Description of maintenance work on thesuperstructure 8.4 Superstructure hydraulic system

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8.5 Main boom

8.5.1 Lubricating the locking pins

To lubricate the locking pins, the main boom must be lowered to the horizontal position and the telescopic sections must be successively extended to allow access to the locking bolts.

The locking pins between the telescopic sections of the main boom need to be sprayed with a spray oil containing molybdenum disulphide (MoS2).

Position of the locking pins

The locking pins are on both sides of the telescopic sections. To lubricate, extend the telescopic sections until the locking pins (1) are accessible. The illustration shows the degree of telescoping required to lubricate the locking pins on telescopic section IV .

Prerequisites To lubricate the locking pins on the main boom, it must be partly extended in horizontal position.

GRisk of overturning when extending in horizontal position!

In the horizontal position the SLI blocks telescoping when there is an attempt to extend a second telescopic section. Override the SLI only when you are prompted to do so in the following section and do not extend the main boom more than indicated. Even with 16.1t of rigged counterweight and the superstructure slewed to the rear you cannot extend all telescope sections. The truck crane would first overturn.

Before lowering or extending the boom, the following conditions must be met:

• Park the truck crane on a flat, even surface.

• Create one of the two following rigging states:

– The truck crane is supported with the outrigger span 8.10 m x 6.00 m (26.6ftx19.7ft) and there is at least 6.8t of counterweight or

– The truck crane is supported with the outrigger span 8.10 m x 7.00 m (26.6ftx23.0ft) and there is at least 3.8t of counterweight.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Fully retract all telescope sections.

• Unreeve the hook block.

• Lower the main boom into a horizontal position.

Lubricating the locking pins

Keep a spray oil containing molydenum disulphide (MoS2) ready for lubricating the locking pins. The following section describes the lubricating procedure for telescopic section IV

GRisk of accidents from slipping off!

There is grease residue on the telescope sections. For this reason, you must not walk on the main boom.

Use the extendable ladders provided with your crane!

Lubricating telescopic section IIIV

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• To lubricate the locking pins, extend telescopic section IV to the fixed length of 100% and lock it.

• Lock the telescoping cylinder in the telescopic section III

• Override the SLI by turning the override key-operated switch to the right.

• Extend telescopic section III about 1.50m (5ft) until the bores of the locking pins for the telescopic section IV are accessible.

• Spray the spray oil into the gap between locking pin and guide bushing on both sides of the telescopic section IV.

• Fully retract telescopic section III and lock it.

• Do not override the SLI anymore.

• Lock the telescoping cylinder in telescopic section IV

• Unlock and lock telescopic section IV several times, so that the oil gets distributed over the locking pin.

• Retract telescope section IV completely.

• Proceed in the same way for telescopic sections III and II

Lubricating telescopic section I

Telescopic section I does not need to be extended for lubricating the locking pins, because the locking points with the main boom basic section are always accessible from the outside.

• Spray the spray oil into the gap between locking pin and guide bushing on both sides of the main boom.

• Unlock and lock telescopic section I several times, so that the oil gets distributed over the locking pin.

8.5.2 Lubricating the telescope slide faces

For lubricating the telescopic slide faces the main boom must be lowered into horizontal position and the telescope sections must be telescoped one after the other in a certain order so that the lubricating points are reached.

GDanger of overturning!

Before the main boom is lowered or extended, observe the requirements explained in this section, p.8-30.

At the corners of telescope sections I to IV there are four slide faces. The two lower slide faces(2) and(3) are lubricated from the outside in fully extended state.

The two upper slide faces(1) and(4) are lubricated by one lubricating nipple each.

The following section shows the position of the lubricating nipples.

Position of lubricating nipples

GRetracting boom poses risk of crushing!

Do not reach into the manhole until the boom has been secured so that it can not retract inadvertently. If you are carrying out this operation with the help of someone else, communicate with the person in the crane cab by means of clear hand signals.

The lubricating nipples(1) are located on the upper booms of the telescope sections and are reached via corresponding lubrication holes(2) in the telescope sections above. The diagram shows the telescope status for the lubrication of telescope section IV

Lubricating nipple forQuantityCan be reached via the lubrication hole in

GDanger of accidents!

Danger of slipping due to grease residue. Do not climb onto the boom. Use the extendable ladder provided with your crane!

Prerequisites The main boom must be partly extended in the horizontal position when carrying out maintenance.

GRisk of overturning when extending in horizontal position!

In the horizontal position the SLI blocks telescoping when there is an attempt to extend a second telescope section. Override the SLI only when you are prompted to do so in the following section and do not extend the main boom more than indicated. Even with 16,1t of rigged counterweight and the superstructure slewed to the rear you cannot extend all telescope sections. The truck crane would first overturn.

Before lowering or extending the boom, the following conditions must be met:

• Park the truck crane on a flat, even surface.

• Create one of the two following rigging states:

–The truck crane is supported by an outrigger span of 8.10 m x 6.00 m and there is at least 3.8t of counterweight or

–The truck crane is supported by an outrigger span of 8.10 m x 7.00 m and there is at least 1.8t of counterweight.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Fully retract all telescope sections.

• Unreeve the hook block.

• Lower the main boom into a horizontal position.

HTo lubricate you must also telescope to intermediate lengths. Therefore telescope the main boom with semi-automatic (Operating manual, chapter on Crane operation; à section on Crane operation with main boom).

Lubricating slide faces of telescope sections

• To lubricate, use only special grease as specified in the Maintenance plan, p.5-13.

• Lower the retracted main boom to the lowest position.

• Start with telescope setion IV

Lubricate telescopic section IV

GRisk of accidents from slipping off!

There is grease residue on the telescope sections. For this reason, you must not walk on the boom.

Use the extendable ladder provided with your crane!

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Telescope telescopic section IV to the middle locking position and lock it.

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section III to approx.58% until the lubricating hole for telescopic section IV can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section III.

• Do not override the SLI anymore.

• Fully extend telescopic section IV.

• Use a spatula to apply a thin layer of grease to the two lower slide faces of telescopic section IV

• Extend and retract telescopic section IV again so that the grease is distributed uniformly on the telescope slide faces.

• Retract telescopic section IV.

Lubricate telescopic section III

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Telescope telescopic section III to the middle locking position and lock it.

Lubricate telescopic section II

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section II to approx. 58% until the lubricating hole for telescopic section III can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section II

• Do not override the SLI anymore.

• Fully extend telescopic section III

• Apply a thin layer of grease to the bottom two slide faces of telescopic section III with a spatula.

• Extend and retract telescopic section III again so that the grease is distributed uniformly on the telescope slide faces.

• Fully retract telescopic section III .

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Telescope telescopic section II to the middle locking position and lock it.

• Override the SLI by turning the Override key switch to the right.

• Extend telescopic section I to approx. 58% until the lubricating hole for telescopic section II can be reached in the top chord.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Fully retract telescopic section I.

• Do not override the SLI anymore.

• Fully extend telescopic section II.

• Use a spatula to apply a thin layer of grease to the bottom two slide faces of telescopic section II

• Extend and retract telescopic section II again so that the grease is distributed uniformly on the telescope slide faces.

• Retract telescopic section II

Lubricating telescopic section I

• Retract all telescopic sections.

• Enter the SLI rigging code for the current rigging mode of the truck crane.

• Extend telescopic section I to 100 %.

You can now reach the lubricating nipples via the front lubricating holes in the top chord of the basic section.

• Inject approx. 100 ml of grease into each lubricating nipple (position 1).

• Use a spatula to apply a thin layer of grease to the bottom two slide faces of telescopic section I

• Extend and retract telescopic section I twice so that the grease is evenly spread on the telescope slide faces.

• Retract telescopic section I.