Transmission 6
6 Transmission
To make the oil checks easier, the
transmissions must be kept clean.
Regularly check the screw and oil lines.
1 - Drive Gear
2 - Retarder
3 - Distributor Gear
(Z 060 505)
Z 060 505
Ensure that the vehicle is in the horizontal
position and apply the parking brake.
(Z 160 077)
Maintenance work
For every oil change (transmission and
retarder) the following maintenance work must
be carried out:
- Clean the oil sieve (transmission)
- Clean the sieve for the pressure control
Z 160 077 valve (retarder)
- Check the fixing screws on the retarder heat
exchanger
- Check all sealing screws to make sure that
they are leak-proof and are fitted correctly
- Carry out a visual check for possible
damage and leaks
Date: 42nd CW/03
e060-2060_b 1/11
6
6.1 Transmission – Checking the Oil
Level
To ensure that the transmission functions
properly, make sure that you observe the
prescribed oil quantity and only use oils which
are contained in the operating fluid tables.
Before checking the oil level, the vehicle
must be secured with chocks or on the
outriggers to prevent it from rolling.
Z 160 077 (Z 160 077)
- Switch off the engine
The gear oil must be at operating
temperature when the level is checked.
RISK OF INJURY!
The oil fill plug is hot (oil temperature)!
Proceed as follows when checking the oil level:
- Unscrew the oil fill plug.
Z 163 833
- The oil level is correct when the oil level is
up to the bottom edge of the threaded hole.
(Z 163 833)
- Slowly top up any oil that is missing via the
hole of the oil fill plug (1) in accordance with
the operating fluid regulations.
If you find that the oil level is low you
should check the transmission gearbox for any
signs of leaks.
Date: 42nd CW/03
- Screw the oil fill plug back in with a new
sealing ring and tighten it.
(tightening torque = 47 Nm).
2/11 e060-2060_b
Transmission 6
6.2 Changing the Drive Gearbox Oil
For replacement intervals see section 4
“Lubrication and Maintenance schedule”
Depending on operating conditions, it may
be necessary to change the oil sooner.
The oil must be changed if there are any signs
of contamination, discolouring, strong smells
or if oil inspections indicate the necessity.
(Z 060 506)
Z 060 506
The oil should be drained when the drive
gear is at operating temperature; therefore the
oil is best drained immediately following road
travel.
Oils that are drained off must be stored in
suitable containers and disposed of
correctly.
Z 160 077
Before the oil check is carried out, the
crane should be secured with blocks to
prevent any rolling movement.
(Z 160 077)
Clean the area around the oil fill plug (1)
and oil drain plug (2) before changing the oil.
(Z 163 832)
Date: 42nd CW/03
Z 163 832
e060-2060_b 3/11
6
Proceed as follows when changing the oil:
- Unscrew oil fill plug (1) and oil drain plug (2).
- Drain off oil and dispose of properly.
- After this screw in the oil drain plug (2) with a
new sealing ring.
(Z 163 832)
- Unscrew the sealing plug (3).
- Clean the oil sieve (4) with suitable cleaning
fluid and blow out with compressed air.
Z 163 832
Check the cleaned oil sieve for any signs of
damage and replace if necessary.
- Insert the springs (5) with oil sieve (4) in the
hole of the sealing plug.
- Screw in the sealing plug (3) with the new
sealing ring and tighten securely.
- Add oil slowly up to the bottom edge of the
oil fill opening.
- Screw in the oil fill plug (1) with a new seal.
(Z 163 833)
Z 163 833
Date: 42nd CW/03
4/11 e060-2060_b
Transmission 6
6.3 Checking the Oil Level on the
Retarder
To ensure that the transmission functions
properly, make sure that you observe the
prescribed contained in the operating fluid tables.
Before checking the oil level, the vehicle
must be secured with chocks or on the
outriggers to prevent it from rolling.
(Z 160 077)
Z 160 077
The gear oil must be at operating
temperature when the level is checked.
- Switch the vehicle ignition ”OFF” and then
”ON” again (reset).
- Activate the retarder on level 3 when the
crane is at a standstill (equals brake level 1)
and switch it off after approx. 5 seconds.
Repeat this procedure two times.
- Switch the retarder off and wait for 5 minutes.
RISK OF INJURY!
The oil fill plug (8) and oil inspection or oil
fill plug (10) are hot (oil temperature)!
When checking the oil level the retarder
must be switched off.
Increased risk of injury as a result of hot oil
being emitted (increased pressure).
(Z 163 835)
Date: 42nd CW/03
Z 163 835
e060-2060_b 5/11
6
- Unscrew the oil inspection
plug (10).
- The oil level is correct when the oil level is
up to the bottom edge of the threaded hole.
If you find that the oil level is low you
should check the retarder for any signs of leaks.
- Check the sealing ring for damage and
replace the sealing ring and/or oil inspection
plug with integrated sealing ring as required.
Z 163 835 - Screw in the oil inspection or filler plug again
(10) and tighten it.
(Tightening torque = 150 Nm)
(Z 163 835)
Date: 42nd CW/03
6/11 e060-2060_b
Transmission 6
6.4 Retarder – Oil Change
To drain off the oil the retarder must be at
operating temperature
(warmer than 60 degrees C), therefore the oil
should be drained off as soon after driving as
possible.
RISK OF INJURY!
When working on the hot retarder, for
example changing the oil or checking the oil
level, there is a risk of serious burns when
touching the hot retarder and heavy scalding
when handling the hot retarder oil.
- The retarder must be switched off
during work.
- Suitable protective clothing must be
worn when working on the hot retarder.
- The switch for the retarder must be
safeguarded to prevent unauthorised
access.
Depending on accessibility the oil can be
added via the hole of oil fill plug 8 or 10.
Z 163 834 Clean the area around the central oil drain
plug (2), the sealing plug (6) and the oil fill plug
(8 or 10) before changing the oil to prevent dirt
etc. entering the oil system.
(Z 163 834, Z 163 835)
Date: 42nd CW/03
Z 163 835
e060-2060_b 7/11
6
Proceed as follows when changing the oil:
- Unscrew the central oil drain plug (2) and
drain off the oil.
Oils that are drained off must be stored in
suitable containers and disposed of
correctly.
- Brush the new O-rings (3 and 4) with
lubricant and pull on to the central drain plug (2).
Z 163 834
- Screw in the central oil drain plug (2) with a
new sealing ring (5).
(Tightening torque = 55 Nm)
- Unscrew the sealing plug (6) from the
retarder housing and clean the sieve in the
sealing plug with cleaning fluid and blow out
with compressed air
(Z 163 834).
- Screw the sealing plug (6) back in
(Tightening torque = 150 Nm)
- Unscrew the oil fill plug (8 or 10).
(Z 163 835)
Z 163 835
- Slowly add the prescribed amount of oil. Date: 42nd CW/03
8/11 e060-2060_b
Transmission 6
For problem-free retarder operation it is
important that the prescribed oil levels are
observed.
- Screw the oil filler plug (8 or 10) back in
(tightening torque = 150 Nm)
(Z 163 835)
Following an oil change, wait to activate
the retarder until you are driving at a speed
Z 163 835 of at least 50 km/h. Activate it five times for
5 seconds each time in position 3 on the
retarder level switch (equals brake level 1).
Date: 42nd CW/03
e060-2060_b 9/11
6
6.5 Distributor Gear - Checking and
Topping Up the Oil Level
Ensure that the vehicle is in the horizontal
position and apply the parking brake.
- Unscrew screw from inspection and filler
opening (3).
(Z 163 838)
The distributor gear is filled correctly when
the oil level reaches up to the lower edge of the
inspection opening or the filler neck.
Z 163 838
- If the oil level is too low, unscrew the filler
plug and fill in oil.
If the oil check is carried out when the gear
is warm, ensure that oil does not spill over
when the inspection plug is opened.
- Then clean screw (3) and screw into place
again with a new seal if necessary.
(Z 160 007)
Z 160 007
Date: 42nd CW/03
10/11 e060-2060_b
Transmission 6
6.6 Distributor Gear - Changing the oil
To drain off the oil the transmission must
be at operating temperature; therefore the oil
should be drained off as soon after driving as
possible.
Proceed as follows when changing the oil:
- Unscrew screw (3) and oil drain plug (2).
(Z 163 838)
- Drain off old oil.
Z 163 838
Oils that are drained off must be stored in
suitable containers and disposed of
correctly.
- Fill the distributor gear with new oil through
the filler hole (3) until the oil runs over from
the opening (3).
- Then clean screw (3) and screw into place
again with a new seal if necessary.
(Z 163 838, Z 060 616)
If during maintenance the serpentine pipe
on the on the right-hand side of the chassis
is opened and the oil it contained runs out
(approx. 1.1 l) , an additional 1.1 l oil must
be filled up again via opening (1) .
Afterwards, clean the screw (1) and screw
into the opening (1) again with a new seal if
necessary.
- After the next journey: check oil level at
the filler neck (3, Z 163 838) and if
necessary, top up oil at the filler neck (3,
Z 163 838) until it runs out of this
Date: 42nd CW/03
opening (3).
Z 060 616
e060-2060_b 11/11
