Removing and Fitting the Superstructure 32

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 Removing and Fitting the Superstructure 32

32 Removing and Fitting the Superstructure

Risk of crushing between the superstructure and crane

chassis! To avoid dangerous situations, pay particular
attention to the safety instructions in section 1.4.8 ”When
Assembling and Dismantling Crane Components”.
In particular, make sure that you allow sufficient safety
clearance. This can be ensured using the available mo-
bile control panel.
The superstructure may only be fitted and removed using
a trained team. In this case, every assembly and dis-
mantling step must be planned exactly.
The crane chassis must be safely supported on outrig-
gers. All component parts must be safely attached to au-
xiliary cranes with sufficient load--bearing capacity be-
fore removal or fitting.

In addition, the crane manufacturer recommends that

preliminary training be carried out on some safe spare
ground to allow the assembly personnel to practise all
the relevant procedures, taking into account all health
and safety considerations, BEFORE the actual on--site
operations.

All assembly, dismantling and supervisory work lies wit-

hin the overall responsibility of the crane operator.

To fit and remove the superstructure, the mobile crane must

be supported on outriggers (see section 12 of the operating
instructions of the crane chassis in part 2).

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Z 54 216

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 Removing and Fitting the Superstructure 32

32.1 General Instructions

To ensure that specific axle loads or a specific transport load is

not exceeded when the mobile crane is driven, the
superstructure must be removed from the crane (”Driving without
Superstructure”, see the operating instructions of the crane
chassis, part 2, section 6), (Z 54 216).

The superstructure is removed and fitted using a mobile crane.

Before removing the superstructure the main boom must be
removed (detail “A”) -- and the luffing cylinders must be braced
using the auxiliary cylinders on the superstructure frame
(detail “B”). The luffing cylinders must be in the horizontal
position.
Instructions on removing the main boom can be found in section
31.2 of these operating instructions.

Before removing the superstructure the crane cab must be

swung to the rear in the transport position and the transport locks
fitted (detail “C”).

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5/1

5/2

Z 48 881

10

8 ”X491”

Z 41 580 Z 49 828

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The slewing rim connection is locked and unlocked by extending

and retracting the locking cylinders (5, Z 48 881), tensioners
(5/1) and positioning cylinders (5/2).

The sequence for extending and retracting the cylinders is shown

on an information sign. This sign is fitted on the cover of the
left--hand control panel of the outriggers (Z 49 828).

Movement of the locking cylinders is controlled using the mobile

control panel (8) by means of selector switch (10) and self--return
rocker switch (9) (Z 41 580).

This control panel enables sufficient safety clearance to be

maintained from the crane during the locking and unlocking
procedure.
As required, it is connected to the joint box (”X491”, Z 49 828) on
the control panel of the outriggers on the left--hand side of the
crane.

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32

S
2

”B”
”A” ”B” ”A”

”B” ”A”

”Y”

860
Z 54 217

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 Removing and Fitting the Superstructure 32

Attachment points
(Z 54 217)

To remove and fit the superstructure without the main boom but
with luffing cylinders, a 4--stranded lifting tackle is required.
The following attachment points should be used:
− the two shackles (A) on the superstructure frame
− both main boom foot bolts (B)

Weight and centre of gravity

(Z 54 217)

The weight of the superstructure without main boom, but with

luffing cylinders, is approx. 25 t.
Select the auxiliary crane accordingly.
With the luffing cylinders tensioned in the horizontal position, the
centre of gravity “Y” is approx. 860 mm from the centre of the slew
ring in the direction of the hoist.
To enable the superstructure to be removed safely, the
attachment elements of the lifting gear must be approx. 4 m long
(see detail “X”). They must be designed for a permitted force of
12.5 t per strand.

To avoid damage to the main boom foot bolts when the

superstructure is fitted and removed (attachment point “B”),
the chains of the lifting tackle must not be used as
attachment elements. Use suitable load handling
attachments that will not damage the pins/bolts (e.g. bands,
lugs). Due to tolerances the superstructure weight and
therefore the centre of gravity can vary slightly. When the
superstructure is first removed, its centre of gravity “Y”
must be exactly calculated. When starting the removal
procedure, checks must be made to ensure that the gap “S”
between the upper bearing race (1) and the lower bearing
race (2) is identical all the way round (see detail “Y”). Only
lift to the extent that the bearing race (1) does not leave the
centring consoles (7) fitted on the outside of the crane
chassis (see detail “W”), otherwise uncontrolled swinging of
the superstructure is possible, RISK OF ACCIDENTS !. If this
is not the case, the length of the affected bracing strand must
be changed accordingly. For this reason we suggest that two
of the four lifting chains be fitted with shortening claws (see
detail “Z”).
The load handling attachments are supplied by the
customer.

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9
10
4

5/1
5/2

2
1

8 1

12 7
10
2
11 11
Z 52 769

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 Removing and Fitting the Superstructure 32

32.2 Slew Ring Quick Connection

32.2.1 Component Parts of the Slew Ring Quick Connection

(Z 52 769)

The quick release is made up of the following parts:

−(1) : Upper bearing race with slew ring
--(2) : Lower bearing race
--(3) : Tension ring
--(4) : Clamp
--(5) : Locking and unlocking cylinder
--(5/1): Tensioner
--(5/2): Positioning cylinder
--(6) : Console with attachment screw
--(7) : Centring console
--(8) : Spigot
--(9) : Spindle (SW24)
--(10): Inspection rod
--(11): Bearing ring
--(12): Kick rod

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9
10
4
3

”Y” 4 1
9
2
10
”X” 9

12 11 12
10

11
Z 49 435

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32.2.2 Quick Release Locked

(Z 49 435)

In the locked condition of the slew ring quick connection both

hydraulic cylinders (5) are completely extended.
The tension ring (3) is pressed outwards by the cylinders and
jams the upper bearing race (1), that is screwed to the slew ring
and the lower bearing race (2) together (see detail “Y”). This lower
bearing race is screwed to the bearing ring (11) of the crane
chassis.
The clamp (4) is pulled into the open tension ring (3) by turning
the spindle (9). This prevents the quick release opening
unwanted.
In the locked condition the inspection rod (10) must protrude out
of the kick rod (12) as far as possible (protrusion of approx. 7mm),
so that the attached marking is clearly visible (see detail “X” / “Y”).

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9
10
4
3 2

5
6 6

”Y” 4
1
”X” 9 9
2

12 10

11 10 12
11

Z 49 436

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32.2.3 Quick Release Unlocked

(Z 49 436)

In the released state the slew ring quick connection is

completely pushed in by the clamp (4).
By turning the spindle (9) this clamp must be pushed inwards until
a mechanical resistance is felt. The inspection rod (10) then
moves inwards in the kick rod (12) (see detail “X” / “Y”). In the
unlocked condition the marking on the inspection rod (10)
(protrudes approx. 5 mm), between bearing ring (11) and kick rod
(12), must be visible.

Both hydraulic cylinders (5) are completely retracted. The tension

ring (3) is then drawn inwards up to the stops (6).
The upper bearing race (1) that is bolted to the slew ring and the
lower bearing race (2) are not clamped together (see detail “Y”).
The connection between the superstructure and crane chassis
is released.

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Z 48 885

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 Removing and Fitting the Superstructure 32

32.3 Removing the Superstructure

Removal of the superstructure, as described below, is only

possible when the crane is equipped with a hydraulic bracing
device for the luffing cylinders.

Before removing the superstructure (1) the mobile crane is in the

following condition (Z 48 885):
− Superstructure in 180° position, i.e. slewed to the rear.
− Mechanical superstructure locking device inserted.
− Luffing cylinders braced by means of the auxiliary cylinders
and inserted in the transport rest.
− Hoist 2 removed and crane cab folded into the transport
position and secured.

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”X”

3 3

”E304”

Z 42 799 Z 44 000

”Q304”

”E304”

”Q305”

”Q306”

Z 48 886

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 Removing and Fitting the Superstructure 32

Proceed as follows to remove the superstructure:

1. Set down the crane on even ground and support on

outriggers (see the “operating instructions for the crane
chassis”, part 2, section 12).

2. Release the electric connections between the

superstructure and crane chassis on the rotary joint. To this
end:

2.1 Release all cable straps of the power cables to the slip
ring “E304” on the cam (3) and on the superstructure
(Z 42 799).

2.2 Unscrew cam (3) in point “X” on the superstructure

frame and remove (Z 44 000).

This is necessary to ensure that, when lifting off the

superstructure, the slip ring “E304” is not damaged.

2.3 Release plug connections “Q304”, “Q305” and “Q306”

(Z 48 886).
Close off the cable plugs as well as the socket with
protection caps.
Feed the released cable in such a way that the plugs
will not become snagged when the superstructure is
subsequently lifted off.

-- After releasing the plug connection “Q304” the lighting

electrics between the crane chassis and superstructure are
interrupted.
-- After releasing the plug connection “Q305” there is no longer
a connection between the pressure contacts in the outrigger
cylinders and the support pressure gauge in the crane
operator’s cab.
The support area sensor is out of operation.
-- After releasing the plug connection “Q306” there is no longer
a connection to the slewing angle sensor in the slip ring
“E304”.

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10

”Q60C”
9

Z 41 580 Z 41 586

24
25

24

24

Z 44 004

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3. As the main boom foot bolts are required as attachment

points for lifting off the superstructure, they must be placed
in the “pinned” position (Z 44 004).
To this end, connect the mobile control panel (8, Z 41 580)
to socket (”Q60C”, Z 41 586) and switch the selector switch
(10) to position “3” (Z 41 580).
With the superstructure engine running, press self--return
rocker switch (9, “S560A”) up and hold.
The pinning cylinders (24, Z 44 004) are extended.

4. To prevent unintentional retraction of the basic bolts, insert

the protective cover (25) and secure (Z 44 004).

Information on inserting and securing the protective cover can be

found in section 31.3.2 “Pinning the main boom foot section” of
these operating instructions.

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10

40
9

39
8

Z 41 580

Z 46 721 Z 44 005

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 Removing and Fitting the Superstructure 32

5. Now check that the luffing cylinders are in the horizontal

position.

This should be checked before the superstructure is re-

moved. Due to movement of the centre of gravity there is
a risk of accidents when lifting off!

If a correction has to be made to the position of the luffing

cylinders, proceed as follows:

5.1 Switch selector switch (10, “S560”) on the mobile

control panel (8) to position “1” (Z 41 580).

5.2 With the superstructure engine running, press down

the self--return rocker switch (9, “S560B”) on the
mobile control panel (8) and hold. The auxiliary
cylinders (39) are retracted, the luffing cylinders (40)
are raised (Z 44 005).

5.3 Remove the cylinder support from the rear of the crane
chassis (Z 46 721).

The area beneath the raised luffing cylinders must be

kept clear at all times. RISK OF ACCIDENTS!
Proceed as follows to remove the cylinder support.

5.4 Lower the luffing cylinders into the horizontal position.

To this end, with the superstructure engine running and
selector switch (10) in position “1” on the mobile
control panel (8, Z 41 580), press self--return rocker
switch (9, “S560A”) upwards and hold. The auxiliary
cylinders (39) are extended, the luffing cylinders (40)
are lowered (Z 44 005).

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R1 R1

117 118

Z 46 715

Z 46 716 Z 44 007

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 Removing and Fitting the Superstructure 32

6. Press switch (117) on the dashboard to lock the slew gear

brake (Z 46 715).

The slew gear brake must be blocked to enable the

superstructure to be fitted in the same position again.

7. Press switch (118) to release the mechanical superstructure

locking device (Z 46 715 and Z 46 716).

8. Attach lifting device (provided by customer) to the auxiliary

crane and connect to the 4 attachment points provided on
the superstructure (Z 44 007).

Observe the instructions in section 32.1 of these operating

instructions: “Attachment points” and “weight and centre of
gravity”.

9. Tension the load handling attachments with the auxiliary

crane slightly.

There must only be a slight increase in the load on the crane

hook of the auxiliary crane (max. 1 t). Otherwise there is the
danger of the quick release connection jamming. This would
lead to problems when opening the quick release.
The auxiliary crane should be as close as possible over the
centre of gravity of the superstructure that is to be raised,
load handling attachments must be evenly tensioned.

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9
10

12 10

11
Z 49 439

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10. Unlock the slewing rim.

The (safety) lock of the slewing rim comprises the following parts
(Z 49 439):
-- the clamp (4)
-- the spindle (9)
-- the inspection rod (10)

Proceed as follows to unlock the slewing rim:

Turn the spindle (9) to move the clamp (4) out of the tension ring
(3) and to push inwards.
Turn the spindle (9) until a clear resistance is felt. The clamp is
pressed against the corresponding stops.

To turn the spindles, for example, a ratchet can be used.

In addition, check the final position of the clamp (4) using the
inspection rod (10).
As this inspection rod is screwed into the clamp (4), it is
drawn into the inside of the lower bearing race. Once the end
position of the clamp (4) has been reached the marking on
the inspection rod (10) (protrudes approx. 5 mm), between
bearing ring (11) and kick rod (12), must be visible.

11. Now check that the superstructure is attached correctly, i.e.

that the correct attachment points have been selected and
the load handling attachments have been adjusted to the
centre of gravity and the superstructure weight.
The load handling attachments must be tensioned at the
same time.

12. Start the engine of the crane chassis.

RISK OF ACCIDENTS!
Before the slewing rim has been unpinned you must
have made sure that there are no obstacles or persons in
the direct vicinity of the crane and that all safety instruc-
tions in section 1.4.8 “When assembling and dismantling
crane components” have been observed.
There is a risk of accidents for the operating personnel
as a result of the released superstructure swinging out-
wards.

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10

8 ”X491”

Z 41 580 Z 49 829

2 3

5/1 6
6
3

1
2

Z 49 811

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13. Unlock the slewing rim. To this end:

13.1 Remove the protection cap of the socket “X491” and

insert the plug “Q60” of the mobile control panel (8)
(Z 41 580 and Z 49 829)

RISK OF ACCIDENTS!
The mobile control panel (8) may only be connected to
socket “X491” when the superstructure is safely atta-
ched to the auxiliary crane and the load handling attach-
ments are lightly tensioned.

To lock and unlock the quick release connection, the retaining

brake must be closed.
The required pressure for retracting the locking cylinders is
dependent on the pressure of the outrigger hydraulics.

13.2 Switch selector switch (10, “S560”) on the mobile

control panel (8) to position “1” (Z 41 580).

13.3 With the chassis engine running, press down the

self--return rocker switch (9, “S560B”) on the mobile
control panel (8) and hold until the noise of the
pressure relief valve can be heard (cylinder fully
retracted) -- (Z 41 580) tensioner (5/1) retracts. The
tension ring (3) is pulled inwards and limited by means
of adjustable stops (6) (Z 49 811).

When unlocking the slewing rim make sure that first the
tensioner (5/1) then the positioning cylinder (5/2) is retracted
(see attached plate, Z 49 829).

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10

8 ”X491”

Z 41 580 Z 49 829

3 6
5/2
1
2

2
1
Z 49 830

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 Removing and Fitting the Superstructure 32

13.4 Switch selector switch (10, “S560”) on the mobile

control panel (8) to position “2” (Z 41 580).

13.5 With the chassis engine running, press down

self--return rocker switch (9, “S560B”) on the mobile
control panel (8) and hold until the noise of the
pressure relief valve can be heard (cylinder fully
retracted) -- (Z 41 580). The positioning cylinder (5/2)
is retracted. The tension ring (3) is also pulled inwards
and limited by means of adjustable stops (6)
(Z 49 830).

The upper bearing race (1) and the lower bearing race (2) are
now no longer jammed together, (detail “Y” -- Z 49 830).
The connection between the superstructure and crane chassis
is released.

Observe the sequence on the information sign (Z 49 829) on

the switch panel cover on the outriggers.
This sequence must be followed. Failure to observe this can
cause the locking elements to be damaged. Risk of damage!

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1
8

Z 49 813

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14. Using the auxiliary crane lift the superstructure vertically

from the crane chassis (Z 49 813).

Make sure that the gap between the superstructure and

crane chassis is increased evenly as soon as the
superstructure starts to lift off. If this is not the case, follow
through with the outrigger cylinders of the crane chassis!
Make sure that the superstructure does not swing one--sided
to the centring consoles (7) but is hanging free between the
4 centring consoles. Before raising the superstructure out of
the outer centring, correct using the auxiliary crane as
required (caution, the superstructure may swing out
unexpectedly, RISK OF ACCIDENTS !.)
Also make sure that the spigots (8) on the upper bearing race
(1), and the centring consoles (7) on the crane chassis are
not damaged.

During the lifting procedure make sure that the super-

structure is held in the horizontal position.

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Z 44 011

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 Removing and Fitting the Superstructure 32

15. Set down the superstructure on a suitable low--loader,

support with wooden supports and lash accordingly
(Z 44 011).

RISK OF ACCIDENTS!
When setting down the superstructure, there is a risk of
crushing between the low--loader and superstructure.
Also observe the information on weight and centre of
gravity listed in section 32.1.

16. Release the load handling attachments from the

superstructure.

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Z 41 585 Z 42 744

”X491”

Z 49 831

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 Removing and Fitting the Superstructure 32

17. Release the connection between the control panel (8, Z 41

585) and socket (”X491”, Z 49 831) and set down the control
panel in the housing provided (Z 42 744). Close off the
socket with the protection cap.

Once the superstructure has been removed or fitted the

control panel (8) must be stored in the housing (Z 42 744)
provided on the swinging arm of the crane operator’s cab to
protect it from moisture.

18. Prepare the crane chassis for driving on the road (see: the
operating instructions of the crane chassis, part 2, section 6.,
”Driving without the Superstructure”).

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4
3 2

16 16

14

13

15

2
12 10

Z 52 771

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 Removing and Fitting the Superstructure 32

32.4 Fitting the Superstructure

The superstructure is fitted in the same way in the reverse order.

When the superstructure has been removed the following work

must be carried out before it is fitted again (Z 52 771) :
− Check that the attachment screws (13) on the slew ring are
fitted firmly and tighten as required. The torque equals
4600 Nm.
− Check that the locking screws (14) of the upper bearing race
and locking screws (15) of the lower bearing race are fitted
firmly in place and tighten if required. The torque equals
4600 Nm.
− Check the locking screws (16) on the 6 consoles of the
centring stops to ensure that they are fitted properly and
tighten as required. The torque equals 265 Nm.
− Check the hydraulic system of the slew rim lock for leaks.
− Check that the clamp (4) is pushed in completely. The
marking on the inspection rod (10) must be clearly visible
between the bearing ring (11) and kick rod (12) (protrudes
approx. 5 mm).
− Make sure that the tension ring (3) is pulled completely
inwards. Both locking cylinders (5) must be completely
retracted.

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1
8

Z 49 815

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 Removing and Fitting the Superstructure 32

Fit the superstructure as follows (Z 49 815):

1. Support the crane chassis on outriggers(see the ”operating

instructions for the crane chassis”, part 2, section 12).

2. Using the auxiliary crane slowly lower the superstructure and

place in the approximate fitting position using the 4 centring
consoles (7) welded on the crane chassis. The exact
positioning is made by means of the 2 centring cams (8)
attached to the upper bearing race (1). These cams serve at
the same time as anti--twist catches.

3. Before fitting the superstructure fully, carry out a visual check

to ensure that the gap between the superstructure and crane
chassis is the same all the way round.
If this is not the case, reposition the crane chassis as
required using the outriggers.

4. Set down the superstructure on the crane chassis, relieve

the auxiliary crane of load and check again that the
superstructure is seated level in position.

Risk of crane tipping over!

When setting down the superstructure on the crane
chassis the superstructure must be held by the auxiliary
crane until the quick release connection is closed, the
slewing rim is secured using the clamp and the plug has
been disconnected from the mobile control panel.

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10

8 ”X491”

Z 41 580 Z 49 832

3 5/2
1
2

2
1
Z 49 833

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5. If the superstructure is positioned correctly and evenly, start

the engine of the crane chassis.

To lock and unlock the slewing rim the retaining brake must be
closed.
The required pressure for extending the locking cylinders is
dependent on the pressure of the outrigger hydraulics.

6. Lock the slewing rim. To this end:

6.1 Remove the protection cap of the socket “X491” and

insert the plug “Q60” of the mobile control panel (8)
(Z 41 580 and Z 49 832)

6.2 Switch selector switch (10, “S560”) on the mobile

control panel (8) to position “2” (Z 41 580).

6.3 With the chassis engine running, press the self--return

rocker switch (9, “S560A”) on the mobile control panel
(8) upwards and hold until the noise of the pressure
relief valve can be heard (cylinder fully retracted) --
(Z 41 580). Positioning cylinder (5/2) is extended. The
tension ring (3) is pressed outwards and positioned
(Z 49 833).

When locking the slewing rim, make sure that the

positioning cylinder (5/2) is extended before the tensioner
(5/1) (see attached plate, Z 49 832).

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10

8 ”X491”

Z 41 580 Z 49 832

5/1

3 1
2

Z 49 834

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 Removing and Fitting the Superstructure 32

6.4 Switch selector switch (10, “S560”) on the mobile

control panel (8) to position “1” (Z 41 580).

6.5 With the chassis engine running, press the self--return

rocker switch (9, “S560A”) on the mobile control panel
(8) upwards and hold until the noise of the pressure
relief valve can be heard (cylinder fully retracted) --
(Z 41 580). The tensioner (5/1) is extended and
presses the tension ring (3) apart. The upper and lower
bearing races are clamped together (Z 49 834).

As the upper bearing race (1) and lower bearing race (2) are now
clamped together, (detail “Y”), the connection between the
superstructure and crane chassis has been made (Z 49 834).

Observe the procedure on the information sign,

(Z 49 832) on the switch panel cover of the outriggers.
This sequence must be followed. Failure to observe this can
cause the locking elements to be damaged. Risk of damage!

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Z 41 585 Z 42 744

”X491”

Z 49 831

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7. Disconnect the control panel (8, Z 41 585) and socket

(”X491”, Z 49 831) and place the control panel in the housing
provided (Z 42 744). Close off the socket with the protection
cap.

Once the superstructure has been removed or fitted the

control panel (8) must be stored in the housing provided
(Z 42 744) to protect it against moisture -- the housing is on
the swinging arm of the crane operator’s cab.

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”X” 9

12
10

Z 49 440

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(Z 49 440)
8. The quick release connection must be secured in the locked
position. To this end, feed the clamp (4) into the tension ring
(3).
Turn spindle (9) until the clamp (4) has reached its final
position (change in position from “a” to “b”).
As the inspection rod (10) is screwed into the clamp (4), it is
moved outwards during this procedure (see detail “X”).

9. Check the end position of the clamp (4) on the inspection rod
(10).
In the locked position, the inspection rod (10) must protrude
out of the kick rod (12) (projection approx. 7 mm) so that the
attached marking is clearly visible (see detail “X”).

RISK OF ACCIDENTS!
Only when the marking is visible is the superstructure
correctly connected to the crane chassis and secured.
For this reason, this check must be carried out.

As the slewing rim connection has now been safely made

between the superstructure and crane chassis, the load handling
attachments between the auxiliary crane and superstructure can
now be removed.

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”X”

3 3

”E304”

Z 42 799 Z 44 000

”Q304”

”E304”

”Q305”

”Q306”

Z 48 886

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10. Reconnect the plugs “Q304”, “Q305” and “Q306” on the slew
ring (Z 48 886).

After reconnecting these plugs:

-- the lighting electrics are reconnected between the crane
chassis and superstructure.
-- the outrigger support area monitoring feature is operational
again.
-- the slewing angle sensor in the slip ring “E304” is operational
again.

11. Insert cam (3) on the slip ring “E304” and screw into position
in point “X” on the superstructure frame (Z 44 000).

12. Secure the connected power cable to the slip ring on the cam
(3) and on the superstructure with cable straps (Z 42 799).

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24
25

24

24

Z 44 014

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13. Before fitting the main boom, remove the protective covers
(25) of the main boom foot bolts and retract the pinning
cylinders (24, Z 44 014) fully.

Information on retracting the pinning cylinders can be found in

section 31.2 “Removing the main boom” in these operating
instructions.

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