Equipment 24

24 Equipment

24.1 Main Boom - Lubricating the Slides

- Inner slides

The basic case and the boom sections are fitted

with one lubricating opening on the left and
right-hand side.
(Z 163 322)
In order to lubricate the inner slides, you must
extend the telescopic sections in accordance
with the table below while the main boom is in a
Z 163 322 horizontal position.

Only extend the boom sections for

lubrication in accordance with the table
below.
(Outrigger support area 7.1 m x 4.5 m:
superstructure 0 degrees to the rear or
outrigger support area 7.1 m x 7.0 m:
superstructure 0 degrees to the rear or to
the side)

Type Min.
CWT
on Extension sequence
superstr. for lubricating the

AC100 11.7 t BC: 45% - 0% - 0% - 0%

BS1: 45% - 90% - 0% - 0%
BS2: 0% - 45% - 90% - 0%
BS3: 0% - 0% - 45% - 90%

Then, using a paint brush, coat the top slides

and if necessary the bottom slides with grease.
Date: 50.CW/05

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24

- Outer slides

Extend all boom sections with the main boom

positioned horizontally.

Only extend the boom sections for

lubrication in accordance with the table
below.
(Outrigger support area 7.1 m x 4.5 m:
superstructure 0 degrees to the rear or
outrigger support area 7.1 m x 7.0 m:
superstructure 0 degrees to the rear or to
Z 160 323 the side)

Type Min.
CWT
on Extension sequence
superstr. for lubricating the…

AC100 11.7 t BC: 100% - 0% - 0% - 0%

BS1: 0% - 100% - 0% - 0%
BS2: 0% - 0% - 100% - 0%
BS3: 0% - 0% - 0% - 100%

Then, using a paint brush, coat the bottom and

if necessary the top slides with grease.
(Z 160 323)

Date: 50.CW/05

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 Equipment 24

24.2 Lubricating the Basic Bolts on

the Main Boom

Grease the two lubricating nipples.

(Z 160 327)

Z 160 327

24.3 Ropes

Danger due to protruding rope wires !

When ropes are handled, protruding wires
can cause injury.
Gloves should be worn for protection at all
times !
(Z 30 316)

Risk of snagging!
Z 30 316 When carrying out maintenance,
inspection and assembly tasks, there is a
risk of becoming entangled and dragged in
the following areas:
- between the rope and the rope winches
- between the rope and the sheaves of the
main boom or additional boom components
- between the rope and the sheaves of the
hook block
Proceed with special caution!

Danger due to friction and scraping!

Date: 50.CW/05

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24

24.3.1 General Notes on Handling and

Assembly
24.3.1.1Transport

When working with cables, problems can be

encountered even at the delivery stage: the fork
of the forklift truck moves beneath the reel or
into the rope bundle thereby damaging the
cable surface.

Wherever possible, the cable, which is

delivered in bundles or on reels, should not
come into direct contact with a hook or with the
Z 29 084 forks of a forklift truck. Rather, it should be
raised by means of wide textile lifting slings.
(Z 29 084)

A reel is best raised by means of a rod placed

through its central axis.
(Z 29 085)

24.3.1.2 Storage

Cables should be stored in a cool, clean, dry

and covered environment. The cables should
not be stored directly on the ground but, for
example, on pallets.
If it is not possible to store the cables indoors,
they must at least be covered so that they do
Z 29 085 not become damp.
A plastic film may provide protection against
rain, but will not, however, prevent
condensation from forming beneath it - which in
turn cannot escape and will possibly damage
the cables permanently. In this instance a
solution may, for example, be provided by using
an intermediate layering made out of sack cloth.
When storing a large number of spare parts, the
general rule should be: first in - first out. This
means that the cables should be used in the
same order as they are delivered.
This will then prevent the instance of a cable
first being used after several years in storage.
Date: 50.CW/05

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 Equipment 24

24.3.1.3 Assembly

When cables are assembled, always ensure

that they are wound from the reel or bundle and
onto the system without the cables becoming
twisted or damaged.
Cable which is supplied on a reel is either
unwound by means of a swivel plate or rolled
out on the ground.In the case of the latter, the
ground should be as clean as possible. Sand,
for example, sticks to the lubricant on the cable
and can lead to cable damage if it gets between
the sheave and the cable on the equipment.
Cable which is wound on a reel is also preferably
unwound using a swivel plate or from a trestle.
Rolling the coil out on the ground, something
which is often recommended in related
literature, does not actually work very well in
practice as the reel gives off increasingly less
cable for the same distance rolled, making it
necessary to pull the cable behind you.
The cable must, however, under no
circumstances be pulled sideways from the
bundle or reel, as with this method a torsion is
created in each turn of the rope as it is
unwound.
Every rope torsion alters the length of lay of the
strands and cable and thereby the ratios of the
rope element lengths and ultimately the load
distribution in the cable.

Cable that is pulled sideways from the bundle

or reel resists the torsion which acts on it and
forms loops. When such a cable is placed
under load, the loops are drawn together and
form a kink, an irreparable deformation. Cables
with kinks are no longer safe to be used and
must be replaced.
(Z 29 086)
Date: 50.CW/05

Z 29 086

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24

Assembly procedure

The best way to mount cable differs from

system to system. In every instance, the
method should be chosen which, with a
representative work schedule, is least likely to
cause a rope torsion or damage to the cable
through contact with structural components.

On certain equipment it may be advisable to

remove the old cable first and then to fit the
new cable.
On other equipment, especially larger models,
it is advisable to draw the new cable through
with the old.
A further possibility, especially in the case of
initial reeving, is to use a thinner auxiliary rope
with which the actual cable can be drawn
through.

In every case, it is necessary to consider

whether it would be better to draw the cable
through the whole rope reeving arrangement or
first to reel it onto the rope drum directly from
the bundle or reel and then reeve the cable by
hand or by means of an auxiliary reeving rope.
If a rope end is fitted with a non-detachable
rope end connection, it is only possible to draw
the free end of the rope through the complete
reeving arrangement.

Date: 50.CW/05

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 Equipment 24

Re-reeling

Every cable takes on a certain bending

tendency from the point of manufacture, where
it is drawn from the stranding basket by means
of delivering disks.
It is then supplied to the customer bent in this
direction.
It is then supplied to the customer bent in this
direction.When re-reeling from the reel onto the
rope drum, ensure that the cable is wound in this
direction.
If the rope strand is reeled on beneath the rope
drum, the mounting reel should be set up so that
the rope strand being reeled off also runs off
Z 29 087 beneath the reel and vice versa.
(Z 29 087)

If the cable is re-reeled against the directional

tendency, the cable will either tend to turn
between the reel and the rope drum or will turn
later on when in operation in order to bend to
the preferred direction.
In both instances, structural changes in the
cable will result.
Date: 50.CW/05

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24

Drawing the cable by means of an auxiliary

reeving rope

If the new cable is to be drawn through by cable

which is to be removed or with an auxiliary
reeving rope, it must be ensured that these
ropes are securely fastened.
In addition, it must also be ensured that the
auxiliary rope cannot become twisted.
For example, non-twisting cable types or
triangular strand wire ropes are particularly
suitable for use as auxiliary reeving ropes.
When using conventional cables, they must at
least have the same direction of lay as the
cable which is being drawn.
Whenever a new cable is drawn through using
the old cable, the two cable ends are often
welded end to end.
Such a connection can cause the torsion of the
old cable, built up during operation, to be
transferred to the new rope causing extensive
damage even at the assembly stage.
This procedure is, however, also problematic
for other reasons:
the weld connection does attain satisfactory
values by use of special electrodes in the case
of a tensile test on the straight strand, but due
to the length of the fixed contact area, the cable
can break due to the bending load caused
when passing over the sheaves.
If the ropes are to be connected in this manner,
the cables should be additionally secured using
a rope stocking.
Date: 50.CW/05

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 Equipment 24

A less problematic method of connecting the

cables is by means of two rings or chain links
welded onto the cable ends.
These are then connected by means of strands
or thin ropes.Such a connection possesses a
satisfactory load bearing capacity, can be bent
and prevents the transfer of torsion from the old
rope to the new.
By using two strands, the number of turns in the
strands following assembly will show to what
degree the old cable on the equipment was
twisted.
(Z 29 088)
Z 29 088 Connecting the cables by means of rope
stockings offers a further possibility. Rope
stockings are plaited rope strands which are
pushed over the cable ends and secured with
adhesive tape.
When under load, the rope stockings are drawn
tighter and hold the cable ends by means of
friction.
When an equal-lay rope is to be drawn, it must
be ensured that the rope stockings can turn on
the rope like a nut on a screw, in spite of the
cord tensions.
This can be achieved by first winding strong
adhesive tape round the cable surfaces which
are to be held by the rope stockings.
(Z 29 089)
Z 29 089
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24

Winding on the rope under load

To wind the cable onto the drum smoothly it is

very important in the case of multiple layer
winding, and especially where so-called lebus
winding is used, that the cables are wound onto
the drum under tension.
If the lower layers are too slack, the upper
layers may be pressed in between the lower
strands when the cable is placed under load.
This can lead to extensive damage to the cable.
As the cable which is being reeled off may even
become stuck at this point, the winding direction
of the drum may be reversed suddenly when
Z 29 090 the cable is being unreeled, causing the
downward moving load to be raised jerkily.
The cables should be pretensioned to
approximately 1 to 2 % of their minimal
breaking force.
While, in many cases, it is sufficient to wind on
the cable normally and then to unwind it and
wind it on again with the aid of an external load,
this is not possible in every instance, for
example in the case of a slewing tower crane
which has not yet reached its highest climbing
height.
In these instances the cable must be
pretensioned at the assembly stage.

This can be achieved, for example, by braking

Z 29 091
the reel flange using a board or by means of a
brake disc attached to the reel.
The brake cords (hemp ropes with a steel core)
are supplied by the cable manufacturer.
(Z 29 090, Z 29 091)

It must not be attempted under any

circumstances to pretension the rope by
jamming it, for example, between two wooden
planks.
The rope would be irreparably deformed due to
structural changes.
(Z 29 092)
Date: 50.CW/05

Z 29 092

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 Equipment 24

Running in

Before a cable is placed in operation following

its assembly, a certain number of load cycles
with small partial loads should first be carried
out.
The cable should be „run in“ so that the cable
elements can settle and adapt to their new
environment.
Unfortunately, the opposite normally proves to
be the case in practice: following assembly of
the cable, overload checks are normally carried
out with loads which are above the permissible
load-bearing capacity of the system.

Cutting into sections

Often cables have to be cut into sections or

shortened by the user.
The cables can be cut in various ways.
Up to a diameter of 8mm, cable cutters can be
used;mechanical or hydraulic cutters are also
available for larger diameters.
If, however, a power source is available, it is
recommended that a pneumatic or electric right-
angle grinder be used.
In any case, the cables must be carefully bound
at the point of separation to prevent fraying of
the rope ends or changes in the cable and
strand laying lengths.
This especially applies when sectioning off non-
rotating or non-twisting cables, the strands of
which are often purposefully left unformed by
the cable manufacturer.
The rope ends must be bound using iron wire;
insulating tape cannot prevent structural
changes in the cables occurring.
Date: 50.CW/05

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24

(Z 29 093)

First the separating point is marked using chalk

or insulating tape.
One end of the seizing wire, approx. four times
the cable diameter in length, is then placed
along the length of the cable and then the wire
and the cable are bound together starting at the
separating point (a).
The cable is now bound tightly along a length of
approx. three times the rope diameter (b).
The length of wire which has been bound is
then pulled tight using pincers and is twisted
together with the second wire end (c).

The length of the entwined wire ends is

shortened to approx. the diameter of the rope
using the pincers.
The wire ends are then forced into a valley
between two outer strands of the cable by
banging them lightly, to prevent the risk of an
accident.

Following corresponding preparation of the

other side of the separating point, the cable can
now be cut through (d).

Instead of one long winding, three windings

approximately one cable diameter wide can be
Z 29 093
placed on either side of the cutting point.
Date: 50.CW/05

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 Equipment 24

24.3.2 Lubricating the Ropes

When manufactured, a cable receives intensive

lubrication which provides protection against
corrosion as well as improving the friction
coefficient of the rope elements internally and
between the cable and sheave or cable and
drum.
This initial lubrication lasts only for a limited
period of time and must be supplemented
regularly.
Cables must be relubricated at regular intervals
depending on the operating environment,
especially in the areas where the cable bends.
If the cable cannot be lubricated on operational
grounds, a shorter lifespan is to be expected
x
and the cables must be carefully monitored.
The effects of lubrication and relubrication on
a
the life expectancy of the rope can be seen in
figure (Z 29 094):

b x Number of reversed bending stresses (%)

y Tensile stress (N/mm2)

c
a greased and regreased

b greased
y

Z 29 094 c without grease

To increase their life expectancy and to protect

against rust, the ropes should be liberally
coated with grease.
It is not sufficient to lightly coat the ropes; the
grease must penetrate through.
This measure should be carried out when the
ropes are reeved.
Lubrication is best carried out using non-acidic
grease which has been thinned before use by
heating.
Date: 50.CW/05

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24

The lubricant can be applied using various

methods:
- with a brush or glove
- applying near a sheave
- running the cable through a lubricant bath
- using a pressure collar

It is important that cables are lubricated

regularly from the very start and not only when
the first signs of damage are discovered.

In addition, observe all existing standards (e.g.

DIN 15 020) or national regulations.

24.3.3 Cleaning the Ropes

Cables which are very dirty should be cleaned

externally from time to time.
This applies especially to cables which are
used in a particularly abrasive environment and/
or in the vicinity of chemically active materials.

24.3.4 Checking the Cables and

Replacing as Necessary

When fitting a new hoist rope, which has

never been placed under load, twisting
problems can occur.
For this reason, we recommend that a spin
stabilizer be used
(example: See Z 075 361).
Date: 50.CW/05

Z 075 361

14/29 e100-3240_b

General
A cable is a commodity with a limited life
expectancy.
Many characteristics of a cable are altered
during its operational period.
For example, its breaking force initially increases
slightly with accrued operating time before falling
rapidly once a maximum value has been reached.
This fall in breaking force is explained by the
increasing loss in the metal cross-section due to
abrasion and corrosion, wire breakage and
structural changes in the cable.
In the cable, the load bearing elements are
connected in parallel.
A cable can therefore remain operationally safe
even after the breakage of a large number of
strands.
One of the purposes of a cable inspection is to
monitor the continuous increase in the number of wire
breakage, so that the cable can be removed before a
state is reached where operational safety is impaired.
A further purpose of the rope inspection is to
spot abnormal cable damage, which as a rule is
normally caused by external influences.
This facilitates, on the one hand, replacement
of the cable in good time and, on the other
hand, helps to spot weak points in the operation
of the rope, enabling measures to be taken
which will prevent similar damage recurring.
Date: 50.CW/05
e100-3240_b
Equipment 24
If it has become apparent during the ropes
inspection that a rope needs changing, you
must use an original rope from the crane
manufacturer.
The type of rope that is fitted depends among
other things on the inspection certificate which
is attached to the crane passport / crane
inspection book.
If it is not clear which type of rope should be
used, you must consult the crane manufacturer
before ordering a new one.
Intervals
DIN 15 020 recommends daily inspection of the
cables and end connections for any signs of
damage.
Furthermore, the cables should be inspected at
regular intervals by specialist personnel to
ensure that they are in safe operating condition.
The length of the intervals is to be determined
in accordance with DIN “in such a way that
damage is ascertainable in advance in good
time.
For this reason the time intervals during the first
few weeks after the laying of a new wire rope,
and after the occurrence of the first wire breaks,
must be selected shorter than the intervals
during the remaining service life of the wire rope.
After the occurrence of unusually high loads or
of suspected but not visible damage, the time
interval must be shortened accordingly (if
necessary to hours).
In addition, such an inspection must take place
when the rope drive is recommissioned after a
prolonged shutdown, or when the lifting
appliances have been dismantled and re-
assembled at a new location, before
recommissioning, or after an accident or
damage which has involved the rope drive”.
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24
Criteria for replacing ropes
A rope should be removed if one or more of the
following conditions are fulfilled. See also the
relevant DIN standards.
a) Wire breakage
A cable must be removed when the permissible
number of wire breakage according to
DIN 15 020 is reached or exceeded.
The cable must be removed if wire breakage
are clustered or if a cord breaks.
b) Rope wear
The cable must be removed if, due to structural
changes, the diameter of a longer section of the
rope has decreased by more than 15% of the
specified size.
c) Corrosion
Corrosion of the outer rope wires can be
determined by visual inspection. Corrosion on
the wires not visible from the outside can,
however, be difficult to determine.
Corrosion can lead to a reduction of the static
breaking strength of the cable, as the metal
rope cross-section is reduced, and can lead to
a reduction in operational stability due to
corrosion pits.
16/29
d) Abrasion
Abrasion of the rope wires occurs as “internal
abrasion” by the cords and wires moving
against each other when the cable is bent.
Abrasion occurs as “external abrasion” by the
cable and sheave moving against each other,
or by the cable slipping on the ground or on the
material to be conveyed.
Abrasion is aided by the lack of, or unsatisfactory,
lubrication and by the effects of dust.
If the rope diameter is reduced by 10 % of the
specified size or more, the cable must be
removed even if no wire breakage are
determined.
e) Rope deformation
Cable deformations are visible in the rope
structure.
Deformation also generally implies that the rope
structure has been loosened, particularly in the
region near the deformation.
By examining the ropes, the most important
deformations can be determined as follows:
- corkscrew type deformation
- “basketwork” formation
- loop formation of wires
- slackening of individual wires or cords
- knots
- constrictions
- flattened areas
- curled type deformation
- kinks and buckles
Date: 50.CW/05
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 Equipment 24

Corkscrew type deformation (Z 1367)

Corkscrew type deformation occurs when the

axis of the unloaded cable becomes a helical
line.

X
The cable must be removed if deformation X
is 1/3 d or greater (d = nominal diameter of
rope)where the deformation is at its worst.

“Basketwork” formation (Z 1368)

Z 1367 “Basketwork” formation (deformation) can occur

in cables with steel inlays if the outer layer of
the wires is loose or if the outer cords are
longer than the inner cords.
The excess length is moved into one place by
movement of the outer wire sections or cord
sections towards the inner ones.

The cable must be removed if

„basketwork“ formation occurs.

Loop formation of wires (Z 1369)

Loop formation of wires occurs when single

Z 1368 wires or wire groups protrude on the side of the
rope which is turned towards the groove of the
sheave in the shape of hair pins.

The cable must be removed if the rope

structure has been changed considerably
by loop formation.
Date: 50.CW/05

Z 1369

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24

Slackening of individual wires or cords

(Z 1370)

Slackening of individual wires or cords occurs

when the outer wires of the loaded cable or of
individual cords can be moved.

They do not then take on the load as intended

and the remaining wires or cords are
overstrained.

When running the ropes over the sheaves,

increased bending stresses can occur which
lead to premature wire breakage.
Z 1370

The cable must be removed if cable

slackening, caused by rust and abrasion,
occurs.
The removal schedule for the ropes is
determined by wire breakage if the cause
of rope slackening is different from that
given above.

Knots (Z 1371)

Knots are recurring points over long sections of

rope which become thicker. The inlay often
protrudes from the cable in the areas where the
Z 1371 rope is thickened.
At the thinner sections of the rope, the cords
support each other in arch-like formations and
wires may therefore break.

Cables displaying considerable knot

deformation must be removed.
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 Equipment 24

Constrictions (Z 1372)

Constrictions are reductions in the diameter of

the cable over short stretches of rope.
The rope sections immediately before the end
fastenings should be checked with extreme
care, as constrictions here are often difficult to
recognise.

Cables which are greatly constricted must

be removed.

Z 1372 Flattened areas (Z 1373)

Flattened areas are permanent deformations of

the cable which are caused by crushing.

Flattened areas in a rope will lead to an

increased occurrence of wire breakage.

Curled type deformation

Curled type deformation occurs if a loaded cable is

drawn over an edge.

Z 1373 Cables displaying curled type deformation

must be removed.

Kinks (Z 1374)

Kinks occur when an eye-shaped rope loop is

pulled straight in such a way that the cable
cannot compensate the deformation by turning
on its axis.

Cables with one or more kinks must be

removed.
Date: 50.CW/05

Z 1374

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24

Buckles (Z 1375)

Buckles are deformations which occur when the

cable is under violent external influences.

Cables with buckles must be removed.

Effects of heat

Cables which have been subject to

Z 1375 abnormal heat must be removed (this can
be recognised on the exterior of the cable
from the colour).

Service life

The correct time for replacing the cables can be

estimated in advance when carrying out the
precautionary maintenance work if enough
information regarding the previous use of the
rope is known and if the same operating
conditions apply and the same cable is being
used.

The criteria stated previously do, however,

determine the replacement schedule.
In borderline cases, or if in doubt, always
replace the ropes.

The criteria for replacing the ropes which

have been listed are meant to act merely as a
reference point for the daily visual inspection.
The description of the regular inspections goes
beyond the bounds of the lubrication and
maintenance instructions.
It is contained in corresponding national
regulations.
Date: 50.CW/05

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 Equipment 24

24.4 Checking the Main Boom for

Weld Cracks

In order to prevent breakage, the weld

joints on the main boom are to be inspected for
cracks once a year.
(Z 160 331)

Z 160 331

If any crack formations are detected, the

necessary repair instructions should be
requested from the Engineering Customer
Service Department.
An exact description of the course of the crack
should be given (relevant page from the spares
catalogue, photos, sketches , etc.).
(Z 160 332)

Z 160 332

Weld repairs may only be carried out by a

qualified welder.

(Z 160 333)
Date: 50.CW/05

Z 160 333

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24

24.5 Inspect Rope Track Rollers

Check all main boom and main boom extension

rope track rollers regularly for wear and ease of
motility in turning.
If clear wear tracks are visible on the track
rollers, they must be replaced.

Rope track rollers which are split by hoist

ropes pose the danger of crane parts
falling from a great height.
(Z 160 500)
Z 160 500

24.6 Checking the Sheaves

y y
Regularly check all sheaves for any sign of
damage, for example cracks, scoring or similar
d damage.
x

Sheaves with this type of damage must be

replaced immediately.

Also check all sheaves regularly for wear.

If the rope groove has worn in more than 3 mm
compared with a new sheave (x)
Z 160 543
or
the lateral surface (y) up to the rope (d) has
worn in more than 5 mm, the sheave must be
replaced.
(Z 160 543)
Date: 50.CW/05

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 Equipment 24

24.7 Sheaves - Checking the Roller

Bearing

Inspect all sheaves on the main boom head and

on all additional equipment once a year for the
following:

- Discharge of grease
- All bearing seals are fitted correctly
- All circlips are fitted correctly
- Running noises, rolling resistance
- Bearing play

Z 160 343 (Z 160 343)

If any faults are discovered on the roller

bearings, the sheave must be replaced.
(Z 160 344)

In this instance, please inform the

Customer Service Department.

Z 160 344

If inspection reveals a damaged circlip, the

circlip must be replaced.
(Z 160 345)

Original Demag circlips with chamfered

edges must be used.
Date: 50.CW/05

Z 160 345

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24

24.8 Sheaves - Lubricating the Roller

Bearings

Lubricate the roller bearings via the lubricating

nipples (x 4).
(Z 160 342)

Z 160 342

24.9 Checking the Pins for Cracks

Check all pins for cracks regularly, e.g. during

assembly and dismantling.

(Z 160 353)

Z 160 353
Date: 50.CW/05

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 Equipment 24

24.10 Checking the Draw Bars

(Shackle on the Main Boom Extension)

The draw bars must be inspected by an

expert at least once a year (in accordance
with accident prevention regulations for
the operation of load lifting equipment /
VBG 9).
The bars should also be inspected by an
expert between these intervals if
necessitated by the operating conditions.
As the inspection intervals are generally
related to operating conditions, if the
crane is in operation for longer periods of
time the intervals should be reduced
accordingly.
Records should be kept of the inspections
(e.g. in the crane log book).

It may be necessary to dismantle the draw

bars to be able to inspect them correctly.

The draw bars must be inspected in their

entirety, i.e. all hidden surfaces and bores
must also be inspected.
Date: 50.CW/05

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The following inspections should be carried

out:

- Checking for cracks:

The draw bars should be checked regularly for

cracks.
A surface crack test (e.g. magnaflux test) must
be carried out at least once every year.
Should cracks be found during the inspection of
a draw bar, the draw bar must be replaced.

Repairs are prohibited.

- Checking the length:

The draw bars are designed so that no

permanent elongation occurs, even under test
load.
No measurable change in length is permitted as
this would impair the function of the bars.
The length of the bars must be measured to
ensure that they have not become overloaded
or damaged.
The upper limit for performance capability (as
for “Condition of ropes for replacement”)is a
change in length of 0.05 %.

If a change in length of >0.05 % is

measured, the tension bracket must be
replaced.
L
Bugles on the main boom extension

The original length of the bugles on the main

boom extension is L = 1039 mm.
(Z 163 819)
Date: 50.CW/05

Z 163 819

26/29 e100-3240_b
 Equipment 24

- Checking for wear:

Check the pin locks, pins and bores for signs of

wear.
It must be ensured that the pin locking
mechanism is functioning correctly.

- Checking for plastic deformation:

If plastic deformation occurs (e.g. bending), the

draw bars may no longer be used.

- Checking the paintwork:

The paintwork must be checked regularly for

signs of corrosion.
Damaged areas should be restored.
The draw bar bearing must not come into
contact with aggressive agents (e.g. sea water).

24.11 Lubricate Main Boom Extension

Bolts

Check all bolts e.g. retaining bolts and bell

cranks on the main boom extension for ease of
operation and lubricate if necessary.
(Z 163 823)
Date: 50.CW/05

Z 163 823

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24.12 Telescopic Main Boom Extension

(Optional) - Lubricate Sliding
Surfaces

Extend the main boom extension while the main

boom is lying horizontally.
Then grease the extended cylinder barrel using
a brush.

(Z 160 370)

Z 160 370

24.13 Telescopic Main Boom Extension

(Optional) - Lubricate the Foot
Bearing

Grease both lubricating nipples on the pins of

the main boom extensions foot bearing.

(Z 160 371)

Z 160 371

24.14 Telescopic Main Boom Extension

(Optional) - Lubricate the Luffing
Cylinder

1- Grease the lubricating nipple on the foot

bearing of the luffing cylinder (x 2).

(Z 160 372)
Date: 50.CW/05

Z 160 372

28/29 e100-3240_b
 Equipment 24

2- Grease the lubricating nipple on the

piston rod bearing of the luffing cylinder.
(Z 160 373)

Z 160 373

24.15 Checking the Welding on the

Telescopic Main Boom Extension
for Cracks (Optional)

Follow the same principle as described in the

Lubrication and Maintenance Manual, Sect.
24.4, “Checking the Main Boom for Weld
Cracks”.
Date: 50.CW/05

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