AC200 1 33291c Part3 - en

Index
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Personnel selection and qualifications . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Particular Types of Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Risks of Crushing / Shearing / Collisions . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Risks of Snagging and Dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Risks of Slipping, Tripping, Falling . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.4 Risks of Thermal Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.5 Risk of Residual Energy in the Hydraulic System . . . . . . . . . . . . . . 7
1.4 Before Commencing Lubrication and Maintenance Work . . . . . . . 9
1.4.1 Cleaning the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Carrying out Lubrication and Maintenance Work . . . . . . . . . . . . . . . 17
1.6 Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Oils, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 Lubrication and Maintenance Schedule . . . . . . . . . . . . . . . . . . . 3

4.1 Initial Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Regular Routine Lubrication and Maintenance . . . . . . . . . . . . . . . . 3
4.3 Tips for Maintaining the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Measures to Maintain the Crane: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1 Engine Quick Stop: Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Slew Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1 Lubricating the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2 Lubricate the ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.3 Checking the screwed connection for firm fitting . . . . . . . . . . . . . . . 5
6.4 Lubricate the mechanical superstructure locking device . . . . . . . . 5
7 Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1 Lubricating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2 Checking and Re−tightening the Screw Connections if
Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.3 Visual and Noise Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.4 Maintenance of the Slew Gear Brake . . . . . . . . . . . . . . . . . . . . . . . . 5
200−1−3000−291b_en 1
Index
8 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1 Hoist 1 and 2 − check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.2 Hoist Gear − Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.3 Checking and Re−tightening the Screw Connections if
Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.4 Lubricating the Rope Drum Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.5 Calculating the Percentage Used of the Theoretical
Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.6 General Overhaul of the Hoist Gear Winches . . . . . . . . . . . . . . . . . 11
8.7 Lower Limit Switch − Checking the Proper Function . . . . . . . . . . . 13
8.8 Hoist limit switch − check that it functions properly . . . . . . . . . . . . . 13
8.9 Lubricating Erection Cylinder Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Luffing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1 Lubricating the Luffing Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 Lubricating the Sliding Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1.1 Creating the Extension Condition by
Automatic Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.2 Lubricating the locking and pinning unit (LPU) . . . . . . . . . . . . . . . . . 11
10.3 Locking and Pinning Unit − Carrying Out a Visual Check . . . . . . . 15
10.4 Locking and Pinning Unit − Checking the Proximity Switches
and Sliding Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.5 Locking and Pinning Unit −
Checking the Preliminary Gas Tension of the Accumulators . . . . . 17
10.6 Checking the Rope of the Length Transducer Drum . . . . . . . . . . . . 21
10.7 Lubricating the Foot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.8 Lubricate the main boom head axles . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.9 Checking the Main Boom for Weld Cracks . . . . . . . . . . . . . . . . . . . . 23
10.10 Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.10.1 Perform visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.10.2 Perform wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.10.3 Checking the roller bearings on the sheaves . . . . . . . . . . . . . . . . . . 27
10.11 Replacing the Rope Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
200−1−3000−291b_en 2
Index
11 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.1 Lubricating the pinning mechanism on the centre of motion . . . . . 3
11.1.2 Checking the Bracing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.3 Lubricating the Spindle (Depending on the Design) . . . . . . . . . . . . 11
11.2 Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.2.1 General Notes on Handling and Assembly . . . . . . . . . . . . . . . . . . . . 13
11.2.2 Cleaning the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.2.3 Lubricating the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.2.4 Visual inspection of the ropes, rope end connections, etc. . . . . . . 31
11.2.5 Check entire ropes, replace if required . . . . . . . . . . . . . . . . . . . . . . . 31
11.3 Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.3.1 Lubricating Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4.1 Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4.2 Replacing the Rope Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 Replacing the Filter Elementsin the Return Flow Filter . . . . . . . . . 3
12.2 Replace the ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.3 Clean/replace the filter element of the high−pressure filter /
oil leakage filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12.3.1 Cleaning the HP Filter (1)
(Type ”LF BN/HC 60”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.3.2 Clean the Overflow Oil Filter (3)
(Type ”HD 062−171”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(Type ”HD 069−171”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.4 Hydraulic Pump − Changing the Add−On Filter . . . . . . . . . . . . . . . . 21
12.5 Hydraulic Tank − Checking the Oil Level / Topping up . . . . . . . . . . 23
12.6 Check hydraulic oil tank return filter for contamination . . . . . . . . . . 25
12.7 Changing Oil in the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.8 Bleed the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.9 Check the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.10 Check the hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.11 Replacing the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.12 Checking the Accumulator Initial Gas Pressure . . . . . . . . . . . . . . . 33
12.13 Biodegradable Hydraulic Oil (Optional) −
Having Serviceability Checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
200−1−3000−291b_en 3
Index
13 Heating and Air Conditioning Equipment . . . . . . . . . . . . . . . . . . 3

13.1 Checking the System is Functioning Correctly . . . . . . . . . . . . . . . . 3
13.1.1 Checking the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13.1.2 Fault Diagnosis with the Heating Timer . . . . . . . . . . . . . . . . . . . . . . 5
13.2 Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.3 Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.4 Bleeding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.5 Air Conditioning Equipment (optional) . . . . . . . . . . . . . . . . . . . . . . . . 19
13.5.1 Switching on the Air Conditioning Equipment . . . . . . . . . . . . . . . . . 19
13.5.2 Servicing the Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . . 19
13.5.3 Having the Air Conditioning Equipment Checked . . . . . . . . . . . . . . 19
14 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Checking the Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Charging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.4 Checking the Contacts at the Slip Ring of the Rope Winches
and the Rotary Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.5 Checking the Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Checking the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16 Cooling, Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . 3

16.1 Cleaning and Replacing the Air Filter Element . . . . . . . . . . . . . . . . 3
16.1.1 Dry Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.2 Wet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.3 Testing the Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2 Replacing the Safety Cartridge (Optional Equipment) . . . . . . . . . . 9
16.3 Air Filter Prefractionator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.5 Checking the Coolant Level and Topping Up as Necessary . . . . . 13
16.6 Replacing the Coolant with Anti−Freeze . . . . . . . . . . . . . . . . . . . . . . 15
16.7 Maintaining the Diesel Exhaust Particulate Filter (Optional) . . . . . 21
16.7.1 Troubleshooting/check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
200−1−3000−291b_en 4
Index
17 Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17.1 Exposed Chrome Surfaces − Applying Protective Grease . . . . . . 1
18 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

18.1 Lubricate the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.2 Check the windscreen washing assembly . . . . . . . . . . . . . . . . . . . . 5
18.3 Fill up the supply tank of the windscreen washing assembly . . . . 5
18.4 Lubricating the Guide Rail of the Sliding Door . . . . . . . . . . . . . . . . . 5
19 Visual Inspections Superstructure . . . . . . . . . . . . . . . . . . . . . . . . 3
20 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1 Central Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.1 Filling up the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.2 Checking the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.3 Cleaning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
22 Examinations of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22.1 Recurrent Inspections of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22.1.1 Inspection of Load−bearing Steel Constructions . . . . . . . . . . . . . . . 15
22.1.2 Inspection of the Disc Wheels (Rims) . . . . . . . . . . . . . . . . . . . . . . . . 49
22.1.3 Inspection of the Winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22.1.4 Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
22.1.5 Inspection of the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
22.1.6 Inspection of the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
22.1.7 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
200−1−3000−291b_en 5
Foreword
Foreword
Part 3: Lubrication and Maintenance Instructions for the

Superstructure
For you,
This instruction manual is provided for the benefit of personnel

carrying out maintenance work, and includes information requi-
red for maintenance and lubrication of the machine and all spe-
cial 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 develop-
ment.
No liability can be accepted for damage resulting from incorrect
maintenance.
In these lubrication and maintenance instructions you will find the

titles or the respective symbols ”Danger”, ”Caution” and ”Note”
used as follows:
DANGER!
”Danger” is used if a maintenance procedure, NOT per-

formed according to the prescriptions given, may cause
death or injury to persons.
CAUTION !
”Caution” is used if a maintenance procedure, NOT perfor-

med according to the instructions given, may cause damage
to the crane or the crane equipment.
NOTE:
”Note” is used for identifying an important maintenance proce-

dure as well as for additional information.
200−1−3002_en 1/3
2/3 200−1−3002_en
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.).
200−1−3002_en 3/3
Safety instructions 1
200−1−3010g_en 1/23
1
2/23 200−1−3010g_en
1 Safety Instructions
1.1 General
This section entitled ”Safety Instructions” gives a concise and

general overview of dangers which may occur when performing
lubrication and maintenance tasks on the crane superstructure
and the crane chassis.
In the corresponding sections of the maintenance and lubrication
instructions, these safety instructions are cross−referenced and
outlined in more detail as required.
For cranes with split lubrication and maintenance instructions,

there is only a cross−reference to this section in the section
“Safety instructions” of the chassis.
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

ladders remain free from dirt, snow and ice at all times.
Ensure that safety clothing, goggles, face masks and other safety
equipment is used when the operating conditions demand it.
When undertaking lubrication and maintenance tasks, do not

permit unauthorised persons to have access to the crane.
Spare parts must satisfy the technical specifications prescribed

by the manufacturer. Therefore only use our original spare parts.
A new examination and authorisation may be required.
The safety instructions listed for lubrication, maintenance

and setting work must also be observed for all maintenance
and repairs.
200−1−3010g_en 3/23
1
Z 30 300
Z 29 801
4/23 200−1−3010g_en
1.2 Personnel selection and qualifications
The crane equipment may only be serviced and calibrated by

specialist personnel!
This especially applied to work on the electrics, hydraulics, travel

gear and brake and steering systems.
1.3 Particular Types of Hazard
Lubrication and maintenance tasks must be undertaken with

particular care in those areas where the dangers listed are
prevented during operation by safety clearance or covers
provided.
Follow the specific instructions that are given in the
corresponding sections of the lubrication and maintenance
instructions.
1.3.1 Risks of Crushing / Shearing / Collisions

(Safety Signs: Z 30 300)
The affected areas are:

− Main Boom
− Slew Ring Connection
− Slew gear pinion
1.3.2 Risks of Snagging and Dragging


− Ropes to winches / all sheaves / hook blocks / fixed and flying
bridle
200−1−3010g_en 5/23
1
Z 29 803
6/23 200−1−3010g_en
1.3.3 Risks of Slipping, Tripping, Falling

Only the walkways and ladders described may be used. These

have sufficient grips for holding on and the catwalks are designed
to be slip−free (for example, sand, corrugated metal, or similar).
1.3.4 Risks of Thermal Effects

− Engine with exhaust system
− Parts of the hydraulic system under covers
1.3.5 Risk of Residual Energy in the Hydraulic System

In certain situations, e.g. damage to the hydraulic components
such as tubes, hoses, valves etc. the machine can come to a
standstill. This is due to the fact that a section of the system
remains pressurised.
It is not always possible to release this pressure (e.g. opening the
lowering brake valves on the telescoping cylinders).
In such cases an auxiliary crane must be used to dismantle the
crane.
Such work may only be carried out by our customer service
department.
200−1−3010g_en 7/23
1
8/23 200−1−3010g_en
1.4 Before Commencing Lubrication and Maintenance

Work
Inform the operating personnel and appoint a supervisor!
Switch off the diesel engine!

The component group, on which maintenance work is to be
carried out, must be switched off and free of load.
The only exception to this requirement is for parts that need to be
powered up for lubrication and maintenance work to be carried
out.
Work may never be carried out with an attached load!
Secure the working equipment by placing it on the ground, setting

on outriggers (ensure that the ground has sufficient load−bearing
capacity) or similar measures to ensure that there is no
subsequent movement!
Make sure that the crane cannot be started up by unauthorised

persons (e.g. lock the cab doors, remove the battery switch
and/or ignition key) and fix corresponding warning signs in place!
Remove the battery switch or ignition key before undertaking any

lubrication and maintenance tasks on the electrical system!
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10/23 200−1−3010g_en
1.4.1 Cleaning the Vehicle

When commencing maintenance, clean the crane, and in
particular all connections and bolts and screws, to remove oil,
fuel or preserving agents! Do not use aggressive cleaners. Use
non−fibrous cloths!
Before cleaning the crane using water, steam jet (pressure

washer) or other cleaning agents, seal or glue up all openings
into which water, steam or cleaning agent must not penetrate for
reasons of safety and / or operation (e.g. switch cabinets)!
Rubber components, such as tyres etc. must be cleaned

particularly carefully. In this case, see the instructions in the
sections ’Wheels and tyres’ in the chassis lubrication and
maintenance manual.
Minimum clearance between high−pressure nozzle and object to

be cleaned for all cleaning work:
− Circular spray nozzles: approx. 700 mm (27.6 inches)
− 25°−Flat spray nozzles and dirt milling cutters: approx. 300 mm
(11.8 inches)
− Steam sprays: 800 mm (31.5 inches)
− Temperature maximum 60 °C (140 °F)
To avoid damage, do not point the water jet directly at door

gaps, hoses, electric components (control devices, starters,
alternators, spotlights) and electric leads (socket con-
nections, cable lead−ins or fuses).
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During cleaning, always keep the water jet moving.

The steam or water jet should be applied across a large surface
area.
The vehicle should be rinsed off with a good quantity of water.
Scouring agents must not be used.
If air−cooled components are fitted on your crane (e.g. retarder),

these must be regularly cleaned in winter or in dusty operating
conditions.
The equipment must be cleaned when it is cold and without
adding solvents.
Dirt and salt residues must be removed. Electric connections
must be cleaned particularly carefully.
In addition, the operating instructions for the steam jet (or

high−pressure cleaner) must be followed.
Sound absorption mats must not be cleaned using

high−pressure cleaners.
Sound absorption mats that are contaminated with fuel or oil are
combustible and flammable and must be replaced immediately.
After cleaning, particularly when using steam jets, the crane must
be lubricated, in particular the slewing rim and joint shafts.
The inside of the cabs may only be cleaned with warm water, with
a little washing−up liquid added.
All surfaces, in particular the fittings and switches, should only be
wiped down with a damp cloth.
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1
Z 18 094
14/23 200−1−3010g_en
After cleaning, remove the covers/any tape completely and carry

out a visual inspection to ensure that water has not entered any
prohibited areas!
After cleaning, check all fuel, engine oil and hydraulic oil lines for
leaks, loose screw connections, shearing points and damage.
Rectify any damage immediately!
As oil can be emitted during maintenance and assembly work,

suitable containers and binding agents must be kept available
and ready.
1.4.2 Fire Protection

(Z 18 094)
Preventative measures against the risk of fire
Keep the crane clean, in particular making sure that there is

no combustible material around. Following maintenance
work on the hydraulic system, engine and fuel system, clean
the crane thoroughly.
Remove any residues of oil, fuel or cleaning agents.
After cleaning the engine room, check all

− Fuel lines
− Engine oil lines
− Hydraulic oil lines
for leaks, loose connections, shear points and damage.

Rectify any damage found immediately.
Check all electric lines, plug connections and terminals for

loose connections and damage.
Rectify any damage found immediately.
Check the turbocharger fixing

Check the exhaust and air inlet lines and lube oil feed and
return lines for any leaks. Rectify any damage found
immediately.
Fire extinguishers must be filled and ready for use.
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1
16/23 200−1−3010g_en
1.5 Carrying out Lubrication and Maintenance Work
Suitable workshop equipment is required in order to undertake

lubrication and maintenance tasks!
Please observe the regulations and instructions specified in the

operating instructions!
The expression ”operating instructions” includes the operating

instructions and the lubrication and maintenance instructions.
Cordon off the required area, leaving sufficient safety clearance!
Individual components and larger component groups must be

attached to suitable lifting equipment and secured when
replacing them, to ensure that all risks are avoided. Only suitable
and fully functional lifting devices and load−handling devices with
sufficient load capacity may be used! Do not stand or work
underneath suspended loads!
Only assign experienced personnel to attach loads and act as

banksmen for crane operators! The banksman must be within
view of the operator or must be in audio contact with him (you
must refer to the section ”Safety instructions” in the operating
instructions)!
When carrying out assembly work above head height, use

suitable climbing aids and operating platforms! Do not use
machine components as climbing aids. Wear safety harnesses
when carrying out maintenance work at height!
When carrying out maintenance work, always tighten up loose

screw connections!
If it is required to dismantle safety equipment during main-

tenance, the safety equipment must be reassembled and
checked immediately after maintenance work.
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18/23 200−1−3010g_en
Make sure that all fuels and lubricants and used parts are
disposed of properly and in an environmentally friendly manner!
Oily rags and highly flammable materials must be stored away to

prevent the risk of fire or disposed of properly!
The electrical equipment of the crane must be inspected /

checked regularly. Any shortcomings such as loose connections
or singed cables must be rectified immediately.
Only electric specialists or trained persons under the

supervision and guidance of an electric specialist may
work on electric systems or operating equipment and only
in accordance with the electronic technicalregulations.
Use only original fuses with the prescribed amperage! Switch the
crane off immediately if there are faults in the electric energy
supply!
Check all lines, hoses and screw/bolt connections on the

hydraulic and pneumatic systems regularly for leaks and
externally visible damage! Rectify any damage immediately (or
have it rectified)!
For the crane chassis, you must also observe the detailed
instructions in the corresponding sections of the lubrication and
maintenance instructions, in particular for the steering,
suspension and brakes.
Work on the hydraulic equipment must only be undertaken

out by persons with specialist knowledge and experience
in hydraulics (the system must be de−pressurized)!
Squirting oil may lead to injury and fires!
When handling oil, grease and other chemical substances,

observe the relevant safety regulations for the product!
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20/23 200−1−3010g_en
Caution when handling hot fuels and lubricants (risk of

burns / scalding).
Make sure not to forget any tools on the crane after

completing lubrication and maintenance work or after
repair. All parts (trims, etc.) must be reattached properly.
Falling or flung tools or parts can cause risk to life and limb!
Adhere to the prescribed time limits for repeated inspections (see

the “Lubrication and maintenance plan” and the section
“Inspections of the crane”)!
All components that hold or brace the main boom or fly jib
(bracing rods and draw bars) must be checked at least once a
year by a specialist engineer − according to the ”Cranes” accident
prevention regulations (BGV D6). In addition they must be
checked by a specialist between these intervals if required by the
operating and site conditions.
The inspection intervals are generally determined by the
operating and site conditions. This means that the more the
equipment is used, the shorter the inspection intervals should be.
All checks and inspections should be documented (e.g. in the
examination log book for the crane).
The following checks should be made:

∗ Check for cracks
∗ Check of length
∗ Checking for Wear
∗ Checking the paint
∗ Check for plastic deformation
∗ Check of weld seams
You will find which components are subject to these measures

and how to carry out the inspections in the section “Equipment”
of these lubrication and maintenance instructions.
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1.6 Repair Work
General repair work is not included in the scope of these

lubrication and maintenance instructions.
Please contact our customer service department.
With regard to such work, however, we have included some

general safety instructions below.
− Only carry out welding, torch cutting and grinding works on
the crane if this expressly permitted (there could be risks of
fire and explosions, for example)!
− Before welding, torch cutting and grinding, clean the crane
and the surrounding area of dust and flammable materials
and provide sufficient ventilation (risk of explosion)!
− When carrying out work on the hydraulics, system sections
that need to be opened must first be depressurised before
work is commenced!
− Do not carry out any changes, fit additional parts or make
modifications to the crane that could affect its safety without
first obtaining permission from the manufacturer! This also
applies when fitting and adjusting the safety equipment and
valves and when welding load−bearing components!
− Make sure not to forget any tools on the crane after
completing lubrication and maintenance work or after repair!
All parts (trims, etc.) must be reattached properly!
Falling or flung tools or parts can cause risk to life and limb!
200−1−3010g_en 23/23
Oils, Lubricants and Capacities 2
2 Oils, Lubricants and Capacities
Permitted fuels and lubricants

The permitted fuels and lubricants / consumables are in the
following tables.
Risk of damage!
If consumables are used which do not satisfy these
requirements, damage may result for which we shall not be
held liable even within the warranty period.
Additional consumable specifications on request.
Ambient temperature
Risk of damage!
The crane may only be operated within the temperature
range indicated in part 1, section 1 “Safety instructions”
using suitable consumables.
When using consumableswith variants which are dependent on

the ambient temperatures, the corresponding one must be used.
Initial filling up is usually in the normal temperature range.
Changing consumables
The ambient temperatures must be within the indicated limits

when changing consumables. You must ensure that the crane is
within the correct temperature range throughout by resting it for
a sufficiently long period within the indicated ambient
temperature range.
Risk of malfunctions! Risk of damage!
There is a risk of the function of safety−relevant components
becoming affected or of them being damaged if the
consumables are not changed within the indicated ambient
temperature range or if the crane is has not been brought to
the correct temperature throughout.
When changing liquid consumables, system components

which have no through−flow (for example, cylinders) must
be rinsed. This is especially important when changing
consumables from the normal temperature range for the
corresponding consumables from the cold temperature
range (and vice versa).
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2
2/7 200−1−3020−291a_en
Filling capacities
The specified capacities are approximate values.
Risk of damage!
After filling up with liquid consumables, check at the
designated check plugs, dipsticks and inspection windows
whether the filling level indicated in the corresponding
section has been reached.
Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US−gall.)
See regulations on consumables in the operating and maintenance
Sect. 5
instructions of the engine OM 906 LA
Drive motor
as well as the Mercedes−Benz regulations
with filter change min. 24 l
Mercedes−Benz
max. 29 l Engine oil
− ACEA E4 Sheet 225.6 / 228.5
(min. 6.3 gall., 5W − 30
or 228.51
max. 7.7 gall.)
Sect. 6.1 High−pressure
DIN 51825, part 3
Roller bearing − lubricant “Shell Alvania EP 2”
KP2K
slewing rim NLGI class 2
Sect. 6.2 Special adhesive
− − “CEPLATTYN Eco S”
Slew ring teeth grease
Sect. 6.3 Order from Terex−
Grease paste
Superstructure − − Demag
NLGI class 1
locking SP no. 634 758 40
DIN 51825, part 3
Bearings − lubricant “Shell Alvania EP 2”
KP2K
Slewing gear NLGI class 2
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2
4/7 200−1−3020−291a_en

in litres
(in US−gall.)
Sect. 8.2
Transmission, 3.5 l each Hydraulic oil
DIN 51524.3 − HVLP “Shell Tellus T 100”
Hoists (0.9 gall.) ISO VG 100

DIN 51825, part 3
Bearing, − lubricant “Shell Alvania EP 2”
KP2K
Hoists NLGI class 2
DIN 51825, part 3
Luffing cylinder − lubricant “Shell Alvania EP 2”
KP2K
NLGI class 2
Sect. 10.1
Order from Terex−
Main boom Adhesive lubricant DIN 51502
− Demag
Sliding surfaces NLGI class 1 MLE 1 N − 40
SP no. 022 029 12
Section 10.2
Locking and Adhesive lubricant
− gleitmo 805−1
pinning unit NLGI class 2
Section 10.7
Lubricating nipple: High−pressure
DIN 51825, part 3
Main boom − lubricant “Shell Alvania EP 2”
KP2K
Foot bearing NLGI class 2
Section 10.8
Lubricating nipple: High−pressure
DIN 51825, part 3
Main boom head − lubricant “Shell Alvania EP 2”
KP2K
axle NLGI class 2
Sect. 11.2 Special adhesive

− “Elaskon 30”
Ropes grease
DIN 51825, part 3
Lubricating nipple, − lubricant “Shell Alvania EP 2”
KP2K
Hook blocks NLGI class 2
DIN 51825, part 3
Sheave bearing − lubricant “Shell Alvania EP 2”
KP2K
NLGI class 2
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2
6/7 200−1−3020−291a_en

in litres
(in US−gall.)
Sect.12.7 Hydraulic oil
Hydraulic system ISO VG 32
(Tank) (−20°C to +20°C)
(−4 5F to +68 5F);
ISO VG 46 DIN 51524.3 −
Shell Tellus STX 46*
(−18 °C to +30 °C) HVLPD
min. 1055 l (−0,45F to +865F);
max. 1185 l ISO VG 68
(min. (−10°C to +40 °C)
278.7 gall., (+14 5F to 104 5F)
max. 313 gall.)
alternative: (for instructions, see section 12)
46.1 mm2/s (cSt) at
40° C (104 5F); “Panolin HLP Synth
BIO hydraulic oil
Solidifying point −58 °C 46”
(−72.4 5F)
Sect.14.4 Order from Terex−
Slip ring contacts, − Contact spray − Demag
Rope drum SP no. 174 427 40
Sect. 16
Cooling system 24 l
(6.3 gal) See regulations on consumables in the 50% water/
− Engine 16.5 l operating and maintenance instructions of 50 % glysantin
(4.36 gal.) the engine, sheet 310 Sheet 325.2
− Compensation 7.5 l
tank (2 gal.)
Section 17
Fuchs company:
Piston rod of the − Protective grease
CTP D 350
hydraulic cylinders
* = When starting operation with temperatures below 0°C (32°F), the following is valid:
The hydraulics must warm up for at least 10 min at 1500 min −1 (rpm). The hydraulic
pumps may only be stressed when the oil viscosity is below 1000 cSt.
200−1−3020−291a_en 7/7
Lubrication and Maintenance Schedule 4
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4
200−1−3040−001h_en
2/14
4 Lubrication and Maintenance Schedule
4.1 Initial Lubrication and Maintenance
Lubrication and maintenance work which occurs before the regu-

lar routine work is identified by ”1X” on the maintenance sche-
dule.
The work must be undertaken once at the time specified.
4.2 Regular Routine Lubrication and Maintenance
Regular routine lubrication and maintenance work is identified by

”X” on the maintenance schedule.
The work must be undertaken once at the interval specified and-
then regularly repeated at this interval.
A ”X” in the column entitled 250 operating hours thus means that
the corresponding work must be undertaken every 250 opera-
ting hours, i.e. after 250, 500, 750 operating hours, etc.
The following details on maintenance intervals are applicable to-

cranes which are subject to normal operating and environmental
influences. For certain applications, the maintenance intervals-
must be adapted according to the operating conditions.
For more infrequent maintenance work, e.g. ”Every 1000 opera-

ting hours”, all those maintenance tasks which are required at
shorter intervals and which coincide with this time must of course
also be undertaken.
This means that for the above example, the maintenance tasks
occurring ”Every 500 operating hours” and those required at
even shorter intervals must also be undertaken.
200−1−3040−001h_en 3/14
4
200−1−3040−001h_en
4/14
4.3 Tips for Maintaining the Crane
The purpose of maintaining the crane is to:

− safeguard operational reliability
− maintain efficiency
− prevent downtimes
− maintain the crane’s value
− reduce repair costs
4.4 Measures to Maintain the Crane:
1. Inspections of the Condition
Inspections of the condition are visual inspections undertaken by

the crane operator at regular intervals in accordance with the lu-
brication and maintenance schedule.
For example:
− Checking oil levels and oil grade
− Checking displays and monitors
− Checking the functioning and clogging of the tank and fil-
tersystems
− Checking the tubing systems for leaks and damage
− Checking bearings for adequate lubrication and abnormal
bearing clearance
− Checking the drive mounts (transmission, motors, valves)
− Checking the ropes for lubrication, dirt and wear
As a result of these regular visual inspections, damage can often

be recognised and eliminated in good time.
This means downtimes are prevented during crane operation.
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200−1−3040−001h_en
6/14
2. Preventative maintenance
Preventative maintenance includes measures which may be un-

dertaken within the framework of an ”inspection of the condi-
tion of the crane”.
The inspection of the condition thus serves to recognise and eli-
minate any wear, damage or defects in good time.
In this way, operational downtimes and repairs can be prevented
during crane operation.
The tasks involved in the inspection of the condition include vi-

sual and performance inspections of the superstructure and un-
dercarriage assemblies and a comparison of the desired and ac-
tualvalues of all measurable quantities.
These tasks must be undertaken by an appropriately trained
specialist.
Various measures are thus required.

For example:
− Checking the safety devices
− Comparing the desired/actual values in the hydraulic and
electrical system.
− Checking the hydraulic and electrical system is functioning
correctly.
− Checking the nitrogen boost pressure of the accumulator
fitted.
− Analysis of the grade of the hydraulic and transmission oil.
− Checking the individual drives for noises and vibrations.
− Checking the bearings for damage and wear.
− Checking the crane equipment for damage and wear.
− Checking the ropes for damage and wear.
The exact visual and performance inspections and their corres-

ponding results are listed in the ”crane inspection sheet “.
A log is created for this inspection of the condition. This inspec-

tion log then forms the basis for any repair measures which may
be required.
Of importance to the success of any such measures is their

correct implementation, their regular repetition and full docu-
mentation of the inspections.
Our ”Mobile Crane Engineering” customer service department in-

Zweibrücken is there to help with any information regarding this
matter.
200−1−3040−001h_en 7/14
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200−1−3040−001h_en
8/14
200−1−3041−001l
4.5 Maintenance List
Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
5 Engine
Engine: OM 906 LA see the operating instructions of the manufacturer
Engine: Check the oil / top up as necessary x x
Engine: Change oil and oil filter for oil quality: in accordance with Mercedes−Benz x2)
fuel regulations 228.5: 6)
for differing oil quality:

see the operating instructions of the manufacturer
other maintenance works see the operating instructions of the manufacturer
5.1 Engine Quick Stop: Function test 1 x year
6 Slew Ring
6.1 Lubricate the slewing ring x x
6.2 Lubricating the ring gear x

6.3 Checking the screwed connection for firm fitting x2)
6.4 Lubricating the mechanical superstructure locking device x
7 Slew Gear
7.1 Lubricate the bearings 1x x2)
7.2 Check screw connections and tighten as nec. x
7.3 Visual inspection and noise check x
7.4 Maintenance of slew gear brake x2)
1* − daily before commencing work 2* − as required 1) − at least every 6 months
2) − at least 1 x year 3) − at least every 2 years 4) − at least every 5 years
5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x per week
9/14
200−1−3041−001l

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
8 Hoist
8.1 Checking oil level, topping up if necessary x
8.2 Changing Oil 1x 1x x2)
8.3 Check screw connections and tighten as nec. x
8.4 Lubricating the Rope Drum Bearings x1)
8.5 Calculating the spent share of the theoretical service life at least once a year
8.6 General Overhaul of the Hoist Gear Winches x5)
8.7 Checking Proper Functioning of Lowering Limit Switch x
8.8 Hoist limit switch − checking for correct function x
8.9 Lubricate erection cylinder for hoist 2 x2)
9 Luffing Gear
9.1 Lubricate luffing cylinder x
10 Main Boom
10.1 Lubricating the Sliding Surfaces x

10.2 Lubricating the locking and pinning unit (LPU) every six months
10.3 Visual inspection of locking and pinning unit every six months
10.4 Locking and Pinning Unit − Checking the Proximity every six months
Switches and Sliding Contacts
10.5 Locking and Pinning Unit − Checking the Preliminary Gas x2)
Tension of the Accumulators
10.6 Checking the Rope of the Length Transducer Drum 1 x year
10.7 Lubricating the Foot Bearing x
10.8 Lubricate the main boom head axles x
10.9 Checking the Main Boom for Weld Cracks x2)
10.10 Checking the Sheaves
10.10.1 Perform visual check x
10.10.2 Perform wear check x1)
10.10.3 Checking the roller bearings on the sheaves x1)
10.11 Replacing the Rope Sheaves every 10 000 4)
operating hours (Bh)
10/14
200−1−3041−001l

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
11 Equipment
11.1 Main boom extension
11.1.1 Lubricating the pinning mechanism on the centre of motion x
11.1.2 Checking the Bracing Elements
11.1.2.1 Checking the Draw Shackles (Depending on the Version) at least once a year
11.1.2.2 Checking the adjusting cylinders (Depending on the at least once a year
Design)
11.1.3 Lubricating the Spindle (Depending on the Design) x
11.2 Ropes
11.2.1 General information on operation and assembly see section 11.2.1
11.2.2 Cleaning the Ropes 2)
11.2.3 Lubricating the Ropes 2)
11.2.4 Visual inspection of the ropes, rope end connections, etc. x
11.2.5 Check entire ropes, replace if required x2)

11.3 Hook Block
11.3.1 Lubricating Hook Blocks x
11.4 Sheaves
11.4.1 Checking the Sheaves
11.4.1.1 Perform visual check x
11.4.1.2 Perform wear check x1)
11.4.1.3 Checking the roller bearings on the sheaves x1)
11.4.2 Replacing the Rope Sheaves every 10 000 4)
operating hours (Bh)
11/14
200−1−3041−001l

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
12 Hydraulic system
12.1 Replace the filter elementsin the return flow filter 1x 1x x x
12.2 Replacing the Aeration Filter 1x x2)
12.3 Clean/replace the filter element of the high−pressure filter / 1x 1x x2)
oil leakage filter
12.3.1 Clean the high−pressure filter (1) x x x
12.3.2 Clean the oil leakage filter (3) x x
12.3.3 Clean the high−pressure filter (2) x x x
12.4 Hydraulic Pump − Changing the Add−On Filter x x
12.5 Hydraulic tank − checking oil level / topping up x x
12.6 Check hydraulic oil tank return filter for contamination 1x x
12.7 Changing the oil in hydraulic tank x
12.8 Bleeding the Hydraulic System x x
12.9 Checking the Hydraulic System 1 x year
12.10 Checking the Hose Lines x

12.11 Replacing the hose lines every 6 years
12.12 Check the initial gas pressure in the accumulator x2)
12.13 Biodegradable hydraulic oil (optional) − having
1x x2)
serviceability checked
13 Heating and Air Conditioning
13.1 Checking the System is Functioning Correctly once a month
13.2 Replacing the Heat Exchanger every 10 years
13.3 Replace fuel filter x
13.4 Bleeding the System x
13.5 Air Conditioning Equipment (optional)
13.5.1 Switching on the Air Conditioning Equipment once a month
13.5.2 Servicing the Air Conditioning Equipment at beginning, middle and end of cooling period
13.5.3 Having the Air Conditioning Equipment Checked 1 x year
12/14
200−1−3041−001l

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
14 Electrical System
14.1 Check the lighting system x
14.2 Batterien warten x
14.3 Checking the fuses x
14.4 Check slipring contacts x
14.5 Elektrische Anlage überprüfen x2)
15 Fuel System
15.1 Checking the Fuel System 1 x year
16 Cooling, Air Intake and Exhaust System
16.1 Cleaning and Replacing the Air Filter Element x3)
16.2 Replacing the Safety Cartridge (Optional Equipment) x
16.3 Cleaning the air filter prefractionator (optional) x
16.4 Cleaning the Cooling System x
16.5 Checking the Coolant Level and Topping Up as Necessary x

16.6 Replacing the Coolant with Antifreeze x3)
16.7 Diesel soot particle filter (optional):
− ”burn off” the filter element x
− Service the filter element x x2)
17 Piston Rods
17.1 Exposed Chrome Surfaces − Applying Protective Grease x
18 Crane operator’s cab
18.1 Lubricating the Tilt Cylinder x
18.2 Checking the Windscreen Washing Assembly x
18.3 Filling up the Supply Tank of the Windscreen Washing x
Assembly
18.4 Lubricating the guide rail of the sliding door x2)
13/14
200−1−3041−001l

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Sect. 2
x 100
19 Visual Inspections Superstructure
19 Visual Inspections Superstructure x
20 Optional equipment
20.1 Central Lubrication System
20.1.1 Filling the Tank x
20.1.2 Checking the System x7)
20.1.3 Cleaning the system x
22 (Having) Crane Inspections (Carried out) at least once a year x

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Engine 5
200−1−3050b_en 1/5
5
6 2
1 7
3 Z 51 703
2/5 200−1−3050b_en
Engine 5
5 Engine
(Z 51 703)
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. The operating instructions for the engine and a
maintenance book are included in Part 5 of this service literature.
The description of the engine is on the bearing plate.

The location of the bearing plate can also be found in the opera-
ting instructions of the engine manufacturer.
Assembly of the Engine
(1) Oil dipstick

(2) Oil filler
(3) Oil drain valve
(4) Oil filter
(5) −
(6) Fuel filter
(7) Hand pump
(8) −
Starter
When cleaning the starter it must always be ensured that,

− when in the fitted position the starter is not sprayed with the
water jet and
− when dismantled the starter is cleaned with the bearing fa-
cing downwards, that is, suspended downwards,
so that moisture does not enter the magnetic switch.
200−1−3050b_en 3/5
5
Z 200 411 Z 47 991
Z 58 696
4/5 200−1−3050b_en
Engine 5
5.1 Engine Quick Stop: Function Test
(Z 200 411, Z 47 991 principle drawing, Z 58 696)
Both engines (drive motors in the chassis and in the superstruc-

ture engine) can be switched off by pressing the engine quick
stop button in the crane operator’s cab and the optional additio-
nal engine quick stop button in the outrigger control area (exam-
ple Z 47 991) on the left− and right−hand side of the crane chassis
vehicle (for instructions, see part 1, section 5 “Engine”).
During the function test you must check that the engines are swit-
ched off by pressing each existing push button.
If the engines are equipped with an air shutoff flap (Z 58 696,

optional equipment), you must also check that it has closed du-
ring the function test.
If the engines are started again, the air shutoff flaps (1) of both
engines must be unlocked manually. Return lever (2) to the star-
ting position.
Risk of damage !
When the shutoff flap is closed the engine cannot be started.
Repeated starting attempts result in engine damage.
Before restarting, all air−carrying hoses − incl. the charge air
hoses between the engine and charge air cooler − must be
checked to ensure that they are fitted correctly and are com-
pletely free of blockages.
200−1−3050b_en 5/5
Slew Ring 6
200−1−3060a_en 1/5
6
Z 29 081
Z 35 741
2/5 200−1−3060a_en
Slew Ring 6
6 Slew Ring
When maintenance work is carried out, there is a danger of

dragging at the slew gear pinion (Z 29 081) − in spite of the
protective covering.
Observe the warning sign which is attached.
Danger of crushing/shearing !
When carrying out the tasks described below, ensure that
no maintenance personnel, with the exception of the crane
operator (in the cab), are situated in the danger areas bet-
ween the main boom, superstructure and chassis or bet-
ween the superstructure and chassis once the engine has
been switched on to carry out the necessary slewing and
luffing movements.
6.1 Lubricating the bearing

(Z 35 741)
Grease the central lubrication.
Optionally, this lubricating point can also be connected to the

central lubricating system (see section 20 of these maintenance
instructions).
Lubricating procedure
First grease the nipples on the slew ring, then turn the superstruc-
ture twice through 360° before greasing the nipple a second time.
After the second lubricating procedure, the grease must be
emitted around the circumference of the slew ring, forming a
collar of grease.
This lubricating procedure must be carried out

− in accordance with the maintenance interval on the main-
tenance list (see section 4)
− following cleaning with steam jets
− before and after a longer operating break / downtime.
200−1−3060a_en 3/5
6
Z 61 440 Z 104 276
Z 46 546
4/5 200−1−3060a_en
Slew Ring 6
6.2 Lubricate the ring gear

(Z 61 440 principle drawing)
Lubricate the ring gear with a special adhesive grease regularly

and after cleaning with high pressure washers; but at the latest
when there are exposed areas in the tooth gears.
6.3 Checking the screwed connection for firm fitting

Check the screwed connection for firm fitting. To do so, apply the
prescribed torque to several screws of the rotating assembly (1),
distributed in the machine.
The screwed connection is firm when the screws do not turn
when the torque is applied.
Item Size Property Torque
class
1 M 24 10.9 880 Nm (650 lbf−ft)
Risk of breaking!
The torque may not be increased.
Accidents may occur.

If screws turn, the customer service team of the crane ma-
nufacturer must be informed. The required measures for
achieving operating safety again must be discussed with
them.
It is never sufficient to simply tighten the loose screws with
the nominal torque again.
6.4 Lubricate the mechanical superstructure locking de-

vice
Using a paintbrush, paint grease on the pins of the mechanical

superstructure locking device regularly and after cleaning with a
high pressure washer.
200−1−3060a_en 5/5
Slew Gear 7
200−1−3070b_en 1/5
7
Z 51 704 Z 51 705
Z 32 031
2/5 200−1−3070b_en
Slew Gear 7
7 Slew Gear
(Z 51 704)
When maintenance work is carried out, there is a risk of

being dragged in at the slew gear pinion (Z 51 704) − in
spite of the protective covering.
Observe the warning sign.
The slew gear mechanism is lubricated for running with hydraulic

oil, which is why a separate oil level check and oil change is not
necessary.
7.1 Lubricating Bearings

(Z 51 705)
Lubricate bearing of the pinion using lubricating nipples (1).
7.2 Checking and Re−tightening the Screw Connections

if Necessary
(Z 32 031)
Using a torque key, regularly check the torque of the exterior

screwed connections.
If required, tighten screws in accordance with the following ta-

bles.
Screw Property
Torque
No. Size class
1 M 12 10.9 108 Nm (80 lbf−ft)
2 M 12 8.8 74 Nm (55 lbf−ft)
3 M 16 10.9 265 Nm (196 lbf−ft)
4 M 12 8.8 74 Nm (55 lbf−ft)
When fitting new screws, lubricate the thread and head support
using roller bearing grease KP2K.
7.3 Visual and Noise Inspections

Carry out visual and noise inspections on the transmission on a
weekly basis.
You must especially check the seals of the transmission. Listen
for unusual noises.
200−1−3070b_en 3/5
7
4/5 200−1−3070b_en
Slew Gear 7
7.4 Maintenance of the Slew Gear Brake
The slew gear brake is maintenance−free.
If there are malfunctions, thermal overload or whenever car-

rying out repairs on the retaining disc brakes,
− discs
− springs
− sealing elements
must be replaced.
200−1−3070b_en 5/5
Hoists 8
200−1−3080f_en 1/13
8
Z 29 082
2/13 200−1−3080f_en
Hoists 8
8 Hoists
R I S K O F A C C I D E N T S!
Measures to achieve safe operating periods:
In accordance with the accident prevention regulations
for winches, hoist and traction equipment, VBG 8, the
operator of the crane is responsible for ensuring that a
crane inspection is carried out at least once a year (see
also ISO 9927−1).
The spent share of the theoretical service life for the win-
ches must also be determined. The crane operator must
employ an expert for the purpose if necessary.
This regulation is legally binding within the scope of the
accident prevention regulations of the trade association.
Apart from this, the crane manufacturer recommends
that the procedure listed is also observed.
See section 22, ”Examinations of the Crane”, of these
lubrication and maintenance instructions
(Z 29 082)
Risk of snagging!
When carrying out maintenance, inspection and mounting
work, special care must be taken in this area as there is a
risk of being caught and dragged into the equipment bet-
ween the winches and hoist ropes.
200−1−3080f_en 3/13
8
Z 46 297
4/13 200−1−3080f_en
Hoists 8
8.1 Hoist 1 and 2 − check the oil level
(Z 46 297)
Check the oil level on the inspection opening. This should

generally be done when the transmission is at a standstill and the
oil has cooled down.
During operation a considerable amount of oil is distributed

around the inside of the gearbox case. We recommend
therefore that the oil level be checked and any oil added
immediately after starting up the system and with the
transmission at a standstill.
If the level is below the ’min.’ marking, proceed as follows:
1. Remove the oil filler plug (1) from the top end of the
inspection glass.
2. Using the funnel or hose, add oil until the marker ’max.’ on
the inspection glass has been reached.
Make sure that you use the correct types of oil as listed in section
2 ”Consumables and Capacities”.
3. Screw the oil filler plug back in (1).
If, when checking the oil, you find a continual loss of oil,
operation must be stopped and the system dismantled.
200−1−3080f_en 5/13
8
Z 46 298
6/13 200−1−3080f_en
Hoists 8
8.2 Hoist Gear − Changing the Oil

(Z 46 298)
Use the oil grade given in section 2 ”Consumables and

Capacities” or on the serial plate. It is preferable to use an oil of
a higher viscosity rather than using a thinner oil.
Different oil types should not be mixed, even if they come from
the same manufacturer.
Fully synthetic oils may only be used with acid−proof seals and
a sufficiently resistant inner coating. Please check with customer
services.
The oil should be warm when it is changed, i.e. following a longer

period of operation:
Risk of burns and scalding!

Both the surface of the transmission and the oil that is
being drained off have high temperatures.
Avoid any contact and wear protective clothing!
1. Remove the oil filler plug (1) from the top end of the inspection
glass.
2. Remove the oil drain plug (2) at the bottom of the inspection
glass and drain the oil off into a suitable container.
4. Add new oil as described in section 8.1
During operation a considerable amount of oil is distributed

around the inside of the gearbox case. We recommend
therefore that the oil level be checked and any oil added
immediately after starting up the system and with the
transmission at a standstill.
200−1−3080f_en 7/13
8
2
3
Z 51 706
8/13 200−1−3080f_en
Hoists 8
8.3 Checking and Re−tightening the Screw Connections

if Necessary
(Z 51 706)
Check the torque of the outer screw connections regularly using

a torque wrench.
Tighten any loose screws, remove broken off or defective screws
and replace them with new ones.
Torques of the gear housing screws:
No. Size Property Torque

class
3 M 16 10.9 290 Nm (214 lbf−ft)
Torques of the fixing bolts for the hydraulic motor and gear
mount:
No. Size Property Torque

class
1 M 10 8.8 43 Nm (32 lbf−ft)
2 M 20 10.9 510 Nm (376 lbf−ft)
4 M 10 10.9 63 Nm (46 lbf−ft)
When new screws are fitted, the thread and head should be
smeared with KP2K roller bearing grease.
200−1−3080f_en 9/13
8
Z 46 547
10/13 200−1−3080f_en
Hoists 8
8.4 Lubricating the Rope Drum Bearing
Lubricate the rope drum bearing via the lubricating nipple on the
top. (Z 46 547)
8.5 Calculating the Percentage Used of the Theoretical

Service Life
A detailed description is given in the section 22 ”Examinations of

the Crane” under the point “Inspection of the winches”.
8.6 General Overhaul of the Hoist Gear Winches
Depending on the remaining service life or when the service life

”D” is reached (see explanation in section 22 “Examinations of
the Crane” under the point “Inspection of the winches”) the
winches must be subjected to a general overhaul.
In any case, a general overhaul must be carried out at

the latest 10 years after the crane is placed in operation
for the first time.
The maximum time period between two general
overhauls may only exceed 10 years in exceptional
cases.
200−1−3080f_en 11/13
8
Z 51 507
12/13 200−1−3080f_en
Hoists 8
8.7 Lower Limit Switch − Checking the Proper Function
Limit switches may be checked only without a load atta-
ched.
The lower limit switch is best checked when a large number of

ropes are reeved and when the main boom is in its highest
position.
Telescope out the main boom and lower the hook block by means
of the hoist until the lower limit switch shuts off the movement for
the corresponding hoist.
Check to make sure that there are at least three turns of the rope
remaining on the rope drum.
Carry out this check at regular intervals whenever the crane is in

the suitable configuration.
8.8 Hoist limit switch − check that it functions properly
Limit switches may be checked only without a load atta-
ched.
Approach the hoist limit switch daily and check that it functions
properly.
To do so, lift the hook block with the hoist accordingly until the shift
weight is relieved. The ”Raise hoist” movement must then be
switched off.
8.9 Lubricating Erection Cylinder Hoist 2

Lubricate the two lubricating nipples every time before fitting
hoist 2 (Z 51 507).
200−1−3080f_en 13/13
Luffing Gear 9
200−1−3090_en 1/3
9
1 A
RA
Z 51 708
2/3 200−1−3090_en
Luffing Gear 9
9 Luffing Gear
9.1 Lubricating the Luffing Cylinders
(Z 51 708)
Danger of crushing / danger due to shearing.

As soon as the engine is started up to carry out the ne-
cessary slewing and luffing movements, ensure, when
the following work is carried out, that there are no main-
tenance personnel other than the crane operator (in the
cab) in the danger area between the main boom, super-
structure and chassis, and superstructure and chassis.
Lubricate the four nipples on the foot bearing (1).
Lubricate the four nipples on the piston rod bearing (2).
200−1−3090_en 3/3
Main Boom 10
200−1−3100−001e_en 1/27
10
T0 T1 T2
LK 95
T2 T3
LK 96
T3 T4
LK 97
T4 T5
LK 98
T5 T6
LK 99
Z 55 774
2/27 200−1−3100−001e_en
Main Boom 10
10 Main Boom
10.1 Lubricating the Sliding Surfaces

(Z 55 774)
Using a paintbrush, a lubricating agent must be applied to the top

(inner) sliding surfaces of the basic boom section (T0) and of the
telescopic sections 1 − 5 (T1 − T5) and to the bottom (outer)
sliding surfaces of the telescopic sections 1 − 6 (T1 − T6).
To this end the main boom must be extended horizontally to the
specified ”lubricating lengths”.
The top (inner) sliding surfaces of the basic boom section (T0)
and telescopic sections 1 − 5 (T1 − T5) are lubricated through the
openings of “lock 90%”.
Before lubricating the basic case, the covers must be removed

from the openings of locking 90%.
Risk of tilting!
Before extending the telescopic sections, the crane must be
supported on outriggers and the counterweight suitable for
the outrigger support area must be fitted (see table).
Risk of crushing!
You may only start lubricating through the opening for
locking once the telescoping process has been
completed.
The following table shows a total overview of the permitted

extension sequences for lubrication of the main boom with notes
on the telescopic sections to be lubricated, the extension
sequences of the telescopic sections, length code (LK for
automatic telescoping) and the minimum requirements for
counterweight and outrigger support area.
Telescopic
Extension state of the
sections to be Minimum Outrigger
telescopic sections (%)
lubricated LK counter- support
inte- exte- weight area
T1 T2 T3 T4 T5 T6
rior rior
T0/T1 T1/T2 100 100 0 0 0 0 95
T2 T3 0 100 100 0 0 0 96
25.3 t 8.2 m
T3 T4 0 0 100 100 0 0 97
(55.7 kip) (26.9 ft)
T4 T5 0 0 0 100 100 0 98
T5 T6 0 0 0 0 100 100 99
200−1−3100−001e_en 3/27
10
T0 T1 T2
LK 95
T2 T3
LK 96
T3 T4
LK 97
T4 T5
LK 98
T5 T6
LK 99
Z 55 774
4/27 200−1−3100−001e_en
Main Boom 10
Depending on the design of the crane, the required extension

sequences of the main boom can be created by manual or
automatic telescoping.
For manual telescoping, see section 12 ’Telescoping’ of the

superstructure operating instructions.
In order to create the extension condition by automatic

telescoping, see subpoint 10.1.1.
10.1.1 Creating the Extension Condition by

Automatic Telescoping
Starting point: Crane in transport position.
Proceed as follows:
1. Support the crane on outriggers as specified and align. Start

the superstructure engine and fit the specified counter-
weight.
Observe the corresponding specifications on the IC−1
display screen for the length codes for lubricating the main
boom (Z 57 682, see the following page), i.e. in this instance:
Minimum counterweight 25.3 t (55.7 kip), outrigger support
area 8.2 m (26.9 ft).
For information on navigating around the IC−1 and

subsequent telescoping procedures, please refer to section
12 “Telescoping” and in particular the section “Telescoping
procedure” and “Length code”.
200−1−3100−001e_en 5/27
10
Z 55 730
17 18 19
25,3 8,2
25,3 8,2
25,3 8,2
25,3 8,2
25,3 8,2
Z 57 682
6/27 200−1−3100−001e_en
Main Boom 10
(Z 55 730, Z 57 682)
2. On the “Tele mode” screen (Z 55 730) select the lubricating

symbol. Screen (Z 57 682) appears with the selection
list for the length codes for lubricating the main boom.
Instead of details on load capacities and radii, values for the
counterweight combination and outrigger support area are
indicated here, which must at least be fulfilled:
(17) − Minimum counterweight
(18) − Minimum outrigger support area
(19) − Button: back to “Tele mode” screen.
Risk of tilting!
Only when the actual crane configuration fulfils the mi-
nimum requirements regarding counterweight combina-
tion and outrigger support area are risk−free telescoping
and lubrication of the main boom ensured.
3. Select longitudinal code for the first lubricating length (here:

LK 95) and exit the screen by pressing .
If the configuration of the crane that is currently stored in the

control system does not satisfy the specified minimum
requirements for the counterweight and outrigger support
area, the corresponding value is displayed in red. The
screen cannot be exited by pressing the ”save” button. The
desired telescoping procedure cannot be carried out.
200−1−3100−001e_en 7/27
10
LK 95
T0 T2
T1
90% 90%
Z 55 772
LK 95
T0 T2
T1
Z 55 773
8/27 200−1−3100−001e_en
Main Boom 10
4. Telescope out the main boom with the selected length code
“LK 95”. The achieved extended state (100/100/0/0/0/0)
means that telescopic sections 1 and 2 are each fully
extended (100%) and all the others remain completely
retracted (0%).
5. Once the telescoping procedure has been completed switch
off the superstructure engine and exit and lock the crane
operator’s cab.
Risk of crushing!
With the following lubricating procedures on the main
boom, it must be ensured that the main boom cannot be
telescoped! Otherwise there is a risk of crushing for the
service personnel.
(Z 55 772)
6. Lubricate the upper (inner) sliding surfaces of basic boom
section (T0) and telescopic section 1 (T1). Insert a suitable
brush through the 90% pinning hole and apply a thick coat
of grease to the opposite upper sliding surface. This
procedure must be carried out on both sides one after the
other.
The grease that is applied is subsequently distributed along
the linings when the system is telescoped.
As the basic boom section is always accessible from the

outside, all openings are closed off with covers to avoid the
risk of crushing. For this reason, the lid over the 90%
pinning hole must be removed first before the lubricating
procedure can be carried out in the interior of the basic
boom section. Immediately after the lubricating procedure
has been completed, the lid must be fitted onto the pinning
hole again.
Otherwise there is a risk of crushing!
(Z 55 773)
7. Lubricate the lower (outer) slideways of the telescopic
sections 1 and 2 with grease.
8. One after the other select the remaining lubricating length
codes (LK 96, LK 97, LK 98 and LK 99) and lubricate the
remaining inside and outside telescopic sections / sliding
surfaces.
Proceed in the same way as detailed on the previous page
for the length code “LK 95” and basic boom section and
telescopic sections 1 and 2.
200−1−3100−001e_en 9/27
10
Z 60 178
10/27 200−1−3100−001e_en
Main Boom 10
10.2 Lubricating the locking and pinning unit (LPU)

(Z 60 178)
1. Support the crane on outriggers and fit the counterweight so

that it is possible to telescope out to (45/0/0/0/0/0) in the
following using LK 2.
Risk of accidents!
See the valid load capacity table with the corresponding
specifications for the necessary extension sequence, e.g.
outrigger support area, counterweight, etc.
2. Luff up the completely retracted main boom to an angle of

approx. 60° .
Select a main boom angle that allows the assembly opening on

the underside of the basic case to be easily accessed.
3. Telescope out the main boom to (45/0/0/0/0/0) with the

selected LK 2.
4. Remove the cover from the assembly opening on the

underside of the basic case.
Risk of crushing!
Do not reach into the opened assembly opening while the
locking and pinning unit is moving.
5. Reposition the locking and pinning unit until it is positioned

just in front of the assembly opening.
To do this, you must switch to “Manual telescoping”.
While carrying out this procedure, you must also observe

the corresponding section “Manual telescoping” and the
following section “Teaching...” in section 12 “Telescoping”
of the operating manual for the superstructure.
200−1−3100−001e_en 11/27
10
Z 60 178
12/27 200−1−3100−001e_en
Main Boom 10
(Z 60 178)
6. Switch off the drive motor and safeguard to prevent it from

being switched on again unintentionally by removing the key
and locking the empty crane operator’s cab. Attach a
warning plate to the latch of the crane operator’s cab.
Risk of crushing!
You must ensure that the LPU cannot be actuated while
lubrication procedures are being carried out inside the
basic case on the LPU.
7. Lubricate all moving parts wit the lubricants described in

section 2, “Oils, lubricants and capacities”. While doing this,
pay particular attention to the sliding surfaces indicated by
arrows.
The LPU state is “unlocked / pinned”. This means that, contrary

to the illustration “Z 60 178”, the locking pins (1) are retracted and
the grippers are extended.
8. Leave the hazardous area (assembly opening or the inside

of the basic case).
Risk of crushing!
Before actuating the LPU, be sure that neither persons nor
body parts are in the LPU area or inside of the basic case.
9. Return to the cab and put the LPU in the “locked / unpinned”
state. The locking pins (1) are then extended as seen in the
illustration (Z 60 178).
200−1−3100−001e_en 13/27
10
Z 60 178
14/27 200−1−3100−001e_en
Main Boom 10
(Z 60 178)
10. Resecure the cab − as described in point 6. − Lubricate the

LPU in the area of the extended locking pins (1) and leave
the hazardous area.
Risk of crushing!
Before actuating the LPU, be sure that neither persons nor
body parts are in the LPU area or inside of the basic case.
11. Return to the cab and actuate the LPU lock / unlock or pin
/ unpin. This evenly distributes the lubrication.
12. Resecure the cab − as described in point 6. − and check that

the LPU has sufficient lubrication.
Repeat the lubrication procedure if necessary.
13. Lock the assembly opening using the cover.
10.3 Locking and Pinning Unit − Carrying Out a Visual

Check
Check the following components to make sure that they are

seated properly and check for damage and leaks.
− Plugs (in particular on the solenoid valves)
− Solenoid valves
− Hoses and cables
10.4 Locking and Pinning Unit − Checking the Proximity

Switches and Sliding Contacts
Check the proximity switches and sliding contacts
− to make sure they are properly seated; they must not be loose
or be able to move around in their housing.
− to make sure that they are undamaged
− to make sure that they move freely, i.e. that the spring return
is working correctly.
200−1−3100−001e_en 15/27
10
Z 160 620
16/27 200−1−3100−001e_en
Main Boom 10
10.5 Locking and Pinning Unit −

Checking the Preliminary Gas Tension of the
Accumulators
(Z 160 620)
The accumulators used in the hydraulics of the main boom are

diaphragm or bubble accumulators with nitrogen.
The corresponding components will only function properly if the
accumulators fitted are charged with the pre−set gas pressure
specified.
A loss in preliminary gas tension or a defect in the accumulator

is indicated by
− very slow completion of the pinning and locking processes
− frequent and long recharging intervals of the feeder valve.
This initial gas pressure must be checked at regular intervals.
A filling and testing device for bubble accumulators is required for

checking the preliminary gas tension.
This inspection may only be performed by a specialist

trained in the use of this filling and testing device.
Please contact our customer service department if you do
not have such a technician and/or this type of testing and
filling equipment.
200−1−3100−001e_en 17/27
10
1
2
Z 51 711
Z 30 194
18/27 200−1−3100−001e_en
Main Boom 10
(Z 30 194)
To test or to fill the accumulator please proceed as follows:
1. Switch off the drive engine on the superstructure and put the
ignition switch into position ”0”.
2. Release the pressure from the hydraulic system.

The accumulator (2) must be completely emptied of
hydraulic oil.
Check this on a pressure gauge if a test nipple is available
or
gently loosen the union nut on the hydraulic line on the oil
connection for the accumulator.
The system is depressurised when no pressure is shown on the

pressure gauge or when no hydraulic oil escapes from the
loosened union nut.
3. Remove the safety guard (1) on the gas valve of the

accumulator (2) and screw the filler and test device (3) in
place.
4. Open the gas valve via the screwed−on filler and test device
and read off the charge pressure on the pressure gauge of
the test device.
Preliminary pressure of the accumulators (Z 51 711):
(2) Pressure accumulator (MP 4) 3 bar (44 psi)
(1) Pressure accumulator (MP 3) 60 bar (870 psi)
5. If the preload pressure is insufficient, then the accumulator

must be filled with nitrogen through the filling device (3) until
the corresponding preload pressure is achieved.
After initial filling, wait for approximately two to three minutes,
check the preliminary tension again and top up as necessary.
200−1−3100−001e_en 19/27
10
5
4
Z 40 074
Z 51 712
20/27 200−1−3100−001e_en
Main Boom 10
(Z 40 074)
Check the pressure gauge at the test nipple ”X” when topping up
the initial gas pressure on the accumulator.
The pressure in the corresponding hydraulic circuit must not rise.
If this is the case, the diaphragm in the accumulator is defective.
The accumulator must be replaced.
Only NITROGEN may be used to fill the accumulator.
If the initial test reveals a larger decrease (approx. 60%) in

pre−set pressure, the accumulator must be checked again after
approx. 3 to 4 weeks.
If another fall in pressure is then observed, the accumulator must
be replaced.
Only NITROGEN may be used to fill the accumulator.

A pressure reducer (5) must be fitted to the nitrogen bottle
(4, Z 40 074).
Accumulators may only be repaired by the manufacturer or
in approved workshops.
Following repair, the accumulator must be checked and
passed by an authorised specialist.
A new test certificate must be provided for the accumulator.
10.6 Checking the Rope of the Length Transducer Drum

(Z 51 712)
Check rope (1) to make sure that it is undamaged.
200−1−3100−001e_en 21/27
10
Z 46 549
Z 550 102
22/27 200−1−3100−001e_en
Main Boom 10
10.7 Lubricating the Foot Bearing

(Z 46 549)
Lubricate the nipple on each side of the main boom base bearing.
10.8 Lubricate the main boom head axles
(Z 550 102 Principle diagram)
Lubricate the lubricating nipples on both sides of the main boom

head axles.
10.9 Checking the Main Boom for Weld Cracks
To avoid fractural damage, the weld seams on the main boom

must be inspected once a year during crane inspections for weld
seam cracks.
If crack formations are found, Terex−Demag service repair

instructions must be requested to carry out repair welding.
An exact description of the course of the crack should be given
(relevant page from the spares catalogue, photos, sketches,
etc.).
Repair welding work may only be carried out by a suitably

qualified welder.
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10
y y
x
Z 160 543
24/27 200−1−3100−001e_en
Main Boom 10
10.10 Checking the Sheaves
Risk of snagging!
Extra care is required when carrying out maintenance,
inspection and assembly work in this area, as there is a risk
of becoming entangled and dragged into the equipment
between the sheaves and ropes.
10.10.1 Perform visual check

Check all sheaves for damage such as cracks, chamfering or any
similar damage.
Sheaves with such damage must be replaced immediately.
10.10.2 Perform wear check

Also check all sheaves for wear:

− Bottom tread “X” max. 3 mm (0.12 inch).
Measure “X” = difference between ∅ new bottom tread and
∅ bottom tread is!
− Side tread “Y” max. 5 mm (0.2 inch).
Measure “Y” measured between rope (S) and tread of the
sheave.
If the sheave has been used almost to its limit on wear, it must be
replaced.
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10
26/27 200−1−3100−001e_en
Main Boom 10
10.10.3 Checking the roller bearings on the sheaves

Check all sheaves annually for:
− Grease emission
− Correct seating of bearing seals
− Correct fitting of sealing rings
− Running noises, rolling resistance
− Bearing play
If faults are found, the entire sheave must be replaced. In this

case, please contact our customer service department.
Risk of accidents!
Special skills and equipment are required for assembling
the individual components of plastic sheaves.
For safety reasons, plastic sheaves may only be replaced
as entire components.
Plastic sheaves are not entirely resistant to chemicals and

paints. This is especially important to take into account in
connection with work carried out in aggressive
environments or for cleaning purposes.
Please consult our customer service technicians for an
exact listing of chemical resistances.
10.11 Replacing the Rope Sheaves
We recommend that all sheaves be replaced after 10 000

operating hours or every 5 years crane operation.
To do so, notify our customer service department.
Risk of accidents!
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Equipment 11
200−1−3110e_en 1/33
11
Z 60 393
2/33 200−1−3110e_en
Equipment 11
11 Equipment
11.1 Main Boom Extension
11.1.1 Lubricating the pinning mechanism on the centre of

motion
(Z 60 393)
Lubricate all lubrication points using the lubricating nipples.
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11
73
Z 51 716
4/33 200−1−3110e_en
Equipment 11
11.1.2 Checking the Bracing Elements
11.1.2.1 Checking the Draw Shackles (Depending on the

Version)
(Z 51 716)
The draw bars for setting the 20° or 40° working angle must
be inspected by an expert at least once a year − according to
the ”Cranes” accident prevention regulations (BGV D6).
In addition they must be checked by a specialist between
these intervals if required by the operating and site conditions.
Since the inspection intervals are normally based on the

operating conditions, they should be correspondingly
shortened if the crane is operated more frequently.
This inspection must be documented when it is carried out

(e.g. in the examination log book for the crane).
It may be necessary to dismantle the draw bars (73) in order to

inspect them properly.
The draw bars must be inspected in their entirety, i.e. all hidden
surfaces and bores must also be inspected.
The following checks should be made:

− Check for cracks
− Check of length
− Checking for Wear
− Checking the paint
− Check for plastic deformation.
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11
74 73
74
73
59
Z 51 718
6/33 200−1−3110e_en
Equipment 11
Check for Cracks
The draw bars should be inspected regularly for cracks. A surface

crack test (e.g. magnaflux test) must be carried out at least once
every year. If cracks are detected during inspection of a bar, it
must be replaced. Modification work is not permitted.
Checking the Length
The draw bars are dimensioned so that, even under test load,
there can be no permanent expansion. No measurable change
in length is permitted as this would create problems in mounting
the bars.
The length of the draw bars must be measured to ensure that
they have not become overloaded or damaged.
The upper limit for serviceability (equals the ”replacement state
of wear for ropes”) is a change in length of 0.05 %. For example,
a maximum of 0.5 mm (0.02 in) for a draw bar length of 1 000 mm
(39.37 in).
If a change in length is detected, our customer service

department should be informed.
(Z 51 718)
The nominal measurement as well as the parts no. of the tension
bars and of the guide to the tension bar for bracing the main boom
extension to the main boom head can be found in the crane
inspection logbook.
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11
8/33 200−1−3110e_en
Equipment 11
Checking for Wear
Pin locks, bolts and bores must be checked for signs of wear. It
must be ensured that the pin locking mechanism is functioning
correctly.
Checking the Paint
The paintwork must be checked regularly for signs of corrosion.

Damaged areas must be repaired.
The draw bars must not be stored in aggressive media (e.g. sea
water).
Check for Plastic Deformation
If plastic deformation occurs (e.g. bending) the draw bar may no

longer be used. It must be replaced.
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11
Z 59 983
Z 51 717
10/33 200−1−3110e_en
Equipment 11
11.1.2.2 Checking the adjusting cylinders (Depending on the

Design)
(Z 59 983)
If the crane has a hydraulically adjustable main boom extension,

this extension is held by two adjusting cylinders (5).
The adjusting cylinders must be inspected by an expert at

least once a year − according to the ”Cranes” accident
prevention regulations (BGV D6).
In addition they must be checked by a specialist between
these intervals if required by the operating and site conditions.
Since the inspection intervals are normally based on the

operating conditions, they should be correspondingly
shortened if the crane is operated more frequently.
This inspection must be documented when it is carried out

(e.g. in the examination log book for the crane).
In particular, perform a visual inspection for the following. For

corresponding points, observe the specifications in
section 11.1.2.1 ”Checking the draw shackles”, starting from
page 5.
− Leaks on the cylinder
− Crack formation on the piston rod, piston rod eye and
attachment points
− Chrome plating of the piston rod
− Damage
− Paintwork
− Plastic deformation.
If defects are found, please contact the customer service of

the crane manufacturer directly.
11.1.3 Lubricating the Spindle (Depending on the Design)

(Z 51 717)
Whenever fitting the main boom extension, the thread of the

spindle must be lubricated using multipurpose grease.
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11
Z 30 316
Z 29 084 Z 29 085
12/33 200−1−3110e_en
Equipment 11
11.2 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)
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
− between the sheaves on the fixed bridle / flying bridle
Proceed with special caution!
Danger due to friction and scraping!
11.2.1 General Notes on Handling and Assembly
11.2.1.1 Transport
(Z 29 084, Z 29 085)
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.
(Z 29 084)
Wherever possible, the cable, which is delivered in bundles or on
reels, should not come into direct contact with a hook or with the
forks of a forklift truck. Rather, it should be raised by means of
wide textile lifting slings.
(Z 29 085)
A reel is best raised by means of a rod placed through its central
axis.
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11
14/33 200−1−3110e_en
Equipment 11
11.2.1.2 Bearing
Cables should be stored in a cool, clean, dry and covered

environment. The cables should not be stored directly on the
ground but, for example, on pallets.
If it is not possible to store the cables 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. This will then
prevent the instance of a cable first being used after several
years in storage.
11.2.1.3 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.
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11
Z 29 086
Z 29 087
16/33 200−1−3110e_en
Equipment 11
(Z 29 086)
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.
Assembly procedure
The best way to mount cable differs from system to system. In

every instance, the method should be chosen which, with a
representative work schedule, is least likely to cause a rope
torsion or damage to the cable through contact with structural
components.
On certain equipment it may be advisable to remove the old cable

first and then to fit the new cable. On other equipment, especially
larger models, it is advisable to draw the new cable through with
the old.
A further possibility, especially in the case of initial reeving, is to
use a thinner auxiliary rope with which the actual cable can be
drawn through.
In every case, it is necessary to consider whether it would be

better to draw the cable through the whole rope reeving
arrangement or first to reel it onto the rope drum directly from the
bundle or reel and then reeve the cable by hand or by means of
an auxiliary reeving rope.
If a rope end is fitted with a non−detachable rope end connection,
it is only possible to draw the free end of the rope through the
complete reeving arrangement.
Re−reeling
(Z 29 087)
Every cable takes on a certain bending tendency from the point

of manufacture, where it is drawn from the stranding basket by
means of delivering disks. It is then supplied to the customer bent
in this direction. It is then supplied to the customer bent in this
direction.When re−reeling from the reel onto the rope drum,
ensure that the cable is wound in this direction.
If the rope strand is reeled on beneath the rope drum, the

mounting reel should be set up so that the rope strand being
reeled off also runs off beneath the reel and vice versa.
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11
18/33 200−1−3110e_en
Equipment 11
If the cable is re−reeled against the directional tendency, the

cable will either tend to turn between the reel and the rope drum
or will turn later on when in operation in order to bend to the
preferred direction. In both instances, structural changes in the
cable will result.
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11
Z 29 088
Z 29 089
20/33 200−1−3110e_en
Equipment 11
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, it must also be
ensured that the auxiliary rope cannot become twisted. For
example, non−twisting cable types or triangular strand wire ropes
are particularly suitable for use as auxiliary reeving ropes. When
using conventional cables, they must at least have the same
direction of lay as the cable which is being drawn.
Whenever a new cable is drawn through using the old cable, the
two 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.
(Z 29 088)
A less problematic method of connecting the cables is by means
of two rings or chain links welded onto the cable ends. These are
then connected by means of strands or thin ropes. Such a
connection possesses a satisfactory load bearing capacity, can
be bent and prevents the transfer of torsion from the old rope to
the new. By using two strands, the number of turns in the strands
following assembly will show to what degree the old cable on the
equipment was twisted.
(Z 29 089)
Connecting the cables by means of rope stockings offers a
further possibility. Rope stockings are plaited rope strands which
are pushed over the cable ends and secured with adhesive tape.
When under load, the rope stockings are drawn tighter and hold
the cable ends by means of friction.
When an equal−lay rope is to be drawn, it must be ensured that
the rope stockings can turn on the rope like a nut on a screw, in
spite of the cord tensions. This can be achieved by first winding
strong adhesive tape round the cable surfaces which are to be
held by the rope stockings.
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11
Z 29 090 Z 29 091
Z 29 092
22/33 200−1−3110e_en
Equipment 11
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 layers may be pressed
in between the lower strands when the cable is placed under
load. This can lead to extensive damage to the cable.
As the cable which is being reeled off may even become stuck at
this point, the winding direction of the drum may be reversed
suddenly when the 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, in many cases, it is sufficient to wind on the cable normally
and then to unwind it and wind it on again with the aid of an
external load, this is not possible in every instance, for example
in the case of a slewing tower crane which has not yet reached
its highest climbing height. In these instances the cable must be
pretensioned at the assembly stage.
(Z 29 090, Z 29 091)
This can be achieved, for example, by braking the reel flange
using a board or by means of a brake disc attached to the reel.
The brake cords (hemp ropes with a steel core) are supplied by
the cable manufacturer.
(Z 29 092)
It must not be attempted under any circumstances to pretension
the rope by jamming it, for example, between two wooden planks.
The rope would be irreparably deformed due to structural
changes.
Retracting
Before a cable is placed in operation following its 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.
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11
Z 29 093
24/33 200−1−3110e_en
Equipment 11
Cutting into sections
Often cables have to be cut into sections or shortened by the

user. The cables can be cut in various ways. Up to a diameter of
8 mm (0.31 in), 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 cable
manufacturer.
The rope ends must be bound using iron wire; insulating tape
cannot prevent structural changes in the cables occurring.
(Z 29 093)
First the separating point is marked using chalk or insulating tape.
One end of the seizing wire, approx. four times the cable diameter
in length, is then placed along the length of the cable and then
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 of wire which has been bound is then pulled tight using
pincers and is twisted together with the second wire end (c).
The length of the entwined wire ends is shortened to approx. the

diameter of the rope using the pincers. The wire ends are then
forced into a valley between two outer strands of the cable by
banging them lightly, 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 placed on either side of the cutting
point.
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11
”Y”
Z 104 648
26/33 200−1−3110e_en
Equipment 11
Shortening or moving cables

(Z 104 648 schematic diagram)
Very often, cables must be removed because short stretches of

rope − for example, the section of rope which must be wound onto
the drum from the first to the second layer − are heavily damaged,
while the rest of the rope is still fault−free.
In such cases, the service life of cables can be increased by
moving ropes along or by shortening them at the fixing point,
which moves the most heavily used rope section out of the area
of the highest stress.
After this procedure, the neighbouring area is subjected to the
heavy demands.
Another typical local point of damage is on the rope drum where

the strand runs against the neighbouring winding (“Y”) and must
be moved to the side. If the damage occurring here is the main
cause for removing the cable, the cable’s service life can be
increased by moving it along several times, thus moving the
areas of stress.
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11
y
Z 29 094
28/33 200−1−3110e_en
Equipment 11
11.2.2 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.
11.2.3 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, for operational reasons, it is not possible to
relubricate the rope, a shorter service life is to be expected and
the ropes must be monitored accordingly. The effects of
lubrication and relubrication on the life expectancy of the rope
can be seen in figure (Z 29 094):
x Number of reversed bending stresses (%)
y Tensile stress (N/mm2)
a greased and regreased
b greased
c without grease
Before relubricating the ropes, they must be cleaned (see

11.2.2).
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11
30/33 200−1−3110e_en
Equipment 11
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 should be carried out when the ropes are reeved.
Lubrication is best carried out using non−acidic grease which has
been thinned before use by heating.
The lubricant can be applied using various methods:

− with a 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.
11.2.4 Visual inspection of the ropes, rope end connections,

etc.
Before reeving and before starting crane work, check the

status of all accessible ropes (including the end
connections), winches and sheaves.
The responsible person in charge must be notified of any

irregularities found during the visual inspection.
In addition, ropes, rope end connections, etc. must be subjected
to a more extensive inspection (in accordance with 11.2.5).
Depending on the damage, the rope can be “moved” (see
corresponding segment) or must be replaced.
11.2.5 Check entire ropes, replace if required

The notes on carrying out the inspection of the entire ropes is
described in detail in section 22 “Inspections of the crane”.
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11
Z 160 318
32/33 200−1−3110e_en
Equipment 11
11.3 Hook Block
11.3.1 Lubricating Hook Blocks
(Z 160 318 schematic diagram)
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!
Lubricate all lubricating nipples of the hook blocks, as well as

those of the hook suspension gear.
11.4 Sheaves
Observe the details given in Chapter 10 ”Main boom” regarding
the maintenance work described below.
11.4.1 Checking the Sheaves
11.4.1.1 Perform visual check
11.4.1.2 Perform wear check
11.4.1.3 Checking the roller bearings on the sheaves
11.4.2 Replacing the Rope Sheaves
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Hydraulic System 12
200−1−3120d_en 1/35
12
7 1 6
Z 51 719
2
3
Z 51 728 Z 7 809
2/35 200−1−3120d_en
Hydraulic System 12
12 Hydraulic system
Danger of burns !
Please note that particularly parts of the hydraulic sy-
stem can be exposed to very high temperatures under
the coverings.
Allow therefore sufficient cooling time or wear appro-
priate clothing etc.
12.1 Replacing the Filter Elementsin the Return Flow Filter
To replace the elements, the filter units must be removed.
Proceed as follows:
1. Lower the suspended load to the ground, retract the telesco-

pic sections and switch off the superstructure engine. The
system must be depressurised.
2. Loosen the nuts (6) on the filter cover (1) and remove both
the filter cover and the O−ring. (Z 51 719, Z 51 728)
3. Remove the filter unit (2, Z 7 809) and place on a clean sur-
face. Ensure that the O−ring is not damaged.
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12
Z 27 827 Z 27 828
Z 27 829
4/35 200−1−3120d_en
Hydraulic System 12
4. Wash the bayonet catch (3, Z 27 827) and the valve connec-
ted to it in diesel oil or petroleum ether and place on a clean
surface.
5. Remove and dispose of the filter element (4) from the filtering
tube (2) (Z 27 828).
6. Drain the remaining oil from the filtering tube (2) into the con-
tainer for old oil and wash out the filtering tube using diesel
oil or petroleum ether.
7. Insert new filter element (4) in the filtering tube (2). (Z 27 828)
8. Insert filtering tube in the hydraulic tank. If necessary, re-

place the O−rings. (Z 27 829)
9. Start the superstructure engine and check the tank for leaks.
The filters should be replaced 50 hours after repair work has been
carried out on the hydraulic system.
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12
7 1 6
Z 51 719
6/35 200−1−3120d_en
Hydraulic System 12
12.2 Replace the ventilation filter

(Z 51 719)
1. Unscrew the filter (7).
2. Screw on new filter (7) and tighten by hand.
200−1−3120d_en 7/35
12
89
Z 200 415
8/35 200−1−3120d_en
Hydraulic System 12
12.3 Clean/replace the filter element of the high−pressure

filter / oil leakage filter
(Z 200 415)
The HP filter for the double pump and the HP filter for the gear
pump are fitted in the pressure line to the pump. The leak oil filter
is located in the return line. The add−on filter is fitted to the hy-
draulic pump. The indicator light (89) on the dashboard is assi-
gned to these filters and to the return oil filters in the hydraulic oil
reservoir.
If this indicator light (89) comes on, it means that one or more filter
elements must be cleaned or changed.
In order to find out which filter must be cleaned or changed, you

must remove the plugs on the pressure switch of the filter one af-
ter another and observe the indicator light (89) in the dashboard.
The filter element of the filter on which they go out must be clea-
ned or replaced.
200−1−3120d_en 9/35
12
10
Z 51 721
10/35 200−1−3120d_en
Hydraulic System 12

(Type ”LF BN/HC 60”)
(Z 51 721)

2. Place a suitable container beneath the filter to catch any oil

that might run off.
3. Remove the filter barrel (5) using wrench SW27 by turning

to the left at hexagonal nut (6).
Ensure that the O−ring (7) is not damaged.
4. Remove and dispose of the paper element (8) by gently mo-

ving it from side to side and pulling it downwards from the hol-
der (9).
5. Drain the remaining oil from the filter barrel (5) into the contai-
ner for old oil and clean the filter barrel with diesel oil or petro-
leum ether. Place the filter barrel (5) on a clean surface.
200−1−3120d_en 11/35
12
10
Z 51 721
12/35 200−1−3120d_en
Hydraulic System 12
(Z 51 721)
6. Check the O−ring (7) is in good condition.

Replace the O−Ring if damaged.
7. Push the new paper element (8) onto holder (9).
Only use original DEMAG spare parts.
8. Carefully push the filter barrel (5) over the paper element (8),
screw in up to the stop on the head piece (10) and tighten
using wrench SW 27.
9. Turn back the filter housing a forth of a turn.
10. Start the superstructure engine and check the filter for leaks.
If, after 1000 operating hours, the respective indicator light

has not come on, we recommend the paper element be repla-
ced.
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12
Z 46 524
14/35 200−1−3120d_en
Hydraulic System 12
12.3.2 Clean the Overflow Oil Filter (3)

(Type ”HD 062−171”)
(Z 46 524)


that might run off. The filter is located at the side of the hy-
draulic tank.
3. Remove socket housing (3) using wrench SW 27.
leum ether.
5. Remove the clogged filter element (4) and dispose of it in an

environmentally friendly manner.
If there is a limited amount of space available for disassembling

the filter barrel (3), the filter element (4) should be pulled off the
drain socket (3) and removed together with the socket housing
(3).
6. Check that the O−ring (2) is in perfect condition.

7. Push the new filter element (4) onto the drain socket (5).
8. Carefully push the socket housing (3) over the filter element
(4), screw in up to the stop on the head piece (1) and tighten
using wrench SW 27.
If there is a limited amount of space available for fitting the filter

element (4), the element should first be placed in the filter barrel
(3). The socket housing and the filter element are then screwed
in up to the stop on the head piece (1) and tightened using wrench
SW 27.
If after 1000 operating hours, the respective indicator light

has not come on, we recommend the filter element be repla-
ced.
200−1−3120d_en 15/35
12
Z 46 522
16/35 200−1−3120d_en
Hydraulic System 12

(Type ”HD 069−171”)
(Z 46 522)


that might run off.
3. Remove the filter barrel (4) using wrench SW36 by turning

to the left at hexagonal nut (6).
Ensure that the O−ring (2) is not damaged.
4. Remove and dispose of the paper element (5) by gently mo-

ving it from side to side and pulling it downwards from the hol-
der (3).
leum ether. Place the filter barrel (4) on a clean surface.
200−1−3120d_en 17/35
12
Z 46 522
18/35 200−1−3120d_en
Hydraulic System 12
(Z 46 522)
6. Check that the O−Ring (2) is in perfect condition.

7. Push the new paper element (5) onto holder (3).
8. Carefully push the filter barrel (4) over the paper element (5),
screw in up to the stop on the head piece (1) and tighten
using wrench SW 36.
9. Turn back the filter housing a forth of a turn.
If, after 1000 operating hours, the respective indicator light

has not come on, we recommend the paper element be repla-
ced.
200−1−3120d_en 19/35
12
Z 51 727
89
Z 200 415
20/35 200−1−3120d_en
Hydraulic System 12
12.4 Hydraulic Pump − Changing the Add−On Filter
(Z 51 727, Z 200 415)
When the indicator light (89) in the crane operator’s cab lights up,
the add−on filter must be checked.
By removing the plug from the electrical contamination indicator
you can determine whether the add−on filter or the leak oil filters
or one of the high pressure filter has to be cleaned. If indicator
light (89) goes out, this filter has to be replaced.
If the indicator light (89) remains lit up, even though the plug has
been removed, or the leak oil filters or one of the high pressure
filter must be serviced (see section 12.3).
Changing the add−on filter.

(Z 51 727)
Unscrew the clogged filter (X).
Screw on a new filter with O−ring.
200−1−3120d_en 21/35
12
Max.
Z 51 723
22/35 200−1−3120d_en
Hydraulic System 12
12.5 Hydraulic Tank − Checking the Oil Level / Topping up

(Z 51 723)
1. Fully retracted all hydraulic cylinders.
2. Position the crane on level, flat ground.
3. Switch off the engine.
4. Check the oil level on the level indicator.
The oil level in the stand pipe must come up to the ”max”
marker on the hydraulic tank.
5. The oil should be topped up if it is below this marker.
6. Investigate the cause of the oil loss and rectify immediately.
If oil must be added, the return oil filters must subsequently

be checked or replaced at the prescribed intervals. See sec-
tion 4 “Lubrication and Maintenance Schedule”.
200−1−3120d_en 23/35
12
89
Z 200 415
24/35 200−1−3120d_en
Hydraulic System 12
12.6 Check hydraulic oil tank return filter for contamina-

tion
(Z 200 415)
Each time the oil is topped up or changed, check that the return
oil filters have not become clogged within a short period of time
(e.g. through contaminated oil).
This is what the indicator light (89) in the dashboard is for. If it is
lit up, the filter elements must be exchanged.
This inspection must be carried out approx. 50 operating hours
after repair work on the hydraulic system or after an oil change.
If the return oil filters are clogged, the filter elements must be re-
placed.
Filter elements are removed and installed as described in section
12.1 of these maintenance instructions.
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12
Z 51 725
6 2
Z 51 726
26/35 200−1−3120d_en
Hydraulic System 12
12.7 Changing Oil in the Hydraulic Tank
1. Position the crane on level, flat ground and set down the sus-
pended load.
2. Retract all hydraulic cylinders.

3. Turn the superstructure in such a way that the draining oil
can be caught in containers which have been placed in posi-
tion.
The oil should be at operating temperature.
4. Switch off the superstructure engine.
5. Unscrew protection cap (4) from the coupling (5) on the un-
derside of the hydraulic tank (Z 51 725).
6. Screw the drain hose onto the coupling (5).
This effects the release of the through−flow cross−section. There

is no need to activate any shut−off valves.
7. Drain off the old hydraulic oil into a suitable container.
8. Release the coupling and remove the drain hose. Screw

back in the protection cap (4).
The hydraulic tank is now sealed tight.
(Z 51 726)
9. Open the cover (2) of the filler neck, fill up with new hydraulic
oil.
Pour oil into the hydraulic tank up to the upper marker on the oil
level gauge (6). This marker is valid at room temperature (approx.
20° C / 68 5F) and when all cylinders are retracted.
10. Bleed the hydraulic system (see section 12.8 ).
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12
28/35 200−1−3120d_en
Hydraulic System 12
12.8 Bleed the hydraulic system
The hydraulic system is bled via the bleeder nozzles provided in

the pipework and vent screws on the hydraulic cylinders and hy-
draulic motors.
At points where no vent fittings are provided, the connection fit-
ting (union nut) can be loosened slightly.
While bleeding the system, with the engine running at slow idling
speed, the vent fittings should be kept open until oil which is free
from air bubbles escapes from the fittings.
In order to avoid damage to seals and hydraulic elements, the sy-

stem should be bled while depressurised.
12.9 Check the hydraulic system
In addition to the visual inspections (e.g. when checking the oil

level), the hydraulic system in the engine compartment should be
inspected once a year. Ensure that all the connection fittings are
not leaking and are sufficiently tight.
Lines and/or hoses damaged due to mechanical, thermal or

other effects must be replaced.
Ensure that all lines and hoses are at a sufficient distance
from hot engine parts (e.g. turbocharger) and are laid so that
they do not chafe.
200−1−3120d_en 29/35
12
Z 35 446
4 SH
20 ∅
NNNNNN 4SH 20 DIN 20 023 3Q94
1 2 3 4 5
Z 30 193
30/35 200−1−3120d_en
Hydraulic System 12
12.10 Check the hose lines

(Z 35 446)
Check all hose lines regularly for damage.

If this visual inspection of the hose lines reveals even the slightest
damage, the defective hose must be replaced immediately.
Examples of possible defects on the hose lines:
1. Damage to the outer layer (1) (areas of abrasion, cuts,

cracks, etc.).
2. Ageing of the material of the outer layer (1) (formation of

cracks)
3. Deformations which do not correspond to the natural form of

the hose line (layers coming away, blistering, crushed points,
kinks, torsioning).
4. Leakage points.
5. Requirements regarding installation and positioning not ob-

served (see DIN 20 066 part 4 ”Installation of Hose Lines).
6. Fixture on the hose fitting (2) is damaged.
7. Hose fitting (2) corroded, deformed or damaged.
8. Storage time or duration of use exceeded

(see point 12.11).
12.11 Replacing the Hose Lines

Even if no damage is detected, the hose lines must be replaced
at the latest after 6 years, including a storage time of, at most,
2 years.
Identification of hydraulic hoses

(Z 30 193)
− (1) Manufacturer
− (2) Hose type (classification)
− (3) Rated width
− (4) DIN standard designation
− (5) Date of manufacture (quarter and year of production)
For the operating or storage life go by the date of manufacture
on the hydraulic hose.
200−1−3120d_en 31/35
12
32/35 200−1−3120d_en
Hydraulic System 12
12.12 Checking the Accumulator Initial Gas Pressure
The accumulators used in the hydraulic system of the crane are

diaphragm−type pressure or bubble reservoir accumulators with
nitrogen filling. The corresponding components will only function
properly if the accumulators fitted are charged with the
preliminary gas pressure specified. This initial gas pressure must
be checked at regular intervals.
A filling and testing device for bubble accumulators is required for

checking the preliminary gas tension.
This check may only be carried out by a specialist who

knows how to work with a filling and inspection device of this
type. Please contact our Service department if a specialist
and for the corresponding equipment is not available.
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12
34/35 200−1−3120d_en
Hydraulic System 12
12.13 Biodegradable Hydraulic Oil (Optional) − Having Ser-

viceability Checked
The serviceability of the biodegradable hydraulic fluid must be

checked at regular intervals by a lab authorised by the hydraulic
fluid’s manufacturer.
With normal use the hydraulic fluid must be inspected at least af-
ter 500 operating hours, after 1000 operating hours and then
every 1000 operating hours; however, it must be checked at least
once a year.
If conditions are more extreme the operating hours are halved.
The following special instructions must be observed when using

biodegradable hydraulic oil:
− when filling new and used machines with biodegradable hy-
draulic fluid, mineral oil remnant may not exceed 8 % of the
total volume.
The hydraulic system must be rinsed with the new hydraulic
fluid with which it is to be filled.
− It is not permitted to mix other biodegradable oils (unsatura-
ted synthetic ester oils and / or rape oil).
− When changing the biodegradable hydraulic fluid, the tank
must be checked for residue.
200−1−3120d_en 35/35
Heating and Air Conditioning Equipment 13
200−1−3130a_en 1/19
13
37.2 41.1 37.1
41.2
42
Z 51 730
6 99
1 2 3 4 5
Z 39 292
2/19 200−1−3130a_en
13 Heating and Air Conditioning Equipment
13.1 Checking the System is Functioning Correctly
The manufacturer’s operating instructions for the hot water-

heater D 5WS must be followed.
Briefly switch on the heating (for approx. 10 seconds) approxima-

telyonce a month, even outside of regular heating periods.This-
prevents the water pump and the burner motor from seizing up.
Do not operate the heating in enclosed spaces.
If the heater assembly does not start after switching on, procee-
das follows:
1. Check the fuel level.
2. Check the components for mechanical damage.
3. When switching to winter operation, check to see if there

isany summer diesel remaining in the fuel line.
4. Check the exhaust and combustion air lines.
5. Check the fuses in the fuse panel (Z 51 730).

Replace blown fuses if necessary.
(see Section 13.1.1 ”Checking the Fuses”.)
6. Switch the heating off and on again. Not more than twice. If-
the heating still fails to start, have the fault repaired in a work-
shop.
7. Check to see if a fault code is indicated in the display (6,

Z 39 292) of the heater (99, Z 39 292) (fault code table see
from page 11).
200−1−3130a_en 3/19
13
37.2 41.1 37.1
41.2
42
Z 51 730
6 99
1 2 3 4 5
Z 39 292
4/19 200−1−3130a_en
13.1.1 Checking the Fuses
The fuses inserted in the fuse panel are allocated as follows:

(Z 51 730)
Pos. 42 − Fuse 25 A: main fuse for heater assembly
Pos. 37.1 − Fuse 10 A: Control (e.g. heater timer)
Pos. 37.2 − Fuse 10 A: Control (e.g. heater timer)
Pos. 41.1 − Fuse 25 A: for cab fan
Pos. 41.2 − Fuse 10 A: for cab fan
If the 25 A fuse has blown, the heater assembly will start but no-
warm air will be circulated.
The blown fuse must be replaced by a new one after the inspec-
tion.
13.1.2 Fault Diagnosis with the Heating Timer

(Z 39 294)
If the control unit recognises a fault when the heater is switche-

don or during operation of the heater, the fault is displayed wit-
hin15 seconds by the heating timer with a letter F and 2−−digit
number.
Indication in the display: e.g. F 64 (current fault)
and flashing heater symbol
200−1−3130a_en 5/19
13
5
4
3
2
1
Z 39 294
6/19 200−1−3130a_en
(Z 39 294)
Calling up the faultmemory in the control unit with the hea-

tertimer
The electronic control unit can save up to 5 faults which are then
read off and displayed using the heater timer. The current fault is
always written in memory position F1.
Previous faults are stored in positions F2 − F5, the content of me-
mory position F5 is overwritten as required.
Calling up the fault memory
Condition: The heater is switched off.
Press button 3 − the heater is switched on − then press button 1,

hold pressed down and press button 2 within 2 seconds.
The heater flashes and the current fault is displayed.
Using buttons 4 and 5, the faults stored in memory positions F1

and F5 can be called up.
Fault code, fault description, comments are described on page

11.
Please note!
Not only the defective component, but also a defective current-

path leads to a fault display.
200−1−3130a_en 7/19
13
5
4
3
2
1
Z 39 294
8/19 200−1−3130a_en
(Z 39 294)
Disabling the control unit
D Overheating
If the heater overheats 10 x in sequence − fault F12 − F15 is
indicated in the display, i.e. the control unit is disabled.
D Too many start attempts

If the heater at tempts 10 starts without success − fault F50
− F50 is indicated in the display, i.e. the control unit is disa-
bled.
Reverse the disabling of the control unit by deleting the fault-

memory − after the cause of the fault has been
Condition: There is an electrical connection fromthe 12−pin

plug,terminal 10 of the heater timer to terminal 15 (ignition). Press
button 3 − the current fault F15 or F50 is displayed
− thenpress button 1, keep pressed down and press button 2 wit-
hin 2 seconds.
The heater timer is now in the program ”call up fault memory”.
Continue operation: (Bedienung fortsetzen):
Switch off ignition (terminal 15).
Press buttons 1 and 2 at the same time, keep pressed down, in-
addition switch on the ignition (terminal 15) and wait until the follo-
wingis shown in the display.
Display on scree- Display flas-
nafter ignition “ON” hing,heater symbol
notflashing
After 3 seconds the control unit is enabled, the heater then start-
sup.
Display on scree- Display flas-
nafter heater has hing,heater symbol
started notflashing
200−1−3130a_en 9/19
13
10/19 200−1−3130a_en
Fault code table

Fault- Fault description Comment
code
010 Overvoltage − shut−−off Overvoltage for at least 20 sec. uninter-
ruptedon the control unit −−> heater wi-
thoutfunction.
011 Low voltage − shut−−off Voltage too low for at least 20 sec. unin-
terruptedon the control unit −−> heater
without function.
012 Overheating (software − threshold value) Temperature on overheating sensor
>125 °C (257 5F).
014 Possible overheating recognised (evalua- Difference in the temperature levels of the
tionof difference) overheating sensor and the temperature
sensor > 25K.
Condition for this fault code display is that
the heater is in operation and the water-
temperature on the overheating sensor
has reached at least 80 °C (176 5F).
015 Operation disabled − system has overhea- The control unit is disabled.
tedmore than the permitted 10 times
017 Overheating detected − EMERGENCY Temperature on overheating sensor
OFF (hardware threshold value) >130 °C (266 5F).
020 Glow plug interruption
021 Glow plug failure − short circuit, overloa-
dor short circuit to ground
030 Speed of the combustion air fan motor Fan wheel or combustion air fan motor-
outside the permitted range blocked (frozen, clogged, restricted, ca-
blestrand brushing against end of shaft
...).
031 Combustion air fan motor interruption
032 Combustion air fan motor − short cir- Fan wheel or combustion air fan motor
cuit,overload or short circuit to ground blocked (frozen, clogged, restricted, ca-
blestrand brushing against end of shaft
...).
038 Relay control of the vehicle fan − interrup-
tion
039 Relay control of the vehicle fan − short cir-
cuit, overload or short circuit to ground
200−1−3130a_en 11/19
13
12/19 200−1−3130a_en

code
041 Water pump − interruption
042 Water pump − Glow plug failure − short
circuit, overloador short circuit to ground
047 Metering pump − short circuit, overload
orshort circuit to ground
048 Metering pump − interruption
050 Operation disabled as too many start at- Too many start attempts, the control devi-
temptshave been made (10 start at- ceis disabled.
tempts,in addition to a start repeat foreach
start attempt)
051 Time out − cold blowing During the start the flame probe detects a
temperature >70 °C (158 5F). for longer
than 240 seconds.
052 Safety time exceeded
053 Flame shut−off at control level “high” Warning
056 Flame shut−off at control level “low” If the flame is shut off from the ”high” or
”low” setting and more start at tempts are
permitted, the heater automatically at-
tempts a new start, if necessary with a
start repeat.
If the new start or the start repeat was
successful, the fault code display is dele-
ted.
Fault (because a further start at tempt is
not permitted).
060 Temperature sensor − interruption

061 Temperature sensor − short circuit, over-
load or short circuit to ground
064 Flame probe − interruption
200−1−3130a_en 13/19
13
14/19 200−1−3130a_en

code
065 Flame probe − short circuit, overload or
short circuit to ground
071 Overheating sensor − interruption
072 Overheating sensor − short circuit, over-
load or short circuit to ground
090 / Control unit defective External interference voltage
092 −
103
091 External interference voltage Malfunction of the control unit as a result
of interference voltages from the onboard-
power supply, possible causes: Poor bat-
teries, charging set, other fault sources;
remedy interference voltages.
200−1−3130a_en 15/19
13
”X”
14
14
Z 51 731
Z 51 732
16/19 200−1−3130a_en
13.2 Replacing the Heat Exchanger
The heat exchanger has a life span of 10 years and must be re-
placed after this period with an original spare by themanufacture-
ror by an approved workshop. The heater assembly should
thenbe labelled with the purchase date of the heat exchanger
and the words ”original spare part”.
13.3 Replacing the Fuel Filter
1. Pinch off the fuel hose between the tank and the fuel filter.
2. Release the two hose clips on the fuel filter (14).

(Z 51 731)
3. Pull the hoses from the fuel filter (”X”).
4. Insert the new filter.
13.4 Bleeding the System
The entire cooling system, including the heater assembly,

mustbe bled to ensure that no air bubbles remain following any
servicing of the system (repairs, changing the coolant). Allow the
superstructure engine to run until air bubbles no longer form in
the expansion tank
(Z 51 732).
All water connections (clamps) must be tightened to ensure they
are perfectly watertight and must be re−tightened after 20 opera-
ting hours.
200−1−3130a_en 17/19
13
4
Z 51 733
Z 51 734
18/19 200−1−3130a_en
13.5 Air Conditioning Equipment (optional)
The details in the manufacturer’s (Woelfe company) docu-

mentation must be adhered to.
This can be found in part 5 of this documentation.
13.5.1 Switching on the Air Conditioning Equipment
To lubricate the compressor, the air conditioning equipmentmust

be switched on for at least 10 minutes every month.
13.5.2 Servicing the Air Conditioning Equipment
Legend:
1 Inspection glass on the dryer/fluid container (Z 51 734)
2 Vaporiser/heat exchanger (Z 51 733)
3 Filter (Z 51 733)
4 Fan (Z 51 733)
5 Capacitor (Z 51 734)
At the beginning, in the middle and at the end of a cooling period,

the following servicing work must be carried out:
1. Check the V−−belt tension and compressor mounting.
2. Check the coolant fill−−up.
The coolant must flow bubble−free through the inspection glass

(1, Z 51 734) of the fluid reservoir when the engine is running and
the airconditioning equipment is at its highest setting (control
knob in the cab for temperature selection and fan level at maxi-
mum setting). After switching off, the fluid level in the reservoir
should sink again. This is the only way to ensure that the reservoir
is not over−filled.
The air conditioning equipment may only be filled by a spe-

cialist workshop.
13.5.3 Having the Air Conditioning Equipment Checked
In order to ensure that the air conditioning equipment remains-

fully operational, an inspection must be carried out at least once
a year by a specialist workshop. We recommend that this be car-
ried out at the beginning of the cooling period.
200−1−3130a_en 19/19
Electrical System 14
200−1−3140b_en 1/15
14
Z 46 535
Z 51 735
2/15 200−1−3140b_en
14 Electrical System
14.1 Checking the Lighting System
(Z 46 535)
Check that the system is functioning correctly and repair any

faults immediately. (For example: aerodynamic safety light, rota-
flare, position light).
14.2 Charging the Batteries
The batteries (1) are located on the left side behind the crane
operator’s cab (Z 51 735).
Observe the fluid level of the batteries. It may fall rapidly be-
cause the batteries are close to heat radiating crane compo-
nents.
For maintenance instructions, see the engine manufacturer’s

operating instructions.
14.3 Fuses
Fuses are located:

− In the main electrical unit of the cab.
− In the battery compartment.
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).
Remove the covering in order to reach the fuses.
200−1−3140b_en 3/15
14
4/15 200−1−3140b_en
− Superstructure (fuses)
OEC Value/A Location Page.Path Potential Function

F0001 50 Bat 5.1 30 Main fuse superstructure
A0303−F1 25 5.4 2 Ignition superstructure
A0303−F2 10 5.7 6 Charge control; quick stop engine; fuel
level sensor superstructure
A0303−F3 10 7.10 25 Voltage supply engine start (Mercedes
ADm2FR), diagnosis ignition
A0303−F4 10 7.13 34 Voltage supply engine control unit
(Mercedes ADm2FR) battery
(Mercedes MR) ignition
A0303−F6 10 7.8 20 Voltage supply quick stop, diagnosis
plug; quickstop
(Mercedes ADm2FR) ignition
(Mercedes MR) battery
A0303−F9 15 11.2 60 Lighter; horn; rotaflare lights; CTW
CEU SS lights; cabin platform
A0303−F10 10 12.5 66 Dashboard illumination
A0303−F11 10 13.6 287 Search light main boom
A0303−F12 10 12.8 71 Cabin light; radio: safety light
A0303−F13 10 15.3 335 Magnetic clutch compressor; blower
condenser
A0303−F14 10 15.8 92 Control unit air conditioning; relay
engine running
A0303−F15 10 16.2 101 Wiper front window; roof window; water
pump
A0303−F16 10 17.10 116 Cabin adjustment; touch screen PC;
levers; control component
A0701,A0702
A0303−F17 10 18.4 126 Touch screen PC
A0303−F18 10 17.11 117 Control component A0703,A0704
A0303−F19 10 17.12 118 Control component A0705,A0706
A0303−F20 2 44.4 376 Position sensors counterweight
OEC = Operating equipment code

CEU SS = Central electrical unit on superstructure
200−1−3140b_en 5/15
14
6/15 200−1−3140b_en
OEC Value/A Location Page.Path Potential Function

A0303−F21 10 28.3 154 SS Condition; outriggers, steering;
main boom extension
A0303−F22 10 34.2 185 Boom sensors; LS and pump
monitoring; SLS; hoist 2
A0303−F23 10 14.14 298 Heater fan
A0303−F24 10 14.8 73 Heater timer
A0303−F25 10 14.12 299 Fan
A0303−F26 10 17.4 114 Supply CAN components SS A0701,
A0703, A0705, can components
carrier; angle sensor
A0303−F27 10 18.11 127 Voltage supply CPU unit superstructure
CEU SS A0701, A0703, A0705
A0303−F28 25 42.2 247 Oil cooler
A0303−F29 10 44.2 263 Counterweight cylinders up /down
A0303−F30 10 14.9 334 Supply heater timer; control valve
temperature adjustment
A0303−F31 10 13.2 340 Working lights hoist
A0303−F32 10 15.1 357 Control pressure cut off; exhaust Valve
A0303−F33 2 17.6 153 CAN Sensors; pressure sensor luffing
Cylinder; angle Sensor Main Boom
Head
A0303−F34 15 28.2 378 Outrigger Illumination Carrier
A0303−F35 10 14.6 74 Control Unit Heater
OEC = Operating equipment code

CEU SS = Central electrical unit on superstructure
200−1−3140b_en 7/15
14
8/15 200−1−3140b_en
14.4 Checking the Contacts at the Slip Ring of the Rope

Winches and the Rotary Joint
Condensation water in the housing may cause the contacts to be-

come filthy or corrode.
1. Unscrew housing cover.
2. Check the slip ring contacts and clean them, if necessary.

Spray the contacts with Contact Spray
(Part no. 174 247 40).
3. Remove condensed water completely.
4. Screw on housing cover and check the respective functions

for proper operation.
200−1−3140b_en 9/15
14
10/15 200−1−3140b_en
14.5 Checking the Electric System
Preventative Measures Against Cable Fires
Cable fires in electric components and systems do not start due

to technical faults but as a result of carelessness or manipula-
tion of components or the circuit. Furthermore, it is required that
you use original parts when exchanging components in the
case of repair work.
It is very difficult to foresee the results of using non original parts
on the electric equipment. This can cause malfunctions in the
individual circuit.
Electric currents can only be recognised by their effects.
One effect is heat.
Each lead with currents normally only heats up minimally. If cur-

rents are not permitted and high, high temperatures and fires
can be the result.
In order to prevent this, fuses have been fitted in the individual
circuits. These fuses interfere with the electric current if it is
above the maximum permitted value.
Fuses protect the cables of the electric equipment if there is

a short circuit!
They may not be bridged, even for a short period of time!
Under no circumstances may larger fuses (higher Ampere
value) be used!
As a result, faulty fuses are one of the main reasons for cable
fires.
200−1−3140b_en 11/15
14
12/15 200−1−3140b_en
Other causes can be :

− non−permissible or defective cables or cable connectors,
(not sufficient cable cross sections)
− non−permissible or defective consumers or operating ele-
ments (relays, engines, switches, lamps, etc.),
− connecting additional consumers to a fuse (cable and fuse
overload),
− installation of a larger−sized or differently constructed battery
(fitting measurements of the battery box are exceeded, risk
of a short circuit due to ground contact at the +−pole),
− penetration of damp in components of the electric equipment
after cleaning with water or a steam jet,
− bad state of the electric equipment due to faulty maintenance
and inspections.
All these points mentioned − either individually or several

points together − can cause scorching or an open cable fire.
You will achieve effective protection by following the measures

listed in the following.
Preventative measures:
− The electric equipment of the crane must be inspected / chek-
ked regularly.
Faults such as loose connections or scorched cables must be
removed immediately. Their causes must be identified and
rectified.
− All electric leads, plug−in connections and terminals must be
checked for loose mountings and damage (to be recognised
by the oxidation on clips or at battery poles).
Rectify identified faults immediately.
Only electric specialists or trained persons under the su-

pervision and guidance of an electric specialist may
work on electric systems or operating equipment and
only in accordance with the electric technical regula-
tions.
200−1−3140b_en 13/15
14
14/15 200−1−3140b_en
− Only use original spare parts and original fuses with the pre-
scribed electricity strength! (See the spare parts catalogue or
electrical circuit diagram.)
Switch off the crane immediately if there are faults in the elec-
tric power supply!
− Do not modify or add or convert any part of the electric system
without the authorisation of the manufacturer!
− Check the electric equipment in accordance with the condi-
tions of use and the operating conditions as required; howe-
ver, it must at least once a year by a specialist!
For example:
Components
generator, mountings, state,
starter, starting aid for function, insulation,
diesel engine,
lighting equipment, must be protection against di-
leads, collectors, slip checked for: rect contact of active
rings, parts
heating, switches, re- protection for indirect
lays, fuses, contact of active
parts
batteries.
200−1−3140b_en 15/15
Fuel System 15
200−1−3150_en 1/3
15
2/3 200−1−3150_en
Fuel System 15
15 Fuel System
15.1 Checking the Fuel System
In addition to the visual inspections (e.g. checking the oil level),

the fuel system in the engine compartment should be inspected
once a year. The following points must then be checked:
− All system fittings must be free of leaks and sufficiently tighte-
ned.
− With re−usable fittings, the hose on the connection to the
hose nipple must be a tight fit. If in doubt, secure the hose ad-
ditionally with a hose clamp or replace the hose completely.
Lines and/or hoses damaged due to mechanical, thermal or

other effects must be replaced.
Ensure that all lines and hoses are an adequate distance

from hot engine parts (e.g. turbo charger) and are laid so that
they do not chafe.
The fuel system of the crane is connected with that of the crane
chassis. Only the fuel system of the crane chassis is filled (see
section 15 in part 4).
200−1−3150_en 3/3
Cooling, Air Intake and Exhaust System 16
200−1−3160c_en 1/25
16
87
Z 200 420 Z 51 736
1 2
Z 42 107 Z 4 965
2/25 200−1−3160c_en
16 Cooling, Air Intake and Exhaust System
16.1 Cleaning and Replacing the Air Filter Element
Never service the air filter with the engine running.
Clean the filter element as soon as indicator light (87) comes on

with the engine running (Z 200 420).
1. Undo the spring−loaded latches (1) and remove cover (2)

from the housing (Z 51 736 and Z 42 107).
2. Remove clogged filter cartridge (4) from the barrel (Z 4965).
3. Clean and check filter cartridge (4). Replace the filter car-
tridge if required.
After having been cleaned 3 times, or if it becomes contami-

nated with soot, the filter cartridge must be replaced. It must,
however, be replaced after 2 years at the latest.
200−1−3160c_en 3/25
16
Z 0 406 Z 0 125
Z 0 126 Z 0 129
4/25 200−1−3160c_en
16.1.1 Dry Cleaning
− Temporarily by tapping out
If the filter cannot be cleaned using compressed air or washing

with water, it is sufficient to tap out the dirt in the element.
Tap the front of the filter element repeatedly against the ball of the
hand to ensure that the dust is removed (Z 0406).
Be careful not to damage the filter element. Clean the surface of

the seals.
− With compressed air
Compressed air − max. 5 bar (73 psi)
Blow dry compressed air at an angle from the outside, then from
the inside (Z 0125 and Z 0126).
16.1.2 Wet Cleaning
First soak the filter element for 10 minutes in hand−hot water with
a small amount of non−foaming detergent (Mann−cleaner 053)
added. Then agitate the element in the washing solution for ap-
prox. 5 minutes.
Rinse well in clear water, shake and dry (Z 0129).
Under no circumstances should petrol, alkaline solutions

or hot liquids be used for cleaning.
200−1−3160c_en 5/25
16
Z 0130 Z 0131
6/25 200−1−3160c_en
16.1.3 Testing the Element
1. Insert bulb into the clean and dry filter element and test the
element. Throw away any damaged elements (Z 0130).
2. Wrap up elements which can be used again, and store them

in a clean and dry place (Z 0131).
When using compressed air to clean the elements, wear

protective goggles and clothing. Maximum air pressure
should not exceed 5 bar (73 psi).
Do not clean elements by beating or banging.

Elements with damaged folds or seals should not be reused.
It is advisable to keep spare elements ready, so that these can

be used while the other elements are being cleaned.
200−1−3160c_en 7/25
16
Z 27 837 Z 27 838
Z 501 336
8/25 200−1−3160c_en
16.2 Replacing the Safety Cartridge (Optional Equipment)
After the filter element has been cleaned three times, the safety
cartridge must also be replaced as follows:
1. Unscrew the fixing nut of the safety cartridge (Z 27 837).
2. Remove the safety cartridge (Z 27 838).
3. Clean the filter barrel of any dirt, but do not blow out with com-
pressed.
4. Fit a new safety cartridge.
5. The cartridge is fitted in the reverse order.
The safety cartridge must not be cleaned but must always be

replaced.
16.3 Air Filter Prefractionator (Optional)
(Z 501 336)
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.
200−1−3160c_en 9/25
16
Z 51 737
10/25 200−1−3160c_en
16.4 Cleaning the Cooling System

(Z 51 737)
Risk of burning and scalding.

Ensure that there is a cooling period of 60 minutes be-
fore carrying out the work described.
Pass compressed air through the cooling system against the air
flow, at a moderate pressure, to ensure that the cooling fins are
not damaged or spray with water until the cooling fins are comple-
tely free from impurities (dust, insects, etc.)
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.
In this instance the cooling system must be thoroughly cleaned,

whereby the entire cooling circuit is degreased, decalcified and
derusted.
Further details can be found in the engine manufacturer’s opera-

ting instructions.
The radiator guard must be removed to clean the cooling ele-

ments.
200−1−3160c_en 11/25
16
Z 51 738
12/25 200−1−3160c_en
16.5 Checking the Coolant Level and Topping Up as Ne-

cessary
Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. Acci-
dents may occur.
1. Turn the cap (Z 51 738) on the expansion tank to the first

notch and release excess pressure.
2. Continue to turn up the second stop, remove cover.
The cooling system is filled correctly when the coolant, according

to system design, is level with the rim of the filler neck or with the
marker on the filler neck.
− Before the onset of winter, check the coolant for anti-

freeze.
− See also the engine manufacturer’s operating instruc-
tions.
200−1−3160c_en 13/25
16
Z 51 738
14/25 200−1−3160c_en
16.6 Replacing the Coolant with Anti−Freeze

(Z 51 738)
The coolant should be mixed with a corrosion proof anti−freeze

throughout the year (see operating instructions for the engine).
The anti−freeze does not have any negative effect on the refined
coolant.
The coolant must be changed as soon as this is necessary

e.g. in the case of repair. The coolant must, however, be
changed at least every two years.
1. Switch off the engine.
Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. Acci-
dents may occur.
2. To be safe, slowly open the cover on the expansion tank up

to the first stop so that any overpressure can be released.
Only then turn the cap further to the 2nd notch and remove.
200−1−3160c_en 15/25
16
Z 46 539
16/25 200−1−3160c_en
3. Drain the engine and the radiator (Z 46 539).

− To drain the engine, the drain plug on the crankcase and,
if fitted, the drain plug on the oil heat exchanger should be
opened.
− To drain the radiator, open the radiator drain plug.
4. When the cooling system has been drained, all the drain
plugs should be screwed back in again.
200−1−3160c_en 17/25
16
Z 51 738
18/25 200−1−3160c_en
5. Fill the cooling system with fresh coolant.
When filling the cooling system make sure that you do not
create any air pockets. Air captured in the system can cause
engine damage.
− Use water free of minerals which can cause boiler scale. Do

not use softened water.
− Pause several times when filling the system so that the coo-
lant is given time to penetrate and settle. This also enables
enclosed air to escape.
− Add coolant until it reaches the marking in the filler neck
(Z 51 738).
6. Start the engine and allow it to idle for a couple of minutes

with the expansion tank open. If necessary, top up the coo-
lant.
7. Replace the cover and close the heating valves.
200−1−3160c_en 19/25
16
130.1 130.2 130.3
3
130.4
130.7 130.5
4
130.6
2 1 380V
130
Z 200 377 Z 075 373
”Y” ”X”
Z 56 116
20/25 200−1−3160c_en
16.7 Maintaining the Diesel Exhaust Particulate Filter

(Optional)
When the display gauge shows a pressure of more than

150 mbar (2 psi) (130, Z 200 377), the diesel soot particle filter
must be burned clean.
Information on the display gauge can be found in section 5 “En-
gine” of the superstructure operating manual.
Procedure for burning clean
1. Connect the burn−off unit’s E−cable (1, Z 075 373) to the

socket (X, Z 56 116) on the crane superstructure.
2. Connect the air hose (2, Z 075 373) to the coupling (Y,
Z 56 116) on the crane superstructure.
3. Connect the electric cable (380 V, Z 075 373) from the bur-
ning unit to the power network.
4. Switch on the power switch (3, Z 075 373) on the burn clea-
ning unit.
The ammeter (4, Z 075 373) indicates whether heating electricity

flows.
5. After 8 hours, the procedure for burning the filter clean is

completed and the ammeter displays “0”.
The cleaning procedure must not be interrupted. The current

and air supply must be completely uninterrupted during the
cleaning procedure.
6. Switch off the power switch (3, Z 075 373) on the burning de-
vice.
7. Disconnect the electric cable (380 V. Z 075 373) from the

power network.
8. Disconnect the electric cable (1, Z 075 373) and air hose (2,
Z 075 373) from the crane superstructure.
9. Stow the cleaning equipment away on the crane
200−1−3160c_en 21/25
16
6 7
Z 075 374
22/25 200−1−3160c_en
Servicing the filter element
The filter element must be cleaned after 1500 operating hours but
at least once per year to remove fuel and lubricant residues.
1. Burn the filter clean as described in the previous paragraph.
2. After burning clean, leave the filter to cool off for 3−4 hours.
3. Release the two clasps (6, Z 075 374 principle drawing) and
remove the filter element.
4. Place the removed, cooled filter element in a vertical position

and rinse through from the top with warm water (do not use
compressed air) until the water is clear.
Dispose of the cleaning water using oil separators in an environ-

mentally friendly manner.
5. Leave the filter element to drip dry.
6. Refit the filter element, using new seals if required.
7. Close the two clasps (6, Z 075 374 principle drawing).
200−1−3160c_en 23/25
16
24/25 200−1−3160c_en
16.7.1 Troubleshooting/check list
Heating element:
The ammeter rea- − Is the burning unit If both are okay, the
ding for the current is connected correctly? heating element is
too low − Are the fuses okay? defective.
(setpoint 7.8 A).
Air supply:
Incomplete burning Are the air supply com- Check the air supply
procedure ponents blocked or components.
dirty? Only use the original
connecting pieces
from the manufactu-
rer.
Timer:
Burning time is too − Timer setting correct? The timing relay (ti-
short and/or the ex- mer) for the heater
haust counterpres- element must be set
sure is too high. to 6 hours.
The timing relay (ti-
mer) for the air pump
’ must be set to 8
hours.
− Are the heating ele-
ment and air supply
functioning correctly?
− Was the voltage a
constant 380 V during
the burning procedure?
− Is the infeed area of
the soot filter free of
soot following the bur-
ning clean process?
− Has the diesel engine The smoke level
been serviced? must not exceed 2.5
Bosch units without
the soot filter.
− Has the soot filter
been cleaned in accor-
dance with the servicing
instructions?
200−1−3160c_en 25/25
Piston Rods 17
17 Piston Rods
17.1 Exposed Chrome Surfaces − Applying Protective

Grease
Despite being of the highest quality, surfaces may be susceptible

to corrosion in an aggressive environment. If the crane is out of
operation for more than one day, exposed surfaces should be
protected against corrosion by applying acid free protective
grease (Recommended: see section 2).
200−1−3170a_en 1/1
Crane Operator’s Cab 18
200−1−3180a_en 1/5
18
Z 40 175
2/5 200−1−3180a_en
18 Crane operator’s cab
18.1 Lubricate the tilt cylinder
Grease the foot bearing and piston rod bearing on the tilt cylinder
(5) of the crane operator’s cab via the lubricating nipple on each
(Z 40 175).
200−1−3180a_en 3/5
18
Z 46 540
4/5 200−1−3180a_en
18.2 Check the windscreen washing assembly
Check at least once a week that the windscreen washing assem-

bly is functioning properly.
18.3 Fill up the supply tank of the windscreen washing as-

sembly
The supply tank of the windscreen washing assembly must al-

ways be filled with water and if necessary with a little cleaning
agent (Z 46 540).
Before the onset of winter, a suitable amount of antifreeze

(depending on the temperature) must be added to the water.
18.4 Lubricating the Guide Rail of the Sliding Door
Using a paintbrush, lightly cover the guide rail of the sliding door
at the top and the bottom with grease.
200−1−3180a_en 5/5
Visual Inspections Superstructure 19
200−1−3190a_en 1/3
19
E A
D
C
F
Z 200 620
2/3 200−1−3190a_en
Visual Inspections Superstructure 19
19 Visual Inspections Superstructure
(Z 200 620)
− Check all caps and covers for damage, check loose or

missing screws.
A − Check slew ring − external toothing for intact lubricating
film.
B − Check hydraulic system for leaks and damage as well as
the oil level.
C − Check engine for oil and fuel leaks and contamination.
D − Check cooler for contamination.
E − Check instruments and displays for damage.
F − Checks ropes for intact lubrication;
check ropes, rope end connections, sheaves as well as
winches for damage.
G − Check batteries to ensure they are clean and dry and for
firmly fitted clips.
H − Check the lighting system for damage.
I − Check the function of the windscreen washing assembly
at least once a week.
The supply tank must always be filled with water and
some cleaning agent, if required.
Before the onset of winter, a suitable amount of

antifreeze (depending on the temperature) must
be added to the water.
200−1−3190a_en 3/3
Special Equipment 20
200−1−3200_en 1/3
20
Z 51 936
2/3 200−1−3200_en
Special Equipment 20
20 Special Equipment
20.1 Central Lubricating System

(Z 51 936)
20.1.1 Filling up the container
Always fill the container (2) of the central lubricating system regu-
larly up to the ”Max.” mark using the filling nipple (4). To do so, use
a commercial grease pump or lever press.
The grease must not be contaminated and may not change

its consistency throughout the course of time.
Never exceed the max. level.
Switch the pump on several times during filling by activating the

key (5).
The lubricants container is filled with high pressure grease (see

section 2 of these maintenance and lubrication instructions). The
pump may require up to 10 minutes running time after it has been
completely emptied in order to achieve the full pump perfor-
mance.
20.1.2 Checking the system
Activate one or several additional lubrication processes and then

check:
− the sealing of the leads
− lubricants leakage at all lubricating points
− time setting of the control system
20.1.3 Cleaning the system
Use petroleum ether or kerosene to clean the system.
The plastic material of the pump container (2) can be dama-

ged if it comes into contact with triethylene dichloride, ace-
tone or other similar cleaning and diluting fluids.
200−1−3200_en 3/3
Examinations of the Crane 22
22 Examinations of the Crane
In order to keep the crane in a safe operating condition, the

operator must take the relevant precautions. An important tool is
regular inspections. These inspections may only be carried out
by specialised employees (ISO 9927−1), i.e. “technical experts”
or “appraiser”.
A technical expert is someone who due to his / her professional

training and experience has sufficient knowledge of cranes and
is familiar enough with the appropriate governmental health and
safety regulations, accident prevention regulations and the
generally recognised regulations of the technology to ascertain
the operational safety of cranes (BGG 905, section 3.2).
An appraiser is someone authorised by the employer’s liability

insurance association or an authorised expert of the technical
surveillance (BGG 905, section 3.1).
22.1 Recurrent Inspections of the Crane
It is the responsibility of the crane operator to have the crane

inspected according to the applicable international and national
regulations at regular intervals. This responsibility is described in
several national regulations regarding the prevention of
accidents (in Germany: BGV D6 and BGV D8) and in
International Standards (for example ISO 9927, ISO 12480,
BS 7121, CSA Z150, ASME B30.5 or others).
The following applies for Germany: Inspections to be performed
yearly by a technical expert, and at least every four years by an
appraiser (yearly, after 12 years of operation).
During this inspection the remaining theoretical service life

of the winches (in accordance with BGV D8, ISO 12482−1,
annex A). To do so, observe the instructions in the relevant
section 22.1.3.1, from page 53.
200−1−3220d_en 1/109
22
2/109 200−1−3220d_en
The following information is based upon the regulations of the

accident prevention regulations ”Crane” (BGV D6) with regard to
regular routine crane inspections.
The section 22.1.7 contains a check list to help the inspector for
the repeated inspections.
This check list is only a general guide. It is not type−related and
does not cover the complete range of all designs.
Inspections according BGV D6 do not replace the applicable

national regulations.
Carrying out the inspection
The routine inspection is primarily a visual and functional check,

mainly comprising:
− Checking the identity of the crane with the information in the
inspection book (crane log book).
− Checking the condition of the components and equipment
with regard to damage, wear, corrosion or other changes.
− Checking the safety equipment and the brakes for
completeness and effectiveness.
− Checking the state of the carrying equipment with regard to
damage, wear, corrosion or other changes.
− Checking to ensure there are decals and that they are
complete and legible.
The results of these inspections must be recorded in the log

book and must be certified by the inspector.
Specialists and trained personnel inspect the crane as matter of

their own responsibility.
After any major changes to the crane or after repair work on

carrying parts, the operator must authorise an inspection by
a technical expert before resuming operation.
200−1−3220d_en 3/109
22
4/109 200−1−3220d_en
The following must be checked:
1. Supporting structures
1.1 Chassis and Superstructure

Components: Checking:
Frame, for: cracks,
Outriggers, deformation,
Slewing rim, wear,
Axles, mountings and locks of removable
Axle suspension, parts,
Wheels corrosion and corrosion protection,
warning paint,
assignment of cables and hoses
1.2 Crane equipment

Boom, for: cracks,
Frame, deformation,
Erecting struts, wear,
Guides, mountings and locks of removable
Braces, parts,
Overextension lock, easy movement of the supports and
Stay bars, guides,
Bracing rod assembly and rope reeving,
corrosion and corrosion protection,
elongation,
plastic deformation,
paint,
1.3 Counterweight
Counterweight to make sure all parts are complete
sections, and properly attached
Base plate
200−1−3220d_en 5/109
22
6/109 200−1−3220d_en
2. Power units
2.1 Drives
Final drive, for: mountings and locks of removable
Slew gear drive, parts,
Crane drive, state, function and noises,
Winch drive jerk−free driving and stopping,
idling,
wear of coupling and brakes,
effectiveness of reverse locks,
wear of the spline shaft connection,
2.2 Rope drives

Rope drums, Configuration and storage of rope
Rope sheaves, sheaves, rope guide rollers and rope
Rope guide rollers sheaves (sheave grooves, flanged
wheels, wear)
2.3 Hydraulic equipment

Hydraulic pumps, Attachment,
Hydraulic motors, condition,
Cylinders, function,
Valves, noises,
Cases, leaks,
Hydraulic hydraulic oil condition and quantity,
accumulator, filling pressures
Leads,
Filters
2.4 Pneumatic equipment

Compressors, Attachment,
Engines, condition,
Cylinders, function,
Valves, noises,
Pressure tanks, leaks
Leads,
Filters
200−1−3220d_en 7/109
22
8/109 200−1−3220d_en
2.5 Electrical equipment
Alternators, motor, Attachment,
Resistors, condition,
Brake vents, function,
Lighting equipment, insulation,
Heating, guard against direct contact with
Leads, collector, active components,
Switches, protectors, guard against indirect contact
Fuses, installation
Batteries,
Lines
Warning devices
2.6 Actuating equipment final drive
Coupling, for: state,
Shifting, function,
Adjustable engine, idling,
Steering, bringing to a standstill,
Brakes easy movement,
play of linkage and cables (dead
gear),
display of the monitors, lamps and
signals,
designation,
brake tests
2.7 Actuating equipment crane drive
Slew gears, for: state,
Hoist gears, function,
Boom derricking idling,
gears, bringing to a standstill,
Brakes easy movement,
play of linkage and cables (dead
gear),
display of the monitors, lamps and
signals,
designation,
brake tests with load (inspection load
in the range of the load capacity)
200−1−3220d_en 9/109
22
10/109 200−1−3220d_en
2.8 Other actuating equipment

Outriggers, for: condition,
Additional function
equipment,
Axle interlock
3. Lubrication
3.1 Oil baths

Transmissions adequately filled,
oil loss
3.2 Lubricating points

Lubricating nipple accessibility,
recognisibility, markings
200−1−3220d_en 11/109
22
12/109 200−1−3220d_en
4. Ladders, protective devices, safety equipment, signs
4.1 Ladders
Ladders Attachment and condition
4.2 Protective devices

Panels, Attachment and condition
Covers, completeness,
Guides effectiveness
4.3 Safety equipment

Load limit device, for: mountings and condition,
Emergency limit completeness,
switch equipment, function
Warning devices,
Locking devices,
Radius indicator,
Tilt indicator,
Air speed indicator,
Wind safeguard
4.4 Signs
Signs Completeness and legibility
200−1−3220d_en 13/109
22
14/109 200−1−3220d_en
22.1.1 Inspection of Load−bearing Steel Constructions
The load−bearing steel constructions must be carefully checked

at least during the prescribed repeated crane inspection (at
least1 x a year).
It is important to check the welded seams in particular.
The principle drawings listed in the following are examples for

load−bearing welded constructions. Inspections must be carried
out at the connections / zones around the points / welded seams
marked by arrows.
The inspector is personally responsible for carrying out the

inspection, as well as for content and extent. The following
principle depictions only serve as examples and additional
aids to the inspector. They make no claim to completeness.
The crane is dimensioned for erection operation according to

ISO 4301−1 and EN 13000.
If the crane was subjected to excessive stress during operation,

e.g. due to an exceptional hit, there must be an immediate
inspection of the load−bearing components.
If damage, e.g. cracks, are found anywhere in the steel

construction, the extent of the damage must be determined by
suitable specialists using recognised material examination
methods (for example: magnetic powder, ultrasound or x−ray
inspections) − with a subsequent decision on the possibility and
type of repair work.
200−1−3220d_en 15/109
22
Z 54 326
16/109 200−1−3220d_en
Frame Chassis
(Z 54 326)
200−1−3220d_en 17/109
22
Z 56 212
18/109 200−1−3220d_en
Front Frame of the Carrier

(Z 56 212)
200−1−3220d_en 19/109
22
Z 54 327
20/109 200−1−3220d_en
Outriggers
(Z 54 327)
200−1−3220d_en 21/109
22
Z 59 730
Z 59 731
22/109 200−1−3220d_en
Frame Superstructure 1
(Z 59 730)
(Z 59 731)
200−1−3220d_en 23/109
22
Z 59 732
Z 59 733
24/109 200−1−3220d_en
(Z 59 732)
(Z 59 733)
200−1−3220d_en 25/109
22
Z 61 472
26/109 200−1−3220d_en
Main Boom
(Z 61 472)
200−1−3220d_en 27/109
22
Z 61 473
Z 61 474
28/109 200−1−3220d_en
Main Boom Extension − Basic Boom

(Z 61 473)
Main Boom Extension − Tip Section

(Z 61 474)
200−1−3220d_en 29/109
22
Z 61 475
Z 61 476
30/109 200−1−3220d_en
Main Boom Extension − Intermediate Sections

(Z 61 475, Z 61 476)
200−1−3220d_en 31/109
22
Z 61 477
Z 61 478
32/109 200−1−3220d_en
Fly Jib − Foot Section

(Z 61 477)
Fly Jib − Reducer

(Z 61 478)
200−1−3220d_en 33/109
22
Z 61 479
Z 61 480
34/109 200−1−3220d_en
Fly Jib − Intermediate Sections

(Z 61 479, Z 61 480)
200−1−3220d_en 35/109
22
Z 61 481
36/109 200−1−3220d_en
Fly Jib − Top Piece

(Z 61 481)
200−1−3220d_en 37/109
22
Z 61 482
Z 61 483
38/109 200−1−3220d_en
Fly Jib − Head Connecting Piece

(Z 61 482)
Fly Jib − Luffing Mast Connecting Piece

(Z 61 483)
200−1−3220d_en 39/109
22
Z 61 484
Z 61 485
40/109 200−1−3220d_en
Fly Jib − Luffing Masts

(Z 61 484, Z 61 485)
200−1−3220d_en 41/109
22
Z 61 486
Z 61 487
42/109 200−1−3220d_en
Fly Jib − Flying Bridle

(Z 61 486)
Fly Jib − Bracing Rods

(Z 61 487)
200−1−3220d_en 43/109
22
Z 61 488
Z 61 489
44/109 200−1−3220d_en
Head Roller
(Z 61 488)
Runner
(Z 61 489)
200−1−3220d_en 45/109
22
Z 61 470
Z 61 471
46/109 200−1−3220d_en
SuperLift
(Z 61 470, Z 61 471)
200−1−3220d_en 47/109
22
Z 51 910
48/109 200−1−3220d_en
22.1.2 Inspection of the Disc Wheels (Rims)

(Z 51 910)
The rim of a wheel is an important component of the mobile crane

which is relevant to safety.
In addition to the annually prescribed inspection of the crane,
there must be a crack inspection of the rims. If it is determined that
cracks are starting to form or if cracks are discovered, the
affected rims must be replaced immediately.
After a running stretch of max. 40 000 km (24 000 miles), the
crane operator must carry out a running observation.
Especially the rims should be inspected for cracks in the basic
material and in the zones marked with arrows.
200−1−3220d_en 49/109
22
50/109 200−1−3220d_en
22.1.3 Inspection of the Winches
An external visual inspection is not sufficient. The service life of

the winches can be reduced by bad servicing, defective seals,
unprofessional operation or overloading. For this reason a
specialist must carry out inspections in accordance with the
following regulation.
Inspections
− Inspections interval − every 1000 operating hours, at least

once a year
− Check the oil level
− Check for colouring of oil
− Check for solid foreign materials − this check must be carried
out by a qualified lab
− Visual inspection
− Check of the brakes on the transmission of the winches
− Check of the spline fitting “engine / brake / transmission”
During the annual crane inspection, the used portion of the

theoretical period of use of the winches must also be
determined. The crane operator must employ a specialist for the
purpose if necessary.
Where accident prevention regulations of the German

employer’s liability insurance association apply, this is
required by law.
Outside of the validity period, the crane manufacturer
recommends that the procedures listed also be observed.
Risk of accidents! Risk of fatalities!

Not complying with these standard settings for
determining the remaining period of use of the winch may
result in unnoticed expiration of the winch and sudden,
unexpected winch failure. This could result in property
damage accidents and fatalities!
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22
52/109 200−1−3220d_en
22.1.3.1 Theoretical Service Life
The design engineer has assumed certain operating conditions

in calculating and dimensioning the winches on your crane.
The winches of your crane are graded as follows (ISO 4301/1,
FEM 1.001, DIN calculation parameters for drives):
Power unit group: M........
Load spectrum: Q....... (L.......)
Load spectrum factor: km = ..........
A theoretical service life, D, is thus calculated.
The individual values can be taken from the table ”Monitoring the
winches” in the crane log book.
The theoretical service life must not be equated with the real
(actual) service life of a winch.
The real period of use of a winch is additionally influenced
by many external conditions, for example:
− Overloading through not using the crane as intended.
− Insufficient maintenance: the oil is not changed in good
time.
− Maloperation such as extreme acceleration or dece-
leration of the load or the load falling into the ropes.
− Maintenance mistakes such as using the wrong oil,
incorrect oil fill or contamination when changing the oil.
− Mounting mistakes when undertaking repairs or
maintenance.
− Leaks not taken into consideration.
− Incorrectly adjusted safety equipment.
− Concealed damage caused by accidents.
− Extreme ambient conditions such as low or high
temperatures, aggressive atmosphere, dust and dirt.
200−1−3220d_en 53/109
22
Z 29 551 Z 29 552
Z 29 553 Z 29 554
54/109 200−1−3220d_en
22.1.3.2 Actual Operating Conditions

Before the spent share of the theoretical service life of the
winches can be determined, the actual operating conditions
(load spectrum) and the operating hours of the hoists per
inspection interval must be determined.
22.1.3.3 Determining the Operating Conditions (Load

Spectrum)
The load collective of the crane is divided into groups (see also
ISO 4301/1, FEM 1.001).
From knowledge of the actual operating conditions, one of the
load spectrums listed below must be selected and recorded in the
crane log book for the relevant inspection interval.
Load Definition Shares of operating time Load
spec- spec-
trum trum
class factor
(Km)
light Power units or parts thereof 10% of operating time
Q1 subject to highest loading under highest load (dead
L1 only as exception but load + 1/1 load capacity)
routinely only subject to 40% of operating time
very low loading under dead load + 1/3 load 0.125
cap.
50% of operating time only
under dead load
see figure Z 29 551
medium Power units or parts thereof 1/6 of operating time under
Q2 subject to highest loading highest load (dead load +
L2 quite often but routinely 1/1 load capacity)
only subject to low loading 1/6 of operating time under
dead load + 2/3 load cap.
1/6 of operating time under
0.25
dead load + 1/3 load cap.
50% of operating time only
under dead load
see figure Z 29 552
heavy Power units or parts thereof 50% of operating time
Q3 often subject to highest under highest load (dead
L3 loading and routinely load + 1/1 load capacity)
subject to medium loading 50% of operating time only
0.5
under dead load
see figure Z 29 553
very Power units or parts thereof 90% of operating time
heavy regularly subject to loading under highest load (dead
Q4 in the realm of highest load + 1/1 load capacity)
L4 loading 10% of operating time only
1
under dead load
see figure Z 29 554
200−1−3220d_en 55/109
22
56/109 200−1−3220d_en
22.1.3.4 Operating Hours of the Hoists per Inspection Interval
Determine the effective number of operating hours per inspection

interval (Ti). This must be recorded in the crane log book for the
relevant inspection interval.
As a rule, the hoist winch share of the total operating hours for the
superstructure is 20 % for mobile cranes used for erection
operation.
If hoist rope reevings are correspondingly reduced for loads

beneath the maximum loads of the selected load table, and
the permitted rope load therefore almost completely used,
this must be taken into consideration when calculating the
winch load.
200−1−3220d_en 57/109
22
58/109 200−1−3220d_en
22.1.3.5 Determining the Spent Share of the Theoretical

Service Life of the Winches
For an inspection interval i (max. 1 year in accordance with

ISO 9927−1 or BGV DB) the used proportion of the theoretical
service life of the winches is calculated according to the following
formula:
kmi
Si = x Ti
km
Si = spent share of theoretical service life
Kmi = factor of the load collective in the inspection interval
”i” in accordance with section 22.1.3.3
Km = load spectrum factor which formed the basis of
calculation for the winch
(here: Km = 0.125)
Ti = effective operating hours in the inspection interval ”i”
in accordance with section 22.1.3.4
This used proportion is deducted after each inspection interval

from the remaining theoretical service life (see example in section
22.1.3.6). Observe the following:
− If a theoretical service life remains which is insufficient for
the next operating period, a general overhaul of the
winches must be carried out.
− If the theoretical service life, D, is achieved, the winch must
only be continued to be operated following a general
overhaul .
In each case a general overhaul is required at the latest 10

years after the crane is placed in operation.
The general overhaul must be arranged by the operator and

carried out by the manufacturer (or persons authorised by
the manufacturer) and must be entered in the crane book.
A new theoretical service life is then declared by the

manufacturer or persons authorised by the manufacturer
following the general overhaul.
The max. time period until the next general overhaul is,
however, at the most 10 years.
200−1−3220d_en 59/109
22
Z 60 292
60/109 200−1−3220d_en
22.1.3.6 Documentation
(Z 60 292)
The crane operator is responsible for documenting how the spent

share of the theoretical service life for the winches has been
determined.
The forms required for this purpose are enclosed in the crane log
book:
− Sample tables (Z 60 292)
− Tables for each winch.
The theoretical remaining service life of each winch must be
documented using these tables.
The crane user is liable for the correctness of the

information!
The specimen table is clarified by the following example:
Inspection No. 1 (year 1)
The crane has been used for erection purposes for the past year:
Load spectrum L 1, i.e. Km1 = 0.125
800 h are recorded on the superstructure hour meter. The winch

has been in operation for approx. 20% of this time, i.e T1 = 160 h.
The spent share S1 of the theoretical service life for the first
inspection is thus:
km1 0.125
S1 = x T1 = x 160 h = 160 h
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
200−1−3220d_en 61/109
22
Z 60 292
62/109 200−1−3220d_en
(Z 60 292)

The crane has been used for harbour unloading operation:
Load spectrum L 3, i.e. Km2 = 0.5.
2000 h are recorded on the superstructure hour meter, i.e. during
this period: 2000 h − 800 h (used in first year of operation) =
1200 h.
The winch has therefore been in operation for approx. 40 % of
this time, i.e. T2 = 480 h.
The spent share S2 of the theoretical service life for the second
inspection interval is thus:
km2 0.5
S2 = x T2 = x 480 h = 1920 h
km 0.125
Theoretical remaining service life after the second year:

D2 = D1 − S2 = 3040 h − 1920 h = 1120 h

The crane has been used for erection operation and occasionally
for harbour unloading operation:
Load spectrum L 2, i. e. Km3 = 0.25.
3000 h are recorded on the superstructure hour meter, i.e. during
this period: 3000 h − 2000 h (used in the first two years of
operation) = 1000 h.
The winch has been in operation for approx. 30 % of this time, i.e.
T3 = 300 h.
The spent share S3 of the theoretical service life for the third
inspection interval is thus:
km3 0.25
S3 = x T3 = x 300 h = 600 h
km 0.125
Theoretical remaining service life after the third year:

D3 = D2 − S3 = 1120 h − 600 h = 520 h
Calculations must now be carried out to determine whether the
remaining theoretical service life is sufficient for the next
operating period. If this is not the case, a general overhaul must
be carried out (see section 22.1.3.5).
200−1−3220d_en 63/109
22
“y” “y1” + “y2” Z 54 325
64/109 200−1−3220d_en
22.1.4 Hooks
(Z 54 325)
The hooks must be checked by a specialist once a year. This

should prevent accidents because faults will be determined early
on. Any faults that are discovered must be documented as well
as their rectification. Then you must check whether the
determined faults have been rectified.
Inspection and Surveillance Measures
Check for deformation, localised cold forming and compression

in the pincer mouth, cracks, wear, rusting.
Lock fitting of the hook nuts.
Deformation
If the hook jaw expands more than 10 % compared to the starting

dimension “y” or “y1”+”y2”, the hook must be replaced.
The starting dimension “y” or “y1”+”y2” is recorded on the hook.

It is measured from grain to grain.
Corrosion
Threads and the operated shaft smut be checked for corrosion

and wear. To do so, the hook nut must be unscrewed from the
shaft.
If aftertreatment is needed to remove the corrosion, the thread

core diameter may not be exceeded by more than 5 % by this
process. Otherwise, the hook must be replaced.
With older hooks the main dimensions must be compared with

the data in DIN 687, 689, 699, newer hooks with the data in
DIN 15401 and 15402 with regard to jaw width, main bending
cross−section, thread core diameter.
200−1−3220d_en 65/109
22
y y
x
Z 160 543
66/109 200−1−3220d_en
22.1.5 Inspection of the Sheaves

Check all rope sheaves for damage as for example notches or

similar damage, and check if the bearings are properly seated
(running smoothly).
Sheaves with such damage must be replaced immediately.
All check all plastic sheaves for wear:

− Lower tread ”X” max. 3 mm (0.12 in)
Dimension ”X” = Difference between ∅ new lower tread and
∅ actual lower tread.
− Side tread ”Y” max. 5 mm (0.2 in)
Dimension ”Y” measured between rope (S) and tread of
sheave.
If the sheave is worn up to the wear limit, it must be replaced.
Risk of accidents!
200−1−3220d_en 67/109
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68/109 200−1−3220d_en
22.1.6 Inspection of the Ropes
General
A cable is a basic consumer item with a limited life span. Many

characteristics of a cable change throughout its period of use. For
example, its breaking force initially increases slightly with
accrued operating time before falling rapidly once a maximum
value has been reached.
This breaking force decrease is due to an increased loss of the

metal percentage caused by wear and corrosion which occur with
wire breakage and structure changes of the cable.
In the cable, the load−bearing elements are connected in

parallel. This is why a cable can still be safe for operation even
if a large number of wires have broken.
One of the purposes of a cable inspection is to monitor the

continuous increase in the amount of wire breakage, so that the
cable can be removed before a state is reached where
operational safety is impaired.
A further purpose of the rope inspection is to spot abnormal cable

damage, which as a rule is normally caused by external
influences.
This facilitates, on the one hand, replacement of the cable in
good time and, on the other hand, helps to spot weak points in
the rope drive, enabling measures to be taken which will prevent
similar damage recurring.
200−1−3220d_en 69/109
22
70/109 200−1−3220d_en
Intervals
Standard ISO 4309 recommends the following:

− daily visual check of the cables and rope end fastenings for
any possible damage
− regular check of the cables by trained specialists to ensure
an operationally safe condition
− Special inspections:
− after exceptional loading or supposed invisible damage
− after longer periods of standing still
− when lifting devices have been removed for a change in
location, before beginning operation at the new operating
location
− after every accident or case of damage occurring in
connection with the rope drive.
Scope of the inspection
Wear from friction, rust markings, rusting, crushing points,

loosening of outer wire threads, clustering of ropes, formation of
loops from cords or wires, twisting, corkscrew formation, kinks,
number of visible wire breakages, clusters of broken wires, cord
breakage.
Determine the rope diameter in relation to the condition of the
sheaves on the drums and rollers.
Fasten to ensure the rope does not spring out.
Check the condition of the fastening of the ends of the rope.
Protect against the effects of heat from fire operations.
It may be necessary to dismantle components before an

accurate assessment of the load−bearing equipment can be
made. Ropes must be inspected over their entire length during
inspection which includes those sections normally concealed,
e.g. bearing surfaces on compensating sheaves, pressure points
under rope clamps and fastening devices at the ends of ropes.
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22
72/109 200−1−3220d_en
Criteria for removal
A rope must be removed when one or several of the following

points are fulfilled. See also the relevant DIN standards.
a) Wire breakage
A cable must be removed when the permitted wire breakage

number is in accordance with DIN 15 020 or exceeds it.
The cable must be removed if there are wire breakage clusters

or if a cord breaks.
b) Rope wear
If the rope diameter in cables is decreased by 15 % or more

during longer journeys compared to the nominal value, the cable
must be removed.
c) Corrosion
You can determine corrosion of the outer rope wires with a visual
inspection. However, it is difficult to determine corrosion on wires
that cannot be seen externally.
Corrosion can lead to a decrease of the static breaking force of

the cable due to reduction of the metallic rope average as well as
a decrease of the operational stability due to corrosion pits.
d) Abrasion
Abrasion of the rope wires can be ”interior abrasion” which is

caused by movements of the cords and wire against each other
when bending the cable up and down or ”external abrasion”
which is caused by movements between the cable and the
sheave or by dragging the cable on the ground or over the
material to be conveyed.
Abrasion is encouraged if lubrication is insufficient or lacking or

by the existence of dust. If the rope diameter is decreased by
10 % or more compared to the nominal value, the cable must be
removed even if no wire breakage was discovered.
200−1−3220d_en 73/109
22
Z 1367
Z 1368
Z 1369
74/109 200−1−3220d_en
e) Rope deformation
Deformation of the cable is visible change to the rope structure.

Deformation generally also causes the rope configuration to
loosen in the area of the deformation. Depending on the
appearance, there is the following differentiation of the most
important deformations:
− Corkscrew−type deformation
− ”Basketwork” formation (deformation)
− Loop formation of the wires
− Loosening of individual wires or cords
− Knots
− Contraction
− Flattening
− Curl−type deformation
− Kinks and bends
Corkscrew−type deformation (Z 1367)
With the corkscrew−type deformation, the axle of the unloaded

cable becomes a corkscrew.
Remove cable, if the deformation X has become 1/3 d larger

or more (d = rope nominal diameter).
”Basketwork” formation (deformation) (Z 1368)
”Basketwork” formation (deformation) can occur in cables with

steel inserts if the outboard bearing of the wires is loosened or the
external cords are longer than the internal ones.
If the external wire or cord positions slip in comparison to the
interior ones, the excessive length share is shifted in one place.
If there is ”basketwork” formation (deformation), the cable

must be removed.
Loop formation of wires (Z 1369)
If there is loop formation of the wires, individual wires or wire

groups poke out of the rope structure like little hairs on the rope
side facing the sheave.
If there is a significant change to the rope structure due to

wire loop formation, the cable must be removed.
200−1−3220d_en 75/109
22
Z 1370
Z 1371
Z1372
76/109 200−1−3220d_en
Loosening of individual wires or cords (Z 1370)
If individual wires or cords loosen, the exterior wires of the loaded

cable or individual cords can be shifted.
This means that they do not assume the share of then tension
force assigned to them, which overloads the other wires or cords.
If the cable runs over sheaves, it can cause increased bending

tension which causes premature wire breakage.
If the wires become loose due to rust and abrasion, the cable
must be removed. If there is another cause for the loosening,
the wire breakage occurring as a consequence determine
the aptitude for removal.
Knots (Z 1371)
A knot is defined as a thickening of the wires which repeatedly

occur over longer periods. Often the inlay pokes out of the cable
at the point of thickening.
At the thinner points in the cable, the cords push against each
other, forming arches, which causes wire breakage.
Cables with several knots must be removed.
Contraction (Z 1372)
Contraction is when the cable’s diameter is decreased on short

stretches.
Cable components immediately in front of end fastenings must
be carefully checked for contraction, which can be difficult to see
at these points.
Cable with a lot of contraction must be removed.
200−1−3220d_en 77/109
22
Z 1373
Z 1374
Z 1375
78/109 200−1−3220d_en
Flattening (Z 1373)
Flattening is defined as permanent deformation of the cable,

which is caused by crushing.
Flattening causes increased wire breakage.
Curl−type deformation
Curl−type deformation is caused when a loaded cable is pulled

over an edge.
Cables with curl−type deformation must be removed.
Kinks (Z 1374)
A kink is a deformation of the cable caused by pulling an

eyelet−shaped rope loop straight without the cable being able to
balance out the deformation by rotating around its axle.
Cables with one or more kinks must be removed.
Bends (Z 1375)
A bend is a deformation of the cable which is caused by forceful

external influences.
Cables with bends must be removed.
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80/109 200−1−3220d_en
Effects of heat
Cables which have been subject to abnormal 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.
200−1−3220d_en 81/109
22
82/109 200−1−3220d_en
22.1.7 Documentation
Instructions for repeated inspections with § 26 sections 1 and 2

of the UVV “Crane” (BVG D6)
Company: Inspector: Date:

Crane manufacturer: TEREX Crane type: Construction number:
Construction year: Inventory no.: Signature
1st Inspection Group: Crane document

Test component A B C D E Remarks
Inspection log book for the crane
Operation / assembly instructions
Load tables
2nd Inspection Group: Notices / Markings

Factory sign
Load / stress details
Notice of operating regulations
Prohibition and regulation notices
Other safety markings
A: existing / complete B: state / servicing C: Function

D: repair / replacement E: subsequent inspection
required
fulfilled = x not fulfilled = − not required = 0
200−1−3220d_en 83/109
22
84/109 200−1−3220d_en

3rd Inspection Group: Travel Gear 1)

Axles
Wheels
Tyre
Bearing
Distributor gear
Cardan shaft
Leaf springs / springs
Shock dampers
Brakes
Hydraulic axle suspension
4th Inspection Group: Chassis 1)

Frame 2)
Axle suspension
Axle interlock
Outriggers 2)
Covering
Steeping surfaces
Steps
Counterweight holding devices 2)
Holding device for block 2)

Boom support 2)
Attachment device

required
200−1−3220d_en 85/109
22
86/109 200−1−3220d_en

5th Inspection Group: Chassis / Crane Operator’s Cab 1)

Doors
Windows / glass
Scheibenwischer
Mirrors
Seat
Heater
Ventilation
Noise absorption
Tachograph
First−aid kit
Replacement bulbs
Hazard warning triangle
Warning jacket
6th Inspection Group: Chassis / Drive 1)

Combustion engine
Exhaust system / combustion
protection
Fuel tank
Fuel lines
Filter
Engine suspension
Oil / coolant levels

required
200−1−3220d_en 87/109
22
88/109 200−1−3220d_en

7th Inspection Group: Chassis / Hydraulics 1)

Oil tank
Filter
Pumps
Engines
Valves
Lines
Hoses
Cylinders
Pressure relief valves
8th Inspection Group: Chassis / Air Pressure System 1)

Compressor
Filter
Air tank
Valves
Lines
Hoses
Cylinders

required
200−1−3220d_en 89/109
22
90/109 200−1−3220d_en

9th Inspection Group: Chassis / Electric System 1)

Engines
Alternators
Batteries
Switch
Lines
Fuses
Resistors
Lighting equipment
Braking lights
Indicators
Tail lights
Flood lights
Signalling devices
Indicator lights
Battery switch
Limit switch:
transmission, steering, drive
Support pressure gauge 2)

required
200−1−3220d_en 91/109
22
92/109 200−1−3220d_en

10th Inspection Group: Chassis / Control Devices 1)

Engine control
Transmissions
Clutches
Circuits
Steering
Control displays
Engine stop pull
Control of the outriggers 2)
Axle suspension
Crane levelling
Rear−axle steering

required
200−1−3220d_en 93/109
22
94/109 200−1−3220d_en

11th Inspection Group: Superstructure

Frame
Coverings
Steeping surfaces
Bearing
Counterweights
Back−stroke safety device
Slewing rim: fastening screw
Slewing rim: toothing
Slew gear: fastening screws
Slew gear: toothing
Slew gear: Drive
Slew gear: lock
Slew gear: Covering

required
200−1−3220d_en 95/109
22
96/109 200−1−3220d_en

12th Inspection Group: Superstructure / Cab

Doors
Windows / glass
Scheibenwischer
Mirrors
Seat
Heating / air conditioning equipment
Ventilation
Mufflers
Control lever for operating functions
Transmission switches
Safety device: points of crushing /
shearing
13th Inspection Group: Superstructure / Retaining Devices and Safety

Guards
Handles and ladders
Coverings
Covers
Flaps

required
200−1−3220d_en 97/109
22
98/109 200−1−3220d_en

14th Inspection Group: Superstructure / Drive

Combustion engine
Exhaust system / combustion
protection
Fuel tank
Fuel lines
Filter
Engine suspension
Noise absorption
Oil / coolant levels
15th Inspection Group: Superstructure / Hydraulic System

Oil tank
Filter
Pumps
Engines
Valves
Lines
Hoses
Cylinders
Pressure relief valves
Lowering brake valves

required
200−1−3220d_en 99/109
22
100/109 200−1−3220d_en

16th Inspection Group: Superstructure / Electric System

Engines
Alternators
Batteries
Switch
Lines
Fuses
Resistors
Lighting equipment
Switch cabinet
Indicator lights
17th Inspection Group: Superstructure / Control Devices

Engine control
Transmissions
Elastic clutches
Circuits
Engine stop
Control displays
Slew brake

required
200−1−3220d_en 101/109
22
102/109 200−1−3220d_en

18th Inspection Group: Superstructure / Rope Drives

Winch H1 3)
Winch H2 3)
Winch W1/H3 3)
Winch W2 3)
Winch E 3)
Winch R 3)
Sheaves
Rope end fixture
Rope for winch H1
Rope for winch H2
Rope for winch W1/H3
Rope for winch W2
Rope for winch E
Rope for winch R
Bracing ropes
19th Inspection Group: Superstructure / Hooks / Hook Blocks

Sheaves
Protecting clamps on the sheaves
Axle stirrups
Hooks
Hook fastenings
Lock−on hook

required
200−1−3220d_en 103/109
22
104/109 200−1−3220d_en

20th Inspection Group: Superstructure / Safety and Switching Devices

Hoist emergency limit switch H1
Hoist emergency limit switch H2
Lowering emergency limit switch H1
Lowering emergency limit switch H2
Boom emergency limit switch E1
Boom emergency limit switch E2
Top section:
Boom emergency limit switch W1
Top section:
Boom emergency limit switch W2
load limit device
Length display: working radius, boom
length
Angle display: boom
Angle display: top section
Angle display: Slew Gear
Safety device: control
Operating range limits
Inclination Indicator
Support pressure gauge
Emergency off

required
200−1−3220d_en 105/109
22
106/109 200−1−3220d_en

21st Inspection Group: Boom

Welded construction
Sheaves
Boom support
Boom pinning
Bracing rods / ropes
Retaining cylinders
Luffing cylinder
Telescoping cylinders
Extension ropes
Pull ropes
22nd Inspection Group: Optional Equipment


required
200−1−3220d_en 107/109
22
108/109 200−1−3220d_en
Remarks
1) It is considered that an inspection of the traffic safety status

of the mobile crane has been carried out if there is a
fault−free result of expert inspection in accordance with the
road traffic licensing regulations. The expert must carry out
an inspection of the traffic safety status on mobile cranes
which are not authorised for travel on public roads (see also
UVV “Vehicles” BGV D29).
2) The expert must still carry out these inspections even if

there is a fault−free result from an expert inspection in
accordance with the road traffic licensing regulations.
3) Inspection of the winches with regard to the used portion of

the theoretical period of use.
200−1−3220d_en 109/109

AC200 1 33291c Part3 - en

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Index

2 Oils, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 Lubrication and Maintenance Schedule . . . . . . . . . . . . . . . . . . . 3

13 Heating and Air Conditioning Equipment . . . . . . . . . . . . . . . . . . 3

16 Cooling, Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . 3

18 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

19 Visual Inspections Superstructure . . . . . . . . . . . . . . . . . . . . . . . . 3

22 Examinations of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Part 3: Lubrication and Maintenance Instructions for the

This instruction manual is provided for the benefit of personnel

The information contained in this manual is correct with regard to

In these lubrication and maintenance instructions you will find the

”Danger” is used if a maintenance procedure, NOT per-

”Caution” is used if a maintenance procedure, NOT perfor-

”Note” is used for identifying an important maintenance proce-

General Recommendations Regarding Lubrication and

− Thoroughly clean all nipples, caps and plugs before grea-

Please contact the Customer Service Department immediately if

This section entitled ”Safety Instructions” gives a concise and

For cranes with split lubrication and maintenance instructions,

Undertake the prescribed adjustment and maintenance tasks at

Ensure that all handles, steps, rails, platforms, stages and

When undertaking lubrication and maintenance tasks, do not

Spare parts must satisfy the technical specifications prescribed

The safety instructions listed for lubrication, maintenance

1.2 Personnel selection and qualifications

The crane equipment may only be serviced and calibrated by

This especially applied to work on the electrics, hydraulics, travel

1.3 Particular Types of Hazard

Lubrication and maintenance tasks must be undertaken with

1.3.1 Risks of Crushing / Shearing / Collisions

The affected areas are:

1.3.2 Risks of Snagging and Dragging

The affected areas are:

1.3.3 Risks of Slipping, Tripping, Falling

Only the walkways and ladders described may be used. These

1.3.4 Risks of Thermal Effects

1.3.5 Risk of Residual Energy in the Hydraulic System

1.4 Before Commencing Lubrication and Maintenance

Inform the operating personnel and appoint a supervisor!

Switch off the diesel engine!

Work may never be carried out with an attached load!

Secure the working equipment by placing it on the ground, setting

Make sure that the crane cannot be started up by unauthorised

Remove the battery switch or ignition key before undertaking any

1.4.1 Cleaning the Vehicle

Before cleaning the crane using water, steam jet (pressure

Rubber components, such as tyres etc. must be cleaned

Minimum clearance between high−pressure nozzle and object to

To avoid damage, do not point the water jet directly at door

During cleaning, always keep the water jet moving.

If air−cooled components are fitted on your crane (e.g. retarder),

In addition, the operating instructions for the steam jet (or

Sound absorption mats must not be cleaned using

After cleaning, remove the covers/any tape completely and carry

As oil can be emitted during maintenance and assembly work,

1.4.2 Fire Protection

Preventative measures against the risk of fire

Keep the crane clean, in particular making sure that there is

 After cleaning the engine room, check all

for leaks, loose connections, shear points and damage.

Check all electric lines, plug connections and terminals for

 Check the turbocharger fixing

After cleaning the engine room, check all

Check the turbocharger fixing

Fire extinguishers must be filled and ready for use.