Cooling, Air Intake and Exhaust System 16

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1 2

61

Z 57 817 Z 42 107

Z 4 965

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16 Cooling, Air Intake and Exhaust System

Risk of burning and scalding.

When carrying out work in the vicinity of the exhaust and
cooling system, allow a cooling off period of 60 minutes or
wear appropriate clothing and gloves.

16.1 Cleaning and Replacing the Air Filter Element

Never service the air filter with the engine running.

(Z 57 817)

Clean the filter element as soon as indicator light (61) comes on

with the engine running.
(Z 42 107, Z 4 965)

1. Open spring--loaded latches (1) and remove cover (2) from

housing (Z 42 107).

2. Remove clogged filter cartridge (4) from the barrel (Z 4965).

3. Clean and check filter cartridge (4). Replace the filter car-
tridge if required.

After having been cleaned 3 times, or if it becomes contami-

nated with soot, the filter cartridge must be replaced. It must,
however, be replaced after 2 years at the latest.

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Z 0 406 Z 0 125

Z 0 126 Z 0 129

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16.1.1 Dry Cleaning

-- Temporarily by tapping out

If the filter cannot be cleaned using compressed air or washing

with water, it is sufficient to tap out the dirt in the element.

Tap the front of the filter element repeatedly against the ball of the
hand to ensure that the dust is removed (Z 0406).

Be careful not to damage the filter element. Clean the surface of

the seals.

-- With compressed air

Compressed air (max. 5 bar)

Blow dry compressed air at an angle from the outside, then from
the inside (Z 0125 and Z 0126).

16.1.2 Wet Cleaning

First soak the filter element for 10 minutes in hand--hot water with
a small amount of non--foaming detergent (Mann--cleaner 053)
added. Then agitate the element in the washing solution for ap-
prox. 5 minutes.

Rinse well in clear water, shake and dry (Z 0129).

Under no circumstances should petrol, alkaline solutions

or hot liquids be used for cleaning.

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Z 0130

Z 0131

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16.1.3 Testing the Element

1. Insert bulb into the clean and dry filter element and test the
element. Throw away any damaged elements (Z 0130).

2. Wrap up elements which can be used again, and store them

in a clean and dry place (Z 0131).

When using compressed air to clean the elements, wear

protective goggles and clothing. Maximum air pressure
should not exceed 5 bar.

Do not clean elements by beating or banging.

Elements with damaged folds or seals should not be reused.

It is advisable to keep spare elements ready, so that these can

be used while the other elements are being cleaned.

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Z 27 837 Z 27 838

Z 501 336

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16.2 Replacing the Safety Cartridge (Optional Equipment)

After the filter element has been cleaned three times, the safety
cartridge must also be replaced as follows:

1. Unscrew the fixing nut of the safety cartridge (Z 27 837).

2. Remove the safety cartridge (Z 27 838).

3. Clean the filter barrel of any dirt, but do not blow out with com-
pressed.

4. Fit a new safety cartridge.

5. The cartridge is fitted in the reverse order.

The safety cartridge must not be cleaned but must always be

replaced.

16.3 Air filter prefractionator (optional)

The air filter prefractionator prevents dirt from getting into the air
filter and the engine due to the suction.

The contamination is discarded through the side ejection hole

(1).
(Z 501 336)

If required, the ejection hole (1) must be cleaned.

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Z 57 815

70

Z 57 816

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16.4 Cleaning the Cooling System

(Z 57 815 principle drawing, Z 57 816)

Risk of burning and scalding.

Ensure that there is a cooling period of 60 minutes be-
fore carrying out the work described.

Pass compressed air through the cooling system against the air
flow, at a moderate pressure, to ensure that the cooling fins are
not damaged or spray with water until the cooling fins are comple-
tely free from impurities (dust, insects, etc.)

If the coolant rises to an unusually high temperature at normal

ambient temperatures, although the cooling system exterior has
been cleaned and there are no other malfunctions, the cooling
system interior may be contaminated.

If the coolant temperature reaches an unpermitted value, the

relevant light--emitting diode (LED) on multifunction display
10 (70, Z 57 816) flashes and a corresponding warning signal
goes off.

In this instance the cooling system must be thoroughly cleaned,

whereby the entire cooling circuit is degreased, decalcified and
derusted.

Further details can be found in the engine manufacturer’s opera-

ting instructions.

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

ments.

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Z 56 077

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16.5 Checking the Coolant Level and Topping Up as Ne-

cessary

(Z 56 077)

Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. Acci-
dents may occur.

1. Turn the cap (1) on the expansion tank to the first notch and
release excess pressure.

2. Continue to turn up the second stop, remove cover.

The cooling system is filled correctly when the coolant, according

to system design, is level with the rim of the filler neck or with the
marker on the filler neck.

-- Before the onset of winter, check the coolant for anti--

freeze.
-- See also the engine manufacturer’s operating instruc-
tions.

16.6 Replacing the Coolant with Anti-- Freeze

(Z 56 077)

The coolant should be mixed with a corrosion proof anti--freeze

throughout the year (see operating instructions for the engine).
The anti--freeze has no negative effect on the improved coolant.

The coolant must be changed as soon as this is necessary

e.g. in the case of repair. The coolant must, however, be
changed at least every two years.

1. Switch off the engine.

Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. Acci-
dents may occur.

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Z 56 077

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2. To be safe, slowly open the cover on the expansion tank up

to the first stop so that any overpressure can be released.
Only then turn the cap further to the 2nd notch and remove.

3. Drain the engine and cooler.

In order to drain the cooling system, the relevant drain plugs
and hose couplings must be opened.

4. Once the cooling system has been drained, all drain plugs
and hose couplings must be closed again.

5. Fill the cooling system with fresh coolant.

When filling the cooling system make sure that you do not
create any air pockets. Air captured in the system can cause
engine damage.

-- Use water free of minerals which can cause boiler scale. Do

not use softened water.
-- Pause several times when filling the system so that the coo-
lant is given time to penetrate and settle. This also enables
enclosed air to escape.
-- Add coolant until it reaches the marking in the filler neck.

6. Start the engine and allow it to idle for a couple of minutes

with the expansion tank open. If necessary, top up the coo-
lant.

7. Replace the cover and close the heating valves.

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130.1 130.2 130.3

3
A

130.4

130.7 130.5
4
130.6
2 1 380V
130

Z 200 377 Z 075 373

”Y” ”X”

Z 56 116

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16.7 Maintaining the Diesel Exhaust Particulate Filter (Op-

tional)

When the display gauge shows a pressure of more than 150

mbar (130, Z 200 377), the diesel soot particle filter must be bur-
ned clean.
Information on the display gauge can be found in see section 4
“Engine” of the operating instructions.

Procedure for burning clean

1. Connect the burn--off unit’s E--cable (1, Z 075 373) to the

socket (X, Z 56 116) on the crane superstructure.

2. Connect the air hose (2, Z 075 373) to the coupling (Y,
Z 56 116) on the crane superstructure.

3. Connect the electric cable (380 V, Z 075 373) from the bur-
ning unit to the power network.

4. Switch on the power switch (3, Z 075 373) on the burn clea-
ning unit.

The ammeter (4, Z 075 373) indicates whether heating electricity

flows.

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

completed and the ammeter displays “0”.

The cleaning procedure must not be interrupted. The current

and air supply must be completely uninterrupted during the
cleaning procedure.

6. Switch off the power switch (3, Z 075 373) on the burning de-
vice.

7. Disconnect the electric cable (380 V. Z 075 373) from the

power network.

8. Disconnect the electric cable (1, Z 075 373) and air hose (2,
Z 075 373) from the crane superstructure.

9. Stow the cleaning equipment away on the crane

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6 7

Z 075 374

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Servicing the filter element

The filter element must be cleaned after 1500 operating hours but
at least once per year to remove fuel and lubricant residues.

1. Burn the filter clean as described in the previous paragraph.

2. After burning clean, leave the filter to cool off for 3--4 hours.

3. Release the two clasps (6, Z 075 374 principle drawing) and
remove the filter element.

4. Place the removed, cooled filter element in a vertical position

and rinse through from the top with warm water (do not use
compressed air) until the water is clear.

Dispose of the cleaning water using oil separators in an environ-

mentally friendly manner.

5. Leave the filter element to drip dry.

6. Refit the filter element, using new seals if required.

7. Close the two clasps (6, Z 075 374 principle drawing).

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16.7.1 Troubleshooting/Check List

Heating element:
The ammeter rea- -- Is the burning unit If both are okay, the
ding for the current is connected correctly? heating element is
too low (setpoint -- Are the fuses okay? defective.
7.8 A).
Air supply:
Incomplete burning Are the air supply com- Check the air supply
procedure ponents blocked or components.
dirty? Only use the original
connecting pieces
from the manufactu-
rer.
Timer:
Burning time is too -- Timer setting correct? The timing relay (ti-
short and/or the ex- mer) for the heater
haust counterpres- element must be set
sure is too high. to 6 hours.
The timing relay (ti-
mer) for the air pump
must be set to 8
-- Are the heating ele- hours.
ments and air supply
functioning correctly?
-- Was the voltage a
constant 380 V during
the burning procedure?
-- Is the intake area of
the soot filter free of
soot following the bur-
ning clean process?
-- Has the diesel engine
been serviced?
The smoke level
must not exceed 2.5
-- Has the soot filter Bosch units without
been cleaned in accor- the soot filter.
dance with the servicing
instructions?

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