R&M Manual

NM170877300
Repair and Maintenance

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NSC 624 E
ADPC
17087700
NM170877300
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Noell Order No. 17087700
Year of manufacture 2011

Publisher Noell Mobile Systems GmbH
Albert-Einstein-Strasse 3
97080 Würzburg, Germany
Phone: +49 (0) 931/2053-0

Fax: +49 (0) 931/2053-10
Issue date 11/11
Copyright © 2011, Noell Mobile Systems GmbH
Neither the content of this published document, nor parts thereof,

may not be forwarded to third parties without the written consent
of Noell Mobile Systems GmbH. All specifications, drawings, etc.
are protected by copyright.
Translation of the original instructions
This document is a translation of the original instructions for use

sent with this specific machine and as such marked. It is not in-
tended to be the basis of any further translation. Please use the
original instructions as reference only, they are marked accord-
ingly.
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Table of Contents
1. Symbol description...............................................................................................5
1.1. Additional information .........................................................................................5
1.2. Signs and symbols used .....................................................................................5
2. Introduction ...........................................................................................................6
3. Hoist cables ...........................................................................................................9
3.1. Handling of cables ..............................................................................................9
3.2. Cleaning and maintenance ...............................................................................13
3.3. Testing ..............................................................................................................14
3.4. Cable Replacement ..........................................................................................18
4. Steering setup .....................................................................................................22
4.1. Setting the steering rods ...................................................................................22
4.2. Alignment of the wheel forks .............................................................................24
4.3. Setting the steering pressure ............................................................................24
5. Wheel change ......................................................................................................25
5.1. Preparation .......................................................................................................25
5.2. Removal of the wheel .......................................................................................25
5.3. Mounting the wheel...........................................................................................26
6. Multi-disk brakes in the hoist winch..................................................................27
6.1. Transmission of wear on brake disks................................................................27
7. Fuel system .........................................................................................................28

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8. Hydraulic systems ..............................................................................................29
8.1. Servicing hydraulic systems..............................................................................29
8.2. Repairs .............................................................................................................34
8.3. Troubleshooting ................................................................................................35
9. Emergency operation .........................................................................................38
9.1. Recovery...........................................................................................................39
10. Screw connections .............................................................................................41
10.1. Tensioner ..........................................................................................................43
10.2. Torque key ........................................................................................................43
10.3. Table for torques and pretension ......................................................................44
10.4. Torques on the wheel bolts...............................................................................45
10.5. Drive shaft flange coupling................................................................................45
10.6. HV bolt connections ..........................................................................................46
11. Introduction to maintenance planning ..............................................................47
12. Daily Inspections.................................................................................................48
13. Maintenance plan during the initial running-in process ..................................48
14. Maintenance plan ................................................................................................49
15. Lubrication and oil change.................................................................................56
16. Lubrication points...............................................................................................58
17. Filter list ...............................................................................................................62
18. Fuels.....................................................................................................................63
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1. Symbol description
1.1. Additional information

In addition to this manual, you must also observe the local
regulations for accident prevention, environmental protection and
the valid operating instructions.
1.2. Signs and symbols used

Note Under the header "Note", you will find
information and helpful tips about optimum use
of the sprinter carrier.
Hazard warning symbol
Warning about a hazard point!
This symbol is used to indicate activities that

may place a person's life or health at risk.
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2. Introduction
This manual contains information about service, maintenance and
repair work.
This manual is intended for maintenance

employees. This manual is intended for
maintenance employees.
Before each repair task, the appropriate section of this manual should
be carefully studied. Some tasks that are being carried out for the first
time can present greater danger to occupational safety. In this case,
employees must be trained. When in doubt, it makes sense to contact
the manufacturer.
Maintenance employees must have solid technical training. For some

work it is necessary that specifically trained and experienced people,
such as engineers and assembly foremen, provide guidance and
supervision.
 Basic safety instructions

see "Operating instructions".
Only qualified and trained personnel may perform

repair and maintenance work on the sprinter
carrier.
The safety regulations must be followed during

all maintenance and repair work.
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During the warranty period, maintenance tasks that can likely cause
damage of a any kind, especially accidental damage, must be
performed only by the manufacturer or by a third party contracted
by the manufacturer.
Intervention by the operator without prior approval from the

manufacturer can lead to voiding of the warranty. The manufacturer
of the sprinter carrier, after agreement with the operator of the
sprinter carrier, can approve warranty work to be carried by the
operators themselves.
The notes listed in this manual have been taken in part from
information provided by suppliers, and they are specifically tailored
to those specific applications of our sprinter carrier.
Special information about components, for which no further details

are provided in this section, can be found in the Appendices.
Specific technical data, e.g., the tire air pressure, can be found
under "Technical specifications" in the Driver's Manual. Settings for
hydraulic system are in the Technical Description of the Hydraulic
System, and information about electrical equipment is in the
Technical Description of Electrical Engineering, as well as in
the attached circuit diagrams.
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 "Driver's Manual," "Repair and Maintenance

Manual," and "Appendices" belong together.
The notes provided in these documents are
to be interpreted in context and followed.
For every maintenance and repair work

performed on the sprinter carrier, the entire
device must be completely shut down.
Prior to welding work,
the batteries are to be disconnected,
along with all plug connections in the switch

cabinet on the machinery platform.
If this important note is ignored, serious damage

could occur due to overvoltage of electronic
components.
While attaching the ground terminal of the

welding device, it is absolutely essential that the
ground terminal is attached as closely as
possible to the component that is being welded.
The transition between the welding currents on
the bearing points, especially for integrated roller
bearings, results in welds on the roller elements
and the destruction of the bearing.
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3. Hoist cables 1
3.1. Handling of cables

The cable is one of the most important elements in the field of
materials handling.
It is a safe and reliable component. Because of the high

resistance to breakage of the wires, considerable forces can be
transmitted. If a wire breaks, the neighboring wires assume the
additional load without any noticeable overload. Due to the
stranding, the broken wire helps to carry the load again a short
distance behind the broken spot.
The wire strands in the cable do not break at the same time, but
instead gradually one by one, due to fatigue after a certain period
of operation. The number of strand breaks per length unit can be
used as a criterion for discarding the cables. If a cable has
become unsuitable for use because of damage and wear, it
presents a great danger to life and property. It must be replaced.
 Discarding of cables, see Paragraph 3.2.1
1 In our sprinter carriers, cables by CASAR Drahtseilwerk Saar GmbH are primarily used. The graphical material was obtained with
kind permission from the product information of CASAR cables.
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Damage is avoidable with proper use; wear and tear can be

minimized with correct maintenance. The relationship between the
possible bending cycles of the cable, during sprinter carrier
operation, and the lubrication condition, is shown in the following
graphic:
 With regular maintenance, the service life of a cable can

be significantly increased.
Figure 1 Lubrication condition and service life
3.1.1. Storage and transport

Cables may only be transported via equipment that does not
damage the cables. It does not matter if the cable is wound onto a
spool or bundled during storage. Under no circumstances may the
cables be pressed flat or compressed by sharp edges.
Cables should be wound onto a spool or bundled for storage.

It makes sense to protect cables from moisture and dirt with a
tarpaulin. This can prevent corrosion and wear prior to usage.
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Figure 2 Storage and transport
3.1.2. Unrolling and re-rolling on spools

If a cable is unrolled from the spool, the spool can be slightly
jacked up and the cable can be removed. It is practical to place
bundled cable on a reel. If a cable must be unrolled on the
ground, the surface must be clean. Then, it makes sense to line
the path with tarpaulins and boards.
Before reeling in the cable, it should first be

cleaned and inspected.
When handling cables, the formation of loops and bends must be

avoided. Such damage makes the cable unusable.
Every cable has a preferred bending direction intended by the

factory. This bending direction must always be maintained for
re-rolling or unrolling. Reversing the bending direction can lead to
damage of the cable.
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Figure 3 Damaged cable
Figure 4 Unrolling and re-rolling

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3.2. Cleaning and maintenance
3.2.1. Cleaning
Thorough cleaning is required before every inspection or mainte-
nance task. Grease tends to bind dirt and dust. Cables that are
heavily soiled, due to embedding of dust in the grease layer, are
subject to much greater wear. On the other hand, careful monitoring
of the status of wear is impossible without prior cleaning.
Soiled cables are cleaned in a dry condition with a wire brush. The
cables should under no circumstances be cleaned with degreasing
cleansers, because these would also dissolve the grease within the
cables. Moisture could then penetrate inside the cables and cause
them to wear from the inside.
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3.2.2. Maintenance
Split and broken wires, the number of which lies below
the maximum allowable rate, must be removed. Under no
circumstances should broken ends be snipped off with wire
cutters. The pliers do not grip deeply enough, and thus a sharp
edge remains after snipping.
The best method is to bend the wires back and forth until they
break, at the point in the strand where they are being held. For
thicker wires, it is recommended to bend the strand with a tool,
moving it back and forth over the cable until it breaks.
3.3. Testing
As needed, cables and fastened cable ends should be visually
inspected for potential damage on a daily basis. The time interval
of the inspections must be scheduled, in order that damage is
detected in a timely manner. Therefore, the time intervals should
be scheduled closer together than usual, following first application
and after the first wire breakages occur.
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3.3.1. Visual inspection

Determining the operating safety of the cable can be carried out
according to the following criteria:
A cable is not fit for use when
1. the allowable number of broken strands is reached or exceeded according to Table 2,

2. the diameter of the cable has diminished by 15%, compared to the nominal diameter
due to excessive stretching,
3. the diameter has diminished by 10% due to rust,
4. the diameter has diminished by 10% due to abrasion,
5. in the case of corkscrew formation, the wave height has exceeded one third of the
nominal diameter,
6. a "birdcage" has formed,
7. loops have formed from the strands,
8. strands have loosened from the cable body,
9. local thickening/knots have formed in the cable,
10. severe neckdowns have formed,
11. lasting deformations have formed because the cable was laid across sharp edges,
12. kinks/slings have resulted, for example from incorrect re-reeling,
13. severe notches/bends are present in the cable,
14. the cable has been subjected to a temperature higher than 300°C.
Table 1 Criteria for determining the discarding of cables
Following each visual inspection, the result

must be recorded in a log.
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In the following are some pictures of damage to cables that must

be discarded:
Figure 5 Discarded cables
Number of visible strand breaks
Group of mechanisms according to FEM Group of mechanisms according to FEM Number of

(DIN) (DIN) supporting
M1 (1Dm) M2 (1Cm) M5 (2m) M6 (3m) strands in the
M3 (1Bm) M4 (1Am) M7 (4m) M8 (5m) outer strands
of the cable
Ordinary lay Lang lay Ordinary lay Lang lay
along a length of along a length of along a length of along a length of
6xd 30xd 6xd 30xd 6xd 30xd 6xd 30xd

5 10 2 5 10 19 5 10 101-120
6 11 3 6 11 22 6 11 121-140
6 13 3 6 13 26 6 13 141-160
7 14 4 7 14 29 7 14 161-180
8 16 4 8 16 32 8 16 181-200
9 18 4 9 18 35 9 18 201-220
Table 2 Allowable number of strand breaks in cables for determining when to discard
Cable winch Categorizing in group of mechanisms according to FEM: M5

Hoist Cable TURBOPLAST Type, Ø 24-1770, ordinary lay,
Number of outer strands 208
Maximum number of strand breaks
along a length of 6 x 24mm = 144mm 18
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3.3.2. Measurement
For the measurement of the diameter of a cable, a caliper gauge
that is especially equipped for this kind of measurement with
wider measurement surfaces is best suited. In the case of such
measuring surfaces, a measurement error can be avoided that
would otherwise result from the cable design.
In the case of uneven numbers of outer strands, the measurement

surfaces of a normal caliper gauge can contact a "valley" on one
side and a "summit" on the other, so that it is not possible to
determine the cable diameter. This situation can be remedied with
two flat plates that are used as a contact surface.
In the case of an even number of outer strands, the use of a

normal caliper gauge is sufficient.
Even before the first use, a test of the nominal

diameter of the unused cable must be made as
a comparison, and this result must be logged.
Each additional inspection or visual check must
be logged.

Additional literature:
Principles Relating to Rope Drives: DIN 15020
Wire Ropes for Mechanical Handling Equipment:

VDI 2358
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Figure 6 Correct measurement of the nominal diameter of the cable
3.4. Cable Replacement

Supervision: properly trained mechanic
Personnel: mechanic, assistant
Equipment: installation tool,
auxiliary cable, cable grip
3.4.1. Preparation
The sprinter carrier is in the park position. Diesel motor is running.
The construction site it secured, the reels or drums with the new
cables are located outside the portal next to the carriage.

Notes on the handling of cables, see Section 3.1
of this manual.
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3.4.2. Procedure
Action
1. Lower spreader to the level of the lower support.
2. Remove cable guards from the drum and cable rollers.
3. Dismantle cable cover and remove cable.
4. Activate the key switch "Bridge emergency-stop" on the control cabinet in the cab.
The encoder of the winch is now bridged.
5. Feed out worn cables from the drum up to the cable anchor.
6. Hold each individual cable, loosen the cable clamps and connect with the auxiliary
cable using the cable grips.
7. Wind the free end of the auxiliary cable around the drum multiple times and pull
tight manually.
8. Switch on drum in the lowering direction and drop the worn cable to the floor.
9. Loosen the cable end connection on the machine platform and let out the cable.
10. Connect new cable with the auxiliary cable and feed in the opposite direction.
11. After laying the cables on the drum, the cable clamps must be screwed down with
the appropriate torque.
12. Set the horizontal position of the spreader on the cable end connections with
the spindle.
13. Slightly feed the new cables with an empty spreader, adjust possible cable
elongations on the spindle or readjust on the drum.
14. Mount cable guards.
15. Move spreader to the upper end position, in order to determine the setting for
the encoder.
16. Activate the key switch "Bridge emergency-stop" on the control cabinet in the cab.
The encoder for the winch is reactivated.
17. Conduct test run and check settings of the limit switches.
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
Additional notes on the subject of screw
connections can be found in Section 10 of this
manual.
It is absolutely imperative to ensure that any

twisting of the old cable that occurred during
operation is not transferred to the new one.
After each cable change, the shutoff points of

the limit switches must be checked and reset.
When applying the cables, the following is valid:
left-hand drum ........................................................ right-lying cable
right-hand drum....................................................... left-lying cable

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3 4
1 right-lying
2 left-lying
3 right-lying
4 left-lying
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4. Steering setup
Pressure relief valves are installed in the pistons of the steering
cylinders. If the steering has changed because of oil leaks, this is
automatically corrected via the pressure relief valves by moving to
the cylinder end positions.
For a mechanical shift of the path (collision), the steering rods

must be reset on both sides.
4.1. Setting the steering rods

Supervision: properly trained master mechanic
Equipment: Mounting tool,
opt. Measuring device
4.1.1. Basic setup of cylinder

Action
1. Move steering cylinder in until it stops (measurement A) and pull back out
(measurement B). Check total lift (260 mm) and determine middle setting.
2. Move the intermediate lever to the middle position.
3. Secure intermediate lever with steering lock.
The following figure shows the real situation on the carriage beam
before the action occurs.
Figure 7 Alignment of the wheel forks

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The following figure shows the calculation of measurement A.
The following figure shows how the flat steel is to be welded on.
Figure 9 Adjusting the steering cylinder
1. Flat steel
2. Intermediate lever
3. Steering cylinder
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4.2. Alignment of the wheel forks

Action
1. Loosen steering rods
2. Individually align each wheel fork at the line by adjusting the steering rod length.
Work from inside out when you do this.
The setup measurement K must be equal on each wheel fork.
3. Secure or attach steering rod.
4. Proceed in the same fashion on the other side of the carriage.
5. Adjust axles electronically (zero setting).
6. Remove the welded on flat steel.
7. Store the right/left end stops.
1. Optical Measuring Device

2. 1. Wheel fork
3. 2. Wheel fork
4. 3. Wheel fork
4.3. Setting the steering pressure

Action
1. Connect manometer to the measuring connection on the pressure filter for
the steering.
2. Move steering until it stops.
3. Set pressure on the pump.
The pressure must not exceed 200 bar!

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5. Wheel change
Supervision: properly trained master mechanic
Equipment: I-beam 160, 820mm long
Hydraulic lifter, 8t
Squared lumber
Mounting tool
5.1. Preparation
The sprinter carrier is in a parking position.
The construction site is secured.
5.2. Removal of the wheel

Action
1. Loosen wheel nuts of the defective wheel.
2. Attach hydraulic lifter, support with squared lumber.
In the case of driven wheel forks, use the I-beam, as indicated in Figure 11.
For non-driven wheel forks, attach the hydraulic lifter in the middle of the
wheel fork.
3. Lift the wheel fork until the wheel is free.

4. Remove wheel nuts and remove wheel.
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5.3. Mounting the wheel

Action
1. Place wheel and hand-tighten wheel nuts.
2. Set aside wheel fork.
3. Tighten wheel nuts applying the appropriate torque.
4. Check air pressure.
Tighten wheel nuts applying the

appropriate torque.
After 100 hours of operation, the wheel

nuts must be retightened.
 For torques, see Paragraph 10.4
Figure 11 Application of the hydraulic lifter
1. Squared lumber
2. Hydraulic hoist I-beam
3. I-beam
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6. Multi-disk brakes in the hoist winch

Supervision: properly trained driver
Equipment: Measuring tool, manual ventilation pump
Status: Diesel motor is not operational, parking brake is locked and the
spreader is discharged and placed in a suitable spot.
6.1. Transmission of wear on brake disks

Action
1 Charge winch brake externally with pressure (A), to open the winch brake
(min. 55bar max. 150bar)
2 Remove locking screw (B) and determine measurement (approx. 40mm).
3
4 Release pressure (A) to close the winch brake.

5 Determine measurement.
6
7 If the determined difference is > 5.5mm, the brake disks must be replaced.
(see Appendices)
8 Close with locking screw (B).
Check winch brakes individually and in sequence.

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7. Fuel system
Attached to the fuel tank (carriage beam) are sink boxes, which are
closed on the bottom by the connecting flange. The feed line and the
return collector line for the diesel fuel jut into the tank via this flange.
Deposits collected in the sink boxes must be removed approx. every

1000 operation hours by opening the drain cock. A remaining amount
of several liters of fuel is sufficient to rinse out the contaminants.
The same is true for the holding tank on the machine platform.
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8. Hydraulic systems
8.1. Servicing hydraulic systems

Important maintenance tasks are:
 Replenish and change operating fluid
 Clean filter
 Visual check for leakage
8.1.1. Inspection of the hydraulic system

Action
1. Oil level check in the hydraulic tank.
2. Visual check of the hydraulic fittings for leakage.
Checking the high-pressure hoses for premature wear.
3. Checking the system pressure.
see Paragraph 8.1.7
4. Extract approximately 2 l of hydraulic oil and have analyzed.
5. Check all oil filters to determine whether a filter change is necessary.
6. Functional test of the hydraulic system
8.1.2. Replenish operating fluid

Action
1. Connection and fill pumps at the correspondingly labeled connection of the
filling device on the carriage.
2. Monitor the oil level on the oil gauge of the oil tank.
Figure 12 Filling equipment

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 As a rule, the same operating fluid that is currently in the

hydraulic system should also be replenished. This is also
valid for mineral oils, because the individual oil manufacturers
augment the mineral oils with different additives.
If fluids of the same type but made by different manufacturers
are mixed, the liability for damages can no longer be
attributed to a certain manufacturer.
 The integrated level switch closes the shut-off valve and

thus prevents overfilling of the oil tank.
8.1.3. Changing the operating fluid

Action
1. The oil is changed when the hydraulic system is at operating temperature.
2. Remove closure screw from the ball valve of the oil tank sump.
3. Screw on the drain hose and open the ball valve.
Collect oil and dispose.
4. When the tank is empty, remove magnet screw, clean and replace.
5. Clean filter housing, replace filter inserts.
6. Insert filter and fill oil. Monitor the oil level on the oil gauge.
Note that during refilling, as well as during

change of operation fluids, the new fluid is
also to be filled via a filter, the pore size of
which must be at least 5m.

See Section 17 Filter List
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 Operation fluids must also be changed when the operation

fluid begins to change chemically and small particle
contamination has increased to such an extent that
increased wear is to be expected.
Required purity class NAS 1638 Required purity class ISO 4406
Fresh oil NAS 6 15/12
Oil change as of NAS 10 as of 19/16
The oil change interval can be increased if an oil

analysis is performed every 1000 operation hours.
Perform oil change depending on the results of the

oil analysis, but no later than after 4000 operating
hours.
 For every fluid change, all tanks / containers etc. must be

cleaned.
 Old oil may only be poured into the disposal container if it

is pure oil.
 Do not pour in any mixtures, such as a gas-oil mixture!

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8.1.4. Maintenance of pressurized tanks

Hydraulic accumulators in hydraulic systems are considered
pressurized tanks. The country-specific regulations for handling
pressurized tanks must be followed without fail.
Before beginning a repair, the system must be

depressurized.
For this purpose, measuring connections are

available near the hydraulic accumulator.
Depressurize the system and drain the oil into a
suitable container using a hose at the appropriate
measuring connection.
8.1.5. Hydraulic high-pressure hoses

In the event of visual changes, indications of porosity and
surfaces with oil residue, especially at the force-fit locations for
the hose connections, all of the affected hoses must be replaced
immediately.
8.1.6. Cleaning the Filters

The filters must be cleaned or replaced for every operating fluid
change. The level of contamination can be determined by using
the contamination display on the filter, or by measuring the
pressure difference before and after the filter.
8.1.7. Reset pressures

All pressure settings must be readjusted. Refer to the hydraulic
plan pressure data.
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8.1.8. Eliminate leaks and clean the system

From time to time, hydraulic systems must be cleaned from the
outside, in order to
 locate leaks,
 prevent the penetration of dirt,
 protect cylinder rods that move in and out of the housing

from dimpling,
 prevent the reduction of radiating heat.
 when cleaning, please take care that no cleaning solutions

enter into the hydraulic system.
 when using high-pressure cleaning systems, ensure that

all closures such as tank covers, shaft seals, etc. can
withstand this type of cleaning.
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8.2. Repairs
Some work in the area of maintenance and inspection is
mandatory under legal provisions and employee association rules.
Due to security reasons for operating personnel, and in order to
prevent possible material damages, these tasks must be carried
out and documented accordingly.
All necessary documentation and the required measuring devices

for restoring the systems should be kept available on location.
Troubleshooting thereby requires less time and is more
successful.
If the maintenance personnel does not have a working knowledge

of both hydraulics and electricity, both a hydraulics expert and
an electrical expert must be present at the same time for speedy
fault localization and troubleshooting.
System restoration should be limited to replacing entire components.
Other than repair work that the user can perform securely and
confidently, devices should be sent to the device manufacturer for
general maintenance.
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8.3. Troubleshooting
8.3.1. Excessive noise

Cause Reason Remedy
1.1. Pump cavitates Suction filter contaminated Clean filter
Local neckdown in the suction line Replace pipe or hose
(e.g., deformed pipe, kinked hose)
Pressure fluid too cold Warm fluid to recommended viscosity
Unsuitable fluid, viscosity too high Use more suitable fluid according to the hydraulic
manufacturer's instructions
Formation of steam in the fluid Lower operating temperature to prescribed value,
fill oil as needed or replace tank contents with
recommended fluid
Pump speed too high Reduce speed to recommended value
Tank ventilation filter plugged Clean or replace filter
1.2. Pump draws air Fluid level in tank too low / suction Fill tank to required fluid value
Unsuitable fluid Use pressure fluid according to recommendation
of the hydraulics manufacturer
Air inlet via damaged Simmerring® Replace Simmerring® and shaft seal, as needed
Fitting or flange not sealed in the suction line Tighten fitting / change O-ring in flange
Porous suction hose Replace hose
1.3. Mechanical Clutch not balanced, not correctly aligned, Balance or align precisely, or replace clutch
oscillations or loose
Oscillate pipe lines Improve pipe anchoring and eliminate pressure
surges
Entire component vibrates Mount motor pump unit elastically or set up next
to tank
1.4. Drive motor Motor bearing damaged Repair or replace motor
Motor ventilation too loud Clean fan grille
1.5. Pump Pump is worn out or damaged Repair or replace
1.6. Pressure surges Pipes not sufficiently secured Improved pipe supports
System runs with oil that flows too thinly Reduce oil temperature or choose oil with higher
viscosity
Too great a portion of undissolved air in the Ventilate system better
system.
For pilot-operated valves, switching time Adjust switching time chokes better, reduce
setting is not optimally set or arranged control pressure
End position damping of the cylinders not set Adjust end position damping better, improve
or insufficiently set constructively as needed
Switching impulses overlap Spread switching impulses out over time
(possibly using a time-lag relay)
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8.3.2. Pressure too low or no pressure

Cause Reason Remedy
2.1. Pump does not Suction line is not water-tight Please take note of 1.2.
deliver
Air in pressure line cannot escape Set the system to no pressure or loosen screws in
pressure line
Vacuum too strong in the suction line Please take note of 1.1.
Wrong direction of rotation Reconnect motor or rebuild pump
2.2. Internal leaks Pump is worn out or damaged Check pump and repair
Hydraulic oil flows too thinly Use pressure fluid according to recommendation of
the hydraulics manufacturer
If too hot, reduce oil temperature (check cooler,
correct setting of thermostat or cool water controller
as necessary, increase water flow)
Pressure limit valve set too low Correct pressure setting
Pressure limit valve does not close, is Check if ejector is in locked position; otherwise clean
contaminated or sticks or repair valve
Control valve or other valve does not close Clean valves, possibly repair or replace, eliminate
because of contamination, has too much play errors in the electrical control
because of wear, or errors in the electrical
control
Check valve pushed in Replace check valve
Damaged cylinder (bore, piston rod or seal) Repair or replace cylinder
Seals used are not resistant to fluid used Use seals made of recommended material
8.3.3. Flow too weak or no flow

Cause Reason Remedy
3.1. Pump does not Please take note of 2.1 Ditto
deliver
3.2. Internal leaks Please take note of 2.2 Ditto
3.3. Pump speed too Clutch slips, motor not properly attached Replace clutch, check motor speed
slow or motor
overloaded
3.4. Settings for Accumulator charge valve or pressure switch Set valves to prescribed values
accumulator not properly set
system not
Gas pressure setting too low or too high Fill nitrogen to prescribed pressure
properly set
NM170877300
Manual Page 37 / 64
8.3.4. Oscillations in the system

Cause Reason Remedy
4.1. Unstable setting Damaged valve seat Repair or replace
at pressure
limiting valves
and pressure
control valves
4.2. Air pockets in System not or insufficiently bled Intensively bleed system
the system
cause
inconsistent
cylinder or motor
movements
4.3. Pump Pump runs irregularly or pulsates Check or repair pump and clutch
4.4. Valve gets stuck Silting effect due to contaminated fluid Clean hydraulic fluid, clean tank, flush system, install
pressure filters as needed
4.5. Pressure surges Please take note of 1.6 Ditto
4.6. Static friction Piston seals or cylinder liners too tight at Use more suitable seals and increase fit clearance for
and the majority the cylinder cylinder liners
of users
Cylinder misaligned Check installation, realign
Acceleration too high or speed too low Improve acceleration process from a circuitry
standpoint
8.3.5. Fluid temperature too high

Cause Reason Remedy
5.1. Internal leaks Please take note of 2.2 Ditto
5.2. Total loss of System pressure is set higher than required Reduce setting value on the pressure limit valve
performance due
Increased spray due to pressure settings that Setting value required
to wrong
are too low
pressure valve
setting Inadequate pressure relief measures Provide suitable pressure relief options (coordinate
with hydraulics suppliers)
5.3. Insufficient Malfunction in the cool water supply or in the Check and eliminate errors
cooling cooling fan
Deposits in the cooling water lines or cooling Clean
fins contaminated
5.4. Pump has Inferior mechanical and volumetric Repair or replace pump
overheated effectiveness due to wear
Pressure fluid flows too thinly Use hydraulic fluid according to the recommendation
of the hydraulics manufacturer
5.5. Too frequent Fluid level in tank too low Fill fluid to recommended level
circulation of the
hydraulic fluid
NM170877300
Manual Page 38 / 64
9. Emergency operation
Supervision: Properly trained driver
Personnel: Electrician, assistant
Equipment: Emergency recovery unit, emergency feed cable, installation tool
Multimeter
Status:
Diesel engine is shut down, and parking brake is closed.

The service brake is ready for operation.
The emergency feed serves for recovering a sprinter carrier type

E, the diesel engine or three-phase generator of which has failed.
A fully operational sprinter carries is connected with the defective
one via an emergency feed cable (master/slave principle). The
drives for
 Lifting unit
 Carriage
 Auxiliary drives
can be operated with reduced power.
The emergency unit fees the hydraulic systems steering, spreader

and brake system.
Prerequisite
 Operational inverter in both sprinter carriers

NM170877300
Manual Page 39 / 64
9.1. Recovery
Action
1 Shut off recovery vehicle
2 Unloading of the intermediate circuits:
Shutdown of the on-board power supplies in both vehicles
3 Attach backup component to defective vehicle
For this purpose, a connection box for filling the hydraulic and motor oil is attached to the right
carriage beam.
Take note of labeling!

4 Open the suction line for the emergency unit below the hydraulic tank.
5 Switch from hydraulic oil filling to pressure supply from emergency unit.
6 Check intermediate circuits for absence of voltage.

7 Remove the dummy plug at both inverter switch cabinets and install the emergency feed
cable. (note master/slave relation)
8 Start up emergency component and set hydraulic lever to ON.
9 Switch on on-board power supply for both vehicles
10 Start diesel motor of the recovery vehicle
The steering of both vehicles recognizes the operating mode "Emergency operation" and
allows operation with diminished performance for both vehicles.
NM170877300
Manual Page 40 / 64
Action
11 Only individual motions are possible for the defective sprinter carrier:
 Emergency lowering
 Adjust spreader, unlock twistlock
 Traveling
 Steering
12 Recover defective device
13 After successful recovery of the diesel engine, stop the recovery vehicle and switch off both
on-board power supplies.
14 Check intermediate circuits for absence of voltage.
15 Stop the emergency unit and reset both taps (suction line and switching pressure line).
16 Take off the emergency feed cable and the hydraulic tubes, and replace the dummy plugs on
both switch cabinets. Dismantle the emergency unit.
During recovery, drive both sprinter carriers

slowly and synchronously.
Driving performance is only available at a

reduced capacity.
NM170877300
Manual Page 41 / 64
10. Screw connections

All fasteners used in our products correspond to the DIN-EN
standards and are marked accordingly with their strength class.
The strength class can be found in the stamp on the screw head
or on the front surface of the nut.
No other strength class may be used when an exchange or loss

occurs.
Examples:
 Normal screw connection
Screw DIN 931 8.8

with it belongs a Nut DIN 934 8
 High-strength bolt connection
Tensioning bolts / screws 10.9

with it belong Nut with hardened washers 10
Bolts with a lower strength class than 8.8, as well as nuts with a
lower strength class than 8, may not be used under any
circumstances.
NM170877300
Manual Page 42 / 64
 Only use thread flanks and a bolt shaft without any visual
damage.
 Install screws that have been slightly oiled or lubricated

with molybdenum disulfide (MoS2). For bolts lubricated
with MoS2, note other tightening torques!
 Tighten bolts using a torque wrench with the default torque or

pretension with a tensioner according to default values. You
can find a table with the required values in Section 10.3.
NM170877300
Manual Page 43 / 64
10.1. Tensioner
For bolts and tensioning bolts that have been pretensioned using
a tensioner: Immediately following the first pretensioning, the
same tensioner should be used to check if the predetermined
pretension value has been reached.
Afterward, only occasional visual checks are necessary.
10.2. Torque key

Screws that are tightened with a torque key should be checked for
the correct torque after 100 operating hours using a calibrated
torque key.
Additional checks approximately once per year with a calibrated

torque key.
Be sure to replace the bolts, if it is determined

during a subsequent inspection that there is too
little tension or one-sided bearing of the bolt
head or the nut.
When inserting bolts, please make certain that

the strength class of the bolt and the strength
class of the bolt nut match.
NM170877300
Manual Page 44 / 64
10.3. Table for torques and pretension

Hexagonal bolts DIN 931, DIN 933 ISO 4014; ISO 4017
Cylinder screws with hexagon socket DIN 912 ISO 4762
HV bolt connections DIN 6914, DIN 6915, DIN 6916
Threaded pins with hexagon socket DIN 914 ISO 4027
Hexagonal screws for steel work DIN 7990
Tensioning bolt according to ZNG HT7329556201
Classification 8.8 * 8.8 ** 10.9 * 10.9 ** Pretensioning Force (kN)
Size Type Tightening torque (NM) 8.8 10.9

Key width
M 12 S&M 19 86 67 120 100 38.3

HV 22 120 100 50
M 16 S&M&Z 24 210 165 295 250 73

HV 27 350 250 100
M 20 S&M 30 410 320 580 450 114

HV 32 600 450 160
M 22 S & M &Z 30 550 440 780 650 141

HV 32 900 650 190
M 24 S&M&Z 36 710 560 1000 800 164

HV 41 1100 800 220
M 27 S&M&Z 41 1050 820 1500 1250 215 330

HV 46 1650 1250 290
M 30 S&M&Z 46 1450 1110 2000 1650 262 405

HV 50 2200 1650 350
M 36 S&M&Z 55 2530 1930 3560 2800 382 550

HV 60 3800 2800 510
M 39 S&M&Z 60 3290 2500 4630 3750 460 665
M 42 S&M&Z 65 4070 3100 5730 4700 526 760
M 45 Tensioning bolts 70 4720 6640 616 890
M 48 Tensioning bolts 75 5700 8020 693 1005
M 52 Tensioning bolts 80 7330 10300 1205
Table 3 Torques and Pretension Forces
Explanations: S = Screws M = Nuts

HV = HV Connection Z = Tensioning bolts
* = Bolt, oiled ** = Bolt lubricated with MoS2
NM170877300
Manual Page 45 / 64
10.4. Torques on the wheel bolts

The torques for the following listed thread sizes relate to the
quality of the nut 10!
Absolutely maintain these values during setup!
Figure 13 Carriage of the sprinter carrier
Wheel Thread diameter (mm) Tightening torques (NM)

Wheel nut
A; 550 – 650 Nm
M 22 x 1,5
B; C
DIN 74361-10 ISO 4107
10.5. Drive shaft flange coupling

Quantit
Order No. Name Component Bolt Torque
y
144100106 2 DRIVE SHAFT TYPE WINCH INTEGRATION M8 35 Nm
144100076 1 DRIVE SHAFT TYPE PUMP INTEGRATION M8 35 Nm
0.107.140
Table 4 Torques for the drive shaft

NM170877300
Manual Page 46 / 64
10.6. HV bolt connections

Order No. Quantity Name Component
110952071 24 6KT BOLT M 24 X 160

BOGIE PIN MOVABLE
113178754 24 6KT NUT M 24 BEARINGS
113522504 48 WASHER 25
110952260 4 6KT BOLT M 27X 280
BG STEERING RODS
113178755 4 6KT NUT M 27
113522505 8 WASHER 28
110952180 14 6KT SCREW M 30 X 100
110952201 6 6KT SCREW M 30 X 90
113178756 20 6KT NUT M 30 BG TENSIONING BOLT 1
SUPPORT RMS
113522506 40 WASHER 31
NM5010200202 2 TENSIONING BOLT M 36 X 610
142200035 4 ROUND NUT TYPE RMS M 36
113178754 10 6KT NUT M 24
113522504 26 WASHER 25 BG CAB SUSPENSION
NK101
110952113 6 6KT SCREW M 24 X 75
110952116 10 6KT SCREW M 24 X 90
111152139 2 FITTED BOLT M 24 X 120
BG CARRIAGE
113178754 2 6KT NUT M 24
113522504 4 WASHER 25
Table 5 HV bolt connections acc. to DIN 6914 and DIN 6915, Torques, see Table 3
NM170877300
Manual Page 47 / 64
11. Introduction to maintenance planning

This maintenance plan is an important basis for the preventive
maintenance of the sprinter carrier. It provides important
information for the maintenance tasks to be performed in specific
operational steps.
The information in the Appendices is to be observed in addition to

the maintenance plan.
Only qualified maintenance and repair personnel may perform the

maintenance work in the maintenance plan.
 The user should take advantage of training provided by

the manufacturer of the sprinter carrier, in order to train
personnel in the specific technical information and the
required maintenance work.
The maintenance plans should guide the maintenance personnel

through the device. They highlight specific important points about
the device that must be observed.
 The maintenance interval is determined according to the

status of the operating hours counter in the cab.
NM170877300
Manual Page 48 / 64
12. Daily Inspections

Instructed drivers are to perform daily inspections.
The plan for daily inspection simplifies visual inspection of the

device for the assigned driver before the start of each shift.
This plan is in the Driver's Manual.
The driver must have received a manual, so that he/she is in a

position to recognize problems that arise.
For certain maintenance intervals, it is recommended to let the

manufacturer perform tasks such as the larger inspections of
diesel motors, because he has access to the required special
knowledge and tools.
13. Maintenance plan during the initial running-in process

The following maintenance plans assume that,
 from the initial startup until 1,000 hours of operation are

reached,
 but particularly in the first 100 hours of operation,
a "running-in process" for the sprinter carrier occurs.
The planning of the maintenance tasks, including the daily

inspection, is structured accordingly.
NM170877300
Manual Page 49 / 64
14. Maintenance plan

The repetition intervals start for the operating time following
completion of maintenance after 100 operating hours, always
starting with daily inspection.
 It is imperative that the indicated maintenance intervals

and fuel requirements be followed.
 For non-compliance with the maintenance intervals and

fuel requirements, the warranty is invalidated.
 When using the sprinter carrier in a more burdened

environment, the maintenance intervals can be shortened.
This results in more frequent cleaning of the sprinter
carrier and filter changes.
NM170877300
Repair and Maintenance Manual
Page 50 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2
Installation location Maintenance point Tasks
A Entire device
1. 0 Initial tasks
If faults, perform 100% maintenance (all
1. 1 x x x x x Entire device Check previous maintenance tasks
maintenance points)
Perform check for damage / accidents Regarding accidents, 100% check (possible
1. 2 x x x x x Entire device
/ conspicuous issues replacement) of all connections
1. 3 x x x x x Entire device Perform basic cleaning
2. 0 Inspection tasks Z= additional work
2. 1 x x x x x Entire device Steel construction for cracks Visual inspection
Hydraulic screw connection / flanges
2. 2 x x x x x Visual inspection for leakage / abrasions
Entire device etc.
2. 3 x x x x x Entire device Hydraulic hoses Visual inspection for leakage / abrasions
2. 4 - x x x x Entire device Hydraulic cylinder Visual inspection
2. 5 - - - - x Entire device Star coupling / Diagonal set Check
2. 17 - - - - Z Accumulators, brake system Accumulators, brake system Visual inspection Z = Pressure test
3. 0 Check bolt connections
3. 1 x - - - x Entire device Screw connections
6. 0 c = Check oil level / w = oil change k=analysis
6. 5 k k k k w Entire device Hydraulic oil Oil change depending on result of oil analysis
8. 0 Electric systems, contacts
8. 5 - - - - x Entire device Limit switch
10. 0 Finishing tasks
Hoist cables and cable end Hoist cables (service life, approx.
10. 1 x x x x x Check, replace as necessary
connections 5000h)
10. 3 x x x x x Device / Spreader Test emergency off Function test
10. 4 x x x x x Limit switch Limit switch, test end positions Function test
NM170877300
Page 51 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2
10. 5 x x x x x Skid plates Skid plates check

Test drive (test all motions and
10. 21 x x x x x Entire device Function test
braking)
B Carriage
2. 0 Inspection tasks Z= additional work
Support, bottom, incl. Tensioning
2. 7 x x x x x Support / carriage beam Visual inspection
bolts
2. 8 x x x x x Carriage Bumper Visual inspection
2. 9 x x x x x Carriage Tires and tire pressure Check
2. 10 x x x x x Carriage Wheels / Wheel suspension Visual inspection
2. 11 - x x x x Carriage Cuffs on the pivot pins Visual inspection
Track rods, visual inspection and straight
2. 12 - x x x x Carriage Steering / GE bearings
track
2. 22 - x x x x Wheel drive Wheel hub motors Visual inspection of leaks / cable attachments
2. 23 - - - - x Wheel drive Multi-disk brake Check for wear of brake disks
2. 24 - - - - x Wheel drive Cable on resolver (wheel hub motor) Visual inspection
3. 3 - x x x x Wheel suspension Wheel suspension
3. 5 x x x x x Wheel nuts Wheel bolts / nuts
4. 0 Lubrication system
Check function and damage, check settings,
4. 1 x x x x x Carriage Central lubrication system
level control
5. 0 Manual lubrication
5. 11 - - - - x Carriage Cuffs on the pivot pins check, replace if necessary
5. 12 - - - - x Carriage Wheel
NM170877300
Page 52 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2

6. 1 w w w w w Carriage Wheel hub motors Shaft sealing rings (8000h) cf. Appendices
6. 2 k k w k w Carriage Brake cooling oil Oil change depending on result of oil analysis
6. 7 w w w w w Carriage Wheel drives
7. 0 Filter change
7. 6 - - x x x Carriage Diesel prefilter
7. 7 - - - - x Tank refilling Suction filter
10. 6 - x x x x Fuel system Tank sump Draining
C Machinery platform
2. 0 Inspection tasks
2. 6 x x x x x Support / Machine platform Support, top Visual inspection
2. 13 x x x x x Cab Cab holder / Arrester cable Visual inspection
2. 14 x x x x x Cab Cab door and lock Visual inspection
2. 15 x x x x x Steps and landings Steps and landings, grates Visual inspection
2. 18 - x x x x Brake system Brake lines / Brake hoses Visual inspection
2. 19 x x x x x Machinery platform Hoist cables / Anchor points Visual inspection, cable inspection
2. 20 - - - - x Lifting unit Brake cable winch Check gear shaft connection
2. 21 - - - - x Acoustic hood Gas-pressured springs Check
Visual inspection of cable ties / Abrasion
2. 26 x x x x x Electric cables Cable ducts
protection
Carriage / hoisting system / pump
2. 27 - x x x x Flexible shafts and coverings Check / Visual check
combination
Carriage beam/support/machinery
3. 2 x x x x x HV connections
platform
3. 4 x x x x x Cable winches Cable winches
NM170877300
Page 53 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2
Carriage / hoisting system / pump

3. 6 x - - - x Flexible shafts and coverings
combination
5. 3 - x x x x Cable rolls Cable rolls, machinery platform
5. 4 - x x x x Drive shaft Cardan shaft, hoist winch
5. 5 - x x x x Drive shaft Cardan shaft, hydraulic pumps
5. 6 x - x - x Cable winch Cable winches / bearings Outer side (max. 32g grease / 6 Month)
5. 8 - - - - - Cables Hoist cable condition + attachment Clean and lubricate according to need
6. 3 w c c c w Cable winch Cable winches
6. 4 - - - - z Cable winch Brakes Z = check gear shaft connection
7. 0 Filter change
7. 1 x x x x x Hydraulics Oil filter
7. 2 x x x x x Hydraulic tank Return filter
7. 3 - - - - x Hydraulic tank Ventilation filter(s)
7. 4 - - - - x Hydraulic tank Suction filter
7. 8 - x x x x Machinery platform Air filter generator Clean, replace if necessary
7. 9 - x x x x Engine Bypass oil filter During maintenance of diesel motor
Fuel filter / Oil filter, see External
7. 10 - - - - - Engine
maintenance
8. 0 Electric systems, contacts
Control cabinets (cab / machinery
8. 1 - - - - x Control cabinet
platform, etc.)
8. 2 - - x - x Battery box Main fuse, 24V tighten
8. 3 - - x - x Check intermediate bus circuits
8. 4 - - - - x Convertor/generator Convertor/generator high voltage side
8. 6 x Z x - x Battery box Batteries Z=lubricate contacts
NM170877300
Page 54 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2
8. 7 - - x - x Generator Generator connection / cable lug

Attachment points of el. system
9. 0
system
9. 1 - - - - x Three-phase generator Generator Velocity stack weld points
9. 3 - - - - x Cable shears Lower stay cable Inspect clamps
10. 7 - x x x x Hydraulic system Tank sump Draining
10. 8 - - - - x End sound damper End sound damper Draining
D Spreader
2. 0 Inspection tasks
2. 25 - x x x x Spreader Limit switch / Suspension / Support Visual inspection
4. 0 Lubrication system
4. 2 x x x x x Crossbeams Central lubrication system (optional)
level control
4. 3 x x x x x Spreader Central lubrication system (optional)
level control
5. 1 - x x x x Crossbeam guide Crossbeam guide
5. 2 - x x x x Cable rolls Cable rolls, crossbeam
5. 9 - x x x x Spreader Spreader
10. 9 - x x x x Spreader Spreader Function test
Automatic spreader positioning
10. 10 - x x x x Spreader Testing
system
Check twistlocks and replace as
10. 11 - - - - x Spreader Function test
necessary
NM170877300
Page 55 / 64
Maintenance
intervals
after 100
1,000
2,000
3,000
4,000
No. 1
No. 2
E Cab
10. 0 Finishing tasks Z= additional work
10. 12 - x x x x Cab Check cab protection Function test
10. 13 x x x x x Cab Windows Visual inspection
10. 14 - x x x x Cab Window washing system Refill antifreeze / function test
10. 15 - x x x x Cab Windshield wipers / wiper blades replace
10. 16 x x x x x Cab/Device Lighting, blinker, hazard lights, horn Testing
10. 17 - - x x x Cab Cab (all switches) Function test
10. 18 - - x x x Cab Driver calling equipment (optional) Function test
10. 19 - x - - Z Cab Steering power simulator Test steering power Z= inspection
F External maintenance tasks
Motor maintenance by the authorized personnel only Z=SOS oil
11. 1 - x x x x Diesel engine
manufacturer diagnostics
11. 2 - - x - x Air conditioning Have air conditionaing serviced
NM170877300
Manual Page 56 / 64
15. Lubrication and oil change

One of the most important measures for malfunction-free
operation is the careful lubrication of the sprinter carrier, checking
the level of lubricating oil, as well as that of the hydraulic oil, and
observing the stipulated oil change intervals.
To this end, you must observe the present maintenance plan, as

well as the lubricant and hydraulic oil recommendations.
It remains at the discretion of the user to take advantage of the

technical services provided by the lubrication manufacturers at the
location of the sprinter carrier. However, the user must consult
with the manufacturer about the use of lubricants other than those
listed in the attached list.
The individual lubrication points of the sprinter carrier are

designated in the maintenance plan.
For determining the lubrication intervals, the
operation hours counter
in the cab of the sprinter carrier is authoritative.
The following notes should be taken into consideration when

performing lubrication services:
 Lubricants, grease and lubricating oils, as well as hydraulic

oils of different types, may never be mixed with one
another.
 Before greasing, all grease nipples must be cleaned

carefully, so that the no dirt can be pressed into the
lubrication point during the subsequent greasing
procedure.
 Filling the bearing locations using lubrication nipples

should occur until fresh grease emerges from the bearing
locations. Excess grease is to be removed.
NM170877300
Manual Page 57 / 64
 During the required lubricating oil or hydraulic oil change,

the oil drain plug must be removed and cleaned carefully.
Before replacing the screw, a new gasket must be put in
place. When a cooling-oil change takes place in the
service brake, not only the coolers, but also the cooling oil
cavities in the wheel gearing must be drained.
 Gummed and caked grease on the cables must be

removed immediately.
 More frequent greasing of the cables with smaller

quantities of grease is more effective than more grease
with longer intervals.
 Never use crude oil, kerosene, paraffin, old oil, or non-

neutral oil to grease the cables.
NM170877300
Manual Page 58 / 64
16. Lubrication points
Pos. Sketch
6.1
6.2
2.23
Oil fill opening Oil drainage opening Bleeding Gauge glass
Grease nipple
NM170877300
Manual Page 59 / 64
Pos. Sketch Pos. Sketch

2.10 5.10
6.2 4.1
4.2
Open grease
Grease nipple Bleeding Gauge glass
point
Central
Oil drain opening, oil
lubrication
fill opening
system
NM170877300
Manual Page 60 / 64
Pos. Sketch
3.4
170691_HW
5.2

5.1 10.1
Oil drainage opening, oil fill opening Oil level Grease nipple
Central lubrication
Dipstick Open grease point
system
NM170877300
Manual Page 61 / 64

10.7 2.25
5.9
10.9
8.7
11.1
Open grease point Grease nipple
Oil level display container Oil fill opening
Dipstick Central lubrication system
1 Fuel filter 2 Motor oil filter
 The position numbers refer to the overviews in Section 5

of this document.
NM170877300
Page 62 / 64
17. Filter list

No. of filters
Order No. Quantity Filter Order No. Filter element Installation location Figure Maintenance interval
Element / Filter
140955262 1 BREATHER, PLASTIC - FUEL SYSTEM M.B.
140955016 1 HIGH-PRESSURE FILTER 1 140955037 MB PLATFORM ADPC NSC

624 E
140955019 1 COMBINATION AIR FILTER 1 140955052, 140955054 BG AIR INTAKE AND
EXHAUST PIPE VA
140955147 1 HIGH-PRESSURE FILTER 1 140955150 MB PLATFORM ADPC NSC
624 E
140955236 1 RETURN FILTER 2 140955062 ZSB OIL CONTAINER ESW
06
140955122 2 SUCTION FILTER ZSB OIL CONTAINER ESW
06
140955228 2 SUCTION FILTER ZSB OIL CONTAINER ESW
06
140955092 1 VENTILATION FILTER - ZSB OIL CONTAINER ESW
06
140955552 1 FILTER SYSTEM 01 – AL58 1 140955553 INSTALLATION OF
SIDESTREAM OIL FILTER
146640035 1 GENERATOR 1 141755619 GENERATOR INSTALLATION
C13
140955009 2 FUEL FILTER 1 140955057 FUEL SYSTEM
LEFT / RIGHT
140955211 1 OIL FILTER
140955152 1 FUEL PREFILTER 1 140955213 11.1

DIESEL ENGINE
CAT C-13
140955214 1 MOTOR VENTILATION FILTER
140955549 1 MAIN FUEL FILTER
Table 6 List of filters

NM170877300
Page 63 / 64
18. Fuels
Application Equipment Standard Specification Filled at the factory
Spur gear, planetary gear, worm Gear oil ISO VG 220 CLP 220 Degol BMB 220 (Aral)
gear, bevel gear DIN 51502 DIN 51517
Rolling and slide bearings in pulleys, Lithium multi-use grease K0K-K2K-20 K0K-K2K-20 Spheerol EPL2 (Castrol)
impellers, drum bearings; flexible DIN 51502 DIN 51825
shafts
Bogie pin movable bearings;
Load hooks, lifting beams;
Cable end connections
Open toothed wheel gearing; Adhesive lubricant OG2K-20, OG2K-20 Spheerol EPL2 (Castrol)
Cables; DIN 51825,
Sliding surfaces and guides; BB BB
Twistlocks DIN 51502 DIN 51513
Wheel drives Gear oil GL-5-90-LS GL-5-90-LS Hypoy LS90 (Castrol)

DIN 51502 API classification
MIL-L-2105
Cooling oil for operating brake in the Cooling oil GL-4- LS API classification Autol Special Fluid N15 (Agip)
wheel drives GL-4
MIL-L-46152C,
MIL L-2104C or D
NM170877300
Page 64 / 64
Application Equipment Standard Specification Filled at the factory
Diesel engine Motor oil SAE 10W40 SAE 10W-40 Tection 10W-40 (Castrol)
DIN 51502 DIN 51511,
CAT DEO or
API classification
CH-4/CI-4
and ECF-1a, ECF-2, ECF-3
Hydraulic component 2 Hydraulic oil ISO VG 46 HVLP 46 Hyspin AWH-M 46 (BP)

DIN 51502 DIN 51524
SAE 10W30
API classification
CD/SF,CE/SF, CE/SG
Diesel engine Coolant with antifreeze Caterpillar Extended Life Coolant Note coolant recommendation from CAT
Diesel engine Diesel fuel Low-sulfur or sulfur-free diesel Note coolant recommendation from CAT
fuel
Air conditioning Coolant FKW-R 134 a

1.1.1.2-Tetrafluoroethane
2 ) See also "Pressure fluids based on mineral oil for axial piston machines" RD 90220-1/11.99 Bosch Rexroth AG

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NM170877300

Repair and Maintenance

Noell Order No. 17087700

Year of manufacture 2011

Phone: +49 (0) 931/2053-0

Issue date 11/11

Copyright © 2011, Noell Mobile Systems GmbH

Neither the content of this published document, nor parts thereof,

Translation of the original instructions

This document is a translation of the original instructions for use

1.1. Additional information .........................................................................................5

1.2. Signs and symbols used .....................................................................................5

3. Hoist cables ...........................................................................................................9

3.1. Handling of cables ..............................................................................................9

3.2. Cleaning and maintenance ...............................................................................13

3.3. Testing ..............................................................................................................14

3.4. Cable Replacement ..........................................................................................18

4. Steering setup .....................................................................................................22

4.1. Setting the steering rods ...................................................................................22

4.2. Alignment of the wheel forks .............................................................................24

4.3. Setting the steering pressure ............................................................................24

5. Wheel change ......................................................................................................25

5.1. Preparation .......................................................................................................25

5.2. Removal of the wheel .......................................................................................25

5.3. Mounting the wheel...........................................................................................26

6. Multi-disk brakes in the hoist winch..................................................................27

6.1. Transmission of wear on brake disks................................................................27

7. Fuel system .........................................................................................................28

8. Hydraulic systems ..............................................................................................29

8.1. Servicing hydraulic systems..............................................................................29

8.2. Repairs .............................................................................................................34

8.3. Troubleshooting ................................................................................................35

9. Emergency operation .........................................................................................38

10. Screw connections .............................................................................................41

10.1. Tensioner ..........................................................................................................43

10.2. Torque key ........................................................................................................43

10.3. Table for torques and pretension ......................................................................44

10.4. Torques on the wheel bolts...............................................................................45

10.5. Drive shaft flange coupling................................................................................45

10.6. HV bolt connections ..........................................................................................46

11. Introduction to maintenance planning ..............................................................47

12. Daily Inspections.................................................................................................48

13. Maintenance plan during the initial running-in process ..................................48

14. Maintenance plan ................................................................................................49

15. Lubrication and oil change.................................................................................56

16. Lubrication points...............................................................................................58

17. Filter list ...............................................................................................................62

1.1. Additional information

1.2. Signs and symbols used

Hazard warning symbol

Warning about a hazard point!

This symbol is used to indicate activities that

This manual is intended for maintenance

Maintenance employees must have solid technical training. For some

 Basic safety instructions

Only qualified and trained personnel may perform

The safety regulations must be followed during

Intervention by the operator without prior approval from the

Special information about components, for which no further details

 "Driver's Manual," "Repair and Maintenance