Unscrew the socket housing.

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

- Drain off the remaining oil from the bottom of

the socket housing and dispose of it.

- Wash out the socket housing with diesel oil

or petrol of a suitable grade for washing
purposes.

Z 160 176

- Remove and dispose of the dirtied paper

element (2) from the outlet pipe (3) by
moving it gently from side to side and pulling
it downwards.
(Z 160 177)
Date: 47.CW/00

Z 160 177

bs_e501-3120 9/19
12

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

(Z 160 178)

Z 160 178

- Apply new paper element (2) on the outlet

pipe (3).
(Z 160 179)

Z 160 179

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

with clean hydraulic oil, carefully place the
filter barrel over the filter element (2) and...
(Z 160 193)
Date: 47.CW/00

Z 160 193

10/19 bs_e501-3120
 Hydraulic System 12

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

with a wrench.
(Z 160 194)

Carry out a test run to ensure that the filter

is fitted correctly.

Z 160 194
Date: 47.CW/00

bs_e501-3120 11/19
12

12.3 Hydraulic Tank - Replacing the

Aeration Filter

The aeration filter must be changed more

regularly in especially harsh operating
conditions.
(Z 501 329)

Z 501 329

- Unscrew the filter and dispose of

appropriately.
(Z 160 188)

Z 160 188

- Screw on the new filter.

(Z 160 189)
Date: 47.CW/00

Z 160 189

12/19 bs_e501-3120
 Hydraulic System 12

12.4 Changing the Hydraulic Oil

The vehicle should be level and the

engine switched off.

- Close shut-off lever (1).

Loosen hydraulic hose (2) at top end,
open shut-off lever (1) again and
drain hydraulic oil into a suitable container.
(Z 501 330)

Z 501 330

- Unscrew screws (3) from the drain pipe

connections on the bottom of the hydraulic
oil container in order to drain the remaining
oil and the residue.
(Z 501 332)

Oils that are drained off must be stored in

suitable containers and disposed of
correctly.

Z 501 332

- If necessary, clean the hydraulic oil tank.

(Z 501 331)
Date: 47.CW/00

Z 501 331

bs_e501-3120 13/19
12

- Secure hydraulic hose (2) again and

tighten screws (3) again.
(Z 501 332)

This seals the hydraulic tank again.

Z 501 332

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

(Z 501 333)

When oil is filled into the hydraulic system

there is a danger of dirt particles
contaminating the hydraulic oil circuit.
In order to prevent malfunctions in the
system caused by impurities, ensure that
the initial fill up and subsequent fill ups are
carried out under extremely clean
conditions.
If necessary, first pass the hydraulic oil
Z 501 333 through a filter.
Date: 47.CW/00

14/19 bs_e501-3120
 Hydraulic System 12

12.5 Bleeding the Hydraulic System

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

i.e. - boom lowered

- vehicle supported on outriggers
- axles lowered
(Z 160 008)
Z 160 008

While the engine is running the hydraulic

system is bled through the vent ports
provided...

...hydraulic pump
(Z 160 195)

Z 160 195

...semi-integral power steering gear

(Z 160 171)

While bleeding the system, with the

engine running at idle speed, the vent fittings
should be kept open until oil which is free from
air bubbles escapes from the fittings.
Date: 47.CW/00

Z 160 171

bs_e501-3120 15/19
12

At points where there are no bleeder

connections, a union (union nut) situated at a
high level is loosened by a small amount.
(Z 160 197)

Z 160 197

At high engine speeds or with a high

suction current, smaller air pockets are sucked
back into the pump where they are broken up
into tiny bubbles; this can lead to foaming and
can cause venting of the system to take much
longer.
(Z 501 334)

Z 501 334
Date: 47.CW/00

16/19 bs_e501-3120
 Hydraulic System 12

12.6 Hydraulic System -

Pressure Accumulator, Checking
the Preliminary Gas Tension

The pressure accumulators fitted in the

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

They are fitted in the following components:

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

The corresponding components can only

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

The preliminary gas tension must be checked at

regular intervals.

To check the preliminary gas tension,

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

This inspection may only be carried out by

specialist personnel who are trained in the
use of the filling and test equipment.
Date: 47.CW/00

bs_e501-3120 17/19
12

To check and fill the pressure accumulator,

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

- Pilot control circuit of the superstructure

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

If the pressure gauge does not indicate a

pressure level, the system is not under
2 pressure.

- Remove the protective device (1) on the gas

Z 30 194 valve of the pressure accumulator (2) and
screw on the filling and test device (3).

- Open the gas valve over the screwed-on

filling and test device and read off the charge
pressure on the pressure gauge of the
testing device.

- If there is insufficient initial pressure, the

pressure accumulator must be filled up with
nitrogen via the filling device (3) up to the
corresponding initial pressure.
(Z 30 194)
After the initial fill-up, wait approximately two to
Date: 47.CW/00

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

18/19 bs_e501-3120
 Hydraulic System 12

When filling up the preliminary gas tension

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

Driving with insufficient preliminary gas

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

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

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

3 Only NITROGEN may be used to fill the

pressure accumulator.
A pressure reducer (5) must be fitted to the
nitrogen link.
5 Pressure accumulators may only be
repaired by the manufacturer or by
approved workshops.
The pressure accumulator must be
approved by an expert following repair
2 work.
4 A new test certificate must be produced for
Date: 47.CW/00

the pressure accumulator.

Z 30 641 (Z 30 641)

bs_e501-3120 19/19
 Outriggers 13

13 Outriggers

13.1 Lubricating the Sliding Surfaces on

the Outrigger Struts

Lubricate the upper guide strips and the

underside of the outrigger struts.
(Z 160 218)

Z 160 218
Date:25.CW/94

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

14 Electrical System

14.1 Checking the Lighting System

Lighting system, determine if it functions

correctly and immediately repair damage.

(Z 160 201)

Z 160 201

14.2 Replacing the Headlamp Bulbs

The headlamp bulbs can be changed from the

back without removing the headlamp.

(Z 160 203)

Z 160 203

14.3 Battery maintenance

For maintenance instructions, see

operating instructions of the engine
manufacturer.

(Z 160 502)
Date: 18th CW/04

Z 160 502

e50_1-3140 1/5
14

14.4 Fuses

14.4.1 Superstructure Fuses

Fuses are located:

- In the central electrical unit in the upper

right-hand corner of the crane cab.

14.4.2 Carrier Fuses

Fuses are located:

- In the battery case.

- Under the cover (of central electrical unit)

between the seats in the carrier cab.

Before you replace a fuse, first identify the

cause of the fault and rectify it.
The fuse numbers are indicated on the fuse
boxes.

A blown fuse must always be replaced by

a fuse with the same number of amps (as
stated on the fuse label).
Date: 18th CW/04

2/5 e50_1-3140
 Electrical System 14

- Superstructure (fuses)

OMC value/A Place of Page.path Potential Description

installment
F101 25 CEU SS 3.5 30 Ignition lock, switches cl.15
F102 5 CEU SS 3.11 30 Interior lighting, radio
F103 10 CEU SS 3.13 15 Plug socket, cigarette lighter, horn,
rotaflare light, air-conditioning system
F104 10 CEU SS 4.7 15 Lamp, outside lighting, adjustable headlamps,
switchgear illumination, timer and fan heating
F105 5 CEU SS 6.1 15 Windscreen wiper; wash water pump
F106 5 CEU SS 7.6 30 Anemometer, double obstacle lighting,
main boom head lighting
F107 5 CEU SS 13.2 15 Slewing indicator, lowering limit switch,
sensor SS lock, pressure switch extend telecyl.
F108 10 CEU SS 8.1 LOAD/K152 raise/lower derricking gear, extend telecyl.,
raise hoists
F109 CEU SS *** FREE ***
F110 5 CEU SS 10.2 15 Overrides tele-control and raise
derricking gear, sensors, telescopic units
F111 5 CEU SS 10.4 15 Operating voltage LMI, Slewing gear choke,
pressure switch pilot pressure
F112 10 CEU SS 16.11 LOAD cab up/down, change-over telescopic unit HW2
and derricking gear HW2
F113 15 CEU SS 17.7 LOAD oil cooler
F114 25 CEU SS 21.2 30 Condenser unit air-conditioning system
F115 25 CEU SS 22.2 30 Heating device
F116 10 CEU SS 22.4 30 Clock timer heating device
F117 10 CEU SS 22.12 30 Blower heating
F118 10 CEU SS 14.2 LOAD dead man’s switch, high speed gear, move
support, operating hours meter MFA10
F119 CEU SS *** FREE ***
F120 5 CEU SS 24.2 30 MFA10
F121 10 CEU SS 8.3 LOAD/K152 slewing gear brake, override raise
derricking gear, retract telecyl., lower hoist
F122 CEU SS ***FREE***
F123 CEU SS *** FREE ***
F124 CEU SS *** FREE ***
F125 CEU SS *** FREE ***
F126 CEU SS *** FREE ***
F127 CEU SS *** FREE ***
F128 CEU SS *** FREE ***
Date: 18th CW/04

OMC = Operating equipment code

CEU SS = Central electrical unit on superstructure

e50_1-3140 3/5
14

- Carrier (fuses)

OMC value/A Place of Page.path Potential Description

installment
F100 2 x 50 Battery main fuse superstructure / chassis
F101 25 CEU CR Ignition lock circuit
F102 10 CEU CR Ignition engine / transmission
F103 5 CEU CR Socket cab
F104 10 CEU CR Upper beam left
F105 10 CEU CR Upper beam right
F106 10 CEU CR Lower beam left
F107 10 CEU CR Lower beam right
F108 25 CEU CR Lighting equipment; upper beam; lower beam
F109 10 CEU CR Cigarette lighter
F110 10 CEU CR Fog lamp
F111 10 CEU CR Outriggers lighting
F112 10 CEU CR Rotaflare light; flasher; hand brake signal;
fan control
F113 10 CEU CR Outriggers
F114 15 CEU CR Revolution meter; rapid stop optional;
transverse longitudinal lock; spring accumulator;
counterweight optional;
switchover steering to superstructure
F115 25 CEU CR Back-up fuse: F114, F120, F113, F201
F116 10 CEU CR Parking light
F117 10 CEU CR Parking light; license plate lighting
F118 5 CEU CR Electricity supply tachograph
F119 5 CEU CR Tachograph; multi-functional display
F120 10 CEU CR Optional: air conditioning equipment;
central lubricating system
F121 25 CEU CR E-clutch; capacitor fan air conditioning
F122 15 CEU CR Horn relay; wiper; mirror heater / adjustment;
elec. window regulator; seat heating; heating fan
F123 5 CEU CR SPS CPU board A360
F124 10 CEU CR SPS board A360; level; raise up axle
F125 10 CEU CR Electricity supply steering computer
F126 5 CEU CR SPS CPU board A361
F127 10 CEU CR SPS board A361; crab walk
F128 15 CEU CR Flasher; voltage converter; radio;
ZE lighting equipment; dome light
Date: 18th CW/04

OMC = Operating equipment code

CEU CR = Central electrical unit on Carrier

4/5 e50_1-3140
 Electrical System 14

- Carrier (fuses)

OMC value/A Place of Page.path Potential Description

installment
F201 10 CEU CR Telma brake
F202 10 CEU CR Engine electronics
F203 10 CEU CR Engine diagnosis socket
F204 10 CEU CR Engine diagnosis socket
F205 10 CEU CR Engine vehicle control
F206 10 CEU CR Engine adaptation module
F207 7.5 CEU CR Transmission
F208 15 CEU CR Auxiliary heating
F209 5 CEU CR Timer auxiliary heating
F210 10 CEU CR Fan auxiliary heating
F211 5 CEU CR ABS
F212 10 CEU CR ABS
F111 10 130
F213 10 CEU CR ABS
F214 15 CEU CR ABS dolly socket

OMC = Operating equipment code

CEU CR = Central electrical unit on Carrier
Date: 18th CW/04

e50_1-3140 5/5
 Fuel System 15

15 Fuel System

Fuel tank

Drain off the water and sediment.

In order to drain the residue which has

accumulated in the fuel tank, open the drain
plug and drain off at least 1 l. of fuel.
(Z 501 335)

This maintenance job is to be performed

only with the fuel tank almost empty.
Z 501 335

Fuel filter

1- Primary fuel filter

2- Fuel filter
(Z 115 526)

For notes on maintenance, please refer to

the maintenance and operating instructions for
the diesel engine contained in Part 4.

Z 115 526
Date: 47.CW/00

bs_e50_1-3150 1/1
 Air Intake and Cooling System 16

16 Air Intake and Cooling

Service the air filter.

Never service the air filter when the engine is

running.
Service the element as soon as the indicator
light comes on with the engine running or at
least every 2 years.
(Z 163 820)
Z 163 820

Remove the filter cartridge.

Clean filter cartridge as required and test.

(Z 115 553)

The filter element must be replaced after it

has been cleaned 2-3 times, however at lost
every 2 years or as soon as it becomes clogged
with soot.

For more information refer to the engine

manufacturer´s operating manual.
Z 115 553

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

out with compressed.
(Z 115 554)
Date: 20th CW/04

Z 115 554

e50_1-3160_a 1/3
16

Air filter prefractionator (optional)

The air filter prefractionator prevents dirt from

getting into the air filter and the engine due to
the suction.

The contamination is discarded through the

side ejection hole (1).

If required, the ejection hole (1) must be

cleaned.

Z 501 336

Date: 20th CW/04

2/3 e50_1-3160_a
 Air Intake and Cooling System 16

Cleaning the cooling system

Pass compressed air through the cooling

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

Z 160 019

If the coolant rises to an unusually high

temperature at normal ambient temperatures
although the cooling system exterior has been
cleaned and there are no other malfunctions,
the cooling system interior may be
contaminated.
(Z 163 245)

In this instance the cooling system must undergo

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

You will find details concerning this in the

Z 163 245 operating instructions of the engine manufacturer.

Check the coolant level and top up as

necessary.

Open the cap of the engine cooling system

only when the coolant is at a temperature of
below 90o C.
(Z 163 021)

Before the onset of winter check the

Date: 20th CW/04

coolant for anti-freeze.

Z 160 021 For more information refer to the engine

manufacturer´s operating manual.

e50_1-3160_a 3/3
 Piston Rods17

17 Piston Rods

Apply protective grease to exposed

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

bs_e908-3170d 1/1
 Optional Equipment 18

18 Optional Equipment

18.1 Auxiliary Heating

Please refer to the manufacturer's

instructions regarding servicing of the
auxiliary heating system.

(Z 160 211)

Z 160 211

18.2 Auxiliary Heating - Checking the

System is Functioning Correctly

Briefly switch on the heating approximately

once a month even outside heating periods.

The following malfunctions can be repaired by

the crane operator:

1. The fan cannot be heard after the heating

has been switched on:

Check the 15-amp main fuse.

2. After the heating has been switched on, the

fan runs for approx. only 3 minutes, the
heating does not start and switches off
automatically:

a) Briefly switch the heating on and off again

(but not more than twice).
(Z 160 205)

b) Switch off the heating system.

Check the fuses ( F 390, F 391, F 392) in
the main electrical unit and if necessary
Date: 47.CW00

have the fault repaired in the workshop.

Z 160 205

bs_e50_1-3180 1/4
18

18.3 Replacing the Heat Exchanger

The heat exchanger has a service life of 10

years and must be replaced with an original part
after this period by the manufacturer or one of
the manufacturer's recommended work shops.
The heating system must then be marked with
the date of sale and the words "Original spare
part".

(Z 160 220)

Z 160 220

18.4 Switching on the Hot Water Heating

Switch on the hot water heating outside the

heating period for approx. 10 minutes in order
to ensure a reliable start at the beginning of the
heating period.

(Z 160 221)

Do not operate the heating in enclosed

spaces.
Z 163 721

18.5 Checking and Replacing the Fuel

Filter

Close the shut-off cock on the fuel tank and

release the two hose clips on the fuel filter.

- Remove the pipes from the fuel filter.

- Fit the new filter.

(Z 163 563)
Date: 47.CW/00

Z 163 563

2/4 bs_e50_1-3180
 Optional Equipment 18

18.6 Lubricating the Dolly Coupling

The dolly coupling should be lubricated when

uncoupled.
(Z 160 207)

The procedure is the same for other types

of dolly coupling.

Z 160 207

18.7 Servicing the Dolly Coupling

If, when disengaging the coupling and engaging

the second lock-in position, the release gear
does not automatically locate in the receiving
jaw, the jaw should be moved into its centreline
position.
(Z 160 208)

The procedure is the same for other types

of dolly coupling.

Z 160 208

- Loosen the screws.

- Allow the release gear to locate in the notch

of the jaw.

- Retighten the screws.

(Z 160 209)
Date: 47.CW00

Z 160 209

bs_e50_1-3180 3/4
18

- Grease the castellated nut.

(Z 160 210)

Z 160 210

18.8 Refilling the Central Lubrication

System

Fill up the reservoir (1) of the central lubricating

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

(Z 075 208)

Never exceed the max. level.

Z 075 208
Date: 47.CW/00

4/4 bs_e50_1-3180
 Visual Inspections 19

19 Visual Inspections

19.1 Visual Inspections - Chassis

The following points should be observed every

day before driving the crane:

- Check the covers and panels for damage.

Check for loose or missing screws.
(Z 501 340)

Z 501 340

- Check the entire hydraulic system for

damage and leaks and check the oil level.
(Z 501 341)

Z 501 341

- Check the engine for oil or fuel leaks and for

clogging.
(Z 501 342)

- Careful attention to the oil level and the

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

- Check the oil cooler for clogging.

Date: 47.CW/00

Z 501 342

bs_e50_1-3190 1/4
19

- Check the instruments and displays for

damage.
(Z 501 343)

Z 501 343

- Check the lighting system for damage.

(Z 160 217)

Z 160 217

- Check the functioning of the windscreen

washing assembly at least once a week.
The supply tank must always be filled with
water.
(Z 160 200)

Before the start of the cold season,

antifreeze in a quantity corresponding to the
temperature must be added to the water.
Date: 47.KW/00

Z 160 200

2/4 bs_e50_1-3190
 Visual Inspections 19

19.2 Visual Inspections - Superstructure

The following points must be observed daily

before the crane is driven:

- Check panels and covers for damage and

check for loose or missing screws.
(Z 501 345)

Z 501 345

- Check instruments and indicators for damage.

(Z 501 346)

Z 501 346

- Check the lighting system for damage.

(Z 163 812)
Date: 47.CW/00

Z 163 812

bs_e50_1-3190 3/4
19

- Check that the windscreen washing

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

Before the start of the cold season,

antifreeze in a quantity corresponding to the
temperature must be added to the water.

Z 160 365

Date: 47.KW/00

4/4 bs_e50_1-3190
 Slew Ring 20

20 Slew Ring

20.1 Lubricate Bearings

The bearings for the roller bearing slewing rim

are to be lubricated by means of central
lubrication distributor's lubricating nipple.

Lubricating Procedure:
First, lubricate by means of the slewing rim
lubricating nipple, then slewing the
superstructure through 360°.
After repeating the lubricant application, it must
Z 160 300 be visible around the whole of the slewing rim,
forming a continuous ring lubricant.
(Z 160 300)

20.2 Lubricating the Gear Ring

Where uncovered areas are visible on the teeth

edges, these should be sprayed immediately
with special adhesive grease.
(Z 160 301)
Date: 09.CW/05

Z 160 301

e50-1-3200_j 1/2
20

20.3 Check slew ring bolt connections

Using a torque wrench, check the tightness of

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

Bolts which can be turned using the

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

AC Item Dimension Material Torque

40 / 95 Item 1 M 20 x 90 12.9 600 Nm

50-E/150 Item 1 M 24 x 110 10.9 880 Nm
50 /155 Item 1 M 24 x 110 10.9 880 Nm
50-1 Item 1 M 24 x 110 10.9 880 Nm
80 / 205 Item 1 M 24 x 145 10.9 880 Nm
80-2 Item 1 M 24 x 145 10.9 880 Nm
90-R Item 1 M 24 x 145 10.9 880 Nm
100 Item 1 M 30 x 150 10.9 1770 Nm
110 Item 1 M 30 x 150 10.9 1770 Nm
120 /395 Item 1 M 30 x 150 10.9 1770 Nm

The above-mentioned screws should be

clean and lightly greased when fitted.
Date: 09.CW/05

2/2 e50-1-3200_j
 Slew Gear 21

21 Slew Gear

21.1 Slew Gear Mechanism - Checking

and Topping Up the Oil Level

Unscrew the filler plug.

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

Z 160 303

21.2 Slew Gear Mechanism - Changing

the Oil

Unscrew the filler plug.

(Z 160 303)

Unscrew the drain plug and drain off the gear

oil.
(Z 160 306)

Oils which are drained off should be caught

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

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

Clean the gear with flushing oil before

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

Z 160 307

bs_e908-3210d /g 1/2
21

21.3 Checking and Tightening the

Screw Connections

Check the torque of the screws using a torque

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

AC Item Dimension Material Torque

Item 1 M 14 x 30 8.8 118 Nm

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

The above-mentioned screws should be

clean and lightly greased when fitted.

When new screws are fitted, the thread

and head should be smeared with MoS2 paste.

Z 160 313 (Z 160 313)

Date: 07.CW/02

2/2 bs_e908-3210d /g
 Hoists 22

22 Hoists

Hazards caused by dragging!

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

Z 501 350

22.1 Hoist Gear - Checking and Topping

Up the Oil Level

Check the oil level on the oil dipstick.

The oil level should be checked

immediately after commencing operations,
while the gear is at a standstill, as a
considerable quantity of the oil is distributed
throughout the inner parts of the housing during
operation.

The correct oil level is achieved when the oil

Z 501 351 comes up to the "max." marking on the oil
dipstick with the crane and boom in a horizontal
position (boom 0 degrees).
(Z 501 350)

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

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

e50_1-3220_a 1/6
22

If the oil falls below the "min" marking proceed

as follows:

- Remove oil dipstick (1).

(Z 501 351)
- Add additional oil using a funnel or hose until
the "max" marking is reached on the oil dipstick.

See section 22.2 and section 2 "Fuels and

Lubricants" for the correct oil types.

- Screw the oil dipstick (1) back in with the

seal cleaned.

If a continual loss of oil is discovered when

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

Z 501 351
Date: 11.CW/04

2/6 e50_1-3220_a
 Hoists 22

22.2 Hoist Gear - Changing the Oil

Use the oil grade given in section 2 "Fuels and

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

Fully synthetic oils may only be used

with acidproof seals and a sufficiently resistant
inner coating.

It is prohibited to mix mineral and synthetic

oils.

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

after a longer operating period, as follows:

- Remove oil dipstick (1).

- Remove oil drain plug (2) and drain off the oil
into a suitable container.
(Z 501 352)

Oils which are drained off should be caught

Z 501 352 in suitable containers and disposed off
appropriately.

- After all the oil has run out, reinsert the

cleaned screw plug.
- Fill in new oil as described in section 22.1.
(Z 501 353)
- Screw the oil dipstick (1) back in with the
seal cleaned.
Date: 11.CW/04

Z 501 353

e50_1-3220_a 3/6
22

22.3 Checking the gear oil

The gear oil which is drained off should be

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

Date: 11.CW/04

4/6 e50_1-3220_a
 Hoists 22

22.4 Lubricating the Rope Drum Bearing

Grease lubricating nipple.

(Z 501 356)

Lubricat until lubricant is emitted evenly

at the seal.

Z 501 356

22.5 Checking and Tightening the

Screw Connections

1 The torque for the screws is as follows:

Item Dimension Material Torque

Item 1 M 10 x 25 8.8 46 Nm

(Z 501 355)
Z 501 355

Item Dimension Material Torque

Item 2 M 16 x 40 10.9 275 Nm

Item 3 M 12 x 40 10.9 108 Nm

(Z 501 354)

When new screws are fitted, the thread

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

Z 501 354

e50_1-3220_a 5/6
22

22.6 Lubricating the Hook Block

Risk of snagging!
When carrying out maintenance,
inspection and assembly work, special
care must be taken in this area as there is a
danger of becoming entangled and
dragged into the equipment between the
hook block pulleys and ropes.
Use the hand grips located on the hook
blocks!
Z 160 318 The lubricating nipples on the hook block
should be smeared before the crane is put
into operation and thereafter every 50 operating
hours.
(Z 160 318)

22.7 Determination of the spent share

of the theoretical service life

A detailled description is given in chap. 1 "Notes

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

6/6 e50_1-3220_a
 Luffing Gear 23

23 Luffing Gear

23.1 Luffing Cylinders - Lubricating the

Foot and Piston Bearings

Grease the foot bearing via two lubricating

nipples.
(Z 160 319)

Z 160 319

Grease the piston rod bearing via one

lubricating nipple.
(Z 160 320)

Z 160 320
Date: 13.CW/94

bs_e908-3230d 1/1
 Equipment 24

24 Equipment

24.1 Main Boom - Lubricating the

Linings

The upper guideways of the boom sections

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

Z 160 321

The basic boom section and the boom section

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

One lubricating nipple must be smeared

on either side of each boom section.
(Z 160 322)
Switch off engine as otherwise
Z 160 322 there is the danger of crushing
Date: 09.CW/05

e50-1-3240_a 1/32
24

24.2 Main Boom - Lubricating the

Sliding Surfaces

Extend all the boom sections with the boom in

the horizontal position.

RiSK OF CRANE OVERTURNING !

The boom sections should only be exten-
ded for lubricating in accordance with
table below.
(With max. outrigger support area)
Z 160 323

Type min. max. extension sequence

counter- or length
weight
on the
AC SS

40 / 95 2,2 t max. 29 m

50-E/150 7,5 t 1st 100% - 0% - 0% - 0%

2nd 0% - 100% - 100% - 100%

50(L)/155L 3,0 t 1st 100% - 0% - 0% - 0%

2nd 0% - 100% - 100% - 100%

50(S)/155S 3,0 t 1st 100% - 0% - 0%

2nd 0% - 100% - 100%

50 -1 7,5 t 1st 100% - 0% - 0% - 0%

2nd 0% - 100% - 100% - 100%

80-2 5,0 t 1st 100% - 0% - 0% - 0% - 0%

90-R 2nd 0% - 100% - 0% - 0% - 0%
80 /205 3rd 0% - 0% - 100% - 100% - 100%

Then coat the lower guideways with grease

using a brush.
(Z 160 323)
Date: 09.CW/05

2/32 e50-1-3240_a
 Equipment 24

24.3 Lubricating the Basic Bolts on the

Main Boom

Smear the two lubricating nipples.

(Z 160 327)

Z 160 327

24.4 Ropes

Danger due to protruding rope wires !

When ropes are handled, protruding wires
can cause injury.
Gloves should be worn for protection at all
times !
(Z 30 316)

Z 30 316
Risk of snagging!
When carrying out maintenance,
inspection and assembly tasks, there is a
risk of becoming entangled and dragged in
the following areas:
- between the rope and the rope winches
- between the rope and the sheaves of the
main boom or additional boom components
- between the rope and the sheaves of the
hook block
Proceed with special caution!
Date: 09.CW/05

Danger due to friction and scraping!

e50-1-3240_a 3/32
24

24.4.1General Notes on Handling and

Assembly

24.4.1.1Transport

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
Z 29 084 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.
(Z 29 084)

A reel is best raised by means of a rod placed

through its central axis.
(Z 29 085)

24.4.1.2 Storage

Cables should be stored in a cool, clean, dry

and covered environment. The cables should
not be stored directly on the ground but, for
example, on pallets.
Z 29 085 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, however, prevent condensation from
forming beneath it - which in turn cannot escape
and will possibly damage the cables permanently.
In this instance a solution may, for example, be
provided by using an intermediate layering
made out of sack cloth.
When storing a large number of spare parts, the
general rule should be: first in - first out.
This means that the cables should be used in
the same order as they are delivered.
Date: 09.CW/05

This will then prevent the instance of a cable

first being used after several years in storage.

4/32 e50-1-3240_a
 Equipment 24

24.4.1.3 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 between
the sheave and the cable on the equipment.
Cable which is wound on a reel is also preferably
unwound using a swivel plate or from a trestle.
Rolling the coil out on the ground, something
which is often recommended in related
literature, does not actually work very well in
practice as the reel gives off increasingly less
cable for the same distance rolled, making it
necessary to pull the cable behind you.
The cable must, however, under no
circumstances be pulled sideways 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.

Cable that is pulled sideways from the bundle

or reel resists the torsion which acts on it and
forms loops.
When such a cable is placed under load, the
loops are drawn together and form a kink,
an irreparable deformation. Cables with kinks
are no longer safe to be used and must be
replaced.

(Z 29 086)
Date: 09.CW/05

Z 29 086

e50-1-3240_a 5/32
24

Assembly procedure

The bestway tomount cable differs fromsystem

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 contactwith 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.
Date: 09.CW/05

6/32 e50-1-3240_a
 Equipment 24

Re-reeling

Every cable takes on a certain bending

tendency from the point of manufacture, where
it is drawn from the stranding basket by means
of delivering disks.
It is then supplied to the customer bent in this
direction.
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, themounting reel should be set up so that
Z 29 087 the rope strand being reeled off also runs off
beneath the reel and vice versa.

(Z 29 087)

If the cable is re-reeled against the directional

tendency, the cable will either tend to turn
between the reel and the rope drum or will turn
later on when in operation in order to bend to
the preferred direction.
In both instances, structural changes in the
cable will result.
Date: 09.CW/05

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24

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 removed or with an auxiliary
reeving rope, it must be ensured that these
ropes are securely fastened.
In addition, itmust also be ensured that the
auxiliary rope cannot become twisted.
For example, non-twisting cable types or tri-
angular strand wire ropes are particularly
suitable for use as auxiliary reeving ropes.
When using conventional cables, they must at
least have the same direction of lay as the
cable which is being drawn.
Whenever a new cable is drawn through using
the old cable, the two 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 other reasons:
the weld connection does attain satisfactory
values by use of special electrodes in the case
of a tensile test on the straight strand, but due
to the length of the fixed contact area, the cable
can break due to the bending load caused
when passing over the sheaves.
If the ropes are to be connected in this manner,
the cables should be additionally secured using
a rope stocking.
Date: 09.CW/05

8/32 e50-1-3240_a
 Equipment 24

A less problematic method of connecting the

cables is by means of two rings or chain links
welded onto the cable ends.
These are then connected by means of strands
or thin ropes.Such a connection possesses a
satisfactory load bearing capacity, can be
bent and prevents the transfer of torsion from
the old rope to the new.
By using two strands, the number of turns in the
strands following assembly will show to what
degree the old cable on the equipment was
twisted.
(Z 29 088)
Z 29 088
Connecting the cables by means of rope
stockings offers a further possibility.
Rope stockings are plaited rope strands which
are pushed over the cable ends and secured
with adhesive tape.
When under load, the rope stockings are drawn
tighter and hold the cable ends by means of
friction.
When an equal-lay rope is to be drawn, it must
be ensured that the rope stockings can turn on
the rope like a nut on a screw, in spite of the
cord tensions. This can be achieved by first
winding strong adhesive tape round the cable
surfaces which are to be held by the rope
stockings.
Z 29 089
(Z 29 089)
Date: 09.CW/05

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24

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 tension.
If the lower layers are too slack, the upper
layersmay be pressed in between the lower
strands when the cable is placed under load.
This can lead to extensive damage to the cable.
As the cable which is being reeled off may even
become stuck at this point, the winding direction
of the drummay be reversed suddenly when the
Z 29 090
cable is being unreeled, causing the downward
moving load to be raised jerkily.
The cables should be pretensioned to
approximately 1 to 2% of their minimal breaking
force.
While, inmany 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 cablemust be
pretensioned at the assembly stage.

This can be achieved, for example, by braking

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

(Z 29 090, 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.
(Z 29 092)
Date: 09.CW/05

Z 29 092

10/32 e50-1-3240_a
 Equipment 24

Running in

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 settle and adapt to their new
environment.
Unfortunately, the opposite normally proves to
be the case in practice: following assembly of
the cable, overload checks are normally carried
out with loads which are above the permissible
load-bearing capacity of the system.

Cutting into sections

Often cables have to be cut into sections or

shortened by the user.
The cables can be cut in various ways.
Up to a diameter of 8mm, cable cutters can be
used;mechanical or hydraulic cutters 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 any case, the cables must be carefully bound
at the point of separation to prevent fraying of
the rope ends or changes in the cable and
strand laying lengths.
This especially applies when sectioning off non-
rotating or non-twisting cables, the strands of
which are often purposefully left unformed by
the cablemanufacturer.
The rope ends must be bound using iron wire;
insulating tape cannot prevent structural
changes in the cables occurring.
Date: 09.CW/05

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24

(Z 29 093)

First the separating point ismarked using chalk

or insulating tape.
One end of the seizingwire, 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 (a).
The cable is now bound tightly along a length of
approx. three times the rope diameter (b).
The length ofwirewhich has been bound is then
pulled tight using pincers and is twisted together
with the second wire end (c).

The length of the entwined wire ends is

shortened to approx. the diameter of the rope
using the pincers.
The wire ends are then forced into a valley
between two outer strands of the cable by
banging them lightly, 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 (d).

Instead of one long winding, three windings

approximately one cable diameter wide can be
Z 29 093 placed on either side of the cutting point.
Date: 09.CW/05

12/32 e50-1-3240_a
 Equipment 24

24.4.2 Lubricating the Ropes

When manufactured, a cable receives intensive

lubrication which provides protection against
corrosion as well as improving the friction
coefficient of the rope elements internally and
between the cable and sheave or cable and
drum.
This initial lubrication lasts only for a limited
period of time and must be supplemented
regularly.
Cables must be relubricated at regular intervals
depending on the operating environment,
especially in the areas where the cable bends.
If the cable cannot be lubricated on operational
grounds, a shorter lifespan is to be expected
x and the cablesmust be carefully monitored.
The effects of lubrication and relubrication
a
on the life expectancy of the rope can be seen
in figure (Z 29 094):

b
x Number of reversed bending stresses (%)

y Tensile stress (N/mm2)

c
a greased and regreased

b greased
y

Z 29 094 c without grease

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.
Date: 09.CW/05

e50-1-3240_a 13/32
24

The lubricant can be applied using various

methods:
- with a brush or glove
- applying near a sheave
- running the cable through a lubricant bath
- using a pressure collar

It is important that cables are lubricated

regularly from the very start and not only when
the first signs of damage are discovered.

In addition, observe all existing standards (e.g.

DIN 15 020) or national regulations.

24.4.3 Cleaning the Ropes

Cables which are very dirty should be cleaned

externally from time to time.
This applies especially to cables which are
used in a particularly abrasive environment and/
or in the vicinity of chemically active materials.

24.4.4 Checking the Cables and

Replacing as Necessary

When fitting a new hoist rope, which has

never been placed under load, twisting
problems can occur.
For this reason, we recommend that a spin
stabilizer be used
(example: See Z 075 361).
Date: 09.CW/05

Z 075 361

14/32 e50-1-3240_a
 Equipment 24

General If it has become apparent during the ropes

inspection that a rope needs changing, you
A cable is a commodity with a limited life must use an original rope from the crane
expectancy. manufacturer.
Many characteristics of a cable are altered The type of rope that is fitted depends among
during its operational period. other things on the inspection certificate which
For example, its breaking force initially increases is attached to the crane passport / crane
slightly with accrued operating time before falling inspection book.
rapidly once a maximum value has been reached. If it is not clear which type of rope should be
used, you must consult the crane manufacturer
This fall in breaking force is explained by the before ordering a new one.
increasing loss in the metal cross-section due
to abrasion and corrosion, wire breakages and Intervals
structural changes in the cable.
DIN 15 020 recommends daily inspection of the
In the cable, the load bearing elements are cables and end connections for any signs of
connected in parallel. damage.
A cable can therefore remain operationally safe
even after the breakage of a large number of Furthermore, the cables should be inspected at
strands. regular intervals by specialist personnel to
One of the purposes of a cable inspection is ensure that they are in safe operating condition.
tomonitor the continuous increase in the The length of the intervals is to be determined
number of wire breakages, so that the cable in accordance with DIN "in such a way that
can be removed before a state is reached damage is ascertainable in advance in good
where operational safety is impaired. time.
For this reason the time intervals during the first
A further purpose of the rope inspection is to few weeks after the laying of a new wire rope,
spot abnormal cable damage, which as a rule is and after the occurrence of the first wire breaks,
normally caused by external influences. must be selected shorter than the intervals
This facilitates, on the one hand, replacement during the remaining service life of the wire rope.
of the cable in good time and, on the other After the occurrence of unusually high loadings
hand, helps to spot weak points in the operation or of suspected but not visible damage,
of the rope, enabling measures to be taken the time interval must be shortened accordingly
which will prevent similar damage recurring. (if necessary to hours).
In addition, such an inspection must take place
when the rope drive is recommissioned after a
prolonged shutdown, or when the lifting
appliances have been dismantled and re-
assembled at a new location, before
recommissioning, or after an accident or
damage which has involved the rope drive".
Date: 09.CW/05

e50-1-3240_a 15/32
24

Criteria for replacing ropes d) Abrasion

A rope should be removed if one or more of the Abrasion of the rope wires occurs as "internal
following conditions are fulfilled. abrasion" by the cords and wires moving
See also the relevant DIN standards. against each other when the cable is bent.
Abrasion occurs as "external abrasion" by the
a) Wire breakages cable and sheave moving against each other,
or by the cable slipping on the ground or on the
A cable must be removed when the permissible material to be conveyed.
number of wire breakages according to Abrasion is aided by the lack of, or unsatisfactory,
DIN 15 020 is reached or exceeded. lubrication and by the effects of dust.
The cable must be removed if wire breakages If the rope diameter is reduced by 10 % of
are clustered or if a cord breaks. the specified size or more, the cable must be
removed even if no wire breakages are
b) Rope wear determined.

The cable must be removed if, due to structural

changes, the diameter of a longer section of the e) Rope deformation
rope has decreased by more than 15% of the
specified size. Cable deformations are visible in the rope
structure.
c) Corrosion Deformation also generally implies that the rope
structure has been loosened, particularly in the
Corrosion of the outer rope wires can be region near the deformation.
determined by visual inspection. Corrosion on By examining the ropes, the most important
the wires not visible from the outside can, deformations can be determined as follows:
however, be difficult to determine.
Corrosion can lead to a reduction of the static - corkscrew type deformation
breaking strength of the cable, as the metal - "basketwork" formation
rope cross-section is reduced, and can lead to - loop formation of wires
a reduction in operational stability due to - slackening of individual wires or cords
corrosion pits. - knots
- constrictions
- flattened areas
- curled type deformation
- kinks and buckles
Date: 09.CW/05

16/32 e50-1-3240_a
 Equipment 24

Corkscrew type deformation (Z 1367)

Corkscrew type deformation occurs when the

axis of the unloaded cable becomes a helical
line.

X The cable must be removed if deformation X

is 1/3 d or greater (d = nominal diameter of
rope)where the deformation is at its worst.

"Basketwork" formation (Z 1368)

Z 1367 “Basketwork” formation (deformation) can occur
in cables with steel inlays if the outer layer of
the wires is loose or if the outer cords are
longer than the inner cords.
The excess length is moved into one place by
movement of the outer wire sections or cord
sections towards the inner ones.

The cable must be removed if

"basketwork" formation occurs.

Loop formation of wires (Z 1369)

Loop formation of wires occurs when single

Z 1368 wires or wire groups protrude on the side of the
rope which is turned towards the groove of the
sheave in the shape of hair pins.

The cable must be removed if the rope

structure has been changed considerably
by loop formation.
Date: 09.CW/05

Z 1369

e50-1-3240_a 17/32
24

Slackening of individual wires or cords

(Z 1370)

Slackening of individual wires or cords occurs

when the outer wires of the loaded cable or of
individual cords can be moved.
They do not then take on the load as intended
and the remaining wires or cords are
overstrained.

When running the ropes over the sheaves,

increased bending stresses can occur which
lead to premature wire breakages.
Z 1370

The cable must be removed if cable

slackening, caused by rust and abrasion,
occurs.
The removal schedule for the ropes is
determined by wire breakages if the cause
of rope slackening is different from that
given above.

Knots (Z 1371)

Knots are recurring points over long sections of

rope which become thicker. The inlay often
protrudes from the cable in the areas where the
rope is thickened.
Z 1371
At the thinner sections of the rope, the cords
support each other in arch-like formations and
wires may therefore break.

Cables displaying considerable knot

deformation must be removed.
Date: 09.CW/05

18/32 e50-1-3240_a
 Equipment 24

Constrictions (Z 1372)

Constrictions are reductions in the diameter of

the cable over short stretches of rope.
The rope sections immediately before the end
fastenings should be checked with extreme
care, as constrictions here are often difficult to
recognise.

Cables which are greatly constricted must

be removed.
Z 1372 Flattened areas (Z 1373)

Flattened areas are permanent deformations of

the cable which are caused by crushing.

Flattened areas in a rope will lead to an

increased occurrence of wire breakages.

Curled type deformation

Curled type deformation occurs if a loaded

cable is drawn over an edge.

Z 1373 Cables displaying curled type deformation

must be removed.

Kinks (Z 1374)

Kinks occur when an eye-shaped rope loop is

pulled straight in such a way that the cable
cannot compensate the deformation by turning
on its axis.

Cables with one or more kinks must be

Date: 09.CW/05

removed.

Z 1374

e50-1-3240_a 19/32
24

Buckles (Z 1375)

Buckles are deformations which occur when the

cable is under violent external influences.

Cables with buckles must be removed.

Effects of heat

Cables which have been subject to abnor-

Z 1375 mal heat must be removed (this can be
recognised on the exterior of the cable
from the colour).

Service life

The correct time for replacing the cables can be

estimated in advance when carrying out the
precautionary maintenance work if enough
information regarding the previous use of the
rope is known and if the same operating
conditions apply and the same cable is being
used.

The criteria stated previously do, however,

determine the replacement schedule.
In borderline cases, or if in doubt, always
replace the ropes.

The criteria for replacing the ropes which

have been listed are meant to act merely as a
reference point for the daily visual inspection.
The description of the regular inspections goes
beyond the bounds of the lubrication and
maintenance instructions.
It is contained in corresponding national
regulations.
Date: 09.CW/05

20/32 e50-1-3240_a
 Equipment 24

24.5 Checking the Main Boom for

Weld Cracks

In order to prevent breakage, the weld

joints on the main boom are to be inspected for
cracks once a year.
(Z 160 331)

Z 160 331

If any crack formations are detected, the

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

Z 160 332

Weld repairs may only be carried out by a

qualified welder.

(Z 160 333)
Date: 09.CW/05

Z 160 333

e50-1-3240_a 21/32
24

24.6 Main Boom - Adjusting Retracting

Ropes ES 1 and ES 2

If the last two boom section retract a few

centimetres when placed under load, retracking
ropes 1 and 2 must be re-tensioned.

Proceed as follows:

- Extend telescopic cylinder 1 or 2, until the

adjusting spindle is visible through the
inspection opening.
(Z 160 334)
Z 160 334

- Release lock nuts (1).

- Re-tension the ropes by tightening

adjusting nuts (2) to a torgue of approx.
150 Nm.
Telescope the main boom in and out
1 or 2 times and repeat the tensioning
procedure.
- Guard adjusting nuts with lock nuts (1).
(Z 160 385)

Z 160 385

When telescoping in, the last boom section

which is retracted and extended by a telescopic
cylinder must reach the stop before the two
smallest boom sections, which are retracted
and extended by the rope drives.
For this, the air gaps between the stops in front
of the two last boom sections must be filled in
by screwing on lining plates.
If the stops of the rope-driven boom sections
touch before the stops of the cylinder-driven
boom sections, the boom must not be retracted
further.
Date: 09.CW/05

Retracking ropes 1 and 2 will otherwise be

stetched.

22/32 e50-1-3240_a
 Equipment 24

In order to avoid this, lining plates must be

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

When the ropes have been tensioned, the

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

24.7 Main Boom - Visual Inspection of

the Extending and Retracking
Ropes

Check the ropes regularly for damage.

- Extend the inner boom sections so that the

inspection openings are aligned.
- Using a powerful torch, perform a visual
inspection of the rope end connections, the
retracking ropes ES 1 and ES 2, and the
extending rope AS 1 as possible.
Z 160 339 (Z 160 339, Z 160 338)
Date: 09.CW/05

Z 160 338

e50-1-3240_a 23/32
24

For visual inspection of extending rope AS 2,

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

Z 160 340

All main boom ropes must be inspected every

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

Ropes must be replaced as soon as they are

discovered to be damaged.

Follow the relevant DIN specifications or

other national regulations.

Z 160 341
Date: 09.CW/05

24/32 e50-1-3240_a
 Equipment 24

24.8 Inspect Rope Track Rollers

Check all main boom and main boom extension

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

Rope track rollers which are split by hoist

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

24.9 Checking the Sheaves

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

Sheaves with this type of damage must be

replaced immediately.

Also check all sheaves regularly for wear.

If the rope groove has worn in more than 3 mm
compared with a new sheave (x)
Z 160 543
or
the lateral surface (y) up to the rope (d) has
worn in more than 5 mm, the sheave must be
replaced.
(Z 160 543)
Date: 09.CW/05

e50-1-3240_a 25/32
24

24.10 Sheaves - Checking the Roller

Bearing

Inspect all sheaves on the main boom head

and on all additional equipment once a year for
the following:

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

Z 160 343 (Z 160 343)

If any faults are discovered on the roller

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

In this instance, please inform the

Customer Service Department.

Z 160 344

If inspection reveals a damaged circlip, the

circlip must be replaced.
(Z 160 345)

Original Demag circlips with chamfered

edges must be used.
Date: 09.CW/05

Z 160 345

26/32 e50-1-3240_a
 Equipment 24

24.11 Sheaves - Lubricating the Roller

Bearings

Lubricate the roller bearings via the lubricating

nipples (x 4).
(Z 160 342)

Z 160 342

24.12 Checking the Pins for Cracks

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

assembly and dismantling.
(Z 160 353)

Z 160 342
Date: 09.CW/05

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24

24.13 Checking the Draw Bars (Schackle

on the Main Boom Extension)

The draw bars must be inspected by an

expert at least once a year (in accordance
with accident prevention regulations for
the operation of load lifiting equipment /
VBG 9).
The bars should also be inspected by an
expert between these intervals if
necessitated by the operating conditions.
Z 160 347 (Z 160 347)

As the inspection intervals are generally

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

It may be necessary to dismantle the draw

bars to be able to inspect them correctly.

The draw bars must be inspected in their

entirety, i.e. all hidden surfaces and bores
must also be inspected.
Z 160 348
(Z 160 348)
Date: 09.CW/05

28/32 e50-1-3240_a
 Equipment 24

The following inspections should be

carried out:

- Checking for cracks:

The draw bars should be checked regularly for

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

Z 160 350 Repairs are prohibited.

(Z 160 350)

- Checking the length:

The draw bars are designed so that no perma-

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

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

the tension bracket must be replaced.

Bugles on the main boom extension

The original length of the bugles on the main

boom extension is L = 921.5 mm.
(Z 160 352)
Date: 09.CW/05

Z 160 352

e50-1-3240_a 29/32
24

- Checking for wear:

Check the pin locks, pins and bores for signs of

wear.
It must be ensured that the pin locking
mechanism is functioning correctly.
(Z 160 347)

Z 160 347

- Checking for plastic deformation:

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

the draw bars may no longer be used.
(Z 160 355)

- Checking the paintwork:

The paintwork must be checked regularly for

signs of corrosion.
Damaged areas should be restored.
The draw bar bearing must not come into
contact with aggressive agents (e.g. sea
water).
Z 160 355
Date: 09.CW/05

30/32 e50-1-3240_a
 Equipment 24

24.14 Telescopic Main Boom

Extension (Optional) -
Greasing Sliding Surfaces

Extend the main boom extension while the

main boom is lying horizontally.
Then grease the extended cylinder barrel
using a brush.
(Z 160 370)

Z 160 370

24.15 Telescopic Main Boom

Extension (Optional) -
Greasing the Foot Bearing

Grease both lubricating nipples on the pins of

the main boom extensions foot bearing.
(Z 160 371)

Z 160 371

24.16 Telescopic Main Boom

Extension (Optional) -
Greasing the Luffing Cylinder

1 - Grease the lubricating nipple on the foot

bearing of the luffing cylinder (x 2).
(Z 160 372)
Date: 09.CW/05

Z 160 372

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24

2- Grease the lubricating nipple on the

piston rod bearing of the luffing cylinder.
(Z 160 373)

Z 160 373

24.17 Checking the welding on the

Telescopic Main Boom
Extension for cracks (Optinal)

Follow the same principle as described in the

Lubrication and Maintenance Manual, Sect. 24.5,
"Checking the Welding on the Main Boom for
Cracks".

Date: 09.CW/05

32/32 e50-1-3240_a
 Heating 25

25 Heating

The manufacturer's operating instructions

for the D1L Eberspächer auxiliary heater
must be followed.
(Z 160 211)

Z 160 211

25.1 Checking and Filling Up the

Fuel Tank

Check the fuel tank regularly during the heating

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

Z 160 357

25.2 Checking and Replacing the

Glow Plug

Clean the glow plug before the beginning of the

heating period as follows:

Remove the cap, loosen hexagonal screw M4

and remove the spark cable.
(Z 160 358)
Date: 25.CW/94

Z 160 358

bs_e908-3250d /a 1/2
25

Unscrew the glow plug using wrench SW 19.

(Z 160 359)

Z 160 359

Inspect the glow plug and replace if necessary.

Before replacing the glow plug, clean the

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

(Z 160 360)

Z 160 360

Screw the glow plug back in.

(Z 160 361)
Date: 25.CW/94

Z 160 361

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