SMT Crane Maintenance Manual

SMT crane maintenance manual
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Index
1.0 Hydraulic System 1
1.1 Pump distribution box 1

1.2 Swing drive 4
1.3 Holding winch 6
1.4 Closing winch 9
1.5 Boom hoist winch 12
1.6 Drive unit 13
1.7 Hydraulic swivel joint 14
1.8 Hydraulic oil and filters 15
1.9 Hydraulic oil cooler 21
2.0 Components 23
2.1 Diesel engine 23
2.2 Slew ring 26
3.0 Greasing points 27
3.1 Boom head sheaves 27

3.2 Boom foot pin 27
3.3 A-frame sheaves 28
3.4 Pendant rope block sheaves / Triangle plate 29
3.5 A-frame pins 30
3.6 Machinery cover pin 30
3.7 Engine compartment door hinge 31
3.8 Boom hoist safety switch 32
3.9 Cardan shaft 33
3.10 Automatic lubrication system 34
4.0 Wire Ropes 35

4.1 Holding ropes 35
4.2 Closing ropes 35
4.3 Boom hoist ropes 36
4.4 Pendant ropes 36
5.0 Loose Gear 38

5.1 Grab (J&B Grabs) 38
6.0 Gantry 39
6.1 Wheel sets 39
6.2 Parking Lock 43
Annex I TOTAL Lubrication / Oil Data Sheets
Annex II Mineral-oil based Pressure Fluids
Annex III Maintenance Checklist
Annex IV Lubrication Checklist
Annex V Lubrication Equivalents
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1.0 Hydraulic System
1.1 Pump distribution box
General information:
Make : Stiebel Getriebebau

Type : 4538
Gear lube oil volume : 50 litre
Recommended Gear lube oil :
Make : Total
Type : Carter SH 220
: Synthetic oil
Ambient temperature : -25 to + 800 C
0
Kinematic Viscosity at 40 C : 220 mm2/s Figure 1.1
For more information about the recommended total gear lube oil see also Annex I.1.
For an equivalent of the recommended gear lube oil (with the same specifications) see Annex VI or contact your oil supplier.
Other oil then the recommended oil must be CLP 220 to DIN 51517.
Maintenance:
After 200 operating hours - First oil change

- Recommended oil according to specifications above
Daily - Visual leak check
Weekly - Check for unusual noise
- Check oil level
Monthly - Check the tightness of all screws and bolts
Semi-annually - Check oil quality
Annually - Change oil
(or after 2000 operating hours whichever is earlier) - Clean air breather filter
- Clean magnetic plug on the drain plug
Every 4000 operating hours - Inspect coupling between diesel engine and cardan shaft,
therefore dismount cardan shaft and flywheel cover. If
there are sign of wear on the rubber element replace it. If
there are no signs of wear inspect every 500 service hours.
Table 1.1 Maintenance schedule
The transmission should be cleaned externally depending on the operating conditions and should every day be checked for any
leaks or loosened threads. Oil samples should be taken. Considerable signs of metal abrasion in the oil or at the drain plug
indicate increased wear of the development of a fault and in such cases the transmission should be examined carefully.
Filling of lubricant:
Check the oil level by loosening the dipstick on top of the pump distribution box (see figure 1.4). The oil level is to be checked
after about 15 minutes running time as oil collects in the mounting flanges or is dammed there to lubricate the splined hollow
shafts.
If necessary, replenish oil up to the specified oil level mark. Repeat this procedure until the oil level no longer changes.
At each oil change check all the seals and screw fittings for any leaks and, if necessary, retighten the screws.
A rise in the oil level in the pump distribution box is a sign of defective seals in the hydraulic units.
Running dry of the pump distribution box as a result of oil loss, causes premature gear unit failure.
Filler cap, breather nipple and oil dipstick may only be removed or loosened when the diesel engine is turned off.
Take always care of the general Safety Precautions on the first page of this manual.
The pump distribution box has its own gear lube oil cooling system. A pump constantly circulates the gear lube oil through the
oil cooler on top of the pump distribution box and through a (red) filter which is mounted on the cooler support.
(see figure 1.2 on the next page).
Replacement element: HYDAC 660 D

Replacement interval: First replacement after 500 operating hours
-1-
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Next replacement every 2000 operating hours
The Filter is equipped with an indicator. If the indicator is red before the end of 2000 operating hours the element has to be
replaced earlier. If the indicator is still green after 2000 operating hours the element still has to be replaced.
-2-
Figure 1.2 Gear lube oil filter pump distribution box
Filter indicator
Filter is equipped with an indicator on top. The

indicator can be used to check the quality of the
filter element. To check the indicator the gear lube
oil has to be at its operating temperature:
Green = Filter has sufficient filtering capacity

Red = Filter has to be changed
-3-
Figure 1.3
Top view pump distribution box
1
.
2 3
. .
Figure 1.4 Detail top view
1 = Dipstick
2 = Filler cap
3 = Breather cap
-4- Figure 1.5 Oil drains / magnetic plug

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1.2 Swing Drive
Make : Zollern Getriebe

Type : ZHP 3.26
Gear lube oil volume : 20.5 litre
Number of swing drives : 2
Make : Total
Type : Carter SH 220
: Synthetic oil
0
Maintenance:

Weekly - Inspect visually
- Check for unusual noise
- Check oil level with non-running gear
Semi-annually - Check oil quality
Every 3 years - Change oil
(or after 3000 operating hours whichever is earlier)
Oil drain Swing Drive
Figure 1.7 Oil drain Swing Drive (Superstructure / front below platform)
Note:
- The oil level can only be inspected with non-running gear. The Zollern swing drives are equipped with an oil level
spyglass and a oil level nipple on the front of the gearunit (see Figure 1.9)
- If possible oil change only with service temperature condition, therefore remove the ventilating filters.
-5-
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- It is recommended to clean with a pre-heated part of new oil when ambient temperature is low, so that abrasion and
contaminations can flow away.
- Refilling of gear lube oil through the ventilating filters. Before refilling remove ventilating cap.
- Gear lube oil drain through the oil drain at the front of the superstructure below the platform.
-6-
Figure 1.8 Swing Drives
Breather nipple / Ventilating filter
Spyglass
Oil level nipple
Spyglass
Figure 1.9 Spyglass / Oil level nipple -7-

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1.3 Holding winch
Make : Lohmann + Stolterfoht

Type : GFT 330 W3
Gear lube oil volume : approx. 50 litre
Make : Total
Type : Transmission SYN FE 75W-90
: Synthetic oil
Kinematic Viscosity at 400 C : 101 mm2/s
Figure 1.10
Other oil then the recommended oil must be CLP 100, synthetic oil to DIN 51517.
Maintenance:

Daily - Check for oil leakage
- Check oil level
Semi-annually Check oil quality
Lubrication nipple
Figure 1.11 Lubrication point support bearing Holding Winch (Superstructure /left side)
The support bearing is connected to the automatic lubrication system.
Automatic lubrication system grease :
-8-
.
Make : Total
Type : CERAN WR 2
For more information about the recommended Total grease see also Annex I.8.
Figure 1.12 General arrangement Lohmann + Stolterfoht GFT 330, Oil inlet and Oil level.
Oil level
Figure 1.13 Holding / Closing gearbox (Drivers cabin side of crane), Oil level.
The holding winch gear box has its own gear lube oil cooling system. A pump constantly circulates the gear lube oil through the
oil cooler on top of the pump distribution box and through 2 filters which is mounted on the left side of the chassis.
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Replacement element (filter no. 1) : HYDAC 240 D010 BN3HC
Replacement interval : First replacement after 500 operating hours
The filters are equipped with an indicator. If the indicator is red before the end of 2000 operating hours the element has to be
-10-
Figure 1.14 Gear lube oil filter no. 1 (Holding winch)
Replacement element: HYDAC 060 D010 BN3HC
Figure 1.15 Gear lube oil filter no. 2 (First filter from chassis =-11-
closing winch, Second filter = holding winch)
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1.4 Closing winch

Type : GFT 330 W3
Make : Total
: Synthetic oil
Figure 1.16
Maintenance:

- Check oil level
Lubrication nipple
Figure 1.17 Lubrication point support bearing Closing Winch (Superstructure / left side)
The support bearing is connected to the automatic lubrication system.
Automatic lubrication system grease :
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Make : Total
Type : CERAN WR 2
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Figure 1.18 General arrangement Lohmann + Stolterfoht GFT 330, Oil inlet and Oil level.
Oil level
Figure 1.19 Holding / Closing gearbox (Drivers cabin side of crane), Oil level.
The closing winch gear box has its own gear lube oil cooling system. A pump constantly circulates the gear lube oil through the
oil cooler on top of the pump distribution box and through 2 filters which are mounted on the left side of the chassis.

Replacement interval : First replacement after 500 operating hours
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The filters are equipped with an indicator. If the indicator is red before the end of 2000 operating hours the element has to be
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Figure 1.20 Gear lube oil filter no. 1 (Holding winch)
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Figure 1.21 Gear lube oil filter no. 2 (First filter from chassis = closing winch, Second filter = holding winch)
1.5 Boom hoist winch

Type : GFT 110 W3
Number of gearboxes : 2
Make : Total
: Synthetic oil
Figure 1.22
Maintenance:

- Check oil level
Breather nipple
Oil level nipple
Oil drain nipple
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Figure 1.23 Maintenance points Boom hoist gearbox GFT 110 W3
1.6 Drive unit (Gantry)

Type : GFT 60
Number of gearboxes : 2 (starboard)
Type : GFT 40
Gear lube oil volume : approx. 4,5 litre
Number of gearboxes : 2 (portside)
Make : Total
: Synthetic oil
Figure 1.13
Maintenance:

- Check oil level
1
. 2
.
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Figure 1.25 Maintenance plugs drive unit (GFT 40 / portside is shown)
To check the oil level in the drive units (GFT 40 and GFT 60) the imaginary line through plug no. 1 and the centre of the gearbox
must be horizontal. Nipple no. 1 can now be used as oil level plug. When plug no. 2 is at the same time at the top of the gearbox
it can be used as a refill nipple. When the gearbox is rotated 180 degrees plug no. 2 can be used as oil drain when the gear
lube oil has to be changed.
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1.7 Hydraulic swivel joint (Rotor Seal)
Make : ALA
Type : A-640
Figure 1.26 Hydraulic swivel joint
Maintenance:
Every 100 operating hours - Inspect visually

- Check for oil leaking
-20-
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To reach the hydraulic swivel joint for inspection remove manhole cover below the holing winch.
The swivel joint (rotor seal) has life time greasing and therefore doesnt have to be greased manually.
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1.8 Hydraulic oil and filters
General information hydraulic system:
Type : closed hydraulic circuit

System volume : approx. 6000 litre
Recommended Hydraulic Fluid
Make : Total
Type : Equivis ZS 68
Maintenance:
Daily - Check hydraulic oil level (hydraulic tank)

- Check on leaks in hydraulic system
- Check if hydraulic oil cooler is clean, polluted oil cooler can
cause overheating of the installation.
Monthly - Check hydraulic hoses for damages
After 500 operating hours - Take sample of hydraulic oil and check quality*
- Change hydraulic oil if the quality is unacceptable**
After every 1000 operating hours - Take sample of hydraulic oil and check quality*
- Change hydraulic oil if quality is unacceptable**
After every 2000 operating hours - Change hydraulic oil filters***
(or sooner when hydraulic oil has to be changed)
* Oil quality check:
The hydraulic oil sample has to be checked for its lubricating capacity and the amount of pollution in the oil. If one or two of the
criteria isnt sufficient the oil has to be changed. A quality check of the oil can be carried out by your oil supplier.
Oil samples can be taken at every testing nipple on the pumps (see figure 1.27).
Required oil volume for quality check approx. 10 cc.
** Oil change:
If the oil quality is unacceptable it has to be changed according to the following procedure:
1. Stop the hydraulic system by turning off the diesel engine.

2. Drain the hydraulic oil from the hydraulic oil tank. This can be done in two different ways (option b is recommended)
a. Unlock the drain plug with magnetic bar on the bottom of the oil tank
b. Pump out the hydraulic oil by connecting a pump with the outlet nipple on top of the tank. On this nipple a
pipe is connected to the bottom of the tank. (see figure 1.28)
3. Clean the magnetic bar in the drain plug. The magnetic bar prevents possible steel parts in the oil from moving
through the hydraulic system and possible damage due to the steel parts. Two drain plugs are positioned on the
bottom of the hydraulic tank/cooler unit above the engine compartment (see figure 1.29).
4. Remove manhole covers and filters from the integrated filter box in top/front of the tank/cooler unit (see figure 1.30).
5. Clean the hydraulic tank and the integrated filter box internally by rinsing it with hydraulic oil. If the oil is not drained by
the drain plugs at the bottom (option a) but with a pump (option b) make sure the two magnetic bars are cleaned.
6. After cleaning close (manhole) covers and insert drain plug and high pressure filter elements.
7. Refill hydraulic oil tank with hydraulic oil according to table specifications above through the filling nipple on top of the
tank. (see figure 1.28). Refill from clean drums through a fine filter of 10 m. The oil has to be free of air bubbles.
8. Refill oil just above halfway the oil level indicator on the hydraulic tank (see figure 1.31).
9. Start the hydraulic system by turning on the diesel engine. Let the hydraulic system run stationary for a few minutes.
Due to the circulation in the system all pumps and motors are filled with oil which causes the hydraulic level to fall.
10. After the diesel engine is turned off again, refill oil till the level is again on the same level as in figure 1.31.
11. Recheck oil level after starting and stopping the hydraulic system.
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.
If the oil level falls below the required oil level due to leaks in the system or loose of oil during repairs the oil also has to be
refilled. Before refill check the date of the last oil change. Usually it is more profitable to change all the oil at once instead of
refilling it. However if the oil is only refilled to the required level make sure the added oil is of the same type / quality as the
existing oil in the tank.
Always write down the oil quantity that is added to conclude the losses and to find the cause of a possible repair more easy.
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*** Hydraulic oil filters:
The crane is equipped with 13 HYDAC hydraulic oil filters. For a reliable filter operation only original HYDAC filter elements
should be used. After every 2000 operating hours or in combination with an earlier oil change all filters should be changed.
The following types of filter elements are used in the hydraulic system of the crane:
- 4x high pressure filter elements mounted in the filter box in top of the hydraulic tank. (see figure 1.32)
The filter elements can be removed from the tank by the four filter covers in top/front of the tank unit (see figure 1.30)
Replacement element : 4x HYDAC 0950 R 010 BN3HC
- 9x low pressure filters mounted on 2 supports in the engine compartment (see figure 1.33).
Replacement element : 9 HYDAC 0240 D 010 BN3HC
For more information see manufacturers information.

A constant circulation filter (CC Jensen filter) is installed in the hydraulic system of the crane (see figure 1.34). This filter system
has its own pump, that constantly circulates the hydraulic oil from the tank through the filter back into the tank when it is turned
on by the switch as shown in figure 1.35. It is recommend to have turned on the CC Jensen filter as long as the crane is in
operation. The filter element of the CC Jensen filter, type HD 27, has to be changed every 2000 operating hours or every year.
Recommended hydraulic oil:
In order to simplify selection, different viscosity grades have been created. The identifying code relates to average viscosity in
mm2/s at 40o C. Viscosity grades (VG) 22 to 100 are in most common use.
VG 22 (A): for artic conditions or for extremely long pipelines

VG 32 (W): for winter conditions in central Europe
VG 46 (S): for summer conditions in central Europe
VG 68 (T): for tropical conditions or for areas with high temperatures
VG 100 (U): for excessively high temperatures.
Selection of viscosity grade is made on the basis of starting viscosity with ambient temperature (consider pour point where
necessary) and optimum operating viscosity according to system and operating data according to diagram 1.1.
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Diagram 1.1 Hydraulic oil selection diagram (Rexroth) For more information see Annex II
-25-
Figure 1.27 Testing nipple for oil sample on hydraulic pump. (Every testing nipple in the hydraulic system can be used)
Detail of testing nipple
1 = Silica filter
2 = Refill nipple
3 = Oil drain nipple for drain pump
The Silica filter extracts the

moisture out of the hydraulic tank.
A clean filter has a green colour.
If the filter has turned blue the
content of the filter has to be
heated to release the moisture
from the silica. After heating the
silica get its green colour back
and can be reused.
1 2 3
. . .
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Figure 1.28
Maintenance nipples top tank unit
Figure 1.29 Oil drain with magnetic plug at the bottom of the tank unit / roof of the engine compartment.
1
.
2 2 2
2 . .
. .
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1 = manhole cover filter box
2 = cover for HYDAC filter
0950 R 010 BN3HC
3 = oil drain filter box
3
.
Figure 1.30 Integrated filter box tank unit
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LEVEL
Figure 1.31 Hydraulic oil level indicator (outside tank unit)
-29-
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Figure 1.32 HYDAC high pressure hydraulic filter element type 0950 R 010 BN3HC
-30-
Figure 1.33 Low pressure hydraulic filters, HYDAC 0240 D 010 BN3HC with indicator
Detail oil filter indicator.
Low pressure oil filters are equipped with an indicator on top. The indicator
can be used to check the quality of the filter element. To check the indicator
The hydraulic oil has to be at its operating temperature:
Green = Filter has sufficient filtering capacity
Red = Filter has to be changed
-31-
Figure 1.34 CC Jensen hydraulic oil filter unit Figure 1.35 Switch CC Jensen filter unit
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1.9 Hydraulic oil cooler
General information hydraulic oil cooler:
Make : Bugge
Type : 013
Number of oil coolers : 3
The hydraulic oil coolers are mounted in the tank / cooler unit on top of the engine compartment. At the air inlet side of the
coolers filter unit clean the air. The coolers and filter units can be reached from the top of the tank / cooler unit (see figure 1.36)
Figure 1.36 Oil cooler hatch closed Oil cooler hatch opened
Each oil cooler has two filter units. Lift the filter units out of the tank / cooler unit and check the pollution of the filters. The
interval to check the filters is daily to weekly, depending on the environment the crane is operation in. After the filter units have
been removed also check the oil cooler itself. Open the oil cooler hatches only with a non-running diesel engine / oil cooler.
If the filter units are polluted, open the unit cover and replace the filter material.
Figure 1.37 Filter unit
The filter material is a glass fibre blanket.

And is called paint stop.
-33-
Figure 1.38 Hydraulic oil cooler seen from inside the tank / cooler unit
Weekly the hydraulic system/ connections of the oil coolers have to be checked for oil leaking. To reach the hydraulic system of
the oil coolers unscrew the bolt of the manhole cover next to the two oil cooler hatches. Make sure that this action may only take
place with a non-running diesel engine/ oil cooler.
Maintenance:
Daily / weekly - Check if the filter units and hydraulic oil coolers are clean.
A polluted oil cooler can cause overheating of the
hydraulic system
Weekly - Check for oil leaking
-34-
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2.0 Components
2.1 Diesel engine
Make : Caterpillar
Type : 3508 B
Capacity for liquids
Cooling system : 114 litre (engine only)
: 170 litre (radiator and water hoses)
: 284 litre (total)
Lube oil system : 227 litre
Recommended Lube oil :
Make : Total
Type : Caprano TD
Grade : SAE 15W-40
Ambient temperature : -15 to + 500 C Figure 2.1
For more information about the recommended total lube oil see also Annex I.5.
For an equivalent of the recommended gear lube oil (with the same specifications) see Annex VI table 2.2 on the next page or
contact your oil supplier.
This chapter only gives a summary of the maintenance manual of Caterpillar, therefore also read the original Caterpillar manual
carefully before any maintenance to the diesel engine is done.
Maintenance:
Daily - Check cooling system coolant level

- Check driven equipment
- Inspect engine air cleaner service indicator
- Check oil filter differential pressue
- Check engine lube oil level
- Drain fuel system / tank water and sediment
- Inspect instrument panels
- Inspect engine visually (walk-around inspection)
Initial 250 service hours - Inspect / adjust engine valve lash
- Inspect / adjust fuel injector
- Clean inspect speed sensor
Every 250 service hours - Check battery electrolyte level
- Inspect / adjust / replace belts
- Obtain cooling system coolant sample
Dlja - Test/add cooling system supplemental coolant additive
- Obtain engine oil sample
- Change engine oil and filter
- Inspect / replace hoses and clamps
Initial 500 service hours - Obtain cooling system coolant sample
Every 500 service hours - Change engine oil and filter
Every 1000 service hours - Clean engine
- Clean crankcase breather
- Change engine oil and filter
- Check engine protective devices
- Clean / inspect / replace fuel system primary filter
- Replace fuel system secondary filter
Every 2000 service hours - Inspect crankshaft vibration damper
- Check engine mounts
- Inspect turbocharger
Every year - Obtain cooling system coolant sample
Every 3000 service hours or 3 years - Change cooling system coolant (DEAC)
- Add cooling system coolant extender (ELC)
Every 4000 service hours - Inspect auxiliary water pump
- Inspect / adjust engine valve lash
- Inspect / adjust fuel injector
Table 2.1/part 1 Maintenance schedule (recommend by Caterpillar)
For more detailed information and exact descriptions of maintenance schedule see manufacturers information of Caterpillar:
-35-
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Operation and Maintenance Manual 3500B Series II Marine Auxiliary Engines.
-36-
Every 6000 service hours or 6 years - Inspect alternator

- Replace cooling system water temperature regulator
- Inspect prelube pump
- Clean / inspect speed sensor
- Inspect starting motor
- Inspect water pump
Every 12000 service hours or 6 years - Change cooling system coolant (ELC)
Overhaul Se - See Caterpillar Manual
Table 2.1/part 2 Maintenance schedule (recommend by Caterpillar)
Recommended lube oil:
Caterpillar recommends lube oil according to the table below. Based on the ambient temperature the viscosity of the lube oil can
be determined (see table 2.2) For more information about lube oil for the Caterpillar 3508B see manufacturers information.
Engine Oil Viscosity

Caterpillar DEO Ambient Temperature
Multigrade
API CH-4
API CI-4 Minimum Maximum
Viscosity Grade
SAE 0W20 -40 oC +10 oC
SAE 0W30 -40 oC +30 oC
SAE 0W40 -40 oC +40 oC
SAE 5W30 -30 oC +30 oC
SAE 5W40 -30 oC +50 oC
SAE 10W30 -18 oC +40 oC
SAE 10W40 -18 oC +50 oC
SAE 15W40 -9.5 0C +50 oC
Table 2.2 Engine oil viscosity
Recommended coolant:
For detailed Cooling System Specifications see manufacturers information.
General coolant information:
NOTICE : Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first.
NOTICE : If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system
must be either protected to the lowest outside temperature or drained completely to prevent damage.
NOTICE : In cold weather, frequently check the specific gravity of the coolant solution to ensure adequate protection.
Coolant is composed of three elements:

1. Water
2. Additives
3. Glycol
All Caterpillar diesel engines equipped with air-to-air aftercooling ATAAC require a minimum of 30% glycol to prevent water
pump cavitation.
Water:
NOTICE : Never use water alone without Supplemental Coolant Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures. Water alone does not provide adequate protection
against boiling or freezing.
Distilled water or deionised water is recommended for use in engine cooling systems. If distilled water or deionised water is not
available use water with the properties that are listed in table 2.3.
Caterpillar Minimum Acceptable Water Requirements

Property Maximum Limit ASTM Test
Chloride (Cl) 40 mg/L D512 / D4327
Sulfate (SO4) 100 mg/L D516
Total Hardness 170 mg/L D1126
Total Solids 340 mg/L D1888
-37-
.
Acidity pH of 5.5 to 9.0 D1293
Table 2.3 Caterpillar Minimum Acceptable Water Requirements
Additives:
Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufficient amounts of additives
enable the following conditions to occur:
- Corrosion
- Formation of mineral deposits
- Rust
- Scale
- Pitting and erosion form cavitations of the cylinder liner
- Foaming of the coolant.
Many additives are depleted during engine operation. These additives must be replaced periodically. This can be done by
adding Supplemental Coolant Additives (SCA) to Diesel Engine Antifreeze/Coolant (DEAC) or by adding ELC Extender tot
Extended Life Coolant (ELC).
Additives must be added at the proper concentration. Over concentration of additives can cause the inhibitors to drop
out-of-solution.
Glycol:
Glycol in the coolant helps to provide protection against the following conditions:
- Boiling
- Freezing
- Cavitation of the water pump and the cylinder liner
For optimum performance, Caterpillar recommends a 1:1 mixture of a water/glycol solution.
Use a mixture that will provide protection against the lowest ambient temperature.
100 percent pure glycol will freeze at a temperature of -23 oC.
Recommended Coolant :
Make : Total
Type : Glycol Freeze
The cooling system is filled with water and the following additives:
1. Mono-ethylene Glycol : 50% (freeze protection to -360 C)
2. Inhibitor : 5%
Prescribed by Caterpillar is a glycol percentage of 30 60 % (freeze protection -15 to -510C) and 3 to 6 % inhibitor.
NOTICE : Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycols
reduced heat transfer capability. Use ethylene glycol in conditions that require additional protection against
boiling or freezing.
For more information about GlycolFreeze see also Annex I.6.
-38-
.
2.2 Slew ring
Make : IMO
Type : A340
Figure 2.2 Central greasing points slew ring
The greasing points divided around the circumference of the raceway of the slew ring are connected to a central greasing block
at the front of the chassis. This greasing block is part of the Automatic Lubrication System, the slew ring does not have to be
greased manually. The Automatic Lubrication System may only be filled with Total Ceran WR 2 grease only. For more
information about the Automatic Lubrication System see chapter 3.10.
Recommended Lubricant:
Make : Total
Type : Carter ENS-EP 700
For more information about the recommended total lubricant

coating for open gears and wire ropes see also Annex I.7.
For an equivalent of the recommended lubricant
(with the same specifications) contact your oil supplier.
The Internal gear must be greased weekly till monthly

(depending on the use of the crane) with open gear lubricant
spray as listed above.
The gear and pinion should always have sufficient grease.
Figure 2.3 Greasing of internal gear and pinion (swing drive)
Maintenance:
Weekly / Monthly - Greasing of internal gear
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-40-
3.0 Greasing points

3.1 Boom head sheaves
Greasing point : Inside of sheaves axles

Greasing method : Automatic Lubrication System (see chapter 3.10)
Number of sheaves : 8
Recommended grease : Total Ceran WR 2
Greasing interval : Automatic
1
.
Detail greasing point
1
.
Figure 3.1 Boom head sheaves (1=locking pin sheave axle)
The PLM 3520 is equipped with an Automatic Lubrication System. The grease dispenser / pump is mounted in the left
machinery house of the superstructure on the chassis between the holding and closing winch support bearings. This system
greases the boom head sheaves automatically. For more information about this system see chapter 3.10. Check sheaves axle
and locking pin of the axle on the outside of the boom frequently, daily to weekly.
3.2 Boom foot pin
Greasing point : Through inside boom foot pin

Number of pins : 2
Check tightness of mounting bolts of

boom foot pin end covers frequently,
daily to weekly.
-41-
Figure 3.2 Left boom foot pin (inside)
3.3 A-frame sheaves
Greasing point : Inside of both sheaves axles

Figure 3.3 A-frame sheaves Figure 3.4 Greasing points
Greasing points on inside of the sheave axles are connected to the Automatic Lubrication System. For more information about
this system see chapter 3.10.
Check sheaves axle and bolts of locking plates on the outside of the A-frame frequently, daily to weekly (see figure 3.5).
Figure 3.5 Sheave axle locking plate
Maintenance:
Daily / weekly - Check sheave axles

- Check sheave axle locking plate bolts
Monthly - Grease sheave cable groove
The cable groove of the A-frame sheaves must be greased approximately monthly (depending on the use of the crane) with the
following lubricant coating spray.
-42-
Make : Total
For more information about the recommended total lubricant coating for open gears and wire ropes see also Annex I.7.
For an equivalent of the recommended lubricant (with the same specifications) see Annex VI or contact your oil supplier.
3.4 Pendant rope block sheaves / Triangle plate
Greasing point : Inside of sheave axles

Number of triangle plates : 1 (greasing point directly on triangle plate shaft)
Figure 3.6 Pendant rope block Figure 3.7 Triangle plate shaft
Greasing points on outside of the sheave axles and triangle plate shaft are connected to the Automatic Lubrication System.
For more information about this system see chapter 3.10.
Check sheave axles and triangle plate shaft locking plate bolts frequently, daily to weekly.
Maintenance:
Daily / weekly - Check sheave axle

- Check locking plate bolts
Monthly - Grease sheave cable groove
The cable groove of the crane body sheaves must be greased approximately monthly (depending on the use of the crane) with
the following lubricant coating spray.
Make : Total
For more information about the recommended total lubricant coating for open gears and wire ropes see also Annex I.7.
For an equivalent of the recommended lubricant (with the same specifications) see Annex VI or contact your oil supplier.
-43-
Figure 3.8 Greasing points and locking plate sheave axle
-44-
.
3.5 A-frame pins
Greasing point : -
Greasing method : A-frame pins are non-running pins and dont have to be greased
Number of pins : 4 (2x front leg / 2x rear leg)
Recommended grease : -
Greasing interval : -
Figure 3.9 Rear A-frame pin Figure 3.10 Front A-frame pin
Check shafts, tightness of locking plate bolts (rear leg pins) and tightness of locking bolts (front leg pins) frequently, daily to
weekly.
3.6 Machinery cover pin
Greasing point : On hinge (see figure 3.11)

Number of hinges : 7 (3x on right cover / 4x on left cover)
Greasing interval : monthly
Figure 3.11 Machinery cover hinge / pin
The hinges must be lubricated manually with EP2 grease

This type of grease may not be used for the automatic lubrication system
Recommended EP2 grease :
-45-
.
Make : Total
Type : MULTIS EP 2
-46-
.
3.7 Engine compartment door hinge
Greasing point : On hinge (see figure 3.12)

Number of hinges : 4 (2 on each door)
Greasing interval : monthly
Figure 3.12 Engine compartment door (right side of crane) Figure 3.13 Door hinge
The greasing points of the door hinges are mounted on the outside of the door.
The hinges must be lubricated manually with EP2 grease

Make : Total
Type : MULTIS EP 2
-47-
.
3.8 Boom hoist safety switch
Greasing point : buffer on right boom foot ear (see figure 3.14)
Number of buffers : 2
Greasing interval : 100 operating hours
Figure 3.14 boom hoist safety switch buffers (example)
The boom stops and boom hoist safety switch must be lubricated manually with EP2 grease
Make : Total
Type : MULTIS EP 2
-48-
.
3.9 Cardan shaft
Greasing point : Cardan shaft between diesel engine and pump distribution box
Number of greasing points : 2 (one at each cardan joint)
Greasing interval : 250 operating hours
Figure 3.15 Cardan shaft with safety cover Figure 3.16 Safety cover hatch
The cardan joints must be lubricated manually with EP2 grease. To reach the greasing points the hatches on the cardan shaft
safety cover (see figure 3.16).
NOTE : THE SAFETY COVER HATCHES MAY ONLY BE OPENED WITH A NON-RUNNING DIESEL ENGINE
Make : Total
Type : MULTIS EP 2
-49-
.
3.10 Automatic Lubrication System
The PLM 3520 is equipped with an Automatic Lubrication System.
Figure 3.17 Grease dispenser/pump (crane chassis)
The grease dispenser/pump is mounted on the left side of the crane on the chassis in the machinery house between the holding
winch and closing winch support bearings.
Dispenser/pump lubricates the following crane parts:
- Boom head sheaves 8x

- A-frame sheaves 6x
- Pendant rope block sheaves 6x
- Pendant rope block triangle plate 1x
- Holding and closing winch support bearing 2x
- Boom foot pins 2x
- Slew ring 1x
DISPENSER MAY ONLY BE FILLED WITH GREASE ACCORDING TO THE SPECIFICATIONS BELOW.
Make sure no standard EP 2 grease is used.
Recommended Grease :
Make : Total
Type : CERAN WR 2
-50-
.
For more information about the Automatic Lubrication System see manufacturers information.
-51-
.
4.0 Wire Ropes
4.1 Holding ropes
Make / type : see wire rope certificate
Maintenance:
Weekly - inspect wire ropes visually

- check wire rope mounting block on drum
3 Monthly - re-greasing
Holding ropes must be weekly inspected visually for:

- damages
- rust
- signs of wear
- diameter
When one or more of the following defaults occur at one or two of the holding ropes, both wire ropes have to be replaced:
- if there is to much rust
- if the cable is cracked (strength decreases with 40 60%)
- if the diameter is decreased with more then 7%
- if the rope or strand is broken (loose ends are visible)
- if the rope is flat
Note: Use only wire ropes with the same specification as mentioned in the wire rope certificate.
It is recommended to use pre-greased wire ropes. If pre-greased wire ropes are not available, non-greased wire ropes can be
used. However before installation the non-greased wire ropes must be greased manually with special wire rope grease.
To increase the length of life, both pre-greased and non-greased wire ropes have to be re-greased approx. 4 times a year.
4.2 Closing ropes
Maintenance:

Closing ropes must be weekly inspected visually for:

- damages
- rust
- signs of wear
- diameter
When one or more of the following defaults occur at one or two of the closing ropes, both wire ropes have to be replaced:
-52-
-53-
.
4.3 Boom hoist ropes
Maintenance:
Weekly - inspect wire rope visually

- check wedge sockets, connected to triangle plate
Every 1000 operating hours - replace boom hoist ropes
Boom hoist ropes must be weekly inspected visually for:

- damages
- rust
- signs of wear
- diameter
After every 1000 operating hours or sooner when one or more of the following defaults occur at one or two of the boom hoist
ropes, both wire ropes have to be replaced:
Both boom hoist ropes are connected by a triangle plate (see figure 3.5 on page 20) between the crane body sheaves.
K-sockets have to be inspected weekly. Check also the pins and locking pins.
4.4 Pendant ropes
Maintenance:

- check open/closed spelter sockets
Every 5000 operating hours - check pendant rope strength
Pendant ropes must be weekly inspected visually for:

- damages
- rust
- signs of wear
- diameter
When one or more of the following defaults occur at one or two of the pendant ropes, both wire ropes have to be replaced:
-54-
.
During closed spelter socket check on both ends of the pendant ropes also check pins and locking pins.
Every 5000 operating hours the strength of all pendant ropes has to be checked by means of a tensile strength test (stretching
test).
-55-
SWING DRIVES
Holding wire rope Holding wire rope

RIGHT hand lay LEFT hand lay
6x36 WS + SC 6x36 WS + SC
30 mm / 1960 N/mm2 30 mm / 1960 N/mm2
Breaking load 665 kN Breaking load 665 kN
HOLDING WINCH
Closing wire rope Closing wire rope

RIGHT hand lay LEFT hand lay
6x36 WS + SC 6x36 WS + SC
30 mm / 1960 N/mm2 CLOSING WINCH 30 mm / 1960 N/mm2
Boom hoist wire rope Boom hoist wire rope

RIGHT hand lay BOOM HOIST WINCH LEFT hand lay
8x26 8x26
24 mm / 1960 N/mm2 24 mm / 1960 N/mm2
Figure 4.1 Winch / wire rope arrangement
-56-
Figure 4.2 Winch / wire rope mounting block
-57-
.
5.0 Loose Gear
5.1 Grab (J&B Grabs)
General information Grab:
Make : Jurg & de Bie b.v.

Capacity : 15.0 m3
All greasing points on the grab have to be lubricated manually with EP2 grease
Make : Total
Type : MULTIS EP 2
Number of sheave axles : 2
Greasing points : 1 axle with greasing points on both sides of axle (lower axle)
: 1 axle with greasing points on both sides of axle (upper axle)
Number of hinges : 13
Greasing points : Directly on hinge pin
Greasing interval : daily
Grab greasing points

F
. 4x A. on outside pin
4x B. on inside pin
4x C. on outside axle
2x D. on both sides of axle
2x E. on both sides of axle
1x F. on outside of pin
B B
. .
E
.
A
A
.
.
D
.
-58-
Figure 5.1
C A
B D F
. .
. . .
-59-
SMT crane maintenance manual A
.
.
6.0 Gantry
Figure 6.1 Gantry side view
A = wheel sets
B = parking lock
Maintenance on the gantry has to be done for two main parts, the wheel sets and the parking locks.
6.1 Wheel sets
1
.
2
.
2
.
3
3 .
.
3
.
4
.
-60-
Figure 6.2 Maintenance points wheel sets

6.1.1 Pivot shaft balance beam
The balance beam pivot shaft has a greasing point and bolted end cover on both sides. (inside and outside of gantry)
Maintenance:
Weekly - Check tightness of end cover bolts

- Grease pivot points on both sides of shaft
Figure 6.3 End cover with bolts and greasing point pivot shaft balance beam (both sides)
6.1.2 Pivot point boogie
The boogie shaft has a greasing point and bolted end cover on both sides. (inside and outside of gantry)
Maintenance:
Weekly - Check tightness of end cover bolts

- Grease pivot points on both sides of shaft
-61-
Figure 6.4 End cover with bolts and greasing point pivot shaft boogie (both sides)
-62-
.
6.1.3 Drive shaft
The drive has a greasing point on both sides and one bolted locking plate on the outside of the gantry.
Maintenance:
Daily / weekly - Check tightness of locking plate bolts

- Grease drive shaft on both sides of shaft
Figure 6.5 Drive shaft with locking plate and greasing point
6.1.4 Drive Unit
For maintenance information about the drive units of the gantry see chapter 1.6 on page 13 of this manual.
-63-
6.1.4 Guide roller
Each boogie is equipped with a guide roller on the inside of the gantry see figure 6.6.
Maintenance:
Weekly - Check tightness of locking plate bolts and frame mounting bolts
- Grease guide roller shaft
1
.
1
.
Figure 6.6 Wheel sets inside gantry with guide rollers. (1=guide roller (frame))
Figure 6.8 Side view guide roller (locking plate bolts)
-64-
Figure 6.7 Guide roller frame greasing point, through hole in frame directly on guide roller shaft.
-65-
.
6.2 Parking Lock
1
.
2
.
3
.
Figure 6.8 Parking lock
6.2.1 Parking lock cylinder
The parking lock pin (no. 3) can be lowered / lifted with a hydraulic cylinder.
Maintenance:
Weekly - Check tightness of locking plate bolts

- Check for oil leaks
-66-
Figure 6.9 locking bolt cylinder / pin Figure 6.10 locking plate cylinder / gantry
6.2.2 Parking lock controls
Maintenance:
Weekly - Check for oil leaks
Figure 6.11 Parking lock control
6.2.3 Parking lock pin
Maintenance:
Daily / weekly - Grease locking pin mounting / pin
-67-
Figure 6.12 Greasing point parking lock pin / greasing pin
-68-
.
Annex I TOTAL Lubrication / Oil Data Sheets
I.1 TOTAL Carter SH

I.2 TOTAL Multis EP 2
I.3 TOTAL Transmission SYN FE 75W-90
I.4 TOTAL Equivis ZS
I.5 TOTAL Caprano TD 15W40
I.6 TOTAL Glycolfreeze
I.7 TOTAL Carter ENS-EP 700
I.8 TOTAL Ceran WR 2
-69-
.
Annex I.1 TOTAL Carter SH
-70-
.
Annex I.2 TOTAL Multis EP 2
-71-
.
Annex I.3 TOTAL TRANSMISSION SYN FE 75W-90
-72-
.
Annex I.4 TOTAL EQUIVIS ZS
-73-
.
Annex I.5 TOTAL CAPRANO TD 15W40
-74-
.
Annex I.6 TOTAL GLYCOLFREEZE
-75-
.
Annex I.7 TOTAL CARTER ENS-EP 700
-76-
.
Annex I.8 TOTAL CERAN WR 2
-77-
.
Annex II Mineral-oil based Pressure Fluids
-78-
.
Annex III Maintenance Checklist
Daily - Visual leak check pump distribution box - Chapter 1.1 - page 1
- Visual leak check holding winch gearbox - Chapter 1.3 - page 6
- Visual leak check closing winch gearbox - Chapter 1.4 - page 9
- Visual leak check boom hoist winch gearbox - Chapter 1.5 - page 12
- Check hydraulic oil level (hydraulic tank) - Chapter 1.8 - page 15
- Check hydraulic system for leaking - Chapter 1.8 - page 15
- Check if hydraulic oil cooler is clean - Chapter 1.9 - page 21
- Check coolant / lube oil level diesel engine - Chapter 2.1 - page 23
- Check diesel engine according to chapter table 2.1 - Chapter 2.1 - page 23
- Check locking pins of pins, bolts and shafts
Weekly - Visual check pump distribution box + unusual noise check - Chapter 1.1 - page 1
- Visual check swing drive + unusual noise check - Chapter 1.2 - page 4
- Visual check holding winch + unusual noise check - Chapter 1.3 - page 6
- Visual check closing winch + unusual noise check - Chapter 1.4 - page 9
- Visual check boom hoist winch + unusual noise check - Chapter 1.5 - page 12
- Visual check drive unit + unusual noise check - Chapter 1.6 - page 13
- Oil level check pump distribution box - Chapter 1.1 - page 1
- Oil level check swing drive - Chapter 1.2 - page 4
- Oil level check holding winch - Chapter 1.3 - page 6
- Oil level check closing winch - Chapter 1.4 - page 9
- Oil level check boom hoist winch - Chapter 1.5 - page 12
- Oil level check drive unit - Chapter 1.6 - page 13
- Visual leak check hydraulic oil coolers - Chapter 1.9 - page 21
- Inspect all wire ropes visually - Chapter 4.0 - page 35
- Check all wire rope mounting blocks on drums - Chapter 4.0 - page 35
- Check all wire rope wedge sockets - Chapter 4.3 - page 36
Monthly - Check bolt tightness of pump distribution box - Chapter 1.1 - page 1
- Check bolt tightness of swing drive - Chapter 1.2 - page 4
- Check bolt tightness of holding winch - Chapter 1.3 - page 6
- Check bolt tightness of closing winch - Chapter 1.4 - page 9
- Check bolt tightness of boom hoist winch - Chapter 1.5 - page 12
- Check bolt tightness of drive unit - Chapter 1.6 - page 13
- Check hydraulic hoses for damages - Chapter 1.8 - page 15
Semi-Annually - Check oil quality pump distribution box - Chapter 1.1 - page 1
- Check oil quality swing drive - Chapter 1.2 - page 4
- Check oil quality holding winch gearbox - Chapter 1.3 - page 6
- Check oil quality closing winch gearbox - Chapter 1.4 - page 9
- Check oil quality boom hoist winch gearbox - Chapter 1.5 - page 12
- Check oil quality drive unit - Chapter 1.6 - page 13
Annually - Change oil pump distribution box (or every 2000 operating hours) - Chapter 1.1 - page 1
- Clean air breather filter pump distribution box - Chapter 1.1 - page 1
- Clean magnetic plug on drain plug pump distribution box - Chapter 1.1 - page 1
- Change oil holding gearbox (or every 1500 operating hours) - Chapter 1.3 - page 6
- Change oil closing gearbox (or every 1500 operating hours) - Chapter 1.4 - page 9
- Change oil boom hoist gearbox (or every 1500 operating hours) - Chapter 1.5 - page 12
- Change oil drive unit (or every 1500 operating hours) - Chapter 1.6 - page 13
- Obtain cooling system coolant sample (diesel engine) - Chapter 2.1 - page 23
(every) 100 - Visual check hydraulic swivel joint - Chapter 1.7 - page 14
operating hours - Check for oil leaking hydraulic swivel joint - Chapter 1.7 - page 14
(first) 150 - First oil change holding winch gearbox - Chapter 1.3 - page 6
operating hours - First oil change closing winch gearbox - Chapter 1.4 - page 9
- First oil change boom hoist winch gearbox - Chapter 1.5 - page 12
- First oil change drive unit - Chapter 1.6 - page 13
(first) 200 - First oil change pump distribution box - Chapter 1.1 - page 1
operating hours - First oil change swing drive - Chapter 1.2 - page 4
(first) 250 - Inspect / adjust engine valve lash (diesel engine) - Chapter 2.1 - page 23
operating hours - Inspect / adjust fuel injector (diesel engine) - Chapter 2.1 - page 23
- Inspect / clean speed sensor (diesel engine) - Chapter 2.1 - page 23
(every) 250 - Every 250 operating hours maintenance according to table 2.1 - Chapter 2.1 - page 23
operating hours
-79-
.
(first) 500 - Check quality of hydraulic oil sample / replace if necessary - Chapter 1.8 - page 15
operating hours - Obtain cooling system coolant sample - Chapter 2.1 - page 23
(every) 500 - Change engine oil and filter (diesel engine) - Chapter 2.1 - page 23
operating hours
(every) 1000 - Check quality of hydraulic oil sample / replace if necessary - Chapter 1.8 - page 15
operating hours - Every 1000 operating hours maintenance according to table 2.1 - Chapter 2.1 - page 23
- Replace boom hoist wire ropes - Chapter 4.3 - page 36
(every) 2000 - Change hydraulic oil filters - Chapter 1.8 - page 15
(every) 3000 - Change oil swing drive (or every 3 years) - Chapter 1.2 - page 4
(every) 4000 - Inspect coupling between cardan shaft and diesel engine - Chapter 1.1 - page 1
contact BTC Cranes B.V. - Check gearbox brake plates, replace brake springs
(every) 5000 - Check pendant rope strength by tensile strength test - Chapter 4.4 - page 36
operating hours
(every) 6000 - Every 6000 operating hours maintenance according to table 2.1 - Chapter 2.1 - page 23
operating hours
(every) 12000 - Change cooling system coolant (ELC) diesel engine - Chapter 2.1 - page 23
operating hours
-80-
Annex IV Lubrication Checklist
Daily - Grab - Chapter 5.1 - page 38

- Drive shaft (gantry) - Chapter 6.1.3 - page 41
- Parking lock pin (gantry) - Chapter 6.2.3 - page 44
Weekly - Slew Ring raceway * - Chapter 2.2 - page 26
- Slew ring internal gear (manually) - Chapter 2.2 - page 26
- Pivot point balance beam (gantry) - Chapter 6.1.1 - page 40
- Pivot point boogie (gantry) - Chapter 6.1.2 - page 40
- Guide roller shaft (gantry) - Chapter 6.1.4 - page 42
Monthly - Holding winch support bearing * - Chapter 1.3 - page 6
- Closing winch support bearing * - Chapter 1.4 - page 9
- Cable groove A-frame sheaves - Chapter 3.3 - page 28
- Cable groove pendant rope block sheaves - Chapter 3.4 - page 29
- Machinery cover pin - Chapter 3.6 - page 30
- Engine compartment door hinge - Chapter 3.7 - page 31
- Grease level dispenser / pumps - Chapter 3.10 - page 34
Automatic Lubrication System
3 Monthly - Wire ropes - Chapter 4.0 - page 35
10-15 operating hours - Boom head sheaves * - Chapter 3.1 - page 27

00025 operating hours - Boom foot pin * - Chapter 3.2 - page 27
- A-frame sheaves * - Chapter 3.3 - page 28
- Pendant rope block sheaves * - Chapter 3.4 - page 29
- Triangle plate shaft * - Chapter 3.4 - page 29
00100 operating hours - Boom hoist safety switch - Chapter 3.8 - page 32
00250 operating hours - Cardan shaft - Chapter 3.9 - page 33
* These crane parts are lubricated automatically by the Automatic Lubrication System.
For more information about greasing of the crane part see maintenance manual.
-81-
.
Annex V Lubrication Equivalents
TOTAL FINA ELF
Carter SH Giran P 220 Reductelf synthese 220

Multis EP 2 Marson EPL 2A Epexa 2 / Epexelf 2
Transmission SYN FE (75W90) Pontonic FDL (75W90) Tranself Synthese FE (75W90)
Equivis ZS (46) Hydran TSX (46) Hydrelf (46)
Caprano TD (15W40) - -
Glycolfreeze - -
Carter ENS-EP 700 Cabline 2750 Fluid Elfnera 400 Y
Ceran WR 2 Ceran WR 2 -
-82-
.
SAFETY PRECAUTIONS:
When changing, replenishing or draining oil or when taking oil samples, it must be
! guaranteed that no oil can escape onto the ground, penetrate the ground or surface
water or enter the sewage system.
! Oil dipsticks and/or overflow screws may be removed at machine in standstill only.
Injury risk!
! Prolonged contact with lubricants can cause injury to your skin. Use a protective skin
ointment
After prolonged operation the lubricant and surface of the gear units may reach
! temperatures which can cause skin burns. When working on hot components, wear
protective clothing, e.g. protective gloves.
! The applicable national, local and plant-specific regulations and requirements

concerning accident prevention and environmental protection are to be observed.
To prevent faults, it is necessary to carry out the regular maintenance and inspection
work prescribed. Any changes compared with normal operation (higher power input,
! temperatures or vibrations, unusual noises or smells, response of monitoring devices
etc.) are an indication that the unit is not functioning properly. To avoid faults which
could result in injury to people or damage to property, the maintenance staff
responsible must be notified immediately. In case of doubt switch off the relevant
item of equipment and ensure it cannot be switched on again.
! To prevent damage from overheating, dirt and dust deposits should be regularly
removed from gear unit surfaces and oil / water cooling surfaces.
Do not touch rotating components.

!
-83-

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SMT Crane Maintenance Manual

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SMT crane maintenance manual

1.0 Hydraulic System 1

1.1 Pump distribution box 1

3.0 Greasing points 27

3.1 Boom head sheaves 27

4.0 Wire Ropes 35

5.0 Loose Gear 38

Annex I TOTAL Lubrication / Oil Data Sheets

Annex II Mineral-oil based Pressure Fluids

Annex III Maintenance Checklist

Annex IV Lubrication Checklist

Annex V Lubrication Equivalents

1.1 Pump distribution box

Make : Stiebel Getriebebau

Recommended Gear lube oil :

After 200 operating hours - First oil change

Table 1.1 Maintenance schedule

Replacement element: HYDAC 660 D

Figure 1.2 Gear lube oil filter pump distribution box

Filter is equipped with an indicator on top. The

Green = Filter has sufficient filtering capacity

Top view pump distribution box

Figure 1.4 Detail top view

-4- Figure 1.5 Oil drains / magnetic plug

Make : Zollern Getriebe

Recommended Gear lube oil :

After 200 operating hours - First oil change

Table 1.2 Maintenance schedule

Oil drain Swing Drive

Figure 1.8 Swing Drives

Breather nipple / Ventilating filter

Oil level nipple

Figure 1.9 Spyglass / Oil level nipple -7-

Make : Lohmann + Stolterfoht

Recommended Gear lube oil :

After 150 operating hours - First oil change

Table 1.3 Maintenance schedule

The support bearing is connected to the automatic lubrication system.

Automatic lubrication system grease :

Figure 1.14 Gear lube oil filter no. 1 (Holding winch)

Replacement element: HYDAC 060 D010 BN3HC

Replacement element: HYDAC 240 D010 BN3HC

Make : Lohmann + Stolterfoht

Recommended Gear lube oil :

After 150 operating hours - First oil change

Table 1.4 Maintenance schedule

The support bearing is connected to the automatic lubrication system.

Automatic lubrication system grease :

Replacement element (filter no. 1) : HYDAC 240 D010 BN3HC

Figure 1.20 Gear lube oil filter no. 1 (Holding winch)

Replacement element: HYDAC 060 D010 BN3HC

Replacement element: HYDAC 240 D010 BN3HC

1.5 Boom hoist winch

Make : Lohmann + Stolterfoht

Recommended Gear lube oil :

After 150 operating hours - First oil change

Table 1.5 Maintenance schedule

Oil level nipple

Oil drain nipple

Figure 1.23 Maintenance points Boom hoist gearbox GFT 110 W3

1.6 Drive unit (Gantry)

Make : Lohmann + Stolterfoht

Recommended Gear lube oil :

After 150 operating hours - First oil change