Notes on Safety 1

1 Notes on Safety

1.1 General Recommendations for the

Lubrication and Maintenance Tasks

Undertake the prescribed adjustment and

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

Ensure that all handles, steps, rails, platforms,

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

Ensure that the crane is kept clean at all

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

Z 160 002

- Thoroughly clean all nipples, caps and plugs

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

Z 160 001

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- Refill the fuel tank at the end of each

working day.
(Z 160 017)

Sufficient ventilation has to be ensured

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

Z 160 017

- Renew the sealing rings for drain, filler,

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

The oil can be drained more easily from

individual units if it is drained at operating
temperature.

When the operating temperature is reached,

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

After cleaning the engine bay, check all

- fuel lines
- engine oil lines
- hydraulic oil lines

for leaks, loose connections, worn patches

and damage.

Repair any damage immediately.

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

Z 160 003

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 Notes on Safety 1

After cleaning the crane, grease all grease

points.

When dry, spray the slew gear teeth with the

recommended grease.
(Z 160 010)

Z 160 010

Check all electrical lines, push-on connections

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

Repair any damage immediately.

(Z 160 504)

Z 160 504

Check the turbocharger mounting.

Check the exhaust and air inlet lines and the

lubricant supply and return lines for leaks.

Repair any damage immediately.

Date: 07.CW/95

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Fire extinguishers must be full and ready for use.

(Z 160 009)

Z 160 009

Never carry out welding repairs without first

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

Z 160 005

- Please contact the Customer Service

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

Z 160 006

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 Notes on Safety 1

1.2 Notes on Safety

The diesel engine must always be switched off

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

Z 160 113

Before carrying out any lubrication or

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

The residual energy or stored energy wich

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

Check that the crane is free of faults.

(Z 160 415)

Z 160 415

Lubrication and maintenance tasks may only be

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

Z 160 008

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Before carrying out any lubrication or

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

Z 160 014

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

i.e. - boom lowered

- vehicle supported on outriggers
- axles lowered

(Z 160 018)
Z 160 018

Wear safety clothing, protective goggles,

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

Do not allow unauthorized persons near

the equipment whilst carrying out maintenance
or lubrication tasks.

Work which could affect the operational

Date: 07.CW/95

and road safety of the crane must only be

carried out by trained personnel.
Z 160 011

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 Notes on Safety 1

If it is necessary for one or more persons to be

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

Z 160 023

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

Z 160 024

Store oil-impregnated rags and flammable

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

Oils that are drained off must be stored in

suitable containers and disposed of
correctly.

These safety instructions are to be

Date: 07.CW/95

observed whenever the crane is operated or

repaired.
Z 160 016

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After service and maintenance work has

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

Z 160 366

After service and maintenance work has

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

Z 160 027

If you vuse electrical equipment for

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

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

Z 160 083

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 Notes on Safety 1

1.3 Recurrent Inspections of the Crane Carrying out the inspection

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

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

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

The VBG 9 inspections do not affect the

national and international regulations
applicable.

Inspection interval

Cranes must be checked by a "Sachkundiger"

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

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1.4 Measures to Ensure Safe
Operating Periods
1.4.1 General
In accordance with the accident prevention
regulations for winches, lifting and dragging
equipment (VBG 8),the crane operator is
obliged to carry out an inspection of the crane
at least once a year (also see ISO 9927-1).
The spend share of the theoretical service
life for the winches must also be determined.
The crane operator must employ a specialist
for the purpose if necessary.
This regulation is legally binding within
the scope of the accident prevention
regulations of the trade association. Out-
side of this realm, the crane manufacturer
recommends that the procedures listed are
also observed.
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1.4.2 Theoretical Service Life
The Design engineer has assumed certain
operating conditions in calculating and
dimensioning the winches on your crane.
The winches on your crane are classified
as follows (ISO 4301/1, FEM 1.001,
DIN calculation principles for power units):
- Power unit group: M............
- Load spectrum: Q............ (L........)
- Load spectrum factor: Km=.......
A theoretical service life, D, is thus calculatet.
The values applicable must be taken from
the "Monitoring the Winches" table given in the
crane log-book.
Date: 07.CW/95
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The theoretical service life must not be
equated with the real (actual) service life of
a winch.
In addition, the real service life of a winch
is affected by a number of external
influences, for example:
- Overloading through not using the crane
as intended.
- Insufficient maintenance: the oil is not
changed in good time.
- Maloperation such as extreme
acceleration or deceleration of the load
or the load falling into the ropes.
- Maintenance mistakes such as using the
wrong oil, incorrect oil fill or contamination
when changing the oil.
- Mounting mistakes when undertaking
repairs or maintenance.
- Leaks not taken into consideration.
- Incorrectly adjusted safety equipment.
- Concealed damage caused by accidents.
- Extreme ambient conditions such as low
or high temperatures, aggressive
atmosphere, dust and dirt.
Date: 07.CW/95
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Notes on Safety 1
1.4.3 Actual Operating Conditions
Before the spent share of the theoretical service
life of the winches can be determined, the actual
operating conditions (load spectrum) and the
operating hours of the hoists per inspection
interval must be determined.
1.4.3.1 Determining the Operating
Conditions (Load Spectrum)
The load spectrum of the crane is divided into
groups (also see ISO 4301/1, FEM 1.001).
From knowledge of the actual operating
conditions, one of the load spectrums listed
below must be selected and recorded in the
crane log-book for the relevant inspection
interval.
1.4.3.2 Operating Hours of the Hoists
per Inspection Interval
Determine the effective number of operating
hours per inspection interval (Ti). This must be
recorded in the crane log-book for the relevant
inspection interval.
For mobile cranes used for erection operation,
the share of the hoist winches is generally
20 % of the total operating hours for the
superstructure and 12 % of the total operating
hours for the entire crane.
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 1
Load Load
spectrum spectrum

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

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

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

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

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

Laufzeit
%
Operating time

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

Laufzeit
%
Operating time

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Date: 07.CW/95
 Notes on Safety 1

1.4.4 Determining the Spent Share of

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

Ti = effective operating hours for inspection

interval "i" as per Section 1.4.3.2

After each inspection interval, the spent share

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

- If the theoretical service life remaining is

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

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

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

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Monitoring the Winches

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

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

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

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

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

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

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

Z 29 555

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Date: 07.CW/95
 Notes on Safety 1

1.4.5 Documentation
(Z 29 555)

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

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

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

The specimen table is clarified by the following Km1 0.125

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

The value for the load spectrum factor

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

Theoretical remaining service life after the

first year:

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

Date: 07.CW/95

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

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

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

Theoretical remaining service life after the

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

It must now be assessed whether the

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

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 Date: 07.CW/95

Monitoring the Winches

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

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

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

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

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