AC100 77001 Part3 - en

Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notes for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Recommendations for the Lubrication and
Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Recurrent Inspections of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Measures to Ensure Safe Operating Periods . . . . . . . . . . . . . . . . . 10
1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.2 Theoretical Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.3.1 Determining the Operating Conditions (Load Spectrum) . . . . . . . . 11
1.4.3.2 Operating Hours of the Hoists per Inspection Interval . . . . . . . . . . 11
1.4.4 Determining the Spent Share of the Theoretical Service Life
of the Winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 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 Multi--Function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Tips for Maintaining the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Measures to Maintain the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1 Engine OM 904 LA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
100--3000b_en 1
Contents
12 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12.1 Hydraulic Tank -- Checking and Topping Up the Oil Level . . . . . . . 2
12.2 Hydraulic Tank -- Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.3 Hydraulic Tank -- Replace the Aeration Filter . . . . . . . . . . . . . . . . . . 10
12.4 Changing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.5 Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12.6 Hydraulic System -- Pressure Accumulator, Checking
the Preliminary Gas Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
14 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14.1 Checking the Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14.2 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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 . . . . . . . . . . . . . . . . . . . . . . 13
16.7 Maintaining the Diesel Exhaust Particulate Filter (Optional) . . . . . 17
16.7.1 Troubleshooting/Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
17 Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
100--3000b_en 2
Contents
18 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18.1 Auxiliary Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18.2 Auxiliary Heating -- Checking the System is Functioning Correctly 1
18.3 Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
18.4 Switching on the Hot Water Heating . . . . . . . . . . . . . . . . . . . . . . . . . 2
18.5 Checking and Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 2
18.6 Fine dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19 Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 Slew Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20.1 Lubricate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20.2 Lubricating the Gear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20.3 Check slew ring bolt connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21.1 Slew Gear Mechanism -- Checking and Topping Up the Oil Level 1
21.2 Slew Gear Mechanism -- Changing the Oil . . . . . . . . . . . . . . . . . . . . 2
21.3 Checking and Tightening the Screw Connections . . . . . . . . . . . . . . 3
22 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22.1 Hoist Gear -- Checking and Topping Up the Oil Level . . . . . . . . . . 1
22.2 Hoist Gear -- Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
22.3 Checking the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
22.4 Lubricating the Rope Drum Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 5
22.5 Checking and Tightening the Screw Connections . . . . . . . . . . . . . . 5
22.6 Lubricating the Hook Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
22.7 Determination of the spent share of the theoretical service life . . 6
100--3000b_en 3
Contents
23 Luffing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23.1 Luffing Cylinders -- Lubricating the Foot and Piston Bearings . . . . 1
24 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24.1 Main Boom -- Lubricating the Slides . . . . . . . . . . . . . . . . . . . . . . . . . 1
24.2 Lubricating the Basic Bolts on the Main Boom . . . . . . . . . . . . . . . . 3
24.3 Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
24.3.1 General Notes on Handling and Assembly . . . . . . . . . . . . . . . . . . . . 4
24.3.1.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
24.3.1.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
24.3.1.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
24.3.2 Lubricating the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
24.3.3 Cleaning the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
24.3.4 Checking the Cables and Replacing as Necessary . . . . . . . . . . . . 14
24.4 Checking the Main Boom for Weld Cracks . . . . . . . . . . . . . . . . . . . 21
24.5 Inspect Rope Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
24.6 Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
24.7 Sheaves -- Checking the Roller Bearing . . . . . . . . . . . . . . . . . . . . . . 23
24.8 Sheaves -- Lubricating the Roller Bearings . . . . . . . . . . . . . . . . . . . 24
24.9 Checking the Pins for Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
24.10 Checking the Draw Bars (Shackle on the Main Boom Extension) 25
24.11 Lubricate Main Boom Extension Bolts . . . . . . . . . . . . . . . . . . . . . . . 27
24.12 Telescopic Main Boom Extension (Optional) --
Lubricate Sliding Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubricate the Foot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubricate the Luffing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24.15 Checking the Welding on the Telescopic Main Boom Extension
for Cracks (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
100--3000b_en 4
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 required for maintenance and
lubrication of the machine and all special equipment.
The information contained in this manual is correct with regard to the

equipment at the time of publication. Data, diagrams and di mensions are
subject to change as a result of technical development.
No liability can be accepted for damage resulting from incorrect
maintenance.
The maintenance work which is described in this manual may only be
carried out by appropriately trained and qualified personnel.
In these lubrication and maintenance instructions you will find the titles or
the respective symbols "Danger", "Caution", "Note" and "Environment" used
as follows:
DANGER !
"Danger" is used for operating procedures where failure to observe
the prescribed assembly sequence or the stipulations made may
result in the death of or injury to persons.
CAUTION !
"Caution" is used for operating procedures, mounting se quences
etc. where failure to observe the stipulations made may result in
damage to the crane or equipment.
NOTE:
"Note" is used to indicate an important operation or mounting procedure or
to draw attention to further information.
Date: 11.CW/04
ENVIRONMENT:
This symbol is used when an action serves to protect the
environment or avoid unnecessary pollution.
e100-3002 1/3
2/3
e100-3002
Date: 11.CW/04
Foreword
General Recommendations Regarding Lubrication and Maintenance

Tasks
- Thoroughly clean all nipples, caps and plugs before greasing.
- 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 damage, resulting
in extensive repairs at considerable cost.
Please contact the Customer Service Department immediately if you

discover cracks in the steelwork of your crane.
Describe the course of the crack as closely as possible (enclose
photograph, page from spare parts catalogue etc.).
Date: 11.CW/04
e100-3002 3/3
Notes for the Operator
The safety instructions for the lubrication and maintenance

tasks for the crane chassis can be found in Section 1.
The specifications for the quality of the lubricant can be found in

Section 2.
The capacities of the individual units are listed in Section 3.
All the service points, ordered according to service intervals, are

listed in section 4.
Service points without fixed service intervals are listed under

"as required".
Service intervals should be determined by the kilometres

driven. Calendrical specifications (daily, weekly, monthly etc.)
can be used. Servicing at the corresponding service intervals is
always carried out at the first specification reached (mileage or
calendrical option).
The servicing activities listed in Section 4 can be found in more

detail in Section 5, 12, 14 - 24.
Definitions:
Service Point = Unit or point on which the maintenance

stipulated is to be carried out (e.g.
engine, grease point).
Service Interval = Number of kilometres after which the

stipulated service task is to be
repeated (e.g."every 100 h": at 100, 200,
300, 400, 500 operating hours, etc.;
"every 200 h": at 200, 400, 600, 800,
1000 operating hours, etc.).
Date: 11.CW/04
e100-3004 1/1
Notes on Safety 1
1 Notes on Safety
1.1 General Recommendations for the

Lubrication and Maintenance Tasks
Undertake the prescribed adjustment and

maintenance tasks at the prescribed times and
observe the details regarding the replacement of
components.
Ensure that all handles, steps, rails, platforms,

stages and laders remain free from dirt, snow and
ice at all times.
(Z160 366)
Z 160 366
Ensure that the crane is kept clean at all

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

before greasing.
(Z 160 001)
Date: 07.CW/95
Z 160 001
bs_e908-3010d /b 1/16
1
- Refill the fuel tank at the end of each

working day.
(Z 160 017)
Sufficient ventilation has to be ensured

when the tank is filled. The tank is not to be
filled with the engine running.
Z 160 017
- Renew the sealing rings for drain, filler,

inspection plugs and filters, before replacing
the screws or filter.
(Z 160 007)
The oil can be drained more easily from

individual units if it is drained at operating
temperature.
When the operating temperature is reached,

switch the engine off and remove the key.
Z 160 007
After cleaning the engine bay, check all
- fuel lines
- engine oil lines
- hydraulic oil lines
for leaks, loose connections, worn patches

and damage.
Repair any damage immediately.

(Z 160 003)
Date: 07.CW/95
Z 160 003
2/16 bs_e908-3010d /b
Notes on Safety 1
After cleaning the crane, grease all grease

points.
When dry, spray the slew gear teeth with the

recommended grease.
(Z 160 010)
Z 160 010
Check all electrical lines, push-on connections

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

(Z 160 504)
Z 160 504
Check the turbocharger mounting.
Check the exhaust and air inlet lines and the

lubricant supply and return lines for leaks.

Date: 07.CW/95
bs_e908-3010d /b 3/16
a / 06/97
1
Fire extinguishers must be full and ready for use.

(Z 160 009)
Z 160 009
Never carry out welding repairs without first

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

Department immediately if you discover cracks
in the steelwork of your crane. Describe the
course of the crack as closely as possible
(enclose photograph, page from spare parts
catalogue, etc.).
(Z 160 006)
Date: 07.CW/95
Z 160 006
4/16 bs_e908-3010d /b
Notes on Safety 1
1.2 Notes on Safety
The diesel engine must always be switched off

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

maintenance tasks, switch off the engine and
remove the keys.
The residual energy or stored energy wich

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

(Z 160 415)
Z 160 415
Lubrication and maintenance tasks may only be

carried out if the working equipment has been
made secure by placing it on the ground, by
extending the outriggers or by any other
appropriate means.
(Z 160 008)
Date: 07.CW/95
Z 160 008
bs_e908-3010d /b 5/16
a / 06/97
1
Before carrying out any lubrication or

maintenance tasks, place a warning sign in the
driver's cab and ensure that no unauthorized
persons can set the crane in operation (e.g.
lock the cab doors and remove the contact
keys).
(Z 160 014)
Z 160 014
DANGER OF INJURY
when hydraulic oil escapes under high
pressure.
Therefore, before carrying out any work on
the hydraulic system, depressurise it.
i.e. - boom lowered

- vehicle supported on outriggers
- axles lowered
(Z 160 018)
Z 160 018
Wear safety clothing, protective goggles,

respiratory mask and other protective equipment
if necessitated by the working conditions.
(Z 160 011)
Do not allow unauthorized persons near

the equipment whilst carrying out maintenance
or lubrication tasks.
Work which could affect the operational

Date: 07.CW/95
and road safety of the crane must only be

carried out by trained personnel.
Z 160 011
6/16 bs_e908-3010d /b
Notes on Safety 1
If it is necessary for one or more persons to be

located on the crane for maintenance work,
they must maintain visual contact with the
crane driver at all times.
(Z160 023)
Z 160 023
DANGER OF INJURY
Always wear protective gloves when handling
and guiding the ropes.
Only use a wooden rod to guide moving
ropes.
(Z 160 024)
Z 160 024
Store oil-impregnated rags and flammable

materials so that they cannot be ignited,
alternatively remove from the area.
(Z 160 016)
Oils that are drained off must be stored in

suitable containers and disposed of
correctly.
These safety instructions are to be

Date: 07.CW/95
observed whenever the crane is operated or

repaired.
Z 160 016
bs_e908-3010d /b 7/16
1
After service and maintenance work has

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

been carried out, check that there are no tools or
loose components on the crane.
(Z 160 027)
Z 160 027
If you vuse electrical equipment for

servicing and maintenance work, check this
equipment to ensure to ensure that it is
functioing correctly and is free of faults.
(Z 160 083)
Date: 07.CW/95
Z 160 083
8/16 bs_e908-3010d /b
Notes on Safety 1
1.3 Recurrent Inspections of the Crane Carrying out the inspection
The company which is operating the crane The recurrent inspection is essentially a visual
must have the crane inspected at least once a and performance inspection which essentially
year by a "Sachkundiger" - person with a includes:
sound knowledge of crane technology, defined
by VBG 9 - and at least every 4 years by a - Checking the identity of the crane against the
"Sachverständiger" - authorized expert, defined details in the inspection book (crane log-book).
by VBG 9 - (ISO 9927-1, VBG 8, VBG 9, 9a).
- Checking the condition of the components
and equipments with regard to damage, wear,
corrosion or other changes.
Within the framework of this inspection, - Checking the sfety equipment and the brakes
the theoretical remaining service life of for completeness and effectiveness.
the winches must be determined.
Observe Section 1.4.
The following details are based on the The results of these inspections must be
instuctions given in the accident preventions recorded in the log-book and must be
for "cranes" (VBG 9 and 9a) regarding recurrent certified by the inspector.
inspections of the crane and they provide a
general view.
The VBG 9 inspections do not affect the

national and international regulations
applicable.
Inspection interval
Cranes must be checked by a "Sachkundiger"

where necessary according to the applications
of use and the operating conditions, but must
be checked at least once a year.
An inspection must be carried out at least once
every 4 years by a "Sachverständiger".
Date: 07.CW/95
bs_e908-3010d /b 9/16
a / 24/95
1
1.4 Measures to Ensure Safe

Operating Periods
1.4.1 General 1.4.2 Theoretical Service Life
In accordance with the accident prevention The Design engineer has assumed certain
regulations for winches, lifting and dragging operating conditions in calculating and
equipment (VBG 8),the crane operator is dimensioning the winches on your crane.
obliged to carry out an inspection of the crane
at least once a year (also see ISO 9927-1). The winches on your crane are classified
as follows (ISO 4301/1, FEM 1.001,
The spend share of the theoretical service DIN calculation principles for power units):
life for the winches must also be determined.
The crane operator must employ a specialist - Power unit group: M............
for the purpose if necessary.
- Load spectrum: Q............ (L........)
- Load spectrum factor: Km=.......
This regulation is legally binding within A theoretical service life, D, is thus calculatet.
the scope of the accident prevention
regulations of the trade association. Out-
side of this realm, the crane manufacturer The values applicable must be taken from
recommends that the procedures listed are the "Monitoring the Winches" table given in the
also observed. crane log-book.
Date: 07.CW/95
10/16 bs_e908-3010d /b
Notes on Safety 1
1.4.3 Actual Operating Conditions
Before the spent share of the theoretical service

The theoretical service life must not be life of the winches can be determined, the actual
equated with the real (actual) service life of operating conditions (load spectrum) and the
a winch. operating hours of the hoists per inspection
In addition, the real service life of a winch interval must be determined.
is affected by a number of external
influences, for example:
1.4.3.1 Determining the Operating
- Overloading through not using the crane Conditions (Load Spectrum)
as intended.
The load spectrum of the crane is divided into
- Insufficient maintenance: the oil is not groups (also see ISO 4301/1, FEM 1.001).
changed in good time. From knowledge of the actual operating
conditions, one of the load spectrums listed
- Maloperation such as extreme below must be selected and recorded in the
acceleration or deceleration of the load crane log-book for the relevant inspection
or the load falling into the ropes. interval.
- Maintenance mistakes such as using the 1.4.3.2 Operating Hours of the Hoists
wrong oil, incorrect oil fill or contamination per Inspection Interval
when changing the oil.
Determine the effective number of operating
- Mounting mistakes when undertaking hours per inspection interval (Ti). This must be
repairs or maintenance. recorded in the crane log-book for the relevant
inspection interval.
- Leaks not taken into consideration.
For mobile cranes used for erection operation,
- Incorrectly adjusted safety equipment. the share of the hoist winches is generally
20 % of the total operating hours for the
- Concealed damage caused by accidents. superstructure and 12 % of the total operating
hours for the entire crane.
- Extreme ambient conditions such as low
or high temperatures, aggressive
atmosphere, dust and dirt.
Date: 07.CW/95
bs_e908-3010d /b 11/16
1
Load Load
spectrum spectrum
12/16
class Definition Shares of operating time factor Graph
Last / Load %
low Power units or parts thereof 10 % of operating time under highest Km = 0.125
Q1 subject to highest loading load (dead load + 1/1 load capacity)
L1 only as exception but routinely 40 % of operating time under
only subject to very low dead load + 1/3 load capacity
loading 50 % of operating time only under
dead load
Laufzeit
%
Operating time
1 Last / Load %
medi- Power units or parts thereof /6 of operating time under highest Km = 0.25
um subject to highest loading load (dead load + 1/1 load capacity)
1
Q2 quite often but routinely only /6 of operating time under
L2 subject to low loading dead load + 2/3 load capacity
1
/6 of operating time under
dead load + 1/3 load capacity
50% of operating time only under Laufzeit
%
dead load Operating time
high Power units or parts thereof 50 % of operating time under highest Km = 0.5 Last / Load %
Q3 often subject to highest load (dead load + 1/1 load capacity)

L3 loading and routinely 50 % of operating time only under
subject to medium loading dead load
Laufzeit
%
Operating time
Last / Load %
very Power units or parts thereof 90 % of operating time under highest Km = 1
high regularly subject to loading load (dead load + 1/1 load capacity)
Q4 in the realm of highest loading 10 % of operating time only under
L4 dead load
Laufzeit
%
Operating time
bs_e908-3010d /b
Date: 07.CW/95
Notes on Safety 1
1.4.4 Determining the Spent Share of

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

interval "i" as per Section 1.4.3.2
After each inspection interval, the spent share

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

not expected to be sufficient for the next
operating period, a general overhaul of the
winch must be undertaken.
- If the theoretical service life, D, is achieved,

the winch must only be continued to be
operated following a general overhaul.
Date: 07.CW/95
bs_e908-3010d /b 13/16
1
14/16
Monitoring the Winches
Table for determining the theoretical remaining service life for winch AC xxx................................
Crane type: 00000..........................
Construction number: 00.00.00......................
Initial commissioning: 0815............................
Serial number of winchgear as per serial plate: ....................................
Design specifications of winch (see crane certification log):
Power unit group: M 3..........................................
Load spectrum: Q 1........................(L...............)
Load spectrum factor: Km = 0,125...................................
Theoretical service life: D = 3200....................................
The (crane) user is liable for the correctness of the information!

Inspection Date of initial Operating Load spectrum Operating Operating Operating Operating Operating hours Spent share of the Theoretical Name of Signed Notes
No. commissioning conditions factor hours elapsed hours elapsed hours elapsed hours elapsed elapsed for the theoretical service remaining inspector
/ date of since last for the entire for the for the for the winch winch since last life, Di service life
inspection inspection (load crane superstructure superstructure inspection, T i
spectrum) since last Si = Kmi / Km * T i Di = Di-1 - Si
inspection
"i" Kmi [h] [h] [h] [h] [h] [h] [h]
0 10. 08. 94 - - - 0 - - - 3200 -
1 05. 06. 95 L1 0,125 - 800 800 - 160 160 3040 Meier

(20% v. 800)
2 20. 05. 96 L3 0,5 - 2000 1200 - 480 1920 1120 Müller
(40% v. 1200)
3 18. 05. 97 L2 0,25 - 3000 1000 - 300 600 520 Müller
(30% v. 1000)
Caution: A general overhaul must be undertaken at least every 10 years Si = Spent share of theoretical service life since last inspection
Di = Theoretical remaining service life
Di-1 = Theoretical remaining service life after previous inspection
General overhaul undertaken on : ........................................... Km = Load spectrum factor which formed the basis of calculation for the winch.
This factor must be taken from the crane certification log.
Kmi = Load spectrum factor for inspection interval "i"
Ti = Effective operating hours for inspection interval "i"
For further notes, see Section 1 in the Lubrication and Maintenance Instructions for the Superstructure
Z 29 555
bs_e908-3010d /b
Date: 07.CW/95
Notes on Safety 1
1.4.5 Documentation
(Z 29 555)
The crane operator is responsible for Inspection No. 1 (year 1)

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

S1 = x T1 = x 160 h = 160 h
exemple: Km 0.125
The value for the load spectrum factor

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

first year:
D1 = D - S1 = 3200 h - 160 h = 3040 h

Date: 07.CW/95
bs_e908-3010d /b 15/16
1
Inspection No. 2 (year 2) Inspection No. 3 (year 3)
The crane has been used for harbour unloading The crane has been used for erection operation
operation: and occasionally for harbour unloading
operation:
- Load spectrum L3, i.e. Km2 = 0.5
- Load spectrum L2, i.e. Km3 = 0.25
2000 h are recorded on the superstructure hour
meter, i.e. during this period: 2000 h - 800 h 3000 h are recorded on the superstructure
(used in first year of operation) = 1200 h. hour meter, i.e. during this period:
3000 h - 2000 h (used in the first two years of
The winch has therefore been in operation for operation) = 1000 h.
approx. 40 % of this time, i.e. T2 = 480 h.
The winch has been in operation for approx.
30 % of this time, i.e. T3 = 300 h.
The spent share S2 of the theoretical service life
for the second inspection interval is thus:
The spent share S3 of the theoretical service
life for the third inspection interval is thus:
Km2 0.5
S2 = x T2 = x 480 h = 1920 h
Km 0.125 km3 0.25
S3 = x T3 = x 300 h = 600 h
km 0.125
Theoretical remaining service life after the

second year: Theoretical remaining service life after the
third year:
D2 = D1 - S2 = 3040 h - 1920 h = 1120 h
D3 = D2 - S3 = 1120 h - 600 h = 520 h
It must now be assessed whether the

theoretical remaining service life is expected
to be sufficient for the next period of operation.
If this is not the case, a general overhaul must
be undertaken (see Section 1.4.4).
Date: 07.CW/95
16/16 bs_e908-3010d /b
Date: 07.CW/95
Monitoring the Winches
bs_e908-3010d /b
Table for determining the theoretical remaining service life for winch ......................................
Crane type: ....................................
Construction number: ....................................
Initial commissioning: ....................................
Serial number of winchgear as per serial plate: ....................................
Design specifications of winch (see crane certification log):
Power unit group: M ............................................
Load spectrum: Q ..........................(L...............)
Load spectrum factor: Km = ............................................
Theoretical service life: D = ............................................
The (crane) user is liable for the correctness of the information!

Inspection Date of initial Operating Load spectrum Operating Operating Operating Operating Operating hours Spent share of the Theoretical Name of Signed Notes
No. commissioning conditions factor hours elapsed hours elapsed hours elapsed hours elapsed elapsed for the theoretical service remaining inspector
/ date of since last for the entire for the for the for the winch winch since last life, Di service life
inspection inspection (load crane superstructure superstructure inspection, T i
spectrum) since last Si = Kmi / Km * T i Di = Di-1 - Si
inspection
"i" Kmi [h] [h] [h] [h] [h] [h] [h]
Caution: A general overhaul must be undertaken at least every 10 years Si = Spent share of theoretical service life since last inspection
Di = Theoretical remaining service life
Di-1 = Theoretical remaining service life after previous inspection
General overhaul undertaken on : ........................................... Km = Load spectrum factor which formed the basis of calculation for the winch.
This factor must be taken from the crane certification log.
Kmi = Load spectrum factor for inspection interval "i"
Ti = Effective operating hours for inspection interval "i"
Notes on Safety 1
17/16
For further notes, see Section 1 in the Lubrication and Maintenance Instructions for the Superstructure
Fuels and Lubricants 2
Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards
2.1 Engine Engine Oil See regulations SAE 10 W 40 for normal and long-
Multigrade Oil for fuels and term oil change
lubricants intervals see
contained in the MB-operating media
instructions for specifications
operation of the sheet 225.6 or 228.5
engine OM 904 LA ACEA E4-98
2.2 Cooling Water / Protection See regulations for fuels and 50 % Water
System Anti-Corrosive lubricants contained in the 50 % Antifreeze
Antifreeze instructions for operation of the
mixture engine OM 904 LA
2.3 Hydraulic Hydraulic Oil -20 to +40 ATF-Typ A Suffix A

System or Dexron II
0 to +60 68 HLP (D) acc.

DIN 51524 additionally
with detergend quality
Biological oil:
-30 to +40 PLANTOSYN 3268
2.4 Fuel Tank Premium See DIN 51 601

Diesel Fuel 0 to +50 regulations ASTM D 975
for fuels and (No.1D and 2D)
lubricants VV-F-800a
Winter -25 to 0 contained in (DF-A,DF-1
Diesel Fuel the instructions and DF-2)
for operation B.S.2869 A1
of the engine (A2 if necess.)
2.5 Slew Gear Hypoid -20 to +40 SAE 80W - 90 API - GL 4 or 5

Mechanism Gear Oil or SAE 90
For ambient temperatures below those given in the table, please refer to the figures given in
Date: 20.CW/04
the operating instructions of the original manufacturer.
e100-3020_b 1/2
2
Service point Fuel/Lubricant Ambient Viscosity Quality

stipulated temp. oC standards
2.6 Hoist Gear Gear Oil -15 to +35 CLP 100 DIN 51517.3
-CLP
see (*)
2.7 Lubricating Lithium Base -15 to +120 NLGI Class 2 DIN 51825 T3
Nipples Saponified KP 2 K
H.P. Grease
with Mineral
Oil Base
2.8 Slew Ring Spray Grease - Special Adhesive Demag

Teeth Grease Order No.:
006 058 98
2.9 Ropes Spray Grease - Special Adhesive Demag

Grease Order No.:
083 371
2.10 Main Boom Grease, -40 to +140 Demag

Sliding Surfaces Berulub PAL 1 Order No.: (1 kg)
654 069 40
2.11 Piston Rods GLEITMO 350 Spray Grease Demag

Order No.:
604 106 40
(*) Shell Tellus T 100

AVIA Multigear VG - FE 75W - 90
Mobil Gear Oil VS 200
DEA Deagear S SAE 75W - 90
Kleenoil Panolin Super Duty Synth 75W - 90
For ambient temperatures below those given in the table, please refer to the figures given
in the operating instructions of the original manufacturer.
Date: 20.CW/04
2/2 e100-3020_b
Capacities 3
Housing or System Metric Capacity US Capacity Initial Fill Up

(Litres) (Gallons)
Engine OM 904 LA 16.00 4.20 Shell RIMULA Ultra

with Filter Change (10 W 40)
Hydraulic System Superstructure 755.00 199.50 ATF...:Shell Donax TM

Hydraulic Tank 715.00 188.90 Typ A Suffix A or
HLP(D)...:Shell Hydrol Do 68
Biological oil:
PLANTOSYN 3268
Fuel Tank 210.00 55.50 Diesel Fuel
Slew Gear 4.50 1.20 Shell Gear Oil 90 LS
Slew Gear Brake 1.00 0.25 Shell Donax TM
Hoist Gear Hoist 1 3.50 0.90 Shell Tellus 100

Hoist 2 3.50 0.90
Radiator Expansion Tank 13.00 3.40 50 % Water

and Pipe 50 % Glysantin
The capacities given are approximate. For more exact measurements, checks should be carried
out at the specified inspection points, such as the inspection plugs, dipsticks and screens.
Date: 20.CW/04
e100-3030_a 1/1
Lubrication and Maintenance Schedule 4
100--3040--001_en 1/15
4
2/15 100--3040--001_en
4 Lubrication and Maintenance Schedule
4.1 Initial Lubrication and Maintenance
Lubrication and maintenance work which is due after the first

operation and before regular work, is marked with ”1X” on the
maintenance list.
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-
tinghours, 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.
Formore infrequent maintenance work, e.g. ”Every 1000 opera-

tinghours”, all those maintenance tasks which are required ats-
horter intervals and which coincide with this time must of cour-
sealso be undertaken.
This means that for the above example, the maintenance task-
soccurring ”Every 500 operating hours” and those required ate-
ven shorter intervals must also be undertaken.
100--3040--001_en 3/15
4
Z 163 243
4/15 100--3040--001_en
4.3 Multi-- Function Display
(Z 163 243)
Confirm the service interval display (SIA)
The service interval display (SIA) indicates a set service interval.
After every 250 engine operating hours

− ”SIA” appears in the display
− all light--emitting diodes (LED) flash
Press any key in the keypad and the master instrument will be re-
set in the normal operating condition.
Every time the ignition is switched on, a confirmed ”SIA” message

is appears again for approx. 5 seconds on the display.
Reset the service interval display (SIA)
Once the lubrication and service work has been completed, the
SIA can be reset while the vehicle is at a standstill.
− Switch off the ignition.
− Press buttons 7 and 8 at the same time, and hold this down.
− Switch on the ignition.
− Wait for the self--test to be completed
− Releas buttons 7 and 8
− The display shows ”SIA 0”
The service interval has now been reset.
100--3040--001_en 5/15
4
6/15 100--3040--001_en
4.4 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
4.5 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.
100--3040--001_en 7/15
4
8/15 100--3040--001_en
2. Preventative maintenance
Preventative maintenance includes measures which may be un-

dertaken within the framework of an ”inspection of the condi-
tionof 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 systemis 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.
100--3040--001_en 9/15
4
10/15 100--3040--001_en
4.6 Maintenance List
Interval (operating hours)
100--3041--001_en
Fuels
F l 1* 50 100 150 250 500 10 15 30 50 2*
Sect. Task
Sect. 2
X 100
5 Engine
Engine: MERCEDES BENZ (OM 904 LA) see the Operating Instructions of the Manufacturer
Engine: Check / replenish oil level Sec. 2.1 x x
Engine: Change oil and oil filter for oil quality: in accordance with Mercedes--Benz x3)
fuel regulations 228.5 7)
for differing oil quality:

see the Operating Instructions of the Manufacturer
other maintenance works see the Operating Instructions of the Manufacturer
12 Hydraulic system
12 Replace the hose lines every 4 years
12.1 Hydraulic tank -- check oil level & top up as nec. Sec.2.3 x
12.2 Hydraulic tank -- return oil filter 1x 1x x x
12.2 Hydraulic tank -- high pressure filter 1x x x
12.3 Hydraulic tank -- replace the aeration filter 1x x
12.4 Change hydraulic oil Sec.2.3 x
12.5 Bleed the hydraulic system x
12.6 Pressure accu., check the preliminary gas tension x
14 Electrical system
14.1 Check the lighting system x
14.2 Service the batteries x
14.3 Check the fuses x
1* -- daily before starting operations 2* -- when necessary 1) -- at least 1 x per week
2) -- at least 1 x per month 3) -- at least 1 x year 4) -- at least every 2 years
5) -- at least every five years 6) -- at least every ten years 7) -- every 900 operating hours
11/15
Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Sect. Task
Sect. 2
X 100
100--3041--001_en
15 Fuel system
15 Fuel tank, drain off sediment and water x
15 Fuel Filter see the Operating Instructions of the Manufacturer
16 Cooling, air intake and exhaust system
16.1 Clean/replace the filter element in the air filter x4)
16.2 Replace the safety cartridge x
16.3 Cleaning the air filter prefractionator (optional) x
16.4 Cleaning the cooling system x
16.5 Check the coolant and top up as necessary x
16.6 Change the coolant and anti--freeze x4)
16.7 Diesel soot particle filter (optional): x
”burn off” the filter element
Service the filter element x x3)
17 Piston rods
17.1 Lubricate piston rods Sec. 2.14 x
12/15
Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Sect. Task
Sect. 2
X 100
100--3041--001_en
18 Optional Equipment
18.1 Auxiliary Heating see the Operating Instructions of the Manufacturer
18.2 Auxiliary Heating -- check system is functioning correctly x
18.3 Replace the heat exchanger x6)
18.4 Switch on the hot water heating x
18.5 Check the fuel filter and replace as necessary x
18.6 Replace the fine dust filter x
19 Visual inspections -- superstructure
19 Hydraulic system x
19 Covers and panels x
19 Engine x
19 Instruments and displays x
19 Lighting system x
19 Windscreen washing assembly -- check for correct function x1)
& top up wash solution
13/15
Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Sect. Task
Sect. 2
X 100
100--3041--001_en
20 Slew Ring
20.1 Lubricate the bearings Sec.2.7 x x2)
20.2 Lubricate the ring gear Sec.2.8 x
20.3 Check screw connections and tighten as nec. x x3)
21 Slew Gear
21.1 Slew Gear mechanism -- Check oil & top up as nec. x
21.2 Slew Gear Mechanism -- Changing the Oil 1x x
21.3 Check screw connections and tighten as nec. x
22 Hoists
22.1 Hoist Gear -- Check oil level & top up as nec. Sec. 2.6 x1)
22.2 Hoist Gear -- Changing the Oil Sec. 2.6 1x 1x x
22.3 Checking the gear oil x
22.4 Lubricate the rope drum bearing Sec.2.7 every 6 months
22.5 Check screw connections and tighten as nec. x
22.6 Lubricate hook block Sec.2.7 x
22.7 Calculation of spent share of the theoretical service life x3)
23 Luffing Gear
23.1 Luffing cylinders -- lubricate the bearing x
14/15
Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Sect. Task
Sect. 2
X 100
100--3041--001_en
24.1 Main boom -- lubricate the inner slides x
24.1 Main boom -- lubricate the outer slides x
24.2 Main boom -- lubricate the basic bolts x
24.3 Ropes
24.3.1 General Notes on Handling and Assembly see section 24.3.1
24.3.2 Lubricate the ropes Sec. 2.14 x
24.3.3 Clean the ropes x
24.3.4 Check ropes, replace if required x3)
24.4 Check the main boom for weld cracks x
24.5 Inspect main boom rope track rollers at least every three months
24.5 Inspect main boom extension rope track rollers during every folding procedure
24.6 Check the sheaves x
24.7 Sheaves -- Check the roller bearing x
24.8 Sheaves -- Lubricate the roller bearing Sec.2.7 x
24.9 Check the pins for cracks x
24.10 Check the draw bars x
24.11 Lubricate main boom extension bolts x
24.12 Tele. main boom ext. lubricate sliding faces Sec.2.10 x
24.13 Tele. main boom ext. -- lubricate the foot bearing Sec.2.7 x
24.14 Tele. main boom ext. lubricate luffing cylinder Sec.2.7 x
24.15 Check the welding on the Telescopic main boom extensions x
15/15
Drive 5
100--3050a_en 1/3
5
Z 163 642
Z 162 048
2/3 100--3050a_en
Drive 5
5 Drive
5.1 Engine OM 904 LA
(Z 163 642)
Risk of injury!
Maintain safety distance to hot, rotating and moving
components.
Danger of burning or scalding.

Before carrying out maintenance work in the engine area,
allow a cooling period of 60 minutes.
Please follow the notes and instructions concerning mainte-

nance of the engine in the operating instructions of the engine
manufacturer.
(see section 5 of this documentation)
The description of the engine is on the bearing plate. The location

of the bearing plate can also be found in the operating instruc-
tions of the engine manufacturer.
Legende:
(Z 162 048)
-- Oil drain plug
The oil drain plug of the engine has a quick--fit coupling for con-
necting a hose extension.
Oils that have to be drained off should be stored in suitable

containers and disposed of properly.
100--3050a_en 3/3
Hydraulic System 12
12 Hydraulic System
Ensure that all lines and hoses are at

sufficient distance toward hot engine parts
(e.g. turbocharger) and are laid so that they
do not chafe.
If lines and hoses are found damaged due

to mechanical, thermal or other effects,
they must be replaced.
(Z 163 700)
Z 163 700
Check all hoses regulary for damages.
If any damages - even if they are minor - are
detected when performing this visual check the
damaged hoses have to be replaced
immediately.
Even if no damages are detected the

hoses have to be replaced at the latest after
4 years.
Date: 15.CW/00
bs_e100-3120 1/16
12
12.1 Hydraulic Tank - Checking and

Topping Up the Oil Level
The hydraulic tank contains the general oil

supply for all hydraulic components.
When checking the oil level:
- Position the crane on level, flat ground.

- Crane in the travel position.
- Suspension cylinders retracted.
- Switch off the engine.
(Z 160 113)
Z 160 113
Read off the oil level at the oil inspection

window.
(Z 163 660)
- If the oil level is below the mark, it should be

topped up.
Find the cause of the oil loss and rectify

immediately.
Z 163 660
Date: 15.CW/00
2/16 bs_e100-3120
Hydraulic System 12
12.2 Hydraulic Tank - Filter
1 - Return oil filter

(Z 163 661)
Z 163 661
2 - HP filter
(Z 163 662)
Z 163 662
For replacement intervals see Section 4

"Lubrication and Maintenance Schedule".
If one of the filters needs to be cleaned or

replaced between the specified intervals, this
will be indicated by the indicator light on the
dashboard.
(Z 163 803)
Date: 15.CW/00
Z 163 803
bs_e100-3120 3/16
12
In order to find out which filter needs

to be changed or cleaned, you must remove the
plugs on the pressure switches of the
filters one after the other and watch the indicator
light on the dashboard.
(Z 163 664, Z 163 665)
Z 163 664
Z 163 665
- Clean the housing of return oil filters
and replace the filters elements.
(Z 163 661)
To clean the filter barrel and to replace the

paper elements, the filter units of retutn filters
must be removed.
DANGER OF INJURY
Date: 15.CW/00
from high hydraulic oil pressure.

Therefore switch off the engine before
Z 163 661 working on the hydraulic system.
4/16 bs_e100-3120
Hydraulic System 12
- Return oil filter
Loosen the hexagon nuts (1) with wrench SW

17 and remove them together with the spring
washers.
(Z 160 250)
Then remove the filter cover (2) while paying

attention to the sealing ring (Z 160 251, item 3)
situated underneath.
Z 160 250
While paying attention to the O-ring (6), pull the

filter unit (4) out of the head piece by means of
the handle (5).
(Z 160 251)
It is advisable to set the filter unit down on

the head piece until the oil in the filter has run
out via the paper elements.
Z 160 251
Place the filter unit (4) on a solid base, press

the handle (5) downwards and return it
approximately 60o to the left or the right.
Remove the handle (5) with the attached valve,
clean the latter in diesel oil or petroleum ether
and place it on a clean base.
(Z 160 252)
Date: 15.CW/00
Z 160 252
bs_e100-3120 5/16
12
Remove paper elements which are marked with

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

paper element with the above-mentioned
code letters must correspond to the
associated element number on the spares
list of the filters.
Z 160 253
Pour the residual oil out of the filter tube into a

container for used oil and rinse out the filter
tube with diesel oil or petroleum ether.
In filters which have a magnet system, the

latter is accomodated in the filter cover.
Remove the dirt with a cleaning rag and diesel
oil or petroleum ether. Place the cleaned filter
cover with the magnet system on a clean base.
The return oil filter 2 is assembled in the

reverse seqence.
Before assembly, seals (3) and (6) must
be checked to ensure that they are in perfect
condition and positioned correctly. Replace
damaged parts. Fit new paper elements in the
filter tube. Press the handle between the
locking plates fastened at the top of the filter
tube downwards and turn it until it has locked in
position in the slots in the cams.
(Z 160 251)
Date: 15.CW/00
Z 160 251 Beim Probelauf Filter auf Dichtheit prüfen.
6/16 bs_e100-3120
Hydraulic System 12
- Cleaning the High Pressure Filter and

Replacing the Element
- Switch off the engine
- Place a suitable container beneath the filter

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

Z 163 662 correctly.
- Unscrew the socket housing.

Apply key SW (32) to the bottom of the
socket housing.
(Z 160 176)
- Drain off the remaining oil from the bottom of

the socket housing and dispose of it.
- Wash out the socket housing with diesel oil

or petrol of a suitable grade for washing
purposes.
Z 160 176
- Remove and dispose of the dirtied paper

element (2) from the outlet pipe (3) by
moving it gently from side to side and pulling
it downwards.
(Z 160 177)
Date: 15.CW/00
Z 160 177
bs_e100-3120 7/16
12
- Replace O-Rings (5) and (6).

(Z 160 178)
Z 160 178
- Apply new paper element (2) on the outlet

pipe (3).
(Z 160 179)
Z 160 179
- Fill the socket housing (1) until about half full

with clean hydraulic oil.
Carefully place the filter barrel over the
filter element (2) and...
(Z 160 193)
Date: 15.CW/00
Z 160 193
8/16 bs_e100-3120
Hydraulic System 12
... screw in fully into the head piece and tighten

with a wrench.
(Z 160 194)
Carry out a test run to ensure that the

filter is fitted correctly.
Z 160 194
Date: 15.CW/00
bs_e100-3120 9/16
12
12.3 Hydraulic Tank - Replace the

Aeration Filter
The aeration filter must be changed

more regularly in especially harsh operating
conditions.
(Z 163 666)
Z 163 666
- Unscrew the filter and dispose of

appropriately.
(Z 160 188)
Z 160 188
- Screw on the new filter.

(Z 160 189)
Date: 15.CW/00
Z 160 189
10/16 bs_e100-3120
Hydraulic System 12
12.4 Changing the Hydraulic Oil
The vehicle should be level and the

engine switched off.

2 correctly.
- Unscrew the screw connections (1) on the

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

suitable containers and dispose of it.
(Z 163 686)
Date: 15.CW/00
Z 163 686
bs_e100-3120 11/16
12
- Clean the hydraulic oil container.

(Z 163 668)
Z 163 668
- Close the drain cocks again.

Loosen the screw connections and remove
the drain hoses.
- Screw the screw connections (1) back on.
(Z 163 690)
This seals the hydraulic tank again.
Z 163 690
- Fill in new hydraulic oil
(also see section 12.1).
(Z 163 669)
When oil is filled into the hydraulic

system there is a danger of dirt particles
contaminating the hydraulic oil circuit.
In order to prevent malfunctions in the
system caused by impurities, ensure that
the initial fill up and subsequent fill ups
are carried out under extremely clean
Date: 15.CW/00
conditions.
If necessary, first pass the hydraulic oil
Z 163 669 through a filter.
12/16 bs_e100-3120
Hydraulic System 12
12.5 Bleeding the Hydraulic System
DANGER OF INJURY
when hydraulic oil escapes at high
pressure.
Therefore, before carrying out any work
on the hydraulic system, depressurise it.
i.e. - boom lowered
(Z 160 008)
Z 160 008
While the engine is running the hydraulic

system is bled through the vent ports
provided...
...hydraulic pump
(Z 163 595)
While bleeding the system, with the

engine running at idle speed, the vent fittings
should be kept open until oil which is free from
air bubbles escapes from the fittings.
Z 163 595
At points where there are no bleeder

connections, a union (union nut) situated at a
high level is loosened by a small amount.
(Z 160 197)
Date: 15.CW/00
Z 160 197
bs_e100-3120 13/16
12
At high engine speeds or with a high

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

Pressure Accumulator, Checking
the Preliminary Gas Tension
The pressure accumulators fitted in the

hydraulic system of the crane are diaphragm or
bubble-type accumulators with nitrogen filling.
They are fitted in the following components:

- Pilot control circuit of the superstructure
hydraulics
The corresponding components can only

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

at regular intervals.
To check the preliminary gas tension,

a filling and test device for diaphram and
bubble-type accumulators is required.
This inspection may only be carried out

Date: 15.CW/00
by specialist personnel who are trained in

the use of the filling and test equipment.
14/16 bs_e100-3120
Hydraulic System 12
To check and fill the pressure accumulator,

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

The pressure accumulator (2) must be
completely emptied of hydraulic fluid.
(Z 30 640)
Check this on the mini-gauge connection "X"

"X" at the pilot control circuit using a manometer.
Z 30 640 (0 bis 10 bar)
If the pressure gauge does not indicate a

pressure level, the system is not under
3 pressure.
- Remove the protective device (1) on the gas

1 valve of the pressure accumulator (2) and
screw on the filling and test device (3).
2
- Open the gas valve over the screwed-on
filling and test device and read off the charge
2 pressure on the pressure gauge of the
testing device.
Z 30 194 - If there is insufficient initial pressure, the

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

three minutes.
Check the preliminary pressure again and top
up as necessary.
Date: 15.CW/00
bs_e100-3120 15/16
12
When filling up the preliminary gas tension

1 on the pressure accumulator observe the
2 pressure gauge on the mini-gauge connection
"X".
The pressure in the corresponding hydraulic
circuit must not be allowed to rise.
If this is the case, the diaphragm in the
pressure accumulator is defective.
The pressure accumulator must be replaced.
(Z 30 640)
"X" Z 30 640
If a large fall in pressure (approx. 50 %) is

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

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

for the pressure accumulator.
Z 30 641 (Z 30 641)
16/16 bs_e100-3120
Electrical system 14
14.1 Checking the lighting system
Check the functioning of the lighting system and

rectify any damage immediately.
(Example: spotlight for working area)
(Z 163 810)
Z 163 810
14.2 Battery maintenance
For maintenance instructions, refer to the

operating instructions supplied by the engine
manufacturer.
(Z 160 502)
Z 160 502
Version: 48.CW/03
e100-3140_a 1/3
14
14.3 Fuses
Fuses are located:
- In the central electrical unit in the upper

right-hand corner of the crane cab.
- In the battery compartment.
Before you replace a fuse, first identify the

cause of the fault and rectify it.
The numbers of the fuses are given on the
circuit boards.
A blown fuse must always be replaced by a

fuse with the same number of amps (as
stated on the fuse label).
Version: 48.CW/03
2/3 e100-3140_a
Electrical system 14
- Superstructure (fuses)
OMC Amps Where installed Page.Path Potential Description

F600 50A Battery compartment 4.1 30 Main fuse SS
B1-F1 25A CEU SS 4.4 2 Ignition lock SS
B1-F2 10A CEU SS 4.10 4 Quick stop for engine,
B1-F3 10A CEU SS 6.5 21 Power supply for ADMFR
(Mercedes engine control unit) battery Plus
B1-F4 10A CEU SS 8.2 65 Rotaflare lights, lighter socket
B1-F5 10A CEU SS 9.2 23 Lighting, wind-speed transmitter,
dashboard lighting
B1-F6 10A CEU SS 10.5 35 Control unit for air-conditioning system
B1-F7 10A CEU SS 9.10 14 Cab lighting, radio
B1-F8 25A CEU SS 10.2 28 Magnetic clutch - compressor,
capacitor blower
B1-F9 10A CEU SS 5.2 201 PAT supply, LMI shutdown
B1-F10 10A CEU SS 9.6 382 Adjustable spotlight
B1-F11 10A CEU SS 11.2 45 Front windscreen wiper, skylight
windscreen wiper, washing pump
B1-F12 10A CEU SS 12.2 56 MFA10 battery
B1-F13 10A CEU SS 14.2 69 Cab up/down, engine stop, direction
switch, A0705 supply
B1-F14 25A CEU SS 32.2 304 Oil cooler
B1-F15 10A CEU SS 11.3 322 Pilot lever right, left, length indicator for
tele, pressure luffing cylinder,
FI converter,length angle sensor
B1-F16 10A CEU SS 32.5 202 Alarm system, outriggers,
crab walk steering
B1-F17 10A CEU SS 33.2 229 Double obstruction light
B1-F18 10A CEU SS 36.6 232 Lowering limit switch, hoist
configuration, angle transmitter on SS,
outrigger pressure sensor
B1-F19 10A CEU SS 39.4 274 Auxiliary heating system timer
B1-F20 10A CEU SS 39.12 284 Step switch for blower
B1-F21 25A CEU SS 39.2 187 Power supply to auxiliary heating
system, Hydronic D5W
B1-F22 10A CEU SS Not used
B1-F23 10A CEU SS Not used
B1-F24 10A CEU SS 5.15 19 Power supply to MR (Mercedes
engine control unit), ignition
B1-F25 10A CEU SS 6.12 16 Engine diagnosis socket (battery Plus)
B1-F26 10A CEU SS 6.13 17 Engine diagnosis socket (ignition)
B1-F27 10A CEU SS 21.2 200 Power supply for A706 ,A707
Version: 48.CW/03
B1-F28 25A CEU SS 42.14 359 Socket for radio unit (Japan option)
OMC = Operating equipment code

CEU SS = Central electrical unit on superstructure
e100-3140_a 3/3
Fuel System 15
15 Fuel System
Fuel tank
Drain off the water and sediment.
In order to drain the residue which has

accumulated in the fuel tank, open the drain
plug and drain off at least 1 l. of fuel.
(Z 163 330)
This maintenance job is to be performed

only with the fuel tank almost empty.
Z 163 330
1 Fuel filter
(Z 163 335)
For notes on maintenance, please refer to

the maintenance and operating instructions for
the diesel engine contained in Part 5.
Z 163 335
Date: 15.CW/00
bs_e100-3150 1/3
15
2 Manual fuel pump
When the fuel system is empty, fuel must be

pumped to the engine using the manual fuel
pump (2):
(Z 163 332)
- Release the vent plug (4) on the fuel

precleaner.
- Operate the manual pump until the filter
housing (5) is completely filled (fuel is emitted
at the vent plug).
- Tighten the vent plug (4) again.
Z 163 332
- Actuate the manual fuel pump at least another
20 times until the fuel is pumped to the engine.
(Z 163 334)
Z 163 334
Date: 15.CW/00
2/3 bs_e100-3150
Fuel System 15
3 Fuel precleaner and separator

(Z 163 332)
Changing the fuel precleaner:

- Press in drain valve (7) and turn.
- Drain off the fuel from the filter housing (6).

Z 163 332 suitable containers and disposed of
correctly.
- Close off drain valve (7) again.

- Unscrew cover (5).
- Replace filter insert.
- Screw cover (5) back on.
- Fill up fuel using manual fuel pump.
Depending on the fuel grades, it may be

necessary to drain off the water in the fuel
system.
In this case proceed as follows:

- Press in drain valve (7) and turn.
- Drain off emulsion until clean fuel is emitted.
- Close drain valve (7) again.
(Z 163 334)
Date: 15.CW/00
Z 163 334
bs_e100-3150 3/3
Cooling, Air Intake and Exhaust System 16
100--3160a_en 1/21
16
1 2
61
Z 57 817 Z 42 107
Z 4 965
2/21 100--3160a_en
16 Cooling, Air Intake and Exhaust System
Risk of burning and scalding.

When carrying out work in the vicinity of the exhaust and
cooling system, allow a cooling off period of 60 minutes or
wear appropriate clothing and gloves.
16.1 Cleaning and Replacing the Air Filter Element
Never service the air filter with the engine running.
(Z 57 817)
Clean the filter element as soon as indicator light (61) comes on

with the engine running.
(Z 42 107, Z 4 965)
1. Open spring--loaded latches (1) and remove cover (2) from

housing (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.
100--3160a_en 3/21
16
Z 0 406 Z 0 125
Z 0 126 Z 0 129
4/21 100--3160a_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)
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.
100--3160a_en 5/21
16
Z 0130
Z 0131
6/21 100--3160a_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.
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.
100--3160a_en 7/21
16
Z 27 837 Z 27 838
Z 501 336
8/21 100--3160a_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)
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).
(Z 501 336)
If required, the ejection hole (1) must be cleaned.
100--3160a_en 9/21
16
Z 57 815
70
Z 57 816
10/21 100--3160a_en
16.4 Cleaning the Cooling System

(Z 57 815 principle drawing, Z 57 816)
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.
If the coolant temperature reaches an unpermitted value, the

relevant light--emitting diode (LED) on multifunction display
10 (70, Z 57 816) flashes and a corresponding warning signal
goes off.
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.
100--3160a_en 11/21
16
Z 56 077
12/21 100--3160a_en
16.5 Checking the Coolant Level and Topping Up as Ne-

cessary
(Z 56 077)
Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. Acci-
dents may occur.
1. Turn the cap (1) 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.
16.6 Replacing the Coolant with Anti-- Freeze

(Z 56 077)
The coolant should be mixed with a corrosion proof anti--freeze

throughout the year (see operating instructions for the engine).
The anti--freeze has no negative effect on the improved 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.
100--3160a_en 13/21
16
Z 56 077
14/21 100--3160a_en
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.
3. Drain the engine and cooler.

In order to drain the cooling system, the relevant drain plugs
and hose couplings must be opened.
4. Once the cooling system has been drained, all drain plugs
and hose couplings must be closed again.
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.
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.
100--3160a_en 15/21
16
130.1 130.2 130.3
3
A
130.4
130.7 130.5
4
130.6
2 1 380V
130
Z 200 377 Z 075 373
”Y” ”X”
Z 56 116
16/21 100--3160a_en
16.7 Maintaining the Diesel Exhaust Particulate Filter (Op-

tional)
When the display gauge shows a pressure of more than 150

mbar (130, Z 200 377), the diesel soot particle filter must be bur-
ned clean.
Information on the display gauge can be found in see section 4
“Engine” of the operating instructions.
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
100--3160a_en 17/21
16
6 7
Z 075 374
18/21 100--3160a_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).
100--3160a_en 19/21
16
20/21 100--3160a_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 (setpoint -- Are the fuses okay? defective.
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
-- Are the heating ele- hours.
ments and air supply
functioning correctly?
-- Was the voltage a
constant 380 V during
the burning procedure?
-- Is the intake area of
the soot filter free of
soot following the bur-
ning clean process?
-- Has the diesel engine
been serviced?
The smoke level
must not exceed 2.5
-- Has the soot filter Bosch units without
been cleaned in accor- the soot filter.
dance with the servicing
instructions?
100--3160a_en 21/21
Piston Rods17
17 Piston Rods
Apply protective grease to exposed

chrome surfaces.
Despite being of the highest quality, surfaces
may be susceptible to corrosion in an agressive
environment. If the crane is out of operation for
more than one day, exposed surfaces should
be protected against corrosion by applying
acid-free protective grease ("GLEITMO 350" is
recommended, order number for aerosol:
604 106 40).
(Z 160 137)
Z 160 137
Date:13.CW/94
bs_e908-3170d 1/1
Optional Equipment 18
18 Optional Equipment
18.1 Auxiliary Heating
Please refer to the manufacturer's

instructions regarding servicing of the
auxiliary heating system (1).
(Z 163 566)
Z 163 566
18.2 Auxiliary Heating - Checking the

System is Functioning Correctly
Briefly switch on the heating

approximately once a month even outside
heating periods.
(Z 160 205)
The following malfunctions can be repaired by

the crane operator:
1. The fan cannot be heard after the heating

Z 160 205 has been switched on:
Check the 15-amp main fuse.
2. After the heating has been switched on,

the fan runs for approx. only 3 minutes,
the heating does not start and switches off
automatically:
a) Briefly switch the heating on and off again

(but not more than twice).
b) Switch off the heating system.

Check the fuses ( F 190, F 191, F 192 )
Date: 15.CW/00
in the main electrical unit and if necessary

have the fault repaired in the workshop.
bs_e100-3180 1/3
18
18.3 Replacing the Heat Exchanger
The heat exchanger has a service life of

10 years and must be replaced with an
original part after this period by the
manufacturer or one of the manufacturer's
recommended work shops.
The heating system must then be
marked with the date of sale and the words
"Original spare part".
(Z 163 566)
Z 163 566
18.4 Switching on the Hot Water Heating
Switch on the hot water heating outside the

heating period for approx. 10 minutes in order
to ensure a reliable start at the beginning of
the heating period.
(Z 163 562)
Do not operate the heating in enclosed

spaces.
Z 163 562
18.5 Checking and Replacing the Fuel

Filter
Close the shut-off cock on the fuel tank and

release the two hose clips on the fuel filter.
- Remove the pipes from the fuel filter.
- Fit the new filter.
(Z 163 563)
Date: 15.CW/00
Z 163 563
2/3 bs_e100-3180
Optional Equipment 18
18.6 Fine dust filter
In order to maintain the heating at full

performance, the fine dust filter must be
exchanged when soiled.
For this, remove bolts (1), (numbering four) and
change fine dust filter.
(Z 075 362)
Z 075 362
Date: 15.CW/00
bs_e100-3180 3/3
Visual Inspections 19
19 Visual Inspections
The following points should be observed every

day before driving the crane:
Check the covers and panels for damage.

Check for loose or missing screws.
(Z 163 672)
Z 163 672
Check the entire hydraulic system for damage

and leaks and check the oil level.
(Z 163 667)
Z 163 667
Check the engine for oil or fuel leaks and for

clogging.
Check the oil cooler for clogging.

Date: 31.CW/05
e100-3190_a 1/2
19
Check the instruments and displays for

damage.
(Z 163 811)
Z 163 811
Check the lighting system for damage.

(Z 163 812)
Z 163 812
Check that the windscreen washing assembly

is functioning correctly at least once a week.
The supply tank must always be filled with
water.
(Z 160 365)
Before the start of the cold season, anti-

freeze in a quantity corresponding to the
temperature must be added to the water.
Date: 31.CW/05
Z 160 365
2/2 e100-3190_a
Slew Ring 20
20 Slew Ring
20.1 Lubricate Bearings
The bearings for the roller bearing slewing rim

are to be lubricated by means of central
lubrication distributor's lubricating nipple.
Lubricating Procedure:
First, lubricate by means of the slewing rim
lubricating nipple, then slewing the
superstructure through 360°.
After repeating the lubricant application, it must
Z 160 300 be visible around the whole of the slewing rim,
forming a continuous ring lubricant.
(Z 160 300)
20.2 Lubricating the Gear Ring
Where uncovered areas are visible on the teeth

edges, these should be sprayed immediately
with special adhesive grease.
(Z 160 301)
Date: 09.CW/05
Z 160 301
e100-3200_j 1/2
20
20.3 Check slew ring bolt connections
Using a torque wrench, check the tightness of

the bolts by applying torque specified.
(Z 160 302)
Bolts which can be turned using the

torque specified must be unscrewed and
checked.
If the bolt in question is waisted, it must
be replaced with a new one.
Z 160 302
AC Item Dimension Material Torque
40 / 95 Item 1 M 20 x 90 12.9 600 Nm

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

clean and lightly greased when fitted.
Date: 09.CW/05
2/2 e100-3200_j
Slew Gear 21
21 Slew Gear
When carrying out maintenance work on

the slew gear, there remains the danger of
being dragged into the equipment at the
pinion - inspite of the safety cover.
Observe the attached warning sign.
Z 163 301
Z 163 301
21.1 Slew Gear Mechanism - Checking

and Topping Up the Oil Level
Only check the oil level when the

transmission is at a standstill.
When filled correctly, the oil level comes up to

the sill of the inspection glass.
Top up oil via filler opening (1) as necessary.
(Z 163 303)
Z 163 303 If there is a continual oil loss, operation

must be stopped and the cause of the loss
ascertained.
Date: 15.KW/00
bs_e100-3210 1/3
21
21.2 Slew Gear Mechanism - Changing

the Oil
The oil should be changed as soon as

possible after operation ceases, while still
warm.
- Unscrew breather (1).
- Unscrew the drain plug (2) and drain off the

gear oil.
(Z 163 304)
Z 163 304

correctly.
- Pour in a small amout of new oil via filler

opening (1) in order to wash out any possible
impurities and abrasive particles.
At lower ambient temperatures the

flushing oil should be warmed.
- After the oil has been drained off, screw the

cleaned drain plug (2) back in, having
replaced the sealing ring.
- Pour in new oil via filler opening (1) until it

comes up to the sill of the inspection glass.
- Clean breather (1), fit new sealing rings and

screw back in again.
Date: 15.KW/00
2/3 bs_e100-3210
Slew Gear 21
21.3 Checking and Tightening the

Screw Connections
Check the torque of the screws using a torque

wrench.
Tighten the screws as necessary.
(Z 163 305)
Item Dimension Material Torque
Pos. 1 M 14 x 30 8.8 118 Nm

Pos. 2 M 16 x 50 10.9 265 Nm
Z 163 305
When new screws are fitted, the thread

and head should be smeared with MoS2 paste.
Date: 15.KW/00
bs_e100-3210 3/3
Hoists 22
22 Hoists
Hazards caused by dragging!

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

hoist 2 as for hoist 1.
22.1 Hoist Gear - Checking and Topping

Up the Oil Level
Check the oil level through the inspection

glass.
The oil level should be checked

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

hoist gear must be drained off and new oil
filled in.
Date: 11.CW/04
e100-3220_a 1/6
22
If the level is below the minimum marking

proceed as follows:
- Remove the filler plug (1) at the upper end

of the inspection glass.
(Z 163 711)
- Using a funnel or hose, fill in oil up to the

"max." marking on the inspection glass.
(Z 163 710)
See section 22.2 and section 2 "Fuels and

Lubricants" for the correct oil types.
Z 163 711
- Screw the filler plug (1) back in.
If a continual loss of oil is discovered

when checking the oil level, operation
must be stopped and the winch gear
checked.
Z 163 710
22.2 Hoist Gear - Changing the Oil
Use the oil grade given in section 2 "Fuels and

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

synthetic oils.
2/6 e100-3220_a
Hoists 22
Fully synthetic oils may only be used

with acidproof seals and a sufficiently resistant
inner coating. Please refer to the Customer
Service Department of Terex-Demag.
The oil should be changed when it is warm, i.e.

after a longer operating period, as follows:
- Remove the filler plug (1) at the upper end of

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

correctly.
- After all the oil has run out, reinsert the

cleaned screw plug.
- Fill in new oil as described in section 22.1.
(Z 163 713)
- Reinsert the cleaned oil filler plug.
Z 163 713
Date: 11.CW/04
e100-3220_a 3/6
22
22.3 Checking the gear oil
The gear oil which is drained off should be

checked once a year.
The gear oil should be drained onto a filtering
tile and inspected for e.g. large grained solid
waste using a magnifying glass. Only foreign
substances (max. 0.15 % of the total volume
of oil) containing fine abrasions with a particle
size of less than 25 micrometers are
permissible. If large grained abrasions (more
than 25 micrometers) or surface flaking from the
faces of the teeth are detected, the gear must
be dismantled back to the drive, regardless of
the volume of the foreign substances. The faces
of the gear teeth should be visually inspected.
After the run-in period and with normal wear,
the surface of the tooth face should be smooth,
bright and shining.
In the case of any other irregularities such as
attrition, scoring, scuffing, pitting, flaking,
cracking and plastic deformation, the gear
wheels should be replaced or a complete
overhaul should be carried out.
In this instance please refer to the Customer
Service Department.
Date: 11.CW/04
4/6 e100-3220_a
Hoists 22
22.4 Lubricating the Rope Drum Bearing
Grease lubricating nipple.

(Z 163 316)
Lubricat until lubricant is emitted evenly

at the seal.
Z 163 316
22.5 Checking and Tightening the

Screw Connections
(Z 163 317, Z 163 414)

The torque for the screws is as follows:
Item Dimension Material Torque
Pos. 1 M 10 x 40 10.9 46 Nm
Pos. 2 M 20 x 70 10.9 558 Nm
Pos. 3 M 16 x 50 10.9 265 Nm
Z 163 317
The same values apply for hoist 2 as for

hoist 1.
When new screws are fitted, the thread

and head should be smeared with KP2K roller
bearing grease.
Date: 11.CW/04
Z 163 414
e100-3220_a 5/6
22
22.6 Lubricating the Hook Block
Risk of snagging!
When carrying out maintenance,
inspection and assembly work, special
care must be taken in this area as there
is a danger of becoming entangled and
dragged into the equipment between the
hook block pulleys and ropes.
Use the hand grips located on the hook
Z 160 318 blocks!
The lubricating nipples on the hook block should

be smeared before the crane is put into operation
and thereafter every 50 operating hours.
(Z 160 318)
22.7 Determination of the spent share

of the theoretical service life
A detailled description is given in chap. 1

"Notes on safety", point 1.4.4.
Date: 11.CW/04
6/6 e100-3220_a
Luffing Gear 23
23 Luffing Gear
23.1 Luffing Cylinders - Lubricating the

Foot and Piston Bearings
Grease the foot bearing via two lubricating

nipples.
(Z 160 319)
Z 160 319
Grease the piston rod bearing via one

lubricating nipple.
(Z 160 320)
Z 160 320
Date: 13.CW/94
bs_e908-3230d 1/1
Equipment 24
24 Equipment
24.1 Main Boom - Lubricating the Slides
- Inner slides
The basic case and the boom sections are fitted

with one lubricating opening on the left and
right-hand side.
(Z 163 322)
In order to lubricate the inner slides, you must
extend the telescopic sections in accordance
with the table below while the main boom is in a
Z 163 322 horizontal position.
Only extend the boom sections for

lubrication in accordance with the table
below.
(Outrigger support area 7.1 m x 4.5 m:
superstructure 0 degrees to the rear or
outrigger support area 7.1 m x 7.0 m:
superstructure 0 degrees to the rear or to
the side)
Type Min.
CWT
on Extension sequence
superstr. for lubricating the
AC100 11.7 t BC: 45% - 0% - 0% - 0%

BS1: 45% - 90% - 0% - 0%
BS2: 0% - 45% - 90% - 0%
BS3: 0% - 0% - 45% - 90%
Then, using a paint brush, coat the top slides

and if necessary the bottom slides with grease.
Date: 50.CW/05
e100-3240_b 1/29
24
- Outer slides
Extend all boom sections with the main boom

positioned horizontally.
Only extend the boom sections for

lubrication in accordance with the table
below.
(Outrigger support area 7.1 m x 4.5 m:
superstructure 0 degrees to the rear or
outrigger support area 7.1 m x 7.0 m:
superstructure 0 degrees to the rear or to
Z 160 323 the side)
Type Min.
CWT
on Extension sequence
superstr. for lubricating the…
AC100 11.7 t BC: 100% - 0% - 0% - 0%

BS1: 0% - 100% - 0% - 0%
BS2: 0% - 0% - 100% - 0%
BS3: 0% - 0% - 0% - 100%
Then, using a paint brush, coat the bottom and

if necessary the top slides with grease.
(Z 160 323)
Date: 50.CW/05
2/29 e100-3240_b
Equipment 24
24.2 Lubricating the Basic Bolts on

the Main Boom
Grease the two lubricating nipples.
(Z 160 327)
Z 160 327
24.3 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!
Z 30 316 When carrying out maintenance,
inspection and assembly tasks, there is a
risk of becoming entangled and dragged in
the following areas:
- between the rope and the rope winches
- between the rope and the sheaves of the
main boom or additional boom components
- between the rope and the sheaves of the
hook block
Proceed with special caution!
Danger due to friction and scraping!

Date: 50.CW/05
e100-3240_b 3/29
24
24.3.1 General Notes on Handling and

Assembly
24.3.1.1Transport
When working with cables, problems can be

encountered even at the delivery stage: the fork
of the forklift truck moves beneath the reel or
into the rope bundle thereby damaging the
cable surface.
Wherever possible, the cable, which is

delivered in bundles or on reels, should not
come into direct contact with a hook or with the
Z 29 084 forks of a forklift truck. Rather, it should be
raised by means of wide textile lifting slings.
(Z 29 084)
A reel is best raised by means of a rod placed

through its central axis.
(Z 29 085)
24.3.1.2 Storage
Cables should be stored in a cool, clean, dry

and covered environment. The cables should
not be stored directly on the ground but, for
example, on pallets.
If it is not possible to store the cables indoors,
they must at least be covered so that they do
Z 29 085 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.
Date: 50.CW/05
4/29 e100-3240_b
Equipment 24
24.3.1.3 Assembly
When cables are assembled, always ensure

that they are wound from the reel or bundle and
onto the system without the cables becoming
twisted or damaged.
Cable which is supplied on a reel is either
unwound by means of a swivel plate or rolled
out on the ground.In the case of the latter, the
ground should be as clean as possible. Sand,
for example, sticks to the lubricant on the cable
and can lead to cable damage if it gets between
the sheave and the cable on the equipment.
Cable which is wound on a reel is also preferably
unwound using a swivel plate or from a trestle.
Rolling the coil out on the ground, something
which is often recommended in related
literature, does not actually work very well in
practice as the reel gives off increasingly less
cable for the same distance rolled, making it
necessary to pull the cable behind you.
The cable must, however, under no
circumstances be pulled sideways from the
bundle or reel, as with this method a torsion is
created in each turn of the rope as it is
unwound.
Every rope torsion alters the length of lay of the
strands and cable and thereby the ratios of the
rope element lengths and ultimately the load
distribution in the cable.
Cable that is pulled sideways from the bundle

or reel resists the torsion which acts on it and
forms loops. When such a cable is placed
under load, the loops are drawn together and
form a kink, an irreparable deformation. Cables
with kinks are no longer safe to be used and
must be replaced.
(Z 29 086)
Date: 50.CW/05
Z 29 086
e100-3240_b 5/29
24
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.
Date: 50.CW/05
6/29 e100-3240_b
Equipment 24
Re-reeling
Every cable takes on a certain bending

tendency from the point of manufacture, where
it is drawn from the stranding basket by means
of delivering disks.
It is then supplied to the customer bent in this
direction.
It is then supplied to the customer bent in this
direction.When re-reeling from the reel onto the
rope drum, ensure that the cable is wound in this
direction.
If the rope strand is reeled on beneath the rope
drum, the mounting reel should be set up so that
the rope strand being reeled off also runs off
Z 29 087 beneath the reel and vice versa.
(Z 29 087)
If the cable is re-reeled against the directional

tendency, the cable will either tend to turn
between the reel and the rope drum or will turn
later on when in operation in order to bend to
the preferred direction.
In both instances, structural changes in the
cable will result.
Date: 50.CW/05
e100-3240_b 7/29
24
Drawing the cable by means of an auxiliary

reeving rope
If the new cable is to be drawn through by cable

which is to be removed or with an auxiliary
reeving rope, it must be ensured that these
ropes are securely fastened.
In addition, 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.
Date: 50.CW/05
8/29 e100-3240_b
Equipment 24
A less problematic method of connecting the

cables is by means of two rings or chain links
welded onto the cable ends.
These are then connected by means of strands
or thin ropes.Such a connection possesses a
satisfactory load bearing capacity, can be bent
and prevents the transfer of torsion from the old
rope to the new.
By using two strands, the number of turns in the
strands following assembly will show to what
degree the old cable on the equipment was
twisted.
(Z 29 088)
Z 29 088 Connecting the cables by means of rope
stockings offers a further possibility. Rope
stockings are plaited rope strands which are
pushed over the cable ends and secured with
adhesive tape.
When under load, the rope stockings are drawn
tighter and hold the cable ends by means of
friction.
When an equal-lay rope is to be drawn, it must
be ensured that the rope stockings can turn on
the rope like a nut on a screw, in spite of the
cord tensions.
This can be achieved by first winding strong
adhesive tape round the cable surfaces which
are to be held by the rope stockings.
(Z 29 089)
Z 29 089
Date: 50.CW/05
e100-3240_b 9/29
24
Winding on the rope under load
To wind the cable onto the drum smoothly it is

very important in the case of multiple layer
winding, and especially where so-called lebus
winding is used, that the cables are wound onto
the drum under tension.
If the lower layers are too slack, the upper
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
Z 29 090 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.
This can be achieved, for example, by braking

Z 29 091
the reel flange using a board or by means of a
brake disc attached to the reel.
The brake cords (hemp ropes with a steel core)
are supplied by the cable manufacturer.
(Z 29 090, Z 29 091)
It must not be attempted under any

circumstances to pretension the rope by
jamming it, for example, between two wooden
planks.
The rope would be irreparably deformed due to
structural changes.
(Z 29 092)
Date: 50.CW/05
Z 29 092
10/29 e100-3240_b
Equipment 24
Running in
Before a cable is placed in operation following

its assembly, a certain number of load cycles
with small partial loads should first be carried
out.
The cable should be „run in“ so that the cable
elements can settle and adapt to their new
environment.
Unfortunately, the opposite normally proves to
be the case in practice: following assembly of
the cable, overload checks are normally carried
out with loads which are above the permissible
load-bearing capacity of the system.
Cutting into sections
Often cables have to be cut into sections or

shortened by the user.
The cables can be cut in various ways.
Up to a diameter of 8mm, cable cutters can be
used;mechanical or hydraulic cutters are also
available for larger diameters.
If, however, a power source is available, it is
recommended that a pneumatic or electric right-
angle grinder be used.
In any case, the cables must be carefully bound
at the point of separation to prevent fraying of
the rope ends or changes in the cable and
strand laying lengths.
This especially applies when sectioning off non-
rotating or non-twisting cables, the strands of
which are often purposefully left unformed by
the cable manufacturer.
The rope ends must be bound using iron wire;
insulating tape cannot prevent structural
changes in the cables occurring.
Date: 50.CW/05
e100-3240_b 11/29
24
(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
Z 29 093
placed on either side of the cutting point.
Date: 50.CW/05
12/29 e100-3240_b
Equipment 24
24.3.2 Lubricating the Ropes
When manufactured, a cable receives intensive

lubrication which provides protection against
corrosion as well as improving the friction
coefficient of the rope elements internally and
between the cable and sheave or cable and
drum.
This initial lubrication lasts only for a limited
period of time and must be supplemented
regularly.
Cables must be relubricated at regular intervals
depending on the operating environment,
especially in the areas where the cable bends.
If the cable cannot be lubricated on operational
grounds, a shorter lifespan is to be expected
x
and the cables must be carefully monitored.
The effects of lubrication and relubrication on
a
the life expectancy of the rope can be seen in
figure (Z 29 094):
b x Number of reversed bending stresses (%)
y Tensile stress (N/mm2)

c
a greased and regreased
b greased
y
Z 29 094 c without grease
To increase their life expectancy and to protect

against rust, the ropes should be liberally
coated with grease.
It is not sufficient to lightly coat the ropes; the
grease must penetrate through.
This measure should be carried out when the
ropes are reeved.
Lubrication is best carried out using non-acidic
grease which has been thinned before use by
heating.
Date: 50.CW/05
e100-3240_b 13/29
24
The lubricant can be applied using various

methods:
- with a brush or glove
- applying near a sheave
- running the cable through a lubricant bath
- using a pressure collar
It is important that cables are lubricated

regularly from the very start and not only when
the first signs of damage are discovered.
In addition, observe all existing standards (e.g.

DIN 15 020) or national regulations.
24.3.3 Cleaning the Ropes
Cables which are very dirty should be cleaned

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

Replacing as Necessary
When fitting a new hoist rope, which has

never been placed under load, twisting
problems can occur.
For this reason, we recommend that a spin
stabilizer be used
(example: See Z 075 361).
Date: 50.CW/05
Z 075 361
14/29 e100-3240_b
Equipment 24
General If it has become apparent during the ropes

inspection that a rope needs changing, you
A cable is a commodity with a limited life must use an original rope from the crane
expectancy. manufacturer.
Many characteristics of a cable are altered The type of rope that is fitted depends among
during its operational period. other things on the inspection certificate which
For example, its breaking force initially increases is attached to the crane passport / crane
slightly with accrued operating time before falling inspection book.
rapidly once a maximum value has been reached. If it is not clear which type of rope should be
used, you must consult the crane manufacturer
This fall in breaking force is explained by the before ordering a new one.
increasing loss in the metal cross-section due to
abrasion and corrosion, wire breakage and Intervals
structural changes in the cable.
DIN 15 020 recommends daily inspection of the
In the cable, the load bearing elements are cables and end connections for any signs of
connected in parallel. damage.
A cable can therefore remain operationally safe
even after the breakage of a large number of Furthermore, the cables should be inspected at
strands. regular intervals by specialist personnel to
One of the purposes of a cable inspection is to ensure that they are in safe operating condition.
monitor the continuous increase in the number of wire The length of the intervals is to be determined
breakage, so that the cable can be removed before a in accordance with DIN “in such a way that
state is reached where operational safety is impaired. damage is ascertainable in advance in good
time.
A further purpose of the rope inspection is to For this reason the time intervals during the first
spot abnormal cable damage, which as a rule is few weeks after the laying of a new wire rope,
normally caused by external influences. and after the occurrence of the first wire breaks,
This facilitates, on the one hand, replacement must be selected shorter than the intervals
of the cable in good time and, on the other during the remaining service life of the wire rope.
hand, helps to spot weak points in the operation After the occurrence of unusually high loads or
of the rope, enabling measures to be taken of suspected but not visible damage, the time
which will prevent similar damage recurring. interval must be shortened accordingly (if
necessary to hours).
In addition, such an inspection must take place
when the rope drive is recommissioned after a
prolonged shutdown, or when the lifting
appliances have been dismantled and re-
assembled at a new location, before
recommissioning, or after an accident or
damage which has involved the rope drive”.
Date: 50.CW/05
e100-3240_b 15/29
24
Criteria for replacing ropes d) Abrasion
A rope should be removed if one or more of the Abrasion of the rope wires occurs as “internal
following conditions are fulfilled. See also the abrasion” by the cords and wires moving
relevant DIN standards. against each other when the cable is bent.
Abrasion occurs as “external abrasion” by the
a) Wire breakage cable and sheave moving against each other,
or by the cable slipping on the ground or on the
A cable must be removed when the permissible material to be conveyed.
number of wire breakage according to Abrasion is aided by the lack of, or unsatisfactory,
DIN 15 020 is reached or exceeded. lubrication and by the effects of dust.
The cable must be removed if wire breakage If the rope diameter is reduced by 10 % of the
are clustered or if a cord breaks. specified size or more, the cable must be
removed even if no wire breakage are
b) Rope wear determined.
The cable must be removed if, due to structural e) Rope deformation

changes, the diameter of a longer section of the
rope has decreased by more than 15% of the Cable deformations are visible in the rope
specified size. structure.
Deformation also generally implies that the rope
c) Corrosion structure has been loosened, particularly in the
region near the deformation.
Corrosion of the outer rope wires can be By examining the ropes, the most important
determined by visual inspection. Corrosion on deformations can be determined as follows:
the wires not visible from the outside can,
however, be difficult to determine. - corkscrew type deformation
Corrosion can lead to a reduction of the static - “basketwork” formation
breaking strength of the cable, as the metal - loop formation of wires
rope cross-section is reduced, and can lead to - slackening of individual wires or cords
a reduction in operational stability due to - knots
corrosion pits. - constrictions
- flattened areas
- curled type deformation
- kinks and buckles
Date: 50.CW/05
16/29 e100-3240_b
Equipment 24
Corkscrew type deformation (Z 1367)
Corkscrew type deformation occurs when the

axis of the unloaded cable becomes a helical
line.
X
The cable must be removed if deformation X
is 1/3 d or greater (d = nominal diameter of
rope)where the deformation is at its worst.
“Basketwork” formation (Z 1368)
Z 1367 “Basketwork” formation (deformation) can occur

in cables with steel inlays if the outer layer of
the wires is loose or if the outer cords are
longer than the inner cords.
The excess length is moved into one place by
movement of the outer wire sections or cord
sections towards the inner ones.
The cable must be removed if

„basketwork“ formation occurs.
Loop formation of wires (Z 1369)
Loop formation of wires occurs when single

Z 1368 wires or wire groups protrude on the side of the
rope which is turned towards the groove of the
sheave in the shape of hair pins.
The cable must be removed if the rope

structure has been changed considerably
by loop formation.
Date: 50.CW/05
Z 1369
e100-3240_b 17/29
24
Slackening of individual wires or cords

(Z 1370)
Slackening of individual wires or cords occurs

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

and the remaining wires or cords are
overstrained.
When running the ropes over the sheaves,

increased bending stresses can occur which
lead to premature wire breakage.
Z 1370
The cable must be removed if cable

slackening, caused by rust and abrasion,
occurs.
The removal schedule for the ropes is
determined by wire breakage if the cause
of rope slackening is different from that
given above.
Knots (Z 1371)
Knots are recurring points over long sections of

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

deformation must be removed.
Date: 50.CW/05
18/29 e100-3240_b
Equipment 24
Constrictions (Z 1372)
Constrictions are reductions in the diameter of

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

be removed.
Z 1372 Flattened areas (Z 1373)
Flattened areas are permanent deformations of

the cable which are caused by crushing.
Flattened areas in a rope will lead to an

increased occurrence of wire breakage.
Curled type deformation
Curled type deformation occurs if a loaded cable is

drawn over an edge.
Z 1373 Cables displaying curled type deformation

must be removed.
Kinks (Z 1374)
Kinks occur when an eye-shaped rope loop is

pulled straight in such a way that the cable
cannot compensate the deformation by turning
on its axis.
Cables with one or more kinks must be

removed.
Date: 50.CW/05
Z 1374
e100-3240_b 19/29
24
Buckles (Z 1375)
Buckles are deformations which occur when the

cable is under violent external influences.
Cables with buckles must be removed.
Effects of heat
Cables which have been subject to

Z 1375 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.
Date: 50.CW/05
20/29 e100-3240_b
Equipment 24
24.4 Checking the Main Boom for

Weld Cracks
In order to prevent breakage, the weld

joints on the main boom are to be inspected for
cracks once a year.
(Z 160 331)
Z 160 331
If any crack formations are detected, the

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

qualified welder.
(Z 160 333)
Date: 50.CW/05
Z 160 333
e100-3240_b 21/29
24
24.5 Inspect Rope Track Rollers
Check all main boom and main boom extension

rope track rollers regularly for wear and ease of
motility in turning.
If clear wear tracks are visible on the track
rollers, they must be replaced.
Rope track rollers which are split by hoist

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

y y
Regularly check all sheaves for any sign of
damage, for example cracks, scoring or similar
d damage.
x
Sheaves with this type of damage must be

replaced immediately.
Also check all sheaves regularly for wear.

If the rope groove has worn in more than 3 mm
compared with a new sheave (x)
Z 160 543
or
the lateral surface (y) up to the rope (d) has
worn in more than 5 mm, the sheave must be
replaced.
(Z 160 543)
Date: 50.CW/05
22/29 e100-3240_b
Equipment 24
24.7 Sheaves - Checking the Roller

Bearing
Inspect all sheaves on the main boom head and

on all additional equipment once a year for the
following:
- Discharge of grease
- All bearing seals are fitted correctly
- All circlips are fitted correctly
- Running noises, rolling resistance
- Bearing play
Z 160 343 (Z 160 343)
If any faults are discovered on the roller

bearings, the sheave must be replaced.
(Z 160 344)
In this instance, please inform the

Customer Service Department.
Z 160 344
If inspection reveals a damaged circlip, the

circlip must be replaced.
(Z 160 345)
Original Demag circlips with chamfered

edges must be used.
Date: 50.CW/05
Z 160 345
e100-3240_b 23/29
24
24.8 Sheaves - Lubricating the Roller

Bearings
Lubricate the roller bearings via the lubricating

nipples (x 4).
(Z 160 342)
Z 160 342
24.9 Checking the Pins for Cracks
Check all pins for cracks regularly, e.g. during

assembly and dismantling.
(Z 160 353)
Z 160 353
Date: 50.CW/05
24/29 e100-3240_b
Equipment 24
24.10 Checking the Draw Bars

(Shackle on the Main Boom Extension)
The draw bars must be inspected by an

expert at least once a year (in accordance
with accident prevention regulations for
the operation of load lifting equipment /
VBG 9).
The bars should also be inspected by an
expert between these intervals if
necessitated by the operating conditions.
As the inspection intervals are generally
related to operating conditions, if the
crane is in operation for longer periods of
time the intervals should be reduced
accordingly.
Records should be kept of the inspections
(e.g. in the crane log book).
It may be necessary to dismantle the draw

bars to be able to inspect them correctly.
The draw bars must be inspected in their

entirety, i.e. all hidden surfaces and bores
must also be inspected.
Date: 50.CW/05
e100-3240_b 25/29
24
The following inspections should be carried

out:
- Checking for cracks:
The draw bars should be checked regularly for

cracks.
A surface crack test (e.g. magnaflux test) must
be carried out at least once every year.
Should cracks be found during the inspection of
a draw bar, the draw bar must be replaced.
Repairs are prohibited.
- Checking the length:
The draw bars are designed so that no

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

measured, the tension bracket must be
replaced.
L
Bugles on the main boom extension
The original length of the bugles on the main

boom extension is L = 1039 mm.
(Z 163 819)
Date: 50.CW/05
Z 163 819
26/29 e100-3240_b
Equipment 24
- Checking for wear:
Check the pin locks, pins and bores for signs of

wear.
It must be ensured that the pin locking
mechanism is functioning correctly.
- Checking for plastic deformation:
If plastic deformation occurs (e.g. bending), the

draw bars may no longer be used.
- Checking the paintwork:
The paintwork must be checked regularly for

signs of corrosion.
Damaged areas should be restored.
The draw bar bearing must not come into
contact with aggressive agents (e.g. sea water).
24.11 Lubricate Main Boom Extension

Bolts
Check all bolts e.g. retaining bolts and bell

cranks on the main boom extension for ease of
operation and lubricate if necessary.
(Z 163 823)
Date: 50.CW/05
Z 163 823
e100-3240_b 27/29
24
24.12 Telescopic Main Boom Extension

(Optional) - Lubricate Sliding
Surfaces
Extend the main boom extension while the main

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

(Optional) - Lubricate the Foot
Bearing
Grease both lubricating nipples on the pins of

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

(Optional) - Lubricate the Luffing
Cylinder
1- Grease the lubricating nipple on the foot

bearing of the luffing cylinder (x 2).
(Z 160 372)
Date: 50.CW/05
Z 160 372
28/29 e100-3240_b
Equipment 24
2- Grease the lubricating nipple on the

piston rod bearing of the luffing cylinder.
(Z 160 373)
Z 160 373
24.15 Checking the Welding on the

Telescopic Main Boom Extension
for Cracks (Optional)
Follow the same principle as described in the

Lubrication and Maintenance Manual, Sect.
24.4, “Checking the Main Boom for Weld
Cracks”.
Date: 50.CW/05
e100-3240_b 29/29

AC100 77001 Part3 - en

Uploaded by

Copyright:

Available Formats

AC100 77001 Part3 - en

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AC100 77001 Part3 - en

Uploaded by

Copyright:

Available Formats

Contents

Notes for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Fuels and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

Part 3: Lubrication and Maintenance instructions for the

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

General Recommendations Regarding Lubrication and Maintenance

- Thoroughly clean all nipples, caps and plugs before greasing.

- After cleaning the crane, grease all lubricating points.

Please contact the Customer Service Department immediately if you

The safety instructions for the lubrication and maintenance

The specifications for the quality of the lubricant can be found in

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

All the service points, ordered according to service intervals, are

Service points without fixed service intervals are listed under

Service intervals should be determined by the kilometres

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

Service Point = Unit or point on which the maintenance

Service Interval = Number of kilometres after which the

1.1 General Recommendations for the

Undertake the prescribed adjustment and

Ensure that all handles, steps, rails, platforms,

Ensure that the crane is kept clean at all

- Thoroughly clean all nipples, caps and plugs

- Refill the fuel tank at the end of each

Sufficient ventilation has to be ensured

- Renew the sealing rings for drain, filler,

The oil can be drained more easily from

When the operating temperature is reached,

After cleaning the engine bay, check all

for leaks, loose connections, worn patches

Repair any damage immediately.

After cleaning the crane, grease all grease

When dry, spray the slew gear teeth with the

Check all electrical lines, push-on connections

Repair any damage immediately.

Check the turbocharger mounting.

Check the exhaust and air inlet lines and the

Repair any damage immediately.

Fire extinguishers must be full and ready for use.

Never carry out welding repairs without first

- Please contact the Customer Service

1.2 Notes on Safety

The diesel engine must always be switched off

Before carrying out any lubrication or

The residual energy or stored energy wich

Check that the crane is free of faults.

Lubrication and maintenance tasks may only be

Before carrying out any lubrication or

i.e. - boom lowered

Wear safety clothing, protective goggles,

Do not allow unauthorized persons near

Work which could affect the operational

and road safety of the crane must only be

If it is necessary for one or more persons to be

Store oil-impregnated rags and flammable

Oils that are drained off must be stored in