140−0000a 1/1

Inhaltsverzeichnis

Manufacturer’s Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Operating Conditions and Computed Design of the Crane . . . . . . 9
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.2 Classification of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.3 Classification of the Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.6 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.7 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.8 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 21
1.3.9 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.2 Personnel selection and qualifications . . . . . . . . . . . . . . . . . . . . . . . 29
1.4.3 Particular types of hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.4 Combination of Hazards with Combined Operation
of Two or More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4.5 Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4.6 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4.7 Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4.8 When Assembling and Dismantling Crane Components . . . . . . . . 69
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 79
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 81

2 Structure of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Safety−Relevant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.1 Ladders and safety harnesses/guards . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.2 Spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.3 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.1 Signs in the Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.2 Signs and Symbols on the Superstructure . . . . . . . . . . . . . . . . . . . . 17
2.5.3 Signs on the Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.4 Signs (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.5 Safety Signs (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5.6 Safety Signs (only USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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4 Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Entering / Exiting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.1 Adjusting the Crane Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.2 Sun Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.3 Lighting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.4 Open / close window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 Engine control/monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.2 Starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.3 To be observed after starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.4 Warming up the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.4.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.4.2 Warming up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.5 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.5.1 Motor Quick Stop (Emergency stop) . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.5.1.1 Motor Quick Stop (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 Operating hour display (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Automatic driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Coolant preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7 Supporting the Crane on Outriggers from the Superstructure

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.2 Initiating a Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Braking the Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.4 Regulating the Slewing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5 Preparation for Dolly (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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9 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 Important Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.3 Load Capacity Tables for Fitting and Removing the
Counterweight Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.4 Counterweight Combination 0 t / 0 lbs . . . . . . . . . . . . . . . . . . . . . . . 7
9.5 Counterweight Combination 6.3 t (13 900 lbs) . . . . . . . . . . . . . . . . . 7
9.5.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.5.2 Fitting the Counterweight Combination 6.3 t (13 900 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.6 Counterweight Combination 8.3 t (18 300 lbs) . . . . . . . . . . . . . . . . . 11
9.6.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.6.2 Fitting the Counterweight Combination 8.3 t (18 300 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.7 Counterweight Combination 10.8 t (23 800 lbs) . . . . . . . . . . . . . . . 15
9.7.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.7.2 Fitting the Counterweight Combination 10.8 t (23 800 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.8 Counterweight Combination 13.5 t (29 800 lbs)
“US−Variant / 1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.8.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.8.2 Fitting the Counterweight Combination 13.5 t (29 800 lbs)
to the Superstructure, ”US−Variant / 1” . . . . . . . . . . . . . . . . . . . . . . . 21
9.9 Counterweight Combination 13.5 t (29 800 lbs)
“US−Variant / 2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.9.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.9.2 Fitting the Counterweight Combination 13.5 t (29 800 lbs)
to the Superstructure, ”US−Variant / 2” . . . . . . . . . . . . . . . . . . . . . . . 25
9.10 Counterweight Combination 18.8 t (41 400 lbs) . . . . . . . . . . . . . . . 27
9.10.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.10.2 Fitting the Counterweight Combination 18.8 t (41 400 lbs)
to the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.11 Counterweight Combination 21.4 t (47 200 lbs) . . . . . . . . . . . . . . . 31
9.11.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.11.2 Fitting the Counterweight Combination 21.4 t (47 200 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.12 Counterweight Combination 23.2 t (51 200 lbs)
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12.2 Fitting the Counterweight Combination 23.2 t (51 200 lbs)
to the Superstructure, ”US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.13 Counterweight Combination 25.8 t (56 900 lbs)
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.13.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.13.2 Fitting the Counterweight Combination 25.8 t (56 900 lbs)
to the Superstructure, ”US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . 41

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9.14 Counterweight Combination 28.4 t (62 600 lbs)

“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.14.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.14.2 Fitting the Counterweight Combination 28.4 t (62 600 lbs)
to the Superstructure, ”US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.15 Counterweight Combination 31.0 t (68 300 lbs) . . . . . . . . . . . . . . . 47
9.15.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.15.2 Fitting the Counterweight Combination 31.0 t (68 300 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.16 Counterweight Combination 31.0 t (68 300 lbs)
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.16.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.16.2 Fitting the Counterweight Combination 31.0 t (68 300 lbs)
to the Superstructure, ”US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.17 Counterweight Combination 39.0 t (86 000 lbs) . . . . . . . . . . . . . . . 55
9.17.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.17.2 Fitting the Counterweight Combination 39.0 t (86 000 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.17.3 Fitting and Removal of the Counterweight Combination
39.0 t (86 000 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.17.3.1 Setting Down the Counterweight Combination on the Crane
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.17.3.2 Fitting and Removing the Counterweight Combination on the
Superstructure Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.17.3.2.1 Manual Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.17.3.2.2 Manual removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.17.3.2.3 Automatic fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.17.3.2.4 Automatic removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.17.3.3 Removing the Counterweight Combination from the Crane
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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10 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 IC−1 crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1.1 Load limit device (LLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.1.2 Control and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.1.3 Operating the IC−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.1.4 System start/Switching the system off . . . . . . . . . . . . . . . . . . . . . . . 21
10.1.5 ”Crane operation” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1.6 ”Main menu” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1.7 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1.7.1 ”System”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1.7.2 Background illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.7.3 ”Crane operation” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.7.4 ”TableViewer”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.7.5 ”Error messages” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1.7.6 ”Control lever configuration” screen . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.1.7.7 ”Hour meter” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.1.7.8 ”Parameter” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.1.7.9 ”Info” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.7.10 ”Emergency operation” screen (optional) . . . . . . . . . . . . . . . . . . . . . 89
10.1.7.11 ”Operating area limit” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.7.12 ”Joystick”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1.7.13 ”I/O”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1.7.14 ”CAN”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1.7.14.1 CAN Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1.7.15 ”LS” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.1.7.16 ”Datalogger” screen (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.1.7.17 ”Function diagnosis” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.1.7.18 ”Main menu” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.1.7.19 ”Telescoping information system” screen . . . . . . . . . . . . . . . . . . . . . 125
10.1.7.20 ”Support pressure/tilt display” screen . . . . . . . . . . . . . . . . . . . . . . . . 127
10.1.7.21 Keys for ”Operating mode of the hydraulic pumps” . . . . . . . . . . . . 131
10.1.7.22 ”Active operating range limits” screen . . . . . . . . . . . . . . . . . . . . . . . . 133
10.1.7.23 ”Engine display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.1.7.24 ”Configure counterweight” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.1.8 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.1.9 Load Monitoring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.1.10 Dead man’s handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.1.11 Malfunction procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.11.1 Malfunction−free operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.11.2 Failure of the display ”touchscreen” feature . . . . . . . . . . . . . . . . . . . 145
10.1.11.3 Display screen failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
10.1.11.4 Failure of the crane control (CAN stop) . . . . . . . . . . . . . . . . . . . . . . 151
10.2 Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2.1 Hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2.2 Lower limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3 Electric safety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.1 Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.2 Operation “Main Boom Extension” . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

140−1000−228 5
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11 Working Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Wind Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.2 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.3 Operation Planning / Monitoring Safety Measures . . . . . . . . . . . . . 19
11.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.2 Condition of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.3 Condition of the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.4 Conversion of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

12 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Locking and Pinning Unit (LPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.1 Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.2 Supply of the LPU with hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.3 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.3.2 Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.3.3 Telescoping display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.3.4 Length code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.3.4.1 Selection of length code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.3.4.2 Selection of the Length Code for Lubrication of the Main Boom . . 35
12.3.5 Automatic telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.3.6 Manual telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3.7 Teaching the extension status of the telescopes . . . . . . . . . . . . . . . 59
12.3.8 Locking and Pinning Positions of the
Telescopic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.4 Lifting Capacities in the Unpinned Condition . . . . . . . . . . . . . . . . . . 65
12.4.1 Lifting Capacities in Intermediate Positions . . . . . . . . . . . . . . . . . . . 67
12.4.2 Lifting capacities that can be telescoped . . . . . . . . . . . . . . . . . . . . . 73
12.5 Main boom state to move the crane in
transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

13 Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1 Luffing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.2 Regulating the luffing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

14 Hoist 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Hoist Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Regulating the hoist speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

140−1000−228 6
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15 Hoist 2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Fitting and Removing Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1.1 Fitting and Removing Hoist 2with the Auxiliary Crane . . . . . . . . . . 5
15.1.1.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.1.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2 Fitting and Removing Hoist 2with Your Own Crane . . . . . . . . . . . . 9
15.2.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15.2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.3 Fitting and Removing the Additional Top Rollers . . . . . . . . . . . . . . . 15
15.4 Rope Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.5 Hook Operation with Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15.5.1 Pilot Control Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15.5.2 Hoist Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

16 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Engine−Dependent Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Engine−Independent Heating with Coolant Preheating System . . 5
16.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.2.2 Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2.3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.2.4 Heating Operation without Preselection . . . . . . . . . . . . . . . . . . . . . . 11
16.2.5 Heating Operation with Preselection . . . . . . . . . . . . . . . . . . . . . . . . . 13
16.2.6 Rectifying Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16.3 Air Conditioning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

17 Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.2 Load Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17.2.1 Hoist Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17.2.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17.2.1.2 Rope Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
17.2.1.2.1 Rope end connection ”with press fitting” . . . . . . . . . . . . . . . . . . . . 13
17.2.1.2.2 Rope end connection ”without press fitting” . . . . . . . . . . . . . . . . . 15
17.2.1.3 Reeving/unreeving the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
17.2.1.3.1 Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
17.2.1.3.2 Unreeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
17.2.2 Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
17.2.2.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
17.2.2.2 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
17.2.2.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
17.3 Reeving the Hoist Rope on the Main Boom Head . . . . . . . . . . . . . . 33
17.4 Reeving the Hoist Rope on the Main Boom Headwith Auxiliary
Sheaves (HD Attachment, Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 35
17.4.1 Assembly and dismantling ”one−sided HD attachment” . . . . . . . . . 37
17.4.2 Assembly and dismantling ”two−sided HD attachment” . . . . . . . . . 41
17.4.3 Electrical safety chain ”HD attachment” . . . . . . . . . . . . . . . . . . . . . . 45
17.4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
17.4.3.2 Safety chain ”One−sided HD attachment” . . . . . . . . . . . . . . . . . . . . 47
17.4.3.3 Safety chain ”two−sided HD attachment” . . . . . . . . . . . . . . . . . . . . . 49
17.4.3.4 Hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

140−1000−228 7
 Inhaltsverzeichnis

18 Main Boom Extension (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18.2 Fitting the Main Boom Extension 9.1 / 17 m (29.9 / 55.8 ft) . . . . . 3
18.3 Folding the Main Boom Extension 9.1 / 17 m (29.9 / 55.8 ft) . . . . 3
18.3.1 Folding the Lattice Mast 9.1m (29.9 ft) from the Transport into
the Operating Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18.3.2 Folding the main boom extension 17.0 m (55.8 ft) from transport
position into working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
18.4 Fitting the Main Boom Extension 25 m / 33 m (82 / 108.3 ft) . . . . 19
18.4.1 Installation of main boom extension 25 m (82 ft) . . . . . . . . . . . . . . . 19
18.4.2 Installation of main boom extension 33 m (108.3 ft) . . . . . . . . . . . . 25
18.5 Configuration and Fitting Program for Erecting or Bending
the Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
18.5.1 Telescoping Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
18.5.2 Selection of the Length Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
18.5.3 For bending the main boom extension from 0 degrees to
operating position 20 degrees or 40 degrees . . . . . . . . . . . . . . . . . . 37
18.5.4 Telescoping the Main Boom with Fitted MBE in the Load Raising
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
18.6 Fitting the main boom extension with auxiliary crane
9.1 / 17 m (29.9 / 55.8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18.6.1 Fitting the 9.1 m main boom extension (29.9 ft) . . . . . . . . . . . . . . . 45
18.6.2 Fitting the main boom extension 17 m (55.8 ft) . . . . . . . . . . . . . . . . 45
18.7 Fixing the Tip Section to the Main Boom . . . . . . . . . . . . . . . . . . . . . 45
18.8 Operation with Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . 47
18.9 Emergency Removal in the Case of Telescoping Problems . . . . . 47
18.10 Electric safety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
18.10.1 Hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

21 Head roller (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

21.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21.2 Assembly and dismantlement of head roller during separate
transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21.3 Folding in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

31 Dismantling and Assembly of the main boom (optional) . . . . 1

31.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31.2 Before dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
31.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
31.3.1 Dismantling luffing cylinder headpin . . . . . . . . . . . . . . . . . . . . . . . . . 17
31.3.2 Dismantling boom foot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
31.4 Main boomassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
31.4.1 Assembly luffing cylinder headpin . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

36 Emergency Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
36.2 Connecting the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.3 Recovering a Small Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

140−1000−228 8
 Inhaltsverzeichnis

41 Runner (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.2 Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41.3 Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
41.3.1 Hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
41.3.2 Electric safety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
41.4 Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
41.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
41.4.2 Folding in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
41.4.3 Folding in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
41.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

46 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . 3

46.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
46.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
46.3 Setting the interval and operating times . . . . . . . . . . . . . . . . . . . . . . 9
46.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.3.2 Time setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.4 Auxiliary lubrication impulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.5 Manual lubrication in the case of an emergency . . . . . . . . . . . . . . . 11
46.6 Filling the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.7 Malfunctions/Elimination of malfunctions . . . . . . . . . . . . . . . . . . . . . 13

140−1000−228 9
 Manufacturer’s Specifications

Manufacturer’s Specifications

The operating, lubricating and maintenance instructions included

here are valid for the mobile crane detailed below.
A quality management system as per DIN EN ISO 9001 forms the
basis of this crane’s construction and its manufacture.

Crane classification Mobile crane

(as per DIN 15001,15018 T3)

Crane type AC 140

Construction number _______________

Maximum capacity 140 t / 308.6 kip

(with additional equipment)

Manufacturer Terex−Demag

140−1001a 1/1
 Foreword

Foreword

For you,

as owner of a crane manufactured by us, we have produced this

manual, comprising the most important instructions for its opera-
tion, lubrication and maintenance.
These instructions should enable you to familiarise yourself with
your crane and to use the operating applications as intended.
The instructions must always be kept to hand at the operating
site.

The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
Part 3 − Lubrication and maintenance instructions for the
superstructure
Part 4 − Lubrication and maintenance instructions for the crane
chassis
Part 5 − Various

Please note that the information contained in this manual corres-

ponds to the state of machine engineering at the time the litera-
ture was drawn up. Deviations in the technical specifications, fi-
gures and dimensions are therefore possible.

In such cases we make every effort to bring your documentation

up to date by sending you modified pages.
But we must ask for your kind cooperation. For it is only you who
can ensure, that such modifications will be included into your ori-
ginal documentation.
This has to be applied also and especially for the part of the docu-
mentation that is permanently with the crane.

140−1002b_en 1/13
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 Foreword

Pass this manual on to your crane operator and driver and to

the specialised personnel responsible for the maintenance of
the crane with the request that they read the instructions carefully
before the crane is operated for the first time and later at regular
intervals.
Important instructions are included which ensure that the crane
is operated safely, correctly and economically.
Observing these instructions will help to avoid dangerous situa-
tions, repair costs and downtimes as well as to increase the relia-
bility and service life of your crane.
Periodic, preventive inspection and maintenance are the surest
way to keep your crane in good operating order. The early reco-
gnition and elimination of minor irregularities and the immediate
replacement of worn and damaged parts prevents downtimes
and the associated costs. Replace any damaged signs or sym-
bols.

You will appreciate that we can accept no claims for damage or

malfunctions attributable to improper use and operation and/or
inadequate maintenance.

Should you discover any mistakes when reading this manual or

if you have further suggestions and hints, please contact:

Terex − Demag GmbH & Co. KG

Dept. 1160
Postfach 1552
D−66465 Zweibrücken
The editors would welcome your involvement.
”Putting experience into practice”

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 Foreword

Handover of the crane

The crane is delivered to you from the works ready for operation,
and is already supplied with fuel and hydraulic oil.
All lubrication points have been greased.

If the crane is delivered from the works with a protective coating

(preserving wax), this does not necessarily have to be removed.
It provides added protection against corrosion.

The protective coating can be removed using:

Washing thinners, e.g. Conrad thinners RV 5339 E 45430

Cold cleaners, e.g. Allpur 150 X or Purtex 65
Stream spray gun

Before commissioning

you should inspect the crane thoroughly together with our service
engineer.

Spare parts

When ordering spare parts, please refer to the first page of our
spare parts catalogue:

”Instructions on using the catalogue”

Use only original spare and wear parts authorized by the crane
manufacturer.

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 Foreword

Service

Please contact the service department if you have any questions

about your crane. Always quote the type designation and con-
struction number of your crane in all correspondence.

From within Germany:

Tel: 0180−300 30 90
Fax: 06332/83 1711
E−Mail: Demag−Service−Germany@terex.com

From outside Germany:

Tel: (49)06332/83−0
Fax: (49)06332/16715
E−Mail: info@terex−demag.com

or do contact the TEREX−Demag−partner in your area.

Modifications to the crane

We would point out that any modifications to the crane (e.g. the
purchase of boom parts, etc.) may invalidate the information in
these operating instructions or make it insufficient.

After modifications or repairs to parts which affect the safety of

the crane, the crane must not be returned to operation until it has
been inspected and approved by a safety inspector where this
has been stipulated in national legislation.

For this reason, please notify us without delay of any modifica-

tions which you carry out or have carried out on your crane.

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 Foreword

...and you can find your way around this manual as follows:

From the example given here, you can see how fast and accura-
tely I can arrive at the required information.

WHAT do I want to know ?

I would like to know for instance what control elements are pro-
vided for outriggers.

WHERE do I find the information required above ?

The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
Part 3 − Lubrication and maintenance instructions for the
superstructure
Part 4 − Lubrication and maintenance instructions for the
crane chassis
Part 5 − Various
These parts are divided by index sheets. I need Part 2 because
the outriggers are part of the crane chassis.

1. I look for the index sheet ”1” (for Part 1), and open the super-
structure operating instructions at this point and find the
Contents of Part 1.

2. I glance over the bold headings of the sections until I come

to Section 11, Working Instructions”.

3. In this Section11 I then find ”Wind speeds” as item 11.1.

The page details on the right−hand side of the page refer to
the page number within the section.

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 Z 26 350

10/13 140−1002b_en
 Foreword

HOW do I find the page in Section 11 ?

1. I take the pages of Part 1 and flick through the pages as

shown in (Z 26 350).
Whilst doing this, I always keep the top, right−hand edge
(1, Z 26 350) in view.
As soon as the required section number appears, I stop flik-
king through the pages.

The name and number of the section are on the top right−hand
edge (1, Z 26 350) of each page.

2. Then, with the help of the page number on the bottom right−
hand edge (2, Z 26 350), I decide whether I must flick back-
wards or forwards in order to reach the page number requi-
red.

The page number within the section is given on the bottom right−
hand side (2, Z 26 350) of each page. This number is given along
with the total number of pages in the section. This means, for in-
stance, that 3 is given as the page number in the contents and
the page itself is numbered 3/39. This makes for better orienta-
tion within a section.

Please note that this option of fast and accurate access to

specific information as described above does not exempt
you from reading the instructions carefully and in full before
the crane is operated for the first time and at regular intervals
afterwards.

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 Foreword

The headings and corresponding symbols ”Danger”, ”Caution”

and ”Note” are used in these operating instructions as follows:

DANGER !

”Danger” is used for operation procedures, mounting se-

quences etc. where failure to observe the stipulations
made may result in death or injury.

CAUTION !

”Caution” is used for operating procedures, mounting se-

quences etc. where failure to observe the stipulations made
may result in damage to the crane or equipment.

NOTE:

”Note” is used to indicate an important operation or mounting pro-

cedure or to draw attention to further information.

Information such as “left” and “right” of the crane must always be

understood as looking in the direction of travel.

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 Safety Instructions 1

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Z 59 992

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 Safety Instructions 1

1 Safety Instructions

1.1 General

This section ”Safety Instructions” provides a compact and

general overview of hazards which can occur in connection with
the operation of the crane superstructure and crane chassis.
Where necessary, these safety instructions are referred to and
dealt with in further detail in the corresponding sections of the
operating instructions.
In the operating instructions of the crane chassis (part 2 of this
documentation) section 1 ”Safety Instructions” simply refers back
to this chapter.

The safety instructions for lubrication, maintenance and service

work can be found in part 3 of this documentation.

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1.2 Intended Use

The crane is designed for lifting loads.

It is prohibited to transport people with personnel carrying

equipment!
In many cases, there have been serious injuries when peo-
ple have been transported using personnel carrying equip-
ment (or even on the hook or on loads). In these cases, they
have no control over crane movements and are not protec-
ted against bumps or falls. Even the smallest of errors can
have fatal consequences.
In exceptional cases (for example, the use of personnel ca-
ges which were not supplied by the crane manufacturer),
please consult the responsible authorities / agencies con-
cerning relevant permits, fixed special conditions, safety
regulations, additional tests and demands on the crane and
similar issues. In Germany, the authority / institution con-
cerned in the first place is the Berufsgenossenschaft.
The use of such additional devices is then the responsibi-
lity of the crane operator following the valid safety and acci-
dent prevention regulations!

Risk of death!
It is expressly forbidden to use the crane for jumps with
rubber ropes (bungee jumping)!
Using the crane for such jumps represents a misuse of the
crane and entails extreme danger for life and limb!

The crane is designed exclusively for assembly operation.

Any other type of use which goes beyond the limits specified, for
example handling of general cargo or grab operation, are not
classified as intended use. The manufacturer shall not be held
liable for any damage that results. The operator carries full
responsibility for this type of use.

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 Safety Instructions 1

Intended use also includes the observation of all load tables, the
operating instructions − in particular with regard to the specified
assembly sequence − and the lubrication and maintenance
specifications.

If operation of the crane for part−load handling or another type

of use is required, please contact the crane manufacturer.

The use of two hoists to raise the load (2−hook operation) is not
permitted.
Special load cases are however permitted in consultation with the
crane manufacturer.

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 Safety Instructions 1

1.3 Operating Conditions and Computed Design of the

Crane

1.3.1 General

The crane has been constructed using state of the art technology
and in accordance with recognised safety regulations.
Nevertheless, its use can lead to hazards for the life and limb of
the operator and third parties, and/or damage to the machine and
other objects.

Use the crane only when it is in full working order and only for its
intended use, paying attention at all times to safety and potential
hazards, and in observance of the operating instructions. In
particular have any malfunctions which might impair safety
rectified immediately.

The term ”operating instructions” refers to the operating

instructions and the lubrication and maintenance instructions.

1.3.2 Classification of the Crane

The crane is classified as follows (ISO 4301−2 and FEM 1.001):

− Operating class => U1
− Load class => Q2
− Crane group => A1

All important components of the crane are designed and

manufactured for normal assembly operation. This assumes that
crane operations under full load, crane operations with lower load
and operating breaks occur in a ratio that is typical for an
assembly crane. More exacting operating conditions necessarily
lead to a shorter life expectancy for the crane.

Operating conditions or types of use other than assembly

operation require the permission of the manufacturer and
normally lead to a reduction in the lifting capacities.

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1.3.3 Classification of the Engines

The power units are also classified in accordance with ISO

4301−2 and FEM1.001. They have been calculated and
designed based on specific operating conditions which are laid
down in European standards.

The winches of your crane are classified as follows:

Power unit group: M........
Load collective: Q....... (L.......)
Factor of the load collective: Km = ..........

Please refer to the table on monitoring the winches in the crane

identification papers for the corresponding values.

The classification of the power units is the basis for their

evaluation during the annual inspection (see part 3, Lubrication
and Maintenance Instructions for the Superstructure).

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1.3.4 Workplace Ergonomics

The noise levels listed in the following table can occur at the
crane operator’s workstation in the cab of the superstructure. To
reduce noise during crane operation, we recommend keeping
the cab doors and windows and the cover flaps of all drive units
closed.
− Engine idle (550 min−1/rpm) < 75 dB(A)
− Maximum engine speed without load < 85 dB(A)
(2750 min−1/rpm)
− Engine speed at highest engine torque < 80 dB(A)
without load (1300 min−1/rpm)

Measurements were taken using a noise level measuring unit

with the test microphone at the ear position of the crane operator.
The A−assessed equivalent permanent sound level at the
operator’s seat measured over the shift duration of 8 hours is
below 70 dB(A). For this purpose, measurements were taken
during operation on construction sites using dosimeters.

The crane operator is protected against mechanical vibrations by

means of a tilting seat which can be adjusted to his weight. The
crane operator’s seat offers infinite adjustment options for the
seat height and tilt, backrests and armrests. It is therefore
possible to select the optimum working position for every driver.

The weighted effective value of acceleration which the upper

body extremities are subject to, is below 2.5 m/s2 (8.2 ft/s2).
The weighted effective value of acceleration, which the body
(feet and seating area) is subject to, is below 0.5 m/s2 (1.6 ft/s2).
Both values are therefore below the statutory specifications.

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 Safety Instructions 1

1.3.5 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the
configuration, boom length and working radius. It is specified by
the crane manufacturer in the load capacity tables.
The load capacity tables supplied with the crane specify limit
values which must not be exceeded.

The load limit of the winches is effectively reached when the rope
force has reached its permitted value. Low loads with a small
amount of reeving can place the winch under just as much load.

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 Safety Instructions 1

1.3.6 Required Ambient Conditions

The permitted temperature range for operating the crane is

−20°C to +40°C (−4°F to +104°F), if the maximum or minimum
temperature occurs only a few days a year.

Optional equipment for other operating conditions can be

supplied.

The crane can be operated under full load up to a height of

1000 m (3281 ft) above mean sea level. It is not hazardous to
operate the crane up to an operating height of 2000 m (6562 ft)
above mean sea level.

The crane can also be operated without danger with high / low
relative air moisture.

Continuous operation in aggressive air (e.g. harbours, chemicals

industry, steelworks etc.) combined with high relative air moisture
can require an adapter kit / optional equipment.

High levels of dust require the filter to be changed more

regularly. Dust concentration levels of up to 35 mg/m3 are
permitted for a short period of time.

Observe the corresponding regulations in the lubrication and

maintenance instructions, parts 3 and 4.

With an oncoming wind the crane operator must follow the rules
outlined in the operating instructions. Please refer to section 11
on operating rules and instructions in the operating instructions
of the superstructure.

The ground, on which the crane is supported − or driven with load

− must be strong enough to support the load.

Use of the crane in a potentially explosive atmosphere or in

operating conditions where combustible gas can be drawn in is
only permitted following corresponding conversion.

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1.3.7 Service Life

Classification of the crane is based on a total operating life

(service life) of 20 years under the following conditions:
− the crane is operated as an assembly crane.

The load capacity tables that are authorised for the crane are
based on assembly operation only. General cargo handling
or grab operation can only be permitted following express
permission from the manufacturer under suitable
conditions.

− the total number of load cycles in this period is less than

32 000 (e. g. 5 − 10 lifts / day on 200 days / year).

A “LOAD CYCLE” encompasses processes which begin when a

load is raised and end when the crane is ready to raise the next
load.

− the type of load (load collective) of the entire crane shows

values no worse than the following:
∗ for 1/10 of the load cycles the crane is placed under max.
load
∗ for 4/10 of the load cycles with 44 % of the max. load
∗ for 5/10 of the load cycles with 16 % of the max. load

“Load” in this context refers to the sum of the load, load−handling

devices and lifting tackle (e.g.: load + hook block + sling ropes).

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 Safety Instructions 1

Under these conditions, assuming that maintenance work is

carried out properly, the theoretical service life can be more than
20 years.
Harder operating conditions naturally lead to a reduction in the
service life.

For the winches, however, the rules for calculating the

remaining theoretical service life must be observed, as
outlined in part 3, Lubrication and Maintenance Instructions,
section 1.8.

Some components (e.g. ropes) are not designed for the

entire service life of the crane, but must be replaced after a
certain amount of time.
Information on this can be found in the lubrication and
maintenance instructions for the superstructure.

1.3.8 Standards and Calculation Regulations

The specifications contained in section 1.3.7 on service life,

loading and utilization of the crane are taken from the European
standards ISO 4301−2 and FEM 1.001, FEM 5.004 and
ISO 9927−1.

The proof of stability for the framework, the components and

parts of the crane is based on the standards: FEM 5.004,
ISO 4301−1, ISO 4301−2, FEM 1.001 and ISO 4308−2.

The ropes are selected and calculated in accordance with ISO

4308−2.

All required proofs of stability (buckling and bending) were

carried out in accordance with DIN 18800. The minimum safety
factors are taken from FEM 5.004.

The proof of standing stability for the crane is based on ISO 4305.

For countries in which different standards and calculation

regulations apply, special calculations or proofs can be carried
out.
If required, these calculations must be specially ordered by the
crane operator. This does not alter the operating conditions for
the crane. If necessary the lifting capacities must be limited.

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1.3.9 Dangers to Air Traffic

As considerable heights are reached when the crane is operated,

this can lead to air traffic being endangered.
For this reason the crane may only be operated in the vicinity of
airports, landing areas and flight safety facilities (so−called
protected or safety zones) following permission from the
corresponding authorities (for example in Germany −
Landesluftfahrtbehörde, Wehrbereichsverwaltung, Deutsche
Flugsicherung GmbH).

In Germany, more information can be obtained from:

Deutsche Flugsicherung GmbH (DFS)
Kaiserstraße 29−35
D−63067 Offenbach a. M.
Tel. 069/8054−0

These regulations apply in Germany. In other countries, the

corresponding national regulations must be observed.

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1.4 Safety Regulations

While carrying out power−driven erection and assembly

procedures only the crane operator is allowed on the crane
(and he must be in the crane operator’s cab). Remaining
personnel must remain clear of the hazardous area on and
around the crane.
The only exception to this rule is when the counterweight
is being fitted and when a load is being attached or released
with the help of a fitter.

When stacking the counterweight the person attaching the

equipment must leave the crane and the slewing area as
soon as the erection work is completed. During stacking,
the person attaching the equipment must remain outside
the hazardous area.

When attaching and disconnecting the load, particular care

should be taken as a result of swinging loads or hook
blocks. The person attaching the equipment must be profi-
cient in handling hook blocks.
Once the load has been attached or released, the fitter must
leave the slewing or hazardous area immediately.

The fitter must be easily recognisable to the crane operator.

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These means of identification should be in a distinctive co-
lour and where possible of an identical design and must be
exclusive to the fitter.

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1.4.1 Organisational Measures

In addition to the operating instructions, applicable national

regulations and any other binding regulations on the prevention
of accidents and protection of the environment must be followed
and passed on. These should be added to the operating
instructions.

Such stipulations may involve, for example, handling hazardous

substances, making available / wearing personal protective
equipment or road traffic regulations.

In addition to the operating instructions and the accident

prevention regulations valid in the country and on the operating
site where the crane is in use, the recognised technical
regulations pertaining to safe and correct working procedures
must also be observed.

The operating instructions should be supplemented by any other

instructions that are necessary, including supervisory and
reporting duties for any special operating occurrences, for
example with regard to work organisation, operating procedures,
allocated personnel etc.
Keep a complete and legible set of all safety and hazard
instructions on the crane at all times.

Safety guards on the crane must not be opened or removed

during crane operation.

Provide instructions on the location and use of fire extinguishing

equipment.

In case of poor visibility or darkness, the immediate area in front

of the crane operator’s cab, the outriggers and the winches must
be illuminated by the spot lights, which are fitted on the crane
(rear outside lighting, front outside lighting, side outside lighting).
The side outside lighting can be switched from the crane
operator’s cab or from the driver’s cab.
Additional surroundings (load, load path, slewing range, driving
area etc.) must be lit with suitable lighting which is independent
of the crane. The crane operator is responsible for this.

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1.4.2 Personnel selection and qualifications

In order to operate a crane optimally within its proper parameters,

the crane operator and personnel working on maintenance,
assembly and dismantling must be properly qualified and trained.
The crane operator / owner is responsible for providing this
training.

Use only reliable, trained and/or experienced personnel for work

on and with the crane.
Make sure that only authorised personnel are allowed to carry out
work .
Pay attention to the minimum working age.

Clearly specify all areas of responsibility:

− for operating, erecting and servicing.
− for the crane driver, also with regard to his responsibilities as
a result of road traffic regulations. Allow him to refuse
instructions from third parties which contravene safety
regulations !

Personnel who are still being trained and instructed in the use of
the crane, or who are completing a general apprenticeship, may
only be allowed to work on the crane under the constant
supervision of an experienced member of staff .

Personnel who are responsible for work on the crane must have
read the operating instructions before commencing work, and
in particular the section on ”safety instructions”.
It is too late in the middle of crane operations.
This applies especially to personnel who only work on the crane
occasionally − e.g. for configuration or maintenance work.

Check − at least now and then − to make sure that all personnel
are working safely and are following the operating instructions.

Personnel are not allowed to wear their hair long, wear loose
clothing or jewellery, including rings. There is a risk of injury, e.g.
as a result of being caught or dragged by moving parts.

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1.4.3 Particular types of hazard

1.4.3.1 Electrical Energy

High voltage

With high voltage lines, any direct contact with the boom or the
hoist rope is always dangerous.
With high voltage lines above 1000 V current can be transferred
even as the lines are approached.

This hazard should be prevented by the following measures:

− Switch off the power to the lines.
− Cover or cordon off the danger zone.

Both measures may only be carried out by qualified

electrical specialists.

If these measures cannot be carried out, a sufficient safety

clearance must be maintained between the crane (hoist rope,
lifting tackle, hook block, load) and current−carrying lines. Risk
to life and limb!
Keep a clearance of at least 10 m (32.8 ft). If this is not possible,
you must obtain information on required minimum safety
distances from the electric power company responsible.

With extremely long boom equipment, these safety clearances

are very difficult to judge. To be on the safe side, increase the
safety clearance to 20 m (65.6 ft).

The safety clearance must still be available for unfavoura-

ble crane or load positions.
Allow for possible swinging of the load or swinging out of
the free line as a result of the wind.

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If, however, the crane accidentally comes into contact with high
voltage power lines:
− Move the crane out of the danger zone: drive out, swing away,
adjust the boom!

If this is not possible:

− Do not leave the crane or driver’s cab.
− Warn those outside not to approach or touch the crane.

If the crane operator leaves the crane or if another person

approaches and touches the crane, they will receive an
electric shock.
Even the ground around the crane is carrying an electric
current. Therefore every step on the crane, to the crane or
away from the crane is potentially dangerous (step vol-
tage)!

− Arrange for the voltage to be switched off.

− Only leave the crane when you are sure that the
touched/damaged line has definitely been disconnected
from the power source.

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High−frequency radiation / operating in vicinity of

transmitters

Charging

It can cause dangerous electrical charging if track−free mobile

cranes are used in the vicinity of transmission systems (e.g. radio
transmitters).

In this case, the following measures must be taken:

− agreement with the operator of the transmitter (possibly
switching off the transmitter).
− grounding (of the track−free mobile crane).
In order to protect the rotating connection the grounding
cable must be fastened directly to the superstructure of the
crane or to the boom.

Risk of injury!
If the prescribed measures are not taken the persons con-
necting the charged components to ground will be violently
and painfully electrified at touch.

Interference with the crane electrics

At the same time, the crane electrics, especially the load limit
device, cannot be considered function safe, depending on the
strength and frequency of the transmitter.

The danger of the load limit device being influenced by

high−frequency radiation has been minimised with up−to−date
technology (shields). However, it cannot be fully discounted,
especially under extreme circumstances.

This is especially valid if the crane is used in the close

vicinity of high−frequency radiation sources (e.g. radar
stations, radio transmission stations, radio and television
stations).

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Lightning

If storms are approaching, if possible lower the crane equipment

and leave the crane.
If this is not possible, lower the load from the hook, switch off the
engine and leave the crane.

Only remain in the crane operator’s cab if you cannot carry out
these measures in good time.

Under no circumstances must the crane operator approach

the crane or its immediate vicinity during the storm. Warn
any other people in the vicinity of the crane.

The general functions of the crane must be checked if it is

suspected that it has been struck by lightening. It is especially
important that the following is checked:
− general electrics, especially:
∗ load limit device; if defective, there is a fault message in the
display.
∗ limit switch for function.
∗ inductive proximity switch for function.
− luffing and outrigger cylinders with a visual inspection for
external damage caused by flashover voltages or melting.
By retracting and extending the relevant cylinders several
times, check if there are suspected internal leaks due to
damaged seals.
− hoists, especially for damage to the ball and roller bearings.

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Z 29 800 Z 29 801

Z 29 802

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1.4.3.2 Gas, Dust, Steam, Smoke

Only operate combustion engines and fuel−operated heaters in

sufficiently ventilated spaces. Make sure that sufficient
ventilation is provided before operating in restricted spaces.

Follow the applicable regulations for the operating site.

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth de-
fects, and other reproductive harm.

1.4.3.3 Crushing / collisions

(Z 29 800)

For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating
instructions.
− Hook block / load when slewing the superstructure

1.4.3.4 Snagging / Dragging

(Z 29 801, Z 29 802)

For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating
instructions.
− Head− and deflection roller
− Hook Blocks
− Winches
− Slew ring toothing (slew pinion)

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1.4.3.5 Crushing / Shearing

(Z 29 800)

For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating
instructions.
− when extending and retracting the main boom
− when lowering the main boom on the foot bearing of the
superstructure frame
− when slewing the superstructure
− when extending and retracting outriggers and cylinders
− when releasing the suspension locking following the
outrigger procedure in the vicinity of the wheels
− in the vicinity of the hook block and load in case of
uncontrolled movements
− when stacking the counterweights
− when fitting and removing hoist 2
− when fitting and removing the main boom and superstructure
− when tilting the crane operator’s cab
− when fitting and removing / erecting additional equipment
(optional), as, e. g., main boom extension.

1.4.3.6 Risk of slipping, tripping, falling

(Z 29 803)

Only the walkways and ladders described may be used. These

provide sufficient gripping points to hold on to and the walkways
are slip−free in design (e.g. sanding, chequer plate etc.).

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1.4.4 Combination of Hazards with Combined Operation

of Two or More Cranes

1.4.4.1 Operating Areas of Several Cranes Overlap

If the operating areas of several cranes overlap, there is a risk of

collisions.
The operating company or its representative must:
− specify the working procedure in advance!
− make sure that there is a clear line of communication with the
crane operator !

If the crane operator does not have spoken or visual contact,

suitable measures must be taken, e.g. use of radios,
spotters/banksmen etc.

If spotters are used, suitable signals must be agreed between the

spotters and the crane operators. In this regard, please refer to
section 1.5 of this chapter ”Safety Instructions”.

Crane operators must operate the crane in such a way that

uncontrolled movements and subsequent collisions are avoided.
They must receive suitable training and instructions to this end.

1.4.4.2 Combined Raising of a Load by More Than One Crane

If a load is to be raised by more than one crane, the operator of

the crane or his representative must first set up a working
procedure and appoint a supervisor, in whose presence the
operations are carried out.

The most important requirement for this type of operation is,

however, careful planning, covering the following points:

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∗ The mass (the weight) and the centre of gravity of the load
must be known exactly.
∗ The load must be shaped in such a way as to avoid extra
hazards during the lifting procedure.
∗ The other cranes which are taking part in the operation must
have nearly the same lifting capacity.
∗ Additional dynamic load effects when the load is raised and
set down and load effects as a result of environmental
influences (e.g. wind) must be allowed for during planning.

The actual danger is during joint lowering of the load. Using

the relevant reeving and control. the lowering speeds of
both cranes must be as similar as possible, otherwise there
is danger of the slow crane becoming overloaded.
The ”Accident Prevention Regulations for Cranes” by the
Employer’s Liability Insurance Association (BGV D6) can
serve as a helpful guide. It contains regulations and safety
instructions for operation with several cranes. It especially
emphasises the importance of sufficient safety reserves
for each crane and that the full load value of the load capa-
city table may never be used.
If there are any doubts concerning the accuracy of the data,
e.g. the accuracy of the details with regard to mass and the
position of the centre of gravity of the load, the safety reser-
ves must be increased accordingly.

Before carrying out heavy−duty operations, the crane

manufacturer should be consulted to see whether the crane can
be fitted with any additional safety devices (e.g. limiters) or
whether the lifting capacity needs to be restricted additionally for
the operation in question.

Avoid pulling a load sideways or at an angle!

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1.4.5 Driving Operation

1.4.5.1 Before Driving

Check the correct function of the brakes, steering and signal and
lighting equipment daily, for cranes that are seldom used − every
time that they are driven.

Before driving the crane, always make sure that there is no−one
in the danger zone of the crane. If necessary give a warning sign
(actuate the horn before starting the engine for example! ).

If you cannot see the hazardous area from the driver’s cab, a
spotter (or banksman) must be used (see section 1.5) !
This also applies if normal voice communication is not possible
as a result of an increased noise level.

Keep the windscreens of the driver’s cab clean to guarantee

good visibility.

Make sure that all accessories are stored safely and cannot
cause an accident.

When driving on public roads, highways and precincts observe

the relevant traffic safety regulations and make sure that the
crane is properly equipped for road travel.

In the case of the axle loads a differentiation is made between

the technically possible load (technical driveability) and the load
permitted in accordance with the road traffic regulations.
”Technical driveability” is only permitted on construction sites or
private roads (with the exception of countries which permit axle
loads over 12 t / 26.4 kip).

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Axle loads over 12 t (26.4 kip) are not authorised for road travel
in countries subject to EU regulations (or to reduced axle loads).
If the crane is driven on the road with axle loads above
12 t (26.4 kip), thenthe crane operator assumes sole
responsibility. All components and installations are designed and
calculated for axle loads of 12 t (26.4 lip) at maximum speed.
If this 12 t (26.4 kip) axle load is exceeded, the service life of
axles, wheel hubs, bearings, suspension cylinders and brakes
will be reduced. In particular wear to the brake linings and the risk
of the brakes overheating and fading are increased.
Deceleration for the brakes (EEC: 50 %) reduces in proportion to
the increase in the axle load or the transport weight of the crane.

1.4.5.2 During Travel

When driving on the road in the transport position, the boom must
be placed in the travel rest and the telescopic sections bolted.

On a slope always adapt the speed of the crane to the local

conditions. Never shift gear once on the slope, but change to a
lower gear before reaching the slope.

When passing flyovers, bridges, tunnels, electric lines etc. make

sure that there is sufficient overhead clearance.

When towing, follow the towing regulations with respect to the

prescribed transport position, permitted speed and distance
travelled.

Passengers may only travel in the cab of the crane chassis on the
proper passenger seats provided.

In an emergency the passenger door can be used as an exit.

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1.4.6 Crane Operation

1.4.6.1 Before Crane Operation

Check the load conditions again before commencing crane

operation: Is the mass (the weight) of the load and the operating
procedure known and is there sufficient lifting capacity, working
radius and lifting height? Compare the values with the load
capacity table.

Using the crane’s display systems, check: Load status, fluid

statuses, motor operation, hydraulic oil pressures and wind
speeds.

Check whether outside conditions such as wind, snow, poor

visibility, unfavourable temperatures etc. could limit crane work.

Make sure that the ground has sufficient load−bearing capacity

when supporting the crane on outriggers.

For more detailed information, see section 11 “Working

Instructions” in the operating instructions of the superstructure
and section 12 “Outriggers” in the operating instructions of the
crane chassis.

Maintain a safe distance between the supported crane and

slopes and ditches.

For more detailed information, see section 11 “Working

Instructions” in the operating instructions of the superstructure.

Before commencing work at the operating site, familiarise

yourself with the working environment. The working environment
includes, for example, obstructions in the operating and traffic
areas, the load−bearing capacity of the ground and the
necessary safety precautions required to cordon off the
construction site from public traffic areas.

To operate the crane safely, clear and unhindered sight of the

crane, load and load path must be ensured. If these are not
guaranteed, the crane operator must provide a communication
system (e.g. voice radio etc.) between the spotter and the crane
driver. This communication system must be checked for safe
functioning before crane work begins.

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Carry out the necessary measures to ensure that the crane is

operated in a safe and functional condition.

Before commencing work, check that all crane movements are

functioning correctly and safely.

Operate the crane only if all safety guards and equipment are
fitted and functional.

Check the correct function of the brakes, signal and lighting

equipment, limit switches and overload cut−off device daily, for
cranes that are seldom used − every time that they are operated.

Before commencing work with the crane make sure that no−one
is in the hazardous area. If necessary give a warning sign
(actuate the horn before starting the engine for example! ).

As oil can be emitted during maintenance and assembly work,

suitable containers and binding agents must be kept available
and ready.

Insofar as necessary or required by regulations, personnel must

wear protective clothing and equipment (e.g. safety harnesses,
safety clothing, goggles, face masks, etc.)!

Remember that protective equipment does not offer 100%

protection! A helmet can protect you against small falling
objects, but not against falling loads!
You should therefore remain attentive and safety−con-
scious at all times!

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The weight of the load must be known.

It is difficult to calculate the load weight during dismantling

work. If a load that is attached to the crane is released from
its previous connection to other parts and is too heavy, the
crane will be unavoidably destroyed or will tip over,
regardless of the load limit switch.
When dismantling hollow components (pipelines, cement
silos etc.) allowance must be made for the weight of possible
residues inside these components.

When determining the size of the components that are to be

dismantled, never utilise the full values allowed in the load
capacity tables of the crane, but allow for a safety buffer.

Select the correct boom length and reeve the hoist rope in
accordance with the individual load case.

Before reeving and before starting crane work, check the status
of all accessible ropes (including the end connections), winches
and sheaves.

Select the lifting tackle in accordance with the weight of the load,
the type of attachment and the angle of inclination.

Only hook blocks supplied by the crane manufacturer may be

used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.

Pay attention to the rules and regulations for working with load
handling equipment (attachment ropes etc.) and load handling
devices (lifting beams etc.). Never use lifting tackle and load
handling devices if there is any doubt as to their lifting capacity.
Check to make sure that the lifting tackle and all load handling
devices are in perfect condition.

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1.4.6.2 During Operation of the Crane

When carrying out power−driven working procedures

(raise / lower load) only the crane operator is allowed on the
crane (and he must be in the crane operator’s cab). Remai-
ning personnel must remain clear of the hazardous area on
and around the crane.

The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work immediately if persons fail to leave the hazardous area
in spite of the warning.

Before movements are started or stopped, ensure that there are

neither persons nor obstacles within the danger zones of
movable crane parts and the moving load.

The crane operator may only start or stop movements if he has

good visibility of the hazardous areas. In case of poor visibility
suitable persons must be selected as spotters and must be
instructed on the correct signals before commencing work (see
section 1.5).
This also applies if normal voice communication is not possible
as a result of an increased noise level.

Keep the windows of the crane operator’s cab clean to maintain

good visibility at all times.

To allow for immediate reaction if the crane is subjected to

changing environmental conditions, it is prohibited to switch off
the drive of the crane when a load is attached and/or to leave the
crane cab.

Exceptions are only permitted in emergency situations. To

avoid hazardous situations, in the final instance the drive
source (diesel engine) can be switched off using the quick−
off−button in the crane operator’s cab. First − where possi-
ble − movements that have been started should be comple-
ted using the control levers.

Before raising a load, you must always make sure that the hook
block is positioned vertically over the load’s centre of gravity.

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The crane (superstructure) may only be placed in operation when

the crane chassis engine is switched off, the driver’s cab closed
and the control panels of the outriggers locked.

The rigged crane may only remain without the presence of an

instructed crane operator (without load), if certain conditions are
complied with (see operating instructions for the crane chassis,
section 14 ”Parking”).

The carrying of persons with the load or the load handling

equipment is prohibited.

The crane may only be accessed and left following agreement

with the crane operator and only when the crane is at a standstill .

Observe all safety and hazard warnings on the crane .

Avoid any actions which may impair safety (e.g. risk to the
stability of the crane).

Never slew loads over people.

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Only start the crane engine from the driver’s seat. Only actuate
the control lever from the cab.

Keep the controls lever within reach as long as a load is

suspended on the crane or the crane is driven.

To prevent the unintended activation of crane movements, both

control levers are equipped with an additional button (dead man’s
button).
The crane movement can only be carried out as long as one of
these buttons is pressed.
The dead man’s switch may only be actuated (pressed and
released) and the limit switches in the instrument panel bridged,
when the corresponding control lever is in the ”O” position and/or
the working movement that is underway has been completed.

RISK OF ACCIDENTS!
Actuation of one of these buttons when the control lever is
fully deflected leads to an abrupt activation or braking of
the corresponding movement.

For all crane movements, pay particular attention to the load, for
unladen operation the load−handling device, and the boom tip !
Watch the slewing radius of the counterweight etc.

In all crane movements, approach the limit ranges especially

slowly and carefully.

Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision.
The load must never come into contact with the framework of the
crane (boom system, superstructure, crane chassis, outriggers
etc.).

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Dragging and scraping of the load is prohibited during crane

operation.

It is prohibited to pull loads free that have become lodged.

Do not jump from the crane! Do not jump from the crane.Use the
ladders and the handrails provided.

Secure the doors with the available locks to prevent them

slamming open or closed.

Check the crane at least once a shift to check for any visible signs
of damage or faults. Any changes (including to operating
behaviour) should be reported immediately to the point / person
responsible. If necessary, switch off and safeguard the crane.

In case of a malfunction on the crane, switch off the crane

immediately and secure it. Have any faults rectified immediately !

Pay attention to the procedures for switching equipment on and

off as well as the behaviour of the indicator lights as outlined in
the operating instructions.

In case of poor visibility and darkness always switch on the

outside lighting. The inside lighting should be switched off to
enable proper sight of the load and the immediate environment
of the crane.

Always keep the operating instructions at the crane operating site

in the storage compartments provided. These are located on the
superstructure on the back wall of the cab and on the crane
chassis on the driver’s door.

Be aware of the location and availability of fire warning and fire

fighting equipment.

Pay attention to the weight and surface area of the load exposed
to the wind.

Loads that are in water are lighter for the crane than those in air
(due to buoyancy). When the load leaves the water it becomes
heavier. If this results in the crane being overloaded the load limit
device would be triggered.
There is a risk to the lifting tackle, however, if this is not measured
for the actual load weight.

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Set the computer of the load limit device in accordance with the
load capacity tables supplied.

Observe the permitted wind speeds.

The superstructure may only be slewed when the crane is

supported on outriggers. Note that slewing is only permitted for
certain crane configurations (e.g. with regard to outrigger support
area, counterweight etc.). Always observe the specifications of
the load capacity tables.
Slewing of the superstructure in the overload range (load limit
device has shut off) is generally prohibited.

In an emergency the wide−opening front window can be used as

an exit.

1.4.6.3 Following Crane Operation

When you leave the crane:

∗ the load must be detached from the crane hook or set down
on the ground.
∗ the engine must be switched off and all control levers placed
in the ”O” position or the ”locked” position.
∗ the heating must be switched off.
∗ the parking brake of the crane chassis must be closed.
∗ the crane must be secured to prevent unauthorised use and
unintentional movement.

If the crane is parked on steep ground, the travel gear must be

additionally secured with chocks, the slew brake applied and the
boom secured.

Close all control panels that are fitted with a lock when they are
not being used.

When parking the crane pay attention to the permitted wind

speeds (also for the time when the crane is at a standstill). If
necessary telescope in and set down the boom.

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1.4.7 Power Supply Failure

General

If the power supply fails, all movements are stopped. An

unintentional restart is not possible. When the diesel engine
comes to a standstill, the driven hydraulic pumps also stop. The
oil which is currently in circulation also comes to a standstill. As
soon as the control pressure reaches zero, all actuators return
spring−loaded to the zero position, regardless of the position of
the pilot control lever.

In the hydraulic circuits which are directly relevant to safety, there

is redundant braking of the winches and cylinders as a result of
the locked position or additional retaining brake.

Winches and cylinders

The oil column on the lever side of the winch motors and cylinders
is safeguarded by means of load−independent brake valves
(lowering brake valves). The winches and cylinders can no longer
be moved in the event of a failure to the power supply. The lower
brake valves are directly fitted to the winch motors and cylinders
(no hose lines).

As the described case is extremely seldom, there is no in−built

option for lowering a load on the hook. In this event the customer
service department must be informed.

If hoses or pipes should burst, therefore, there will be no

dangerous crane movements as a result.

In addition, in the case of a standstill the hydraulically actuated

disc brake of the slew gear is applied.

Driving the crane in the erect (configured) condition

When the crane is driven in the configured position, the load rests
on the suspension cylinders. These are not equipped with pipe
burst valves, in order to guarantee problem−free suspension
behaviour during driving of the crane. To avoid hazardous
situations, the regulations outlined in the operating instructions
for the crane chassis, section 6, ”Driving in the Configured
Condition” must be strictly observed.

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1.4.8 When Assembling and Dismantling Crane

Components

Although all possible protective and safety measures have

been provided, there is still a risk of crushing during
assembly and dismantling work.
To avoid these remaining dangers the following rules must
be observed.

In these operating instructions, the standard, normal assembly

sequence is described.

The equipment must be dismantled exactly in the reverse order

(unless otherwise described).

Crane equipment must under no circumstances be assembled

and dismantled by untrained personnel. This also applies to staff
providing temporary help.
Incorrect assembly can result in danger to life and limb.

As a result of the risk of slipping, stumbling and falling, it is

prohibited to walk on the boom and equipment − or parts thereof.
All assembly work is to be carried out with the help of suitable
accessories (ladders, hoist platforms, scaffolding, auxiliary crane
etc.). The assembling personnel must be sufficiently secured.
Furthermore access is only permitted to areas where there is no
risk of falling.

Exceptions are only permitted if access areas are provided.

This requires additional safety measures however.

Normal assembly prescribes that all component parts which are

transported separately are transported near to the ground with
suitable auxiliary cranes and lifting tackle (ropes) − and are safely
connected to the basic crane.

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Before assembly personnel approach suspended loads, for

example counterweights, outrigger struts, intermediate sections,
boom foot section and top pieces, luffing masts or fly jib, these
loads must be placed on the ground, on trestles or other supports
with sufficient load bearing capacity.

Persons in the vicinity of suspended loads are exposed to

the danger of being hit or crushed by loads swinging side-
ways.

During the assembly procedure, or at any other time, per-

sonnel must never walk or stand beneath loads, especially
before the load has been properly attached!

If, during assembly work, certain crane movements have to be

carried out, the crane operator must ensure that no−one is in the
hazardous area affected.

A load is properly attached when the suspended load is firmly

connected to the lowered component of the crane, e.g. following
fixation with the bolts of an intermediate section or the tightening
of all the bolts of a bolted connection to the prescribed tightening
torque etc.

A safe distance should be kept from unavoidable crushing

hazard points, in particular outrigger struts, between the
superstructure and crane chassis, cylinders, on the telescopic
boom and on the entire lattice mast fly jib, as long as a component
is suspended in the air during assembly and/or is not safely
secured and/or as long as the engine of the crane or the auxiliary
assembly crane is running.

Connecting bolts are always knocked in from the outside inwards

during the assembly of fly jibs, unless the operating instructions
expressly state otherwise.
Only when all bolts of a construction element have been driven
in is it possible to secure them with auxiliary bolts and clip pins.

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Connecting bolts may only be knocked out during the dismantling

of fly jib components or other parts when all individual
components are safely supported symmetrical to their centre of
gravity. The responsible site supervisor must make sure that,
before bolts are released, the procedure can be carried out
without any risk of unexpected falling or folding movements
being caused as a result. In case of doubt, a service specialist
from the crane manufacturer should be consulted.

In particular the knocking out of bolts must be carefully planned

and it must be ensured that no−one is standing inside the fly jib,
at risk of being crushed. The falling movement of a bolt which has
been knocked out, a released rope or another component must
be carefully planned and safeguarded.

Make sure that no tools are forgotten following the completion of

work. Falling or flung tools can cause risk to life and limb!

Often it is necessary to bridge limiters (e.g. limit switches) during

assembly and dismantling work. This can also lead to additional
hazards. The systems may therefore only be bridged if this is
required in the operating instructions for a certain piece of work.

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1.5 Hand Signals

If the crane operator cannot oversee the operation and working

direction (and/or hazardous areas) from the crane operator’s cab
(or driver’s cab), a spotter must be used.
This also applies if normal spoken communication is not possible
as a result of the increased noise level.

Only responsible and reliable persons who know the symbols

may be employed as spotters.

The spotter should be in a safe position, from where he can SEE

THE LOAD and can himself be clearly SEEN BY THE CRANE
OPERATOR.

The spotter must be easily recognisable for the crane operator.

The spotter should wear one or more suitable means of identifi-
cation e.g. jacket, helmet, collars, armbands, signalling discs.
These signs of identification must be in a distinctive colour and
uniform in design and must be worn exclusively by the spotter.

If the load is attached by several people, only one person may

give the signals. These must be made known to the crane oper-
ator.

If the crane operator does not fully understand a signal, he

should not carry out any movement with the crane. Before
commencing work the crane operator and spotter must work
out a signal for this scenario.

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1.5.1 General Hand Signals

(Z 26 024)

1. START
Attention, pay attention to the following signals

Arms stretched out horizontally sideways, palms of the

hands facing forwards.

2. STOP !
Interruption, end a movement

Right arm raised, palm of the right hand facing forwards.

3. END
of a movement

Hands folded at chest height.

4. DANGER !
Emergency stop

Both arms raised, palms of the hand facing forwards.

RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.

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1.5.2 Hand Signals for Working Movements

(Z 26 026)

1. RAISE load
Right arm raised, palm of the right hand facing forward,
moving slowly in a circle.

2. LOWER load
Right arm down, palm of the hand facing inwards, moving
slowly in a circle.

3. RAISE boom
Signal with one hand. Right arm stretched outwards, thumb
pointing upwards.

4. LOWER boom
Signal with one hand. Right arm stretched outwards, thumb
pointing downwards.

5. TELESCOPE OUT boom

Signal with both hands. Thumbs pointing outwards.

6. TELESCOPE IN boom
Signal with both hands. Thumbs pointing inwards.

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1.5.3 Hand Signals for Driving Movements

(Z 26 025)

1. Drive FORWARDS
Arms angled upwards; palms facing inwards; lower arms
making slow movements towards the body.

2. Drive BACKWARDS
Arms angled upwards; palms facing outwards; lower arms
making slow movements away from the body.

3. Drive to the RIGHT (seen from the spotter)

Right arm stretched out more or less horizontally, palm of the
right hand facing downwards, small movements in the
direction indicated.

4. Drive to the LEFT (seen from the spotter)

Left arm stretched out more or less horizontally, palm of the
left hand facing downwards, small movements in the
direction shown.

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 Structure of the Crane 2

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 2

2/39
16010

14180

”X”

1543 1830

max. 4000
2572 (14.00R25)
max.3000

Z 64 165

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 Structure of the Crane 2

2 Structure of the Crane

2.1 Technical Data

(Z 64 165, principle illustrations)

All dimensions and figures apply only to the standard design

(e.g. tyres 14.00 R 25).

Length of entire crane 14 180 mm (46.5 ft)

Length of entire crane with tag
16 010 mm (52.6 ft)
axle, optional (”X”)
Height of entire crane 4000 mm (13.1 ft)
Width of entire crane 3000 mm (9.8 ft)
Max. load capacity 140 t (308.6 kip) bei 3 m (9.8 ft) ra-
dius (with special equipment)
120 t (264.5 kip) bei 3 m (9.8 ft) ra-
dius (with additional equipment)
Max. main boom length 60 m (196.9 ft)
Max. system length with main boom
93 m (305.2 ft)
extension
Max. rope speed hoist 145 m/min (476 ft/min)
Drive motor, DaimlerChrysler OM 904 LA,
129 kW, (175 HP)
675 Nm (498 lbf−ft)
Operating voltage 24 V
Dimensions and weights of compo- You can find the data in the chapter
nents of the relevant component (e.g.:
Counterweight in sect. 9)

The dimensions in the figure opposite are reference values (see

also part 2, section 2 ”Crane chassis” under ”Technical Data”) .

You can find more technical data for possible optional equipment
in the section of the relevant component or in the appendix part
5 of this documentation.

The load capacity tables contained in the brochure are only for
information purposes.

Only the load capacity tables which are supplied with the
crane may be used for operation of the crane.

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2

7 3

6 4

Z 54 011

4/39 140−1020−228
 Structure of the Crane 2

2.2 Overview
(Z 54 011, principal drawing)

(1) Main boom

(2) Luffing cylinder

(3) Hoist gear 1

(4) Crane operator’s cab

(5) Crane chassis

(see part 2, chassis)

(6) Counterweight

(7) Hook block or hook suspension gear

140−1020−228 5/39
2

1 2 3

4 5

10 9 8 7 6

Z 64 166

6/39 140−1020−228
 Structure of the Crane 2

2.3 Superstructure
(Z 64 166, principle illustrations)

Superstructure side, right:

(1)− Diesel engine

(2) − Hydraulic pumps

(3)− Hydraulic oil tank

Superstructure side, left:

(4)− Main electrical unit, cab

(5)− Superstructure frame

(6)− Hydraulic control block

(7)− Diesel tank, capacity 234 l (61.8 US gal)

(for autom. tank fill−up, buffer tank 200 l / 52.8 US gal)

(8)− Batteries

(9)− Slew gear

(10)− Roller bearing slewing rim

The listed elements are for the most part only visible and accessi-
ble after opening/removing the corresponding cover.

140−1020−228 7/39
2

3
4

1d
2A

2b

1a
Z 54 013

1c

”X”

1b
1a Z 54 014

8/39 140−1020−228
 Structure of the Crane 2

2.4 Safety−Relevant Components

2.4.1 Ladders and safety harnesses/guards
(Z 54 013, Z 54 014; principle illustrations)

In addition to suitable and safe accessories provided, only

the ladders described may be used to access the super-
structure. There are sufficient gripping points to hold onto.
The catwalks are designed to be slip−free (sanding, chek-
ker plating etc.).

(1a) − Ladder, hinged

(1b) − Hanging ladder, mobile
Whenever the hinged ladders (1a) and the hanging ladders
(1b) are not being used or are to be transported, they must
be folded up and secured in the transport position. This is
shown on the following page in figure (Z 54 015) and descri-
bed in the text opposite.

(1c) − Ladder on the hydraulic oil reservoir, can be folded up or

down
(lock with spring bolt, see detail “X”, Z 54 014)
During slewing of the main boom extension from the trans-
port to the operating position or vice versa or when opera-
ting with a folded main boom extension, the ladder (1b) on
the hydraulic oil reservoir must always be folded against the
oil reservoir.
Risk of falling!
This ladder may only be used to carry out servicing− and re-
pair work. Proceed with appropriate caution!

(1d) − Ladder, integrated in the superstructure cover

2a/b − Platforms on crane operator’s cab
To allow the platform (2b) to be used across its full width, the
door of the crane operator’s cab must be closed.

3 − Grab rail
4 − Rail (in transport position)
Handling of the rail is described on the following page.

140−1020−228 9/39
2

1a

1a 1b
Z 54 015

4 12
”A”
1.
2.

11 12
”B”

Z 53 422

10/39 140−1020−228
 Structure of the Crane 2

Transport position of the mobile ladders

(Z 54 015, principle illustrations)

When they are not being used or are to be transported, the hin-
ged ladders (1a) and the hanging ladders (1b) must be placed in
the transport position, i.e. they must be laid on the crane chassis
and secured as shown in figure (Z 54 015).

Risk of accidents! Risk of damage!

If these ladders remain folded down in position and are
hanging or if they are not secured when in the transport po-
sition, it can cause unchecked changes to the positions
with the corresponding risks.

Using the rail on the superstructure frame

(Z 53 422, principle illustrations)

When climbing in the area closed in by the rail (4), after leaving
the corresponding ladder, the rail must immediately be folded
from the transport position (”A”) into position (”B”).

If this doesn’t happen, there is a risk of falling when walking

in this area due to the insufficient height of the rail!

To fold up, remove the locking bolt (11) and fold the hinged upper
section of the rail through 180° so that the guide pins (12) first
slide forwards (1st stage) and then downwards (2nd stage) up to
the stop.
The upper section of the rail folded into the vertical position then
remains safely in this position ”B” due to its own dead weight.

Immediately before leaving the area, fold down the upper part of
the rail again and secure. Otherwise the crane height of 4 m
(13.1 ft) is exceeded.
Proceed in the same way as when folding up the rail, only in the
reverse order.

When folding down the rail there is a risk of crushing bet-

ween the hinged and fixed part of the rail!
Proceed with appropriate caution!

140−1020−228 11/39
2

12/39 140−1020−228
 Structure of the Crane 2

2.4.2 Spotlights

Depending on the version, spotlights are mounted on the super-

structure:
− on the basic case of the main boom, electrically adjustable
from cab,
− on the front of the cab,
− on the back of the cab,
− in the engine compartment, automatically actuated by the
door contact switch.
− on the hydraulic crossbar on the main boom

2.4.3 Emergency exit

The front window of the superstructure can be opened wide to the

front. It is therefore suitable as an emergency exit.

140−1020−228 13/39
2

FAHREREINWEISUNG UND EXAKTES BEFOLGEN DER

BEDIENUNGSANLEITUNG SIND NOTWENDIGE VORAUS−
SETZUNG FÜR DEN SICHEREN KRANBETRIEB,DAHER
MUSS VOR DER INBETRIEBNAHME DES KRANES DIE
BEDIENUNGSANLEITUNG VOM KRANFÜHRER DURCH−
GEARBEITET UND VERSTANDEN WERDEN!

OPERATOR TRAINING AND STRICT OBSERVATION

OF THE OPERATING MANUAL ARE REQUIRED TO
ENSURE SAFE OPERATION. OPERATOR MUST
FULLY READ AND UNDERSTAND THE MANUAL
BEFORE USING THE CRANE! 2
LA FORMATION DE GRUTIER ET L’APPLICATION
EXACTE DU MODE D’EMPLOI SONT NECESSAIRES
POUR L’UTILISATION DE LA GRUE EN TOUTE
SECURITE. AINSI NOUS DEMANDONS AUX GRUTIERS
D’ETUDIER ET D’ASSIMILER IMPERATIVEMENT
LE MANUEL DE SERVICE AVANT LA MISE EN
ROUTE DE L’ENGIN!

Do not deface or remove this label from the machine.

512 216 40 Order replace labels from your T E R E X dealer.

Z 63 747

14/39 140−1020−228
 Structure of the Crane 2

2.5 Signs

Obtain all signs specified in the following and make sure

they are legible!

2.5.1 Signs in the Crane Operator’s Cab

(Z 63 747)

(1) − Warning plate: Slewing, telescoping and luffing prohibi-

ted without extended outriggers
(2) − Plate: Driver instructions and observation of the opera-
ting manual

140−1020−228 15/39
2

2 3

4 5

Z 64 143d

16/39 140−1020−228
 Structure of the Crane 2

2.5.2 Signs and Symbols on the Superstructure

(Z 64 143)

(1) − Warning plate: Hazardous area

(2) − Plate: Hydraulic oil (on the hydraulic oil tank)
(3) − Plate: Diesel (on the fuel tank)
(4) − Plate: Quick releases
(5) − Warning sign: Caution during welding work
(6) − Plate: 108 dB(A); Specification of the maximum sound
output level outside the cab

See the appendix after this section for signs in the corresponding
language.

140−1020−228 17/39
2

X Y

X Y 1

Y X

X Y
Z 50 675

Z 63 905 Z 63 910

18/39 140−1020−228
 Structure of the Crane 2

2.5.3 Signs on the Main Boom Extension

(Z 50 675, Z 63 905, Z 63 910)

(1) − Warning sign for stowing / assembly of main boom exten-

sion
(2) − Warning sign: Risk of crushing hands
(3) − Warning sign: Risk of crushing bodies

140−1020−228 19/39
2

FAHREREINWEISUNG UND EXAKTES BEFOLGEN DER

BEDIENUNGSANLEITUNG SIND NOTWENDIGE VORAUS−
SETZUNG FÜR DEN SICHEREN KRANBETRIEB,DAHER
MUSS VOR DER INBETRIEBNAHME DES KRANES DIE
BEDIENUNGSANLEITUNG VOM KRANFÜHRER DURCH−
GEARBEITET UND VERSTANDEN WERDEN!

OPERATOR TRAINING AND STRICT OBSERVATION

OF THE OPERATING MANUAL ARE REQUIRED TO
ENSURE SAFE OPERATION. OPERATOR MUST
FULLY READ AND UNDERSTAND THE MANUAL
BEFORE USING THE CRANE!

LA FORMATION DE GRUTIER ET L’APPLICATION

EXACTE DU MODE D’EMPLOI SONT NECESSAIRES
POUR L’UTILISATION DE LA GRUE EN TOUTE
SECURITE. AINSI NOUS DEMANDONS AUX GRUTIERS
D’ETUDIER ET D’ASSIMILER IMPERATIVEMENT
LE MANUEL DE SERVICE AVANT LA MISE EN
ROUTE DE L’ENGIN!

Do not deface or remove this label from the machine.

512 216 40 Order replace labels from your T E R E X dealer.

Z 63 746

20/39 140−1020−228
 Structure of the Crane 2

(Z 63 746)

(4) − Plate: Driver instructions and observation of the opera-

ting manual

140−1020−228 21/39
2

11

12

Z 62 492

13

Z 54 016

22/39 140−1020−228
 Structure of the Crane 2

2.5.4 Signs (optional)

Only for China

(Z 62 492)

(11) − Warning sign: Hazardous area (superstructure, left and

right side)
(12) − Warning plate, general (main boom, left and right side)

Only for Germany

(Z 54 016).

(13) − Plate: Operating regulations for cranes in accordance

with accident prevention regulations ”Cranes” (VBG 9)

140−1020−228 23/39
2

16

Z 63 729

17

Z 64 163

24/39 140−1020−228
 Structure of the Crane 2

Only for Dolly preparation (optional)

(Z 63 729, Z 64 163)

(16) − Warning sign in the crane cabin

(17) − Warning sign on the slew gear:

140−1020−228 25/39
2

20

Z 63 732

26/39 140−1020−228
 Structure of the Crane 2

Only for Russia

(Z 63 732)

(20) − Warning sign: High voltage

140−1020−228 27/39
2

1 1 12 9 7 4 3 2

11 10 1 7 8 6 5 1

6 5 7 1 1

1 7 1 6 5
Z 64 164

28/39 140−1020−228
 Structure of the Crane 2

2.5.5 Safety Signs (CE)

(Z 64 164)

Item Item no. Type of risk

1 511 675 98 Warning: Crushing / collisions
2 511 676 98 Warning: Dragging / entanglement
3 511 678 98 Warning: Risk of falling
4 511 684 98 Prohibited: Access prohibited
511 679 98 Warning: Risk of fireProhibited: Naked
5, 6
511 682 98 flames
Prohibited: Entry by unauthorised per-
7 511 683 98
sonnel
8 511 677 98 Warning: Crushing
9 511 680 98 Warning: Swinging load
10 511 685 98 Note: Fire extinguishers

The fire extinguisher supplied is located in the cab of the crane

chassis.

11 511 686 98 Note: First aid

First aid box − and other accessories in accordance with German

road traffic licensing regulations − must be taken by the crane
operator from the pallet supplied and placed in the cab of the
crane chassis.

12 512 150 98 Sign: CE

All safety instructions on the crane must be complete and in

legible condition.

140−1020−228 29/39
2

24
5 1 2,7,8,13,14 15 9 23 18 5

5
20
4

14,22 23 12 1 9 6 5 23 5 9 6 5

Z 60 288

12 12 11 25 5 5 11 24
25

10
4 11

25

5 6 25 5 25 18 9 6 5 12 1 20 16 26 1 9 9
19

Z 60 289

30/39 140−1020−228
 Structure of the Crane 2

2.5.6 Safety Signs (only USA)

(Z 60 288, Z 60 289, principle illustrations)

Each individual sign can be clearly identified thanks to the item

number on each sign. The individual signs are depicted on the
following pages.

All safety instructions on the crane must be complete and in

legible condition.

Item Item no. Figure no. Type of risk

1 178 722 12 Z 63 901 DANGER: Voltage (high)
2 178 702 12 Z 63 902 DANGER: Voltage
4 178 705 12 Z 63 904 Risk due to machines
5 178 706 12 Z 63 905 Risk of crushing hands
6 178 707 12 Z 63 906 Risk due to outriggers
7 178 708 12 Z 63 907 Warning before crane operation
8 178 709 12 Z 63 908 Warning: Raising persons
9 178 710 12 Z 63 909 RISK OF FALLING
10 178 711 12 Z 63 910 Risk of crushing bodies
11 178 712 12 Z 63 911 DANGER: Pulling in
12 178 713 12 Z 63 912 Fire hazard
13 178 714 12 Z 63 913 Crane operation
14 178 715 12 Z 63 914 Risk of tilting!
15 178 716 12 Z 63 915 Hand Signals USA
16 511 685 98 Z 63 916 Fire extinguisher

The fire extinguisher supplied is located in the cab of the crane

chassis.

140−1020−228 31/39
2

24
5 1 2,7,8,13,14 15 9 23 18 5

5
20
4

14,22 23 12 1 9 6 5 23 5 9 6 5

Z 60 288

12 12 11 25 5 5 11 24
25

10
4 11

25

5 6 25 5 25 18 9 6 5 12 1 20 16 26 1 9 9
19

Z 60 289

32/39 140−1020−228
 Structure of the Crane 2

Continued: Safety Signs (only USA)

(Z 60 288, Z 60 289, principle illustrations)

17 178 718 12 Z 63 917 Risk of combustion

18 178 719 12 Z 63 918 Warning: Blower
19 178 720 12 Z 63 919 DANGER: Pressure
20 178 721 12 Z 63 920 DANGER: Battery
22 178 727 12 Z 63 922 Risk to passenger
23 178 728 12 Z 63 923 Welding prohibited
24 178 729 12 Z 63 924 DANGER: Assembly work
25 179 564 12 Z 63 921 DANGER: Oil stream
26 511 686 98 Z 63 925 Note: First aid

First aid box − and other accessories in accordance with German

road traffic licensing regulations − must be taken by the crane
operator from the pallet supplied and placed in the cab of the
crane chassis.

140−1020−228 33/39
2

Z 63 901

Z 63 902

Z 63 904

34/39 140−1020−228
 Structure of the Crane 2

Z 63 905 Z 63 906

Z 63 907 Z 63 908

Z 63 909

140−1020−228 35/39
2

Z 63 910 Z 63 911

Z 63 912 Z 63 913

Z 63 914

36/39 140−1020−228
 Structure of the Crane 2

Z 63 915

140−1020−228 37/39
2

Z 63 916 Z 63 917

Z 63 918 Z 63 919

Z 63 920

38/39 140−1020−228
 Structure of the Crane 2

Z 63 922 Z 63 923

Z 63 924 Z 63 925

Z 63 921

140−1020−228 39/39
 Crane Operator’s Cab 4

140−1040−228 1/37
4

1 2 3 4 5 7 8 9 10 11

1 2 3
0 4

14
30 15
31 16
32

26
34 25
17
35 24
36
28 40

38 23 39

ÁÁ
ÁÁ
22
18 21
20

19 13
Z 64 170

2/37 140−1040−228
 Crane Operator’s Cab 4

4 Crane Operator’s Cab

4.1 Controls and Displays
(Z 64 170)

No. Element Designation Function

1 P 1212 Fuel gauge Revolution counter
2 P 1367 Fuel gauge Engine oil pressure
3 P 1351 Fuel gauge Engine temperature
4 P 3251 Fuel gauge Hydraulic oil temperature
5 P 0460 Fuel gauge Level fuel tank
7 A 5155 Timer Control of the engine−indepen-
dent heater
8 S 5152 Rotary switch Fan
9 R 5170 Rotary switch Thermostat
10 S 5183 Luminous switch Circulation on/off
11 S 5176 Luminous switch Air conditioning equipment on/off
13 Control unit Diesel particle filter (*)
14 Self−return rocker Precision control (%) for luffing
switch gear and hoist 1
15 Hoist rotation indi- Display: Hoist 1 rotating
cator
16 Control lever Hoist 1 / luffing gear (mode 1, for
control lever assignments, see
section 10)
17 Switch box Main electrical unit cab
18 Lever Release cab door
19 S 9333 Self−return rocker Extend/retract platform (no. 22)
switch

Risk of accidents!
As several variants can be selected for assignment of the lever using
the IC−1 (see section 10), it is the responsibility of the crane operator
to make sure he knows what the current function of the lever is before
he commences a crane movement.
Otherwise there is risk of accidents if accidental crane movements are
triggered!

(*) = Optional

140−1040−228 3/37
4

1 2 3 4 5 7 8 9 10 11

1 2 3
0 4

14
30 15
31 16
32

26
34 25
17
35 24
36
28 40

38 23 39

ÁÁ
ÁÁ
22
18 21
20

19 13
Z 64 170

4/37 140−1040−228
 Crane Operator’s Cab 4

Continued: Controls and Displays

(Z 64 170)

No. Element Designation Function

20 B 1251 Pedal Speed adjustment of the engine
21 B 8806 Pedal Slew gear brake
22 Step Cab entry / exit
23 S 7111 Foot switch Horn
24 Control lever Telescopic sections / slew gear
(mode 1, for control lever assign-
ments, see section 10)
25 Hoist rotation in- Display: Hoist 2 (*) rotating
dicator
26 Self−return rocker Precision control (%) for the slew
switch gear and hoist 2 (*)
28 Operating panel Radio / CD
30 Push button High range mode
31 Push button Precision control (%) for the luf-
fing gear and hoist 1 (together
with item 14)
32 Button Dead man’s switch
34 Push button w/o function
35 Push button Precision control (%) for slew
gear and hoist 2 (*), (together
with item 26)
36 Button Dead man’s switch

Risk of accidents!
As several variants can be selected for assignment of the lever using
the IC−1 (see section 10), it is the responsibility of the crane operator
to make sure he knows what the current function of the lever is before
he commences a crane movement.
Otherwise there is risk of accidents if accidental crane movements are
triggered!

(*) = Optional

140−1040−228 5/37
4

1 2 3 4 5 7 8 9 10 11

1 2 3
0 4

14
30 15
31 16
32

26
34 25
17
35 24
36
28 40

38 23 39

ÁÁ
ÁÁ
22
18 21
20

19 13
Z 64 170

6/37 140−1040−228
 Crane Operator’s Cab 4

Continued: Controls and Displays

(Z 64 170)

No. Element Designation Function

Warning light:
38 H 7116.1 − green Display of the state of the load
H 7116.2 − yellow limit device and the crane load
H 7116.3 − red
39 S 7924 Key−operated push- To bridge the load limit device
button (function only for crane control
software in accordance to
EN 13000)
(**)
40 Flashing lamp: Radio remote control operating
mode
H 7119 − blue (*)

(*) = Optional

(**) = To check whether the crane is equipped with control

software in accordance to EN 13000, select the “Crane
Information” display on the crane control. In this case there is a
corresponding note.

140−1040−228 7/37
4

24V

Á 42 43
Á
Á 41 44

47

45 48

46
51
49 52
50

Á
53
Á
54 Á
Z 64 172

8/37 140−1040−228
 Crane Operator’s Cab 4

(Z 64 172)

No. Element Designation Function

41 S 6540 Luminous switch Aircraft warning light
42 S 6421 Luminous switch Rotaflare light
43 S 1262 Luminous switch Dash board illumination
44 S 6130 Luminous switch Lighting equipment operating
range; front and rear of the cab

45 S 6211 Luminous switch Lighting equipment outrigger

area;
integrated on the crane chassis in
the covers
46 S 6140 Luminous switch Lighting equipment operating
range, can be adjusted electri-
cally;
fitted on the basic boom section,
left−hand side
47 S 6145 Luminous push- Adjustment of spotlight (item 46)
button
48 S 6120 Luminous switch Lighting equipment superstruc-
ture;
left−hand side to the rear (*)

49 S 5251 Luminous switch Roof window wiper, 2−level (inter-

mittent / continuous)
50 S 5261 Luminous push- Windscreen washing assembly
button
51 S 5253 Luminous switch Wiper, front, 2−level (intermittent /
continuous)
52 S 9310 Self−return rocker Tilt cab
switch
53 H 8040 Indicator light Release of the radio remote con-
trol (*)
54 S 8040 Key switch Release of the radio remote con-
trol (*)

(*) = Optional

140−1040−228 9/37
4

24V

24V
61 62 63 64
65 66

67 68

Z 56 990

10/37 140−1040−228
 Crane Operator’s Cab 4

(Z 56 990)

No. Element Designation Function

61 S 1260 Luminous touch Quick stop of the engine
contact
62 S 300 Ignition lock Engine start / engine stop
63 Adjustment knob Tilt adjustment of the monitor
64 Monitor Intelligent Control System (IC−1)
65 X 5453 Service socket Cigarette lighter and power supply
24V DC
66 X 5452 Service socket Power supply 24V DC
67 Service socket USB connection for crane control
68 Service socket Ethernet RJ45 CAT 5 − connec-
tion for crane control

140−1040−228 11/37
4

24V

71

74

75 76

78

Z 56 991

12/37 140−1040−228
 Crane Operator’s Cab 4

(Z 56 991)

No. Element Designation Function

71 S 9380 Luminous push- Raise / lower counterweight
button
red
74 S 0960 Luminous switch Unlock / lock superstructure lok-
red king device
75 S 8805 Luminous switch Release / block the slew gear
red brake (slew gear parking brake)
76 S 8817 Luminous switch Switchover slew gear: open / clo-
yellow sed circuit
78 S 1210 Luminous switch Engine chassis; START / STOP
green only when the ignition of the chas-
sis is in position ON

140−1040−228 13/37
4

24V

81 82 83 84 85

89
1
86 90
87
88

Z 56 992

14/37 140−1040−228
 Crane Operator’s Cab 4

(Z 56 992)

No. Element Designation Function

81 H 0451 Indicator light Battery charge indicator
82 H 1363 Indicator light Monitor engine oil level
83 H 1377 Indicator light Engine stop
84 H 1260 Indicator light Engine quick stop
85 H 1375 Indicator light Engine fault: if indicator light is il-
luminated, switch off the engine
and check
86 H 1355 Indicator light Fault chassis engine:
− Air filter clogged
− Engine malfunction
− Malfunction transmission
− Filter hydraulic oil
chassis clogged
87 H 1372 Indicator light Air filter check
88 H 0420 Indicator light Monitoring of the fuel level, war-
ning on “reserve”
89 H 3350 Indicator light Hydraulic oil filter control
90 H 3351 Indicator light Hydraulic oil temperature control

140−1040−228 15/37
4

24V

101 102

100

108 103

107 104

106 105
Z 56 993

16/37 140−1040−228
 Crane Operator’s Cab 4

(Z 56 993)

No. Element Designation Function

100 S 4331 Double key Outriggers complete,
retract / extend vertically
101 S 4316 Double key Outrigger front left,
retract / extend horizontally
102 S 4315 Double key Outriggers front right,
retract / extend horizontally
103 S 4319 Double key Front right jack,
retract/extend vertically
104 S 4321 Double key Outrigger rear right,
retract / extend vertically
105 S 4317 Double key Outrigger rear right,
retract / extend horizontally
106 S 4318 Double key Outrigger rear left,
retract / extend horizontally
107 S 4322 Double key Outriggers rear left,
retract / extend vertically
108 S 4320 Double key Outrigger front left,
retract / extend vertically

140−1040−228 17/37
4

24V

111

112

113

114

115
117
116

Z 56 994

18/37 140−1040−228
 Crane Operator’s Cab 4

(Z 56 994)

No. Element Designation Function

111 H 7924 Indicator light Configuration button activated
(function only within the EU with
software in accordance with
EN 13000); otherwise:
Load limit device bridged
112 S 7924 Key−operated Activate configuration button
pushbutton (function only within the EU with
software in accordance with
EN 13000); otherwise:
Bridge the load limit device (in-
stead of item 39)
113 H 7270 Indicator light Hoist limit switch bridged
114 S 7270 Key−operated Bridging of the hoist limit switch
pushbutton
115 H 7925 Indicator light Load−moment−reducing move-
ment “raise luffing gear” bridged
116 S 7925 Key−operated Bridging of the load−moment−re-
pushbutton ducing movement “raise luffing
gear”
117 S 0460 Luminous push- Refuelling pump (*)
button “tank fill−up from the chassis to
the superstructure”

(*) = Optional

140−1040−228 19/37
4

38

Z 64 171

20/37 140−1040−228
 Crane Operator’s Cab 4

Warning light
(Z 64 171)

Warning light’s (38) function is to indicate the load of the max.

permitted load moment also outside of the crane operator’s cab:
− Green: load moment in the permitted range (0% − 90%)
− yellow: load moment in the prewarning range (90% − 100%)
− red: overload (over 100%); load limit device switches off.

140−1040−228 21/37
4

”A” 3b

41

3c
”B” 42

22

43

44

Z 62 466

32 31
18
52

19
Z 52 910 Z 52 967

22/37 140−1040−228
 Crane Operator’s Cab 4

4.2 Entering / Exiting the Cab

(Z 62 466, Z 52 910, Z 52 967)

Depending on the position of the cab in relation to the crane

chassis, the cab is accessed using a ladder (43) or integrated
steps in the frame of the crane chassis.

To open the cab door from the outside use the lockable door
catch (41). The door lock is unlocked and the cab door can be
opened (or closed) using handle (42).
The two grips (3b) and (3c) inside the cab can be held onto.

To enter / leave the cab, platform (22) should be completely

extended. To retract and extend the platform, use rocker switch
(19).

In order to drive the crane the platform (22) must be

completely retracted (transport position).

Platform (44) at the front of the crane operator’s cab is foldable.

It should, where possible, be kept in the lowered position (”B”)
where it can be used as a step.

The opened cab door is locked in place when it reaches its end
position, to avoid it closing accidentally.
To close the cab door first press lever (18) lightly outwards. A
spring then releases the lock on the cab door. The door can then
be slid closed using handle (31).

Risk of crushing!
When closing the door, there is a risk of crushing between
the door and the cab frame. Therefore use the handles pro-
vided to avoid placing your hands in dangerous areas!
Also make sure that your hand is not trapped between the
handle (31) and grip (52) of the front window.

To open the cab door from the inside press lever (32) lightly
backwards. The cab door opens and can be pushed open using
handle (31).

140−1040−228 23/37
4

52

Z 52 911

24/37 140−1040−228
 Crane Operator’s Cab 4

4.3 Tilting the Cab

(Z 52 911)

To enable work with the crane to be followed more easily, the cab
can be tilted backwards using hydraulic cylinders (max. 18°).

Press self−return rocker switch (52) up − tilt cab forwards.

Press self−return rocker switch (52) down (on the symbol) − tilt
cab backwards.

There is a risk of crushing when tilting the cab!

Persons must stay clear of the hazardous area!

140−1040−228 25/37
4

9
8
7 4

6
Z 62 467

26/37 140−1040−228
 Crane Operator’s Cab 4

4.4 Workplace Ergonomics

4.4.1 Adjusting the Crane Operator’s Seat

(Z 62 467)

The crane operator is protected against mechanical vibrations by

means of a hydraulically dampened seat. In addition, the seat
can be adjusted individually to the weight of the individual crane
operator.

The seat offers infinite adjustment options for the seat height and
tilt, backrests and armrests. This enables the seat to be set to the
optimum operating position for every operator.

The seat can be adjusted infinitely variably using the following

equipment:
(1) − Control knob for angle adjustment of the arm rests

Risk of crushing!
The arm rests can be folded away. When folding down from
the upright into the horizontal position, there is a risk of
crushing between the armrest and the side console.
Proceed with caution!

(2) − Control knob for setting the lumbar support

(3) − Control element for adjusting the backrest
(4) − Bar for horizontal adjustment of the seat (without
console)
(5) − Control knob for weight adjustment
(6) − Bar for horizontal adjustment of the seat (with console)
(7) − Luminous switch seat heating on / off

After it is switched on, the seat heating is thermostat controlled,

i.e. it switches off and on automatically to maintain a certain
temperature, as long as the switch is switched to position “On”.
The integrated indicator light lights up.

(8) − Control element for adjusting the angle of the seat

surface
(9) − Control element for vertical adjustment of the seat.

140−1040−228 27/37
4

21

22

23

Z 52 960

31

Z 52 961

28/37 140−1040−228
 Crane Operator’s Cab 4

4.4.2 Sun Shield

(Z 52 960, Z 52 961)

The crane operator’s cab is fitted with roll−down sun visors on the
roof window, rear window and side window. These can be
lowered down to the desired level as required to avoid being
dazzled by the sun or the cab becoming too warm.

The window shade on the roof window can be moved backwards

and forwards as required on the corresponding flap (21).

The vertical window shades can be pulled down to the desired

position on the corresponding flap (23). Once the shade has
been pulled down to the required level, it stays in that position.
To roll the shade back up, pull it down slightly first using the lever
on the cord (22). The window shade is then rolled up fully.

The sun visor (31, Z 52 961) on the front window can be pivoted
around into different positions as required.

140−1040−228 29/37
4

41 42

Z 52 962

43

44

Z 52 963

30/37 140−1040−228
 Crane Operator’s Cab 4

4.4.3 Lighting equipment

(Z 52 962, Z 52 963)

The interior cab light (41) is located to the rear of the roof of the
cab and is actuated using switch (42).
Switch (42) has three possible positions:
− upper position (as shown in “Z 52 962”): Light OFF
− middle position: Light OFF
− bottom position: Light ON.

In addition there is a reading light in the right−hand corner of the

instrument panel (44, Z 52 963). It is fitted on a flexible arm (swan
neck) and can therefore be pivoted into any position within its
extension radius.
It is switched on and off on the light itself using switch (43).

140−1040−228 31/37
4

46

47.1

47

47.2

Z 52 964

32/37 140−1040−228
 Crane Operator’s Cab 4

4.4.4 Open / close window

4.4.4.1 Side window, rear window

(Z 52 964)

The side window (Z 52 964) which forms the upper part of the cab
door and the window in the rear wall of the cab are sliding
windows.

When closed, the catch (47) on the window element and the fixed
counterpiece (46) on the cab frame support are locked together.

To open the individual window press the catch on the gripping

piece together (47.2) as shown in figure (Z 52 964). The locking
nose (47.1) is lifted and the window element can be
closed/opened.

Risk of crushing!
When closing, there is risk of crushing between the window
element and the door / cab frame support. Only use the
handles provided to ensure that your hand does not get
caught!

140−1040−228 33/37
4

51
”A”
52.1

52.2

”B”

52
Z 62 468

34/37 140−1040−228
 Crane Operator’s Cab 4

4.4.4.2 Front window

(Z 62 468)

The front of the cab is fitted with a large front window.

When closed, the two handles (52) are in position (”A”). The
corresponding locking nose (52.2) is then in the transverse
position behind the fixed locking plate (52.1) on the cab frame.

To open the front window turn both handles inward by 90°. They
are then in position (”B”). Press the window element outwards
lightly with your hand. The window is then opened completely by
means of the two gas−operated positioners (51).

To close the window, the retaining pressure of the gas springs

must be overcome and handles (52) returned to position (”A”).

Risk of crushing!
When closing the window there is a risk of crushing bet-
ween the window element and the cab frame. Use the hand-
les provided to ensure that your hands are not caught in the
hazardous areas!

In case of emergency, the wide−opening front window can be

used as an emergency exit.

140−1040−228 35/37
4

61

62a

63

62b

Z 53 493

36/37 140−1040−228
 Crane Operator’s Cab 4

4.4.5 Storage
(Z 53 493).

There are a number of storage areas in the cab where things can
be put down:
− on top of the instrument panel
− behind the seat of the crane operator (e.g. for storing the
operating instructions)
− plastic elements (63) in the footwell, right−hand side
− ashtray (61) on the right−hand side panel and further ones in
the consoles of the control levers.
− fold−out cup holders (62a) and (62b) on the consoles
beneath the control levers.

These cup holders must be folded out to hold drinks

containers. This is shown for cup holder (62a) in the drawing.
When the cup holders are not needed, they should be folded
back in. This is shown for cup holder (62b) in the drawing
opposite.

140−1040−228 37/37
 Engine 5

5 Engine

The engine OM 904 LA is a six−cylinder engine with direct injec-

tion, exhaust turbocharger and charge air cooling. It has particu-
larly low pollutant emissions and has an electronic control system
(control devices and sensors).

Safety measures for engines with electronic control devices

The following safety measures must be observed, in order

to avoid injury to persons and damage to the engine, com-
ponents or cables.

− Only start the engine when the batteries are properly con-
nected. Never disconnect the batteries when the engine is
running.
− Only start the engine with the revolution pick−up fitted.
− Do not use a high−speed charger to start the engine.
Jump starting only permitted with separate batteries.
− For high−speed charging of the batteries, the battery clamps
must be removed. Follow the operating instructions for the
high−speed charger.
− In case of electric welding work, the batteries must be discon-
nected and the two cables “+” and “−” connected firmly to-
gether.
− The connections of the control devices may only be fitted and
removed when the electrical system is switched off.
− Reversal of the polarity for the supply voltage of the control
devices (e.g. reversal of the battery poles) can lead to the
control devices being destroyed.
− Tighten the connections on the injection system with the pre-
scribed tightening torque.
− With forecast temperatures of over 80° C / 176°F (e.g. dry fur-
naces) the control devices must be removed.
− For measurements on plug connections, use only suitable
test lines (connecting set of the engine manufacturer).
− Telephones and radios that are not connected to an outside
antenna can lead to malfunctions on the vehicle electronics
and can thus endanger the operational reliability of the en-
gine.

140−1050b_en 1/29
5

Cable channel 60X25X40.5 (30)

A0303
F1 25 A F8 25 A F15 10A F22 10 A F29

F2 10 A F9 15A F16 10 A F23 10A F30 10 A

F3 10 A F10 10A F17 10 A F24 10A F31 10 A

F4 10 A F11 10 A F18 10 A F25 10 A F32 10A

X1

X2

X3

X4

X5

X6
F5 10 A F12 10 A F19 10 A F26 10 A F33 ›2‹a

F6 10 A F13 10 A F20 F27 10 A F34 15A

(31)
F7 25 A F14 10A F21 10 A F28 25A F35 25A
A0513

Cable channel 60X25X31

V11 V22 K5 K10 K5 K10 25A
R16 R15
V10 V21 15A
R13 R14
V9 XV2 V20 X2 X2 10A
R11 R12
V8 V19 K4 K9 K4 K9 10A
R9 R10
V7 V18
10A

A0591

A0583
5a

A0561

A0564
X1 K3 K8 K3 K8
5a

17
V6 V17
R7 R8 5a
V5 V16
R5 R6
V4 V15 K2 K7 K2 K7
R3 R4 XV1 X1 X1
V3 V14
R1 R2
V2 V13
V1 V12 K1 K6 K1 K6

Cable channel 60X40X37 (29)

A0562 A0563

K3
X2
K6 K3
X2
K6
15 18 12 21
17a

(28)
K2 K5 K2 K5

A1157
ADM

Cable channel 73X49X23.5

X1 X1

K1 K4 K1 K4

17b
X0859
X0701 X0858
K8000

X0703 X0705
VOLTAGE CONVERTER

K0552 K0551
A0154

B5252 B5253

Z 54 700

85

Z 54 701

2/29 140−1050b_en
 Engine 5

5.1 Engine control/monitoring

(Z 54 700, Z 54 701)

Detailed information on this subject as well as fault codes

can be found in the operating instructions of the engine
manufacturer (see part 5 of these documents).
These must be observed in addition to the basic information
given below.

The engine is equipped with a fully electronic control system incl.

self−diagnosis, that, in addition to the engine and the corre-
sponding sensors, comprises the following components:
− MR−control device (direct on the engine)
− ADM adaptation module (17a) incl. FR−control device in the
area of the main electrical unit (17) in the crane operator’s
cab.

They are connected together by means of a CAN (Controller Area

Network) line, via which all necessary data / information can be
exchanged.

If the engine monitoring system recognises a fault, this is dis-

played (indicator light “85”, Z 54 701), saved in the control de-
vices as a fault code and evaluated.
Depending on the faults that occur, a safety or emergency pro-
gram can be activated.

Fault messages are read from a diagnosis device (to be con-

nected to the socket “17b”). Please contact our customer service
department in this regard.

The gravity of the fault can only be determined using the

diagnosis unit.
Thus: as soon as the indicator light (85, Z 54 701) lights up
indicating a motor fault, the motor must be shut down imme-
diately and the cause of the fault must be determined (to
avoid damage to the motor).
Operation of the crane is only permitted again once the fault
has been rectified.

Risk of accidents!
If this is not possible due to an existing hazardous situa-
tion, different engine running characteristics (emergency
running program) or possible engine damage are to be ex-
pected. Proceed with appropriate caution.

140−1050b_en 3/29
5

Z 53 438

4/29 140−1050b_en
 Engine 5

5.2 Starting

5.2.1 Before starting

(Z 53 438)

Before operating the engine for the first time, the operating
instructions of the engine manufacturer for the diesel engine
OM 904 LA must be observed. These can be found in section
5 of these documents.
The following information is limited to the factors that di-
rectly affect the crane.

1. Check before starting:

− the hydraulic oil level
− the engine oil level
− the coolant level.

To proceed, observe the corresponding sections of the mainte-

nance and lubrication instructions of the superstructure.

− the fuel level on the fuel gauge (5).

The indicating instrument (5) displays correctly when the

ignition is switched on.

140−1050b_en 5/29
5

81

62 62a
Z 54 702

23

20

Z 53 440

6/29 140−1050b_en
 Engine 5

5.2.2 Starting procedure

(Z 54 702, Z 53 440)

Before starting, check that all control levers are in the off
position.

1. Insert the ignition key in the “0” position in the ignition lock
(62) and turn clockwise up to the second notch.
After about 1 s, only the charge control lamp (81) is lit up.

The key−operated switch (62a) of the ignition lock is a four−

position switch:
− ”0” position: ”Off” position. The key can be removed in
this position.
− ”P” position: Parking position. Voltage supply for radio,
fan, aircraft warning light. The key can be re-
moved in this position.
− ”1” position: ”On” lock−in position. The ignition is
switched on.
− ”2” position: ”Start” switch position. The engine starts.

Before starting the engine or carrying out crane move-

ments the crane operator must actuate the horn using foot
switch (23), in order to warn persons who are in the vicinity
of the crane.

2. Place the setpoint sensor, i.e. pedal (20) in the idle position.

The engine speed can alternatively be adjusted using the

IC−1 control. This is described on the next page.

140−1050b_en 7/29
5

800

0.0

Z 54 703

81

Z 54 704

8/29 140−1050b_en
 Engine 5

(Z 54 703, Z 54 704)

To adjust the engine speed via the IC−1 control press the key
in the displayed “Quick Menu” mask (Z 54 703, left−hand
side). The “engine display” mask appears.

Here the engine speed can be regulated between maximum and

minimum by using the arrows or moving the slide control (1).
The current speed is displayed directly beneath the slide control
switch and additionally behind the corresponding symbol.

3. Turn the ignition key further up to the stop and hold in this
position until the engine starts. If required, stop the starting
procedure after max. 20 s and repeat again after approx.
60 s.
When the engine is running, the charge control light (81) must
go out.

Release the ignition key as soon as the engine starts. On no

account should the starter be operated with the engine run-
ning.
If the indicator light (81) does not go out, there is a fault in
the power supply.
The corresponding instructions in the operating instruc-
tions of the engine manufacturer must be observed.

140−1050b_en 9/29
5

Z 53 456

85

87

Z 54 705

10/29 140−1050b_en
 Engine 5

5.2.3 To be observed after starting

(Z 53 456, Z 54 705)

− Directly after starting, check the oil pressure on pressure

gauge (2).
The oil pressure is also displayed via the mask “engine dis-
play” of the IC−1. To call up this mask, observe the description
on page 9.
Do not rev up the engine if there is no oil pressure displayed.
If after 10 seconds no oil pressure is displayed, switch off the
engine and determine the cause of the fault.

When the operating temperature has been reached, the en-

gine oil pressure must not drop below the following values:
− 2.5 bar (36.3 psi) at rated speed
− 0.5 bar (7.3 psi) at idle speed.
If the pressure falls below these values, switch off the engine
and determine the cause of the fault.
− If the indicator light (85) lights up, there is an engine fault.

Switch off the engine immediately and determine the cause

of the fault (to avoid damage to the engine).
Operation of the crane is only permitted again once the fault
has been rectified.

Risk of accidents!
If this is not possible due to an existing hazardous situa-
tion, different engine running characteristics (emergency
running program) or possible engine damage are to be ex-
pected. Proceed with appropriate caution.

− If the indicator light (87) lights up, service the air filter (see
maintenance and lubrication instructions of the superstruc-
ture).

140−1050b_en 11/29
5

3 4

Z 53 457

82 85

89 90

Z 54 706

12/29 140−1050b_en
 Engine 5

(Z 53 457, Z 54 706)

− If indicator light (90) lights up, the hydraulic oil temperature

is too high.

Leave the diesel engine running at low revs so that the hy-
draulic oil can be cooled down via the oil cooler.
The round instrument (4, Z 53 457) should also be observed
in this respect. The hydraulic oil temperature must not exceed
approx. 85°C (185°F).
− If the indicator light (89) lights up, service the hydraulic oil filter
(see maintenance and lubrication instructions of the super-
structure).

This only applies when the hydraulic oil is at operating tempera-

ture.
At lower temperatures, it is possible that this lamp does not go out
for a short period, even though no fault is present.

− Observe the coolant temperature on round instrument (3).

The coolant temperature is also displayed via the mask “en-
gine display” of the IC−1. To call up this mask, observe the de-
scription on page 9.
If the maximum permitted temperature is exceeded, indicator
(85) lights up.

As soon as indicator light (85, Z 54 706) lights up and dis-

plays an engine fault, the engine must be switched off imme-
diately and the cause of the fault determined (to prevent
damage to the engine).
Operation of the crane is only permitted again once the fault
has been rectified.

− If the indicator light (82) lights up, check the engine oil level
(see operating instructions of the engine manufacturer).
The engine oil amount (%) is also displayed via the mask “en-
gine display” of the IC−1. To call up this mask, observe the de-
scription on page 9.

This display of the motor oil level (%) is only meant as addi-
tional information. The monitoring of the oil level may only
be done using the oil−level stick.
Depending on the version, it is possible that this display
function is not possible for technical reasons. The respec-
tive display at the IC−1 will then always be 0%.
If this is the case, the indicator light (82) is not displayed ei-
ther.

140−1050b_en 13/29
5

88
Z 54 707 Z 53 453

31

117

Z 54 708

14/29 140−1050b_en
 Engine 5

(Z 54 707, Z 53 453, Z 54 708)

− If the indicator light (88) lights up, fuel must be topped up; the
fuel level in the tank is down to reserve.
For the fuel level observe the fuel gauge (5).

Indicating instrument (5) displays the fuel level superstructure

tank. The indicating instrument (5) displays correctly when the
ignition is switched on.

Refuelling is normally carried out using the filling nozzle (31), ac-
cessible by using the ladder behind the cab.

Optionally, one can also fit the device with a fuel tank filling sys-
tem for filling the superstructure tank through the tank of the
crane chassis. The fuel tank filling system is operated using a lu-
minous pushbutton (117).

Information about filling the tank of the crane chassis can be

found in the operating instructions or in the crane chassis lubrica-
tion und maintenance instructions, part 4 of these operating in-
structions.

140−1050b_en 15/29
5

23

20

Z 53 440

16/29 140−1050b_en
 Engine 5

(Z 53 440)

− At extreme minus temperatures do not place the cold engine

under full load.

Before the engine can be operated under full load, the hy-
draulic oil must be warmed to operating temperature. Infor-
mation on warming up the hydraulic system can be found in
section 5.2.4 of these operating instructions.

Switch off the engine immediately if:

− the oil pressure falls or fluctuates violently.
− the output and speed falls without the position of pedal
(20) being changed.
− the exhaust is smoking heavily.
− the coolant and oil temperature climbs abnormally.
− abnormal noises suddenly occur in the engine or turbo-
charger.

140−1050b_en 17/29
5

2000000
1000000
500000
300000
200000
100000
Viskosität−Temperatur−Blatt
70000
50000 nach Prof. Ubbelohde
30000
20000 Temperaturachse: log(abs. Temperatur)
10000 Viskositätsachse: log(log(kin. Viskosität + 0,8))
7000
5000
4000
3000
2000
1500
1000

500
kinematische Viskosität [mm**2/s]

400
300

200
150

100
90
80
70
60
1
50 2
40

30
25 Tellus TX 46
20
18
16
14
12

10
9
8
7

5
4.5
4
Shell Tellus TX 32
3.5 V40: 32; V100: 6,5
Shell Tellus TX 46
3
V40: 46; V100: 8,4
Shell Tellus TX 68
2.5 V40: 68; V100: 11,4

2
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Öltemperatur [°C]

Z 59 740

18/29 140−1050b_en
 Engine 5

5.2.4 Warming up the hydraulic system

Warming up the hydraulic system is only required when:
− in relation to the ambient temperature the oil viscosity is bet-
ween 1000 and 1600 cSt (that means, with a standard hy-
draulic oil filling between −13°C and −18°C / +8.6°F and
−0.4°F, see Table)

and
− the hydraulic oil has cooled down to ambient temperature fol-
lowing a longer standstill (approximately 8 to 10 hours).

5.2.4.1 Hydraulic oil

(Z 59 740)

Make sure that, in relation to the oil temperature and visco-

sity, a suitable hydraulic oil is added. The corresponding oil
viscosity depends on the oil that is used.
Details can be obtained from the following Table.

Standard hydraulic oil fill for average temperatures

Oil tempe-
Oil viscosity Diesel engine
Shell Tellus TX 46 rature
(cSt) speed (rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idle speed)
min −13 / +8.6 1000
Operation (2) max
max +92 / +198 10

The conditions that are listed in the table must be observed.

Otherwise safe operation of the crane cannot be guaranteed
and hydraulic components could be damaged.

When using comparable oils, make sure that these corres-

pond to the recommended oils, especially with regard to the
listed characteristics.

140−1050b_en 19/29
5

2000000
1000000
500000
300000
200000
100000
Viskosität−Temperatur−Blatt
70000
50000 nach Prof. Ubbelohde
30000
20000 Temperaturachse: log(abs. Temperatur)
10000 Viskositätsachse: log(log(kin. Viskosität + 0,8))
7000
5000
4000
3000
2000
1500
1000

500
kinematische Viskosität [mm**2/s]

400
300

200
150

100
90
80
70
60
1
50 2
40

30
25 Tellus TX 46
20
18
16
14
12

10
9
8
7

5
4.5
4
Shell Tellus TX 32
3.5 V40: 32; V100: 6,5
Shell Tellus TX 46
3
V40: 46; V100: 8,4
Shell Tellus TX 68
2.5 V40: 68; V100: 11,4

2
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Öltemperatur [°C]

Z 59 740

20/29 140−1050b_en
 Engine 5

5.2.4.2 Warming up procedure

(Z 59 740)

1. Make sure, using the following table, that a correct hydraulic

oil is added in relation to the prevailing temperatures. The vi-
scosity of the oil must be below 1600 cSt.

2. Start the diesel engine.

The correspondingly permitted engine speeds are specified in

the following table.

Standard hydraulic oil fill for average temperatures

Oil tempe-
Oil viscosity Diesel engine
Shell Tellus TX 46 rature
(cSt) speed (rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idle speed)
min −13 / +8.6 1000
Operation (2) max
max +92 / +198 10

As soon as the diesel engine is running − first in idle −, the hydrau-

lic pumps are automatically started. In this way the hydraulic oil
circulates without pressure and heats up.

The hydraulic system must run itself warm until the viscosity of
the oil is below 1000 cSt.

With a running time of 30 minutes and approximately 1000 rpm

the hydraulic oil is warmed by 4° to 5°C (7° bis 9°F).

3. After this carry out all movements again after approximately

10 to 15 minutes without load. The warming up procedure is
then completed.

140−1050b_en 21/29
5

800

0.0
23
0

20

Z 53 440 Z 54 709

62 62a
Z 54 710

22/29 140−1050b_en
 Engine 5

5.2.5 Switching off

(Z 53 440, Z 54 709, Z 54 710)

1. Place the pedal for speed adjustment (20) in the ”idle” posi-
tion or set the corresponding speed on the ”engine display”
mask of the IC−1.
To call up this mask, observe the description on page 9.

After operating with full engine output or high coolant tem-

perature, leave the engine running without load for 1 − 2 min-
utes at idle speed.

2. Turn ignition key (62a, Z 54 710) anti−clockwise (to posi-

tion ”0”) and remove the ignition key.

When leaving the crane, remove the ignition key and lock the
cab.

140−1050b_en 23/29
5

61

84

Z 54 711

“X”

“B”

“A”

Z 54 092

24/29 140−1050b_en
 Engine 5

5.2.5.1 Motor Quick Stop (Emergency stop)

(Z 54 711)

The crane is equipped with a motor quick stop device. The motor
quick stop button (61) is built into the control panel in the super-
structure cab as standard.

Use the quick stop button (61) to switch off the engine only
in an emergency.
In this case, press the ”quick stop” button. It latches in
places in the activated position. Indicator light (84) lights up.
The previously pressed ”quick stop button” must first be re-
leased again before starting up the motor again. To this end,
turn the button slightly.

5.2.5.1.1 Motor Quick Stop (Optional)

(Z 54 092)

The crane can optionally be equipped with two motor quick stop
buttons. These are then to be found on the crane chassis on the
left and right in the outrigger controls area (“X”).

The functioning of both these motor quick stop buttons is assured

only when the parking brake is activated in the carrier cab and the
gear box is in “neutral”.

If the crane is equipped with an optional motor quick stop device,

“all motors” are switched off upon pressing one motor quick stop
button. The indicator light (84) lights up.
The flaps in the air intake channels of the motor are closed and
must be manually opened again before restarting the motor (le-
ver at the air intake channel).

Before restarting, the flap in the air inlet channel to the su-
perstructure engine must be opened manually by pulling the
chain.
If the air shut−off valve is closed, the engine must not be
started and can’t be started. Even one attempt at starting the
engine will lead to damage to the engine.
− “A” = flap open
− “B” = flap closed

140−1050b_en 25/29
5

›2‹a

− ›1‹a
+

›2‹b
›1‹b
+ −

3
Z 54 712

26/29 140−1050b_en
 Engine 5

5.3 Jump starting

(Z 54 712)

Observe the operating instructions for the crane chassis. Sec-

tion 5 “Engine”, sub−point “Jump starting with external batteries”.

140−1050b_en 27/29
5

Z 54 713

28/29 140−1050b_en
 Engine 5

5.4 Operating hour display (engine)

(Z 54 713)

The operating hour display is located in the bottom line of the ”en-
gine display” mask. To call up, use the key in the displayed
“Quick Menu” mask (Z 54 713, left−hand side).
Use the arrows or the slide control switch (1) to display the operat-
ing hours

5.5 Automatic driving

(Z 54 713)

With “automatic driving” the engine speed is automatically ad-

justed as the control lever is moved. This ensures comfortable
working processes as the engine speed does not need to be ad-
ditionally activated by the crane operator.

To activate “automatic driving” press key in the displayed

“Quick Menu” mask (Z 54 713, left−hand side). The “engine dis-
play” mask appears. Press button here. It is highlighted in
green.

To switch off “automatic driving” press key again. In the de-

activated state, the button is grey in colour.

5.6 Coolant preheating

Please see section 16 “Heating”.

140−1050b_en 29/29
 Supporting the Crane on Outriggers from the Superstructure Cab 7

7 Supporting the Crane on Outriggers from the Super-

structure Cab

Before supporting the crane on outriggers from the super-

structure cab, all procedural and health and safety instruc-
tions as outlined in section 12 “Outriggers”, part 2 must be
observed.

As a general rule, the outriggers should be set using the con-

trols in the outrigger control panels on the crane chassis.
(see section 12, part 2)
For subsequent levelling, however, it is possible to adjust
the outriggers from the superstructure cab.

This should only be done in exceptional cases and only when the
crane operator has a clear and unobstructed view of all outrigger
jacks.
(If necessary, a banksman should be used)

140−1070_en 1/3
7

101 102

100
74

108 103

75

107 104

106 105
Z 54 019

2/3 140−1070_en
 Supporting the Crane on Outriggers from the Superstructure Cab 7

(Z 54 019)

For additional (subsequent) levelling, proceed as follows:

− Slew the superstructure to the rear (see section 8 “Slewing the superstruc-
ture”) and, using button (74, S0960), lock the superstructure.
− Actuate the slew gear parking brake using button (75, S8805).

The outriggers are controlled using the following buttons:

Ite Element Designation Function

m
100 S 4331 Dual button All outriggers,
retract/extend vertically
101 S 4316 Dual button Front left jack,
retract/extend horizontally
102 S 4315 Dual button Front right jack,
retract/extend horizontally
103 S 4319 Dual button Front right jack,
retract/extend vertically
104 S 4321 Dual button Rear right jack,
retract/extend vertically
105 S 4317 Dual button Rear right jack,
retract/extend horizontally
106 S 4318 Dual button Rear left jack,
retract/extend horizontally
107 S 4322 Dual button Rear left jack,
retract/extend vertically
108 S 4320 Dual button Front left jack,
retract/extend vertically

Risk of crushing between the wheels and road surface when the crane
is lowered onto its wheels by retracting the outriggers.
Before lowering, make sure that this area is completely free of people.

The equipment may only be operated in areas where the crane operator
can see the outrigger jacks directly or via the mirrors. Check all mirror
positions before operating the outriggers.

140−1070_en 3/3
 Slewing the Superstructure 8

140−1080 1/23
8

74

75 76

Z 53 461

180°

Z 54 004

2/23 140−1080
 Slewing the Superstructure 8

8 Slewing the Superstructure

8.1 General
(Z 53 461, Z 54 004)

Depending on the preferred method of operation, the slew gear

can be operated optionally in the closed or in the open circuit.
− Luminous switch (76, Z 53 461) not activated (indicator light
in the switch does not light up) − closed circuit.

In a closed circuit, the speed of the slewing movement de-

pends directly on the movement of the corresponding control
lever. Therefore, it is possible
− to specifically decrease the slewing speed by taking the
control lever back or even
− to directly stop the slewing movement by taking the control
lever back into the neutral position.
− Luminous switch (76) activated (indicator light in the switch
lights up) − open circuit.
In addition, symbol appears next to symbol on
IC−1 display (Z 54 004).

In the open circuit, the torque of the slewing movement is not

stopped abruptly if the corresponding control lever has been
brought back into the neutral position. The movement slowly
runs its course and comes to a stop during freewheeling.
It is also possible to place the boom head in a vertical posi-
tion over the load without any problems.

140−1080 3/23
8

180

90 270

180° 0
360

Z 54 055

4/23 140−1080
 Slewing the Superstructure 8

(Z 54 055)

180° Before initiating a slewing movement, always take into consider-

ation the symbol with the details of the corresponding
slewing angle (here: 180°). The slewing angle indicates the
position of the superstructure to the crane chassis.
In this example (Z 54 055), the superstructure is in position 180°,
i.e. the superstructure (main boom) is aligned with the crane
chassis in the direction of the crane chassis cab.
In order to slew the superstructure to the 90° position, for exam-
ple, it would have to be slewed a quarter turn to the left (anti−
clockwise).

The symbol consists of two semicircle arrows with the fol-

lowing meanings:

− left−hand half of arrow − slew to the left

− right−hand half of arrow − slew to the right. .

140−1080 5/23
8

180

90 270

180° 0
360

Z 54 055

6/23 140−1080
 Slewing the Superstructure 8

(Z 54 055)

These directions relate to the movement which the crane opera-

tor carries out with the cab.

The colour of each arrow half indicates which slewing direction

the crane operator can even steer (slewing release):
− both arrow halves green: crane operator decides
left−hand arrow half green,
− only slewing to the left
right−hand arrow half red:
left−hand arrow half red,
− only slewing to the right
right−hand arrow half green:
− both arrow halves red: slewing not permitted

Risk of accidents!
It is prohibited to slew the superstructure if the counter-
weight has not been raised to its final position.

In this case, crane controls stops the slewing movement.

However, if crane control is bridged after a malfunction,
there risk still exists.
Determine cause of the fault immediately and rectify it.

Check regularly that the raised counterweight has not be-

come lowered (for example, in the case of extreme temper-
ature variations after the equipment has been idle for a lon-
ger period or because of leaks). If this has happened, raise
the counterweight completely.

140−1080 7/23
8

Z 53 468 Z 53 459

8/23 140−1080
 Slewing the Superstructure 8

Danger of tipping over!

(Z 53 468)
The superstructure can only be slewed if the crane is sup-
ported on outriggers in accordance with regulations.

(Z 53 459)
After the crane has been supported on outriggers and the
counterweight has been fitted, the existing outrigger sup-
port area must be inspected BEFORE the superstructure
may be slewed.

Take the details in the load capacity tables into consider-

ation. If the outrigger support area is reduced, only the
maximum permitted counterweight which is listed in the
load capacity table may be fitted.
If, despite this, larger counterweights are fitted, the super-
structure may not be slewed.

It is only permitted to slew the superstructure in the range

of reach for which load capacity values are still indicated
in the tables.

It is generally prohibited to slew the superstructure in the

overload range (load limit device has switched off).

Risk of accidents!
When slewing the superstructure, the following dangers
are present:
Risk of crushing in the area of the disconnecting point be-
tween the superstructure and the chassis.
Risk of crushing between the back end of the superstruc-
ture (counterweight) and obstacles in the vicinity.
Therefore persons must stay clear of the slewing range at
all times.

Do not slew over people. Do not jump in front of slewing

crane.

Risk of accidents!
If your crane is prepared for driving with a dolly (optional),
you must observe section 8.5 as well as the corresponding
passages in the operating instructions of the crane chas-
sis, part 2 − section 6 “Driving”.

140−1080 9/23
8

180°

Z 54 005

10/23 140−1080
 Slewing the Superstructure 8

8.2 Initiating a Slewing Movement

(Z 54 005)

In order to initiate a slewing movement, proceed as follows:

1. Support crane on outriggers in accordance with regulations

and align (see part 2, operating instructions of the crane
chassis, section 12 “Outriggers”).

2. Start the superstructure engine.

3. Check which mode has been selected for the assignment of

the control levers. The current mode (here: 1) is shown by the
display of the corresponding symbol in the top line of
the IC−1 display.

You will find detailed information on the selection and range of the
different modes in section 10 “Safety devices”.

Risk of accidents!
It is the crane operator’s responsibility to check the current
control lever assignment before initiating a crane move-
ment.
Otherwise, there is a risk of accidents if accidental crane
movements are initiated.

4. Raise main boom so that it cannot get caught by other crane

components (see section 13 “Luffing”).

140−1080 11/23
8

64

66

74

75 76

Z 53 461 Z 53 462

180°

21
Z 53 464 Z 54 005

12/23 140−1080
 Slewing the Superstructure 8

(Z 53 461, Z 53 462, Z 53 464, Z 54 005)

5. Release the mechanical superstructure locking device by

pressing luminous switch (74). The indicator light in the
switch lights up. The locking pin (64) is extended outwards
from the locking strip (66) into the position shown. In the top
line of the IC−1 display symbol must appear.
Each state of the superstructure locking device is displayed
using the following symbols:

Superstructure unpinned

Superstructure pinned

Red, fault in the superstructure pinning.

Slewing is only authorised if the locking pin is driven upwards in

accordance with regulations.

6. Release the lock on the slew gear parking brake by pressing

the luminous switch (75). The indicator light in the switch
lights up.

Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewheel-
ing. This can cause accidental slewing movements or inde-
pendent afterrunning of the superstructure due to wind or
oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (21).

140−1080 13/23
8

30 16

31
32
24
34

35
36

Z 54 006

14/23 140−1080
 Slewing the Superstructure 8

(Z 54 006)

7. Initiate slewing movement by pressing one of the buttons

(32/36) “dead man’s handle” and carefully moving the corre-
sponding control lever (16/24).

Control lever (16/24) to the right − slew to the right

Control lever (16/24) to the left − slew to the left.

You must take the current assignment of the control levers

into consideration.

In order to prevent accidental initiation of crane movements, both

control levers are equipped with an additional button (dead man’s
handle). A crane movement may only be carried out as long as
one of these buttons is pressed.
You may only activate (press as well as release) a dead man’s
switch if the corresponding control lever is in the “neutral position”
and/or the initiated working movement has been completed.

Risk of accidents!
Pressing / releasing one of these dead man’s switches
when the control lever is fully steered causes abrupt initia-
tion / braking of the corresponding movement.

Risk of accidents!
Only by adapting the acceleration or speeds of all crane
movements can you avoid that the load or the hook block
swings out, causing risk of crushing or crashing when
each movement is switched off.

Control levers (16/24) may not be switched to the opposite

slewing direction, but must first remain in the neutral posi-
tion. Slew the superstructure in the opposite direction only
when the superstructure has come to a standstill.

RISK OF DAMAGE!
Never initiate a slewing movement using the control lever
without first having unpinned the superstructure or released
the slew gear brake.

140−1080 15/23
8

74

75 76
21
Z 53 461 Z 53 464

30 16

31
32
24
34

35
36

Z 54 006

16/23 140−1080
 Slewing the Superstructure 8

8.3 Braking the Slewing Movement

(Z 53 461, Z 53 464, Z 54 006)

The slew gear has two braking systems:

− Slew gear parking brake
Static retaining brake, spring−loaded, for stopping / locking
the slew gear. This brake is activated using luminous switch
(75).
− Dynamic brake for braking / preventing slewing movements.
This brake is activated using pedal (21).

Slewing the superstructure is generally prevented using the slew

gear parking brake.
If luminous switch (75) has not been activated (indicator light in
the switch does not light up), the slew gear parking brake is
locked. Slewing is not possible.
If luminous switch (75) is activated (indicator light in the switch
lights up), the slew gear parking brake is not locked. Slewing is
possible by moving the control lever (16/24) if the dynamic brake
is not activated using pedal (21).

Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewheel-
ing. This can cause accidental slewing movements or inde-
pendent afterrunning of the superstructure due to wind or
oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (21).

140−1080 17/23
8

30 16

31
32
24
34

35
36

21
Z 54 006 Z 53 464

74

75 76

Z 53 461

18/23 140−1080
 Slewing the Superstructure 8

(Z 53 461, Z 53 464, Z 54 006)

In order to brake slewing movements, bring control lever (16/24)

slowly into the neutral position.
− in the closed circuit the slewing movement is directly brought
to a halt due to the fixed oil pillar.
However, due to external influences in connection with leak-
ing oil, gradual continued slewing movements can occur. This
is why you must also activate one of the slew gear brakes.
− in the open circuit the slewing movement gradually runs out.
If desired, it must be stopped using pedal (21). Then lock the
slew gear parking brake using the luminous switch (75).

The effect of the dynamic brake (activated using pedal “21”) is

identical for the open and closed circuits.

Risk of accidents!
Handle the slew gear and slew brake with care. Select low
slewing speeds. Brake carefully.
This is especially valid for operation with main boom exten-
sion or under special local conditions.

When the slew gear brake is released, the superstructure

can swing of its own accord if the crane is at an angle or un-
der the influence of wind forces. Maintain a safe distance
from buildings. If the crane is not supported on outriggers,
the slew gear brake must be locked.

Before leaving the crane operator’s cab, e.g. during work

breaks or at the end of work, the slew gear brake must be
locked. Press switch (75). The indicator light in the switch
must not light up.

140−1080 19/23
8

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

180°

Z 54 008

20/23 140−1080
 Slewing the Superstructure 8

8.4 Regulating the Slewing Speed

(Z 54 007, Z 54 008)

The slew gear is electrically pre−controlled. The slewing speed

depends on the engine speed and the movement of the corre-
sponding control lever (16/24).

In addition, it is possible to fine tune the slewing speed. To do so,

quickly press push button (31/35), i.e. the left−hand button on the
corresponding control lever. On the right−hand side of the IC−1
display the mask “Percentage display” (Z 53 466) will appear.
As long as this mask is displayed, the indicated percentage and
thereby the speed can be modified as follows:
− by using self−return rocker switch (14/26) on the correspond-
ing control lever if the movement is controlled by moving the
control lever horizontally (left / right).
− by using self−return rocker switch (14/26) and by pressing
push button (31/35) on the corresponding control lever at the
same time if the movement is controlled by moving the control
lever vertically (forwards / backwards).

The value is reduced or increased depending on whether the

self−return rocker switch is pressed to the left or right.

If there is no adjustment of the percentages, the mask disappears

again after 5 seconds.

Look out for low slewing speeds (lower scale region):− for
operation with loads > 30% of the load capacity
− with a long boom
− with a fitted main boom extension.

140−1080 21/23
8

64
65

65

65

62
63
Z 54 009

22/23 140−1080
 Slewing the Superstructure 8

8.5 Preparation for Dolly (Option)

(Z 54 009)

If your crane has been prepared for driving with a dolly, you must
follow the instructions in section 6 of the operating instructions of
the crane chassis (part 2 of these operation manual) under point
“Driving with Dolly”. This section describes how and when the set-
tings listed in the following should be made.

Risk of accidents!
The following conditions must be fulfilled for CRANE OP-
ERATION and for DRIVING WITHOUT DOLLY.

The shift rod (62) must be extended as far as possible, as

shown. The “B” position must be secured using padlock
(63).
The shift rod (62) in the inserted “A” position would mean
that multiple−disk brake of the slewing gear transmission
is blocked in an opened condition.
This could cause unchecked slewing of the superstructure
and to the crane tilting.

The locking pin (64) of the mechanical superstructure lock-

ing device may not be secured mechanically against ex-
tending with the use of fore lock (65). The fore lock must be
in the transport position as shown.

If these conditions are not fulfilled, operation of the crane is not

permitted.

Also observe the corresponding warning signs on the slew

gear and in both cabs (see also section 2.5 “Signs”).
Make sure that these signs are complete and are easily read-
able.

140−1080 23/23
 Counterweight 9

9 Counterweight

9.1 General

When planning a load case, the required counterweight

combination is determined using the load capacity tables. This
counterweight combination represents an important part of the
crane configuration, especially for safe operation of the crane.

The crane operator is responsible for making sure that the

required counterweight combination is actually fitted and that the
load limit device is set accordingly (via the IC−1). This is because
the control system does not monitor it.

The slewing radius of the superstructure from the centre of the

slew ring to the rear edge of the counterweight is 4.10 m (13.5 ft)
for all counterweight combinations.

Only counterweight combinations listed in this section

may be fitted. There is risk of damage and accidents if other
counterweight combinations are used!
In order to ensure exact fitting, only counterweight ele-
ments may be fitted which are marked with the construc-
tion number of the crane.

140−1090−103b 1/105
9

2/105 140−1090−103b
 Counterweight 9

9.2 Important Assembly Instructions

Risk of crushing!
When fitting and removing individual counterweight ele-
ments, there is a risk of crushing between the individual
counterweight elements, between the counterweight and
the superstructure frame as well as between the counter-
weight and the undercarriage (counterweight support)!
To avoid these risks, the safety instructions in section 1,
sub−point ”When Assembling and Dismantling Crane
Components” must be observed.
In particular, maintain a sufficient safety clearance!
The counterweight elements are set down on the crane
chassis with the help of an additionally trained person,
who, as an exception, is on the crane with the crane opera-
tor during this procedure. This person must leave the
crane and the area at risk immediately after the setting
down procedure has been completed.
The crane operator must be in constant visual contact with
this person and must make sure that there is no−one in the
hazardous area. Before the superstructure is slewed, the
crane operator must have made sure that this person has
left the crane and/or the endangered area.
When turning, there is a risk of crushing between the coun-
terweight and obstacles in the vicinity.
Persons must not stand or walk beneath suspended loads
or in areas where loads/equipment could fall.

RISK OF TIPPING!
If the outrigger support areas are reduced, the maximum
counterweight that may be fitted is the largest one as-
signed to the configuration as indicated in the table.
To do so, follow the corresponding details in the load ca-
pacity tables.
If a larger counterweight is fitted, there is a risk of tipping
backward during slewing.

140−1090−103b 3/105
9

min. 2o

Z 55 421

10

Z 55 422

4/105 140−1090−103b
 Counterweight 9

Risk of collision!
During the configuration of all counterweight combina-
tions and when turning the superstructure, there is a ”dan-
ger of collision” of the rear main boom drum with the coun-
terweight elements (Z 55 421), if the main boom was low-
ered to 0 beforehand.
Therefore, turning the superstructure is only permissible if
the main boom is lifted up at least 2 ” when the counter-
weight elements have been placed on the counterweight
platform of the crane chassis.
Otherwise the cable reel will be damaged.

ACCIDENTS MAY OCCUR.

All pins required for fastening the counterweight elements
to the superstructure frame and which will not be used de-
pending on the counterweight combination (in this case 0 t
/ 0 lbs), must be parked in the storage container on the left
side of the superstructure frame (Z 55 422).
The two fixing pins (930 mm / 3.05 ft) that are parked in the
transport position must be secured with a locking spring to
prevent them from jumping out of the rack.

9.3 Load Capacity Tables for Fitting and Removing the

Counterweight Elements

As a general rule, all counterweight elements can be fitted using

your own crane. To do so, the load capacity tables 0 t / 0 lbs
must be used and the load limit device must be set accordingly.

To fit, remove and modify the counterweight combination,

the crane must be supported on outriggers. Observe the
instructions in section 12 of the operating instructions of the
crane chassis.

Crane operation is only permitted when all required ele-

ments of the counterweight combination which corre-
spond to the details in the load capacity tables are fitted!
If this is not observed, the risk of accidents is increased!

140−1090−103b 5/105
9

10
Z 55 422

10
10 6

R L

6R
6L

1a
1a

Z 54 020 Z 54 021

6/105 140−1090−103b
 Counterweight 9

9.4 Counterweight Combination 0 t / 0 lbs

For the 0 t / 0 lbs counterweight combination, no counterweight

elements and no hoist 2 is required.

All pins needed for fastening the counterweight elements to the

superstructure frame are parked in the storage container in
transport position (Z 55 422) with counterweight combination 0 t
/ 0 lbs.

ACCIDENTS MAY OCCUR.

The two fixing pins (930 mm / 3.05 ft) that are parked in the
transport position must be secured with a locking spring to
prevent them from jumping out of the rack.

9.5 Counterweight Combination 6.3 t (13 900 lbs)

(Z 54 020, Z 54 021)

In the following you will see the depictions of the individual

counterweight combinations from the viewpoint of the crane
operator in the superstructure cab when setting down the
counterweights (here: Z 54 020) and when completed and fitted
on the superstructure frame (here: Z 54 021).

9.5.1 Components
(Z 54 020, Z 54 021)

The 6.3 t counterweight combination (13 900 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(10) − Single−hand locking pins (6x)

140−1090−103b 7/105
9

10

10

6L

6R

1a

5
”X”

1a

Z 54 034

8/105 140−1090−103b
 Counterweight 9

9.5.2 Fitting the Counterweight Combination 6.3 t

(13 900 lbs) to the Superstructure
(Z 54 034).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit the counterweight section (5) to the supporting surface
(”X”) on the jack.
3. fit sections (6 L + 6 R) on section (5).
4. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
5. Pin sections (6 L + 6 R) to the supporting consoles using
the single−hand locking pins (10) (3 x for each section).
6. Set down counterweight base plate (1a) with counterweight
section (5) back on the counterweight support of the chassis
(see section 9.17.3.2.2 “Manual Removal” from page 95, or
section 9.17.3.2.4 “Automatic Removal” from page 105).
7. Lift counterweight section (5) off the counterweight base
plate (1a) and set down safely on the ground.
8. Fit counterweight base plate (1a) for the last time
(see point 4. of this fitting sequence).

The fitting and removal sequences are described in detail in

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .

The counterweight sections 6L + 6R can remain pinned after the

first fitting to the superstructure frame.
When fitting further counterweight combinations as described in
the following, this step can be dropped in the fitting sequence.

140−1090−103b 9/105
9

10
10 6

R L

6R
6L

1b 1b
1a
1a

Z 54 022 Z 54 023

10/105 140−1090−103b
 Counterweight 9

9.6 Counterweight Combination 8.3 t (18 300 lbs)

9.6.1 Components
(Z 54 022, Z 54 023)

The 8.3 t counterweight combination (18 300 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(10) − Single−hand locking pins (6x)

140−1090−103b 11/105
9

10
10

6L

6R

1b
1a

5 ”X”

1b
1a

Z 54 035

12/105 140−1090−103b
 Counterweight 9

9.6.2 Fitting the Counterweight Combination 8.3 t

(18 300 lbs) to the Superstructure
(Z 54 035).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are both manufactured
from the same basic component. Make sure that you only
use 2 components marked with the same 5−digit serial
number (xxxxx−A + xxxxx−B).

3. Fit the counterweight section (5) to the supporting surface

(”X”) on the jack.
4. Fit sections (6 L + 6 R) to section (5).
5. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
6. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).
7. Set counterweight base plate (1a) with cover plate (1b) and
counterweight section (5) back on the counterweight support
of the chassis
(see section 9.17.3.2.2 “Manual Removal” from page 95, or
section 9.17.3.2.4 “Automatic Removal” from page 105).
8. Lift counterweight section (5) off of the counterweight base
plate (1a) and set down safely on the ground.
9. Fit counterweight base plate (1a) with cover plate (1b) for the
last time
(see point 5. of this fitting sequence).

The fitting and removal sequences are described in detail in

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .

140−1090−103b 13/105
9

10
10 6
6R
R L

5 9
5
6L

1b
1b 1a
1a

Z 54 024 Z 54 025

14/105 140−1090−103b
 Counterweight 9

9.7 Counterweight Combination 10.8 t (23 800 lbs)

9.7.1 Components
(Z 54 024, Z 54 025)

The 10.8 t counterweight combination (23 800 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (6x)

140−1090−103b 15/105
9

10

10

6L 6R

5
9

1b
1a

5 ”X”

1b
1a

Z 54 036

16/105 140−1090−103b
 Counterweight 9

9.7.2 Fitting the Counterweight Combination 10.8 t

(23 800 lbs) to the Superstructure
(Z 54 036).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (5) to the supporting surface (”X”)

on the jack.
4. Fit sections (6 L + 6 R) to section (5).
5. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
6. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

7. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail in

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .

140−1090−103b 17/105
9

10
10 6
9
R L 6R

5
4 10 5
4
6L

1b
1b 1a
1a

Z 55 380 Z 55 381

18/105 140−1090−103b
 Counterweight 9

9.8 Counterweight Combination 13.5 t (29 800 lbs)

“US−Variant / 1”

9.8.1 Components
(Z 55 380, Z 55 381)

The 13.5 t counterweight combination (29 800 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(4) − Counterweight section 2.63 t (5 800 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (9x)

140−1090−103b 19/105
9

10

10
6R
9 5
4

6L 10

1b
1a

6
5
4
”X”

1b
1a

Z 55 382

20/105 140−1090−103b
 Counterweight 9

9.8.2 Fitting the Counterweight Combination 13.5 t (29 800

lbs) to the Superstructure, ”US−Variant / 1”
(Z 55 382).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Set counterweight section (4) down safely on the ground. If

required, place strips of timber underneath.
4. Fit counterweight section (5) to section (4). Pin using
single−hand locking pins (10) (3x).
5. Fit both counterweight sections (4 + 5), which are now one
unit, to the supporting surface (”X”) on the jack.
6. Fit sections (6 L + 6 R) to section (5).
7. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
8. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

9. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 21/105
9

1b 2
1a 1b
1a

Z 55 383 Z 55 384

22/105 140−1090−103b
 Counterweight 9

9.9 Counterweight Combination 13.5 t (29 800 lbs)

“US−Variant / 2”

9.9.1 Components
(Z 55 383, Z 55 384)

The 13.5 t counterweight combination (29 800 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)

140−1090−103b 23/105
9

2
1b
1a

1b
1a

Z 55 385

24/105 140−1090−103b
 Counterweight 9

9.9.2 Fitting the Counterweight Combination 13.5 t (29 800

lbs) to the Superstructure, ”US−Variant / 2”
(Z 55 385).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 25/105
9

10
10 6
6R

R L

5 9
5
6L
2
2
1b
1b 1a
1a

Z 54 026 Z 54 027

26/105 140−1090−103b
 Counterweight 9

9.10 Counterweight Combination 18.8 t (41 400 lbs)

9.10.1 Components
(Z 54 026, Z 54 027)

The 18.8 t counterweight combination (41 400 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (6x)

140−1090−103b 27/105
9

10

10

6R
6L

5
9

2
1b
1a

5 ”X”

2
1b
1a

Z 54 037

28/105 140−1090−103b
 Counterweight 9

9.10.2 Fitting the Counterweight Combination 18.8 t

(41 400 lbs) to the superstructure
(Z 54 037).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Set down the counterweight section (2) on the cover plate

(1b).
4. Fit the counterweight section (5) to the supporting surface
(”X”) on the jack.
5. Fit sections (6 L + 6 R) to section (5).
6. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
7. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

8. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail in

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .

140−1090−103b 29/105
9

10
10 6
6R
9
R L

5 5
4 10 4
6L
2 2
1b
1b 1a
1a

Z 54 028 Z 54 029

30/105 140−1090−103b
 Counterweight 9

9.11 Counterweight Combination 21.4 t (47 200 lbs)

9.11.1 Components
(Z 54 028, Z 54 029)

The 21.4 t counterweight combination (47 200 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(4) − Counterweight section 2.63 t (5 800 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (9x)

140−1090−103b 31/105
9

10
10
6R
9 5
4

6L 10
2
1b
1a

6
5
4
”X”
2
1b
1a

Z 54 038

32/105 140−1090−103b
 Counterweight 9

9.11.2 Fitting the Counterweight Combination 21.4 t

(47 200 lbs) to the Superstructure
(Z 54 038).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Set counterweight section (4) down safely on the ground. If
required, place strips of timber underneath.
5. Fit counterweight section (5) to the section (4). Pin using
single−hand locking pins (10) (3x).
6. Fit both counterweight sections (4 + 5), which are now one
unit, to the supporting surface (”X”) on the jack.
7. Fit sections (6 L + 6 R) to section (5).
8. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
9. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

10. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 33/105
9

3
2
3
2
1b
1b
1a 1a

Z 55 386 Z 55 387

34/105 140−1090−103b
 Counterweight 9

9.12 Counterweight Combination 23.2 t (51 200 lbs)

“US−Variant”

9.12.1 Components
(Z 55 386, Z 55 387)

The 23.2 t counterweight combination (51 200 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)

140−1090−103b 35/105
9

3
2

1b
1a

3
2

1b
1a

Z 55 388

36/105 140−1090−103b
 Counterweight 9

9.12.2 Fitting the Counterweight Combination 23.2 t (51 200

lbs) to the Superstructure, ”US−Variant”
(Z 55 388).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 37/105
9

10
10
6

L 6R
R

6L 3
3
2 2
1b
1b 1a
1a

Z 55 389 Z 55 390

38/105 140−1090−103b
 Counterweight 9

9.13 Counterweight Combination 25.8 t (56 900 lbs)

“US−Variant”

9.13.1 Components
(Z 55 389, Z 55 390)

The 25.8 t counterweight combination (56 900 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(10) − Single−hand locking pins (6x)

140−1090−103b 39/105
9

10

10

9 6R

3
6L 2

1b
1a

2
1b
1a

Z 55 391

40/105 140−1090−103b
 Counterweight 9

9.13.2 Fitting the Counterweight Combination 25.8 t (56 900

lbs) to the Superstructure, ”US−Variant”
(Z 55 391).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Fit sections (6 L + 6 R) to section (3).
6. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
7. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 41/105
9

5 5
4 10
4
3 3
2 2
1b
1b 1a
1a

Z 55 392 Z 55 393

42/105 140−1090−103b
 Counterweight 9

9.14 Counterweight Combination 28.4 t (62 600 lbs)

“US−Variant”

9.14.1 Components
(Z 55 392, Z 55 393)

The 28.4 t counterweight combination (62 600 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)
(4) − Counterweight section 2.63 t (5 800 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (3x)

140−1090−103b 43/105
9

4
10
3

2
1b
1a

5
4
3

1b
1a

Z 55 394

44/105 140−1090−103b
 Counterweight 9

9.14.2 Fitting the Counterweight Combination 28.4 t (62 600

lbs) to the Superstructure, ”US−Variant”
(Z 55 394).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Fit counterweight section (4) to section (3).
6. Fit counterweight section (5) to section (4). Pin using
single−hand locking pins (10) (3x).
7. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).

8. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55.

140−1090−103b 45/105
9

10
10 6
6R
9
R L

5
5
4 10
6L 4
3 3
2 2
1b
1a
1b
1a

Z 54 030 Z 54 031

46/105 140−1090−103b
 Counterweight 9

9.15 Counterweight Combination 31.0 t (68 300 lbs)

9.15.1 Components
(Z 54 030, Z 54 031)

The 31.0 t counterweight combination (68 300 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)
(4) − Counterweight section 2.63 t (5 800 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (9x)

140−1090−103b 47/105
9

10

10
6R
9
5
4

6L
3 10
2
1b
1a

6
5
4
3
2
1b
1a

Z 54 039

48/105 140−1090−103b
 Counterweight 9

9.15.2 Fitting the Counterweight Combination 31.0 t

(68 300 lbs) to the Superstructure
(Z 54 039).

Fitting with your own crane

1. Set down counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured form
the same basic component. Make sure that you use 2
components with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to thecover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Fit counterweight section (4) to section (3).
6. Fit counterweight section (5) to section (4). Pin using
single−hand locking pins (10) (3x).
7. Both counterweight sections (4 + 5) are now one unit.
8. Fit sections (6 L + 6 R) to section (5).
9. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
10. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

11. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

The fitting and removal sequences are described in detail in

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .

140−1090−103b 49/105
9

7L

7R
3
2
1b
1a

Z 55 395

7R

7L
3 2 1b
1a

Z 55 396

50/105 140−1090−103b
 Counterweight 9

9.16 Counterweight Combination 31.0 t (68 300 lbs)

“US−Variant”

9.16.1 Components
(Z 55 395, Z 55 396)

The 31.0 t counterweight combination (68 300 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)
(7) − Counterweight saddle L/R 4.01 t (8 845 lbs)

140−1090−103b 51/105
9

7R

7L
3 2 1b
1a

3
2
1b 7
1a

Z 55 397

52/105 140−1090−103b
 Counterweight 9

9.16.2 Fitting the Counterweight Combination 31.0 t (68 300

lbs) to the Superstructure, ”US−Variant”
(Z 55 397).

Fitting with your own crane

1. Set down the counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Hang saddle weight (7 L + 7 R) into the counterweight
section (3) on the left− and right−hand side with both hooks
in the corresponding cast−iron pins.
6. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).

140−1090−103b 53/105
9

10
10
9
6L
6R
5
4
10
7L

7R
3
2
1b
1a
Z 54 032

6R

7R
6L

7L 1b
5 4 3 2 1a

Z 54 033

54/105 140−1090−103b
 Counterweight 9

9.17 Counterweight Combination 39.0 t (86 000 lbs)

9.17.1 Components
(Z 54 032, Z 54 033)

The 39.0 t counterweight combination (86 000 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)
(3) − Counterweight section 9.65 t (21 280 lbs)
(4) − Counterweight section 2.63 t (5 800 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(7) − Counterweight saddle L/R 4.01 t (8 845 lbs)
(9) − Pins with clip pins (2x)
(10) − Single−hand locking pins (9x)

140−1090−103b 55/105
9

10

10
6R
9
7R

6L
10
7L
1b
3 2 1a
5 4

6
5
4
3
2
1b 7
1a

Z 54 040

56/105 140−1090−103b
 Counterweight 9

9.17.2 Fitting the Counterweight Combination 39.0 t

(86 000 lbs) to the Superstructure
(Z 54 040).

Fitting with your own crane

1. Set down counterweight base plate (1a) on the

counterweight support of the chassis.
2. Fit cover plate (1b) to the counterweight base plate (1a).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).

3. Fit counterweight section (2) to the cover plate (1b).

4. Fit counterweight section (3) to section (2).
5. Fit counterweight section (4) to section (3).
6. Fit counterweight section (5) to section (4). Pin using
single−hand locking pins (10) (3x).
7. Both counterweight sections (4 + 5) are now one unit.
8. Hang saddle weight (7 L + 7 R) into the counterweight
section (3) on the left− and right−hand side with both hooks
in the corresponding cast−iron pins.
9. Fit sections (6 L + 6 R) to section (5).
10. Proceed with fitting of the counterweight combination
(see section 9.17.3.2.1 “Manual Fitting” from page 77, or
section 9.17.3.2.3 “Automatic Fitting” from page 97).
11. Pin sections (6 L + 6 R) to the supporting consoles using
single−hand locking pins (10) (3x for each section).

12. Pin counterweight section (5) to the superstructure frame

using 2 pins (9) and secure using clip pins (∅ 5 mm).

140−1090−103b 57/105
9

Z 54 041

58/105 140−1090−103b
 Counterweight 9

9.17.3 Fitting and Removal of the Counterweight

Combination
39.0 t (86 000 lbs)

The fitting procedure consists of two processes which follow

each other:
− setting down the counterweight combination on the crane
chassis (see section 9.17.3.1 from page 61).
− fitting and removal of the counterweight combination onto
and from the superstructure frame (see section 9.17.3.2,
from page 73).

All counterweight sections and saddle weights are always

marked (Z 54 041) with:

− Item no.
− Counterweight weight in kg / lbs
− Manufacturer ’s details

− Crane construction number

140−1090−103b 59/105
9

0.0

7.50
15

Z 54 042

60/105 140−1090−103b
 Counterweight 9

9.17.3.1 Setting Down the Counterweight Combination on the

Crane Chassis
(Z 54 042).

1. Support the crane on outriggers and align. Select the

outrigger support area in accordance with the subsequent
crane operation.

RISK OF TIPPING!
If outrigger support areas are reduced, the maximum coun-
terweight that may be fitted is the largest one in the table
which corresponds to the configuration.
To do so, follow the corresponding details in the load ca-
pacity tables.
If a larger counterweight is fitted, there is a risk of tipping
backward during slewing.

2. Drive up counterweight element (s) on the low−loader up to

the crane.

3. Set the load limit device to the current load case. In order to
fit the counterweight elements the 0 t / 0 lbs tables must be
used.

You will find a detailed description on how to set the load limit
device to the current crane configuration via the mask for
operating mode preselection (Z 54 042) in section 10 “Safety
Devices”.
You will find a short description in this section from page 91.

140−1090−103b 61/105
9

17

18

1a 19

Z 54 043 Z 54 044

Z 54 045

62/105 140−1090−103b
 Counterweight 9

(Z 54 043, Z 54 044, Z 54 045)

4. Using your own crane, attach counterweight base plate
3.66 t / 8 060 lbs (1a, Z 54 043) with 4 falls at the relevant
attachment points and position over the counterweight
support of the crane chassis (Z 54 044).
In this position (Z 54 045, principle depiction), the area of the
counterweight support is directly in front of the
superstructure cab on the crane chassis.

140−1090−103b 63/105
9

11
22
22 1b

1a

Z 54 046 Z 54 047

33
33 3
44
34 44 4

34

Z 54 048 Z 54 049

64/105 140−1090−103b
 Counterweight 9

(Z 54 046, Z 54 047, Z 54 048, Z 54 049)

RISK OF ACCIDENTS!
You must take the safety instructions listed in the following
into consideration when attaching the counterweight ele-
ments!

All counterweight elements must be attached in the prescribed

attachment points. The attachment points are designed for the
individual max. dead weight of the counterweight elements. The
attachment points may not be loaded more than this. They are as
follows:
− Hanging hook (11) on the base plate (1a, Z 54 046).
− Hanging hook (22) on the cover plate (1b, Z 54 047).
− Pins (33) which are cast into cast−iron components, e.g. in
the counterweight section (3, Z 54 048).
− Bollards (34) which are cast into cast−iron components,
e.g. in the counterweight section (3, Z 54 048).
− Hanging eyelets (44) which are cast into cast−iron compo-
nents (44), e.g. in the counterweight section (4, Z 54 049).

Only use load handling attachments which are suitable for

the counterweight elements to be raised and are sufficiently
dimensioned.
It is especially important that only flat lifting slings made of
plastic are used for hanging for the cast bollards.

Make sure that the attached counterweight element is not

crooked and does not swing out.

The attachment points are designed for the dead weight of

the counterweight elements. Only individual elements may
be attached.
The exceptions are the counterweight base plate and the
cover plate as one unit and the counterweight sections
(4 + 5), which form a unit when pinned together (see sec-
tion 9.11.2., page 33).
If this is not adhered to, risk of accidents is increased!

140−1090−103b 65/105
9

17

18

19

Z 54 044 Z 54 050

18

1a

19
Z 54 051

66/105 140−1090−103b
 Counterweight 9

(Z 54 044, Z 54 050, Z 54 051)

A trained assembly assistant must get on the crane chas-

sis in order to align and remove the counterweight ele-
ments (Z 54 050). He should get on by climbing up one of
the hinged ladders on the left− or right−hand side of the
chassis.
There is risk of crushing between the counterweight sec-
tion and the crane chassis and between the individual
counterweight elements! Proceed with appropriate cau-
tion! Maintain a sufficient safety clearance. Stay in the area
between the set down counterweight and the cab of the
crane chassis.
Persons must not stand or walk beneath suspended loads
or in areas where loads/equipment could fall.
If these instructions are not followed, the risk of accidents
is increased!

5. Position the base plate (1a) over the counterweight support

so that both spigots (18) are flush with the corresponding
central holes on the bottom of the base plate.
Then lower the base plate so that it is level on the
counterweight support. Spigots (18) determine the correct
position of the base plate (Z 54 044, Z 54 050).

A spigot (19) are needed for removing the combination base

plate (1a) with cover plate (1b). It helps to centre things when the
unit is removed.
The rear holders (17) protect bordering components from
damage when the counterweight sections are set down.

140−1090−103b 67/105
9

6R 6L

7L
4
7R

3
2

1b

1a

13

Z 54 052

68/105 140−1090−103b
 Counterweight 9

6. As the base plate (1a) 3.66 t / 8 060 lbs is now fitted to the
crane chassis, all other counterweight sections are fitted to
this one or hung onto the side saddle weights one by one.
To do so, proceed as follows: (Z 54 052).

Risk of accidents! Risk of crushing!

There is risk of crushing between the counterweight sec-
tion and the crane chassis and between the individual
counterweight elements! Proceed with appropriate cau-
tion.
Take special care to follow all safety instructions listed pre-
viously in this section for attaching / removing the counter-
weight elements!

6.1 Using your own crane, attach cover plate (1b) 1.66 t /
4 390 lbs with 4 falls and position over the already
removed base plate (1a).
Lower cover plate (1a). Make sure that the draw bars
(13) are within the grooves of the cover plate (1b).

6.2 Using your own crane, attach counterweight section

(2) 7.92 t / 17 455 lbs with 4 falls and position over the
already removed cover plate (1b).

Lower section (2). Make sure that the draw bars (13)
are within the grooves of the section (2).

6.3 Using your own crane, attach counterweight section

(3) 9.65 t / 21 280 lbs with 4 falls and position over the
already removed section (2).

Lower section (3). Make sure that the draw bars (13)
are within the grooves of the section (3).

6.4 Using your own crane, attach counterweight section

(4) 2.63 t / 5 800 lbs lbs with 4 falls and position over
the already removed section (3).

Lower section (4). Make sure that the spigots of the

section (3) dip into the centre holes on the bottom of
the section (4).

140−1090−103b 69/105
9

6R 6L

7L
4
7R

3
2

1b

1a

13

”X”
Z 54 053

70/105 140−1090−103b
 Counterweight 9

(Z 54 053).

6.5 Using your own crane, attach counterweight section

(5) 2.59 t / 5 700 lbs with 4 falls and position over the
already removed section (4).
Lower section (5). Make sure that the spigots of the
section (4) dip into the centre holes on the bottom of
the section (5).
Using single−hand locking pins (3x), pin the section (5)
to section (4).

6.6 Using your own crane, attach one of the two

counterweight sections (6L / 6R) 1.295 t / 2 855 lbs
with 2 falls and position over the section (5) which has
already been set down.
Lower section (6L / 6R). Make sure that the spigots of
section (5) dip into the centre holes on the bottom of
the section (6L / 6R).
Proceed as previously described in order to fit the
second section.

6.7 Using your own crane, attach one of the two saddle
weights (7L / 7R) 4.01 t / 8 845 lbs with 3 falls and
position at the side of the counterweight section (3).
Hang saddle weight (7L / 7R) with both hooks in the
corresponding pins onto section (3).
Make sure that the hooks lie securely on the pins.
Proceed as previously described to hang the second
saddle weight.

If these two exterior saddle weights have been hung, the

procedure of setting down the desired counterweight
combination 39.0 t (86 000 lbs) onto the counterweight support
(see detail “X”) has been completed.

Make sure that all counterweight elements are correctly

fitted or attached.

Risk of accidents! Risk of crushing!

After the desired counterweight stack has been set down
onto the counterweight support of the crane chassis, the
assembly assistant must leave the crane and the endan-
gered area. He should leave by using one of the hinged lad-
ders on the left−hand or right−hand side of the chassis.
Only then can the fitting procedure be continued as de-
scribed on the following pages.

140−1090−103b 71/105
9

180°

Z 54 054

min. 2o

Z 55 421

72/105 140−1090−103b
 Counterweight 9

9.17.3.2 Fitting and Removing the Counterweight

Combination on the
Superstructure Frame

Requirements

− desired counterweight combination must be set down as

described in section 9.17.3.1 “Setting down the
Counterweight Combination on the Crane Chassis”, from
page 61.
− the crane operator has made sure that no−one is on the
superstructure or in the endangered area.

Risk of accidents! Risk of crushing!

If these instructions are not followed, there is risk of crush-
ing as soon as a slewing movement is introduced.

Proceed as follows if these requirements are fulfilled:

(Z 54 054).
1. Call up mask (Z 54 054) on the monitor of the IC−1. It
appears after the ignition has been switched on and
confirmation of enquiry for the current configuration
(operating mode selection) has been called up automatically
or by corresponding navigation.
For detailed information see section 10 “Safety Devices”.

The relevant keys or display areas are marked in the individual

figures.

Risk of collision!
During the configuration of all counterweight combina-
tions and when turning the superstructure, there is a ”dan-
ger of collision” of the rear main boom drum with the coun-
terweight elements (Z 55 421), if the main boom was low-
ered to beforehand.
Therefore, turning the superstructure is only permissible if
the main boom is lifted up at least 2 ” when the counter-
weight elements have been placed on the counterweight
platform of the crane chassis.
Otherwise the cable reel will be damaged.

140−1090−103b 73/105
9

180

90 270

180° 0
360

Z 54 055

180

90 270

10°

0
360
Z 54 056

74/105 140−1090−103b
 Counterweight 9

(Z 54 055, Z 54 056)

In the following, the movement ”Slewing” is to be driven.

Before introducing slewing for the first time, check how the
assignment of the control levers has been selected and
whether the slew gear has been switched in open or closed
circuit (see section 8 “Slewing”).
180° Before introducing the slewing movement, take the symbol with
the details of the corresponding slewing angle into consideration.
Starting point is 180° (Z 54 055), i.e. the superstructure is flush
with the crane chassis (situation after the counterweight
elements have been set down on the crane chassis). The crane
operator in the superstructure cab faces the direction of the cab
of the crane chassis.
Subsequently, it is to be slewed to the left.

The symbol consists of two arrows shaped as semi−circles

with the following meaning:

− left−hand half of the arrow − slew to the left

− right−hand half of the arrow − slew to the right .

These directions pertain to the movement that the crane operator

carries out using the cab (and not to the movement of the
superstructure frame in the back with the counterweight lift
cylinders).
The colour of each individual arrow halves determine which
slewing direction the crane operator can select:
both arrow halves are
− the crane operator decides
green:
left arrow half is green,
− only slew to the left
right arrow half is red:
left arrow half is red,
− only slew to the right
right arrow half is green:
− both arrow halves are red: slewing is not permitted.

2. Slew superstructure until a position of 0° / 360° ±10° has

been achieved (Z 54 056). The value of the slewing angle
which is to be driven is then:
− when slewing to the right: 350°
− when slewing to the left: 510≥
IN the following example, we will assume a slewing
movement to the left is being undertaken.

140−1090−103b 75/105
9

10°

Z 54 057

10°

Z 54 058

76/105 140−1090−103b
 Counterweight 9

(Z 54 057, Z 54 058)
3. In mask “Quick Menu” (Z 54 057), press key
The mask “Configure counterweight” appears (Z 54 058).

The mask “Configure counterweight” contains all information

which is required in the following for fitting the counterweight.
The slewing angle symbol is identical with the same
symbol on the left−hand side of the monitor; however, it does
not indicate the current slewing angle in (°).

The slewing angle is only displayed in the mask “Configure

counterweight” for the range 0°/360° ± 5.0 ° in the bar display
under the slewing angle symbol .

Further fitting can be undertaken either automatically or

manually .
In order to improve comprehension of the connections, first
manual fitting is described in detail.
Automatic fitting is described in section 9.17.3.2.3. from page 97.

9.17.3.2.1 Manual Fitting

(Z 54 058).

If, as described above, the mask “Configure counterweight” is

opened after the quick menu has been selected, the
superstructure frame with the fitted counterweight is displayed in
the top left−hand corner. The counterweight configuration is
shown which was determined in the mask for operating mode
selection (here: 0t / 0 lbs).

Press button has a grey background and is not crossed

through and symbolises the operating mode “manual”. This
means that for the desired manual fitting procedure the correct
selection is already determined.

The status display is under this key (here: S:0). As this is only
relevant for internal control processes, it has not been taken into
consideration in the following description.

140−1090−103b 77/105
9

4.0°

Z 54 059

Z 54 060

78/105 140−1090−103b
 Counterweight 9

(Z 54 059, Z 54 060)
1. Continue to slew the superstructure to the left until a slewing
angle of approx. 4.0 ° has been achieved. The slewing speed
is automatically reduced.
The mask “Configure counterweight” on the right−hand side
of the monitor is changed (Z 54 059).

As the value of the slewing angle is now also displayed in this

area, only the right−hand side of the monitor is shown in the
further description, i.e. the mask “Configure counterweight”
(Z 54 060).

The set counterweight configuration is no longer displayed

in the top left−hand corner, instead only the superstructure
frame with the counterweight lift cylinders and the
counterweight base plate with the draw bars are shown. The
following processes can be illustrated very well using these
components.
This depiction does not depend on the actual counterweight
combination to be fitted.

The current value of the slewing angle is indicated in the

slewing angle display under the slewing angle symbol
by using a horizontal bar (here: °

The slewing angle symbol itself indicates whether

slewing is permitted and in which direction.

The depicted symbol represents the luminous pushbutton in

the superstructure cab for lowering ( ) / raising ( ) the
counterweight hoist cylinders. Both arrows indicate with their
colour which movement is possible or permitted:
− arrow green: movement possible / permitted
− arrow red: movement not possible / permitted.

140−1090−103b 79/105
9

13 38 13 3

71

−1,0
+1,0
4 + 1,0
Z 54 061 Z 52 979

10% 10%

Z 54 062

80/105 140−1090−103b
 Counterweight 9

For all counterweight combinations for the described fitting

procedure the counterweight lift cylinders may only be
lowered in exactly this position 4 1.0. This range in the
slewing angle display has a green background.
Only this can ensure that the counterweight lift cylinders are
extended down through the kidney−shaped grooves (38) of
the counterweight sections (here: 3, Z 54 061) into the
counterweight stack and that they cannot collide with the
brackets (13) of the base plate.

This is monitored by the control system − also in the manual

operating mode. It will only be permitted to extend the
counterweight lift cylinders (symbolised by “ ”), if a
position has been achieved in the area permitted therefore.

(Z 52 979, Z 54 062)
2. Extend counterweight lift cylinders. To do so, press luminous
pushbutton (71) in the bottom half and hold in this position.
This is symbolised on the monitor by the a grey background
behind the corresponding symbol.

At the status display of the counterweight lift cylinders, the

10 % 10 % top horizontal line (as display for counterweight lift cylinders
completely retracted) is is replaced by (as display for
extending counterweight lift cylinders). The percentage
(here: 10%) is changed successively from 0% (completely
retracted) up to approx. 98% −100% (completely extended).

140−1090−103b 81/105
9

Z 54 063

Z 54 064

82/105 140−1090−103b
 Counterweight 9

(Z 54 063).

If the counterweight lift cylinders are completely extended, the

display changes accordingly. The mushroom−shaped ends of
the piston rods of the counterweight lift cylinder are on the side
next to the accordingly shaped receptacles of the draw bar of the
counterweight base plate.

The percentage display (here: 98%) does not change any more.
The arrow between both cylinder symbols has disappeared and
instead the bottom horizontal line is shown which symbolises that
the counterweight lift cylinders are completely extended.

If the counterweight combination does not just consist of the base

and cover plate, the counterweight lift cylinders are within the
counterweight stack. This is symbolised by .
Subsequently, slewing takes place within the counterweight
stack.

(Z 54 064).
3. Slew superstructure from the current position 4.0° ±1.0° in
the direction 0°/360°, in this example to the left. The slewing
speed is automatically reduced.
Observe the angle indicator. As soon as position 0°/360° has
been achieved, stop slewing movement. The angle indicator
indicates 0°.

The depiction changes. The mushroom−shaped ends of the

piston rods of the counterweight lift cylinder retract into the
accordingly shaped receptacles of the draw bars of the
counterweight base plate.

Only in this 0°/360° ±0.1° position is it permitted to raise the

counterweight combination. The arrow pointing upwards
( ) at the corresponding symbol must be green.

140−1090−103b 83/105
9

71

Z 52 979

85 % 85 %

35 bar

Z 54 065

84/105 140−1090−103b
 Counterweight 9

(Z 52 979, Z 54 065)
4. Retract counterweight lift cylinders in order to raise the
counterweight combination. To do so, press the top half of
luminous pushbutton (71) and hold in this position. This is
symbolised on the monitor by the a grey background behind
the corresponding symbol.

At the status display of the counterweight lift cylinders, the

85 % 85 % top horizontal line (as display for counterweight lift cylinders
completely extended) is is replaced by (as display for
retracting counterweight lift cylinders). The percentage
(here: 85%) is reduced successively.

p= 35 bar The pressure display indicates the pressure in the

counterweight lift cylinders and changes depending on the
mass of the attached counterweight combination (here:
35 bar / 508 psi).

140−1090−103b 85/105
9

71

Z 52 979

57 % 57 %

153 bar

Z 54 066

86/105 140−1090−103b
 Counterweight 9

(Z 52 979, Z 54 066)
5. Press luminous pushbutton (71) until raising is switched
off. Engine speed is reduced.

Authorisation for slewing is given as soon as the

counterweight combination is raised to a sufficient height
over the crane chassis, but before the top end position has
been reached. However, raising must be completed as
described above.

The depiction changes. At the superstructure symbol, the

counterweight combination is shown which was determined
in the mask for operating mode selection (here: 0t / 0 lbs).

At the status display the counterweight lift cylinder is (as

display for retracting counterweight lift cylinders) replaced by
a horizontal line at the top (as display for counterweight lift
cylinders retracted in the highest possible position). The
percentages (here: 57%) do not change any longer.

The percentages cannot go back to 0% as the retraction

movement of the counterweight lift cylinders is limited due to the
driving of the upper rim of the draw bars (or the highest
counterweight section) against the bottom rim of the
superstructure frame.

140−1090−103b 87/105
9

10
10
10

10

3 9 6R
9 10
6L 5 4

Z 54 067

10

6R

13
10
14
6L

1a
Z 54 068

88/105 140−1090−103b
 Counterweight 9

(Z 54 067, Z 54 068)

This completes the actual manual fitting / raising of the counterweight

combination (here 39 t / 86 000 lbs) to the superstructure frame.
However, before a slewing movement can be carried out, the crane
operator must pin the top counterweight sections and with a visual
inspection make sure that the following conditions have been met.

Conditions: Counterweight combination completely raised and

pinned

5.1 Both of the top counterweight sections (6L + 6R) must be fitted
evenly to the supporting consoles of the superstructure frame in the
pinning position (see arrows in figure “Z 54 067”). Each section
must be pinned with 3 single−hand locking pins (10).
5.2 The counterweight section (5) must be pinned to the superstructure
frame with 2 pins (9) and each pin must be secured with a clip pin.
5.3 The counterweight section (4) must be pinned to the section (5) with
3 single−hand locking pins (10).
5.4 The counterweight section (3) must lie flat on the section (4). The
2 centring pins of the section (3) are dipped into the centre holes
of the section (4).
5.5 For counterweight combinations (here 6.3 / 13 900 lbs) which are
smaller than the one described in the fitting procedure above, the
draw bars (13) of the base plate (1a) must be fitted to the
superstructure frame (see arrows in figure “Z 54 068”).
The top counterweight sections are pinned as previously
described.
The mushroom−shaped ends (14) of the piston rods of the
counterweight lift cylinders must lie in the centre in the
corresponding receptacles of the draw bars (13).
RISK OF ACCIDENTS!
No crane movement may be initiated if not ALL of the previously
listed conditions are fulfilled! If necessary, the fitting / raising pro-
cedure must be repeated!

Check regularly to ensure that the raised counterweight has not

lowered itself on its own (for example, due to extreme temperature
shifts after the machine has stood still for a longer period of time
or due to leaks). In such a case, completely raise the counterweight
again.

140−1090−103b 89/105
9

57 % 57 %

0° 153 bar 0°

Z 54 069 Z 54 070

0.0

7.50
15

Z 54 071 Z 52 988

90/105 140−1090−103b
 Counterweight 9

After the actual fitting of a counterweight combination, the load

limit device must be set immediately in accordance with the
modified configuration.

RISK OF ACCIDENTS!
If the load limit device is not adapted to the actual crane
configuration, no crane movement is permitted!

(Z 54 069, Z 54 070)
1. Press button and then key . You will enter the
mask for operating mode preselection (Z 54 071).

(Z 54 071).
2. Once you have entered the mask for operating mode
preselection, select the actually fitted counterweight.
To do so, open the counterweight in the corresponding field
using the pull−down−menu and select actual fitted
counterweight (here: 39.0 t / 86 000 lbs).

(Z 54 071, Z 52 988)
3. In order to confirm the modification, quit the mask via .
While the preparation procedure is proceeding, mask
(Z 52 998) is displayed.

If your selection does not become active, press key .

140−1090−103b 91/105
9

0°

Z 54 072

57 % 57 %

0° 153 bar

Z 54 073

92/105 140−1090−103b
 Counterweight 9

(Z 54 072, Z 54 073)
4. After preparations have been completed, mask (Z 54 072)
appears. If key is pressed in this mask, the mask
“Erect counterweight” is displayed in the modified
configuration (Z 54 073).
The counterweight combination, here: 39.0 t (86 000 lbs), is
depicted and it is permitted to slew in both directions.

Press key you return to the starting mask (Z 54 072).

5. Check crane levelling, if necessary, repeat procedure(see

section 12, Outriggers, in the operating instructions of the
crane chassis).

RISK OF ACCIDENTS!
Before the superstructure may be slewed or a load may be
attached, the load limit device must be set to the current
crane configuration and the crane must be levelled cor-
rectly.

Bridging control

Even in manual operation only movements (slewing, lower / raise

counterweight lift cylinder) are permitted which have been
authorised by control.
You must bridge in order to cancel surveillance by control.
This may be done − but only in exceptional cases − for
example, if there is a fault.

Risk of damage !
When bridged, control does not monitor anymore. Only the
crane operator decides which movements are safe and
therefore can be carried out.
This is why only the crane operator may bridge if he is ac-
quainted with the counterweight assembly in accordance
with the operating instructions and he is aware of the exist-
ing dangers.
If, as an exception, assistants must get back on the crane
for trouble shooting, there is RISK OF CRUSHING!

140−1090−103b 93/105
9

10°

Z 54 074 Z 52 990

0% 0%

10° 0 bar

Z 54 075

94/105 140−1090−103b
 Counterweight 9

(Z 54 074, Z 52 990, Z 54 075)

1. In order to bridge control press the depicted key in mask

(Z 54 074). Mask (Z 52 990) is displayed which expressly
warns the crane operator of existing dangers.

If you then do not want to bridge, you can cancel by pressing

key “Return”. The starting mask (Z 54 074) then appears
again unchanged.

If existing dangers are consciously risked, press key

“Continue”. Only then will bridging actually be activated.

The bridged state is shown in two places. On the right−hand

side of the monitor, the originally pressed key changes to a
warning symbol with a red frame (Z 54 075).

In addition, the displayed warning symbol appears on the

left−hand side of the monitor (Z 54 075).
This ensures that the bridged state is always displayed, even
when the mask “Erect counterweight” is quit (the state
“bridged” remains).
2. Press the displayed key again in order to cancel bridging.
The symbol changes back to the state “not bridged”.
The warning symbol on the left−hand side of the monitor
disappears (Z 54 074).

9.17.3.2.2 Manual removal

As with the fitting procedure, the following basic requirements

must be satisfied:
− Support the crane on outriggers / align
− Set the load limit device (0 t / 0 lbs tables).

The equipment is removed as it is fitted, in the reverse order.

140−1090−103b 95/105
9

10°

Z 54 076

96/105 140−1090−103b
 Counterweight 9

9.17.3.2.3 Automatic fitting

In the case of automatic fitting, the crane operator is only

minimally involved in the procedures. For this reason, the
following description is not in great detail.
You will find details which will improve understanding of the
procedures in section 9.17.3.2.1“ Manual Fitting”, from page 77.

For the numerous additional general rules and regulations that

are also relevant to automatic fitting, reading of this chapter is
required. Such points include:
− Allocation of the control levers
− Slewing directions
− Navigating on the IC−1
− Explanation of the symbols in the mask “configuring the
counterweight” (Z 50 076).

The starting condition is as described from page 73 to page 77.

(Z 50 076).
1. In the mask “configure counterweight” press . The
symbol changes to and is highlighted in green.
The automatic operating mode is then selected.

Automatic mode can only be selected when the counterweight lift

cylinders are retracted as far as possible.

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9

98/105 140−1090−103b
 Counterweight 9

2. Actuate the corresponding control levers so that the

superstructure turns out of the 10°/350° position further in
the direction 0°/360°. Hold the control lever in the extended
position.
For the position of 10° taken in the example, this means:
Slew to the left.

This determining of the slewing direction by corresponding

movement of the control lever and holding the control lever
in this position, are the only movements that need to be
actively carried out by the crane operator. The remaining
procedure is then carried out automatically and can be
observed on the screen.

The automatic process can be interrupted at any time by

releasing the control lever and can be reinstated by
actuating the controls again.

After the control lever is actuated for slewing, the control system
checks by means of sensors to see if the counterweight is fitted
or not and then carries out the corresponding procedure (here:
fitting).

In automatic operation the slew gear works in closed circuit (see

section 8). This setting cannot be changed.
To ensure sufficient sensitivity, the engine speed is regulated by
the control system.

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9

10°

Z 54 076

100/105 140−1090−103b
 Counterweight 9

When the control lever is actuated the following steps are carried
out automatically:
− Slew to 4.0 1.0°±°.
− Extend the counterweight lift cylinders into the counterweight
stack.
− Slew to 0° with the lowered counterweight lift cylinders within
the counterweight stack.
− Raising the counterweight stack into the end position.

(Z 54 076).
3. When the movement is switched off and the engine speed
has been reduced, release the control lever, i.e. place in the
neutral position.
The symbol for automatic operation changes back to
the symbol “manual” .

The actual automatic fitting procedure is concluded.

As with the manual fitting procedure, certain additional tasks

must still be carried out:
− Check that the counterweight combination has been
completely raised.
− Check that the counterweight combination is located central
to the superstructure frame.
− The top counterweight sections must be pinned, see the
detailed description under point 5.1 to point 5.5, page 89.
− Set the load limit device to the changed crane configuration.
− Check the crane levelling.

Observe the corresponding description from page 89 to page 93.

RISK OF ACCIDENTS!
Crane movements may only be carried out once all tasks
have been completed.

Bridging of the control with automatic fitting is identical to bridging

in manual operation. If required, follow the corresponding
description on page 95.

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9

−1,0
+1,0
4 + 1,0
Z 54 077

102/105 140−1090−103b
 Counterweight 9

Special case
(Z 54 077).

If the automatic system is not activated in the superstructure

position of approx. 10 / 350 − as specified in point 2., page 75
− a differentiation must be made between two different cases:
− 1stcase: Position 4/356 1.0

This is the range in which lowering of the counterweight lift

cylinders into the counterweight stack is permitted.
A differentiation must then be made with regard to the
selected slewing direction:
∗ Selected slewing direction 0°/360° (e.g. for starting
position 4°: slew to the left);
after actuating the control lever the automatic fitting
procedure is carried out as previously described; only the
first step “slew to 4 1.0°±°” is omitted, as this position has
already been reached.
∗ Selected slewing direction opposite the direction 0°/360°
(e.g. for starting position 4°: slew to the right);
after actuating the control lever, the counterweight lift
cylinders also move into the counterweight stack; however
further slewing in this direction is then no longer
possible/permitted within the counterweight stack − this
would lead to a collision between the counterweight lift
cylinders and the counterweight stack. The fitting
procedure is not continued.
For this reason, the control lever must be moved in the
opposite direction. Only then is the remaining procedure
carried out automatically.
− 2nd case: Position 0 3.0

After actuating the control lever, the superstructure first

moves in the selected direction until a position of 4/356 1.0
°°±°is reached; the counterweight lift cylinders then move into
the counterweight stack.
Within the counterweight stack, the equipment can then no
longer be turned in this direction. The fitting procedure is not
continued.
For this reason, the control lever must be moved in the
opposite direction. Only then is the remaining procedure
carried out automatically.

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9

104/105 140−1090−103b
 Counterweight 9

9.17.3.2.4 Automatic removal

Automatic removal is the same as automatic fitting, only in the

reverse order.
The following requirements must be satisfied:
− Crane supported on outriggers and correctly aligned.
− The load limit device must be set correctly (0 t / 0 lbs table).
− Position 10°/350° selected.

If the automatic system is then activated and the control lever

actuated for slewing, the control system checks by means of
sensors whether the counterweight is fitted or removed and then
carries out the required procedure (here: removal).

The following steps are then carried out automatically:

− Moving to the 0° position.
− Lowering the fitted counterweight combination onto the
counterweight support.
− Turning within the counterweight stack to 4/360 1.0°°±°.
− Complete raising of the unladen counterweight lift cylinder.

After releasing the control lever the automatic removal procedure

is ended.

9.17.3.3 Removing the Counterweight Combination from the

Crane Chassis.

The counterweight combination is removed from the crane

chassis is the same way as it is set down, just in the opposite
sequence (see section 9.17.3.1, from page 61).
In any case the following requirements must be satisfied:
− Crane supported on outriggers and correctly aligned.
− The load limit device must be set correctly (0 t / 0 lbs table).

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 Safety Equipment 10

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Z 56 930

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 Safety Equipment 10

10 Safety Equipment
(Z 56 930)

10.1 IC−1 crane control

The crane control IC−1 (Intelligent Control System) combines se-

veral devices which provide the crane driver with essential infor-
mation for operating the crane within the parameters specified by
the manufacturer:

− Overload cut−off device (load limit device LLD)

− Telescoping Information System
− Display of numerous crane functions, for example, support
pressure, tilt, crane configuration, lifting capacities etc.
− Warning (optical and acoustic) in case of prohibited condi-
tions.

This crane control (incl. load limit device) is an operating aid. It

provides the crane operator with essential information concer-
ning crane data such as length and angle of the boom, sheave
head height, nominal lifting capacity, the total load suspended
from the boom, etc. and gives warning when an overload condi-
tion is being approached or when the hook block gets too close
to the boom head.

This safety device is no substitute for the judgement and ex-

perience of the crane operator and use of recognised safe
operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility for
safe operation of the crane.

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10

0,0°

LMB

Z 54 751

4/161 140−1100−181_en
 Safety Equipment 10

10.1.1 Load limit device (LLD)

10.1.1.1 Function
(Z 54 751)

If, when raising a load or increasing the working radius with load,
the permissible load moment/the permissible load is exceeded,
both the movements which increase the load moment and the
movement which decreases the load moment ”Raise luffing gear”
and ”Raise load on hook” are disabled. ”Lower load on hook” is
permitted.
A continuous tone sounds and the Stop symbol appears.
The warning message LLD appears (red). In addition, the colour
of the bar display (C) changes from yellow to red. Lifting of loads
is not permitted!
After a shutdown by the load limit device, only movements which
decrease the load moment may now be initiated.

RISK OF ACCIDENTS!
It is absolutely forbidden to override the load limit device
to overload the crane above its load bearing capacity!
Lifting a load with the load limit device overridden is prohi-
bited!

The load limit device should only be activated in an emer-

gency situation. Under no circumstances may it be used as
a standard operating tool!
This means that the crane operator must be satisfied, before
hoisting the load, that the load bearing capacity of the crane
is not exceeded by the load to be lifted. Loads that are too
heavy and exceed the load bearing capacity of the crane
must not be accepted, even if there is a load limit device in-
stalled!

Even without a load, the boom may only be moved in those

ranges where load bearing capacities are specified.

Before a load is raised, its weight must be known. The safety de-
vice may not be used to determine the weight.

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 Safety Equipment 10

To ensure that the load limit device functions properly, it must:

− be set by the crane operator in accordance with the crane
configuration before work is commenced (as soon as the
configuration is achieved) after the ignition/engine is swit-
ched on.
− reset by the crane operator in accordance with the new ope-
rating mode once the crane configuration has been changed.

This is set by selecting the operating mode (detailed des-

cription as of p.).51
Only when the load limit device has been correctly set by the
crane operator in accordance with the current operating
mode/crane configuration, can it operate automatically.
The crane operator is responsible for the correct setting by
acknowledging the crane configuration.

Danger of accident − limits of the load limit device!

Despite a functional load limit device that is correctly set in
accordance with the crane configuration, the load limit de-
vice can become ineffective in particular cases/operating
errors:
− insufficient load bearing capacity on the ground used for
the set−up site of the crane
− support errors
− not switching on the prescribed telescoping sequences
− influence of the wind
− diagonal pull
− dynamic influences, e.g. by crane movements that are
too fast and end with an abrupt stop
− dismounting work, if loads are unscrewed/burnt off after
slinging, then hang loosely from the crane and prove to
be too heavy
− lifting overloads with the luffing gear
− co−operation of several cranes.
The crane operator must observe these system limits
when setting up and operating the crane!

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8/161 140−1100−181_en
 Safety Equipment 10

The load may only be taken up by the hoist in hook opera-

tion.
If the load is still in contact with the ground and raising of
the hoist has been switched off, the load is too heavy. In this
case, activating the ”Lift main boom” movement is not per-
mitted!
This movement is not to be used to lift the load under any
circumstances!

It is essential for the operating safety of the crane that the

IC−1 crane control functions in its original condition.
Necessary updates can be obtained from the after−sales
service department of the crane manufacturer.

Danger of crushing!

The swinging−out of the load during switch−off cannot al-

ways be avoided, even with the use of automatic safety de-
vices!
It can be avoided only by all crane movements being car-
ried out at appropriate speeds.
Also take note of the continuous display of the load mo-
ment with preliminary warning at 90% of the permissible
load moment prior to switch−off.

Risk of crane control system being influenced!

The risk of the load limit device being influenced by high−
frequency radiation is minimised by the latest technology
(shielding). It cannot, however, be completely excluded − in
particular under extreme conditions, for example near po-
werful transmitters.
See in particular the instruction ”High−frequency radia-
tion” in Section 1.4.3 ”Special safety instructions”.

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10

115
116

Z 54 599

LMI

0,0°

Z 54 752

10/161 140−1100−181_en
 Safety Equipment 10

10.1.1.2 Bridging load limit device

10.1.1.2.1 Bridging shutdown of movement which decreases

the load moment ”Raise luffing gear”
(Z 54 599, Z 54 752)

If a prohibited overload condition has occurred, the load−mo-

ment−reducing movement ”Raise luffing gear” is also shut down
by the load limit device. Only lowering of the load on the hook is
permitted.

Once an overload condition has been switched off by the load li-
mit device, load moment reducing movements can be carried out
to move a freely suspended load out of the overload range
again, back into the normal operating range. In this case the key−
operated pushbutton (116) must be pressed. Indicator light (115)
lights up.
The status display ”LLD” (or LMI) changes from red to black on
the IC−1 display.

The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.

RISK OF ACCIDENTS!
This load moment reducing movement may only be ena-
bled if it does not present a hazard. Make sure that this is
the case before pressing the key−operated pushbutton.

If the load is still in contact with the ground and raising of

the hoist has been switched off, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!

This movement is not to be used to lift the load under any

circumstances!

Danger of falling backwards!

In some cases, enabling the movements which reduce the
load moment is not permissible.
This is the case, for example, if ”Raise luffing gear” is swit-
ched off due to the permissible minimum radius being re-
ached.
In this instance, bridging is not allowed and the load−mo-
ment−reducing movement ”Raise luffing gear” cannot be
continued, because the crane could tip over backwards.

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111
112

Z 55 101

LMI

0,0°

Z 54 752

12/161 140−1100−181_en
 Safety Equipment 10

10.1.1.2.2 Bridging the shutdown of all movements

(Z 54 752, Z 55 101)

The load limit device can be overridden using key−operated

pushbutton (112).

The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.

The button must be turned in the clockwise direction and held in

this position.

When overridden, indicator light (111) lights up.

The status display ”LLD” (or LMI) changes from red to black on
the IC−1 display.

The load limit device may only be overridden in exceptional

cases, for example in case of repairs, fitting a rope etc.
This can only be done by authorised personnel who are fa-
miliar with the operation of the crane!
The bridging of the load limit device may not be used to in-
crease the load moment under any circumstances.
Lifting a load with the load limit device overridden is prohi-
bited!

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64

64.1 64.11

64.2 64.12

64.3 64.13

64.4
64.14

64.15
64.6
64.7
64.8 64.16
63

64.19

Z 56 931

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 Safety Equipment 10

10.1.2 Control and display elements

(Z 56 931)

(63) − Adjustment toggle for adjusting inclination of the display

(64) − IC−1 display
This display has a large colour monitor to enable the in-
formation shown to be read easier. The brightness ad-
justs itself automatically to the ambient conditions.
All keys are activated by tapping the symbol (touch
screen) directly with the finger.
An exact description can be found on the following page
under Section 10.1.3 ”Operating the IC−1”.

RISK OF DAMAGE!
Adhesive materials may not be affixed to the monitor! Moun-
ting stick−on labels would destroy the monitor (touch-
screen)!

You will get the best results when cleaning the monitor by using
a clean, damp, non−abrasive cloth and any commercially−availa-
ble window cleaning agent without ammonia. The window clea-
ning agent should be applied to the cloth first instead of directly
onto the surface of the monitor.

(64.1)− On/Off switch

For rebooting the IC−1 when necessary: switch off igni-
tion, wait at least 30 s, press switch for at least 3 s.
Switch ignition on again.

(64.2)− key: brightness ”+” (manual)

(64.3)− key: brightness ”−” (manual)

(64.4)− key not allocated

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64

64.1 64.11

64.2 64.12

64.3 64.13

64.4
64.14

64.15
64.6
64.7
64.8 64.16
63

64.19

Z 56 931

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 Safety Equipment 10

(Z 56 931)

(64.6)− lamp: temperature warning

If the temperature in the computer is lower than 05 C (325 F), the

LED lights up red and the computer is heated internally. When the
temperature is more than 0 5 C (325 F), the computer starts auto-
matically. The heating procedure can take between one and eight
minutes, depending on the outside temperature.
The computer is ready for use as soon as the red LED (temp,
64.6) goes out and the green LED (power, 64.8) illuminates.
If the display cancels the operation (monitor goes black) and at
the same time the temperature warning light comes on, then the
ambient temperature may be too high. The cab will then need to
be cooled down with the air conditioner. As soon as the tempera-
ture has once again fallen to an acceptable level, the display will
attempt once again to dial into the CAN network.

(64.7) − lamp: hard drive access

(64.8) − lamp: operating condition

(64.11)− key: move the mouse cursor upwards

(64.12)− key: move the mouse cursor downwards

(64.13)− key: move the mouse cursor to the left

(64.14)− key: move the mouse cursor to the right

(64.15)− key: switch key/mouse operation on/off

(64.16)− key: trigger one mouse−click (touch pressure)

(64.19)− USB connections on the underside of the display. If

these are to be used, then the display should first be
taken out.

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Z 54 753

18/161 140−1100−181_en
 Safety Equipment 10

10.1.3 Operating the IC−1

(Z 54 753)

For this system, all functions are operated by ”tapping” the keys
or buttons shown on the monitor (touchscreen).

By tapping a key/active button, a selection window is opened for

parameter selection (1), or the display changes to another selec-
tion window.
When opening a selection window, a list of selection options
(pull−down menu) appears in the selected area. A value must
then be selected from the selection list. If the set value is not to
be modified, then the previous value must be selected again from
the selection list.

The values selected are always dependent on the previously se-

lected settings. If, for example, crane mode is selected without
main boom extension, then no values are offered for setting the
parameter with main boom extension. These keys then only ap-
pear ”grey”. All parameters which can be set appear on a key in
a black frame.

In principle, the following applies:

”Save” symbol:
Diskette selected setting is saved, and the display is
changed
”Exit” symbol:
Door the display is left without saving the modi-
fied settings
The displayed value must be changed or, at
”Red” en- least, confirmed by tapping. Otherwise, the
tries settings for the crane mode can not be sa-
ved.

Operation at ambient temperatures in excess of 50
C

(122
F)

To avoid malfunctioning of the display, the air conditioner should

be used to cool the cabin both before and during crane opera-
tions when ambient temperatures are in excess of 50° C (122° F).
Direct sunlight should then be avoided on the display.
An appropriate cooling−down stage should be prescribed if ne-
cessary for the period before work begins.

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STOP STOP

Z 54 754 Z 54 755

39,0
7,50

Z 54 756

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 Safety Equipment 10

10.1.4 System start/Switching the system off

(Z 54 754, Z 54 755, Z 54 756)

The IC−1 is automatically started when the ignition is switched

on. At the same time, a system check is made automatically. De-
pending on the temperature of the computer (monitor), the dis-
play of the previously set crane status with the ”CAN initialisation”
screen positioned above it appears after an appropriate warm−
up time.

Momentary ”error” displays appearing during the automatic

check serve to test the functional reliability of the system, and are
of no importance to you.

If the computer is recognised by the PLC within 30 s, the CAN in-

itialisation screen closes automatically. The CAN status in the up-
permost line changes to ”OK”.
The CAN status can have the following conditions:
STOP crane operation not permissible
a subscriber is missing, but not relevant
OK crane operation permissible

If CAN initialisation is not initialised within 30 s, the screen is not

closed automatically. The two keys and ”CAN reset” are acti-
vated and must be actuated manually:

1. Option: actuate ”CAN reset”: the initialisation is restarted. If

that doesn’t work:

2. Option: actuate: a screen appears (Z 54 756) for selec-

ting the operating mode in non−active status. That means that an
entry is not possible for the ”type” field, so crane operation is not
permissible.
The existing error must be located − for example, with the help
of diagnostics screens − and removed. It is only then that the in-
itialisation can be restarted.

”Operating mode selection” (Z 54 756) screen appears after the

CAN initialisation is completed.

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39,0
7,50

Z 54 756

0,0°

Z 54 757

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 Safety Equipment 10

(Z 54 756, Z 54 757)

If the assembly or operating condition remains unchanged, the

screen can be exited via (54 756) .

If the assembly or operating condition has been changed, the

specifications in the screen must be adjusted accordingly
(Z 54 756). In order to be able to transfer the modifications to the
control system, the screen must be exited in this case via .

In both cases, the ”Crane operation” screen then appears

(Z 54 757).
A detailed description on selection of operating mode can be
found in Section 10.1.7.4.1, from page 51, and on ”Crane opera-
tion” in Section 10.1.5, from page 27.

As a starting point for using the IC−1 functions, the most impor-
tant screens are ”crane operation, (Z 54 757)” − and specifically
area ”e”, the screen ”Quick Menu” (see Section 10.1.5.5, from
p.35) − and the screen ”main menu (see Section 10.1.6, from
page 39).

Using these screens the desired functions can be selected by cal-

ling up the corresponding submenus (see Section 10.1.7, from
page 43).

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Z 54 537

24/161 140−1100−181_en
 Safety Equipment 10

Power control
(Z 54 537)

When the electric power supply fails, or after switching off the
ignition, the display changes automatically to the ”Power control”
screen. The remaining time (starting at 15 min.) up to switching
off the computer is displayed here. If the ignition is switched on
again within this time, the display changes directly to the ”Opera-
ting mode selection” screen. IC−1 is immediately ready for use
again.

The ignition can be checked after three minutes. If the ignition is

switched on and then switched off directly after, it can take ap-
prox. three minutes until the ”Power control” screen is selected.

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B C

0,0°

Z 54 758

0,0°

1 2 3 4 5 6 7 8 9 10 11

12

Z 54 759

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 Safety Equipment 10

10.1.5 ”Crane operation” screen

(Z 54 758, Z 54 759)

The ”Crane operation” screen appears automatically after actua-

ting the ”Operating mode selection” screen. It is the display for
normal work with the crane. All current and selected crane para-
meters are shown in it.

The ”Crane operation” screen is divided into five sections. At the

same time, the contents of the Sections ”A” to ”D” are fixed.
Section ”e”, on the other hand, can − as and when required − be
assigned with different contents/screens.

10.1.5.1 Section (A): display of current loading information

(1) − Designation of the type of operating mode:

HA − Main boom
HA−0 − Main boom − special case 0° (to the rear)
MBE − Main boom extension
MS − Runner (assembly top section)
HA−RSV − Configuring the front supports (optional)
(2) − counterweight
(3) − outrigger span
(4) − reeving number
(5) − longitudinal code no. LC
(6) − status of the superstructure lock (for detailed information,
see Section 8 ”Slewing”)
(7) − CAN bus status (for detailed information, see page)21
(8) − permissible slewing range
(9) − configuration of the control lever (for detailed information,
see page)69
(10) − warning buzzer
After the warning buzzer sounds, it can be acknowledged
by pressing the loudspeaker symbol, and is switched off
in doing so.
(11) − time
(12) − software version

RISK OF ACCIDENTS!
The displayed values must comply with the actual crane
status. If this is not the case, crane operation is not permis-
sible. The operating mode must be reset. This is described
in Section 10.1.7.4.1””, from page 51.

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B C

0,0°

1 2 3 4 C

Z 54 760

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 Safety Equipment 10

10.1.5.2 Section (B): display of load and radius

(Z 54 760)

(1) − Net load

By pressing the ”Net” button, the current load is tared (see
Section 10.1.9 ”load monitoring device”, from p. 139).
(2) − Maximum load (for the set crane configuration)
For loading in the longitudinal code (LC 1), the loading
symbol appears instead of the maximum is dis-
played. It is then prohibited to raise loads (see Sec-
tion 10.1.8 ”Configuration mode”, p. 137).
(3) − Current total load (gross load)
This includes load, hook block, all lifting tackle and, if ap-
plicable, additional device attached.
(4) − Current radius

10.1.5.3 Section (C): loaded display

(Z 54 760)

Continuously changing display of the load moment as ”bar dis-

play” with superimposed display percentage/overload display.
For loading in longitudinal code (LC 1), the whole field (C) is
shown in red with 3 stars instead of the bar display .
Raising of loads is prohibited (see Section 10.1.8 ”Configuration
mode”, p. 137).

A warning buzzer sounds when the prewarning range

(90−100% of the max. permissible load moment) is reached, and
a warning symbol appears in Section ”D” (see following
page). In addition, the colour of the bar display changes from
green to yellow.

When the overload range is reached, the load limit device shuts
down movements which increase the load moment and ”Raise
luffing gear”. A continuous tone sounds and the Stop symbol
appears in Section ”D” (see following page). In addition,
the colour of the bar display changes from yellow to red. Lifting
of loads is not permitted!

In order to indicate the actual rating of the max. permitted load

moment additionally outside the crane cabin there is a warning
light (option). It is shown and described in Sect. 4 “Cabin”.

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0,0°

1 2 3 4 5 6 7
8

9
28
10

11
27
12
13
26
25 15
16
24
17
18

23

22 21 20 19
Z 54 761

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 Safety Equipment 10

10.1.5.4 Section (D): display of status information on crane

condition
(Z 54 761)

(1) − ”Error” display: is superimposed when an error occurs

(2) − ”HES (red)”: lifting limit switch triggered, and not bypas-
sed
”HES (black)”: lifting limit switch bypassed, regardless
whether triggered or not
(3) − ”SES (red)”: lowering limit switch triggered, and not by-
passed
(4) − Emergency operation (optional) is active (see Section 36)
(5) − ”LLD (or LMI) (red)”: load limit device is switched off, and
is not bypassed
”LLD (or LMI) (black)”: , load limit device is bypassed, re-
gardless whether it is switched off or not;
simultaneously appears (also see item ”8”)
(6) − Reading below min. permissible outrigger pressure
(< 1 t)
(7) − Current wind speed
(8) − Fade−in of different symbols:
: Prewarning range; 90%−99% of the permissible

crane load reached

: − Load limit device is switched off
− Load limit device is bypassed
: Load capacity table being loaded; only appears
for a few seconds; crane operation is not
permissible during this time
(9) − Counterweight control overridden (see Section 9 ”Coun-
terweight”)
(10) − Current tilt (see Section 10.1.7.20, from p. 127)
(11) − Working range limit (see Section 10.1.7.11, from p. 91)
active; can be deactivated by tapping
(12) − Length main boom

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0,0°

1 2 3 4 5 6 7
8

9
28
10

11
27
12
13
26
25 15
16
24
17
18

23

22 21 20 19
Z 54 761

32/161 140−1100−181_en
 Safety Equipment 10

(Z 54 761)

(13) − Max. main boom length reached

(15) − High speed
(16) − Configuration mode: raising of loads prohibited (see Sec-
tion 10.1.8 ”Configuration mode”, p. 137).
(17) − Current slewing angle (see Section 8 ”Slewing”)
(18) − Slewing operation in open circuit (see Section 8 ”Sle-
wing”)
(19) − Key for calling up the ”Quick menu” screen; is used espe-
cially if the free Section ”e” (see next page) is assigned
with a submenu which otherwise provides no option to
exit.
(20) − Current radius
(21) − LLD relevant LC and radius step

(22) − (red): min./max. radius reached,

LLD switches off

(black)”: min./max. radius reached

LLD shutdown bypassed

(23) − Angle of the main boom to horizontal (foot angle)
(24) − (red): min./max. main boom angle
reached, LLD switches off
(black)”: min./max. main boom angle
reached, LLD shutdown bypassed
(25) − Telescoping is only possible with bridging of the load limit
device due to telescoping error (see Section 12 ”Telesco-
ping”)
(26) − Head height
(27) − Radio remote control (optional) active (see Section 34);
operation no longer possible on the IC−1 display
(28) − Angle of the main boom to horizontal (head angle)

More displays, for example in connection with additional devices,

are described in the corresponding sections.

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0,0°

2 5 6 7

9 10 11 12
17 18 19 20

21 22 23
Z 54 762

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 Safety Equipment 10

10.1.5.5 Section (e): assignment with different screens is pos-

sible (here: Quick menu)
(Z 54 762)

Call up the screen ”main menu” (see Section 10.1.6,

(1)
from p.39)

Call up the screen ”system” (see Section 10.1.7.1,

(2)
p. 43)

Call up the screen ”TableViewer” (see Section 10.1.7.4,

(5)
from p. 49)

Call up the screen ”parameter” (see Section 10.1.7.8,

(6)
from p. 75)

Call up the screen ”control lever assignment” (see Sec-

(7)
tion 10.1.7.6, from p. 69)

Call up the screen ”operating range limit” (see Sec-

(8)
tion 10.1.7.11, from p. 91)

Call up the diagnostics screen ”joystick” (see Sec-

(9)
tion 10.1.7.12, p. 103)

Call up the diagnostics screen ”I/O” (see Sec-

(10)
tion 10.1.7.13, p. 103)

Call up the diagnostics screen ”CAN” (see Sec-

(11)
tion 10.1.7.14, p. 105)

Call up the diagnostics screen ”LS” (see Sec-

(12)
tion 10.1.7.15, p. 117)

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0,0°

2 5 6 7

9 10 11 12
17 18 19 20

21 22 23
Z 54 762

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 Safety Equipment 10

(Z 54 762)

Call up the screen ”telescoping information system”

(17)
(see Section 12 ”Telescoping”)

Call up the screen ”support pressure/tilt display” (see

(18)
Section 10.1.7.20, from p. 127)

Select/display ”operating mode of the hydraulic pumps”

(19)
(see Section 10.1.7.21, from page 131)

Display ”operating mode of the hydraulic pumps” (see

(20)
Section 10.1.7.21, from page 131)

Call up the screen ”active operating range limits” (see

(21)
Section 10.1.7.11, from p. 91)

Call up the screen ”engine display” (see Section 5 ”en-

(22)
gine”)

Call up the screen ”configure counterweight” (see Sec-

(23)
tion 9 ”counterweight”)

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10

0,0°

7 8 9 10 11

1 2

13 14 15 16
19 20 21 22 23 24
Z 54 763

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 Safety Equipment 10

10.1.6 ”Main menu” screen

(Z 54 763)

The ”Main menu” screen can be called up by pressing the key

on the ”Quick menu” screen.
The name, time, and version number of the software are dis-
played in the top section of the screen.

Call up the screen ”system” (see Section 10.1.7.1,

(1)
p. 43)

Switch off the background lighting (see Sec-

(2)
tion 10.1.7.2, p. 47)

Call up the screen ”crane operation” (see Sec-

(7)
tion 10.1.5, from p. 27)

Call up the screen ”TableViewer” (see Section 10.1.7.4,

(8)
from p. 49)

Call up the screen ”fault messages” (see Sec-

(9)
tion 10.1.7.5, p. 67)

Call up the screen ”control lever assignment” (see Sec-

(10)
tion 10.1.7.6, from p. 69)

Call up the screen ”hour meter” (see Section 10.1.7.7,

(11)
p. 73)

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10

0,0°

7 8 9 10 11

1 2

13 14 15 16
19 20 21 22 23 24
Z 54 763

40/161 140−1100−181_en
 Safety Equipment 10

(Z 54 763)

Call up the screen ”parameter” (see Section 10.1.7.8,

(13)
from p. 75)

(14) Call up the screen ”info” (see Section 10.1.7.9, p. 89)

Activate/deactivate the ”emergency control” (optional),

(15)
(see Section 36 ”emergency control”)

Call up the screen ”operating range limit” (see Sec-

(16)
tion 10.1.7.11, from p. 91)

Call up the diagnostics screen ”joystick” (see Sec-

(19)
tion 10.1.7.12, p. 103)

Call up the diagnostics screen ”I/O” (see Sec-

(20)
tion 10.1.7.13, p. 103)

Call up the diagnostics screen ”CAN” (see Sec-

(21)
tion 10.1.7.14, p. 105)

Call up the diagnostics screen ”LS” (see Sec-

(22)
tion 10.1.7.15, p. 117)

Call up the ”Datalogger” screen (optional), (see Sec-

(23)
tion 10.1.7.16, from p. 119)

Call up the screen ”function diagnosis” (see Sec-

(24)
tion 10.1.7.17, p. 123)

Functions which are not enabled although available as an option

are displayed in grey.

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10

Z 54 764

Z 60 020

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 Safety Equipment 10

10.1.7 Submenus
(Z 54 764)

Submenus which can be called up from the ”Main menu” or the

”Quick menu” are described below:
The sequence is based at first on the arrangement of the symbols
in the ”Main menu” screen (Z 54 764, left side, from the top left
to the bottom right).
If the function can be called up from the ”Main menu” as well as
from the ”Quick menu”, the position of the corresponding key is
also shown in the ”Quick menu” (Z 54 764, right side).
Finally (from Section 10.1.7.18, p. 125) the buttons that only occur
in the ”Quick Menu” are described.

10.1.7.1 ”System”screen
(Z 54 764, Z 60 020)

Press button the ”System” (Z 60 020) screen is called up.

The parameters displayed on the screen are fixed display values
and changeable (*) values.
By pressing the corresponding button, the display is activated
and the current set value can be changed.

Language: * selection of the language setting

Unit: * selection of the unit display.
You can select between ”Metric” and ”Feet”.
Date: * setting option for the date
Time: * setting option for the time
Audio: * not assigned (optional)
APP: Display of the version number of the crane
software
OS−IPC: Display of the version number of the opera-
ting system

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Z 60 020

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 Safety Equipment 10

(Z 60 020)

Continued screen ”system”:

CPU−FAN− Display of the current ventilating fan speed.
RPM: Not possible with all devices. If the fan does
not have a speed indicator, rectangles are
superimposed.
CPU: Display of the current CPU temperature
Software: A screen is opened by pressing the key.
The version numbers of all configuration or
parameter files are listed on this screen.
Demag Pin: * for customer serviceonly
Calibration:* the crane application is ended by pressing
the key. After this, different items have to be
pressed on the display as prompted. After
the calibration has ended, the crane appli-
cation is automatically started.
Server: for customer serviceonly

Save: If modifications in language, unit, date, time, or

audio have been carried out, they must be sa-
ved by pressing this key.

Exit via key without saving .

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10

Z 54 765

0,0°

Z 54 766

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 Safety Equipment 10

10.1.7.2 Background illumination

(Z 54 765)

Press button to switch off the background lighting. The

background illumination is switched on by pressing on the screen
centre.

10.1.7.3 ”Crane operation” screen

(Z 54 766)

Press button to call up the ”crane operation” screen

(right−hand side with ”quick menu” screen).
With regards to this, please observe Section 10.1.5 ”Crane ope-
ration screen”, from page 27.

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Z 54 767

1 2

39,0
7,50

Z 54 768

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 Safety Equipment 10

10.1.7.4 ”TableViewer”screen
(Z 54 767, Z 54 768)

Press button to call up the ”TableViewer” (Z 54 768)

screen.
This comprises of 4 secondary screens which are allocated to the
corresponding register symbols (1) as follows:

− ”Selection of operating mode” screen (see from

page 51)

This secondary screen always appears first when calling up the

”TableViewer” screen.

− ”View table” screen (see from page 59)

− ”Search configuration for load case” screen (see from

page 63)

LC − ”Length code LC” screen (see p. 65)

The display of the load bearing capacity dependent on the set

reeving number is superimposed in the position indicated (2,
Z 54 768) in all secondary screens for the ”TableViewer” screen.

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G
39,0
7,50

Z 54 769

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 Safety Equipment 10

10.1.7.4.1 ”Selection of operating mode” screen

(Z 54 769)

This screen appears:

− after every restart, as soon as the IC−1 has run through the
starting procedure
− as input screen if the ”TableViewer” screen is called up
(49see page)

− if the register symbol is actuated within the ”TableVie-

wer” screen.

The single parameters which are relevant to the operating mode/

crane configuration are listed on this screen.

RISK OF ACCIDENTS!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane. This responsibility lies with the crane operator
alone. It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation.

If the specifications shown in the heading (F) or in selection area

”G” are consistent with the actual crane status when the screen
appears, the screen can be exited by pressing the key.
The previously shown screen then appears, or, if it is the first time
that this screen has been exited after a restart, the ”Crane opera-
tion” screen.

Exiting this screen via key can also be used to gain informa-
tion on or locate the details on certain configurations.
One can, for example, select ”MS” type to check under outrigger
span which outrigger spans can be used, or to call up the lifting
capacity tables for this equipment.
When this screen is exited via key , the settings which have
just been carried out are rejected, and the original configuration
remains set.

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10

Z 54 770

52/161 140−1100−181_en
 Safety Equipment 10

(Z 54 770)

If the specifications shown are not consistent with the crane sta-
tus, the operating mode must be reset. Proceed as follows to
set/change the parameters:

Beginning in the first field open ”Type” via the matching pull−
down menu and select according to the required equipment (e.g.
”HA” for working with the main boom).

The corresponding abbreviations (such as ”HA”) can be found in

all lifting capacity tables. The meanings of all abbreviations can
be found on page 27.
The special case HA−0 can only be selected in a slewing range
of 05 + 25.

Depending on the amount of corresponding selection elements,

these pull−down menus are opened with or without scroll bars.
An element in the list must then always be selected in the pull−
down menu so that the pull−down menu can be closed.
This has to happen if one decides, after opening the pull−down
menu, to keep the original selection.

The selection for the ”Type” field determines the content of all the
other fields. Proceed in the same way for all other parameters
that have to be changed. The field lengths and angles are only
relevant when working with additional equipment.

Selection elements which only contain one parameter can not be

changed. Its text is shown in grey.
If, when changing a parameter, another parameter is also
changed automatically by the system, (here, for example, a
fictitious outrigger span of 5.14 m / 16.9 ft), this is then
shown in red lettering. Values in ”red” must be confirmed by
the user; this means the key must be actuated again.
If the key then appears with a red background and black let-
tering (here fictitious equipment MBE), this configuration can
not be set due to the current crane status.

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10

G
39,0
7,50

Z 54 771

Z 54 550 Z 54 551

54/161 140−1100−181_en
 Safety Equipment 10

(Z 54 771, Z 54 550, Z 54 551)

If all the fields in selection area ”G” are filled in correctly in accor-
dance with the actual configuration of the crane, exit the screen
to transfer the reset values by pressing the key .

If a parameter was highlighted red on the screen, an error mes-

sage appears ”Selection incorrect!” (Z 54 550, top). Return via
key and execute the selection correctly, as described on the
previous page.

After actuating the key , a check is made as to whether the

current extending sequence of the telescopic sections exists as
longitudinal codes (LC) for the selected crane configuration.
If this is not the case, error message (Z 54 550, bottom) appears.
Return via key to the ”Selection of operating mode” screen,
and after actuating the register symbol LC , check which per-
missible longitudinal codes there are for the selected configura-
tion. Re−telescope main boom to one of the permissible lengths.

If authorisation is given once the length code (LC) has been chek-
ked, the set configuration is transferred to the control system. The
screen (Z 54 551) is displayed during the transfer.

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0,0°

Z 54 772

56/161 140−1100−181_en
 Safety Equipment 10

(Z 54 772)

After the transfer has ended, the screen from which the ”Selec-
tion of operating mode” was selected, appears again. After a re-
start, this is always the ”Crane operation” (Z 54 772) screen. The
parameter values just selected appear there in the left−hand area
of the top line.

RISK OF ACCIDENTS!
If these values are not consistent with the actual crane sta-
tus, crane operation is not permissible!

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10

2
10 1 3 4 5 6 2 8 9
3

16 15 12 9 8 14 12 9

8
22156512
7
6 5 Z 54 773

58/161 140−1100−181_en
 Safety Equipment 10

10.1.7.4.2 ”View table” screen

(Z 54 773)

In the ”TableViewer” screen (10), all stored lifting capacity tables

for the set crane configuration can be called up by pres-
sing key (9).
The following details can be found in these lifting capacity tables
stored in the system:

(1) − pinned lifting capacities

Risk of overturning! RISK OF BREAKAGE!
The lifting capacities outlined in the lifting capacity tables
represent 100% of the permitted maximum load for each
crane configuration. If these limit values are exceeded,
there is a risk of the crane overturning and/or crane compo-
nents and auxiliary equipment breaking.

(2) −
no. of the longitudinal codes (LC)
(3) −
main boom length
(4) −
scroll bar
(5) −
ID No. of the lifting capacity table
(6) −
button for calling up information on a special load
(7) −
key for calling up the unpinned load bearing capacities.
For this, please observe Section ”Lifting capacities in un-
pinned condition” in Section 12 ”Telescoping”.
(8) − minimum reeving
(9) − radius
(10) − with luffing boom extensions, the current angle step
(e.g. 10°) is also displayed here. By pressing this key, the
other angle steps can be called up one after the other.

Please refer to the lifting capacity tables, which you will receive
with the crane − either on paper or as a CD−ROM − for more de-
tails on lifting capacities.
Please observe the following page.

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10

B C
A

D
E
F
G
H

P
Z 54 774

60/161 140−1100−181_en
 Safety Equipment 10

Lifting capacity table (on paper or CD)

(Z 54 774)

The following example shows where you can find which details
in the lifting capacity table.

The following lifting capacity table is only a specimen. Only

the load capacity tables which are supplied with the crane
may be used for operation of the crane.

(A) − crane type and construction no. of the crane

(B) − lifting capacities on the main boom, all telescopic sec-
tions pinned
(C) − abbreviation of operating mode (here: HA for working
with the main boom)

The meaning of all abbreviations is described on page 27.

(D) −
permissible slewing range: 0° − 360°
(e) −
outrigger length (here: 8.23 m / 27 ft)
(F) −
outrigger width (here: 7.5 m / 24.6 ft)
(G) −
counterweight (here: 39.0 t / 86000 lbs)
(H) −
main boom length (here: 16.8 m / 55.1 ft)
(I) −
radius (here: 7 m / 23 ft)
(K) −
lifting capacity (pinned), (here: 57.8 t / 127.4 kip)
(L) −
minimum reeve count of hoist cable (here: 12−rope)
(M) −
longitudinal code no. (LC) of extension sequence (here:
4)
(N) − extension length of telescopic sections:
Tele 1 − 0%
Tele 2 − 0%
Tele 3 − 45%
Tele 4 − 0%
Tele 5 − 0%

(O) − restrictions/health and safety issues,

make sure these are stringently observed (here:
none)
(P) − ID No. of the lifting capacity table

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10

7,50

Z 54 775

7,50

Z 54 776

62/161 140−1100−181_en
 Safety Equipment 10

10.1.7.4.3 ”Search configuration for load case” screen

(Z 54 775, Z 54 776)

Within the ”TableViewer” screen (Z 54 775), press button

to call up the screen ” search configuration for load case”
(Z 54 776).
On this screen, the possible configuration modes for the current
load and radius can be viewed. Proceed as follows:

4. tap entry field below ”Load (t/kip)”. A numerical pad appears

where the required list can be entered − within the limits spe-
cified in the head of the numerical pad. If the entry is outside
the permissible range, it will be shown in red.
By pressing , the previously entered character can be
deleted.

5. Either by pressing the key reject entry or by pressing the

key accept entry and return to start screen.

6. Select radius. Proceed in the same way as described for the

load.

7. If both fields for load and radius are filled with the required
entries, search by pressing key start.

All configurations found are entered into the corresponding field

(Z 54 776, marked range). By pressing on , the whole selec-
tion is opened.

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7,50

Z 54 777

Z 54 778

64/161 140−1100−181_en
 Safety Equipment 10

(Z 54 777)

An entry such as HA (0.0/0.0) 15.0 7.5 means:

− Main boom operation
− the specifications in brackets (length/angle) are only relevant
for working with additional equipment
− Counterweight combination: 15.0 t / 33.1 kip
− Outrigger span: 7.5 m / 24.6 ft

The required configuration can be selected by tapping key, and

is then transferred to the screen for selecting the operating mode.

10.1.7.4.4 ”Extension conditions of main boom” screen

(Z 54 778)

Within the ”TableViewer” screen, the ”Extension conditions”

screen can be called up by pressing the register symbol ”LC”.
Listed here are − depending on the currently set configuration −
the possible extension states of the main boom with specification
of longitudinal code (LC), main boom length, extension condition
of the single telescopic sections, and possible lifting capacities.

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Z 54 779

Z 54 563

66/161 140−1100−181_en
 Safety Equipment 10

10.1.7.5 ”Error messages” screen

(Z 54 779, Z 54 563)

Press button / to call up the list of the existing PLC

errors (Z 54 563).
In any case, all error messages are retained until they have been
viewed. This is especially useful for identifying errors which only
occur for a short time, and then disappear automatically.

The corresponding symbol can − with the exception of the ”Main

menu” screen − also appear in various other screens as soon as
an error occurs or is cancelled.

− the list of error messages is either empty or all error

messages have already been displayed once

− new (not yet displayed) errors have arisen, or existing

errors are cancelled − or both at the same time

RISK OF ACCIDENTS!
As soon as an error is displayed, shut off operations and
immediately have the error identified and eliminated!
Only qualified personnel (e.g. Customer Service) may eli-
minate errors.
If non−qualified personnel attempt to eliminate errors, they
could be fatally injured and/or cause serious damage!

Providing the update key is white in the ”Error messages”

(Z 54 563) screen , the list shows the current status for the
error messages.
Currently red, must be updated by tapping the key. This
may be necessary again should the symbol stay red.

If − when the ”Error messages” screen is open − new errors occur,

or are cancelled, or both at the same time, the update key
is red. It must then be tapped, if necessary, repeatedly − until it
is white again.
Only after this is the list of displayed errors complete, and the
screen can be exited via .

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10

Z 54 780

Z 54 565

68/161 140−1100−181_en
 Safety Equipment 10

10.1.7.6 ”Control lever configuration” screen

(Z 54 780, Z 54 565)

Press button to call up the ”Control lever configuration”

(Z 54 565) screen.
It is here that the current configuration of the control lever is dis-
played.

This is where the various options for configuration of the control

lever can be selected (mode 1 − 6). By tapping one of the corres-
ponding fields (e.g. mode 1), the corresponding configuration of
the control lever can be selected. It is then displayed on the con-
trol lever symbols.

RISK OF ACCIDENTS!
It is the crane operator’s responsibility to check the current
control lever configuration before initiating a crane move-
ment.
Otherwise there is risk of accidents if accidental crane mo-
vements are triggered!

The configuration of the control lever is also linked to the assign-

ment of the rocker switch and pushbutton in the head of the con-
trol lever. These are adjusted to the new configuration.
More detailed information on this theme can be found in the cor-
responding sections which describe the crane movements (for
example, Section 8 ”Slewing”).

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10

Z 54 565

0,0°

Z 54 781

70/161 140−1100−181_en
 Safety Equipment 10

(Z 54 565, Z 54 781)

The following table contains the control lever assignments for the
different modes:
Mode 1: SLH = slew gear SRH = luffing gear
SLV = tele SRV = Hoist 1
Mode 2: SLH = slew gear SRH = luffing gear
SLV = Hoist 2 SRV = Hoist 1
Mode 3: SLH = slew gear SRH = Hoist 2
SLV = tele SRV = Hoist 1

Mode 4: SLH = luffing gear SRH = slew gear

SLV = tele SRV = Hoist 1
Mode 5: SLH = luffing gear SRH = slew gear
SLV = Hoist 2 SRV = Hoist 1
Mode 6: SLH = slew gear SRH = tele
SLV = luffing gear SRV = Hoist 1

(S = control lever, R = right, L = left, H = horizontal, V = vertical)

The mode no. of the current control lever setting is shown in the
top line of the IC−1 display (Z 54 781).

Set−up − This button only appears when the screen is started

from the main menu. Additional possible programming
can only be carried out with the help of our service de-
partment.

− Exit the screen without changing the lever setting

− Exit the screen with a change to the lever setting

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10

Z 54 782

Z 54 567

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10.1.7.7 ”Hour meter” screen

(Z 54 782, Z 54 567)

Press button to call up the screen ”hour meter”

(Z 54 567).
This is where the operating hours for the crane drives slew gear,
hoists, luffing gear and tele unit are displayed. The operating
hours are displayed in the format ”hours : minutes”.

In the bottom left−hand corner of the display, press to select

the corresponding crane operation from a pull−down menu.

In the case of the hoist unit (e.g. H1−L, H1−S) a differentiation is

made between the load and rope load.

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10

Z 54 783

2
1
3

9 8 7 6
Z 54 569

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 Safety Equipment 10

10.1.7.8 ”Parameter” screen

(Z 54 783, Z 54 569)

Press button to call up the ”Parameter” (Z 54 569) screen.

This is where the solenoid valve data for the individually crane
functions are displayed and set in relation to the movement of the
corresponding control lever.

The detailed list of the individual parameters from field (1) can be
found from the following page.

As crane movements can also be carried out when setting the pa-
rameters for test purposes, the load utilisation display (2) of the
load limit device is also displayed in this screen.
The crane operator is therefore continually informed of the cur-
rent load range of the crane.

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Z 54 596

Z 54 597

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 Safety Equipment 10

(Z 54 596, Z 54 597)

In field (1) the following parameters are displayed and can be set:

The current set values of the parameters are displayed graphi-

cally in field (4). Use button (5) to select between the display of
the current ramp (Z 54 596, y−axis [mA]) or the time ramp
(Z 54 597, y−axis [s]).
For the parameters ”Start1” to ”stop limit” it is best to choose the
time ramp display, for the remaining parameters, the current
ramp.

− Start1 [s] (here: 0.5):

The time that passes when the control lever is fully activated
for the control lever movement from zero up to the defined
start limit (point P1, see graphic).
− Start2 [s] (here: 0.5):
The time that passes when the control lever is fully activated
for the control lever movement from the defined start limit
(point P1, see graphic) up to the end point (P2, see graphic).
− Start limit [%] (here: 30%):
Specification of the control lever movement for point (P1, see
graphic).
− Stop1 [s] (here: 0.5):
The time that passes when the control lever is suddenly retur-
ned to neutral for the control lever movement from the end
point (P2, see graphic) to the defined stop limit (point P1, see
graphic).
− Stop2 [s] (here: 0.5):
The time that passes when the control lever is suddenly retur-
ned to neutral for the control lever movement from the defined
stop limit (point P1, see graphic) to zero.
− Stop limit [%] (here: 70%):
Specification of the control lever movement for point (P1, see
graphic).

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Z 54 596

Z 54 597

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(Z 54 596, Z 54 597)

− Y1 [mA] (here: 250):

Current slightly beneath the current for movement start Y2,
which serves to ensure a smooth commencement of the mo-
vement when Y2 is reached.
− Y2 [mA] (here: 270):
Current at which the selected movement starts.

The values Y1 and Y2 have been optimised ex works and should,

as a rule, remain unchanged.

− X 3 [%] (here: 70):

Value for the movement of the control lever for a defined cur-
rent Y3 (between the current for the start of the movement Y2
and the final current Y4).
− Y3 [mA] (here: 340):
Current between the current for the start of the movement Y2
and max. current Y4.

If Y3 is defined as such that − as in the example shown − the

straight line between Y2 and Y3 is very flat, the corresponding
crane movement can be influenced very precisely in this move-
ment range of the control lever. In the steep range of the straight
line between Y3 and Y4 movements of the control lever are ap-
plied more directly.

− Y4 [mA] (here: 800):

Max. current to the solenoid valve.

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8 7 6
Z 54 598

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(Z 54 598)

When changing to the ”Parameter” screen, the data set ”slew

gear left” of the PLC is always displayed. The remaining crane
functions can then be selected − after opening a pull−down menu
with button − in field (3). The PLC then sends its data directly
to the display.

If the menu points pump 1 or pump 2 are called up, only parame-
ter Y2 is assigned.

If the menu points ”luffing gear” or ”tele” are called up, the pump
symbol appears as well (pumps activated).
By tapping on this pump symbol the two pumps of the hydraulic
circuits 1 and 2 can be blocked. The symbol changes to .
It is then possible to carry out the setting for pump 3 in isolation.
Once the setting has been made, the pumps can be reactivated
by tapping on the pump symbol again .

Status display

(6) − to no. (7) corresponding output current to the solenoid

valves

(7) − movement of the control lever in increments (0 − 500)

(8) − Data set that is currently saved in the PLC ( 1, 2, 3, D ).

When the data set of the PLC does not align with any sto-
red on the computer, PLC appears in the symbol. Other-
wise, the number of the corresponding data set is dis-
played.

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Z 54 572

Z 54 570

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Entering/changing a parameter
(Z 54 570, Z 54 572)

Tap the entry field that belongs to the desired parameter (here:
to Stop1).

A numerical pad appears on which the desired value − within the

limits specified at the top of the block − can be entered. If the entry
is outside the permissible range, it will be shown in red.
By pressing , the previously entered character can be de-
leted.
Either by pressing the key reject entry or by pressing the key
save the entry and transfer directly to the PLC.

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9
Z 55 108

9.1

9.2

9.3

9.4

9.5

9.6

9.7
Z 54 571

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Selecting a stored data set

(Z 55 108, Z 54 571)

Press key (9) ”Menu” to open the selection window (Z 54 571).

(9.1) − Load setting 1
(9.2) − Load setting 2
(9.3) − Load setting 3
(9.4) − Load Demag default setting
(9.5) − Load current setting of the PLC
(9.6) − Save settings
(9.7) − Exit ”Parameter” menu

This is where different settings can be loaded or saved. Using

the ”Parameter” menu is ended and exited.

If a new setting is loaded from the computer, key this key. The
setting is then transferred to the PLC.

The default setting cannot be modified. For the functions ”tele in

and out” and ”slew gear brake” only the default setting can be se-
lected, i.e. the crane operator cannot make a personal setting. In
the case of the slew gear setting, the values for Y1 and Y2 cannot
be changed.

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9 8
Z 55 121

9.1

9.2

9.3

9.4

9.5

9.6

9.7
Z 54 571

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Copying a data set

(Z 55 121, Z 54 571)

If, for example, you want to assign the default setting to setting
1, proceed as follows:

1. Press key (9, Z 55 121) to open the ”Menu” selection window

(Z 54 571) and then press key to load the Demag de-
fault setting. Selection window (Z 54 571) closes.

2. Press the ”Menu” key again and in the selection window

(Z 54 571) press to save. Selection window (Z 54 571)
closes.

3. Press the ”Menu” key again and in the selection window

(Z 54 571) press key . Selection window (Z 54 571)
closes.

4. Press the ”Menu” key again and in selection window

(Z 54 571) press key to load the current PLC setting
in the data set ”setting 1”. Item (8, Z 55 121) changes to
. Selection window (Z 54 571) closes.

5. Press the ”Menu” button again and in the selection window

(Z 54 571) press save to complete the selection. Selec-
tion window (Z 54 571) closes.

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Z 54 784

AC140

14101

Z 56 932

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10.1.7.9 ”Info” screen

(Z 54 784, Z 56 932)

Press button to call up the ”INFO” (Z 56 932) screen.

It contains the specifications concerning:

− crane type
− Construction No.
− Software Versions No.

10.1.7.10 ”Emergency operation” screen (optional)

(Z 54 784)

Press the key or to switch the emergency opera-

tion on/off.

All information on this option can be found in Section 36 ”Emer-

gency operation”.

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Z 54 785

C
E

Z 54 577

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10.1.7.11 ”Operating area limit” screen

(Z 54 785, Z 54 577)

Press button to call up the ”operating area limit”

(Z 54 577) screen. This is where operating area limits can be ob-
served, defined and activated/deactivated.

The operating area which is defined by active operating area li-

mits is displayed in field ”A” as a green area. The black square
(1) shows the current position of the main boom head.

Field ”B” contains the current values for the load, radius and load
utilisation.

Field ”C” contains a bar diagram for the values for the actual and
max. permitted height of the boom head.

Field ”e” shows the current values for the slewing angle and main
boom angle on the symbols.

To exit the screen press key .

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H
F

G Z 55 109

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 Safety Equipment 10

(Z 55 109)

To ensure that the crane and/or boom stays clear of existing ha-
zardous areas − for example in the vicinity of power cables − the
crane operator can define the following limits for the operating
range:
− Slewing angle limit (field ”H”)
− Radius limit (field ”G”)
− Height limit (field ”D”)
− Operating area limit by means of a virtual wall (field ”F”)

This safety device is no substitute for the judgement and

experience of the crane operator and use of recognised
safe operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility
for safe operation of the crane.

Make sure that you deactivate the activated limits as soon as

work in a limited operating range has been completed.
Otherwise, when the crane is next operated in an open area,
crane movements may suddenly and abruptly be stopped,
causing the hook block/load to swing outwards.

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Z 54 578

0,0°

Z 54 786

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10.1.7.11.1 Slewing angle limit (field ”H”)

(Z 54 578, Z 54 786)

− Activate/deactivate the slewing angle limit

− Teaching the left−hand slewing angle

Move to the left−hand limit point and press this key; the
angle setting above the button is overwritten by the cur-
rent slewing angle.
Active: key is green; not active: key is grey.

− Teaching the right−hand slewing angle:

Move to the right−hand limit point and press this button;
the angle setting above the button is overwritten by the
current slewing angle.
Active: key is green; not active: key is grey.

Follow the instructions in Section 8 ”Slewing”.

In particular, make sure that the selected angle limit (= shu-
toff point) actually guarantees sufficient safety clearance to
the hazardous area in extreme situations (e.g. if the hook
block swings out once the crane movement has been shut
off)!
All crane movements should be carried out at a suitable
speed!
After setting the angle limits, carry out a test run to check
that the crane movements are shut down at the intended
points.

Press key . If one of the limits is still active (e.g. slewing angle
limit), the crane operation screen (Z 54 786) displays the symbol
.
Press this key in the ”crane operation” screen to switch off all ac-
tive operating range limits in one go.

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G
Z 54 579

Z 55 110

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10.1.7.11.2 Radius limit (field ”G”)

(Z 54 579)

− Activate/deactivate the max. radius limit

− Teach the max. radius

− Activate/deactivate the min. radius limit

− Teach the min. radius

With regard to changes in the colour, the teaching procedu-

res, exiting the screen and warning instructions, see the
description of the slewing angle limit (p. 95).

10.1.7.11.3 Height limit (field ”D”)

(Z 55 110)

− Activate/deactivate the height limit

− Teaching the max. height

With regard to changes in the colour, the teaching procedu-

res, exiting the screen and warning instructions, see the
description of the slewing angle limit (p. 95).

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P1

Y+

X− X+

Y−

P2

Z 55 112

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 Safety Equipment 10

10.1.7.11.4 Limitation by a virtual wall(field ”F”)

(Z 55 112)

− Activate/deactivate the limit by means of a virtual wall

− Teaching the first wall point (P1)

Approach the desired wall point with the hook block
and confirm this with this key. On the display (field
”A”) a red dot appears (P1).
The co−ordinates for this dot (in this case: ”0” as a va-
lue on the x−axis, +31,92 as a value on the y−axis)
are displayed.

− Teaching the second wall point (P2)

Approach the desired wall point with the hook block
and confirm this with this key. On the display (field
”A”) a blue dot appears (P2).
The co−ordinates for this dot (in this case: ”−18,62”
as a value for the x−axis, ”−25,92” as a value for the
y−axis) are displayed.
The second wall point must be at least 8 m (26.3 ft)
from the first wall point. Otherwise the range is high-
lighted in red with the co−ordinate information.

If, after teaching the two wall points, the limits are activated with
key , the two points are automatically linked with a line.
The resulting permitted operating range is displayed as a green
area.

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Z 54 580

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 Safety Equipment 10

(Z 54 580)

− Switching over the permitted operating range

If the other side of the wall is to be defined as the per-
mitted operating range, press this key; its appea-
rance changes from to , i.e. it is high-
lighted in green.

In particular, make sure that the selected limit

(= shutoff point) guarantees sufficient safety clearance from
the hazardous area in extreme situations (e.g. if the hook
block swings out when a crane movement is shut down)!
All crane movements should be carried out at a suitable
speed!
After setting the angle limits, carry out a test run to check
that the crane movements are shut down at the intended
points.

To exit the screen press key .

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Z 54 787

Z 54 581 Z 54 582

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 Safety Equipment 10

10.1.7.12 ”Joystick”screen
(Z 54 787, Z 54 581)

Press button to call up the ”joystick” (Z 54 581) screen in

order to diagnose the control lever.

The function can be checked by moving the control lever.

To exit the screen press key .

10.1.7.13 ”I/O”screen
(Z 54 787, Z 54 582)

Press button to call up the ”I/O” screen (Z 54 582) for dia-

gnosing the individual in− and outputs for the control unit.

By pressing to open a pull−down menu and make the required

selection.

If the selected element is a CPU, the version no. is also displayed.

To exit the screen press key .

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Z 54 787

Z 56 933

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10.1.7.14 ”CAN”screen
(Z 54 787, Z 56 933)

Press button to call up the ”CAN” screen (Z 56 933) to dia-

gnose the CAN bus.

This screen can be used to check the status of each individual

CAN participant. The status of a participant is OK when the Bits
B1 and B2 are set at ”1”.

In addition, the possibility exists of using the CANLogger to view

bus error lists (Emergency) or logs of guarding errors. This infor-
mation is important for our service department in case of a fault.
Configuration of the CAN participants is also possible in special
cases.

To exit the screen press key .

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1 2 3 4

Z 56 934

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 Safety Equipment 10

10.1.7.14.1 CAN Diagnostics

1. CAN screen (Z 56 934)

1 Bus participants table

2 Key data
3 Bus status
4 Button, call up of CANLogger
(call−up possible only ”by customer service techni-
cians” using a PIN Code)

1.1 Bus participants table (1, Z 56 934)

B1 B2 Description
0 0 Node not available:
Participant is not on the ”bus”
0 1 Node preoperational:
Participant was set to Preoperational by the Ma-
ster.
1 0 Stopped:
Participant was set to stopped by the Master.
1 1 Operational:
Participant is on the bus and is behaving cor-
rectly, meaning that it is participating in guarding
(normal operative state)

All bus participants are listed in the Table. The state of the bus
participants is described by two status bits, the meaning of which
can be obtained from the Table. Under normal operating condi-
tions, B1 and B2 are set to 1.

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1 2 3 4

Z 56 934

3A

“a”

“b”

Z 56 935

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1.2 Key data (2, Z 56 934)

3 key data are shown in the display (2) of the CAN screen
(Z 56 934), which can also provide indication of any possible er-
rors.
The three numerical values mean the following, in the sequence
shown:
− Overruns (OR): number of messages lost at the time of recep-
tion (PDO)
− Java State (JS): shows in the form of numerical values the
status that the Java application has assumed.
There are three possible statuses: Preoperational = 127,
Operational = 5, Stopped = 4.
− Task State (TS): shows which status the CAN Demon (CAN
Task) has assumed.
Here, too, there are three possible statuses: Preoperational
= 127, Operational = 5, Stopped = 4.

Communications between CAN Task and application are disrup-

ted when there are different values in ((JS) and (TS).
− Display in error−free normal operation:
”CAN−OR−JS−TS: 0−5−5”

1.3 Bus status (3, Z 56 934)

The current bus status is shown in the display (3) of the CAN
screen (Z 56 934).
− The green bar (”a”, Z 56 935) means that the DloG is recei-
ving data from the CAN bus.
− If a red bar is visible that is interrupted by a lightning symbol
(”b”, Z 56 935), then the computer is receiving no data from
the CAN bus.

Press button Communications between the application

and the CAN Task can be tested by pressing the button
(3A, Z 56 935).
If the connection is OD, then the monitor screen of the symbol
(3A) needs to be changing back and forth between blue and
green.

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1 2 3 4

Z 56 934

1 2 3

6 5 4
Z 56 936

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1.4 CANLogger button (4, Z 56 934/Z 56 936)

Press button One can switch to the CANLogger by pres-

sing the button (4) in the CAN screen (Z 56 934/Z 56 936).

This call−up for this mask cannot be enabled except by means

of the PIN code being entered by trained customer service techni-
cians.

1.5 Appearance of an error

(Z 56 936)

Two additional buttons are displayed in the event of a CAN error:

− The monitor is completely restarted when key (6) ”Reboot
IPC” is actuated.
− The ”Reset CAN” pushbutton (5) causes a restart of the pro-
gram parts that are responsible for communications with the
CAN card.

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1 2 3 7 8

6 5 4 13 10

Z 56 936 Z 56 937

7 8 9

13 10 12 11 10

Z 56 938 Z 56 939

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2. CANLogger

(Z 56 936, Z 56 937, Z 56 938)

Press button One can switch to the CANLogger by pres-

sing the button (4) in the CAN screen (Z 56 936).

This call−up for this mask cannot be enabled except by means

of the PIN code being entered by trained customer service techni-
cians.

The number of messages is shown in the display (7) of the CAN-

Logger screen (Z 56 937),
if the number of messages (MSG) > 0, then the CAN lists can be
transmitted from the PLC to the DloG computer by pressing key
(13) ”PLC”. Depending on the quantity, the data transfer may
take several seconds.
The ”Data transfer” pop−up shown in the illustration (Z 56 938)
will be displayed during the transfer.

A switchover to the ”CANEmergency screen” fault display is ef-

fected by actuation of key (10) ”Emergency”.

2.1 Status of the CAN bus participant (9, Z 56 939)

The current status of the CAN bus participant is shown in the dis-
play of the CANLogger screen (Z 56 939)
(also see in this connection Point 1.2 ”Key data”, Page 109).

0= Not available
1= Configured, but without message
4= Stopped
5= Operational
127 = Preoperational

Actuating the ”Save” key (11) causes the data on the PLC to be
saved on the DloG computer.

Actuating the ”Reset” key (12) causes the data on the PLC to
be deleted.

A switchover to the ”CANEmergency screen” fault list display,

page 115 is effected by actuation of key (10) ”Emergency”.

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10

12 11 10 13 10B

Z 56 939 Z 56 940

10B

Z 56 941

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 Safety Equipment 10

2.2 Error list display (CANEmergency)

(Z 56 939, Z 56 940)

The ”CANEmergency screen” (Z 56 940) fault display is shown

by actuating the ”Emergency” key (10, Z 56 939).

If the number of messages (MSG) is > 0, then the CAN emergen-

cies can be transmitted from the PLC to the DloG computer by
pressing the ”PLC” key (13).

Illustration (Z 56 941) shows the error lists displaywith the errors

that were transmitted.

One can switch back to the CANLogger view (Z 56 939) by actua-

ting the ”State” key (10B, Z 56 941).

2.3 General fault messages

(independent of the screen that is currently present)

If the master PLC (A0624) fails, then the E102 error message is
reported: ”Display gets no data from A0621.”
The DloG and its connection to the CAN bus are running in or-
derly fashion in such cases.

If the computer is receiving no signals from the CAN bus, then er-
ror E101 is reported: ”Monitor is receiving no CAN data”.

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Z 54 787

1 2

Z 54 789

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 Safety Equipment 10

10.1.7.15 ”LS” screen

(Z 54 787, Z 54 789)

Press button to call up the ”LS” screen (Z 54 789) to dia-

gnose the electric ”Load Sensing” system.

On this screen the status of the pumps, ”coupled” or ”separate”,

is displayed. At the same time the pump pressure and the electric
control of each pump can be read off. (Pump mode 3 only with
Hoist 2, optional)

Depending on the mode selection the screen display changes

(Z 54 789). The left−hand mode key can be pres-
sed. The selected mode is displayed top left in the left−hand key
area.
As an example for all pump modes:
Mode 1 = deactivated (left−hand display, Z 54 789)
Mode 2 = activated (right−hand display, Z 54 789)

LS operation is deactivated by pressing key . The bridging

key is displayed in red . In addition, the warning symbol
is displayed.

To exit the screen press key .

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Z 54 790

Z 54 585

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10.1.7.16 ”Datalogger” screen (optional)

(Z 54 790, Z 54 585)

Press button to call up the ”Datalogger” (Z 54 585)

screen.
The Datalogger saves every set configuration of the crane.
The current configuration is displayed in grey (1).
The date and time show when these configurations were set.

No: The number of data sets currently stored

Current:The currently visible data sets
LLD: 0= Enabled
1= Not enabled

CAN: 0= CAN bus OK

1= CAN bus error

U−LMI 0= Bridging switch load limit device not actua-

ted
1= Bridging switch load limit device actuated

U−HES: 0= Bridging switch HES (hoist limit switch) not

actuated
1= Bridging switch HES (hoist limit switch) ac-
tuated

U_AUF 0= Bridging switch UP (luff up) not actuated

1= Bridging switch UP (luff up) actuated

TELE_M: 0 = Tele automatic active

1= Tele manual active

LC: Selected length code

LK−RV: The relevant length code for the load cal-

culation

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Z 54 585

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(Z 54 585)

EIN: Hoist rope reeving

AUSL: Current crane load

MAX: Maximum load

Last/ Current load

load:

RAD: Current radius

RAD−RV Radius relevant to load calculation

HA−W: Current boom angle

HA−KW: Current main boom head angle

HA−L: Current main boom length

DREHW: Current superstructure slewing angle

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Z 60 257

Z 54 587

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10.1.7.17 ”Function diagnosis” screen

(Z 60 257, Z 54 587)

Press button to call up the ”function diagnosis” (Z 54 587)

screen.

By pressing to open a pull−down menu and make the required

selection.

For the selected function, the setpoint and actual values can be
compared to diagnose an existing malfunction.

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Z 54 792

Z 54 793

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The following provides a description of the keys that can only be

pressed on the ”Quick Menu” screen.

10.1.7.18 ”Main menu” screen

(Z 54 792)

Press button to change to the main menu.

10.1.7.19 ”Telescoping information system” screen

(Z 54 793)

Press button to change to the ”telescoping information sy-

stem”.
Detailed information on this subject can be found in Section 12
”Telescoping”.

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Z 54 794

75,0 75,0

95,0 95,0

Z 54 795

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10.1.7.20 ”Support pressure/tilt display” screen

(Z 54 794, Z 54 795)

Press button to call up the ”support pressure−/tilt display”

(Z 54 795) screen.

This screen displays:

− the current support pressure (upper range)
− current crane tilt (lower range)

Support pressure gauge

The current support forces are recorded by pressure contacts in

the vertical outrigger cylinders.

RISK OF ACCIDENTS!
For the supporting procedure refer to Chapter 12 ”Sup-
porting on outriggers”.
If the vertical outrigger cylinders − contrary to the pre-
scribed procedure − are extended fully up to the stop, the
support forces displayed will be inaccurate.

For correct crane operation in accordance with the specifications

in the load capacity tables, the maximum (permitted) support for-
ces are:
front − max. 75 t (165 kip)
rear − max. 95 t (209 kip).

If the permitted limit values are exceeded there is a risk

of accidents!
Depending on the load−bearing capacity of the ground
where the crane is parked, it may well be that the permit-
ted support forces are much lower.
Observe the permitted limit values when supporting the
crane on outriggers and when operating the crane.

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0,0°

STB

Z 54 795 Z 54 797

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 Safety Equipment 10

(Z 54 795, Z 54 797)

On the ”support pressure” screen (Z 54 795) the current and the

max. permitted/occurring support pressure are displayed for
each of the 4 supports.
For support pressures in the limit range, i.e. < 5% or > 95%, the
display bars are shown in red.

If the support pressure falls below 1 t (2.2 kip), the warning buz-
zer sounds and the ”crane operation” screen (Z 54 797) displays
the warning ”STB” (red).

If the crane is equipped with support area monitoring (optional),

the recorded outrigger support area is displayed on the struts.

Inclination display

Before commencing crane operations, the crane must be sup-

ported on outriggers and aligned horizontally. Observe the cor-
responding information in the operating manual of the crane
chassis, Section 12 ”outriggers”.

In the display of the ”support pressure/tilt display” screen

(Z 54 795) one line represents 1°.

The current tilt is permanently displayed on the ”crane operation”

screen (Z 54 797) by means of the symbol .

Risk of overturning!
Operation of the crane is only permitted when the crane
is aligned horizontally.

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10

Z 54 798

Z 54 799

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 Safety Equipment 10

10.1.7.21 Keys for ”Operating mode of the hydraulic pumps”

(Z 54 798, Z 54 799)

Preferred hydraulic circuits can be assigned to the crane move-

ments ”luffing” and ”telescoping”.
The hydraulic pumps can be assigned so that they combine to
supply all hydraulic functions.
To achieve improved operation/activation, the pumps can be se-
parated.

Select the operating mode of the hydraulic pumps.

Press the left−hand key (Z 54 798). The selected
operating mode is displayed in the top left−hand corner of the
left−hand key pad. In both keys the movements of
the assigned pumps are now displayed.
By repeatedly pressing the left−hand button additional operating
modes can be selected.

The key displays change in accordance with the selected opera-

ting mode.

When ”operating mode 4” is selected, telescoping is not

possible.
When attempting to telescope, an information message is
shown on the display (Z 54 799). To enable telescoping, an-
other operating mode must now be selected.

Press key to call up the assigned screen ”LS” to diagnose

the operating mode selection. See Section 10.1.7.15 ”LS
screen”, page117.

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10

Z 55 350

0°

Z 55 351

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 Safety Equipment 10

10.1.7.22 ”Active operating range limits” screen

(Z 55 350, Z 55 351)

Press button to call up the screen ”Active operating range

limits” (Z 55 351) on the right−hand half of the screen.

In status line (1) the corresponding active limits are displayed

using the corresponding symbols (here: height limit, max. radius
and virtual wall).

The graphic display shows the permitted operating range as a

green area.
The current position of the main boom head is displayed as a
black square.

On the bar display (2) the blue bar shows the actual height of the
main boom head in relation to the max. permitted head height
(green).

Press button (Z 55 351) to switch off all active operating

range limits in one go.

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Z 55 352

Z 55 353

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10.1.7.23 ”Engine display” screen

(Z 55 352)

Press button to call up the ”engine display” screen.

Detailed information on this subject can be found in Section 5

”engine”.

10.1.7.24 ”Configure counterweight” screen

(Z 55 353)

Press button to call up the screen ”configure counter-

weight”.

Detailed information on this subject can be found in Section 9

”Counterweight”.

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Z 55 354

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 Safety Equipment 10

10.1.8 Configuration
(Z 55 354)

If, when configuring with the length code (LC 1) − i.e. the main
boom is completely retracted − there are no table readings for the
current crane configuration, the opposite symbols are displayed
and the load utilisation display of the load limit device is
displayed in red (with 3 stars) .

In configuration operation no lifting capacities are enabled!

The raising of loads is not permitted!

Risk of overturning!
The crane may only be configured in an erected state (ou-
triggers, counterweight etc.) for which there are load capa-
city tables.
During configuration, the crane cannot be monitored by the
load limit device.

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10

B1

B2

0,0°

Z 55 355

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 Safety Equipment 10

10.1.9 Load Monitoring Assembly

(Z 55 355)

With the help of the computer of the load limit device it is possible
to check the weight of the raised load (net load).

The load monitoring assembly may not be used to calculate

the load, but is used to check the weights of loads that have
been previously calculated in order to calculate better the
load hoist and to avoid potentially hazardous situations.

Before raising the load, the maximum load corresponding to the

driving operation must be determined. It is displayed in relation
to the selected operating mode on the screen in the MAX (t / kip)
display (B2).

Load monitoring

1. With the hook block hanging free (without load, with load−
handling device) press the button of the net display NET
(t / kip) (B1). The lifting tackle is tared and set at 0.0 t
(0.0 kip) net load.

2. Raise the load with the hoist.

The net display now shows the net load (actual load on the
hook without load−handling device).

The gross load contains − in addition to the load weight − the

weight percentage of the main boom extension in the transport
position, the weight of the hook block and all load−handling
equipment. The net load is the actual load on the hook block wi-
thout the load handling devices. Display errors are possible be-
cause of outside factors, e.g. wind, which have an effect on both
the crane and the load.

The load may only be raised with the hoist. Raising the load
by extending the telescopic sections or luffing cylinders is
prohibited.

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10

30 16

31
32
24
34

35
36

Z 54 006

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 Safety Equipment 10

10.1.10 Dead man’s handle

(Z 54 006)

To prevent unintentional activation of crane movements, both

control levers are fitted with an additional button (32/36, dead
man’s handle). A crane movement can only be carried out as long
as one of these buttons is pressed.
For example, a movement can be carried out with the left−hand
control lever while the dead man’s handle is pressed in the right−
hand control lever.
The dead man’s handle may only be actuated (pressed and re-
leased) when the corresponding control lever is in the ”neutral po-
sition” and/or the operating movement has been completed.

RISK OF ACCIDENTS!
If one of these dead man’s switches is pressed or released
when a control lever is fully actuated, the corresponding
movement will be started/braked abruptly.

RISK OF ACCIDENTS!
All crane movements should be started and carried out at
suitable speeds to avoid the load or hook block swinging
out when the corresponding movement is switched off and
the subsequent risk of crushing or collision.

The control levers (16/24) may not be switched directly in the

opposite direction before first being returned to the neutral
position. Only when the superstructure is at a standstill may
the opposite movement be carried out.

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10

B C

0,0°

Z 55 378

Z 55 379

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 Safety Equipment 10

10.1.11 Malfunction procedure

10.1.11.1 Malfunction−free operation

(Z 55 378, Z 55 379)

When crane operation is free of malfunctions, the menus and

screens currently configured are shown on the IC−D display
(DLOG). Crane movements can be executed with the aid of the
control lever.
The individual areas ’A’ to ’e’ are arranged on the display In the
”Crane operation” mask (Z 55 378). For fault−free operation the
spaces between the individual fields are separated with a grey
background colour.
In the main menu and in other submenus, the top line is displayed
in blue for fault−free operation (Z 55 379).
In the case of fault, the colour of the top line changes to red.

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10

64.1 64.11
64.2 64.12
64.3 64.13
64.4 64.14

64.15
64.6
64.7
64.8 64.16
63

64.19

Z 58 745

67

Z 56 192

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 Safety Equipment 10

10.1.11.2 Failure of the display ”touchscreen” feature

(Z 58 745, Z 56 192)

If no more entries can be made on the display (DLOG) by tou-

ching the monitor screen surface (touch screen), even though no
other malfunctions are present, then the functioning of the load
limit device is ensured. The monitor view is shown the same as
with ”Malfunction−free operation” (see p. 143).

One possible cause for the failure of the ”touchscreen” could be

the operation of the display when ambient temperatures are too
high. The crane cab will then need to be cooled down with the air
conditioner. Direct sunlight on the display must be avoided.

In order to continue directly with crane operation, the keys (64.11)

− (64.16) on the right−hand side of the screen can be used:
(64.11)− key: move the mouse cursor upwards

(64.12)− key: move the mouse cursor downwards

(64.13)− key: move the mouse cursor to the left

(64.14)− key: move the mouse cursor to the right

(64.15)− key: switch key/mouse operation on/off

(64.16)− key: trigger one mouse−click (touch pressure).

If these keys are not present, then a commercially available com-

puter input device with USB connection (e.g. USB mouse, USB
trackball or similar) can be connected in order to be able to under-
take entries at the screen.

A USB connection (67, optional) can be located for this purpose

on the cabin instrument panel.
If this kind of USB connection is not present in the instrument pa-
nel, then the display (Z 58 745) must be removed. Two USB con-
nections (64.19) are located on its underside.

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10

B C

0,0°

Z 55 378

Z 55 379

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 Safety Equipment 10

10.1.11.3 Display screen failure

(Z 55 378, Z 55 379)

If only the display (DLOG) fails, then the functioning of the load
limit device is ensured.

The display can fail in two ways:

1. Option:

The background colour switches to red and/or the header is

shown in red.
The configured menus/masks continue to be displayed, but now
they are no longer being updated, either to a partial extent or ent-
irely.

RISK OF ACCIDENTS!
Please note that the load and radius display is not updated!

2nd option:

Monitor failure − the monitor turns black.

What is to be done?

Proceed with both types of monitor malfunction as follows:

1. Place load down.

2. Look for the source of the error.

3. Rectify the error.

RISK OF ACCIDENTS!
No crane operation is permissible when the display fails!
The error must be eliminated before crane operation is per-
mitted to resume!

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39,0
7,50

Z 54 756

64.6

Z 58 747

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 Safety Equipment 10

(Z 54 756)

The display of the crane control (DLOG) attempts to register au-

tomatically with the crane network. Once registration has been
completed, the screen ”Operating mode selection” will appear.

All crane movements are stopped for as long as the ”Operating

mode selection” screen is displayed. The crane control reacts as
with a new start.

Once the operating mode has been selected, you can proceed
further, as described in detail starting on page 51.

If automatic registration with the crane network fails, the CAN

mask can be selected to search for the fault. Here checks can be
carried out to see which components are in the network.

Depending on which faults exist the load can still be set

down using the hoist.
The main boom can be telescoped in by means of actuation
of the corresponding control lever in the telescoping−in de-
vice (dependent on the control lever function configura-
tion). If telescoping retraction is not possible, then the
crane and/or the load must be put down with an auxiliary
crane as an emergency measure.
It must be observed that the load and radius display are not
updated.
In this event, please contact our customer service depart-
ment.

Monitor failure due to ambient temperatures being too high

(Z 58 747)

If there is monitor failure (”black screen”) at the same time that the
”Temp” warning lamp (64.6) is illuminated, then the ambient tem-
perature is too high. The crane cab will then need to be cooled
down with the air conditioner. Direct sunlight on the crane con-
trols display must be avoided.
As soon as the ambient temperature has been reduced to a per-
mitted value, the display (DLOG) will once again report to the
crane network on its own.

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 Safety Equipment 10

10.1.11.4 Failure of the crane control (CAN stop)

In the event of crane control failure all crane movements are stop-
ped within one second.
No further crane movements can then be driven using the control
lever. Only such inputs as affect diagnostics can be carried out
via the display (DLOG).

Before continuing operation of the crane, the fault must first

be rectified.

RISK OF ACCIDENTS!
If necessary, the crane and load must be emergency lowe-
red using an auxiliary crane.
In this event, please contact our customer service depart-
ment.

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10

Hoist limit switch

0,0°

Z 55 356

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 Safety Equipment 10

10.2 Limit switch

10.2.1 Hoist limit switch

10.2.1.1 Function
(Z 55 356)

Hoist limit switches are safety devices that limit the upwards mo-
vement of hoist ropes and hook blocks.
This avoids collisions between the hook block and boom head
and therefore possible damage to these parts and/or the hoist
rope, which could cause the load to fall.

For this reason, the crane may only be operated with fully func-
tional hoist limit switches that have not been triggered.

RISK OF ACCIDENT!
Approach the hoist limit switch daily and check that it func-
tions properly!

If a hoist limit switch is triggered (and not overridden), HES (red)

appears on the IC−1 display and the warning buzzer sounds. The
following crane movements are shut down:
− Raise hoists
− Extend telescopic sections
− Lower luffing gear and raise luffing gear.

Then either lower the hoist or telescope in in order to end this pro-
hibited condition.

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113
114

Z 55 102

0,0°

Z 55 357

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 Safety Equipment 10

10.2.1.2 Bridging the Hoist Limit Switch

(Z 55 102, Z 55 357)

Key−operated pushbutton (114) is used to bridge the hoist limit

switches ”raise hoists”.
When the limit switches are overridden, the indicator light (113)
lights up.

On the IC−1 display HES appears (black). This means that the
hoist limit switches are overridden, regardless of whether they
are triggered or not.

The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.

The limit switches may only be overridden in exceptional ca-

ses, e.g. when configuring the crane (fitting or changing
equipment components, fitting ropes etc.).

Operation of the crane with the limit switches overridden

is prohibited. RISK OF ACCIDENTS!

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0,0°

Z 55 358

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 Safety Equipment 10

10.2.2 Lower limit switches

10.2.2.1 Function
(Z 55 358)

Lower limit switches are safety devices which shut down the un-
reeling function of the hoist rope when it is down to 3 remaining
turns on the drum. This prevents the rope being wound back on
in the opposite direction.

If a lower limit switch has been triggered (and not overridden), the
IC−1 Display shows SES (red) and the warning buzzer sounds.
”Lower hoist” is switched off. Only ”raise hoist” is possible.

10.2.2.2 Bridging the Lower Limit Switch

A lower limit switch must be overridden directly at the correspon-

ding proximity switch.

The lower limit switches may only be overridden in exceptio-

nal cases (e.g. to change or fit ropes).

Operation of the crane with the limit switches overridden

is prohibited. RISK OF ACCIDENTS!

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10

”X0550”
2

3 5

4
6

Option Option Option

X0560
X0561 X0550
X6540

X7811
X7272
X7811
X6540

X7272

H6263
X6540
X7271 H6262

B7513
+341−X7811 X7811 X7811

HES
HES HES
Z 56 945

”Y”

”X”

7
Z 56 946

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 Safety Equipment 10

10.3 Electric safety chain

(Z 56 945, Z 56 946)

On distribution box ”X0550” on the main boom head the electric safety
chain for operation of the crane is connected.

10.3.1 Main boom operation

For main boom operation the sockets on the distribution box ”X0550”
must be assigned on the main boom head as follows:

Socket (3)

− either with the plug of the wind speed rotor (2)

− or with the connection plug for the main boom extension
− or with bridging plug “17−poles” (6).

Socket (3) must in any case be fitted with one of the named plugs.

Socket (4)

− with the plug for the aircraft warning light (1) (as shown)
− or protection cap.

The aircraft warning light is secured− as shown − with two wing nuts on
the main boom head.

Cable (5) of the hoist limit switch (7)

− Hoist limit switch (7) is screw−connected to switch box ”X0550” via

cable (5).

iThe plug−in connection of the hoist limit switch is to be found on the

opposite side of the main boom head (Z 56 946).

To guarantee the function of the hoist limit switch (7) on the main
boom head, the shift weight must hang freely and the hoist limit
switch may not be bridged.
Make sure that the hoist limit switch retainer (red flag) is inserted
in the storage position (Z 56 946, “X”).
Hoist limit switch ”bridged” is shown in (Z 56 946, “Y”).

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10

”B”
”A”

4 1
7 2

1
Z 56 947

”B”
”A”

Z 56 948

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 Safety Equipment 10

Removing and storing the hoist limit switch retainer.

To change the retainer from the locking position to the storage

position, proceed as follows (Z 56 947, Z 56 948):

1. Pull hoist limit switch cable downwards 1 , then bend back-

wards parallel to the boom and hold in this position 2
(Z 56 947).

2. Move the retainer down 3 , and then to the 4 left. Release

the hoist limit switch cable (Z 56 947).

3. To store, push the retainer from the left over the hoist limit
switch (7) 5 until the two clips “A“ lock in the hole “B” of the
hoist limit switch (Z 56 948).

10.3.2 Operation “Main Boom Extension”

Information on connecting the safety chain for crane operation on

the main boom extension can be found in section 18.3 of these
operating instructions.

For crane operation open hoist limit switch connections at

components of the main boom extension have to be bridged
via plug (2 poles).
Only then it is guaranteed, that the signal of the hoist limit
switch may be looped through the components.

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 Working Instructions 11

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2
3

Z 54 714

180°

Z 54 715

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 Working Instructions 11

11 Working Instructions

11.1 Wind Speeds

(Z 54 714, Z 54 715)

It is essential that you observe the permitted maximum wind

speeds. To check the wind speed, the crane is equipped with an
air speed indicator (anemometer).
This comprises two elements:

(Z 54 714)
1. the rotor (1), which must be fitted to the head of the main
boom or main boom extension at the prescribed bracket (2).
To do so, insert the rotor into the bracket, screw the lock nut
(3) onto the thread of the bottom rotor component and
tighten.

With an attached rotor, the transport height of 4 m (13.1 ft) is

exceeded.

(Z 54 715)
2. the display on the IC−1 screen with the corresponding sym-
bol.
The rotational movement of the rotor caused by the wind is
converted into an electrical signal which is displayed on the
IC−1 display in the crane operator’s cab. The crane operator
can read off the wind speed here in m/s (mph).

Before commencing work or erecting the equipment it must

be ensured that the anemometer is fully functional. This is
the case if the displayed value changes when the rotor is ro-
tated.
If there is no wind, this must be simulated by manual rotation
of the rotor.

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11

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 Working Instructions 11

The wind speeds specified below are maximum values.

In any case, pay attention to the information in the lifting ca-
pacity tables, as there can, under certain circumstances,
be reductions in the permitted wind speeds.
National regulations must also be observed.

Wind speed What you have to do....

up to 9.8 m/s (21.9 mph) operation of the crane is per-
mitted without any restrictions
over 9.8 m/s (21.9 mph) stop operation of the crane
above 15 m/s (33.6 mph) telescope main boom in,
main boom extension can re-
main in the operating posi-
tion.
If possible, place the boom
system into the wind.
above 20 m/s (44.7 mph) bring the boom system into
the transport position.

Before the crane is operated, the local weather authority

should be contacted for information on expected wind con-
ditions during the entire operation of the crane.

For the wind speeds listed in the load capacity tables, a load sur-
face area exposed to the wind of 1.0 m2/t (4.88 ft2/kip) − at least
2 m2 (21.5 ft2) − and a wind resistance value cw of 1.2 has been
calculated.

Also take the detailed information in “Instructions on opera-

tion of the crane” into consideration, which were supplied
with the load capacity tables.
For loads with a larger surface area exposed to the wind,
please contact the crane manufacturer.

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 Working Instructions 11

If the crane is to be left unattended for a longer period of

time, e.g. overnight, the main boom must be telescoped in
and any additional equipment which is fitted set down on
the ground.
If wind speeds exceeding 20 m/s (44.7 mph) are to be ex-
pected, set the boom system in transport position.

At the work site make sure that sufficient space is left in the
vicinity of the crane so that the main boom can be tele-
scoped in and the additional equipment placed on the
ground, if a (strong) wind suddenly occurs.

If site conditions do not allow the boom system to be low-

ered to the ground, a weather forecast must be obtained for
the whole of the work period.
A suitable and safe contingency plan must be put in place
to lower the boom system in the event of (strong) winds.

For all crane configurations the boom system may only be

erected (raised from the ground) if the expected wind speeds
(weather forecast) are also permitted for operation of the crane.

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 Working Instructions 11

11.2 Crane Operation

Before starting the engine or starting crane movements the

crane operator must sound the horn to warn persons who
are in the vicinity of the crane.

The crane may only be placed in operation when:

∗ the engine of the crane chassis is switched off.
∗ the cab of the crane chassis is closed.
∗ the control panels of the outriggers are closed.
To increase the operating speed, four movements can be carried
out at the same time and independently of each other.

Before each load case, the corresponding limit switches must be

checked to make sure that they are functioning correctly.

When operating the main boom, observe section 10.4 of these

operating instructions for information on how to connect the elec-
trical lines (closing the safety chain).

The procedures for operating the crane with additional equip-

ment are contained in the individual sections (e.g. main boom ex-
tension).

Simultaneous raising of a load on the main boom extension and

on the main boom is not permitted.

Danger of tipping over!

Two−hook operation is not secured by the load limit de-
vice and can lead to overloads and tilting of the crane.

It is not permitted to raise a load on the main boom with the main
boom extension in operating position (loaded or unloaded).

If the main boom is extended and pinned in its final operating

length, the locking and pinning unit must be completely retracted.

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11

80 o

1 1 4

70 o

Z 54 090 Z 54 091

10/25 140−1110c_en
 Working Instructions 11

There are load capacity tables for which a permitted minimum

radius must be observed. The corresponding crane movements
are then shut down.

This minimum radius must not be exceeded.

Risk of falling backwards!

There is one load capacity table that only allows operation of the
crane with the superstructure in the 0 ° position, i.e. the super-
structure to the rear. In this case:

∗ Slew superstructure to a position of 0° +/− 2°.

∗ Select “HA−0” operating mode(refer to sect. 10 of these oper-
ating instructions).

Failure to observe this can lead to a RISK OF TIPPING.

If not otherwise instructed in the load capacity tables, the number

of the reevings may not be smaller than 2−falls.
However, if a 1−fall reeving is required, the load capacities listed
in the table must be reduced by 20%. This also applies if the lifting
capacity lies beneath the maximum permitted cable tension of
8.1 t (17.9 kip) per rope fall.

(Z 54 090)
RISK OF DAMAGE!
If the main boom is in the high position (80−82) and is com-
pletely telescoped in, the crane movements must be carried
out with appropriate care and at slow speeds. By doing this
you prevent swinging movements of the hook block (1),
which could cause collisions with the luffing cylinder (2).

(Z 54 091)
RISK OF DAMAGE!
If the main boom basic case is fitted with dolly supports (op-
tion “dolly operation”), the main boom angle must not ex-
ceed 70 towards horizontal when telescoping from basic
length (LK 1).
If the angle exceeds 70, there is a danger of collisions be-
tween hook block (1) / hoist limit switch (3) and dolly sup-
ports (4).

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11

12/25 140−1110c_en
 Working Instructions 11

The weight of the hook blocks and lifting tackle must be taken off
the values in the load capacity tables.

When raising a load on the main boom with the main boom exten-
sion locked in the transport position, the load capacities specified
in the load capacity tables are reduced. You also calculate mini-
mum loads.

With regard to “hook block weights” and “minimum loads”

observe the “Instructions on Operating the Crane”, which
are supplied with the load capacity tables.

Operation of the crane is only permitted when supported on out-

riggers and horizontally aligned. Only values which are listed in
the load capacity tables are valid as a support base area.

If no specifications are present in the load capacity table concern-

ing the outrigger span, work with the crane should be carried out
on outriggers and with fully extended supports (outrigger span:
7.5 m (24.6 ft), extend as far as the mark).

For the reduced outrigger support area, the maximum counter-

weight that can be fitted is the one listed in the corresponding
load capacity table.

If, in contrast with these specifications, larger counter-

weights are fitted, the superstructure may not be rotated.
RISK OF TIPPING!

If the crane is equipped with a follower axle (option), the maxi-

mum counterweight mounted must not exceed the counterweight
stated in the corresponding load chart.
For this especially refer to Section 9 ”Counterweight” , subitems
” Configuring the counterweight on the crane chassis support at
the front or rear”.

If, in contrast with these specifications, larger counter-

weights are fitted, the superstructure may not be rotated.
RISK OF TIPPING!

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14/25 140−1110c_en
 Working Instructions 11

Handle the slew gear and slew brake carefully. Select a low slew-
ing speed. Brake carefully.
This applies especially to operation with the main boom exten-
sion or fly jib or special site conditions.

Risk of crushing!

In spite of the use of state of the art automatic safety equip-

ment, the load cannot always be prevented from swinging
out when a movement is switched off.
This can only be prevented by braking and accelerating all
crane movements carefully and appropriately.

To allow for immediate reaction if the crane is subjected to chang-

ing environmental conditions, it is prohibited to switch off the drive
of the crane when a load is attached and / or to leave the crane
cab.

An exception is only permitted in emergency situations. To

avoid dangerous situations, as a last option the power
source (diesel engine) can be switched off using the quick
off switch in the crane operator’s cab. First, where pos-
sible, any movements which have been started should be
completed using the control lever.

The erected crane without load may only be left without the su-
pervision of a trained crane operator if certain conditions are met
(see part 2, operating instructions for the crane chassis, Sect. 14
”Parking”).

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11

Z 53 498

16/25 140−1110c_en
 Working Instructions 11

To prevent the unintentional activation of crane movements, both

control levers are fitted with an additional button (dead man’s
switch).
A crane movement may only be carried out as long as one of
these buttons is pressed.
The dead man’s switch in the control levers may only be actuated
(pressed and released) and the limit switches may only be
bridged on the instrument panel when the corresponding lever is
in the neutral position and/or the working movement has been
completed.

Risk of accidents!
If one of these buttons is actuated when the lever is fully de-
flected, the current movement is stopped suddenly and
abruptly.

(Z 53 498)
During operation of the crane observe display (4). The tempera-
ture of the hydraulic oil must not exceed 85° C (185° F).

This applies to the oil filled ex works. For oils with a different vis-
cosity, observe the corresponding characteristic curves or get in
touch with the crane manufacturer.

If this value is exceeded, operation of the crane should be

stopped temporarily. Leave the diesel engine running at low revs
so that the hydraulic oil can be cooled down via the oil cooler.

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18/25 140−1110c_en
 Working Instructions 11

11.3 Operation Planning / Monitoring Safety Measures

Before commencing work, i.e. before taking up a load, the condi-

tions described below must be fulfilled.

11.3.1 General

For every crane operation that is planned, the crane operator /

operation planner must place ready a suitable crane with suffi-
cient lifting capacity, hoist height and working radius.

The weight of the load must be known.

Move the load as low above the ground as possible.

Avoid excessive operating speeds which could cause the load to

swing. Large loads must be guided from the ground with ropes.

11.3.2 Condition of the Crane

− correctly supported on outriggers and horizontally aligned.

− all four outriggers extended to the support base area speci-
fied in the corresponding load capacity table.
− all four outriggers safeguarded with pins to prevent them
shifting.
− all four vertical outrigger cylinders extended so that all axles
are relieved of load i.e. so that no tyres are in contact with the
ground.
− support plates locked.
− suspension system of the crane chassis switched to “raise
axles” or “hold axles”.

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20/25 140−1110c_en
 Working Instructions 11

11.3.3 Condition of the Environment

Load−bearing capacity of the ground

The ground must have sufficient load−bearing capacity to take

the maximum support pressures which occur. If necessary, in-
crease the support area by stacking suitable materials under the
outrigger plates.

Specifications concerning the maximal outrigger pressure occur-

ring as well as further important information concerning safe out-
rigging can be found in sect. 12 ”Outrigging” of the crane chassis
operating instructions (Part 2 of these operating instructions).

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22/25 140−1110c_en
 Working Instructions 11

11.4 Conversion of units

Instructions:

Multiply the known value by the conversion factor to obtain the

result in the desired units.

Example: 2 kg in lbs (US) as follows:

2 x 2.2046 = 4.4092 lbs (US)

Converting from in Multiply by

kg lbs 2.2046
lbs kg 0.45359
lbs kip 0.001
kip lbs 1000
kg kip 0.002205
kip kg 453.6
t (SI) ton (US) 1.103
ton (US) t (SI) 0.907
kip ton (US) 0.5
ton (US) kip 2.0
mm inch 0.039
in mm 25.4
cm inch 2.54
inch cm 0.394
m ft 3.281
ft m 0.3048
km mile 0.621
mile km 1.6093
cm2 inch2 0.155
inch2 cm2 6.4516
ft2 m2 9.2903 x 10−2
m2 ft2 10.746

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24/25 140−1110c_en
 Working Instructions 11

Continuation of conversion of units

Converting from in Multiply by

m/s ft/sec 3.281
ft/sec m/s 0.3048
m/s ft/min 196.86
ft/min m/s 0.00508
m/s mph 2.236
mph m/s 0.447
km/h mph 0.621
mph km/h 1.6093
bar psi 14.513
psi bar 0.0689
psf lbs/ft2 1.0
lbs/ft2 psf 1.0
ltr gal (US) 0.264
gal (US) ltr 3.7854
ltr barrel 0.0063
barrel ltr 158.99
oC oF toF= 1.8 (toC) + 32
oF oC toC= (toF−32) / 1.8

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 Telescoping 12

140−1120−101a 1/77
12

Z 54 716

3 3

5 Z 54 717

2/77 140−1120−101a
 Telescoping 12

12 Telescoping

12.1 General
(Z 54 716, Z 54 717)

”Telescoping“ means retracting or extending the main boom.

The main boom consists of a basic case and five telescopic sec-
tions.
When fully retracted, the main boom is 12.5 m (41 ft) long, when
fully extended it is 60 m (196.9 ft). All telescopic sections must al-
ways be pinned at these and all other working lengths.
This means that each boom section is locked to the next largest
boom section by a spring−loaded pin or bolt (3) on the left−hand
and right−hand side at the rear.

There are also load capacities in the unpinned condition. Refer

to section 12.4.1 ”Lifting Capacity at Intermediate Conditions”,
starting at page 67.

All five telescopic sections are retracted and extended using the
following elements:
− − a telescoping cylinder (1), which is fastened to the back of
the basic case.
− a safety and locking unit “LPU” (5) attached to the cylinder
pipe.
It is connected with the top of the piston rod of the telescoping
cylinder via a pulling frame (6) and is therefore moved as
soon as the telescoping cylinder is moved.
− − the LPU is activated via two hydraulic cylinders.

When retracting and extending, there is a risk of crushing

at the bearing points of the telescopic sections.
Persons must therefore remain clear of the danger zone.

140−1120−101a 3/77
12

4/77 140−1120−101a
 Telescoping 12

All necessary steps are shown to the crane driver by the telesco-
ping information system.

To extend the boom, the telescopic sections to be extended must

be extended one after the other.
When extending, begin with the smallest telescopic section (the
one nearest the centre).
During telescoping, the telescopic section is locked at the LPU
(locking and pinning unit).
To telescope out the next telescopic section, the telescoping cy-
linder with fitted LPU must first be moved back in empty an empty
state.

Before each telescoping procedure, all telescopic sections must

be pinned and unlocked. The corresponding telescopic section
is then locked and unpinned.
After each telescoping procedure, the individual telescopic sec-
tion is pinned and unlocked before the next telescopic section is
extended.

All telescopic sections can be pinned at 0% / 45% / 90% and

100%. Length codes exist for all extension states used in load ca-
pacity tables.

If the main boom has been extended or retracted to its final

operating length and pinned, the LPU must be completely re-
tracted.
Lifting capacities are valid only after the LPU has been com-
pletely retracted.

Telescoping of the main boom without the load on the hook and
without the auxiliary equipment fitted is described below.

For telescoping when a load is present, refer to Sect. 12.4.2 “Te-

lescoping with Loads”, page 73.
Telescoping of the main boom when additional equipment fitted
is described in the section where the corresponding additional
equipment is outlined, e.g., Sect.18 ”Main Boom Extension
(MBE)”.

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Z 54 716

6/77 140−1120−101a
 Telescoping 12

12.2 Locking and Pinning Unit (LPU)

12.2.1 Functional Characteristics

(Z 54 716)

The LPU (5) is attached to the pipe of the telescopic cylinder (1).
It is connected with the top of the piston rod of the telescoping cy-
linder via a pulling frame (6) and is therefore moved as soon as
the telescoping cylinder is moved.

Each procedure runs automatically at the LPU and consists of

two interlinked processes:
− Locking and unpinning
− Pinning and unlocking.

The locking and pinning unit is designed in such a way that

once the corresponding procedure has been activated, the
telescopic sections are always locked (or pinned) before the
following action of unpinning (or unlocking) can be carried
out mechanically.
This ensures that the system is never in an unsafe condition
(unpinned and unlocked at the same time).

140−1120−101a 7/77
12

1
2

2
A A
4 4

3 B B 3

1
2

2
D D
4 4

3 C C 3

Z 200 036

8/77 140−1120−101a
 Telescoping 12

(Z 200 036)

Locking / unpinning

Two pins (2) on both sides of the LPU are used for mechanical
locking between the locking and pinning unit and the corres-
ponding boom section. This is described as “locking” (A).

“Unpinning” (B) follows immediately after the locking proce-

dure. In this case, the grippers (4) draw the pins (3) in the lateral
walls inwards to loosen the lock between the one boom section
and the next largest section.

In this state, telescoping can be carried out. The LPU is moved

at the same time.

Pinning / unlocking

Is carried out in the same way as locking / unpinning. First the

grippers (4) of the spring−loaded pins (3) re−establish the lock
between the two respective telescopic sections (”Lock, C”), then
the two horizontal locking pins (2) are retracted (”Unlock, D”) so
that there is no connection between the LPU and the telescopic
section.

140−1120−101a 9/77
12

A B

45%

90%

100%

90%

45%

10° 28%

Z 54 718

23.9 m

10°

Z 60 350

10/77 140−1120−101a
 Telescoping 12

12.2.2 Supply of the LPU with hydraulic oil

(Z 54 718, Z 60 350)

Supply of the LPU with hydraulic oil is done through the telesco-
ping cylinder with an internal oil conduit. A hydraulic accumulator
is needed to do this. This accumulator should always be within
a pressure range of 65 − 85 bar (943 − 1233 psi).

The pressure display is shown at (3) in the display “TeleManual”

(Z 60 350). This can be activated in the following way:

On the screen ”Quick Menu” (Z 54 718, ”A”) press the key

. The input screen of the telescoping information system,
the ”telescoping display” (Z 54 178, ”B”), appears instead of the
”Quick Menu”. Press the button there.

If the pressure in the accumulator falls below 76 bar (1100 psi),

normally the loading procedure is started automatically.
The loading procedure is not carried out if:

1. the pressure in the accumulator is >86 bar

(1247 psi)
2. the telescopic cylinder is retracted
3. the LPU is in the state ”locked / unpinned” and the
telescopic cylinder is not telescoped (unpinned
loads)
4. the LPU is in the state ”unlocked / pinned”, the
telescopic cylinder is not telescoped and the entire
telescoping drive is telescoped out less than 1.5 m
(4.9 ft)
5. the LPU is in the approach position, fine position or
follow−up position during the locking and pinning
procedure

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12

23.9 m

10°

Z 60 350

12/77 140−1120−101a
 Telescoping 12

(Z 60 350)

If the pressure sensor malfunctions, the fault symbol ap-

pears on the left side of the IC−1 display. When the fault message
is called up, the fault code no. “E:325” appears.

Then the accumulator pressure has to be manually brought into

the normal range of 65 − 85 bar (943 − 1233 psi). The button
next to the accumulator symbol has to be pushed to do this.
The button is left green when the pressure is within the normal
range and is left red when the pressure is NOT within the normal
range.
During the loading procedure − a maximum of 15 s − the button
is yellow.

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14/77 140−1120−101a
 Telescoping 12

12.3 Telescoping

12.3.1 General

There are two possible operating modes for telescoping the main
boom:
− Automatic telescoping (see section 12.3.5, from page 37);
As long as there is no fault, telescoping must always be car-
ried out in automatic operation.
Automatic telescoping is carried out with the help of the tele-
scoping information system.

The telescoping information system is an aid to operation.

It is not a replacement in any way for the judgement and ex-

perience of the crane operator as well as recognised safe
operating procedures for the operation of cranes.

When using the operating aid, the crane operator still re-
mains fully responsible for the safe operation of the crane.
He must ensure that he fully understands and follows the no-
tes and instructions in their entirety. The system can only be
guaranteed to work correctly if it is checked daily and used
in accordance with the operating instructions.

− Manual telescoping see section 12.3.6, from page 41);

Manual telescoping is done without monitoring by the load li-
mit device, which is why it is only permitted in exceptional
cases :
− when the automatic telescoping system is not working
(e.g., fault with a sensor)
− to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).

140−1120−101a 15/77
12

39.0
7.50

1
0°

Z 54 720 Z 54 721

180°

Z 54 722

16/77 140−1120−101a
 Telescoping 12

12.3.2 Telescoping Procedure

(Z 54 720, Z 54 721, Z 54 722)

Proceed in the following manner when telescoping:

1. Support and align the crane on outriggers in accordance with

the regulations (see operating instructions of the crane chas-
sis, section 12 “Outriggers”).

2. Start the superstructure engine.

(Z 52 986, Z 54 104)
3. Enter the operating mode. Press the button there.
The screen for preselecting the operating mode (Z 54 104)
appears. Make a selection of all relevant fields in accordance
with the actual state of the crane (e.g. “type” here: main
boom) and exit the screen via .
For more detailed information, refer to Section 10 “Safety
Equipment”.

(Z 53 470)
4. Check which mode has been selected for the assignment of
the control levers. The current mode (here: 1) is displayed by
the corresponding symbol in the top line of the IC−1
display.

Detailed information on the selection and limits of the different

modes can be found in Section 10 “Safety Equipment”.

RISK OF ACCIDENTS
It is the crane operator’s responsibility to check the current
control lever assignment before initiating a crane move-
ment.
Otherwise there is risk of accidents if accidental crane mo-
vements are triggered.

140−1120−101a 17/77
12

180°

Z 54 723

18/77 140−1120−101a
 Telescoping 12

(Z 54 723)
5. Select the operating mode of the hydraulic pumps.

The hydraulic pumps can be connected so that they supply

all hydraulic functions together.
The pumps can be separated for improved control.
To do so, press the left−hand key. The selected
mode “1 − 4” is displayed in the top left−hand corner in the
key field. Then the movements of the assigned pumps are
displayed in the two keys.

The key displays change according to the mode selection.

Follow the instructions under point ”Operating mode of the hy-
draulic pumps” in these operating instructions in section 10 “Sa-
fety equipment”.

140−1120−101a 19/77
12

30 16

31
32
24
34

35
36

Z 54 006

20/77 140−1120−101a
 Telescoping 12

(Z 54 006)

6. Start telescoping by pressing one of the buttons (32/36)

“dead man’s control” and carefully moving the corresponding
control lever (16/24):

Automatic Manual tele-

telescoping scoping
Activate control after entering the LK Telescoping
lever (16/24) for- (length code) of the out
wards / to the preselected process (see from
right (see from page 37) page 41)
Control lever Activate LK 1 (length Telescoping
(16/24) back- code 1) and activate in
wards / to the left complete telescoping in (see from
of the main boom (see page 41)
from page 37)

You must take the current position of the control levers into
consideration.

In order to prevent accidental initiation of crane movements, both

control levers are equipped with an additional key (dead man’s
control). Only when one of the buttons is pressed is it possible to
carry out a crane movement.
You may only activate (press or release) a dead man’s switch if
the corresponding control lever is in the neutral position and/or
the initiated working movement has been completed.

RISK OF ACCIDENTS
Pressing/releasing one of these dead man’s switches
when the control lever is fully engaged causes abrupt in-
itiation/braking of the corresponding movement.

RISK OF ACCIDENTS
Only by adapting the acceleration or speeds of all crane
movements can you avoid that the load or the hook block
swings out, causing risk of crushing or crashing when
each movement is switched off.

140−1120−101a 21/77
12

30 16

31
32
24
34

35
36

Z 54 006

22/77 140−1120−101a
 Telescoping 12

(Z 54 006)

Control levers (16/24) may not be switched directly to the op-

posite direction, but must first remain in the neutral position.
Only initiate the opposite movement once the movement has
come to a standstill.

The control lever automatically returns to the zero position once

released. The current crane movement is stopped.

If the hook is raised, and if the hoist limit switch has triggered, the
main boom can no longer be extended. First the hoist (the hook)
must be lowered (see section 14).

140−1120−101a 23/77
12

10°

Z 54 724

1 2 3

45%

90%

100%

90%
9
45%

28%

7 6 5 4
Z 54 725

24/77 140−1120−101a
 Telescoping 12

12.3.3 Telescoping display

(Z 54 724, Z 54 725 principle depiction)

On the screen ”Quick Menu” (Z 54 724) press the key .

The input screen of the telescoping information system, the ”tele-
scoping display” (Z 54 725), appears instead of the ”Quick
Menu”.
This is where submenus can be selected and information on the
status of the telescoping system can be found:

(1) Entering the length Refer to Section 12.3.4.1 ”Selection

code of the length code”, starting at
page 31
Grey: The selected length code has not
been achieved.
Green: The selected length code has been
achieved.
(2) Final length of the main boom
(3) Actual length of the main boom

140−1120−101a 25/77
12

1 2 3

45%

90%

100%

9 90%

45%

28%

7 6 5 4
Z 54 725

A B C

Z 54 726

26/77 140−1120−101a
 Telescoping 12

(Z 54 725, Z 54 726 principle depiction)

(4) Changes to the display of the tele aid (Z 54 726)

Electrical limit switches are fitted on the LPU and on the drive
unit of the LPU:
B 9160 − B 9163 used to recognise the telescopic
section (Z 54 726, ”D”). The corres-
ponding digit after the designation
“tele” indicates which boom section
is being dealt with.
Example: 1st boom section; des-
cription “Tele 1”:
As shown, both lamps are illumina-
ted, which symbolise the limit swit-
ches B 9160 and B 9161.
B 9164 − B 9165 show the position of the LPU to the
telescopic section (Z 54 726). When
both light up, the LPU can lock the
affected telescopic section, i.e.,
create the connection to the tele-
scopic section.
B 9156, B 9157, B 9158, show the status of the LPU.
B 9168, B 9169
Z 54 726 “A”: pinned / unlocked
Z 54 726 “B”: pinned / locked
Z 54 726 “C”: unpinned / locked

(5) Display of the current condition of the telescopic cylinder

and/or of the LPU
/ forwards / backwards with reduced
speed
/ forwards / backwards with high
speed
/ Telescopic section pinned / unpin-
ned
/ LPU locked / unlocked
Point black: telescoping system
stop
Point red: fault in the telescoping
system (see section 10).

140−1120−101a 27/77
12

1 2 3

45%

90%

100%

9 90%

45%

28%

7 6 5 4
Z 54 725

28/77 140−1120−101a
 Telescoping 12

(Z 54 725)

(6) Telescoping speed display of main boom / telescoping cy-

linder
Just before the pinning position is reached, the telescoping
speed is reduced, so that the telescopic sections can be pin-
ned.
(7) Switches to the “TeleManual” screen (see sect. 12.3.6, as
from page 41)
(8) LPU position display
(9) Extension length for a telescopic section in per cent
telescopic section blue: these telescopic sections are al-
ready extended to the selected
length code
telescopic section grey: these telescopic sections are retrac-
ted and yet to be extended
telescopic section black: in combination with grey back-
ground: this telescopic section must
be retracted for the new LK (length
code), and extended again later

in combination with white back-

ground: this telescopic section must
be retracted for the new LK(length
code)
telescopic section yellow: this telescopic section extends or
retracts with the LPU
telescopic section white: these telescopic sections are retrac-
ted
telescopic section this telescopic section’s position is
orange: teached (see sect. 12.3.7, as from
p. 59).

140−1120−101a 29/77
12

45%

90%

100%
23.9 m
90%

45%

10° 28%

Z 54 727

3 4 5 6 7

1 8

12 10 11 10 9
Z 54 728

30/77 140−1120−101a
 Telescoping 12

12.3.4 Length code

12.3.4.1 Selection of length code

(Z 54 727, Z 54 728 principle depiction)

In order to select the length code (LK) for the desired main boom
length, press ”LK” button (Z 54 727). The “Tele operation mode”
screen appears (Z 54 728).
Here, all length codes are displayed that can be selected and that
are compatible with the selected operating mode, including main
boom length, extension configuration for the individual telesco-
pes and possible max. lifting capacities.

Press to select the desired length code (entire line 1, Z 54 728,

is touch−sensitive). By pressing the button, the length code
is saved and you exit the screen. Now the “Telescoping display”
screen appears (Z 54 727).

The “LK” button with the newly selected length code now has a
grey background. <This means that the corresponding length
has not yet been reached. This LK code is also displayed in black
in the topmost line of the IC−1 display.
As soon as the following telescoping procedure has been com-
pleted and thus the appropriate target length reached, both dis-
plays change their colour to green.

140−1120−101a 31/77
12

3 4 5 6 7
8
2

1 9

14 13 12 11 10
Z 54 728

32/77 140−1120−101a
 Telescoping 12

“Tele operating mode” screen

(Z 54 728 principle depiction)

(1) − Length code number (LK No.)

(2) − Main boom length
(3) − Extension configuration of telescopes 1 to 5 (from left to
right)

0 % extended 90 % extended

45 % extended 100 % extended

(4) − Max. lifting capacity in high position

(5) − Radius in high position
(6) − Max. lifting capacity in low position
(7) − Radius in low position
(8) − Activation of the mask for selection of the length code for
lubrication of the main boom (only for operating mode
HA)
(9) − Scrollbar for browsing through the length codes, line by
line
(10) − Exit the mask with save; the settings are assumed
(11) − Leafing through the length code, page by page:
> one page down;
(12) − Length code selection for the LPU position for moving the
crane (only for operation mode HA)
(13) − Leafing through the length code, page by page:
< one page up
(14) − Exit the mask without save; the settings are not assumed

140−1120−101a 33/77
12

Z 54 746

17 18 19

31,5 21,4 7.5

31,5 21,4 7.5

31,5 21,4 7.5

31,2 21,4 7.5

−−− −−− −−− −−−

Z 55 399

34/77 140−1120−101a
 Telescoping 12

12.3.4.2 Selection of the Length Code for Lubrication of the

Main Boom
(Z 54 746 principle depiction, Z 55 399)

In order to select the length code (LK) for lubrication of the main
boom, the crane must be switched to operating mode ’HA’ (’main
boom operation’).
In the mask ’Tele operating mode’ (Z 54 746), the ’lubrication
symbol’ is displayed at the marked place.
By selecting the lubrication symbol mask (Z 55 399) is dis-
played with the selection list of the corresponding length code.
Instead of displayed the details on load capacities and radius, the
values for counterweight combination and outrigger support area
are indicated, which must be fulfilled at the very least:
(17) − minimum counterweight
(18) − minimum outrigger support area
(19) − key: back to the mask “Tele operating mode”

Risk of tipping!
Only when the actual crane configuration fulfils the mini-
mum requirements for counterweight combination and ou-
trigger support area is it ensured that lubrication of the
main boom is risk−free.
You will find the actual lubrication procedure in the mainte-
nance and lubrication instructions of the superstructure,
section 10 “Main boom”.

After activating the corresponding length code for lubrication of

the main boom, you can exit the mask with ’Save’.

If the configuration of the crane currently reserved in control does

not fulfil the indicated minimum requirements for counterweight
and outrigger support area, the relevant value will be displayed
in red. The mask then cannot be exited with ’Save’.

140−1120−101a 35/77
12

16

24

Z 54 101 Z 54 119

45%

90%

100%
23.9 m
90%

45%

10° 28%

Z 54 729

36/77 140−1120−101a
 Telescoping 12

12.3.5 Automatic telescoping

(Z 54 101, Z 54 119, Z 54 729)

The IC−1 enables automatic telescoping, after selecting the re-

quired final length (by entering the corresponding length code
“LK”), by operating the corresponding control lever (Z 54 101).
This means that if the boom is to be extracted to a new length,
the corresponding control lever must be moved explicitly in ex-
tending direction and held (when selecting an operating mode
with which telescoping is possible).

This is also the case, if the new main boom length is less than the
current length.
If the control lever is moved to retracting direction, then LK 1 (all
telescopes 0%) is activated and the automatic system begins to
retract the main boom entirely.

The telescoping speed varies throughout the procedure.

Just before the pinning position is reached, the telescoping

speed is reduced, so that the telescopic sections can be pinned.

The telescoping procedure can be observed at the telescope dis-

play on the right side of the IC−1 display (Z 54 729). As soon as
the desired final length is reached, the colour of the ”LK” button
switches from grey to green.

During the telescoping procedure, the current total length of the

main boom as well as other geometric data are displayed at the
crane symbol to the left of the IC−1 display (Z 54 729).

Also, the configuration of sensors and pins for the LPU can be
monitored during the telescoping procedure. To do so operate “?”
button. The screen (Z 54 119) appears.
The displayed configuration is unlocked and pinned.

140−1120−101a 37/77
12

45%

90%

100%

90%

45%

28%

Z 54 730 Z 54 119

45%

90%

100%
23.9 m
90%

45%

10° 28%

Z 54 731

38/77 140−1120−101a
 Telescoping 12

(Z 54 119, Z 54 730, Z 54 731)

The system uses the Is−values, provided by the length transmit-

ter, to calculate the most advantageous run sequence, by making
comparisons with the stored operating programs and other fac-
tors. The sequence is displayed using different coloured telesco-
pic sections in illustration (Z 54 730). Each step required is dis-
played until the telescoping procedure is completed.

The display of the movement of the individual telescope levels as

well as the locking and pinning unit (LPU) and the configuration
of the locking and pinning elements is continuously adapted to
correspond to the changes made (Z 54 119).

If work has to be stopped, the system automatically saves the va-

lues last displayed, so that work can be resumed accordingly.

Error routines monitor the correct locking / pinning of the main

boom. System errors are displayed by a red mark (see illustration
“Z 54 730”). At the same time a symbol appears to the left
of the IC−1 display (Z 54 731). The error must then be identified
and eliminated.

For more detailed information on calling up error messages see

section 10 “Safety devices”.

After eliminating the error, work can only be continued, once the
error message has been acknowledged.

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12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

40/77 140−1120−101a
 Telescoping 12

12.3.6 Manual telescoping

(Z 54 133)

Manual telescoping is carried out without the supervision of the

load limit device and is therefore only permitted in exceptional
cases:
− if the automatic telesystem fails (e.g. malfunction of a sen-
sor).
− to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).

In manual operation, it is not possible to monitor of the

crane via the LMI! Maximum risk of accidents!
The crane operator is responsible for any damage or acci-
dents that might be caused in this situation!

Under certain circumstances (no monitoring of the crane

control during manual telescoping) the telescopic drive can
be extended so much that it slides off the inner guide rails.
For this reason there is a table with the LPU’s approximate
locking and pinning positions under subpoint 12.3.8
“Locking and pinning positions of the telescopic drive” on
page 63.
The table values correspond with the LPU position (1) in the
’TeleManuell’ mask.
The corresponding locking and pinning positions may be
exceeded by approx. 0.05 m (approx. 0.164 ft) at the most.
If the corresponding locking and pinning position is not
found, probably several electronic sensors are defective at
once. In this case or when the telescopic drive has come off
the inner sliding rails please contact our customer services
department.

If the telescopic drive has come off the inner guiding slides,
telescoping is no longer possible. Locking and pinning (or
unpinning) the telescopic sections of the main boom is then no
longer possible either. The telescopic drive can be extended but
will always stick at the same place when being retracted.

140−1120−101a 41/77
12

A B

45%

90%

100%

90%

45%

10° 28%

Z 54 718

Z 54 110

42/77 140−1120−101a
 Telescoping 12

(Z 54 110, Z 54 718)

You will find the required information − specially on position and

configuration of the LPU − in the ”TeleManual” screen (Z 54 110).

In order to call up the “TeleManual” screen, press the button in the

“Quick Menu” screen (Z 54 718, ”A”) . The “Telescoping
display” (Z 54 718, ”B”) appears in place of the ”Quick menu”.
Press the button button − the “TeleManual” screen ap-
pears (Z 54 110).

When the “TeleManual” screen opens, the hand symbol is cros-

sed out . This means that the automatic mode is still ac-
tive. One can then take a look at information e.g. on the configu-
ration of the initiators and then return to the original screen.

The procedure for manual telescoping is described in

sect. 12.3.6.2, as from page 49.

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2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

44/77 140−1120−101a
 Telescoping 12

12.3.6.1 “TeleManual” screen

(Z 54 133)

(1) − LPU position

(2) − LPU speed
(3) − Hydraulic supply for LPU (see sect. 12.2.2, from p. 11)
(4) − Number of the telescopic section, which is connected to
the LPU; the depicted no. “0” means that the LPU is not
connected to any telescopic section and can be driven
”empty” in the basic case.
(5) − Secure preselection
(6) − Status display telescoping system (see sect. 12.3.3 “Te-
lescoping display”, point 5, p. 27)
(7) − Pinning
(8) − Unpinning
(9) − Locking
(10) − Unlocking
(11) − Back to the telescoping display; is locked after hand ope-
ration
(12) − Teaching (setting and saving) telescope position
(13) − Switching between automatic (hand symbol crossed out)
and manual telescoping operation (hand symbol not
crossed out)

140−1120−101a 45/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

46/77 140−1120−101a
 Telescoping 12

(Z 54 133)

(14) − Initiators for the configuration of the LPU (connected in-

itiators are highlighted in red)

The following states are indicated by letters in German and by a

number in brackets in all other languages:

ES / VB (1) Unlocked / Pinned

? / VB (12) Intermediate position
GS / VB (2) Locked / Pinned
GS / ? (23) Intermediate position
GS / EB (3) Locked / Unpinned
(15) − Initiators for the identification of the telescopes. The te-
lescope currently identified by the LPU is specified at
pos. 4 (switched initiators on a red background)
(16) − Initiators for initial and subsequent position for locking
(switched initiators on a red background)
(17) − Initiators for initial and subsequent position for pinning
(switched initiators on a red background)

140−1120−101a 47/77
12

Z 54 135

111

112

10°

Z 54 111 Z 54 732

48/77 140−1120−101a
 Telescoping 12

12.3.6.2 Manual telescoping procedure

(Z 54 111, Z 54 135, Z 54 732)

Please make sure you observe the instructions on the permissi-

ble employment of manual telescoping and on calling up the “Te-
leManual” screen (Z 54 135) in Sect. 12.3.6, from page 41.
To activate manual telescoping in the “TeleManual” screen, press
the key . It turns into .

High risk of accidents!

In manual operation mode it is not possible to monitor the
crane with the load limit device. The load limit device must
be bypassed.
It is only permitted to bypass the load limit device in excep-
tions! Bypassing must be reversed immediately after ma-
nual telescoping!
Crane operation with bypassed load limit device is FOR-
BIDDEN!

To bypass the load limit device, operate the key−operated button

(112). The corresponding indicator light (111) goes on.

The telesystem must be informed about the extension status of

the main boom after manually telescoping the main boom. This
procedure is called ”teaching” (refer to Sect. 12.3.7, beginning on
page 59). The ”TeleManual” screen cannot be exited without
”teaching”.

After the manual telescoping or “teaching” procedure the load li-

mit device can only be operated again and hence be reactivated
after passing or reaching a valid length code.
If the telesystem is activated without bypassing the LMI before re-
aching a valid length code (key (Z 54 135),
(Z 54 732) appears in the crane display symbol.

On principle, the smallest (furthest inward) telescopic section to

be telescoped must be started with whenever the main boom is
to be extended.
The largest (furthest outward) telescopic section to be telesco-
ped must be started with whenever the main boom is to be retrac-
ted.

140−1120−101a 49/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

50/77 140−1120−101a
 Telescoping 12

Example of manual telescoping (Z 54 133):

The 1st boom section must be driven out of the 100% pinning
hole into the 0% pinning hole.

1. Check the “TeleManual” screen, (14, right field), to see whe-

ther the LPU is unlocked and pinned ( or digit “1”).
The LPU can be operated in this state using the respective
control lever without moving any telescopic section.
This can be seen in the mask “TeleManual” at (2): a speed
value > 0 mm/s (ft/min) must then be displayed without the
main boom moving.

2. Since the LPU has been fully retracted (1, LPU position
0.000 m / ft), it must be “extended” in order to be locked (as
desired) to the fully extended first telescopic section.
Steer the respective control lever in order to extend the LPU.
The LPU is driven to the 1st boom section.
As soon as the 1st boom section has been reached, the dis-
play (4) changes from “IK 0” to “IK 1”.

Then the telescopic drive is telescoped out approx. 9,595 m

(31.48 ft) (1st boom section, 100% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.3.8 “Locking and pinning positions of the telescopic drive”
on page 63).

During the following procedure, telescoping can be interrupted or

resumed with the appropriate control lever, depending on which
action step is specified.

140−1120−101a 51/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

52/77 140−1120−101a
 Telescoping 12

(Z 54 133)

3. Interrupt telescoping, then actuate the Preselection key,

(5, )press the lock key (9, ) and slowly continue
telescoping.

The keys are displayed on a red background after actuation.

They automatically turn grey again as soon as the selected pro-
cedure is over.

You must make sure that you follow the correct sequence:
first preselection, then locking! The locking process is now
automatically actuated when the fine position is approa-
ched. In the “Lock” fine position, the two initiators VPS and
NPS (16) are active, i. e. on a green background.

The locking process is over as soon as the locked and pinned

state is indicated for the LPU by the symbol or digit ’2’ at
(14, at the end of the line).

4. The telescopic section must be locked manually if it is unable

to be locked automatically. Operate the key (9, ).

This key may only be operated in the “Lock” fine position

(VPS and NPS “16” active, i. e. on a green background).

After locking the telescopic section the pinning fine position must
be reached, i.e. both initiators NPV and VPV (17) must be on a
green background. Only then may the unpinning process begin.

5. To unpin, actuate key (8, ).

The keys are displayed on a red background after actuation.

They automatically turn grey again as soon as the selected pro-
cedure is over.

140−1120−101a 53/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

54/77 140−1120−101a
 Telescoping 12

(Z 54 133)

6. Extend the LPU about 1 to 2 cm (0.5 − 1 in) by steering the

respective control lever. The unpinning process is then car-
ried out.

The unpinning procedure is over as soon as the locked and un-

pinned state is indicated for the LPU by the symbol or di-
git ’3’ at (14, at the end of the line).
In this state, the telescopic section is attached to the LPU and can
be retracted in the following.
(Z 54 133)

7. Retract the first telescopic section from the 100% locking

hole to the 0% locking hole locked to the LPU by steering the
control lever accordingly.

The 90% and 45% pinning hole positions are crossed during the
retraction process. The initiators for pinning then indicate whe-
ther any potential pinning positions have been crossed. In this
case the two initiators “VPV” and “NPV” (17) are on a green back-
ground.
The unpinning procedure may only be actuated once the two in-
itiators “VPV” and “NPV” (17) are on a green background after re-
aching the 0% pinning position.

Then the telescopic drive is telescoped out approx. 0,035 m

(0.115 ft) (1st boom section, 0% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.3.8 “Locking and pinning positions of the telescopic drive” on
page 63).

8. As soon as the two initiators “VPV” and “NPV” (17) for the 0%
pinning hole of telescopic section 1 are on a green back-
ground, actuate key (7, ). It is displayed on a red back-
ground.

The pinning procedure is accomplished as soon as the locked

and pinned state is indicated for the LPU by the symbol
or digit ’2’ at (14, at the end of the line).

140−1120−101a 55/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

56/77 140−1120−101a
 Telescoping 12

(Z 54 133)

9. In this state, actuate the key (7, ) again in order to

complete the pinning procedure. It turns grey again.

The respective valve remains in a switched position and the key

remains on a red background if the key (7) is not actuated again.

10. To unlock the LPU, press first the Preselect key , (5, )
then the Unlock key (10, ) and slowly continue tele-
scoping.
The unlocking procedure is then actuated automatically
when the fine position (VPS and NPS “16” initiators active,
i. e. on green background) is approached.

The keys are displayed on a red background after actuation.

They automatically turn grey again as soon as the selected pro-
cedure is over.

(Z 54 133)

If the unlocking procedure can not be started automatically, it can

be started manually by pressing the unlock button. (10).
In this case the Preselection key (5, ) may not be actuated.

The unlocking procedure is over as soon as the locked and pin-

ned state is indicated for the LPU by the symbol or digit ’1’
at (14, at the end of the line).

As a result, the sample manual telescoping procedure is in effect

over.

In order to now switch to the automatic telescoping, the posi-

tions of all individual telescopic sections ”must be taught” (defi-
ned and saved) (refer to Sect. 12.3.7 on the following pages).

140−1120−101a 57/77
12

Z 54 733

Z 54 734

58/77 140−1120−101a
 Telescoping 12

12.3.7 Teaching the extension status of the telescopes

(Z 54 733, Z 54 734)

The telescoping system must be informed about the extension

status of each telescope after manually telescoping the main
boom. This procedure is referred to as ”teaching”.

Proceed as follows:
(Z 54 733)

1. Push button on the “TeleManual” screen (Z 54 733,

left side). The “TeleTeach” screen (Z 54 733, right side) ap-
pears.

All of the keys assigned to individual telescopes T1 − T5 are at

first only filled in with a star. Subsequently, the current extension
statuses for all telescopes must be selected manually. There are
the following possibilities for selection:
“0”, “45”, “90” and “100” for the pinned state and “LPU” when the
telescopic section is unpinned and locked to the LPU.

(Z 54 734)
2. Press key next to T1 until the value appears which corres-
ponds to the actual extension state of T1 (here: 0, i.e. tele-
scopic section 1 is 0% extended).

3. Repeat the procedure specified for telescope 1 accordingly

for the remaining telescopes T2 − T5.

4. Make sure the defined status corresponds to the actual ex-

tension status for all telescopes. If so, actuate the “Teach”
key. The initial screen “TeleManuell” appears.
The saved values are adopted by the control system in preci-
sely the same way. Incorrect values are unable to be identi-
fied as such.

RISK OF ACCIDENTS
During the “teaching” process only those values may be
transferred to the control system which correspond to
the actual state. The crane operator is solely responsible
for this!

140−1120−101a 59/77
12

Z 54 735

60/77 140−1120−101a
 Telescoping 12

(Z 54 735)

If the extension state of the telescopic sections correspond with

a length code, the selection can be made faster than described:
press key “LK” and select the line of the length code which corres-
ponds to the actual extension state of the telescopic sections.
Use button to exit the screen.
The screen ”TeleManual” appears again and all field concerning
the individual telescopes are then filled out together.

140−1120−101a 61/77
12

2
17
3
16
4
15
14
5

13 6
12 7
11 8

10 9
Z 54 133

62/77 140−1120−101a
 Telescoping 12

12.3.8 Locking and Pinning Positions of the

Telescopic Drive
(Z 54 133)

The locking and pinning positions are required during manual

telescoping.
Observe the entry (1, LPU position) of the following table in order
to tell beyond doubt at which pinning hole the LPU is located for
the respective telescopic section (indication of the telescopic
section at “4”):

The indicated extension lengths may be exceeded by

approx. 0.05 m (approx. 0.164 ft) at the most during manual
telescoping so that the telescopic drive does not come off
the inner guide rails.

Telesco- Pinning LPU−Position Telesco- Pinning LPU Position

pic hole (%) pic hole (%)
section [m] [ft] section [m] [ft]
0 0,035 0.115 0 0,575 1.886
45 4,585 15.043 45 4,875 15.994
1 4
90 8,635 28.329 90 9,175 30.102
100 9,595 31.479 100 10,075 33.054
0 0,215 0.705 0 0,755 2.477
45 4,515 14.813 45 5,055 16.585
2 5
90 8,815 28.921 90 9,355 30.692
100 9,765 32.037 100 10,055 32.988
0 0,395 1.296
45 4,695 15.404
3
90 8,995 29.511
100 9,945 32.628

140−1120−101a 63/77
12

Z 54 736

1 3 4 5 6 2 8 9

16 15 12 9 8 14 12 9

22156512
Z 54 737

64/77 140−1120−101a
 Telescoping 12

12.4 Lifting Capacities in the Unpinned Condition

(Z 54 736, Z 54 737)

The lifting capacities that are specified in the load capacity tables
in relation to the radius (see marked area in the display) only ap-
ply when all telescopic sections are pinned.

The lifting capacities can either be read from the load capacity ta-
bles which come with the machinery (Excerpt from a sample ta-
ble, Z 54 736) or else be taken from the IC−1 display for the parti-
cular actual configuration (Z 54 737).

The following load table is only a specimen. Only the load ta-
bles supplied with the crane may be used for operating the
crane.

There are also load capacities for the case that one telescope is
not pinned:
− Unpinned lifting capacities for which the main boom length re-
mains unchanged, so−called “lifting capacities in interme-
diate positions”. Refer to Section 12.4.1.
− Unpinned load capacities, for which the main boom length is
changed under load, so−called “telescoping load capaci-
ties“. Refer to Section 12.4.2.

140−1120−101a 65/77
12

A
1 3 4 5 6 2 8 9

B C

16 15 12 9 8 14 12 9

22156512
Z 54 738

A
3 4 5 6 2 8 9 10

B D

5 5 6 6 5 5 5 6

22142012
Z 54 739

66/77 140−1120−101a
 Telescoping 12

12.4.1 Lifting Capacities in Intermediate Positions

(Z 54 738, Z 54 739)

The lifting capacities that are specified in the load capacity tables
in relation to the radius only apply when all telescopic sections
are pinned.

At a main boom length (A) of 16.8 / 55.1 ft m (with LK 5) and a

radius (B) of 8 m (26.2 ft), the corresponding pinned lifting capa-
city (C) is then 40.7 t (89.7 ft) (Z 54 738).

There are also lifting capacities for the unpinned state of a tele-
scopic element (only for main boom operation). These allow lif-
ting when working with unpinned lengths because of particular
space constraints. The bottom extended telescopic section is
then connected to the telescoping cylinder via the LPU.

When attaching loads in unpinned intermediate positions, the at-

tachable loads are limited additionally by the load capacity of the
telescoping cylinder and the bend of the main boom.

These effects are dealt with in “Unpinned Loading Capacities”

(Z 54 739).

This would mean with regard to the example above:

if the main boom length (A) is 16.8 m / 55.1 ft (with LK 5) and the
radius (B) is 8 m (26.2 ft), the corresponding unpinned load ca-
pacity (D) would then be 36.6 t (80.7 kip).

The unpinned lifting capacities quoted are only maximum

values and are not valid in all cases.
This ”unpinned” maximum value is adjusted to the ”pinned”
value using the load limit device − corresponding to the ra-
dius in question.
If the ”pinned” value of 40.7 t / 89.7 kip (C) is greater than the
”unpinned” value of 36.6 t/ 80.7 kip (D) − as is the case here
− the permitted lifting capacity is then reduced to 36.6 t
(80.7 kip).
If the unpinned value were smaller than the unpinned value,
then the permitted lifting capacity would be reduced to the
pinned value.

140−1120−101a 67/77
12

A B

39.0

10°

Z 54 740

1 3 4 5 6 2 8 9 3 4 5 6 2 8 9 10

16 15 12 9 8 14 12 9 5 5 6 6 5 5 5 6

22156512 22142012

Z 54 741 Z 54 742

68/77 140−1120−101a
 Telescoping 12

(Z 54 740, Z 54 741, Z 54 742)

The load limit device automatically carries out this comparison

between the pinned and unpinned lifting capacities. The value is
then displayed in the mask “Operation of the crane” (Z 54 740)
(here: MAX (t) 13.0 / 28.7 kip), which is a result of the comparison
of both values as the max. permitted one.

The unpinned/pinned lifting capacities can then be read from the

IC−1 Display as follows:

1. In the Quick menu (Z 54 740, ”A”), press the there.

The “Operating Mode Preselection” screen then appears
(Z 54 740, ”B”).

2. In this screen, press the there. The “Table View”

screen then appears (Z 54 741).
The pinned lifting capacities (marked region) for the opera-
ting mode selected appear there.

Differently to the display of unpinned lifting capacities, the boom

symbol in the bottom left corner does not have a double arrow.
The appearance of the displays is otherwise very similar.

3. Push button there. The unpinned lifting capacities

(marked region) for the operating mode selected appear
(Z 54 742).

The boom symbol in the bottom left−hand corner is marked with

a double arrow.

140−1120−101a 69/77
12

A
1 3 4 5 6 2 8 9

B C

16 15 12 9 8 14 12 9

22156512
Z 54 738

A
3 4 5 6 2 8 9 10

B D

5 5 6 6 5 5 5 6

22142012
Z 54 739

70/77 140−1120−101a
 Telescoping 12

Example
(Z 54 738, Z 54 739)

Operational planning has determined that, due to restricted

space, a main boom length of approx. 15 m (49.2 ft) is required
for a radius of 8 m (26.2 ft). The weight of the load to be raised
equals 38 t (83.7 kip).

Proceed then as follows:

− Select the locked main boom length above the one actually
required (here: 16.8 m / 55.1 ft).
− Select the length combination which offers the best values for
the desired radius (here: LK 5, 0/0/0/45/0).
− Enter corresponding length code (here: LK 5) and telescope
the main boom out unloaded in accordance with the speci-
fications of the telescoping information system until telesco-
pic section 4 is locked in the state and is telescoped out while
unpinned up to the required entire main boom length of ap-
prox. 15 m (49.2 ft).
At this point interrupt the telescoping, despite the specifica-
tions from the telescoping information system.

The permitted unpinned load capacity corresponds with the va-

lue from the depiction “unpinned” (Z 54 739, here: 36.6 t /
80.7 kip), as it is lower than the value “pinned” (here: 40.7 t /
89.7 kip).

So the load of 38 t (83.7 kip) in an unpinned state for telescopic

section 4 cannot be lifted.

140−1120−101a 71/77
12

72/77 140−1120−101a
 Telescoping 12

12.4.2 Lifting capacities that can be telescoped

The lifting capacities in intermediate positions described in the
sect. 12.4.1 will also be released during a telescoping procedure.

However, the lifting capacities that are actually achievable du-

ring telescoping under load are only given as approximate values
due to the large number of variable external influences.

The load capacities which can be telescoped (on request) are

achieved under the following conditions:
− Sliding surfaces well lubricated
− Normal ambient temperature
− The systematic of the tele control system when carrying out
the extension sequences are predetermined and do not need
to be determined by the crane operator.
− During telescoping, the main boom angle may not be chan-
ged using the luffing cylinder.

140−1120−101a 73/77
12

39.0
7.50

Z 54 721 Z 54 743

A B

45%

90%

100%

90%

45%

10° 28%

Z 54 744

74/77 140−1120−101a
 Telescoping 12

12.5 Main boom state to move the crane in

transport position
(Z 54 721, Z 54 743, Z 54 744)

To move the crane in transport position, all telescopic sections

have to be completely retracted and pinned and the LPU has to
be secured for transport configuration in the prescribed position
(5th telescopic section).

Otherwise there is a risk of the locking and pinning unit mo-

ving/sliding by itself in an uncontrolled manner. If the LPU is
secured in the wrong place the indicated axle loads are in-
correct.

Staring situation:
main boom telescoped in and set down on the crane chassis in
transport position; current LK = 1.

Proceed then as follows:

1. Switch on the ignition on the superstructure and start the en-

gine. The IC−1 will start and the and the “Operation mode
preselection” (Z 54 721) will then appear.

2. Select “HA” operating mode and save by actuating the

button.
The input screen “Quick Menu” appears on the right side of
the IC−1 display (Z 54 744, ”A”).

3. Push button there. The mask “Telescoping display”

(Z 54 744, “B”) appears.

4. Push the “LK” button. The “Tele operating mode” screen ap-
pears (Z 54 743).

140−1120−101a 75/77
12

Z 54 745

76/77 140−1120−101a
 Telescoping 12

(Z 54 745)

5. Press push button and steer the corresponding con-

trol lever in the direction “Telescoping out” − the LPU is driven
accordingly and locked onto the 5th boom section.

The control lever has to be actuated long enough that crane re-
presented on the screen appears (Z 54 745, right side).
Only then is the main boom (including the LPU) in transport posi-
tion for moving the crane.

After moving, a length code can be selected again for the main
boom working range using the “LK” button.

140−1120−101a 77/77
 Luffing 13

140−1130a_en 1/13
13

Z 54 748

180°

Z 54 722

2/13 140−1130a_en
 Luffing 13

13 Luffing

13.1 Luffing Operation

(Z 54 748, Z 54 722)

The main boom is raised and lowered (luffed) by extending and

retracting the luffing cylinder (Z 54 748).

It is prohibited to raise the load from the ground using the

luffing gear! This should only be done using the hoist!

Proceed as follows to luff the main boom:

1. Support the crane on outriggers in accordance with the regu-

lations and align (see the operating instructions of the crane
chassis, section 12 “Outriggers”).

2. Start the superstructure engine.

3. Make sure you are aware which mode has been selected for
the control lever settings. The current mode (in this case: 1)
is indicated by the corresponding symbol in the upper
line of the IC−1 display.

Detailed information on the selection and scope of the different

modes can be found in section 10 “Safety equipment”.

Risk of accidents!
It is the responsibility of the crane operator to make sure
which mode is currently selected for the control lever set-
tings before commencing any crane movements.
Otherwise accidents could occur as a result of unintended
crane movements!

140−1130a_en 3/13
13

180°

Z 54 723

H1

Z 54 749

4/13 140−1130a_en
 Luffing 13

(Z 54 723)
4. Select the operating mode for the hydraulic pumps.

The hydraulic pumps can be set so that they combine to sup-

ply all hydraulic functions.
To achieve better activation, the pumps can be separated.
To do this press the left−hand button. The se-
lected mode “1 − 4” is displayed top left in the button field. In
both buttons the movements of the assigned
pumps are then displayed.

The button displays change depending on the selected mode.

Please follow the instructions in this manual, in section 10 “safety
equipment”, under the point “operating mode of the hydraulic
pumps”.

(Z 54 749)
5. If your crane is equipped for driving with a dolly (optional), the
ball cock (H1) must be in the position “not blocked” (as shown
in figure “Z 54 749”).
If this ball cock is in the locked position, the luffing cylinder
cannot be actuated.

140−1130a_en 5/13
13

30 16

31
32
24
34

35
36

Z 54 006

6/13 140−1130a_en
 Luffing 13

(Z 54 006)

6. Start the luffing movement by pressing one of the buttons

(32/36) “dead man’s handle” and carefully moving the corre-
sponding control lever (16/24).

Control lever (16/24) to the right − Lower main boom

/ to the front (luff down)
Control lever (16/24) to the left / − Raise main boom
to the rear (luff up)

The current setting for the control lever must be observed!

To avoid unintentional crane movements being activated, both

control levers are fitted with an additional button (dead man’s
handle). The crane movement can only be carried out as long as
one of these buttons is pressed.
The dead man’s handle may only be actuated (pressed or re-
leased) when the corresponding control lever is in the neutral
position and/or the operating movement has been completed.

Risk of accidents!
Pressing or releasing one of these dead man’s handles
with the control lever fully actuated causes the corre-
sponding movement to be started or stopped very abruptly.

Risk of accidents!
Only by adapting the acceleration or speeds of all crane
movements can you avoid that the load or the hook block
swings out, causing risk of crushing or crashing when
each movement is switched off.

Control levers (16/24) may not be switched directly to the op-

posite direction without first being placed in neutral. Do not
switch to the opposite direction until the main boom has
come to a halt.

140−1130a_en 7/13
13

115

116

Z 53 475

8/13 140−1130a_en
 Luffing 13

The control lever automatically returns to the neutral position

when it is released. The crane movement which has been started
is stopped.

If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the
hook) must be lowered (see section 14).

(Z 53 475)
If a prohibited overload condition has occurred, the load−
moment−reducing movement ”raise main boom” is also
shut down by the load limit device. This movement can be
carried out after actuating and holding key−operated push-
button (116) in order to move a free−hanging load back out
of the overload range into the normal range. Indicator light
(115) lights up to display the bridged condition.

This load−moment−reducing movement may only be car-

ried out if it is safe to do so. Make sure that it is safe before
actuating the key button.
If the load is still in contact with the ground and raising of
the hoist has been shut down, the load is too heavy. The
movement ”raise main boom” may not be enabled!

The movement ”raise main boom” may not be used under

any circumstances to raise the load!

Risk of falling backwards!

In some cases it is not possible to enable load−moment−re-

ducing movements.
Example: the permitted minimum radius is 3 m (9.8 ft) and
”luffing up” is switched off.
The system cannot then be bridged and the load−moment−
reducing movement “luff up” be continued, as the crane
could tip backwards − with a large counterweight.

140−1130a_en 9/13
13

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

180°

Z 54 750

10/13 140−1130a_en
 Luffing 13

13.2 Regulating the luffing speed

(Z 54 007, Z 54 750)

The luffing gear is electrically pre−controlled. The luffing speed

is determined by the engine speed and the movement of the cor-
responding control lever (16/24).

High speed “raise main boom”

To raise the main boom (luff up) the high speed can be activated.
To this end, press push button (30) on control lever (16). The
high−speed remains activated as long as this button is pressed.
The activated high speed is shown using the symbol in the
IC−1 display.

In the following cases, high−speed may not be activated:

− when working with loads > 30% of the load capacity
− with a main boom extension fitted
− when raising and lowering the fully or partially retracted

main boom from the low position

− with a long main boom.

Activating the luffing gear at high speed for main boom op-
eration without load is only permitted up to a point well be-
fore the load limit device shuts down the movement (maxi-
mum up to the advanced warning).
Risk of crane tipping as a result of the ensuing crane dynam-
ics!

140−1130a_en 11/13
13

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

180°

Z 54 008

12/13 140−1130a_en
 Luffing 13

Precision control “lower main boom”

(Z 54 007, Z 54 008)

In addition, to lower the main boom (luff down) the speed can be
precision controlled. To this end, first press push button (31/35),
i.e. the left−hand button on the corresponding control lever,
briefly. On the right−hand side of the IC−1 display the ”percent-
age display” mask appears (Z 54 008).
As long as this mask is displayed, the displayed percentage value
and the speed can be changed as follows:
− using self−return rocker switch (14/26) on the corresponding
control lever, when the movement is activated by horizontal
(left / right) movement of the control lever.
− using self−return rocker switch (14/26) and at the same time
by pressing push button (31/35) on the corresponding control
lever when the movement is activated by vertical (front / rear)
movement of the control lever.

Depending on whether the self−return rocker switch is actuated

on the left or right, the value is either reduced or increased.

If the percentage values have not been adjusted, the mask disap-
pears again after 5 s.

140−1130a_en 13/13
 Hoist 1 14

140−1140 1/11
14

48

71

Z 54 078 Z 54 079

180°

Z 54 722

2/11 140−1140
 Hoist 1 14

14 Hoist 1

14.1 Hoist Operation

(Z 54 078, Z 54 079, Z 54 722)

Loads are raised and lowered by reeling the hoist rope on and off
the rope drum of the hoist.

Risk of accidents!
The load may only be raised using the hoist!

Set the mirror (71) in the cab so that you can observe the reeling
of the hoist using the additional mirror located next to the hoist.
Switch on the hoist lighting (optional) if required using luminous
switch (48).

Proceed as follows to actuate the hoist:

1. Support the crane on outriggers in accordance with the regu-

lations (see operating instructions of the crane chassis, sec-
tion 12 “Outriggers”).

2. Start the superstructure engine.

3. Make sure of which mode has been selected for the control
levers. The current mode (in this case: 1) is displayed by
means of the corresponding symbol in the upper line
of the IC−1 display.

Detailed information of the selection and scope of the different

modes can be found in section 10 “Safety equipment”.

Risk of accidents!
It is the responsibility of the crane operator to check the
current lever assignment before commencing work.
Otherwise there is a risk of unintentional crane movements
being activated!

140−1140 3/11
14

30 16

31
32
24
34

35
36

Z 54 006

4/11 140−1140
 Hoist 1 14

(Z 54 006)

4. Start the hoist movement by pressing one of the buttons

(32/36) “dead man’s handle” and carefully moving the corre-
sponding control lever (16/24).

Control lever (16/24) − Load / hook

forwards / to the right lower
Control lever (16/24) − Load / hook
to the rear / to the left raise

Beware of the current lever assignment!

To prevent the unintentional activation of crane movements, both

control levers are fitted with an additional button (dead man’s
handle). The crane movement can only be carried out as long as
one of these buttons is pressed.
The dead man’s handle may only be actuated (pressed and re-
leased) when the corresponding control lever is in the neutral
position and/or the operating movement that has been started
has been completed.

Risk of accidents!
Pressing or releasing the dead man’s handle when the con-
trol lever is fully actuated leads to the corresponding move-
ment being started or stopped abruptly.

Risk of accidents!
Only by adapting the acceleration or speeds of all crane
movements can you avoid the load or hook block swinging
out, causing risk of crushing or crashing when each move-
ment is switched off.

The control levers (16/24) may not be switched directly in the

opposite hoist direction, but must first be placed in the neu-
tral position. Only start the contrary movement when the
hoist movement is at a standstill.

140−1140 5/11
14

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

6/11 140−1140
 Hoist 1 14

(Z 54 007)

The control lever automatically returns to the zero position when

released. The crane movement which has been started is
stopped.

When using control lever (16/24), touch hoist rotation indicator

(15). You will feel definite vibration there as soon as the hoist ro-
tates,.

The movement ”raise load” is automatically switched off when the

:
* load limit device has tripped.
* the hook block in the hoist limit switch is activated.
Lowering of the load is possible.

The movement ”lower load” is automatically shut down, when the

lower limit switch for hoist 1 has tripped.
Raising of the load is possible.

140−1140 7/11
14

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

180°

Z 54 750

8/11 140−1140
 Hoist 1 14

14.2 Regulating the hoist speed

(Z 54 007, Z 54 750)

The hoist is pilot controlled electrically. The hoist speed changes

in accordance with the engine speed and the movement of the
corresponding control lever (16/24).

High speed

High speed can be activated for the hoist. To this end, press push
button (30) on control lever (16). The high−speed function re-
mains activated as long as this button is pressed. The activated
high speed is displayed with the symbol in the IC−1 dis-
play.

In the following cases, high−speed may not be activated:

− when working with loads > 30% of the load capacity
− with single−rope operation of the main boom−
extension.

140−1140 9/11
14

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

180°

Z 54 750

10/11 140−1140
 Hoist 1 14

Precision control
(Z 54 007, Z 54 750)

In addition, the speed can be precision−controlled for the hoist.

First press push button (31/35) briefly, i.e. the left−hand button on
the corresponding control lever. On the right−hand side of the
IC−1 display the mask “percentage display” (Z 54 750) appears.

As long as the mask is displayed, the displayed percentage value

and the speed can be changed as follows:
− using self−return rocker switch (14/26) on the corresponding
control lever, when the movement is controlled by means of
horizontal (left / right) movement of the control lever.
− using self−return rocker switch (14/26) and at the same time
pressing push button (31/35) on the corresponding control le-
ver, when the movement is controlled by vertical (forward /
backward) movement of the control lever.

Depending on whether the self−return rocker switch is actuated

to the left or right, the value is either reduced or increased corre-
spondingly.

If there is no adjustment of the percentage values, the mask dis-

appears again after 5 seconds.

140−1140 11/11
 Hoist 2 15

140−1150−001b 1/21
15

1a

1b

Z 55 371

2/21 140−1150−001b
 Hoist 2 15

15 Hoist 2 (Optional)
You have the option of using the second hoist when working with
the main boom extension and when using the auxiliary head
sheave and/or a runner.

15.1 Fitting and Removing Hoist 2

(Z 55 371)

Equipment may only be fitted and removed by trained

and qualified personnel!

The attachment of hoist 2 (1a) can be performed with an auxiliary

crane or with your own crane together with the assembly aid (1b)
in combination with the additional block (2) as a support.
In transport configuration, the actual hoist 2 (1a) is mounted
together with the assembly aid (1b).
Figure (Z 55 371) shows the transport configuration, mounted on
the additional block (2) on the crane chassis.

Risk of overturning!
The hoist 2 needs to be secured against falling when
transported separately.

The weight of hoist 2 including the hoist rope and the mounting
device is approx. 1650 kg (3638 lbs).
The weight of the additional frame is approx. 100 kg (221 lbs).

There is a risk of crushing between the hoist housing

and the superstructure frame and the set down counter-
weight when fitting hoist 2.
The outrigger span needs to be selected in accordance
with subsequent crane operation.

140−1150−001b 3/21
15

A A

1a
5
3
4 3a

1b
3b
Z 55 372

Z 55 373

4/21 140−1150−001b
 Hoist 2 15

15.1.1 Fitting and Removing Hoist 2with the Auxiliary Crane

15.1.1.1 Fitting
(Z 55 372, Z 55 373)

1. Support the crane on outriggers and make it level.

2. Attach the entire hoist 2 to the auxiliary crane in attachment

points (A) and raise slightly (Z 55 372).

The weight of hoist 2 including the hoist rope is approx. 1500 kg

(3307 lbs).

Persons must not stand or walk beneath suspended

loads or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until
the bolting at all locking points has been completed.

3. Disconnecting hoist 2 (1a) from the mounting device (1b):

Release pins (3) and (4).
The rod of the hydraulic cylinder (5) cannot be pinned with
pins (3) in point (3b) until after the connection with
thesuperstructure hydraulic system is made.

4. Using the upper securing forks, place hoist 2 on the guide rail
on the superstructure frame and push towards the
superstructure. Pin and secure hoist 2 with the 4 biconical
pins (6/7) (Z 55 373).

Risk of crushing!
These is a risk of crushing between hoist 2 and the re-
spective fastening points on the superstructure frame.

5. Release the auxiliary crane.

6. Set up hydraulics and electrical connections between hoist 2

and the superstructure frame.
The hydraulic lines and connections are equipped with signs
which indicate their assignment.

All hydraulic couplings are fitted with protective caps which

mustbe removed before fitting.

140−1150−001b 5/21
15

9B 9
5 9A

3
F1 3a

Z 55 374

Z 170 939

6/21 140−1150−001b
 Hoist 2 15

(Z 55 374 , Z 170 939), principle illustration

6.1 Plug in the hydraulic couplings (raising and lowering

hoist 2) (G1 to G2).

6.2 Also plug in the hydraulic couplings (leakage oil (H1 to

H2), control pressure (K1 to K2) ) for hoist 2.

6.3 Attach the hydraulic system connections of the

erection cylinders (F1 to F2).

Always make sure that the hydraulic lines are connected

properly, i.e. that the couplings open correctly.
It is only permitted to create and disconnect hydraulic
connections in the depressurised state, i.e.the
superstructure engine may not be running.

Connect the mobile control panel (9) to connection (Q,

“X0029”).

7. Retract the erection cylinders (5) using the key (9B) on the
mobile control panel to such an extent that the rods can be
pegged and secured with the pins (3) at point (3a).

8. The attachment of hoist 2 is thus completed. Do a test run

and check all hydraulics connections against leaks.

9. Reeve the hoist rope of hoist 2 as needed.

15.1.1.2 Removal

Proceed in reverse sequence when removing hoist 2 with the aid

of an auxiliary crane.

No personnel are permitted in areas where loads/equip-

ment could fall while the biconical pins are being re-
leased.

140−1150−001b 7/21
15

9B 9
9A
5

3
F1 3a

”1” ”2” ”3”

A ”AA” 6
6c 6b 6a A

1a 7
5 7a
3
3
3a
4
1b
8 3b

Z 55 375

8/21 140−1150−001b
 Hoist 2 15

15.2 Fitting and Removing Hoist 2with Your Own Crane

15.2.1 Fitting
(Z 55 375)

Fitting and removing hoist 2 with your own crane is carried out
using the assembly aid (1b).

The weight of hoist 2 including the hoist rope and the mounting
device is approx. 1650 kg (3638 lbs).

A risk of crushing exists when fitting and removing hoist

2 between the individual elements and the superstruc-
ture frame and the crane chassis!
To avoid dangerous situations, pay particular attention to
the safety instructions in section 1.4.8 ”When Assem-
bling and Dismantling Crane Components”.
In particular, make sure that you allow sufficient safety
clearance.

Persons must not stand or walk beneath suspended

loads or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until
the pinning in all pinning points has been completed.

1. stabilise crane and make it level.

2. Adjust crane controls in accordance with the configuration.

3. Place additional block (2), on the crane chassis and fasten

it if it has not yet been mounted.

4. Fit hoist 2 (1a) with the fitted assembly aid (1b) in the 4
attachment points (A), place on additional frame (2) and pin
and secure to the additional frame with 4 pins (8).
Select lifting gear in such a way that hoist 2 is suspended
horizontally from the auxiliary crane. Lengthen the
suspension chain on the ”AA” attachment side somewhat as
needed by lengthening a shackle.
Failure to observe this will lead to inclined positioning,
resulting in problems when lifting and/or placing down on
the additional block and/or the assembly aid.

5. Release lifting tackle.

140−1150−001b 9/21
15

9B 9
9A
5

3
F1 3a

”1” ”2” ”3”

A ”AA” 6
6c 6b 6a A

1a 7
5 7a
3
3
3a
4
1b
8 3b

Z 55 375

10/21 140−1150−001b
 Hoist 2 15

(Z 55 375)

6. Rotate superstructure to the rear and pin (superstructure) to

the undercarriage.

7. Create hydraulic and electrical connections between hoist

and superstructure frame (see for this section 15.1.1.1,
starting from page 5).

All hydraulic couplings are fitted with protective caps which

mustbe removed before fitting.

Always make sure that the hydraulic lines are connected

properly, i.e. that the couplings open correctly.
It is only permitted to create and disconnect hydraulic
connections in the depressurised state, i.e.the
superstructure engine may not be running.

Connect the mobile control panel (9) to connection (Q,

“X0029”).

8. Extend the erection cylinders (5) using the key (9A) on the
mobile control panel (9).
Hoist 2 carries out a movement by which the upper securing
forks (6a) are guided along the guide rails (6b) of the
superstructure frame. Continue the adjustment movement of
the erection cylinders (5) until the biconical pins (6) in point
(6c) can be pegged (”1”).

9. Pin and secure hoist 2 with the biconical pins (6) in point (6c)
(2 x) (”2”).

10. Remove pins (4) (”2”).

11. Retract the erection cylinders (5) using the key (9B) on the
mobile control panel until the pins (7) in point (7a) can be
mounted (”3”).

12. Pin and secure hoist 2 with the biconical pins (7) in point (7a)
(2 x) (”3”).

13. Retract erection cylinders (5) using the key (9B) on the
mobile control panel until the rod eye can be pinned with the
pin (3) in point (3b) − secure pins (2 x) (”3”).

140−1150−001b 11/21
15

B B

1b
8
9B 9
9A
2

Z 55 376

12/21 140−1150−001b
 Hoist 2 15

(Z 55 376)

14. Remove the mobile control panel (9).

15. Lift the assembly aid (1b) down from the additional block (2)
using your own crane apparatus.
To do so, attach the suspension chain in four strands to the
lifting eyes (B), lift slightly and remove the pins (8).

The weight of the mounting device is approx. 145 kg (320 lbs).

The assembly aid must be lifted off hoist 2 after assembly,

otherwise there is a danger of collision with the
superstructure when rotating.

Risk of injury!
As soon as a load is lifted, no one is permitted beneath it
or in areas where loads/equipment could fall.

16. Reeve the hoist rope of hoist 2 as needed.

15.2.2 Removal

Proceed in reverse sequence when removing hoist 2 .

Risk of injury!
Wind the hoist rope onto the drum completely prior to
dismantling the hoist and fasten the rope end to the
frame of hoist 2.
No personnel are permitted in areas where loads/equip-
ment could fall while the biconical pins are being re-
leased.

140−1150−001b 13/21
15

11
12
3 2
5

13

14

Z 64 173

14/21 140−1150−001b
 Hoist 2 15

15.3 Fitting and Removing the Additional Top Rollers

(Z 64 173)

To prevent the hoist ropes of hoist 1 (11) and hoist 2 (12) from
rubbing against each other, they must be separated by additional
top rollers.

The two additional top rollers (2 and 3) must be fastened to the

2nd and 3rd boom sections using 4 screws (5) each.

These additional top rollers must be removed to maintain the

vehicle height of 4.0 m / 13.1 ft (transport condition).
Risk of load being torn off!

The additional top rollers are removed in the same way in the
opposite sequence.

The supplied folding / sliding ladder or another suitable

aid, for example a lift stage, etc., must be used to carry
out the assembly work described.

140−1150−001b 15/21
15

11
12
3 2
5

13

14

Z 64 173

16/21 140−1150−001b
 Hoist 2 15

15.4 Rope Guide

(Z 64 173)

When reeving the two hoists together during main boom

operation, hoist rope (11) of hoist 1 is guided between the rope
guides of the standard top rollers and the additional top rollers (2
and 3) and laid on the main boom head over the sheave (14).

Hoist rope (12) of hoist 2 must be fitted over the upper additional
top rollers (2 and 3) and over the sheave (13, optional HW 2) on
the main boom head (centre of the main boom head).
For the runner and the head sheave, hoist rope (12) of hoist 2
is fitted over the sheave (13).
For the main boom extension, hoist rope (12) of hoist 2 is fitted
over the deflection roller, which is at the back on the basic boom
of the main boom extension.

Now the hoist limit switches must be fitted in accordance with the
equipment used.

140−1150−001b 17/21
15

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

0.0°

Z 55 363

18/21 140−1150−001b
 Hoist 2 15

15.5 Hook Operation with Hoist 2

15.5.1 Pilot Control Assignment

(Z 54 007)

Depending on the crane equipment, different control lever

assignments can be selected.

See section 10 (Safety equipment) ”Pilot Control Assignment”.

To prevent accidental activation of crane movements, both

control levers are fitted with an additional button (32/36) (dead
man’s switch).
All crane movements can be performed if one of the keys is
pressed.

In order to avoid unplanned movements, take each selection

of pilot control assignment into consideration. Risk of
accidents!

The movement “Raising loads“ is automatically shut down when:

* the load limit device has shut down.
Load capacity of 100 % is reached (bar display D, Z 55 363)

* The hook block is driven in hoist limit switch.

Lowering load is possible.

The movement ”Lower load” is automatically switched off if the

lower limit switch for hoist 2 has been activated.
Raising of the load is possible.

140−1150−001b 19/21
15

14
30 15
31 16
32

26
34 25
35 24
36

Z 54 007

A
B
C
D

180°

Z 55 364

20/21 140−1150−001b
 Hoist 2 15

(Z 54 007, Z 55 364)

When activating control lever (16 / 24), touch the cone of the hoist
rotation indicator (15/25).
As soon as the hoist rotates, you will feel a definite vibration there.

15.5.2 Hoist Speeds

(Z 54 007)

The hoist is pilot controlled electrically. The hoist speed is

influenced by the engine speed, steering of the control lever as
well as the number of movements carried out at the same time.

Fine tuning:

The speed of the crane movement ”Hoist 2” can be additionally

fine tuned. The movements which are carried out by the X−axle
(horizontal steering of the pilot control lever) of each pilot control
lever can be controlled by the corresponding self−return rocker
switch (14/ 26) (key moved to the right − fast; Taster nach links
betätigt − langsam) reguliert werden. The movements which are
controlled by the Y−axle (vertical steering of the pilot control
lever) of each pilot control lever, can be controlled by the
corresponding self−return rocker switch (14/ 26) and by pressing
key (31/ 35) at the same time; from the front of the pilot control
lever always left in the forward direction.
As long as the speed is adjusted via key (14 / 26), the
corresponding percentage appears in the display of the LLD (D,
Z 55 364) (see also section 10).

High range :

The high range for Hoist 2 is activated by pressing key (30 / 34)
and control lever (5 /10) at the same time.

To ensure progressive acceleration of the crane

movements, the crane movement must already be initiated
before switching to high−speed mode.
High−speed mode may only be used for up to a maximum of
30% of the corresponding load capacity.
High speed may not be used for one−rope crane operation
with main boom extension.

140−1150−001b 21/21
 Heating and Ventilation 16

140−1160−003a 1/21
16

7 8 9 10

2
1 3
0 4

11

Z 54 530

12a 12b
zum Motor

zum Wärmetauscher
Heizung

Motor
Zulauf

vom Wärmetauscher

12c 12d 12e

Z 55 361

2/21 140−1160−003a
 Heating and Ventilation 16

16 Heating and Ventilation

(Z 54 530, Z 55 361)

16.1 Engine−Dependent Heating

This heating is dependent on the coolant temperature of the

engine. The heating temperature in the cab is regulated using
rotary switch (9).

The fan can be switched to 4 different settings using rotary switch

(8) or switched off (setting “0”). The air exchange in the can be
accelerated accordingly by using the fan.

Using luminous switch (10), you can select between fresh air and
surround air operation:
− Luminous switch (10) not activated; the indicator light in the
switch does not light up: fresh air operation.
− Luminous switch (10) activated; the indicator light in the
switch lights up: surround air operation.

There are several air nozzles (12) in the cab. The air nozzles
(12b−e) can be opened or closed individually as required.
In order for the defroster nozzles (12a) to have as great an effect
as possible, the other air nozzles (12b−e) should be closed.

140−1160−003a 3/21
16

7 8 9 10

2
1 3
0 4

11

Z 54 530

4/21 140−1160−003a
 Heating and Ventilation 16

16.2 Engine−Independent Heating with Coolant Preheating

System

In addition, observe the operating instructions of the

manufacturer in part 5 of this documentation.
They are in much greater detail and include additional areas
(such as fitting, safety devices and others).

16.2.1 General
(Z 54 530)

The mobile crane is equipped with an engine−independent

coolant preheating system for the superstructure engine. When
external temperatures are low, down to −20°C ( −4 °F), it makes
the engine start−up easier.
You must preheat the coolant under −20°C ( −4 °F). There is a
timer (7) in the crane cab for operation of the system.
Coolant preheating without preheating the cab: set the rotary
switch (9) to minimum.
Coolant preheating with preheating the cab: set rotary switch (9)
to maximum. The fan automatically starts up after a certain
coolant temperature which has been set that switch (8).

The heating system may only be used for the purposes

indicated by the manufacturer and while following the
supplied operating instructions.
Operation is not permitted:
− where flammable fumes or dust can be produced (i.e. near
fuel, coal dust, wood dust, wheat depots, or similar
places)
− in closed rooms (e.g. garages) due to risk of poisoning
− when refuelling.

When carrying out electric welding work on the vehicle, the

positive terminal must be disconnected from the battery to
protect the control unit and connected to ground.

140−1160−003a 5/21
16

8 9 10

MO ºC
7
3 20:30 11

1 2 3 4 5

Z 36 772

6/21 140−1160−003a
 Heating and Ventilation 16

If the coolant has been replaced or if larger quantities of

coolant have been topped up, the operating temperature of
the engine must be brought to approx. 80 C (176 F)
( = opening point coolant thermostat) before the
engine−independent heating is switched on. The coolant
circuit and the circuit for the engine−independent heating
can then be ventilated automatically.

16.2.2 Operating Elements

(Z 36 772)

(1) − Time
(2) − Preselection
(3) − Heater
(4) − Backwards
(5) − Forwards
Display of the timer
(6) − Memory
(7) − Symbol for radio remote control
(8) − Week day / selected day
(9) − Current time / selected time
(10) − Temperature
(11) − Service indicator light

The heater should be switched on briefly (approx. 10 s)

outside of the normal heating periods at least once a month.
Thisprevents the water pump and the burner motor from
seizing up.

You must carry out a test run with the heater before the
heating period. If there is a development of thick smoke
which remains a longer period of time or if there are unusual
burner noises or a definite stench of burning, the heating
must be switched off and put out of operation by removing
the fuse. The equipment should only be restarted once it has
been tested by an authorised service outlet.

140−1160−003a 7/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

8/21 140−1160−003a
 Heating and Ventilation 16

16.2.3 Settings
(Z 36 739)

After the power supply has been connected, all signals flash on
the display − all setting of the timer must be set. In this condition,
the heater assembly cannot be switched on.

16.2.3.1 Setting Time and Weekday for the First Time

Press briefly; time display flashes 12:00.

Set the current time.
Note: If two keys are shown next to each other, one or the
other must be pressed.
As soon as this stops flashing, it is saved. Then the weekday
flashes.
Set the current week day.
As soon as this stops flashing, it is saved.
If ignition is switched “On”, the display remains, if ignition is
switched “Off”, it goes out after 10 seconds.

16.2.3.2 Resetting Time and Weekday

Press longer until the time flashes. Then proceed as de-

scribed above in section 16.2.3.1.
If you press 2 x after the time has been reset, you can skip
the resetting function for weekdays.
If you press after the weekday has been reset, the flashing
of the weekday can be decreased.

With the ignition switched on the time and week day are
constantly displayed. With the ignition switched off, the
display goes out after 15 s.
Power failures are bridged by the heating timer.
All signals flash in the display after power failures. The
system must be completely reset!

140−1160−003a 9/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

10/21 140−1160−003a
 Heating and Ventilation 16

16.2.4 Heating Operation without Preselection

(Z 36 739)

Before switching the heating on for the first time, bring the
engine temperature of the superstructure engine to approx.
80° C (176 F) before every heating period so that the heating
system is ventilated 100 %.

16.2.4.1 ... for Ignition “OFF”

Switch on the heater

Heating symbol = observe the service indicator light.
Press briefly.

Display: Operation, heating time.

The heating time is set at a default of 120 minutes. It can be

modified once or permanently.

Modifying the heating period once

Switch on the heating.
Press − shorten (min. 1 minutes) or lengthen (max. 120 min-
utes) heating time

Modifying the heating period permanently

Do not switch on the heating
Keep pressed for approx. 3 seconds until the display ap-
pears and flashes. Release briefly.
Press − shorten (min. 10 minutes) or lengthen (max. 120
minutes) heating time
When the display goes out, the new heating time is saved.

Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.

140−1160−003a 11/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

12/21 140−1160−003a
 Heating and Ventilation 16

16.2.4.2 ... for Ignition “ON”

(Z 36 739)

Switch on the heater

Press briefly.

Display: Operation, time, day of week.

The heater remains in operation as long as the ignition is

switched on. After ignition has been switched off, there are 15
minutes remaining heating time.

Changing the residual heating time

Switch on the heating.
Press − shorten (min. 1 minute) or lengthen (max. 120 min-
utes) residual heating time.

Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.

16.2.5 Heating Operation with Preselection

(Z 36 739)

Starting point: Neutral position, as long as the display is visible.

No memory activated.

Three switch−on times within the next 24 hours or one switch−on

time up to seven days beforehand can be preselected.
Only one switch−on time can be activated.

Before switching on the heating for the first time, bring the
engine temperature of the superstructure engine to approx.
80° C (176 F) so that the heating system is ventilated 100 %.

140−1160−003a 13/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

14/21 140−1160−003a
 Heating and Ventilation 16

16.2.5.1 Heating Start Within 24 Hours

Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.

and is displayed as follows.

Press briefly and release. The preselected time is displayed

flashing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Press to select a memory again.

Set the preselected day

The preselected day is set automatically. It is therefore not
necessary to set it.

Preselected time and day are saved as soon as the time dis-
play goes out or it switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.

Check the activated memory

The preselected time of the displayed memory is shown for
approx. 5 seconds. It then goes out or the time is displayed
(with the ignition ON).
Press once to call up the preselected time with preselected
day (for 5 seconds).

140−1160−003a 15/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

16/21 140−1160−003a
 Heating and Ventilation 16

16.2.5.2 Heating Start Later than 24 Hours (Max. 7 Days)

(Z 36 739)

Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.

and is displayed as follows.

Press briefly and release. The preselected time is displayed

flashing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.

Set the preselected day

The preselected day is shown flashing approx. 5 seconds
after the preselected time has been set.
Press to set the preselected day for the heater.

Preselected time and day are saved as soon as the time dis-
play goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.

Check the activated memory

The preselected time of the displayed memory is displayed
for approx. 5 seconds. It then goes out or the time is dis-
played (with the ignition ON).
Press once to call up the preselected time with preselected
day(for 5 seconds).

140−1160−003a 17/21
16

MO ºC
6
3 20:30
P

1 2 3 4 5

Z 36 739

18/21 140−1160−003a
 Heating and Ventilation 16

16.2.6 Rectifying Faults

In case of faults or damage to the heater, an authorised service
outlet must be contacted to repair the damage using original
spare parts.
Repairs in house are therefore not permitted.

Proceed as follows:
− switch off and on (not more than twice)
− check main fuses
− check that the air flow is not blocked
− go to a workshop.

If there is a fault when the heating is switched on and the

diagnosis lead is connected, the service indicator light will flash
and the fault code no. is displayed (go to a workshop).

140−1160−003a 19/21
16

7 8 9 10

2
1 3
0 4

11

Z 54 530

20/21 140−1160−003a
 Heating and Ventilation 16

16.3 Air Conditioning Unit

(Z 54 530)

The air conditioning unit only works when the engine is running
and the fan is switched on. Proceed as follows in order to operate
the air conditioning unit:

1. Set switch (8) to the desired fan setting.

2. Press luminous switch (11); the indicator light in the switch

lights up.

The air conditioning unit works permanently with maximum

performance. The actual cooling performance is determined by
the selection of the fan setting.

In order achieve maximum cooling in the cab:

− Set fan to highest setting using switch (8).
− Turn switch (9) fully to the left (anti−clockwise) up to the stop.
− Fully open the ventilation nozzles.
− Activate luminous switch (10) for surround operation.
− Close windows and doors of the cab.

Instructions on operating the air conditioning unit

If the cooling performance of the air conditioning unit decreases

noticeably even though the switch settings have not been
changed, it is possible that the vaporiser has become iced up.
In this case, switch the air conditioning unit off for approx.
3 minutes with the vaporiser fan still running. The ice on the
vaporiser will melt.

On damp days the air conditioning unit can dehumidify the cab
air. Cooling is compensated by the heating. This then achieves
a pleasant cab climate and prevents windows fogging up.

Cold air coming out of the ventilation nozzles must not be allowed
to flow directly over unprotected skin.

The air conditioning unit must be switched on at least once

a month for a short period of time (compressor lubrication).

140−1160−003a 21/21
 Reeving 17

140−1170−204a 1/51
17

Z 53 401

2/51 140−1170−204a
 Reeving 17

17 Reeving

17.1 General
(Z 53 401, similar depiction)

The safety of the crane is endangered by incorrect reeving.

Every configuration is assigned a corresponding reeving

number that is shown in the load capacity tables supplied.
Work only in accordance with the reeving numbers listed!
The corresponding reeving number must be set on the load
limit device (IC−1).

Unless otherwise specified in the load capacity tables, the

number of reevings must not be lower than 2 rope lines.
If, however, single−line reeving is required, the lifting capa-
cities specified in the table must be reduced by 20%. This
also applies when the lifting capacity is less than the maxi-
mum permitted cable tension per strand of 8.1 t (17.9 kip).

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 (1, Z 53 401, similar
depiction)).

140−1170−204a 3/51
17

Z 53 401

”A” ”B”

approx.
1250
approx.
1500

Z 55 732

4/51 140−1170−204a
 Reeving 17

(Z 53 401, Z 55 732)

If a spin stabilizer (1) is fitted to the rope attachment point of

the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to the bottom edge of the
hoist limit switch) must be AT LEAST approx. 1500 mm
(59.1 in) (see ”a” in figure Z 55 732). Only then is it ensured
that the switch−off of ”Raise hoist” is carried out by the hoist
limit switch within a sufficient distance of the lowest point of
the main boom head. Otherwise there is risk of damage!
If the chain is not long enough for this, the additional chain
which is supplied with the spin stabilizer must be fitted as an
extension.

If a spin stabilizer is not fitted to the rope attachment point

of the main boom head, the length of the chain of the shift
weight of the hoist limit switch (up to bottom edge of the ho-
ist limit switch) must be AT LEAST approx. 1250 mm (49.2 in)
(see ”b” in figure Z 55 732).
In order to achieve maximum hoist heights, a longer chain
could be used once it is shortened. However, the length must
always be at least 1250 mm (49.2 in). RISK OF DAMAGE!

140−1170−204a 5/51
17

3
2

Z 52 210

6/51 140−1170−204a
 Reeving 17

17.2 Load Handling Equipment

(Z 52 210)

If a load is to be raised with the crane, so−called load handling

equipment are required to raise the said load. These are:
− Carrying Equipment
Carrying equipment is permanently connected to the crane.
This includes:
− Hoist ropes (1, see Sect. 17.2.1, page 9)
− Hook blocks (3, see Sect. 17.2.2, page 27).
− Load−handling devices
Load−handling devices are equipment, for example lifting be-
ams, that are not part of the crane. They are connected to the
carrying equipment and take up the load.
Their selection and safe operation lie within the responsibility
of the crane operator.
− Lifting tackle
Lifting tackle is equipment, e.g. sling ropes, which does not
belong to the crane. They connect the carrying equipment
with the load or the carrying equipment with the load handling
devices.
Their selection and safe operation lie within the responsibility
of the crane operator.

To ensure that the load−handling equipment is used cor-

rectly the individual national regulations, for example the ac-
cident prevention regulations ”Load handling equipment in
hoist operations” (VBG 9a / BGV D6) must be observed.

140−1170−204a 7/51
17

8/51 140−1170−204a
 Reeving 17

17.2.1 Hoist Ropes

17.2.1.1 General

Information on how to handle ropes safely and correctly is contai-

ned in Section 11 of the lubrication and maintenance instructions
for the superstructure.

During reeving, there is a danger that the ropes will become

twisted or drawn in at the head roller or deflection roller and
at the hook blocks!
Proceed with appropriate caution and make sure that sa-
fety equipment, e.g. safety guards, is fitted.

Risk of overloading and accidents!

If a rope has to be replaced, the new rope must satisfy the
technical parameters of the original rope, for example with
regard to rope diameter, nominal tensile strength, calcula-
ted breakage force, minimum breakage force, type of lay
etc. in accordance with the rope certificate in the crane log-
book.
If this is not the case, the operational reliability of the crane
in the normally permitted lifting capacity range is no longer
guaranteed!

The length of the ropes of hoist 1 and hoist 2 is 305 m (approx.

1000 ft) each.

140−1170−204a 9/51
17

Z 55 368 Z 55 369

10/51 140−1170−204a
 Reeving 17

17.2.1.2 Rope Connections

(Z 55 368, Z 55 369, similar depiction)

Risk of accidents!
If the rope connection is not made correctly as described
below, the hook block / load could fall!

The hoist ropes’ rope ends are equipped with different rope sok-
kets:
− Rope socket ”with press fitting”: Z 55 368,
(see Sect. 17.2.1.2.1, page 13)
− Rope socket ”without press fitting”: Z 55 369,
(see Sect. 17.2.1.2.2, page 15)

The drawings of the rope socket and rope clamp are only ex-
amples and may not correspond exactly with the compo-
nents supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.

140−1170−204a 11/51
17

2
4

Z 41 375

1 1

4
2

3 3

Z 41 383 Z 41 384

12/51 140−1170−204a
 Reeving 17

17.2.1.2.1 Rope end connection ”with press fitting”

(Z 41 375, Z 41 383, Z 41 384, similar depiction)

The rope end connection of rope ”Hoist 1” consists of the follo-

wing components (Z 41 375):
(1) − Rope pouch
(2) − Protect trap
(3) − Press fitting on the end of the hoist rope
(4) − Locking pin and mushroom handle

The press fitting (3) is part of the hoist rope and is connected
firmly to it.

Proceed as follows to make the rope end connection as descri-

bed below.
1. Release the locking pin (4) from the lock on the correspon-
ding hole of rope pocket (1) − by pulling on the mushroom
handle against the spring pressure − and fold up the safety
flap (2).
2. Attach hoist rope with press fitting (3) to rope pocket (1).
3. Fold over the safety flap (2) on the mushroom handle of lok-
king pin (4) into position ”lock” and allow the locking pin (4)
to lock in the corresponding hole of rope socket (1).
The safety flap (2) prevents the press fitting (3) from beco-
ming detached from the rope pocket when the hoist rope is
not carrying a load (e.g. when the hook block lands heavily
on the ground).
Risk of accidents!
The hoist rope may only be placed under load later when
the press fitting (3) is secured with safety flap (2) and the
locking pin (4) is locked in place.

In the version described and shown, the rope pocket may

only be used for minimum−rotating/non−rotating ropes.

Before reeving a hoist rope with press fitting all rope protec-
tion arrangements such as rollers or bolts on the deflection
rollers or idlers to be reeved must be removed or opened.
If this is not done the hoist rope cannot be drawn through
with the press fitting or may cause damages.

140−1170−204a 13/51
17

1
2

Z 41 377

1
1

5
4a 4b

4a
Z 200 177 Z 41 379

14/51 140−1170−204a
 Reeving 17

17.2.1.2.2 Rope end connection ”without press fitting”

(Z 41 377, Z 200 177, Z 41 379, similar depiction)

The illustrations of the rope socket (1) and the cable clip (3)
are principle drawings and do not correspond exactly with
the components supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.

In order to fit the rope socket (1), first the free rope end is pulled
through the conical rope pocket, laid in a loop and then pulled out
of the rope pocket again. The rope key (2) is laid into the rope loop
and the hoist rope is pulled through the rope socket (1), so that
the free end juts out by approx. 8 times the width of the rope dia-
meter. The free end must be secured against pulling using a ca-
ble clip (3) of the correct size.

Danger of the load and / or the hook block falling down!

140−1170−204a 15/51
17

Z 200 342 Z 200 343

1
1

5
4a 4b

4a
Z 200 177 Z 41 379

16/51 140−1170−204a
 Reeving 17

Using a cable clip (3), the ”unloaded” rope end (4a; Z 41 378) is
now secured where it comes out of the rope socket at a distance
of approx. 3 times the width of the rope, so that the hoist rope is
not pulled through.
The free end is connected with Litz wire (5) ø1.5 mm (0.06 in)
from the rope clamp to prevent the hoist rope from being pulled
through.

(Z 41 379)
Risk of damage to the rope!
The cable clip may not be attached in such a way that it con-
nects the ”loaded” (4b) and ”unloaded” ropes (4a) with each
other.

(Z 200 342)
When fitting the rope socket you must make sure that the ”loa-
ded” rope (4b) runs through the rope socket in such a way that
the tension force’s line of action runs exactly through the faste-
ning pin without bending the cable when the end connection is
loaded.

(Z 200 343)
When fitted incorrectly, the end connection will align itself
whenever loaded so that the tension force’s line of action
runs through the fastening pin, bending the highly loaded
”loaded” rope of the cable at the rope pocket exit every time.
On one hand, this reduces the maximum transmittable ten-
sion force of the end connection, on the other hand the pres-
sure coupled with the frequent bending within a very small
radius creates a premature wear of the rope cables in this
area, so that the end connection can fail prematurely even
when there are only small tension forces.

140−1170−204a 17/51
17

E1

11 3−TOP

12

13

K
Z 52 200 Z 53 402

18/51 140−1170−204a
 Reeving 17

17.2.1.3 Reeving/unreeving the hoist rope

(Z 52 200) (Z 53 402, similar depiction)

17.2.1.3.1 Reeving

Before reeving and before starting crane work, check the

status of all accessible ropes (including the end connec-
tions), winches and sheaves.

1. Position the hook block under the main boom head in such
a way that it is stable.

Risk of overturning!
Only work on the hook block (reeved or unreeved) when it
is stably positioned on hard ground.

2. Remove the rope guard pin (11) from the hook block and fold
out the rope guard plate (12).

3. Remove the rope guard pin (13) from the main boom head.

4. Guide the hoist rope from the hoist via the main boom to the
guide sheave (E1) on the main boom head.

Guide sheave (E2) is option.

While the crane operator is operating the hoist, the hoist

rope must be guided by an assistant in such a way that slack
rope cannot form.

If it is impossible to do this without stepping onto the main

boom, suitable safety measures must be adopted.
There is a danger of accidents resulting from
slipping/tripping on the main boom, or as a result of
incorrect operation of the hoist.

140−1170−204a 19/51
17

E1

11 3−TOP

12

13

K
Z 52 200 Z 53 402

20/51 140−1170−204a
 Reeving 17

(Z 52 200) (Z 53 402, similar depiction)

5. Guide the hoist rope via guide sheave (E1) to the sheaves
(K) in the main boom head and reeve in accordance with the
corresponding reeving diagram (see section 17.3).

6. Reattach and secure the rope guard pin (11) to the hook
block and (13) main boom head. To this end the rope protec-
tion plate (12) must be folded in again on the hook block.

7. Fit rope end into rope socket (if this has not already been-
done). Observe section 17.2.1.2 ”Rope End Connections”.

140−1170−204a 21/51
17

”A”

f KR

f Kl

Z 53 409

2 1

FU

3
2

2a 2b
Z 52 214 Z 52 209

22/51 140−1170−204a
 Reeving 17

(Z 53 409, Z 52 214, Z 52 209)

8. Pin the rope socket or rope pocket to the corresponding fi-

xing point:
− with uneven number of rope strands fixing point on the
hook block (FU, Z 52 209)
− with even number of rope strands fixing point on the main
boom head, here: right side − (Z 53 409)

9. Release the shift weight of the hoist limit switch from the
transport position (”A”, Z 53 409), remove both clip pins and
pull the two halves (2a) and (2b) of the shift weight apart.

10. Guide the separated halves of the shift weight around the ho-
ist rope and secure again with clip pins.
The condition shown in picture (Z 52 209) must be shown.

The shift weight should be attached to the “resting” rope.

This avoids wearing of the hoist rope and shift weight.
The ”resting” rope is the rope line that goes to the fixing
point.

Make sure that the shift weight is hanging free. Its functio-
ning is only guaranteed when this is the case.

Risk of damage!
If the shift weight of the hoist limit switch is not − as descri-
bed − fitted on the hoist rope, the hoist stroke limitation
does not work.
There is a risk of damage to the rope, sheave and shift
weight.

140−1170−204a 23/51
17

24/51 140−1170−204a
 Reeving 17

17.2.1.3.2 Unreeving
The procedure for unreeving corresponds in general to the pro-
cedure for reeving, but carried out in the reverse order.
In particular pay attention to the following points:

∗ Tipping over of the set−down hook block

Risk of overturning!
Only work on the hook block (reeved or unreeved) when it
is stably positioned on hard ground.

∗ sudden expulsion of the hoist rope end from the hook block

Risk of accidents!
When unreeving, the hoist must be operated with great care
and the hoist rope unwound gradually.
No−one may be in the dangerous area around the hook
block.

∗ Pay attention to how the hoist rope winds on. Slack rope must
not form.

140−1170−204a 25/51
17

Z 50 696

26/51 140−1170−204a
 Reeving 17

17.2.2 Hook Blocks

(Z 50 696)

17.2.2.1 Definition

In DIN 15002 the hook block is defined as the ”multiple line sus-
pension of carrying equipment with a hook”.

A single−line suspension would be referred to as hook suspen-

sion gear. As this differentiation is not relevant for the following
general contexts, only the description ”hook block” is used.

Only hook blocks may be used which have been obtained

from the crane manufacturer.
The use of other hook blocks is only permitted following
consultation with the crane manufacturer.

17.2.2.2 Markings

The following information must be permanently and clearly mar-

ked on the hook block:
− Warning marking
− Manufacturer or supplier
− Year of construction
− Type, if the type description exists
− Make or serial number
− Permitted load
− Rope diameter
− Drive group
− Dead weight.

140−1170−204a 27/51
17

Z 42 980

28/51 140−1170−204a
 Reeving 17

17.2.2.3 Operation
(Z 42 980)

When reeving, there is a danger of twisting, drawing in and

crushing at all rotating and moving parts of the hook
blocks!
Proceed with appropriate caution and make sure that sa-
fety equipment, e.g. safety guards, is fitted.

In particular pay attention to the following points:

− The personnel (person attaching/detaching the load) must be
qualified and conversant with the handling of hook blocks and
must be wearing suitable protective clothing.

When attaching and disconnecting the load, particular care

should be taken as a result of swinging loads or hook
blocks.
Once the load has been attached or released, the fitter must
leave the slewing or hazardous area immediately.

The fitter must be easily recognisable to the crane operator.

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These items of recognition must be of a distinctive colour
and preferably all in the same design and must be worn/car-
ried exclusively by the person connecting up the load.

Before starting movements of the winches (raising or lowe-

ring) all persons must leave the danger zone in the proxi-
mity of the rope drums and rope sheaves.

The crane operator must have visual contact with the ope-
rating personnel and must give a warning signal before
starting the crane movements.

140−1170−204a 29/51
17

Z 42 975

Z 50 697 Z 42 976

30/51 140−1170−204a
 Reeving 17

(Z 50 697, Z 42 975, Z 42 976)

− Touch the hook block only using the handrails provided. The
hands must be KEPT CLEAR of the following areas:
∗ between the sheaves, side plates and covers.
∗ in the area of the fixing points (sometimes of a folding de-
sign), the hook, the hook nut, the lifting beam or the protec-
ting cages.
− Make sure that items of clothing do not get caught in rotating
parts.
− Work on the hook block may only be carried out (i.e. reeving),
when it is set down in a stable position on firm ground.

Risk of overturning!
Be aware that the hook block could still tip over however!
Proceed with appropriate caution!

− Only use the hook block for lifting in the vertical direction. Pul-
ling sideways is not permitted.
− Place the hook block under load slowly and evenly.
No sudden loads! No one−sided loads!
− Always fit the load / load handling devices in the middle of the
hook (hook jaw), never at the tip.
− Never load only one side of the twin hook.

Welding on the hook block is prohibited.

140−1170−204a 31/51
 17

32/51
1−fold 2−fold 3−fold 3−fold 4−fold 5−fold 6−fold

2 6
4
2 2 4 4 2
3 2 5 2
3 3 5 3
1 1 1 3 1
1 1 1

7−fold 7−fold 8−fold 9−fold 10−fold 11−fold

9 10
6 4 8 8 6 10
8 6 11 8 6
2 6 4
2
6 4 4 2
7 5 7 5 7 5 2 7 5 9 7 4 2 9 7 4 2
3 1 3 1 3 1 3 1 5 3 5 3
1 1

12−fold 13−fold 14−fold 15−fold 16−fold

HW2 HW2 HW2 HW2
HW1 HW1 HW1 HW1

14 15 16
12 12 12 14 12 14 12
10 8 6 10 8 10 8 10 8 10 8
4 2
2 4 2 4 2 4 2 4
11 9 6 6 6
7 5 13 11 13 11 13 15 13
3 1 9 7 9 7 11 9 11 9
1 1 7 7
3 5 3 5 1 3 5 1 3 5

Z 55 366

140−1170−204a
 Reeving 17

17.3 Reeving the Hoist Rope on the Main Boom Head

(Z 55 366)

The safety of the crane is impaired by incorrect reeving!

Therefore observe the reeving examples on the opposite il-
lustration Z 55 366.

Other reeving configurations would disrupt the function of

the load limit device.

The following hook blocks can be used:

Type 200−9/21−D 9−sheaves, double hook, weight 1750 kg

(3858 lbs) with mutual HD attachment or
with one−sided HD attachment (max.16
falls)
Type 100−7/21−D 7−sheaves, max. 13 falls, single
hook,weight 1000 kg (2205 lbs)
Type 80−5/21−E 5−sheaves, max. 11 falls, single
hook,weight 945 kg (2084 lbs)
Type 80−5/21−D 5−sheaves, max. 11 falls, double
hook,weight 945 kg (2084 lbs)
Type 63−3/21−E 3−sheaves, max. 7 falls, single hook,weight
700 kg (1543 lbs)
Type 63−3/21−D 3−sheaves, max. 7 falls, double hook,weight
700 kg (1543 lbs)
Type 32−1/21−E 1−sheaves, max. 3 falls, single hook,weight
550 kg (1213 lbs)
Type 32−1/21−D 1−sheaves, max. 3 falls, double hook,weight
550 kg (1213 lbs)
Type 8−0/21−E Hook suspension gear,
weight 250 kg (551 lbs)

140−1170−204a 33/51
17

5
2
3b
1
3A

7b
7a

Z Z 60 294

34/51 140−1170−204a
 Reeving 17

The weights of ”the hook blocks, hook suspension gear, lif-

ting devices, etc.” must be deducted from the working loads
in the tables.

Only use original hook blocks, hook suspension gear, lif-

ting tackle, etc. suitable for this crane. If you wish to use
other components, you must first contact our Customer
Service Department.

17.4 Reeving the Hoist Rope on the Main Boom Headwith

Auxiliary Sheaves (HD Attachment, Optional)
(Z 60 294, similar depiction)

− 17.4.1 ”One−sided HD attachment” (3a)

(for a description, see starting on page 37)

− 17.4.2 ”Two−sided HD attachment” (3a + 3b)

(for a description, see starting on page 41)

Risk of accidents!

Only the original HD attachment of the crane manufacturer

for this crane type may be used!
For the use of other additional equipment the crane opera-
tor carries sole responsibility.

140−1170−204a 35/51
17

HW1

5
2

1
3A

7a

Z Z 60 295

36/51 140−1170−204a
 Reeving 17

17.4.1 Assembly and dismantling ”one−sided HD attach-

ment”
(Z 60 295, similar depiction)

In the standard design there are 5 sheaves on the axle (2) of the
main boom.
For reevings exceeding 10 strands, it is possible to attach two ad-
ditional sheaves (3a, ”One−sided HD attachment”) to the right−
hand side of the head.
Up to 11−fold reevings are possible with the ”Type 80” 5−sheave
hook block and up to 12−fold reevings with the ”Type 100”
7−sheave hook block.
See in this connection the 11−fold and 12−fold reeving examples
in the illustration (Z 55 366) for page 33.

The hook block is thus reeved over the left−hand run−in roller with
the hoist rope of hoist 1 (HW1).

The weight of the HD attachment is approx. 165 kg (approx.

363.8 lbs).

Carry out the fitting as follows:

1. Stand the main boom axle (2) on its end, bore hole is horizon-
tal.

2. Push HD attachment onto the axle (2) and peg with pins (1)
as illustrated.

3. Secure the bolts (1) on both sides with locking pins (5).

To reeve the hoist rope on the HD attachment (3a) the three rope
locking pins (4) can be removed.
Immediately after fitting the hoist rope, all 3 rope locking pins (4)
must be fitted back on again and secured with locking pins.

140−1170−204a 37/51
17

HW1

5
2

1
3A

7a

Z Z 60 295

38/51 140−1170−204a
 Reeving 17

(Z 60 295, similar depiction)

When using the ”one−sided HD attachment”, you must move the

hoist limit switch (74) from the main boom head and hang it onto
the HD attachment. The existing locking pin must be used for
pegging.

1. Attach hoist limit switch (7a) with associated switching

weight to the HD attachment.
To do so, peg the hoist limit switch to the respective device
at the rope securing pin (4) of the HD attachment − as shown
− and secure with a locking pin.

The hoist limit switch and its associated switching weight can be
used on all additional devices. That is the reason that there is
only one of them for all additional equipment. It may therefore be
required that they be dismantled from a different auxiliary device
in order to be able to be used on the HD attachment.

2. Fit the shift weight of the hoist limit switch to the hoist rope
of the HD attachment (3a) (see in this connection Par. 9. and
10., page 23).

Make sure that the shift weight is hanging free. Its functio-
ning is only guaranteed when this is the case.

The HD attachment is removed in the same way, in the reverse

order.

140−1170−204a 39/51
17

HW1

HW2

5
1
2
3b
1
3A

7b
7a

Z Z 60 296

40/51 140−1170−204a
 Reeving 17

17.4.2 Assembly and dismantling ”two−sided HD attach-

ment”
(Z 60 296, similar depiction)

In the standard design there are 5 sheaves on the axle (2) of the
main boom.
For reevings exceeding 12 strands, it is possible to attach two ad-
ditional sheaves each (3a + 3b, ”two−sided HD attachment”) to
the right−hand and left−hand side of the head.

Up to 15−fold reeving is possible together with the ”Type 100”

7−sheave hook block. See in this connection the 13−fold and
15−fold reeving examples in the illustration (Z 55 366) for
page 33.

Up to 16−fold reeving is possible together with the ”Type 200”

9−sheave hook block. See in this connection the reeving exam-
ples in the illustration (Z 55 366) for page 33.

The hook block is thereby reeved over both run−in sheaves with
the hoist ropes of hoist 1 (HW1) and hoist 2 (HW2).

The weight of each HD attachment is approx. 165 kg / 363.8 lbs,

(combined approx. 330 kg / 727.6 lbs).

Carry out the fitting as follows:

1. Stand the main boom axle (2) on its end, bore hole is horizon-
tal.

2. Push HD attachment onto the axle (2), right−hand and left−

hand side of the head, and peg with pins (1) in each instance
as illustrated.

3. Secure pins (1), right−hand and left−hand side of the head,

on both sides with locking pins (5).

To reeve the hoist rope on the HD attachment (3a + 3b) the three
rope locking pins (4) can be removed.
Immediately after fitting the hoist rope, all 3 rope locking pins (4)
must be refitted back on each HD attachment and secured with
locking pins.

140−1170−204a 41/51
17

HW1

HW2

5
1
2
3b
1
3A

7b
7a

Z Z 60 296

42/51 140−1170−204a
 Reeving 17

(Z 60 296, similar depiction)

A second hoist limit switch (7b) is to be installed on the left−hand

HD attachment (3b) when ”two−sided HD attachment” is used.
The existing locking pin must be used for pegging.

1. Attach hoist limit switch (7b) with associated switching

weight to the HD attachment (3b). To do so, peg the hoist limit
switch to the respective device at the rope securing pin (4)
of the HD attachment − as shown − and secure with a locking
pin.

The hoist limit switch and associated shift weight are component
parts of the HD attachment (3b) on the left−hand side of the head.

2. Fit the shift weight of the hoist limit switch to the hoist rope
of the HD attachment (3b) (see in this connection Par. 9. and
10., page 23).

Make sure that the shift weight is hanging free. Its functio-
ning is only guaranteed when this is the case.

The HD attachment is removed in the same way, in the reverse

order.

140−1170−204a 43/51
17

”X0550”
2
4
3
5

5.1
Z 60 297

Box top piece MBE basic boom Intermediate sect. 2 Intermediate sect. 1 HA (main boom) head
jib boom extension intermediate section 2 intermediate section 1main boom head
342 341 300

H6540 B7811
H6540 H6540
S7272
B7811
HES−R
optional
X0560 optional optional optional
X0580
X7811

X7272

X6540

H6263
X7811

X7272

X6540

X0550 H6262
B7513
X7271

X6540
X7811

X7811 X7811
X7271.2
X7271.1

X6540.1
X7811.3
X7811.2
X7811.1

S7272
S7271
HES
HES o. HES−L
S7272
HES Runner
X7271.3

without head rollers

H6540 or head roller

S7272
X0566
X6540
HES
X7271.4

HD attachment
X7811

HD attachment

B7811 S7272
HES

Z 60 298

44/51 140−1170−204a
 Reeving 17

17.4.3 Electrical safety chain ”HD attachment”

17.4.3.1 General
Close the electrical safety chain of the HD attachment at the dis-
tributor box ”X0550” main boom head and at the corresponding
HD attachment. See in this connection:

− 17.4.3.2 ”One−sided HD attachment”

(for a description, see starting on page 47)

− 17.4.3.3 ”Two−sided HD attachment”

(for a description, see starting on page 49)

The function can be ensured only if the safety chain is set up

correctly with the corresponding plugs. The bus system of
the control system is otherwise not closed and is therefore
not capable of functioning.

Caption to:
(Z 60 297, Z 60 298)

− ”X0550” Distributor box ”Main Boom Head”

1. Obstruction light

2. Anemometer

3. Socket (X7811) for connection, alternately:

− Anemometer (X7811.1)
− Main boom extension / runner / head roller (X7811.2)
− Adapter cable heavy−load hoist limit switch ”HES”
(X7811.3)
− Bridging plug (6) ”17−pin”

4. Socket (X6540): Obstruction light (X6540.1)

5. Socket (X7271) for connection, alternately:

5.1 Bridging plug ”2 pin”HES
− Hoist limit switch connection HES−L (X7271.1)
− Hoist limit switch connection HES−R (X7271.2)

6. Anemometer bridging plug ”17−pin”

140−1170−204a 45/51
17

”X0550”
2
4
3
5

5.1
Z 60 297

Box top piece MBE basic boom Intermediate sect. 2 Intermediate sect. 1 HA (main boom) head
jib boom extension intermediate section 2 intermediate section 1main boom head
342 341 300

H6540 B7811
H6540 H6540
S7272
B7811
HES−R
optional
X0560 optional optional optional
X0580
X7811

X7272

X6540

H6263
X7811

X7272

X6540

X0550 H6262
B7513
X7271

X6540
X7811

X7811 X7811
X7271.2
X7271.1

X6540.1
X7811.3
X7811.2
X7811.1

S7272
S7271
HES
HES o. HES−L
S7272
HES Runner
X7271.3

without head rollers

H6540 or head roller

S7272
X0566
X6540
HES
X7271.4

HD attachment
X7811

HD attachment

B7811 S7272
HES

Z 60 298

46/51 140−1170−204a
 Reeving 17

17.4.3.2 Safety chain ”One−sided HD attachment”

(Z 60 297, Z 60 298)

The sockets on the distributor box ”X0550” are to be assigned as

follows:
− Socket (3, X7811), alternately:
− Plug ”X7811.1 of the anemometer connection cable (2)
or bridging plug (6, ”17−pin”).
− Socket (4, X6540):
− Plug ”X6540.1 of obstruction light connection cable (1).
− Socket (5, X7271), alternately:
− Plug ”X7271.2 of the connection cable for hoist limit switch
(HES−R) or (HES−L)
or bridging plug (5.1, ”2−pin”).

Connect the hoist limit switch (HES−R) for ”one−sided HD attach-

ment” to the socket (5) as described below.
To this end:
− Plug in plug ”X7271.2” of the hoist limit switch (HES−R) con-
nection cable to the socket (5) and secure in place.
− If hoist limit switch (HES−L) plug ”X7271.2” or bridging plug
(5.1, ”2−pin”) is plugged in to the socket (5), then it must
be removed beforehand.
− Seal open plugs / sockets with protective caps.

If no hoist limit switch (HES−R) is used, then close the safety

chain with the aid of the bridging plug (5.1, ”2−pin”) at socket (5).

140−1170−204a 47/51
17

”X0550”
2
4
3
5

5.1
Z 60 297

Box top piece MBE basic boom Intermediate sect. 2 Intermediate sect. 1 HA (main boom) head
jib boom extension intermediate section 2 intermediate section 1main boom head
342 341 300

H6540 B7811
H6540 H6540
S7272
B7811
HES−R
optional
X0560 optional optional optional
X0580
X7811

X7272

X6540

H6263
X7811

X7272

X6540

X0550 H6262
B7513
X7271

X6540
X7811

X7811 X7811
X7271.2
X7271.1

X6540.1
X7811.3
X7811.2
X7811.1

S7272
S7271
HES
HES o. HES−L
S7272
HES Runner
X7271.3

without head rollers

H6540 or head roller

S7272
X0566
X6540
HES
X7271.4

HD attachment
X7811

HD attachment

B7811 S7272
HES

Z 60 298

48/51 140−1170−204a
 Reeving 17

17.4.3.3 Safety chain ”two−sided HD attachment”

(Z 60 297, Z 60 298)

The sockets on the distributor box ”X0550” are to be assigned as follows:

− Socket (3, X7811), alternately:
− Plug ”X7811.3” of heavy−load hoist limit switch ”HES” adapter cable
(X7811.3)
or bridging plug (6, ”17−pin”).
− Socket (4, X6540):
− Plug ”X6540.1 of obstruction light connection cable (1).
− Socket (5, X7271), alternately:
− Plug ”X7271.2” of the connection cable for hoist limit switch (HES−R)
or bridging plug (5.1, ”2−pin”).

No anemometer operation is possible when the ”two−sided HD at-

tachment” is used.

Connect hoist limit switch (HES−R) for ”two−sided HD attachment” (right−

hand side of the head) to socket (5) (see in this connection Sect. 17.4.3.2,
page 47).

Connect hoist limit switch (HES) for ”two−sided HD attachment” (left−hand

side of the head) as described below to socket (3).
To this end:
− Remove plug ”X7811.1” from Anemometer (2) at socket (3).
− Plug in plug ”X7811.3” of heavy−load hoist limit switch ”HES” adapter ca-
ble (length approx. 1.5 m / 3.3 ft) to the socket (3) and secure in place.
− Connect plug ”X7271.3” of ”HD attachment” hoist limit switch (HES) with
adapter cable (length ca. 1.5 m / 3.3 ft).
− Seal open plugs / sockets with protective caps.

If no ”two−sided HD attachment” (left−hand side of the head) hoist limit switch

(HES) is used, then the safety chain of the ”one−sided HD attachment” is to
be used (see in this connection Sect. 17.4.3.2, page 47).

If no hoist limit switch (HES−R) is used, then close the safety chain with the
aid of the bridging plug (5.1, ”2−pin”) at socket (5).

140−1170−204a 49/51
17

”B”
”A”

4 1
7 2

1
Z 56 947

”B”
”A”

Z 56 948

50/51 140−1170−204a
 Reeving 17

17.4.3.4 Hoist limit switch

(Z 56 947, Z 56 948)

Removing and storing the hoist limit switch retainer.

To switch the restraint from the locking position into the storage
position proceed as follows (Z 56 947, Z 56 948):

1. Pull hoist limit switch rope downwards 1 , then bend back-

wards parallel to the boom and hold in this position 2
(Z 56 947).

2. Move the retainer down 3 , and then to the 4 left. Release

the hoist limit switch rope (Z 56 947).

3. To store, push the retainer from the left over the hoist limit
switch (7) 5 until the two clips ”A” lock in the hole ”B” of the
hoist limit switch (Z 56 948).

Illustration (Z 56 947) shows the hoist limit switch in blocking po-

sition.
The hoist limit switch is shown in functional configuration in the
illustration (Z 56 948).

Open hoist limit switch connections on components of the

main boom extension are to be closed with 2−pin plugs du-
ring crane operation.
This is the only way to ensure that the hoist limit switch si-
gnal can be looped through the components.

140−1170−204a 51/51
 Main Boom Extension 18

18 Main Boom Extension (Option)

18.1 General

The bugles of the main boom extension must be inspected at least

once a year by a specialist (in accordance with the local accident
prevention regulations for load−handling equipment).
They should also be checked by a specialist in the meantime
depending on the applications of use and the operating
conditions. The inspection intervals generally depend on the
operating conditions and the applications for which the
equipment is used. This means that if the equipment is used more
often, the inspection intervals should be shortened accordingly.

The performance of these inspections must be recorded (e.g. in

the crane log book).

The following inspections should be performed:

* Inspection for cracks

* Inspection of length
* Inspection for wear
* Inspection of paint work
* Inspection for vivid deformation

You will find how the inspection must be carried out in the
”Maintenance and lubrication instructions of the superstructure”,
part 3, section 24).

You must also make sure that there is no damage to the tubes
in the lattice mast components. If damaged tubing is discov-
ered during visual inspections, further operation of the main
boom extension is prohibited.

There are the following combination lengths for the main boom
extension (MBE):
− 9.1 m / 29.9 ft
− 17 m / 55.8 ft
− 25 m / 82.0 ft
− 33 m / 108.3 ft

When an anemometer is mounted onto the main boom exten-

sion, the anemometer previously removed from the crane
must be used.
Failure to observe this can cause damage to the anemometer.

140−1180−181_en 1/51
18

”A”

Z 54 080

2/51 140−1180−181_en
 Main Boom Extension 18

When slewing the main boom extension from the transport

to the operating position or vice versa or when operating
with a folded main boom extension on the main boom, the
ladder (1) on the hydraulic oil reservoir must always be
folded against the oil reservoir. (Z 170 841).

RISK OF ACCIDENTS!
When carrying out installation work on the main boom
extension, use the supplied folding−sliding−ladder. It is
prohibited to walk on the main boom extension or on the
top of the main boom!
Always position the ladder so that is standing securely
and so that the resting point cannot slide away (i.e. after
loosening a pin).

RISK OF ACCIDENTS!
Only biconical pins which are cylindrical at one end may
be used for fitting the main boom extension (A, Z 54 080).

Each pin must be secured with 2 functioning locking

springs.

18.2 Fitting the Main Boom Extension 9.1 / 17 m

(29.9 / 55.8 ft)

When in the transport position or as long as the main boom

extension is not required, it can be carried along on the main
boom. The main boom extension is then folded alongside the
main boom and locked in place (Z 155 151). The permissible axle
loads must be observed.

For crane operation with the main boom extension locked in

the transport position, the loads specified in the load table
are reduced, i.e. the proportional weight of the main boom
extension in the transport position must be added to the load
that is to be lifted (see Notes on Crane Operation).

The following is a description of how you can get the main boom
extension from the transport position into the operating position.

18.3 Folding the Main Boom Extension 9.1 / 17 m

(29.9 / 55.8 ft)

Before folding the main boom out, it must be fully retracted

(catches must be flush, Z 170 608).

140−1180−181_en 3/51
18

4/51 140−1180−181_en
 Main Boom Extension 18

18.3.1 Folding the Lattice Mast 9.1m (29.9 ft) from the
Transport into the Operating Position

The conditions listed in the following must be observed for folding

out of the transport into the operating position and vice versa.
∗ Crane supported on outriggers and horizontally aligned.
∗ Counterweight fitted in accordance with the planned
configuration of the crane. To do so, follow the corresponding
details in the load capacity tables.
∗ Superstructure turned to the rear while supported on
outriggers and main boom set down (Z 170 610).
∗ Slew gear brake applied.
∗ Main boom in transport position (fully telescoped in and
pinned).
Safety and locking unit secured on the last (fifth) telescopic
section (see section 12 ”Telescoping”).
∗ The catches must (right and left on the main boom) be flush
(Z 170 608, page 2).

Operating position 0

1. Pull out pins (2) at point (C) using remote control (3)
(Z 170 609) and remove locking pin (7) (Z 170 611).

2. Slew main boom extension around the side center of motion

(E) (Z 155 154).

To avoid damage, a guide rope should be secured at the head

of the lattice mast.
The main boom extension can be pulled and braked with the
aid of the rope.

140−1180−181_en 5/51
18

Z 54 089

6/51 140−1180−181_en
 Main Boom Extension 18

3. Pin main boom extension at the boom head axles in fixing

points (F) and (G) using pins (3) and secure with locking
spring (4). (Z 54 089).

The pins (3) and locking springs (4) can be found at point (Q). (Z
54 089)

The double cones must be well greased before each pinning

and unpinning procedure.

The telescopic sections must be completely telescoped in to

fold the main boom extension into the working position.

In order for slewing round to function without any problems, the

main boom must be fully retracted. The stops between the
telescopic sections must be flush. Some of the stops have been
fitted so that they are covered. This is why you cannot tell if the
stops are flush just by looking.

If required, extend the main boom somewhat and recreate the

transport condition (Display) using the telescoping information
system (see in section 12: LPU in the position ”Transporting by
road”) again or manually retract the telepinion secured to the last
telescopic section (see section12 telescroping information
system ”Manual telescoping”).

140−1180−181_en 7/51
18

(3 + 4)

8/51 140−1180−181_en
 Main Boom Extension 18

4. Remove both pins from the side center of motion:

− pull out the pin (5) using abellcrank (Z 170 899)
− knock out the pin (6) (Z 170 899)

First remove the pin (5) from the centre of motion marked
with coloured decals, if pinning and locking has taken
place at the points (F) and (G) which are also marked
with colours.

5. Slew the main boom extension round to the front.

Here it must be ensured that the stop pin (8) slots into place
on the cross axle the left−hand (Z 170 613).

6. Pin in points (H) and (I) using pins (3) and secure with locking
spring (4) (Z 155 157) and (Z 54 089, page 6).

The pins (3) shall be inserted on the top and at the bottom.
Both pins shall be beaten far in alternately until the locking
springs can be mounted to secure the pins.

7. Attach the hoist limit switch and shift weight to the position
intended for this purpose on the main boom extension. (Z
155 200)

Check that all pins and locking elements are seated cor-
rectly.

8. Remove anemometer and aircraft warning light from the main

boom head and install them on the intended places on the
main boom extension.

140−1180−181_en 9/51
18

”X0550”
3

”X0560”

4
3 X0560 9,1m
Option
8,0m
Option
8,0m
X0550
X6540

X7272
X7811

H6263
X6540

5 H6262
X7271

B7513
+341−X7811 X7811 X7811
7

”X” HES HES

Z 60 250

10/51 140−1180−181_en
 Main Boom Extension 18

(Z 60 250).

9. Insert the plug of the cable (”X7811”) of the main boom

extension in the socket (3) at the distributor box (“X0550”) on
the main boom head.

10. Insert the plug of the anemometer in socket (3) on the

distributor box (“X0560”) of the main boom extension
(detail “X”).

11. Insert the plug of the aircraft warning light in socket (4) on the
distributor box (“X0560”) of the main boom extension
(detail “X”).

12. Insert the plug of the hoist limit switch in socket (5) on the
distributor box (“X0560”) of the main boom extension
(detail “X”).
First, the 2−pin bridging plug (7) may have to be removed
from socket (5).

RISK OF ACCIDENTS!
Open hoist limit switch connections on components of the
main boom extension must be ”2−pin” bridged in crane op-
eration at the appropriate distributor box/plug connection
(5) by means of bridging plug (7).
That is the only way to ensure that the safety chain is
closed and the hoist limit switch signal can be looped over
the components.

13. Reeve hook block. (see section 17).

14. For erecting the main boom with fitted main boom extension,
see from section 18.5, page 29.

Conversion to the travel position is the reverse of the above

procedure.

The pins in the coloured points (F) and (G) may only be
removed if the
main boom extension has been slewed back and has
been pinned and locked in the coloured point (E) again
(Z 155 147, page 12).

140−1180−181_en 11/51
18

14

12

12/51 140−1180−181_en
 Main Boom Extension 18

18.3.2 Folding the main boom extension 17.0 m (55.8 ft)

from transport position into working position
(Z 155 147).

Slew the superstructure to the back while supported on

outriggers and set down the main boom (take min. counterweight
into consideration).
During operation with the 17.0 m (55.8 ft) main boom extension
(lattice mast and tip section), ensure the following:
− the tip section must be pinned and locked to the lattice mast
at the rear end using pins (9) and (10). (Z 155 161, Z
155 147)
− the tip section must be locked to the lattice mast at the front
using the locking bolt (8) at point (R). (Z 170 613, Z 155 147)
− pin (12) must be pulled out at point (R) using the
bellcrank (Z 170 612, Z 155 147).

For details on folding the 9.1 m (29.9 ft) lattice mast with folded
tip section from the transport to the operating position, see
section 18.3.1, page 5.

1. Pull out pin (2) point (C) using remote control (3) (Z 170 609).

2. Unlock the locking bolt (7) at the runway (B) (Z 170 611).

3. Fold main boom extension (lattice mast 9.1 m / 29.9 ft with

folded tip section) from the transport into the operating
position.

For details on folding the 9.1 m (29.9 ft) lattice mast with folded
tip section from the transport to the operating position, see
section 18.3.1, page 5.

4. Loosen locking bolt (14) at point (R) (Z 155 147).

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18

14/51 140−1180−181_en
 Main Boom Extension 18

(Z 155 167, Z 155 169, Z 170 134)

5. Slew tip section round pins (9) and (10).

Here it must be ensured that stop pin (8) slots into place
afterwards (Z 155 169).
To avoid damage, a guide rope should be secured at the head
of the lattice mast.
The main boom extension can be pulled and braked with the
aid of the rope.

6. Pin and secure tip section in points (K) and (L) using pins (13
and 14) (Z 155 167).
The pins (13) and (14) shall be inserted on the top and at the
bottom. Both pins shall be beaten far in alternately until the
locking springs can be mounted to secure the pins.

7. Attach the hoist limit switch and shift weight to the top box
piece at the position intended for this purpose (Z 170 134).
Check that all pins and locking elements are seated cor-
rectly.

8. Remove anemometer and aircraft warning light from the main

boom head and install them on the intended places on the
box top piece.

140−1180−181_en 15/51
18

”X0550”
3
”X0560” 6

4 4
3 4
5
7

”X”

”X0561”

3 4
”Y” 5

Option Option Option

X0560 9,1m 8,0m 8,0m
X0561 X0550
X6540

X7272
X7811
X7811
X6540

X7272

H6263
X6540

H6262
X7271

B7513
+341−X7811 X7811 X7811

HES
HES HES

Z 60 251

16/51 140−1180−181_en
 Main Boom Extension 18

(Z 60 251).

9. Insert the plug of the cable (”X7811”) of the main boom

extension in the socket (3) at the distributor box (“X0550”) on
the main boom head.

10. Insert the plug of the cable (”X7811”) of the box top piece in
the socket (3) at the distributor box (“X0560”) on the main
boom extension (detail ”X”).

11. Insert the plug of the anemometer in socket (3) on the

distributor box (“X0561”) of the main boom extension
(detail “Y”).

12. Insert the plug of the aircraft warning light in socket (4) on the
distributor box (“X0561”) of the main boom extension
(detail “Y”).

13. Insert the plug of the hoist limit switch in socket (5) on the
distributor box (“X0561”) of the main boom extension
(detail “Y”).
First, the 2−pin bridging plug (7) may have to be removed
from socket (5).

RISK OF ACCIDENTS!
Open hoist limit switch connections on components of the
main boom extension must be ”2−pin” bridged in crane op-
eration at the appropriate distributor box/plug connection
(5) by means of bridging plug (7).
That is the only way to ensure that the safety chain is
closed and the hoist limit switch signal can be looped over
the components.

14. Reeve hook block. (see section 17).

15. For erecting the main boom with fitted main boom extension,
see from section 18.5, page 29.

Conversion to the travel position is the reverse of the above

procedure. The biconical pins (9 + 10, Z 155 169, page 14) in the
points (F) und (G) may not be removed until the box top piece has
been swivelled back and bolted and secured in point (E)
(Z 155 147, page 12).

140−1180−181_en 17/51
18

”A”

Z 54 080

18/51 140−1180−181_en
 Main Boom Extension 18

18.4 Fitting the Main Boom Extension 25 m / 33 m

(82 / 108.3 ft)
Slew the superstructure to the rear while supported on outriggers
luff the main boom down horizontally (0°). Create the minimum
counterweight as well as the minimum support base area. To do
so, follow the corresponding details in the load capacity tables.

RISK OF ACCIDENTS!
Only biconical pins which are cylindrical at one end may
be used for fitting the main boom extension (A, Z 54 080).

Each pin must be secured with 2 functioning locking

springs.

Use the folding−sliding ladder that was delivered with the

crane for pinning and locking the main boom extension.
Make sure that the climbing aid is on firm / secure ground.

Persons must not stand or walk beneath suspended

loads or in areas where loads/equipment could fall.
The auxiliary crane must hold the load until pin locking is
completed at all pin lock points.

The single components of the main boom extension may

only be fitted individually.

18.4.1 Installation of main boom extension 25 m (82 ft)

(Z 170 954).

Proceed as follows in order to fit the main boom extension 25 m

(82 ft):

Before fitting the main boom must be completely retracted

and pinned.

Only use the attachment points designed for lifting which are on
the individual components of the main boom extension, see
detail X, (Z 170 954).

1. Raise the first intermediate section (8 m / 26.3 ft; with

deflection roller (Y)), using an auxiliary crane, in front of the
main boom head (main boom and intermediate section
compose a line) and pin lock and secure at the fixing points.

2. Using an auxiliary crane, raise the lattice mast 9.1 m (29.9 ft)
in front of the intermediate section and pin and lock in the
fixing points.

140−1180−181_en 19/51
18

20/51 140−1180−181_en
 Main Boom Extension 18

(Z 170 134, Z 170 955)

3. Lift the box top piece with an auxiliary crane in front of the
intermediate section and pin lock and secure at the fixing
points(Z 170 955).

4. Attach the hoist limit switch and shift weight to the top box
piece at the position intended for this purpose (Z 170 134).

5. Attach the anemometer and aircraft warning light to the top

box piece at the position intended for this purpose.

140−1180−181_en 21/51
18

”X0550”
3
”X0560” 6

4 4
3 4
5
7

”X”

”X0561”

3 4
”Y” 5

Option Option Option

X0560 9,1m 8,0m 8,0m
X0561 X0550
X6540

X7272
X7811
X7811
X6540

X7272

H6263
X6540

H6262
X7271

B7513
+341−X7811 X7811 X7811

HES
HES HES

Z 60 251

22/51 140−1180−181_en
 Main Boom Extension 18

(Z 60 251).

6. Connect the plug of the cable (”X7811”) of the main boom

extension 9.1 m (29.9 ft) to the socket of the cable (”X7811”)
of the main boom extension 8.0 m.

7. Insert the plug of the cable (”X7811”) of the main boom

extension 8 m / 26.3 ft in the socket (3) at the distributor box
(“X0550”) on the main boom head.
8. Insert the plug of the cable (”X7811”) of the box top piece in
the socket (3) at the distributor box (“X0560”) on the main
boom extension (detail ”X”).

9. Insert the plug of the anemometer in socket (3) on the

distributor box (“X0561”) of the main boom extension
(detail “Y”).
10. Insert the plug of the aircraft warning light in socket (4) on the
distributor box (“X0561”) of the main boom extension
(detail “Y”).

11. Insert the plug of the hoist limit switch in socket (5) on the
distributor box (“X0561”) of the main boom extension
(detail “Y”).
First, the 2−pin bridging plug (7) may have to be removed
from socket (5).

RISK OF ACCIDENTS!
Open hoist limit switch connections on components of the
main boom extension must be ”2−pin” bridged in crane op-
eration at the appropriate distributor box/plug connection
(5) by means of bridging plug (7).
That is the only way to ensure that the safety chain is
closed and the hoist limit switch signal can be looped over
the components.

Check that all pins and locking elements are seated cor-
rectly.

12. Reeve hook block. (see section 17).

13. For erecting the main boom with fitted main boom extension,
see from section 18.5, page 29.

Dismantling is carried out in the same manner, but in the opposite

order.

No persons may be in the area where there is a risk of

falling items when loosening the biconical bolts.

140−1180−181_en 23/51
18

24/51 140−1180−181_en
 Main Boom Extension 18

18.4.2 Installation of main boom extension 33 m (108.3 ft)

(Z 170 955).

Proceed as follows in order to fit the main boom extension 33 m

(108.3 ft):

Before fitting the main boom must be completely retracted

and pinned.

1. Raise the first intermediate section (8 m / 26.3 ft; without

deflection roller), using an auxiliary crane, in front of the main
boom head (main boom and intermediate section compose
a line) and pin lock and secure at the fixing points.

2. Raise the second intermediate section (8 m / 26.3 ft; with

deflection roller (Y)) with an auxiliary crane in front of the first
intermediate section and pin lock and secure at the fixing
points.

3. Using an auxiliary crane, raise the lattice mast 9.1 m (29.9 ft)
in front of the intermediate section and pin and lock in the
fixing points.

4. Lift the box top piece with an auxiliary crane in front of the
intermediate section and pin lock and secure at the fixing
points.

For the further procedure, see section 18.4.1 from point 4., page
21.

For bending the main boom extension from 05 to operating

position 205 or 405, see section 18.5.3, page 37.

140−1180−181_en 25/51
18

26/51 140−1180−181_en
 Main Boom Extension 18

(Z 170 955).

1. Raise the first intermediate section (8 m / 26.3 ft; without

deflection roller), using an auxiliary crane, in front of the main
boom head (main boom and intermediate section compose
a line) and pin lock and secure at the fixing points.

2. Raise the second intermediate section (8 m / 26.3 ft; with

deflection roller (Y)) with an auxiliary crane in front of the first
intermediate section and pin lock and secure at the fixing
points.

3. Using an auxiliary crane, raise the lattice mast 9.6 m (31.4 ft)
in front of the intermediate section and pin and lock in the
fixing points.

4. Using an auxiliary crane, raise the box top piece 7.4 m

(24.3 ft) in front of the intermediate section and pin and lock
in the fixing points.

For the further procedure, see section 18.4.1 from point 4., page
21.

For bending the main boom extension from 05 to operating

position 205 or 405, see section 18.5.3, page 37.

140−1180−181_en 27/51
18

(82 / 108.2 ft)

25m / 33m = 45 % 0/0/0/0 %
(29.9 / 55.8 ft)
9.1m / 17m = 100 % 0/0/0/0 %

Z 54 082

28/51 140−1180−181_en
 Main Boom Extension 18

18.5 Configuration and Fitting Program for Erecting or

Bending the Main Boom Extension

In order to configure the main boom extension using a frame (0°,

20°, 40°), a special configuration program is required.
The selection of the configuration program is described in section
18.5.1, page 31 and in section 18.5.2, page 33.

(Z 54 082).

Main boom extension 9.1 / 17.0 m (29.9 / 71.5 ft):

− maximum permitted main boom erection length 21.8 m
(71.5 ft)
(extension sequence 0/0/0/0/100%; LK code 12).

Main boom extension 25 / 33 m (82 / 108.3 ft):

− maximum permitted main boom erection length 16.8 m
(55.1 ft)
(extension sequence 0/0/0/0/45%; LK code 6)

Requirements for configuration:

− the superstructure must be slewed to the rear (0°) and pinned

− the main boom angle is between −2° and +0° to the horizontal
− counterweight is in accordance with the load capacity tables
− the outrigger support area corresponds to the load capacity
tables

Additional loads must not be attached once the erection and

assembly programme has been set.

140−1180−181_en 29/51
18

10°

Z 60 253

1 2 3

45 %

90 %

100 %

90 %

4 45 %

28 %

Z 60 254

30/51 140−1180−181_en
 Main Boom Extension 18

18.5.1 Telescoping Display

(Z 60 253, Z 60 254)

In mask “Quick Menu” (Z 60 253), press key . Instead of

the “Quick Menu”, the entry mask of the telescoping information
system will appear, the “Telescoping Display” (Z 60 253).
You can select submenus here as well as information on the state
of the telescoping system.

(Z 60 254).

(1) Length code selection see section 18.5.2 ”Selection of the

longitudinal code”, from page 33
grey: the selected length code has not
been achieved.
green: the selected length code has been
achieved.
(2) End length of the main boom
(3) Actual length of the main boom
(4) Extension length of one telescopic section in percentage

140−1180−181_en 31/51
18

45 %

90 %

100 %
23.9 M
90 %

45 %

10° 28 %

Z 54 727

3 4 5 6 7
8
2

1 9

14 13 12 11 10
Z 54 728

32/51 140−1180−181_en
 Main Boom Extension 18

18.5.2 Selection of the Length Code

(Z 54 727, Z 54 728)

In order to select the length code (LK) for the desired main boom
length, press key ”LK” (Z 54 727). The mask “Tele operation
mode” will appear (Z 54 728).
All length codes are displayed here, including the corresponding
main boom length, extension state of the individual telescopic
sections and possible max. lifting capacities which are permitted
and can be selected for the chosen operating mode.
Call up the desired length code line using arrow keys (8 or 10).

You activate the desired length code by pressing it (the entire line
1, Z 54 728, is sensitive to touch). You exit the mask by pressing
key , the length code is saved and the mask “Telescoping
display” appears again (Z 54 727).

The key “LK” with its newly selected length code now has a grey
background. This means that the corresponding length must yet
be activated. This LK code is also displayed in black in the top line
of the IC−1 display.
As soon as the following telescoping procedure has been
completed, meaning that the corresponding aimed length has
been achieved, both displays change their colour to green.

140−1180−181_en 33/51
18

3 4 5 6 7
8
2

1 9

14 13 12 11 10
Z 54 728

34/51 140−1180−181_en
 Main Boom Extension 18

Mask “Tele operation mode”

(Z 54 728)

(1) − Number of the length code (LK no.)

(2) − Length of the main boom
(3) − Extension state of the telescopic sections 1 to 5 (from left
to right)

0 % extended 90 % extended

45 % extended 100 % extended

(4) − Max. lifting capacity in high position

(5) − Radius in high position
(6) − Max. lifting capacity in low position
(7) − Radius in low position
(8) − Scrollbar for flicking thorough the length codes, line by
line
(9) − Exiting the mask with save; the settings are saved
(10) − Flicking through the length codes, page by page:
> one page down; < one page up
(11) − Length code selection for the position of the LPU for
driving the crane (only for operating mode HA)
(12) − Exiting the mask without save; the settings are not saved.

140−1180−181_en 35/51
18

36/51 140−1180−181_en
 Main Boom Extension 18

18.5.3 For bending the main boom extension from 0 degrees

to operating position 20 degrees or 40 degrees

1. For requirements see 18.5, from page 29.

2. Main boom extension installed in 0° working position (see

18.3, from page 3 or 18.4, from page 19)

3. Configuration and Fitting Program for the Main Boom

Extension:
− at 9.1 / 17 m (29.9 / 55.8 ft), select LK code 12,
Display 090030
− at 25 / 33 m (82 / 108.3 ft), select LK code 6,
Display 090033

4. Pull out pin (18) at point (M), unfold roller strut and pin and
lock diagonal movable tube in point (N) with pin (18)
(Z 155 148).

140−1180−181_en 37/51
18

(82 / 108.2 ft)

25m / 33m = 45 % 0/0/0/0 %
(29.9 / 55.8 ft)
9.1m / 17m = 100 % 0/0/0/0 %

Z 54 082

Z 54 084

38/51 140−1180−181_en
 Main Boom Extension 18

− Lay down hook block on the ground

− Slew superstructure slightly to the side

5. Extend main boom in accordance with the configuration

program and luff it downwards until the roller strut is sitting on
the ground (Z 54 082) and the biconical pins (3) are relieved
of load in the points (F) and (H) (Z 54 084).

6. Remove biconical bolts (3) and store in the prepared bearing

plates (Q) in the main boom extension and secure with
locking spring (4). (Z 54 084).

140−1180−181_en 39/51
18

21 21

20 19

20

Z 54 085 Z 54 086

20o 40 o
20 20
19 19

0o
20

19

20 19 20
”O” 19

”P”

Z 54 087

40/51 140−1180−181_en
 Main Boom Extension 18

(Z 54 085, Z 54 086, Z 54 087)

7. Pull out pin (20) and slide tension bars (21) into the fitting
position (Z 54 085, Z 54 086); pin lock using pin (20), and
guard (Z 155 567).
Depending on the desired operating position, pin and lock the
shackles in the fitting position (for 20°−position at point “O”)
or (for 40°−position at point “P”) on the main boom extension
using pins (19) (Z 54 087).

8. Raise the roller struts so that they come off the ground. To do
so:

8.1 for 9.1 m (29.9 ft) extension:

Luff the main boom upwards until the roller strut lifts off
the ground.

8.2 for 17.0 m / 25 m / 33 m (55.8 ft / 82 ft / 108.3 ft)

extension:
Luff the main boom forward until the main boom
extension is lying on the plastic roller of the tip section
and roller strut is lifted off the ground.

140−1180−181_en 41/51
18

42/51 140−1180−181_en
 Main Boom Extension 18

9. Remove pins (18) of the roller struts between the frame and
the movable tube (point N).

10. Fold diagonal movable tube and frame of the roller strut
upwards.

11. Pin and lock the frame of the roller struts on the lattice mast
in point (M) using pins (18). (Z 155 177).

12. The conversion of 20°/40° to 0° operating position is carried

out in a similar manner, in the opposite sequence.
Risk of tilting when bending the main boom extension.
Adhere to max. extension length and extension se-
quence in % (see section 18.5, page 29)

18.5.4 Telescoping the Main Boom with Fitted MBE in the

Load Raising Position

Before raising or telescoping, check that all required

pins are fitted and that there are no objects that are not
tied down (e.g. hammers) on the main boom or the MBE.

1. Raise the main boom with fitted main boom extension off the
ground and place in a steep position (approx. 82°).

2. Telescope main boom in fully, while pulling in the hoist rope.

3. Set the load limit device to the desired operating length (to
select LK code, see section 18.5.1, page 31 and section
18.5.2, page 33, or section 12 “Telescoping” of these
operating instructions).
Make sure that the details of each individually valid load
capacity table correspond to the current crane configuration
(e.g. main boom length, fitted counterweight, etc.).

When the main boom extension 9.1 / 17 m (29.9 / 55.8 ft) is

folded up, the load values in the tables are reduced.

4. Telescope main boom out to the planned final length.

5. Telescoping in is done in a similar manner, in the opposite

sequence.

140−1180−181_en 43/51
18

12

Z 54 088

44/51 140−1180−181_en
 Main Boom Extension 18

18.6 Fitting the main boom extension with auxiliary crane

9.1 / 17 m (29.9 / 55.8 ft)

18.6.1 Fitting the 9.1 m main boom extension (29.9 ft)

1. Using the auxiliary crane, attach the basic boom MBE at the
prescribed attachment points and hang in front of the main
boom head (Z 54 088).

2. Knock in the fixing pins in points (F, G, H, I) and secure.

3. Fit the hoist limit switch, set the operating angle, reeve in
hook block.

4. Establish electric safety chain, see section 18.10, from page

49.

18.6.2 Fitting the main boom extension 17 m (55.8 ft)

Fitting individually

Place basic boom MBE and tip section individually in the

corresponding fitting positions, similar to 18.6.1, pin and lock.

18.7 Fixing the Tip Section to the Main Boom

If the crane is equipped with a 17.0 m (55.8 ft) main boom

extension, but work is only to be done with a lattice mast 9.6 m
(31.4 ft):

1. Pin pins (2) in point (C) using remote control (3), (Z 170 609).

2. Pin pins (12) to the main boom in point (S) using the bellcrank
(Z 155 202), (Z 170 612).

3. Remove connecting pins (9 and 10) in points (K and L) and

hang onto the lattice mast in the support plates (Q1) and
secure. (Z 155 202).

4. Further procedure as described in 18.3.1, from page 5.

5. Establish electric safety chain, see section 18.10, from page

49.

140−1180−181_en 45/51
18

46/51 140−1180−181_en
 Main Boom Extension 18

18.8 Operation with Main Boom Extension

1. Fit the main boom extension in the desired operating position

(load rasing position) and reeve in hoist rope 2−fold.

Depending on the starting point, consult the corresponding

subpoint.

2. Setting the crane configuration in the operating mode

preselection mask (section 10. Safety devices)

Type: MBE
other settings in accordance with set−up state

When selecting the operating mode MBE when already

telescoped out, you must remember
that the selected and currently relevant length code
(LK) must also exist as the extension sequence with MBE.
Otherwise it is not possible to change the operating mode.

The loads of the load tables are valid for 2−fold hoist
rope reeving.
If the hoist rope is reeved in only once:
− You must set simple reeving in the operating mode
preselection mask.
− The table values valid for 2−fold reeving are reduced by
20%. Then the already reduced value is displayed.
− It is prohibited to use high speed.

18.9 Emergency Removal in the Case of Telescoping

Problems

If telescoping the main boom in is not possible due to a fault, the

main boom must be removed as an emergency measure.
Depending on the state of assembly (outriggers, counterweight),
the
main boom can be removed directly. Otherwise you must use an
auxiliary crane. You can receive corresponding details on
request.

140−1180−181_en 47/51
18

1 5

”X0550”
2

3 5

4
6

Option Option Option

X0560
X0561 X0550
X6540

X7811
X7272
X7811
X6540

X7272

H6263
X6540 H6262
X7271
B7513
+341−X7811 X7811 X7811

HES
HES HES
Z 60 255

”X0561” ”X0560”

8 4
3 4 3
5
5
7
8

Z 60 256

48/51 140−1180−181_en
 Main Boom Extension 18

18.10 Electric safety chain

(Z 60 255, Z 60 256)

The electric safety chain for operation of the crane is connected

at the distributor boxes ”X0550”, ”X0560” and ”X0561”.
− ”X0550” Main Boom Head
− ”X0560” Basic boom main boom extension
− ”X0561” Box top piece

Caption to (Z 60 255, Z 60 256)

1. Aircraft warning light

2. Anemometer

3. Socket:
− Anemometer
− Connecting cable for main boom extension
− Bridging plug “17 pin” (6)

4. Socket: Aircraft warning light (1)

5. Cable / socket: Hoist limit switch

− Bridging plug “2 pin” (7)

6. Bridging plug “17 pin”

7. Bridging plug “2 pin”

8. Connection cable / plug “X7811”

(connection to the distributor boxes)

RISK OF ACCIDENTS!

When several components of the main boom extension are

in operation, it must be ensured that the anemometer (2),
the plug of cable connection (8) or the bridging plug (6) “17
pin” is attached at the appropriate distributor box connec-
tion (3).

Open hoist limit switch connections must be ”2−pin”

bridged in crane operation at the appropriate distributor
box/plug connection (5) by means of bridging plug (7).

That is the only way to ensure that the safety chain is

closed and the hoist limit switch signal can be looped over
the components.

140−1180−181_en 49/51
18

”B”
”A”

4 1
7 2

1
Z 56 947

”B”
”A”

Z 56 948

50/51 140−1180−181_en
 Main Boom Extension 18

18.10.1 Hoist limit switch

(Z 56 947, Z 56 948)

Removing and storing the hoist limit switch retainer.

To switch the restraint from the locking position into the storage
position proceed as follows (Z 56 947, Z 56 948):

1. Pull hoist limit switch cable downwards 1 , then bend

backwards parallel to the boom and hold in this position 2
(Z 56 947).

2. Move the retainer down 3 , and then to the 4 left. Release

the hoist limit switch cable (Z 56 947).

3. To store, push the retainer from the left over the hoist limit
switch (7) 5 until the two clips ”A” lock in the hole ”B” of the
hoist limit switch (Z 56 948).

RISK OF ACCIDENTS!

Open hoist limit switch connections on components of the

main boom extension must be ”2−pin” bridged in crane op-
eration at the appropriate distributor box/plug connection
(5) by means of bridging plug (7).

That is the only way to ensure that the safety chain is

closed and the hoist limit switch signal can be looped over
the components.

140−1180−181_en 51/51
 Head roller 21

140−1210a_en 1/13
21

E2 E1

Z 200 183

2/13 140−1210a_en
 Head roller 21

21 Head roller (option)

(Z 200 183)

21.1 General

The head roller (1) is used for lifting smaller loads (max. 8,1 t
(17,8 kip), single−strand), whereby the hook block on the main
boom head can stay reeved.

The head roller can be folded, and can be folded laterally onto the
main boom for transport.

The head roller consists of the frame and a bolted−on collapsible

rocker.

The head roller is marked with the factory number of the

crane. The head roller may only be assembled on the crane
with this factory number.
Exceptions are only permissible if this is explicitly noted in
the vehicle documents for the crane (e.g. crane pass).

140−1210a_en 3/13
21

”A”
9

1
1a
1b
”B”

8
”C”

Z 200 184

4/13 140−1210a_en
 Head roller 21

There is a danger of crushing when assembling or dis-

mantling the head roller between the main boom head
and the head roller.
Please pay particular attention to the inctructions on
dangers in chap. 1.4.8 “Assembly and dismantling of
crane components“ and the subsequent procedures des-
cribed.
Several types of assembly work are to be carried out
using suitable aid(ladders, lifting platforms, scaffolding,
auxiliary crane). Stepping onto the boom is strictly for-
bidden !

21.2 Assembly and dismantlement of head roller during

separate transport
(Z 200 184)

4. Move head roller against auxiliary crane.

The head roller must not be leaning or swinging during lifting.

The head roller is in transport position, i.e. the collapsible rocker

( 1b) is connected in point ( C) with bolts ( 8), and secured with
a forelock.
The weight of the head roller is approx. 160 kg (approx. 353 lbs).

5. Bring the head roller (1) into assembly position using auxi-
liary crane on the main boom head. For this purpose, the re-
spective bore holes for the fastening shackles of the head
roller must be in alignment with those for the corresponding
fastening shackles on the left (point “A”) and right (point “B“)
main boom head.
Rig both points with bolts (9), and secure these using fore-
locks.

As long as the head roller is only pushed against or not

completely bolted onto the auxiliary crane, no person
may be allowed in the crash range !

140−1210a_en 5/13
21

”C”

B
”D”
1b

”C”

”D”

Z 200 185

6/13 140−1210a_en
 Head roller 21

The head roller is now fastened on the main boom head.

To reach the actual working position, it must still be fol-
ded downwards!
Please make sure, therefore, you observe the following
points!

(Z 200 185, A)

1. Lift the collapsible rocker (1b) slightly to relieve bolts (8) and
to remove the bolts (8) from position (C).
Gas−operated positioner holds the rocker in the horizontal
position.

Danger of crushing!
There is a danger of crushing between the rocker and
frame of the head roller as soon as the rocker moves or
is moved.
Please take the appropriate measures to ensure safety!

(Z 200 185, B)

2. Manually press the rocker (1b) downwards against the pres-

sure of the gas−operated positioner until the matching hole
for the rocker is in alignment with the hole on the frame of the
head roller.
Then rig bolts (8) in position (D), and secure.

Only after this has happened is the head roller in working posi-
tion.

Danger of accident!
The head roller may not, in any case, be operated in the
folded up position (transport position)!

3. Insert the plug of the hoist limit switch for the head roller into
the free socket on the main boom head.

140−1210a_en 7/13
21

8/13 140−1210a_en
 Head roller 21

4. To avoid endangering persons or causing damage to the

equipment, hang up the shift weight of the hoist limit switch
on the head of the main boom in transport position (dis-
mantle if necessary).
If the hoist limit switch for the main boom is dismounted, then
the bridge plug must be mounted instead of the HES plug.

If the main boom is also equipped with a hoist rope when opera-
ting auxiliary devices such as a head roller, then the shift weight
of the hoist limit switch on the main boom must hang freely, and
the hoist limit switch must not be bypassed.

The head roller is dismantled in the reverse sequence accordin-

gly.

21.3 Folding in transport position

If the head roller is not required, then it can be folded laterally onto
the main boom head.

When folding the head roller, there is a danger of crus-

hing between the main boom head and the head roller.
Please take the appropriate measures to ensure safety!
During the folding process, no person is permitted in the
crash range !

1. Unload the hoist rope and wind up on rope drum.

2. Disconnect the electrical connection between the hoist limit

switch for the head roller and socket for the main boom head.

3. Rig the shift weight of the hoist limit switch in transport posi-
tion, and secure using locking spring.

140−1210a_en 9/13
21

A B

”C” 9

”A” 9
8

8 ”B”
”D” ”C”

”D”
1b
”A” 9
C D

9 10
”B” ”E” ”F” ”B”
”E”,”F”

11

Z 200 186

10/13 140−1210a_en
 Head roller 21

Fold the head roller upwards in transport position.

(Z 200 186, A)
1. Lift the collapsible rocker (1b) slightly to relieve bolts (8) and
to remove the bolts (8) from position (D).

Danger of crushing!
There is a danger of crushing between the rocker and
frame of the head roller as soon as the rocker moves or
is moved.
Please take the appropriate measures to ensure safety!

(Z 200 186, B)
2. Manually press the rocker (1b) upwards using the support of
the gas−operated positioneruntil the matching hole for the
rocker is in alignment with the hole on the frame of the head
roller.
Then rig bolts (8) in position (C), and secure.

Danger of accident!
The head roller may not, in any case, be operated in the
folded up position (transport position)!

(Z 200 186, C)
3. Remove the bolts on the right−hand side (9) from point (A).

(Z 200 186, D)
4. Turn head roller around point (B) until the bore hole (F) mat-
ches up on the main boom head.

5. Rig bolts (10) at the congruent bore holes (E, F).

(Z 200 186, E)
6. Remove bolts (9) at position (B).

7. Turn head roller around point (E, F) until bolts (11) can be rig-
ged on the welding holder of the head.
Rig bolts (11), and secure.

The head roller can be swivelled aroung from transport position

to working position in the reverse sequence accordingly.

140−1210a_en 11/13
21

E2 E1

Z 200 183

12/13 140−1210a_en
 Head roller 21

21.4 Operation
(Z 200 183)
1. Assemble head roller in working position

2. Release shift weight (3) of hoist limit switch from transport

position.

3. Reeve hoist rope single−strand. In doing so, make absolu-

tely sure the hoist rope is guided through the shift weight (3).

The rope guide for the hoist rope (2) must ensue via the upper
run−in roller (E2) on the head of the main boom to the rope
sheave in the head roller (1).

When reeving, there is a danger of coiling and being pul-

led in at the head− and deflection roller.
Please take the appropriate measures to ensure safety!

4. Bolt on hook suspension gear, type 12.5 (4).

5. Set the IC−1 in accordance with the crane configuration.

(Chap. 10 “Safety device“).
Type HA
Reeving 1
Other settings in accordance with construction state

140−1210a_en 13/13
 Dismantling and Assembly of the Main Boom (optional) 31

31 Dismantling and Assembly of the main boom (optio-

nal)

In the course of assembling and dismantling the main

boom there is the danger of being crushed:
− between the main boom foot and the bearings.
− between the main boom and the superstructure frame.
This is why no person is permitted in the danger zone!
Pay special attention to the notes on dangers in section
1.4.8 In the course of assembling and dismantling
crane components as well as the procedure described
in the following.
All assembly work is to be carried out using suitable
equipment (ladders, lifting platforms, frames, auxiliary
crane).
Should it not be possible to carry out work either using
such equipment or from the ground, then the assembling
personnel must protect themselves with suitable means
(e.g. safety belt) against the RISK OF FALLING!
In particular, it is prohibited to stay in the areas beneath
the suspended load where loads & equipment might fall
during the assembly or dismantling process (main
boom)!
Always keep safe distance!

Main boom assembly and dismantling must be carried

out by a well coordinated team. When doing this, each
assembling or dismantling step has to be planned care-
fully. All individual components have to be supported sa-
fely or secured by auxiliary cranes.

Moreover, the crane manufacturer recommends pre−trai-

ning at a secure location so that the course of action −
taking into account all safety measures for the assembly
personnel − can be practised BEFORE the first use.

The responsibility for installation or dismounting the

crane and leading the activities are part of the overall re-
sponsibility of the crane operator.

140−1310−102a_en 1/25
31

11

Z 55 400

Z 55 401

2/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.1 General
In various countries, the regulations on crane and traffic appro-
vals demand modified axle loads.

If necessary, the main boom must be removed from the super-

structure in order to achieve country−specific axle loads or to
carry out repairs. Therefore two auxiliary cranes are necessary.
The transport condition without a main boom is described in the
crane chassis operating instructions, part 2, sect. 6 “driving”.

The assembly and dismantling procedures described in this sec-

tion only apply if your crane is equipped with these devices (op-
tional).

(Z 55 400, Z 55 401)

Upon completion of the work, the railing (4) tilted up in order to

mount/dismount the crane must be tilted down and secured in its
standard transport position during road travel.
If the railing remains in a tilted−up position, the crane height of
4 m (13.1 ft) will be exceeded.

During road travel, the railing must always be tilted and se-
cured in its transport position (Z 55 400).

Especially the operations listed in the following that are

necessary to draw out the main boom foot pin must be
carried out with special care and in accordance with all
necessary safety measures because there is a repeated
risk of stumbling and falling.

During these operations the railing (4) must absolutely

be in tilted−up position. Otherwise there is danger of fal-
ling!

Upon completion of these operations the support bracket (1,

Z 55 401) attached to the superstructure frame for mounting/dis-
mounting the main boom foot pin must always be removed.

140−1310−102a_en 3/25
31

Z 42 980

”A”

Z 55 402

4/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.2 Before dismantling

1. Put the crane on outriggers and adjust it horizontally. Use the

big outrigger span.

When assembling or dismantling the main boom, the crane

must always be on outriggers.

2. Please ensure that:

− The telescopic sections are retracted and pinned.
− There is no main boom extension attached (please refer
to sect. 18 of this operating instruction).
− There is no laterally tiltable head sheave available (please
refer to sect. 21 of this operating instruction).
− There are no counterweights attached any more (please
refer to sect. 9 of this operating instruction).
− Hoist 2 is removed (please refer to sect. 15 of this opera-
ting instruction).

3. Unreeve the bottom hook block or the hook suspension gear

and wind the hoist rope onto the rope drum.

While unreeving, there is risk of winding and retracting at

the head and deflection sheaves as well as at the bottom
hook blocks!
Please act carefully.
Please touch the bottom hook block with the available
hand grips (Z 42 980). Your hands are explicitly not allo-
wed to come into the following areas:
* between rope pulleys, side panels, and coverings.
* into the area of the locating points (sometimes with
tiltable design), the hook, the hook nut, the cross head
or the hoop guards.
You’re only allowed to work at the bottom hook block
(reeved) if it is parked solidly on firm ground.

4. In transport position peg and secure the switching weight of

the hoist limit switch at the main boom head (Z 55 402, ma-
gnifying glass “A”).

140−1310−102a_en 5/25
31

31

Z 55 403

74

Z 55 404

6/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.3 Dismantling

1. Using the luffing gear, lift the main boom to approx. 45° and
rotate the superstructure approx. 15° to the side.
This will ensure that the assembly personnel does not need
to stay beneath the lifted main boom during the subsequent
attachment of the luffing cylinder support (31).

Danger of accident!
Staying beneath the lifted main boom is forbidden!
Proceed accordingly when assembling the luffing cylin-
der support.

(Z 55 403)
2. Assemble the luffing cylinder support (31) in the designated
area at the end of the chassis frame between stopper plate
and the load−securing plate.
The load−securing strap to fasten the removed luffing cylin-
der will be located on these plates later on.

Use theluffing cylinder support solely to place the luffing cy-

linder. Otherwise it has to be removed.

(Z 55 404)
3. Rotate the superstructure in a way that the main boom points
to the rear and insert the mechanical superstructure locking
device. Therefore, operate the light switch (74). The pin (1)
must retract into the stop device (2) The indicator light inside
the switch must go out.

140−1310−102a_en 7/25
31

31

Z 55 405

8/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

(Z 55 405)
4. Lower the main boom by using the luffing gear until the luffing
cylinder is situated directly (3−5 mm / 0.1−0.2 in) above the
luffing cylinder support (31).

Risk of damage!
The luffing cylinder support is designed only to bear the
weight of the luffing cylinder. Therefore, the weight of the
main boom shall not be transmitted to the luffing cylinder
support by the luffing cylinder.

140−1310−102a_en 9/25
31
”B”

12500

5896
”A”

Z 55 406

10/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

(Z 55 406)
5. Sling the main boom with a 2−string suspension gear re-
spectively to two auxiliary cranes:
− Slinging points at the main boom foot: please see magni-
fying glass “A”
− Slinging points at the main boom head: please see magni-
fying glass “B”.

Position the auxiliary cranes such as to bring the boom head

exactly into a vertical position above the corresponding slin-
ging points.

The main boom weight amounts to approx. 15.6 t (34 392 lbs).
The resulting vertical loads for hauling amount to:
− at the main boom foot (”A”): approx. 8.25 t (18 188 lbs)
− at the main boom head (”B”): approx. 7.35 t (16 204 lbs).

The main boom centre of gravity is located 5896 mm away from

the main boom foot bearing in direction of the sheave head.

Danger of accident!
Select the auxiliary cranes and the lifting tackle accor-
dingly to the prescribed main boom weight (or the loads
for hauling).
The necessary lifting capacities including adequate sa-
fety factors − especially in respect of the simultaneous
operation of two cranes − are to be defined according to
the regulations of the country of operation.

6. Tighten the lifting gear with auxiliary cranes. The auxiliary

cranes must take over the main boom load.

140−1310−102a_en 11/25
31

Z 55 407

800

Z 55 408

12/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

(Z 55 407, Z 55 408)
7. Make sure that the luffing cylinder is depressurised.
For this purpose, call the ”I/O” mask on the IC−1 display in
the superstructure cab for the diagnosis of inlets and outlets.
In this mask, by pushing ” Select ”Open pull−down menu
and “ A0701” for the control unit.
Then, scroll through the display until you find the last entry
“pressure absorber luffing cylinder”. The displayed value
must be included in the range “800”. This is the only way to
guarantee that the luffing cylinder is depressurised.

A display of 800 “increments” corresponds to a pressure

of bar / psi.

If the displayed value exceeds “800” you have to do the following

in order to depressurise the luffing cylinder:
− Make sure that both auxiliary cranes have taken over the
main boom load completely.
− Rock the luffing cylinder slightly by manipulating the corres-
ponding control lever until a value of approx. “800” is obtai-
ned.

As long as the luffing cylinder is not depressurised, the dra-

wing of the luffing cylinder pin described in the following is
not possible.

140−1310−102a_en 13/25
31

”B”
4

H1
5
61

”A”
H1
64
64
3

Z 55 409

14/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

(Z 55 409)

8. Turn off the superstructure engine.

9. Release the hydraulic connections. Therefore:

Release the quick−release closures of the hydraulic cou-
plings to the telescopic cylinder (1, “ST”), (2, “B1”), (3, “B2”),
(4, “P”) and (5, “T”) on the hydraulic console, in the area left
of the boom foot section and lock them using the correspon-
ding protecting caps.

The hydraulic hoses arrangement makes sure that no mistake

occurs while reestablishing the hydraulics connections.
The identification number in the facing diagram (Z 55 409) is for
informational purposes only.

10. Lock the ground hydraulic connection of the luffing cylinder

using the ball tap (H1) on the luffing cylinder “A”.

The loosening and establishing of hydraulic connections is

only permissible in depressurised condition, i.e. the super-
structure engine has to be turned off.

11. Disconnect electrical connections. For this purpose:

Detach the three plugs (61) on the angle sheet and the plug
connection (64) of the violet bus cable.
Lock all disconnected joints with protective caps.

140−1310−102a_en 15/25
31

A
K1

Z 55 410

31

Z 55 411

16/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.3.1 Dismantling luffing cylinder headpin

(Z 55 410, Z 55 411)

1. Unscrew the safety device (K1) on the luffing cylinder head-

pin (Z 55 410).

2. Pull out the luffing cylinder headpin by means of the extrac-

tion device (A).

Risk of overturning:
Shortly before the luffing cylinder headpin is pulled out
completely there is risk of overturning for the extraction
device with the suspended pin.

Weight:
pin approx. 19.2 kg (42.33 lbs)
extraction device approx. 19.2 kg (42.33 lbs)

After the main boom was removed, push the pin into the luffing
cylinder head bedding in order to park and secure it.

3. Tie down the luffing cylinder to the luffing cylinder support

(31) using the load−securing strap (Z 55 411).

140−1310−102a_en 17/25
31

A
K2

1
2

”2”
”1”

Z 55 412

18/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.3.2 Dismantling boom foot pin

(Z 55 412)

1. Tightening of the lifting gear on the main boom by means of

auxiliary cranes. The auxiliary cranes have to take over the
main boom load, i.e. the boom foot pin must be free.

2. Remove safety device (K2) on the boom foot pin.

3. Pull out the boom foot pin as far as possible using the extrac-
tion device (A).

4. Secure the provided pin support (1) to the superstructure

frame by means of two pins (2).

5. Pull out the main boom foot pin to the end of the pin support
or drive it out with a mandrel (e.g. a brass mandrel).

Risk of overturning:
Shortly before the boom foot pin has been completely
retracted, there is a risk that the pin will overturn.
Weight: pin approx. 120 kg (264.55 lbs)

6. Slowly drive out the main boom by means of auxiliary cranes

horizontally for the moment from the superstructure frame
foot bearing (“1”).

In this working step it is necessary to take special care on

free passage between luffing cylinder and main boom basic
case.
Make sure that tilting of the main boom on the bearing points
is avoided.

7. When the main boom foot bearing as well as the bearing of

the luffing cylinder at the basic case are free, lift the main
boom vertically out of the superstructure frame (“2”).

DANGER OF ACCIDENT!
While lifting the main boom, take care that it does not begin
to swing!

No persons are allowed to approach the suspended main

boom!

Risk of being crushed!

While lifting the main boom, there is risk of being crushed
between main boom and superstructure frame.

140−1310−102a_en 19/25
31

Z 55 413

Z 55 414

20/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

(Z 55 413, Z 55 414)

8. Placing the main boom on the transport vehicle, packing it

accordingly and lashing it (Z 55 413).

Risk of crushing!
While putting down the main boom, there is a danger of be-
coming trapped between main boom and the support on the
ground or the support on the transport vehicle.

9. Loosen the lifting tackle from the main boom and remove it.

10. For transport purposes, push the main boom foot pin into the
superstructure frame far enough so that can be secured with
both locking pins (3) in the support (1) (Z 55 414).

11. Retracting the crane stabilisers.

Pay special attention to the corresponding specifications in

the crane chassis operating instruction, section 6, when dri-
ving the crane in this configuration.

140−1310−102a_en 21/25
31

31

Z 55 405

K1

7
8

K2
7

Z 55 415

22/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.4 Main boomassembly

(Z 55 405, Z 55 415)

Assembly of the main boom occurs in reverse order to dismant-

ling.

Pay attention that:

− The crane is supported and adjusted by big outrigger span,
− The load securing strap at the luffing cylinder is released,
− The main boom foot and the luffing cylinder head correctly re-
tract into their bearings.
− The retracting of the luffing cylinder into the corresponding
bearing at the main boom is explicitly described on page
25 in sect. 31.4.1.
− The electrical and hydraulic connections are restored cor-
rectly.
− Plugs and plug−in connections have the same marking
and the hydraulic couplings must open correctly.

After reattaching of the main boom foot pin and the connec-
ting pin main boom/luffing cylinder these pins must be secu-
red unconditionally. Therefore, fasten with screws the re-
spective axis holders (K1) by the luffing cylinder headpin
and (K2) by the main boom foot pin. The screws to use to that
purpose (7), M 24 must be tightened with a tightening torque
of approx. 880 Nm (649 lbf−ft) and the screws (8), M 20 with
a tightening torque of approx. 510 Nm (376 lbf−ft).
As long as these two axis holders are not attached correctly,
crane operation is not permissible.

The battering of the pins as well as the attaching of the axis hol-
ders can be carried out best as long as the auxiliary cranes still
take over the load of the main boom.

Once the main boom is reattached and the luffing cylinder is

pinned with the main boom the unloaded luffing cylinder
support (31) must be removed and transported separately.

After assembly of the boom foot pin and before crane opera-
tion the foot pin support (1) must be removed.

140−1310−102a_en 23/25
31

”A” ”B”

H1

Z 55 416

24/25 140−1310−102a_en
 Dismantling and Assembly of the Main Boom (optional) 31

31.4.1 Assembly luffing cylinder headpin

Procedure of retracting the luffing cylinder into the bearing

on the main boom.
(Z 55 416)

Before retracting the luffing cylinder into the bearing on the main
boom it first has to be retracted “actively”.
Therefore, please proceed as described in the following.
− Start superstructure engine.
− Retract the luffing cylinder by operating the corresponding
control lever in the crane cab (downluffing).
Once the luffing cylinder is retracted completely put the con-
trol lever into neutral position. The luffing cylinder piston rod
begins to come out of the cylinder pipe step by step (or must
be drawn out step by step by operating the control lever tem-
porarily).
Once the piston rod mounting eyelet of the luffing cylinder is
in alignment with the corresponding bearing on the main
boom the luffing cylinder pin can be pushed in.

Before pushing in, look out for the centering of the pin axles
so that the receiving bushes will not be damaged.
As a rule, only a soft iron (e. g. a brass mandrel) may be used
to hammer directly on the pins in order to drive the pins in
or out.
To push in the pins a pin extractor may be used as well.
Before starting the engine make absolutely sure that the ball
tap (H1) on the luffing cylinder is closed “A” because other-
wise the luffing cylinder will drive out some centimetres
(problems with pin assembling).

Once the luffing cylinder pin is embedded completely and

secured with the axis holder it is essential to restore the
shut off valve (H 1) into its initial position (open “B”).
Any failure to carry out this step may result in serious da-
mage to the hydraulic system.

140−1310−102a_en 25/25
 Emergency Operation 36

140−1360 1/11
36

6
5 P
T
L UW

T UW 4
P
UW

Z 200 171

2/11 140−1360
 Emergency Operation 36

36 Emergency Operation (Optional)

Follow all safety instructions which are also valid for nor-
mal operation!

The emergency operation procedures described in the following

are only for when the superstructure engine or a pump fail so that
small loads (load pressures < 210 bar / 3046 psi) can be recove-
red safely.
Emergency operation is not equipped or suitable for maintaining
normal crane operation.

36.1 General

The required connections (hydraulic interfaces) are standardi-

sed.
The required auxiliary power unit is a hydraulic transformer,
which basically consists of a pump and an engine.
Such a transformer can be ordered from the crane manufacturer.

(Z 200 171)
The transformer has the following connections:
TUW − Tank connection crane chassis
LUW − Leakage oil connection crane chassis
PUW − Pressure connection crane chassis
T − Tank connection superstructure
P − Pressure connection superstructure

The shut−off lever (6, Z 200 171) of the hydraulic transformer is

set to open throughfeed and is only closed when a movement is
to be driven immediately afterwards.
The engine of the transformer (4) is driven by an external hydrau-
lic system (e.g. from the crane chassis, a second crane or a spe-
cial unit) and it then drives the transformer pump (5), which sup-
plies the superstructure hydraulic system.
The following movements can then be driven by activating the
control lever in the superstructure:
− Luffing
− Raising / lowering hoists
− Rotating (in connection with a stop valve on the super-
structure)
The required hydraulic transformer and all required hoses must
be supplied by the customer or can be delivered as optional
equipment.

140−1360 3/11
36

6
5 P
T
L UW

T UW 4
P
UW

Z 200 171

4/11 140−1360
 Emergency Operation 36

36.2 Connecting the Transformer

(Z 200 171)

Initial situation:

− Crane in relevant operating configuration (outrigger support

area, counterweight and similar) with hanging small load.
− Superstructure:
∗ Failure of diesel engine or pump
∗ Hydraulics and electrics functioning
∗ Engine and ignition off
− Crane chassis:
∗ Hydraulic external supply from the crane chassis or exter-
nal machine with connections for driving the transformer
∗ Engine and ignition off
− Use of a standard transformer In the following, an example
of the transformer (Z 200 171) supplied by the crane manu-
facturer is described.

12. Unfold protection caps on the relevant couplings of the trans-

former and unscrew hydraulic hoses.

140−1360 5/11
36

6
5 P
T
L UW

T UW 4
PUW
Z 200 171

Á 2.1 1.1 P
Á
S

Á
7
T
D
H

TUW
4
5 6
m P
PUW
LUW LUW
PUW

TUW
Z 60 208

6/11 140−1360
 Emergency Operation 36

(Z 200 171, Z 60 208)

13. Connect transformer engine (4) to the corresponding hy-

draulic couplings on the crane chassis using hoses.

These hydraulic couplings (x 3) are on the left−hand side of the

chassis between the wheels of axles 2 and 3 on the bottom of the
covering (Z 60 208). There are protection caps on the hydraulic
couplings which must be removed.

The coupling sleeves and plugs which belong together can

be marked with plates as follows:
TUW − Tank connection crane chassis
LUW − Leak oil crane chassis
PUW − Pressure connection crane chassis

There is no risk of them being confused as the connections of the

different hoses have different sizes.

In transformers without a leak oil connection the coupling ”LUW”

on the crane chassis remains free.

The shut−off lever (6, Z 200 171) of the hydraulic transformer is

set to ”open throughfeed”. Figure (Z 200 171) shows the stop
valve (6) in the closed position.

14. Connect pump (5) of the transformer to the corresponding

hydraulic couplings of the superstructure using hoses.
To do so, unscrew each protection cap and screw on the hy-
draulic hose.
The coupling sleeves and plugs which belong together can
be marked with plates as follows:
P − Pressure connection superstructure
T − Tank connection superstructure

There is no risk of them being confused as the connections of the

different hoses have different sizes.

Stop valve (7) must be opened once tank connection ”T” has
been set up (Z 60 208).

15. Connect bridging hose ”S” on the superstructure between

the connections 1.1 and 2.1 (rotate for function Superstruc-
ture).

140−1360 7/11
36

25

203.3
A
Z 200 173

103
Z 200 174

8/11 140−1360
 Emergency Operation 36

36.3 Recovering a Small Load

(Z 200 173, Z 200 174)

1. Connect the transformer in accordance with section 36.2.

2. Switch on the ignition of the superstructure.

3. Activate the function Emergency lowering (optional) (203.3,

Z 200 173) in the service line in the main menu of the crane
control system.
The function surface then displays “ON”.
When the crane operating mask is switched on, a red cross
with “ON“ written on it is displayed at (25, Z 200 173) in the
crane display (A, Z 200 173).

4. Open stop valve (6) of the hydraulic transformer (= pres-

sure−free circuit from pump side), if this has not already been
done!

The stop valve is only closed shortly before a movement is execu-

ted.

5. Start up the engine of the crane chassis.

6. Press switch (103, S 2430) (Z 200 174) in the chassis cab.

To do so, the hand brake must be applied and the transmis-
sion must be in “neutral position“.

The engine of the hydraulic transformer is supplied with oil.

7. Close stop valve (6) of the hydraulic transformer: The super-

structure hydraulic system is supplied with oil.

The further procedure depends on the movement to be carried:

Hoist and luffing

8. The crane movements “Hoist and luffing“ can be carried out

as before using the joystick.

140−1360 9/11
36

Á
Á
S 2.1 1.1 P

Á 7
T
D
H

TUW
4
5 6
M P
PUW
LUW LUW
PUW

TUW
Z 60 209

103
Z 200 174

10/11 140−1360
 Emergency Operation 36

(Z 60 209, Z 200 174)

Rotating the superstructure

9. In order to rotate the superstructure, the position of the stop valve (H)
must be modified:
During normal crane operation, the stop valve (H) is in the middle posi-
tion. In order to rotate the superstructure clockwise, the lever of the
stop valve must be pressed inwards. In order to rotate the super-
structure anti−clockwise the lever of the stop valve must be pulled
outward.
The lever of the stop valve is moved in the final position each time (locks
in place!)

The speed of the slewing movement is set using the knob of the throttle (D).
You will have a slewing speed that is easily manageable when you turn the
rotating knob half a turn from the completely screwed−in position (clo-
sed).Further opening of the throttle results in an increase of the slewing
speed.
The actual slewing movement is introduced by pressing the corresponding
joystick to the right or the left.
(Steering direction immaterial!)

Risk of crushing and pushing!

The slewing direction of the superstructure is determined
by the position of the hand stop valve (H) and not by
steering the joystick.

10. Open stop valve (6) of the hydraulic transformer after the movement has
been carried out (= pressure−free circuit from pump side).

Only operate the transformer as long as is required for recovering the

load and do not let it run at idle speeds for longer periods of time.
The oil can overheat if the transformer is operated for a longer period
of time.

11. After the load has been recovered, switch off the ignition in the super-
structure and with there was a slewing movement previously: return
hand stop valve (H) to the middle position (locks in place).
12. Switch off switch (103, S 2430) in the crane chassis and turn off the engi-
ne.
13. Remove all connections to the transformer again and cover couplings
with protection caps.

Stop valve (7) must be closed before tank connection ”T” is

disconnected (Z 60 209).

140−1360 11/11
 Runner 41

140−1410−181 1/25
41

”A”

Z 60 210

2/25 140−1410−181
 Runner 41

41 Runner (optional)
(Z 60 210)

41.1 General

The runner (1) is for lifting small loads (see the ”MS” load capacity
table); during this procedure the hook block can remain reeved
on the main boom head.
Figure (Z 60 210) shows the runner with the reeved hook block
in working position.

The runner can be folded and can be folded into parking position
at the side on the main boom (detail ”A”), in line with the permitted
axle loads for transportation or for main boom operation without
runner.

Operating the main boom with the runner attached will lead
to the lifting capacity of the crane being reduced.
In this case, pay particular attention to the ”MS” load ca-
pacity table supplied with the crane.
Non−compliance leads to greater risk of accidents!

The Runner is marked with the construction number of the

crane. It may only be fitted to the crane with this construction
number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).

Risk of accidents !
When fitting or removing the runner, there is risk of crush-
ing between the main boom head and the runner.
You must take special care to follow the instructions on
risks in Section 1.4.8 ”When fitting and removing crane
components” and the procedure described in the follow-
ing.
All assembly work is to be carried out with the help of suit-
able equipment (ladders, hoist platforms, scaffolding, aux-
iliary crane).
It is prohibited to walk on the boom.

140−1410−181 3/25
41

22

1c

1b
1a
1
E

”B”

Z 60 211

4/25 140−1410−181
 Runner 41

41.2 Fitting and Removal

(Z 60 211)

Before attaching, the runner (1) is on the ground on the fork ends
and the standing tubes of the runner frame (1a).
It is ”folded”, e. g., the runner frame (1a) is pulled on to the runner
adapter (1b) using an auxiliary winch (22) and on the bracing rods
using locking bolts (1c) pegged on both sides.

The weight of the runners is about 500 kg / 1102.3 lbs.

Sling the runner on to the auxiliary crane in such a way that it
neither off centre nor swings when raised.

1. Attach runner (1) to the auxiliary crane at the 4 attachment

points (E) with suitable lifting tackle and bring the main boom
head into the fitting position.
To do so, each drilled hole in the fork ends of the runner
adapter (1b) must be flush with the ones on the right− and
left−hand head axle, top and bottom.

RISK OF ACCIDENTS!
No one may be in the area at risk of falling equipment, etc.
as long as the runner is attached to the auxiliary crane or
has not yet been completely pinned!

2. Knock 4 biconical bolts at the pinning points and secure each

one with 2 locking springs.

The ”folded” fitting position which has then been achieved

(representation ”B”) is only for driving on a construction site
(technical drivability − take axle loads into consideration; see
section 6 “Driving” in the operating instructions of the crane
chassis).

RISK OF ACCIDENTS!
This “folded” fitting position may NEVER be used for rais-
ing loads. To do so, the runner must first be brought in the
operating position. To do this, refer to section41.3 ”Fold-
ing”, from page 7.

The runner must also be removed in the ”folded” position. To do

so, proceed in the same manner just in the opposite sequence.

140−1410−181 5/25
41

21 22

24 24
1b
1c

1a 23

25
30
31
31
Z 60 212

6/25 140−1410−181
 Runner 41

41.3 Folding
(Z 60 212)

Proceed as follows to fold the runner from the transport position

to the working position:

1. Lower runner frame (1a). To do so:

1.1 Remove the locking bolts (1c) at the bracing rods (24)
on both sides and peg them in the parking position.

1.2 Fit the crank (25) onto the hanging eyelet (23) of the
auxiliary winch (22) and unreel rope (21) of the
auxiliary winch until the bracing rods (24) are straight
on both sides.

1.3 While in the operating position of the runner (bracing

rods straight), loosen rope by unreeling it slightly so
that it is never loaded during runner operation.

2. For even reevings, loosen carabiner hook (30) from the

fastening chain of the rope attachment point: rope
attachment point (31) swings down.

3. Feed hoist rope from the hoist drum to the intake sheaves on
the main boom head.
Observe for this the detailed specifications contained in
Chap. 17 ”Reeving” in the Subpoint ”Reeving the hoist rope
in and out”.

140−1410−181 7/25
41

R2
E2

R1
E1

Z 60 213

”A” 4 3 2

E2 E2 E2
E1 E1 E1

R2 R2 R1 R2
FR R1 R1
fR fR
FU
3 2 2
3 4
1 2 1 1
U3 U2 fU U3 U2 U3 U2
U1 U1 U1

Z 60 214

8/25 140−1410−181
 Runner 41

(Z 60 213)
4. Feed hoist rope to the sheave (R1) of the runner via intake
sheave (E2).

The rope may not be fed via intake sheave (E1) as this would
make the deviation angle of the hoist rope too large. Risk of
damage to the rope.

Risk of accidents!
During reeving, there is a risk that all involved sheaves be-
come wrapped and wound up. Proceed with appropriate
caution!

(Z 60 214)
5. Reeve the hoist rope to the hook block (4−ropes, 3−ropes or
2−ropes).

The safety of the crane is impaired by incorrect reeving!

Therefore observe the following reeving examples.

Example: Hook block type 63, 3−sheave

The weight of the 3−sheave hook block is 700 kg (1543.22 lbs).

”A” − Reeving plan direction of sight

E − Intake sheaves on the main boom head
R − Sheaves on the runner
U − Hook block pulleys
FR − Fixing point on the runner
FU − Fixing point on the hook block

The hoist rope may only be reeved in accordance with the

following table. Other reeving configurations would disrupt
the function of the load limit device.

Num-
ber of Guidance of rope over the sheaves
strands
4 E2−R1−U1−R2−U3−FR
3 E2−R1−U2−R2−FU
2 E2−R1−U2−FR

140−1410−181 9/25
41

27
27

26

Z 60 263

10/25 140−1410−181
 Runner 41

41.3.1 Hoist limit switch

(Z 60 263)
1. Attach hoist limit switch (27) with associated switching
weight to the runner. For this, peg the hoist limit switch to the
respective mandrel at the top section of the runner on the
left−hand side − as shown − and secure with a linchpin.

This hoist limit switch and und associated shift weight can be
used on all additional equipment (main boom extension, box top
piece, etc.). That is the reason that there is only one of them for
all additional equipment. It may therefore be required that they be
dismantled from a different auxiliary device in order to be able to
be used on the runner.

2. Fit the shift weight (26) of the hoist limit switch to the hoist
rope of the runner.

The shift weight should be attached to the ”resting” rope.

This avoids wearing of the hoist rope and shift weight.
The “resting” rope is the rope line that goes to the fixing
point:
Make sure that the shift weight is hanging free. Its
functioning is only guaranteed when this is the case.

140−1410−181 11/25
41

”B”

7 ”A”

27
3
26

4 1
2

1
Z 60 264

”B”
”A”

Z 56 948

12/25 140−1410−181
 Runner 41

(Z 60 264, Z 56 948)

Removing and storing the hoist limit switch retainer.

To switch the restraint from the locking position into the storage
position proceed as follows (Z 60 264, Z 56 948):

1. Pull hoist limit switch cable downwards 1 , then bend

backwards parallel to the boom and hold in this position 2
(Z 60 264).

2. Move the retainer down 3 , and then to the 4 left. Release

the hoist limit switch cable (Z 60 264).

3. To store, push the retainer from the left over the hoist limit
switch 5 until the two clips ”A” lock in the hole ”B” of the hoist
limit switch (Z 56 948).

Open hoist limit switch connections must be bridged with

2−pin plugs in crane operation.
That is the only way to ensure that the hoist limit switch can
be looped over the components.

140−1410−181 13/25
41

”X0560.2”

27 3
”X0550”
3 5

Z 60 265

”X0550”
2

3 5

4
6

Option
X0560.2
X0550
X0560.2

H6263
X6540
X7274

H6262
X7271

B7513

X7811

HES HES

HES HES

Z 60 266

14/25 140−1410−181
 Runner 41

41.3.2 Electric safety chain

(Z 60 265, Z 60 266)

The electric safety chain for operation of the crane is connected at the
distributor boxes ”X0550” and ”X0560.2”.
− ”X0550” Main boom head
− ”X0560.2” Runner

Close safety chain, i.e. the sockets on the distributor boxes are to be
allocated as follows:

1. Insert the plug of the hoist limit switch (27) in socket (5) on the distributor
box (“X0560.2”) (Z 60 265).
First remove the protective cap on the socket.
Securely lay the connection cable.

If there is no hoist limit switch installed on the main boom head, then the open
hoist limit switch plug connection must be bridged using a “2−pin bridging
plug” (right side of main boom head).

2. Remove plug (3) of the anemometer (2) on the distributor box “X0550”
main boom head (Z 60 266).
Insert plug (3) on the distributor box “X0560.2” runner in socket (3)
(Z 60 265).
First remove the protective cap on the socket.
Securely lay the connection cable.

The anemometer (2) remains installed on the main boom head.

3. Guide the plug from the connection cable distributor box “X0560.2” to the
distributor box “X0550” and plug it in socket (3). If the 17−pin bridging
plug (6) is plugged in, remove it. Securely lay the connection cable.

4. If the aircraft warning light (1) is not attached, attach it to the main boom
head on the left side of the head (Z 60 266).
Plug in the plug to socket (4) on distributor box “X 550” on the main boom
head.
First remove the protective cap on the socket.
Securely lay the connection cable.

When working with a runner, make sure the safety chain is closed, as
described above.
That is the only way to ensure that the hoist limit switch can be looped
over the components.

Unfolding from the working position into transport position is done a similar
manner in the opposite order.

140−1410−181 15/25
41

A B
4

Z 60 217

16/25 140−1410−181
 Runner 41

41.4 Flaps

41.4.1 General
(Z 60 217)

If the runner is not needed, then this can be folded into the folded
position (detail ”A”) at the main boom head (left side) (detail “B”).

Preconditions for the procedure:

− The runner is in folded position at the main boom head (detail
“A”); for more, see section 41.3 ”Folding”, from page 7.
− The main boom head is equipped on the left side with holder
bearings (4 and 5) (detail “C”).

Before folding on the main boom side, the runner has to be

folded out of the working position into the transport position
(detail ”A”) !

Risk of accidents!
When folding the runner, there is risk of crushing be-
tween the main boom head and the runner. Proceed with
appropriate caution!
During the folding process, no person may be in the area
at risk from falling equipment!

If the runner is fitted to the left−hand side of the head in the

transport position, the main boom extension can not be
attached in working position (see section 18) and the head
roller (see section 21) can not be attached in working
position or in transport position.

For actually folding out of the working position into the transport
position and back again, one needs a pulling and guiding rope.
The main boom extension’s pulling and guiding rope can be used
for this.

140−1410−181 17/25
41

A B
4.1 4

5.2 5.1 5

C 3−”F(G)”

3−”H(J)” E

3−”H(J)” 3
4/5 5
4.1/5.1 5.2

Z 60 218

18/25 140−1410−181
 Runner 41

41.4.2 Folding in transport position

(Z 60 218)

Fold the runner as described in the following working steps into

the transport position. To do so:

1. Attach the pulling and guiding rope to the attachment eyelet

on the runner frame.

RISK OF ACCIDENTS! Risk of falling!

For the following unblocking: Do not lean the ladder on
the runner.

2. Remove the biconical pin (3) from points (F / G, detail ”C”).

Hold the runner in position while doing this with the pulling
and guiding rope.

In case the runner is NOT kept in position, this can be folded

away to the side when the pins are unpinned (3, F / G).

3. Fold the runner around using the pulling and guiding rope
until it is in the holder bearings’ storage brackets (4 and 5,
detail ”D”).
− Before folding, remove the lock pins (4.1 / 5.1) as well as
the locking bolts (5.2) at the storage bracket (detail ”A”).

4. Peg the runner using lock pins (4.1 / 5.1) in the holder
bearings (4 und 5) and secure them on both sides
(detail ”D”).

5. If the runner is secured at the holder bearings (4/5), remove

the biconical pin (3) at points (H / J, detail ”D”).
Hold the runner in position while doing this with the pulling
and guiding rope.

6. Use the pulling and guiding rope to further fold the runner
until it is in die second bearing on the holder bearing (5) with
the lower storage bracket (detail ”E”).

7. Peg and secure the runner using locking bolts (5.2) in the
holder bearing (5) (detail ”E”).

140−1410−181 19/25
41

A B
4.1 4

5.2 5.1 5

C 3−”F(G)”

3−”H(J)” E

3−”H(J)” 3
4/5 5
4.1/5.1 5.2

Z 60 219

20/25 140−1410−181
 Runner 41

(Z 60 219)

8. Peg the biconical pins (3) on the fork heads on the runner in
park position and secure them on both sides with locking
springs (detail ”E”).

The aircraft warning light (optional) can stay attached or can be

attached to the attachment apparatus on the main boom head,
on the left side.

41.4.3 Folding in working position

(Z 60 219)

Fold the runner towards the front as described in the following

working steps into the working position. To do so:

1. Attach the pulling and guiding rope to the attachment eyelet

on the runner frame.

2. Remove the biconical pins (3) on the four fork heads on the
runner (detail “E”).

3. Remove the locking bolts (5.2) in the holder bearing (5)

(detail “E”).

4. Use the pulling and guiding rope to position the runner at the
attachment points (H / J, detail ”D”) in pinning position.
To do this, the fork−head bore holes of the runner adapter
have to be flush above and below with the bore holes of the
left head axle.

5. At the upper and lower locking points (H / J, detail ”D”),

knock in one biconical pin (3) each and secure each one with
two locking springs.

Risk of accidents !
As long as the runner is not completely pinned at the lock-
ing points (H / J), then the lock pins (4.1 / 5.1) at the points
(4 / 5) may not be removed and no one may be in the area
where equipment could fall.

140−1410−181 21/25
41

A B
4.1 4

5.2 5.1 5

C 3−”F(G)”

3−”H(J)” E

3−”H(J)” 3
4/5 5
4.1/5.1 5.2

Z 60 219

22/25 140−1410−181
 Runner 41

(Z 60 219)

6. If the runner is secured at the locking points (H / J), remove

lock pins (4.1 / 5.1) in the holder bearings (4 / 5) (detail ”D”).

7. Use the pulling and guiding rope to position the runner at the
attachment points (F / G, detail ”C”) in pinning position.
To do this, the fork−head bore holes of the runner adapter
have to be flush above and below with the bore holes of the
right head axle.

8. At the upper and lower locking points (F / G, detail ”C”),

knock in one biconical pin (3) each and secure each one with
two locking springs.

Risk of accidents! Risk of falling

For pinning: Do not lean the ladder on the runner.

9. Peg the lock pins (4.1 / 5.1) as well as the locking bolts (5.2)
at the storage bracket (detail ”A”) in park position and secure
with locking springs.

10. Remove pulling and guiding rope an the runner frame.

11. Fold down the runner into working position (see section 41.3,
from page 7).

The runner has to be folded downwards before reeving the

hoist rope into working position.

140−1410−181 23/25
41

HA

HA 1.

2.

Z 60 220

HA

HA

Z 60 221

24/25 140−1410−181
 Runner 41

41.5 Operation
(Z 60 220, Z 60 221)

After all the mechanical prerequisites for the operation of the

runner have been met (runner attached, put in working position
folded down, and the hoist rope has been reeved as in the
specifications), the operating mode for runner operation has to
be selected. To do so:

1. Select the ”MS” variant in the ”Type” field in the ”Operating

mode selection” screen (Z 60 220) (see section 10.1.7.4.ff,
”Selection of the operating mode”).

2. Select all the other parameters (counterweight and reeving)

according to the actual crane configuration − which have to
correspond to the respective ”MS” load capacity table
(Z 60 221).
If correct values appear in red, they must first be confirmed
by pressing on them lightly.

3. Save the operating mode selection by pressing the key

and leave the screen with the key.

You can find detailed information about operating mode selection

in section 10 ”Safety devices” at section 10.1.7.4.ff in the
”TableViewer” screen.

140−1410−181 25/25
 Central lubricating system 46

140−1460−148a_en 1/17
 46

2/17
A

B 4.1

1.0

”Y”

3.1
2.2 2.1
C

5.0 ”X”

6.0

Z 55 935

140−1460−148a_en
 Central lubricating system 46

46 Central lubricating system (optional)

(Z 55 935)

The central lubricating system (comprising a central lubrication

pump with an integrated control circuit board, a progressive main
distributor (B) and a progressive subdistribution (C) makes pos-
sible the automatic lubrication of all safety−relevant lubrication
points during crane operation.

Legend ”A − D” for (Z 55 935):

(A) Pump element with control circuit board and safety valve
(B) Progressive main distributor
(C) Progressive subdistributor
(D) Distributor, ball bearing slewing
(”X”) Quick coupling connection, hoist 2
(”Y”) Disconnectable tube connection 3x
(option for dismounting the main boom)

If hoist 2 is not fitted, the lubrication line (1) from the subdis-
tributor (C) must be connected with the lube pump return line
(R) using the quick coupling connection (”X”).

Legend ”1.0 − 6.0” to (Z 55 935):

(1.0) Ball bearing slewing
(2.1 / 2.2) Main boom foot section bearing
(3.1) Luffing cylinder foot section bearing
(4.1) Luffing cylinder head bearing
(5.0) Winch, hoist 1
(6.0) Winch, hoist 2 (option)

140−1460−148a_en 3/17
46

6
Z 55 936

P I
8
9
15 M
7 10

T
11

Z 55 937

4/17 140−1460−148a_en
 Central lubricating system 46

46.1 Components
(Z 55 936, Z 55 937)

(1) Grease container (2 l. / 0.53 US gal)

(2) Pump element (K6, ca. 2.8 cm3/min / 0.17 in3/min)
(3) Safety valve
(4) Filling nipple, installation (emergency lubrication possible)
(5) Filling nipple, pump (for filling grease container)
(6) Sealing cap, control circuit board<HR>

After the sealing cap (6) has been removed, the control board
with the following details becomes visible (Z 55 937):

(7) LED on the left ”Battery voltage applied”

(8) Rotary switch blue ”Pause time”
(9) Rotary switch red ”Operating time”
(10 LED on the right ”Display lubrication procedure”
(11) Button for additional lubrication impulse

140−1460−148a_en 5/17
46

6
Z 55 936

P I
8
9
15 M
7 10

T
11

Z 55 937

6/17 140−1460−148a_en
 Central lubricating system 46

46.2 Function
(Z 55 936, Z 55 937)

The central lubrication pump automatically supplies the con-

nected lubrication points with grease via the main distributor and
the local subdistributor.
The control circuit board of the central lubrication pump controls
the preset cycles of pause and operating times.
The sequence of pause and operating times is activated when
the ignition unit in the superstructure is switched on.
The pause time
− determines the time period in which no lubrication cycle takes
place
(an exception is possible via auxiliary lubrication impulse to
be carried out manually by pressing the pushbutton (11).
The operating time
− determines the time period in which the lubrication cycle oc-
curs.

A precise description of ”Setting the pause and operating time”

can be found in Chap. 46.3, page 9.

The pressure limitation valve (safety valve −3−)

− limits the build−up of pressure in the lubrication system.
− opens in the presence of unauthorised overpressure.
If lubricant emerges at the pressure limitation valve (safety
valve −3−), this indicates a malfunction in the lubrication system.

A precise description of how to react to malfunctions can be

found in Chap. 46.7 ”Malfunctions/Elimination of malfunctions”,
starting from page 13.

Function test
A test run is possible for the purpose of testing the functioning of
the lubrication system. To do so:
1. Switch on ignition unit, the integrated LED (7) must light up.
2. Hold down the auxiliary lubrication impulse pushbutton (11)
for as long as it takes (>2 seconds) for the right−hand LED
(10) to light up.
The pause time proceeds in abbreviated fashion thereby. A
normal lubrication sequence follows afterwards.
Additional manual lubrication procedures are possible at any
time.

140−1460−148a_en 7/17
46

P I
8
9
15 M
7 10

T
11

Z 55 937

8/17 140−1460−148a_en
 Central lubricating system 46

46.3 Setting the interval and operating times

(Z 55 937)

46.3.1 General
The pause and operating times are controlled electronically via
the control circuit board.
The pause time begins its sequence as soon as the ignition unit
in the superstructure is switched on.
When the interval time has expired, the operating time starts,
which is the actual lubrication cycle.
46.3.2 Time setting
The length of a lubrication cycle depends on the lubrication re-
quirements of the safety−relevant lubrication points.
The pause and operating times are determined at the factory and
are set as follows:
− Pause time: 2 hours
− Switch position, rotary switch blue (8) = 2
− Operating time: 4 minutes
− Switch position, rotary switch red (9) = 2

The pause and operating times are set at the factory .

In order to ensure sufficient lubrication at the safety−rele-
vant lubrication points, it is not permitted to modify the times
that have been configured.

Pause time
If the preset time of 2 hours is interrupted by shutting off the igni-
tion unit, i.e. after 30 min., then the time which has passed prior
to this point will be stored in the memory. Once the ignition unit
is switched back on, the time period resumes its sequence at the
point that it was switched off.
Operating time
If the preset time of 4 minutes is interrupted by shutting off the
ignition unit, i.e. after 30 sec., then the time which has passed
prior to this point will be stored in the memory. Once the ignition
unit is switched back on, the time period resumes its sequence
at the point that it was switched off.
Storing time in the memory
The amounts of time which has elapsed remains stored in the
memory for an indefinite period when the ignition unit is switched
off.
Once the ignition unit is switched back on, the control system re-
sumes its sequence at the point that it was switched off.

140−1460−148a_en 9/17
46

6
Z 55 936

P I
8
9
15 M
7 10

T
11

Z 55 937

10/17 140−1460−148a_en
 Central lubricating system 46

(Z 55 936, Z 55 937)

46.4 Auxiliary lubrication impulse

When you are not within an automatic lubrication cycle, it is pos-

sible to end the interval time prematurely and to introduce addi-
tional lubrication procedures. To do so:
1. Switch on ignition unit, the integrated LED (7) must light up.
2. Hold down the auxiliary lubrication impulse pushbutton (11)
for as long as it takes (>2 seconds) for the right−hand LED
(10) to light up.
The pause time proceeds in abbreviated fashion thereby. A
normal lubrication sequence follows afterwards.
Additional manual lubrication procedures are possible at any
time.

After the additional lubrication procedure has completed its se-

quence, it is followed automatically by a normal electronically
controlled lubrication cycle.

46.5 Manual lubrication in the case of an emergency

If the lube pump fails, the lubricating pointscan also be lubricated

manually using grease.
To do so, grease is fed into the system via the lubricating nipple
(4) using a grease gun.

46.6 Filling the grease container

The grease container (1) is filled via the filling nipple (5) up to the
”Max.” marking, capacity = 2 l. (0.53 US gal)
The filling takes place in an appropriate manner with a standard
commercial grease pump or a hand lever press.
The pump must be put into operation during the filling procedure
(through advance activation of the auxiliary lubrication impulse).

After complete drainage, the pump can require up to 10 minutes

running time to reach maximum delivery rate.

The grease that is filled in must be free of any contamination

and must not lose its consistency with time.

Follow the instructions for prescribed lubricants in “Maintenance

and lubrication instructions for the superstructure” (Part 3)!

140−1460−148a_en 11/17
46

12/17 140−1460−148a_en
 Central lubricating system 46

46.7 Malfunctions/Elimination of malfunctions

The function of the pump can be recognised from the outside by the rotation of the agitator
blade (e.g. by initiating an additional lubrication cycle) or at the LEDs of the control circuit
board.

Fault: The engine of the pump is not running

Cause Remedy
Electricity supply interrupted. Check electricity supply/(safety) fuses. Rectify
malfunction/if required replace (safety) fuses.
Inspect the line to the plug of the pump/to the
control circuit board.

Fault: Pump is not delivering

Cause Remedy
Container is empty. Fill up container with clean grease, allow
pumpto run (triggering additional lubrication),
untillubricant emerges at all lubricating points.

Note: Depending on the ambient temperature

and/or the lubricant, the pump elements can
require up to 10 minutes in order to achieve
the full pumping capacity.
Air trapped in the lubricant. Activate additional lubrication impulse. Re-
move exhaust screw from the safety valve.
The lubricant must emerge without any
bubbles.
Unsuitable lubricant used. Renew lubricant, see lubrication table
(“Maintenance and lubrication instructions of
the superstructure”, Part 3).
Suction bore hole of the pump element Remove pump element and examine intake
blocked. bore for foreign bodies and remove if neces-
sary.
Pump piston worn. Replace pump element.
Non−return valve in the pump element defec- Replace pump element.
tive or blocked.

Fault: different quantities of lubricant at the lubrication points

Cause Remedy
Corresponding valve body was fitted without a Remove valve body and check if there is a
clamping ring. clamping ring. If not, fit a clamping ring.

140−1460−148a_en 13/17
46

4.1

3.1

”X”
B
A

C
”Y”

2.1

5.0

6.0
D

1.0

2.2

Z 55 935

14/17 140−1460−148a_en
 Central lubricating system 46

Malfunctions/Elimination of malfunctions, continued

Fault: Blockage in the progressive system that is connected in series,

see in this connection the lubrication chart (Z 55 935)
Cause Remedy
Bearing, lines or distributor Find and remove cause of blockage − as described in the
blocked. following example.

The malfunction can beidentified 1. Allow the pump to keep running

by the followingcharacteristics: (initiate auxiliary lubrication impulse, see in this connec-
tion Chap. 46.4, page 11).
a) Grease leaking from the 2. At the main distributor (B), remove all main lines (G) to
safety valve (A). the subdistributors one after the other. If, for example,
b) The check bolts (if present) grease emerges from outlet (1/3/5/7) of the main distribu-
fitted to the distributor piston tor (B), under pressure, the cause of the blockage is in
are not moving. the lubricating circuit of the subdistributor (C).
Note:
If there is a blockage in the progressive installation con-
nected in series, the lubrication lines will be under pres-
sure. The plug−in connection parts of the lubrication lines
will be almost impossible to disconnect in such cases.
Pressure on the installation is to be relieved by removing
the filling nipple on the safety valve (A).
Caution:
The installation is under pressure. Carefully loosen/
remove the lubrication lines and/or filling nipple.
3. Let the pump continue to run.
4. Remove all lubricating point lines of the subdistributor (D)
one after the other. If, for example, grease escapes at the
exhaust (1/2) of the distributor (C) when pressure is ap-
plied, the blockage is to be looked for in the exhaust line
(1/2) or in the connected bearing.
5. Pump through blocked line/bearing with a hand pump.
Note:
To check the individual outlets, leave each outlet loose for
a longer period of time, as only one piston stroke is car-
ried out for each rotation of the pump. However, several
strokes are required for a complete run of all distributors.
6. Check the safety valve (A), replacing it if necessary.

140−1460−148a_en 15/17
46

16/17 140−1460−148a_en
 Central lubricating system 46

Malfunctions/Elimination of malfunctions, continued

Fault: Blockage in the progressive installation connected in series

Cause Remedy
c) Distributor blocked, Exchange distributor or clean as described in the following:
(when a distributor is blocked,
no lubricant emerges at any 1. Remove all pipe connection screws.
exit point). 2. Unscrew piston sealing screws.
3. Push pistons out, if possible using a small mandrel
( smaller than 6 mm/0.24 in. ).
Important note:
The pistons are fitted flush in the distributor bores. After
they have been removed, mark the fitting position and di-
rection of the pistons for refitting. They must not be con-
fused during fitting.
4. Clean distributor bodies thoroughly in a fat−dissolving
cleaner and blow out using compressed air.
5. Using a pin, press the sloped channels (ø 1.5 mm/0.059
in) through at the thread ends of the piston bore holes.
6. Clean and blow out distributors again.
7. Assemble distributors. Replace copper washers.
8. If possible, pump oil through the distributor several times
using a hand pump before screwing the hose connecting
screws in place. The pressure in the distributor must not
exceed 25 bar ( 362.6 psi).
9. If a pressure build−up in excess of 25 bar ( 362.6 psi) oc-
curs in the distributor, then it should be replaced.

140−1460−148a_en 17/17
 Index

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1.1 Dimensions, weights, axle loads for chassis / crane vehicle . . . . . 1
2.1.2 Driving speed of crane vehicle 60 t (132 kip) . . . . . . . . . . . . . . . . . . 1
2.1.3 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.4 Climatic operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.5 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.6 Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overview of the crane chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 Signs in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.2 Signs on the crane chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.3 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Chassis and construction number . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Preparation for emergency control, superstructure . . . . . . . . . . . . . 23
2.6 Additional fuel tank (”additional tank” 300 l / 80 gallons)
in the crane chassis (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7 Separate fuel tank (”extra tank” 300 l 80 gallons) in
the chassis for superstructure operation (optional) . . . . . . . . . . . . . 27

4 Driver’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1 Operator’s Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1.1 Ignition−starter switch (15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1.2 Steering wheel setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.3 Driver’s Seat / Passenger’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.4 Folding the Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.5 Headrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.6 Safety belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.7 Door Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.8 Window Controls (Z 200 141, Z 200 142) . . . . . . . . . . . . . . . . . . . . . 23
4.1.9 Combination Switch (on the left of the steering column) . . . . . . . . 27
4.1.10 Combination Switch (on right of steering column) . . . . . . . . . . . . . . 29
4.2 Instrument Controls (assignment overview) . . . . . . . . . . . . . . . . . . . 31
4.3 Driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.1 “Driver information system” (43) display . . . . . . . . . . . . . . . . . . . . . . 35
4.3.2 Indicator lights in the driver information system . . . . . . . . . . . . . . . 49
4.3.3 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3.4 Function buttons on the steering wheel . . . . . . . . . . . . . . . . . . . . . . 61
4.3.5 Switch on the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4 Hinged Bed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.4.1 Procedure for Folding the Bed down . . . . . . . . . . . . . . . . . . . . . . . . . 71

140−2000−201c 1
 Index

5 Engine (OM 502 LA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.1 Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2 Starting Aid with External Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 Ignition−starter switch (see section 4 ”Driver’s cab”) . . . . . . . . . . . 9
5.4 Starting Procedure (Engine Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4.1 Starting the Engine in the Driver’s Cab . . . . . . . . . . . . . . . . . . . . . . . 9
5.4.2 Starting the Engine at the Outrigger Controls
(External Engine Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.5 After Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.6 Before Switching Off the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.7 Switching Off (Engine Stop) in Normal Circumstances . . . . . . . . . 15
5.7.1 Switching off the Engine in the Driver’s Cab . . . . . . . . . . . . . . . . . . 15
5.7.2 Switching Off the Engine on the Outrigger Control . . . . . . . . . . . . . 15
5.8 Switching Off the Engine in an Emergency . . . . . . . . . . . . . . . . . . . 17
5.8.1 Switching Off Procedure ”Quick Stop” (Optional Equipment) . . . . 17
5.8.2 ”Quick Stop” with Air Shut−off Valve . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.9 Electronic Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9.1 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9.2 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.9.3 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9.4 Limiter (for Limiting the Maximum Speed) . . . . . . . . . . . . . . . . . . . . 27
5.9.5 Monitoring the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.9.6 Reading Off the Fault Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.9.7 Evaluation of the Displayed Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Driving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6.1 Instructions for all Types of Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.2 Checks Before Driving the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3 Transport Safety Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Axle Loads / Speeds / Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.4.1 Calculating Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.2 Calculating Axle Loads on a Metric Basis;
in Kilograms (kg) / Tons (t) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.3 Calculating Axle Loads in British / American Units;
in Pounds (lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.4 Possible Axle Loads / Permitted Speeds . . . . . . . . . . . . . . . . . . . . . 27
6.4.5 Driving with Uneven Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.6 Driving with Reduced Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4.7 Driving with Axle Loads Exceeding 12 t (26.4 kip) . . . . . . . . . . . . . 39
6.4.8 Shorter Maintenance Intervals for Axle Loads above
12.5 t (27.6 kip). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5 Driving on Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5.1 Driving with Axle Loads of 12 t (26.4 kip) . . . . . . . . . . . . . . . . . . . . . 49
6.5.2 Driving in the United Kingdom (UK Approval) . . . . . . . . . . . . . . . . . 49
6.5.3 Checks Always to Be Done before Driving on the Road . . . . . . . . 51

140−2000−201c 2
 Index

6.6 Defined Driving Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.6.1 Driving with the Total Weight 60 t (132.3 kip)
(Approval Condition in Accordance with EEC Directive) . . . . . . . . 57
6.6.2 Driving with an Overall Weight of 35.4 t (78 kip)
(without Main Boom, with Luffing Cylinder) . . . . . . . . . . . . . . . . . . . 63
6.6.3 Driving with an Overall Weight of 74 t (163.1 kip)
(”Technical Drivability”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.7 Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.8 Driving over Hill Summits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.9 Checking the Operation Functions During the Journey . . . . . . . . . 77
6.9.1 Monitoring Elements in the Instrument Controls . . . . . . . . . . . . . . . 77
6.9.2 Indicator Lights on the Display (43)
“Driver Information System” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.9.3 On the Display (75)
“Transmission Information” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.10 Driving on the Construction Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.10.1 Driving in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.11 Driving the Crane with the Equipment Erected
“Driving in Erect Mode” (with main boom / equipment erected) . . 87
6.11.1 Instructions on ”Driving in Erect Mode” . . . . . . . . . . . . . . . . . . . . . . . 87
6.11.2 Driving Tables with Metric Dimension Units . . . . . . . . . . . . . . . . . . . 95
6.11.3 Driving Tableswith British / American Dimension Units . . . . . . . . . 113
6.11.4 Driving the Crane with a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.12 Driving with Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.12.1 Important Instructions for “Dolly Operation” . . . . . . . . . . . . . . . . . . . 133
6.12.2 Dolly Equipment for the Towing Vehicle (Optional) . . . . . . . . . . . . . 135
6.12.3 Measures for “Dolly Operation” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.12.4 Dolly not Contained in Crane Manufacturer’s Scope of Supply . . 153
6.12.5 Dolly Contained in the Manufacturer’s Scope of Supply . . . . . . . . 153
6.13 Dolly Coupling / Supply Connections (Optional) . . . . . . . . . . . . . . . 155
6.13.1 Coupling and Uncoupling a Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.14 Attaching and Removing the Spare Wheel (Spare Wheel Holder,
Hoist Arrangement, Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6.15 Reversing Check System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.15.1 General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.15.2 Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.15.3 Registering Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.15.4 Protruding Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.15.5 Critical Situations in the Registering Range . . . . . . . . . . . . . . . . . . . 169
6.15.6 First Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.15.6.1 Relation between Display and Tone Sequence with
Varying Distance to the Obstacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.15.6.2 Colours of the Light−emitting Diodes (LED’s) . . . . . . . . . . . . . . . . . 173
6.15.6.3 Example of a Display:
Obstacle at a Distance of 1.20 m (3.9 ft) . . . . . . . . . . . . . . . . . . . . . 175
6.15.6.4 Example of a Display:
Distance to the obstacle smaller than 0.40 m (1.3 ft) . . . . . . . . . . . 175
6.15.7 Activating and Using the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.15.8 Testing the Function / Diagnosis Function . . . . . . . . . . . . . . . . . . . . 179
6.15.9 Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.15.10 Maintenance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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 Index

7 Drive gearbox / distributor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7.1 Drive gearbox: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1.1 Description of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1.2 System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.1.3 Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.1.4 (75) “Transmission information” display (Z 51 348) . . . . . . . . . . . . 11
7.1.5 (43) “Driver information system” display . . . . . . . . . . . . . . . . . . . . . . 13
7.1.6 Driving and Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1.7 Change transmission mode: Manual / automatic . . . . . . . . . . . . . . 17
7.1.8 Changing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.9 Reverse driving / changing the driving direction . . . . . . . . . . . . . . . 23
7.1.10 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.11 Shutting off the engine and vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.12 Manoeuvring (Distance < 1m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.14 Towing start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.15 Rolling down a downhill slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.16 Exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.17 Clutch protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.18 Overspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.19 Roller dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Hydraulic Retarder (System “ZF Intarder”) . . . . . . . . . . . . . . . . . . . . 37
7.3 System malfunctions / error diagnosis . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.1 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.2 Reading off the fault code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3.3 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4 Distributor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.4.1 Operating the distributor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.5 Driving stuck cranefree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1 Emergency pressure supply − braking system . . . . . . . . . . . . . . . . 3
8.2 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.4 Brake Pressure Limit
(Optional equipment / national regulations) . . . . . . . . . . . . . . . . . . . 9
8.5 Retarder Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.5.1 Engine Brake (Exhaust Brake and Constant Throttle) . . . . . . . . . . 13
8.5.2 Hydraulic Retarder (System “ZF Intarder”) . . . . . . . . . . . . . . . . . . . . 15
8.5.3 Function “Sustained−Action Brake Cruise Control” . . . . . . . . . . . . . 17
8.6 Anti−Blocking−System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.6.1 ABS: Full function / off−road mode . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.6.2 ABS Functions Check / Fault Display . . . . . . . . . . . . . . . . . . . . . . . . 23
8.6.3 Braking with ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.6.4 ABS with Dolly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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 Index

9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1 General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.2.1 Safety instructions for protecting the system . . . . . . . . . . . . . . . . . . 3
9.2.2 Safety instructions for the protection of life and limb
for maintenance / service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.3 Monitoring functions for all steering programs . . . . . . . . . . . . . . . . . 7
9.3.1 Monitoring the steering / emergency steering pump . . . . . . . . . . . . 9
9.3.2 Monitoring the electro−hydraulic rear axle steering . . . . . . . . . . . . . 11
9.4 Steering programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.4.1 Selection of the Steering Programme “Road Travel” or
“Construction Site Operation” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.4.2 Steering program “road travel” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.4.3 Steering program “construction site mode” . . . . . . . . . . . . . . . . . . . 19
9.4.4 Synchronising the wheels when changing program . . . . . . . . . . . . 33
9.4.5 Raising/Lowering the “Lift Axle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.5 Steering Computer / Fault Diagnosis / Fault List . . . . . . . . . . . . . . . 37
9.5.1 Operating functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.5.2 Registration of a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.5.3 error memory / fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.5.4 Fault categories / fault reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5.5 Fault list (following) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.6 Manual emergency steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

10 Differentials / Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10.1 Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10.2 Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10.3 Activating the Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.3.1 Activating the Longitudinal Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.3.2 Activating the Transverse Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

11 Hydraulic Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Distribution of the suspension circuits / assignment of
the pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.1 In normal situations: Four−circuit System . . . . . . . . . . . . . . . . . . . . . 5
11.1.2 Exception: Three−circuit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.2 Setting for Driving in the Transport Position . . . . . . . . . . . . . . . . . . . 7
11.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.2 “Automatic” setting road travel level . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.3 “Manual” Setting of the Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.3 Monitoring the Hydraulic Suspension . . . . . . . . . . . . . . . . . . . . . . . . 13
11.3.1 Monitoring the Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.3.2 Level Control, Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11.4 to lock the suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.4.1 Activating the Suspension Block
. . . Before Driving in an Erect Mode . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.5 Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.6 Raising Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.7 Hold axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.8 Lowering Brake Valves in the Basic Suspension Block . . . . . . . . . 23
11.9 Selecting the Operating Modes
(”Axle loads 12 t / 26.5 kip” or “Reduced axle loads”) . . . . . . . . . . . 25

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 Index

12 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12.1 Notes on Outriggers: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12.2 Arrangement of Outrigger Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12.3 Information System for the Outrigger Controls . . . . . . . . . . . . . . . . 9
12.3.1 Indicators on the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.3.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.3.3 Support Pressure Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.3.4 Inclination Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.4 Automatic Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.5 ”Hold Axles” / ”Raise Axles” Functions . . . . . . . . . . . . . . . . . . . . . . . 29
12.5.1 “Hold Axles” Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.5.2 “Raise Axles” Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.6 Measures before Stabilising: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.7 Supporting the Outrigger Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.7.1 Permitted Ground Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.8 Safe Distance to Slopes and Pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12.8.1 Pinning positions of the outrigger struts . . . . . . . . . . . . . . . . . . . . . . 49
12.9 Stabilising Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.9.1 Extend support (outrigger support area 8.23 m x
7.50 m/27 ft x 24.6 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.9.2 Checking the Level at the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 61
12.9.3 Retracting the Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.10 Levelling with the Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12.11 Supporting Spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.11.1 Normal Outrigger Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.11.2 Reduced Outrigger Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.12 Removal and installation of the outrigger struts with auxiliary crane
(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
12.12.1 Notes on removing and installing the outrigger struts . . . . . . . . . . . 73
12.12.2 Removing the outrigger struts with the auxiliary crane . . . . . . . . . . 75
12.12.3 Installation of the outrigger struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

13 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.1 Crane in the Transport Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13.2 Crane in Erect Condition and Supported on Outriggers . . . . . . . . . 3

14 Tow−starting and Towing the Crane . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 Towing start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2.1 Important General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2.2 Recovering from a Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2.3 Towing with Engine Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
14.2.4 Towing with Damage to the Drive Gearbox . . . . . . . . . . . . . . . . . . . 9
14.2.5 Towing with Damage to the Distributor Gear . . . . . . . . . . . . . . . . . . 11
14.2.6 Neutral Position of the Distributor Gear for Towing
with Damage to Engine / Transmission . . . . . . . . . . . . . . . . . . . . . . . 13
14.3 Towing Free From Rough Terrain . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 Index

15 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15.1 Cab Heater Arrangement (Dependent of Engine) . . . . . . . . . . . . . . 3
15.2 Hot Water Heater Arrangement with Preheating for coolant
(independent of engine), Optional Equipment . . . . . . . . . . . . . . . . . 5
15.3 Petrol Gas Heating (independent of engine),
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.4 Air conditioner, Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 21
15.5 Instructions for Winter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

16 Central Lubricating System (Optional Equipment) . . . . . . . . . 3

16.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.3 Setting the Pause and Operating Time . . . . . . . . . . . . . . . . . . . . . . . 7
16.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.3.2 Setting the Pause Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.3.3 Setting the Operating Time/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Additional Lubricating Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.5 Manual Lubrication in Case of an Emergency . . . . . . . . . . . . . . . . . 11
16.6 Filling the Grease Container (Lube Tank) . . . . . . . . . . . . . . . . . . . . . 11
16.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

140−2000−201c 7
 Safety Instructions 1

1 Safety Instructions

All risidual risks which may occur with operation of the crane
chassis are given in Part 1, operating instructions for the super-
structure, Section 1, ”Safety Instructions”.

Therefore, first read this Section carefully before starting opera-

tion.

140−2010 1/1
 Crane Chassis 2

2 Crane Chassis

2.1 Technical Data

All specifications apply to tyres 16.00 R 25.

2.1.1 Dimensions, weights, axle loads for chassis / crane

vehicle

Total length of the crane vehicle: 14.18 m (46.5 ft)

Total height of the crane vehicle (transport condition): 4.00 m

(13.1 ft)

Length of the crane chassis: 12.35 m (40.5 ft)

Vehicle width: 3.00 m (9.7 ft)

Turning radius on the main boom head: 11.43 m (35.5 ft)

Transport weight crane vehicle (road travel): max. 60 t (132 kip)

Axle loads for road travel: 5 x 12 t (5 x 26.4 kip)

Number of axles: 5

2.1.2 Driving speed of crane vehicle 60 t (132 kip)

Technically possible maximum speed: 85 km/h (53 mph)

Permitted maximum speed for axle loads 12 t (26.4 kip: 80 km/h

(50 mph)

Climbing ability:
− 37 % in road gear
− 71 % in off−road gear

Starting on hills:
− 34 % in road gear
− 71 % in off−road gear

140−2020 1/27
2

2/27 140−2020
 Crane Chassis 2

2.1.3 Drive

Engine
DAIMLERCHRYSLER 8−cylinder diesel engine, type OM 502
LA, water−cooled
Output: 380 kW at 1800 rpm
Torque: 2400 Nm at 1200 rpm

Transmission
ZF AS−TRONIC type 16 AS 2602
16 forward gears, 2 reverse gears

Distributor gear
with road− and off−road gear

2.1.4 Climatic operating conditions

An exact description can be found in part 1, section 1 of this

documentation.

2.1.5 Tyres

− 14.00 R 25
on rim 9.5−25 / 1.7”
Vehicle width: 3.00 m (9.8 ft)
Vehicle height: 3.95 m (13 ft)
Permissible distance per hour at an axle load of 12 t (26.4
kip): 70 km (43.5 mph)
− 16.00 R 25
on rim 11.00−25 / 1.7”
Vehicle width: 3.00 m (9.8 ft)
Vehicle height: 4.00 m (13.1 ft)
− 17.5 R 25
on rim 14.00−25 / 1.7”
Vehicle width: 3.00 m (9.8 ft)
Vehicle height: 3.95 m (13 ft)
Permissible distance per hour at an axle load of 12 t (26.4
kip): 70 km (43.5 mph)
− 20.5 R 25
on rim 17.00−25 / 1.7”
Vehicle width: 3.12 m (10.2 ft)
Vehicle height: 4.00 m (13.1 ft)

2.1.6 Optional equipment

140−2020 3/27
2

10 1 2

4 5 6 5 5

7 7

8 8
9 9

Z 53 755

4/27 140−2020
 Crane Chassis 2

2.2 Overview of the crane chassis

(Z 53 755)

(1) Frame

(2) Spare wheel

(3) Driver’s cab

(4) Axle non−driven / steered

(5) Axle driven / steered

(6) Lift axle; can be raised for various ”steering programmes”

cannot be steered (rigid), transmission can be activated

(7) Outrigger strut

(8) Outrigger cylinder

(9) Outrigger pad

(10) Counterweight support

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2

I II III

IV V VI

Z 200 290e

6/27 140−2020
 Crane Chassis 2

2.3 Signs

2.3.1 Signs in the driver’s cab

(Z 200 290)

(1) − Instructions on driving with a locked differential

(2) − Instructions on tightening the wheel nuts
(3) − Relation between pressure gauges and suspension
circuits

140−2020 7/27
2

12.10

12.1 12.11

12.2 12.12

12.3 12.13

12.4 12.14
12.15
12.5

12.6

12.7
12.8
12.9

12

13 Z 53 750

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 Crane Chassis 2

(Z 53 750)

(12) − Serial plate

Legend:
12.1 Crane type
12.2 Vehicle type
12.3 Construction number
12.4 Maximum lifting capacity
12.5 First year of operation
12.6 Year of construction
12.7 Engine output superstructure
12.8 Engine output carrier
12.9 Exhaust air emission value
12.10 Vehicle manufacturer
12.11 Vehicle identification number
12.12 EU operating approval
12.13 Permitted overall vehicle weight
12.14 Permitted overall weight of the towed vehicle
12.15 Permitted axle load

(13) − Warning for separate rear−axle steering when driving on

the road (optional equipment)

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2

14

Z 42 256

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 Crane Chassis 2

(Z 42 256)

(14) − Information sign on vehicle height (national regulation)

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2

15

15

Z 51 334

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 Crane Chassis 2

(Z 31 334)

(15) − Warning sign for driving with a dolly (optional equipment)

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2

Z 42 250e

14/27 140−2020
 Crane Chassis 2

2.3.2 Signs on the crane chassis

(Z 42 250)

(1) − Caution when welding

(2) − ”Diesel” on the fuel tank
(3) − ”Hydraulic oil” on the hydraulic oil tank

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2

Z 38 738

16/27 140−2020
 Crane Chassis 2

(Z 38 738)

6 − Plate: “Quick coupling” on the outrigger struts

140−2020 17/27
2

1 12 3 9 7 6 5

10

11 7 1 5 6 7 8 1

2 4 3 1

1 7 1 7

Z 200 291

18/27 140−2020
 Crane Chassis 2

2.3.3 Safety signs

(Z 200 291)

All safety instructions on the crane must be complete and in

legible condition.

(1) − Warning: Crushing / collisions

(2) − Warning: Dragging / entanglement
(3) − Warning: Risk of falling
(4) − Warning: General hazard warning
(5) − Warning: Fire hazard
(6) − Prohibited: Naked flames

Plates (5) and (6) on the fuel / hydraulic oil reservoir of the
superstructure and chassis!

(7) − Prohibited: Entry by unauthorised personnel

(8) − Warning: Crushing
(9) − Warning: Swinging load
(10) − Note: Fire extinguishers

The fire extinguisher is in the driver’s cab, in the passenger

compartment.

(11) − Note: First aid

First aid boxes − and additional accessories in accordance with

the German “road traffic licensing regulations” − must be taken
by the crane operator from the equipment supplied and placed
in the driver’s cab.

(12) − Prohibited: Access prohibited

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2

20/27 140−2020
 Crane Chassis 2

2.4 Chassis and construction number

The chassis number is on the chassis frame −
to the front on the right−hand side of the crane − in the area of the
front outrigger section.

The construction number is to be found (punched) :

− to the rear of the vehicle, on the right−hand side.

− on the front bumper brace next to the trailer coupling.

The chassis and construction numbers are additionally imprinted

on the serial plate.
The serial plate is located inside the driver’s cab. (Driver’s /
passenger door).

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2

Z 200 292

22/27 140−2020
 Crane Chassis 2

(Z 200 292)

2.5 Preparation for emergency control, superstructure

On each side of the chassis (between axles 2 / 3), there are 3

hydraulic connections:

1 connection Tchassis (tank)

2 connection Lchassis (leakage)

3 connection Pchassis (pressure oil)

If the superstructure power units break down, a hydraulic

transformer can be connected at these points, which enables
limited superstructure functions.
For exact details, see the operating instructions of the
superstructure, section 36.

The hydraulic connections 1 − 3 may only be used with a

hydraulic transformer.
A direct connection to the superstructure hydraulic system
is not permitted as there is no capacity for this in the oil tank.

140−2020 23/27
2

Z 53 014

97
51

Z 53 016 Z 53 017

24/27 140−2020
 Crane Chassis 2

(Z 53 014, Z 53 016, Z 53 017)

2.6 Additional fuel tank (”additional tank” 300 l / 80

gallons) in the crane chassis (optional)

The vehicle’s tank capacity (500 l / 132 gallons) can be increased

by 300 litres (80 gallons) with an additional fuel tank (additional
tank).
The additional tank is located in the frame area of the chassis,
beneath the cover. It is filled independently of the normal fuel tank
(1) = main tank via its own filler neck (2) near axle 4 (right−hand
side of vehicle). The same type of fuel (diesel) is added to the
additional tank as to the main tank.

Changeover

The contents of the additional tank can be moved to the main tank
(1) using an electric supply pump via a fixed installation line.

When moving fuel while the crane is being driven it must be

ensured that the changeover is carried out in good time, to avoid
the crane stalling due to a lack of fuel.

The electric supply pump is switched on/off using the dual button
(97) in the dashboard of the chassis cab.
Press dual button (97B) = start changeover.
Press dual button (97A) = end changeover.
Press and hold dual button (97A) = switch over fuel gauge (51)
from main tank to additional tank.

The levels in both tanks are monitored during the changeover by

means of level switches.

A changeover of fuel is only possible if the levels in the giving and

taking tank permit it (additional tank filled above minimum; main
tank ready).

The changeover must always be started manually and can also

be ended manually at any time.
It is automatically ended when a certain minimum level is
exceeded in the additional tank (protects the supply pump from
running dry) or the maximum level is reached in the main tank
(overload protection).

Exact instructions for filling/switching tanks are contained in part

4 (lubrication/ maintenance instructions) section 15.

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2

Z 53 014

Z 53 018

26/27 140−2020
 Crane Chassis 2

(Z 53 014, Z 53 018)

2.7 Separate fuel tank (”extra tank” 300 l 80 gallons) in

the chassis for superstructure operation (optional)

To supply fuel to the superstructure engine a separate fuel tank

(extra tank 300 l / 80 gallons) can be installed. It is not linked to
the fuel system of the chassis.
The extra tank is located in the frame area of the chassis,
beneath the cover. It is filled, independently of the normal fuel
tank (1) = main tank, via its own filler neck (2) near axle 4
(right−hand side of the vehicle).

Changeover

The content of the extra tank is automatically fed to the

superstructure tank via a fixed line/rotary joint, by means of an
electric supply pump.
Levels in both tanks are monitored during the changeover by
means of level switches.

The changeover begins when a certain lower level is reached in

the superstructure tank.
It is ended when the level in the extra tank falls below a certain
point (protects the supply pump against running dry) or when the
maximum level is reached in the superstructure tank (overflow
protection).

The capacity in the extra tank is displayed in the superstructure

cab on instrument (5).

Exact instructions for filling/switching tanks are contained in part

4 (lubrication/ maintenance instructions) section 15.

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 Driver’s Cab 4

140−2040−201a_en 1/71
4

5
6
7
26 29 27 28

4
2 8
3
9
10

16
1
17
15

11

12
18 13
19 14
21
20 22
23
24

25

Z 200 316

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 Driver’s Cab 4

4 Driver’s Cab

4.1 Operator’s Platform

(Z 200 316)

No. Designation Function

1 Combination switch, Lower beam, upper beam, headlamp
on the left of the flash, indicators, wipers, windscreen
steering column washer, horn
(S 6115)
2 EU Tachograph Tachograph
(A 5320) Display basic with time, speed, mi-
leage.
(Observe the operating instructions of
the manufacturer.)
3 Combination switch, Engine control (engine idle speed,
on the right of the cruise control, limiter)
steering column (S Retarder (exhaust brake, retarder, re-
4120) tarder cruise control)
4 Autoradio (A 5511)
5 Pressure gauge Pressure display axles 1 and 2, right
6 Pressure gauge Pressure display* axle 3, right
7 Pressure gauge Pressure display* axles 4, 5, right
8 Pressure gauge Pressure display axles 1 and 2, left
9 Pressure gauge Pressure display* axle 3, left
10 Pressure gauge Pressure display* axles 4, 5, left
11 Dual button Window passenger side
(S 5192) (controls in passenger door trim)
12 Switch lever Gear shifting high / back
(toggle) (A 2211) Manual / automatic operating mode
13 Rotary switch F = Forwards / B = Backwards /
(A 2211) N = Neutral
(in position “N” = switch lever without
function)
14 Lever Parking Brake
15 Ignition−starter Ignition on / off
switch Engine start / engine stop
(S 1271) Standby start external

* Separate (different) pressure display, when axle 3 is in its raised

condition; otherwise, the same indicator value with axles 4 and
5.

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4

5
6
7
26 29 27 28

4
2 8
3
9
10

16
1
17
15

11

12
18 13
19 14
21
20 22
23
24

25

Z 200 316

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 Driver’s Cab 4

(Z 200 316)

No. Designation Function

16 Push button, pneu- Steering wheel control
matic Steering wheel unlocking / locking
17 Alarm buzzer one−time warning signal = malfunc-
(H 1336) tion
(“Caution” (36) lights up)
repeating warning signals = serious
malfunction (“STOP” (35) lights up)
18 Accelerator pedal Speed adjustment
19 Brake pedal Foot brake
20 Steering wheel
21 Driver’s seat
22 Safety belt
23 Rotary / rocker switch Outside mirror adjustment
(S 5435) Driver’s side / passenger side
24 Dual button Window passenger side
(S 5192) (Controls in driver’s door trim)
25 Dual button Window driver’s side
(S 5191) (controls in driver’s door trim)
26 Reading light
27 Switch for reading push forward = reading light off
light push back = reading light on
(E 6614)
28 Interior light
29 Switch for interior push forward = interior light off
light push back = interior light on (lights up
(E 6614) when door is opened,
goes out when door is closed)

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4

16

15

Z 48 995

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 Driver’s Cab 4

(Z 48 995)

4.1.1 Ignition−starter switch (15)

Position ”1”:
All users are separated from the battery, except: tachograph,
radio. Engine stop after external starting procedure.
Removable key.

Position ”2”:
Ignition standby for external starting procedure. Removable key.

Position ”3”:
Driving position
The ignition is switched on. Blower can be switched on.

Position ”4”:
Starting position
The engine starts.

− Only remove the key when the vehicle is stationary.

− Even if you are leaving the vehicle for a short time re-
move the key, so that unauthorised persons cannot start
the vehicle.
− When stowing / parking the vehicle, only remove the key
in position “1”.

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4

16

15

Z 48 995

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 Driver’s Cab 4

(Z 48 995)

4.1.2 Steering wheel setting

Both the height and tilt of the steering wheel can be adjusted. The
steering wheel is pneumatically unlocked (or locked according to
the setting).

Steering wheel is set as follows:

1. Stop the vehicle and engage the parking brake.

2. Hold the steering wheel and press the push button (16).

3. Hold the push button (16) down and set the steering wheel.

4. After the steering wheel has been set, release the push
button (16).

Only set when the vehicle is standing still and theparking

brake is set.

Always hold the steering wheel when making settings,

since otherwise the seat will rebound when pressing the
push button (16) and you could be caught between the
steering wheel and the seat.

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4

14

13

8
15
16
17

1 2 3 4 5 6 7 10 11 12 9 Z 61 344

14

8
15
16
17

12 11 10 7 6 5 4 3 2 1 9
Z 61 345

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 Driver’s Cab 4

(Z 61 344, 61 345)

4.1.3 Driver’s Seat / Passenger’s Seat

The air−sprung seat (shock−cushioning seat) with automatic

weight adjustment protects the driver / passenger against
mechanical vibrations. The vibration behaviour can be adjusted
to the conditions (road surface, axle load, suspension). The seat
is equipped with a safety belt (three−point belt). It can be set to
any position and can be locked at seat height.
Set the seat according to your own requirements.

Driver’s seat (Z 61 344), passenger’s seat (Z 61 345)

1 Set the seat horizontally

Entire seat back and forth.

2 Seat cushion back and forth

3 Lower seat (exit assistance)

Pull lever = lower all the way
Press lever = return to set height

4 Set seat angle

Change the seat angle by shifting weight in the front part of
the seat.

5 Set the seat height (infinitely adjustable)

Pull lever = lift
Press lever = lower

6 Set backrest
Use your body weight to set the correct position.

7 Set seat damping (infinitely adjustable)

Pull lever = maximum damping
Push lever = minimum damping

8 Seat heating (switch on − off)

only driver’s seat
Electric heating elements in the seat and back
components.

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4

14

13

8
15
16
17

1 2 3 4 5 6 7 10 11 12 9 Z 61 344

14

8
15
16
17

12 11 10 7 6 5 4 3 2 1 9
Z 61 345

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 Driver’s Cab 4

(Z 61 344, Z 61 345)

9 Lock horizontal suspension

Lever to the left = locked
Lever to the right = suspended

10 Lumbar support, lower

Filling / emptying air cushion (switch + / −)

11 Lumbar support, upper

Filling / emptying air cushion (switch + / −)

12 Lumbar support, lateral

Filling / emptying air cushion (switch + / −)

13 Set arm rests (only driver’s seat)

Control knob for angle adjustment

14 Headrest (see sect. 4.1.5, page 19)

15 Latch plate of the safety belt (see section 4.1.6, page 19)

16 Belt buckle (see sect. 4.1.6, page 19)

17 Red button in the buckle (see section 4.1.6, page 19)

Driver’s seat:
− Only set when the vehicle is stationary and the parking
brake is engaged. Setting the seat while driving can dis-
tract the driver from the traffic situation. The seat fixing
device has to latch audibly into place.
− When setting the seat, assume a relaxed, −non−strenu-
ous position and be sure that the safety belt is properly
put on.
− Before getting out, lower the seat completely (button 3
press exiting aid), otherwise the seat will rebound and
your legs could be caught between the steering wheel
and the seat. Lift the armrest up and then turn back / pull
out the ignition key.

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4

”A”

1 ”B”
2 3

”C”

Z 104 102

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 Driver’s Cab 4

4.1.4 Folding the Passenger Seat

There are various electronic components under the passenger

seat. In order to reach the components, the entire seat must be
folded up.

Folding the passenger seat up:

(Z 104 102)

1. Completely lower the seat (1, Z 104 102 ”A”).

2. Slide the seat completely to the front (2, Z 104 102 ”A”).

3. Slide the neckrest in entirely (3, Z 104 102 ”B”).

4. Adjust the armrest as far back as

possible (4, Z 104 102 ”B”).

5. Unlock the passenger seat with your left hand and grip the
belt where it comes out at the top with your right hand. Fold
the seat to the front until it has reached its final position
(5, Z 104 102 ”C”).

Risk of crushing between the swivelling cover (y) − to

which the seat is fastened − and the lock (z) on the cab
wall when folding the seat forward.

Risk of injury!
Check that the passenger seat is held safely in place.
If this is not the case, the folded seat must also be secu-
red against falling back.

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4

Z 104 100

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 Driver’s Cab 4

Opening the cover of the electronic compartment:

(Z 104 100)

1. Loosen the screws.

2. Open the cover (1) and secure against falling back (for
example, tie it up using a tie (2)).

Closing the cover on the electronic compartment:

1. Ensure that the material under the cover is in the correct

place and does not obstruct the closing procedure.

2. Close the cover and screw in place.

Folding the passenger seat back:

1. Ensure that the material under the seat is in the correct place
and does not obstruct the seat when locking in place.

2. Using both hands, grip the seat where the belt comes out at
the top and let it fall back carefully. The seat locks into place
due to its own weight.

Risk of injury!
Check that the passenger seat has locked into place sa-
fely.
If the passenger seat is not locked in place correctly, the
seat could fold to the front during braking.

3. Adjust the seat to the desired position.

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4

14

13

8
15
16
17

1 2 3 4 5 6 7 10 11 12 9 Z 61 344

14

8
15
16
17

12 11 10 7 6 5 4 3 2 1 9
Z 61 345

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 Driver’s Cab 4

(Z 61 344, Z61 345)

4.1.5 Headrest

The headrest (14) can be adjusted for height and angle

independent of the backrest.

Set the headrest so that the rear part of the head is sup-
ported at about the height of the eyes.

4.1.6 Safety belt

The safety belt system incl. the seat belt anchorage points is an
essential part of the driver’s seat. No subsequent modifications
are allowed. If modifications are made, the operating licence will
expire.

The use of safety belts is a regulation in many countries.

In the interest of your own safety, always put on the safety belts.

Fastening the safety belt:

− Pull the belt with the latch plate (15) over your shoulder and
lap. The belt may not be twisted.
− Press the latch plate (15) into the belt buckle (16) and until it
catches audibly.
− The belt must always be taut. Check for tightness regularly.
If need be, tension the lap belt by pulling the shoulder belt
upwards.

Releasing the safety belt:

− Press the red button (17) in the belt buckle (16).
− Bring the latch plate (15) back to the initial position.

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20/71 140−2040−201a_en
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Automatic safety belt winder − operation

The automatic safety belt winder for the safety belt locks the belt
pull−out during vehicle deceleration in all directions and when
pulling down on the belt quickly.

Functional test
The locking function of the automatic can be checked by pulling
the belt quickly.

− Fasten your safety belt before driving

− Use all safety belts only for one person at a time.
− Three−point seat belts are not for people shorter than
150 cm (4.9 ft). These people require special equipment
for protection in the case of an accident (because safety
belt were no correctly fastened).
− Avoid seat positions, that interfere with the correct
course of the safety belt . Set the backrest to almost 90°.
Your back should touch the backrest. The belt must run
across the middle of your shoulder. Safety belts that
were damaged during and accident must be replaced.
Have belt anchors checked by a specialist workshop.
− Replace damaged safety belts.
− Belts may not run across sharp edges.
− No changes may be made to the safety belts.

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4

A
A
24 B
B

25

11

Z 200 141 Z 200 142

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 Driver’s Cab 4

4.1.7 Door Controls

Risk of accidents and injury!

Only drive with correctly closed doors.

4.1.8 Window Controls (Z 200 141, Z 200 142)

The vehicle is equipped with automatic electric windows.

Risk of injuries from becoming trapped.

Take extra care when closing the windows. in case you
get caught, the system does not have an automatic auto−
reversal / switch off for the closing motion; i.e. the win-
dow panel presses with all its strength upwards until the
“Open window” command is given.
The windows may only be closed when the operator has
a clear view of the windows and is sure that no−one
could become trapped in the closing window.
Only the vehicle driver may activate the electrical win-
dow opener; other passengers are to be warned of the
danger by the vehicle driver.

Risk to life and limb, in particular with children!

To avoid someone becoming trapped as a result of incor-
rect use, the vehicle operator may only leave the cab,
when he has removed the ignition key from the ignition
lock.
The vehicle driver must be aware of the situation; this is
his responsibility.

Allocation and arrangement of the controls:

The controls (dual button 11, 24, 25) are located in the door
mouldings on the driver / passenger side.

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4

A
A
24 B
B

25

11

Z 200 141 Z 200 142

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 Driver’s Cab 4

Driver’s side: (Z 200 141)

Dual button (24) for window on passenger’s side.

Dual button (25) for window on driver’s side.

Passenger side: (Z 200 142)

Dual button (11) for window on passenger’s side.

Controls for the automatic electric windows:

Turn the ignition key in the driving direction.

Push the dual button forwards (A), hold = close window.

Push the dual button backwards (B), hold = open window.
Tap dual button = open or close window partially.

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4

1
3
2
4

3 1

4 6

5
5
2

Z 306 016

INT

II

Z 306 017

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 Driver’s Cab 4

4.1.9 Combination Switch (on the left of the steering

column)

(Z 306 016, Z 306 017)

1 Lower beam

2 Upper beam

3 Headlamp flash

4 Indicators right
Up to pressure point = short indication
Beyond pressure point = continual indication

5 Indicators left
Up to pressure point = short indication
Beyond pressure point = continual indication

6 Horn

7 Wiper
“0” Switched off
“INT” Intermittent wiping
Basic setting of the wiping pause: 5 seconds.
“I” Slow
“II” Fast

8 Windscreen washing assembly

Press switch = switched on

Check the wiper blades regularly for dirt and damage.

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4

3
1
4
4

5
5

3
2
Z 306 015

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 Driver’s Cab 4

4.1.10 Combination Switch (on right of steering column)

(Z 306 015)

Switch functions:
4. Engine control
= idle speed, cruise control, limiter

5. Sustained−action brake
= exhaust brake, retarder, retarder cruise control

1 Engine control:
Increase idle speed,
accelerate vehicle,
store speed.

Sustained−action brake:
Reduce braking effect (increase speed, store).

2 Engine control:
Reduce idle speed,
decelerate vehicle,
store speed.

Sustained−action brake:
Increase braking effect, (reduce speed, save)
Level 1 = exhaust brake
Level 2−5 = exhaust brake and retarder

3 Switch on Sustained−action brake :

4 Engine control
Switch off idle speed increase,
Switch off cruise control,
Switch off limiter

5 Engine control
Switch on limiter

Using the limiter the driving speed can be limited above 30 km/h
(19 mph).

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4

31 32 33 34 35 36 37 38 39 40

70 71 43 76 77

72 73 74 78 79

80 81

75 41 41.1 42 51 52 53 54 55 56 57 58 50 50.1

61 64

62 65

63 66

60 67

85

86 87 88 89

115
105 106 107
114
90

92 93 94 95 96 97 98 113

99 100 101 102 103 104

112
111
109 110
108

Z 53 021

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 Driver’s Cab 4

4.2 Instrument Controls (assignment overview)

(Z 53 021)

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4

31 32 33 34 35 36 37 38 39 40

43

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1

75

61 64

62 65

63 66

60 67

Z 200 144

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 Driver’s Cab 4

4.3 Driver information system

(Z 200 144)

The operator’s platform is equipped with a driver information

system. This provides the driver with important information on the
vehicle when it is in driving mode.
The driver information system consists of the instrument panel
(with the pos. 31 − 58) and the function buttons 60 − 67 on the
steering wheel.
The ”Driver information” system (43) display is in the middle of the
instrument panel.
To the left of the instrument panel, there is another display
“Transmission information” (75) which displays the transmission
functions(gear display / error messages).

Self−test
The electrical system performs a self−test when the ignition is
switched on; the most important signal connections are checked.
At the same time, a control signal sounds twice and all indicator
lights (31−40 and 50.1) flash.
The function control is ended after the control signals go out.
The ”CH” display appears on the “Transmission information“ (75)
display.

Function buttons on the steering wheel

The function buttons (60−67) are used for navigating in the menu
structure of the driver information system and for confirming,
acknowledging or hiding messages.

The menus 1−6 can be selected using the “Digit” buttons

(61−66). At the same time, the digits correspond to the buttons
of the segment numbering on the “Driver information system“ (43)
display.

You can scroll upwards in the menu structure with the “Arrow”
button (60) (leave menu item and go back to previous display).

The main menu can be called up with the “M” button (67)
− and
− can be returned directly to the basic display “Indicator lights”
from any menu item.

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4

10:07:2003
16:47

Z 200 145

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 Driver’s Cab 4

4.3.1 “Driver information system” (43) display

Display fields (Z 200 145)

The display field is automatically divided into different segments.
A difference is made between permanent and changing displays.

The following is shown in the 3 permanent display fields (upper

bar):
Left field: Not assigned
Middle field: Not assigned
Right field: Date, time of day

In the changing displays, the previously used display field can

be used for other display functions according to certain criteria.
The display is divided into segments 1−6 and is laterally marked
with these digits.

The brightness of the display can be changed with the button

(57).

All possible displays are assigned certain display priorities.

These control the urgency of each message. By setting these
priorities, you can automatically change from the current display
into a new display with higher priority, if needed.

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4

Z 200 147

31 32 33 34 35 36 37 38 39 40

Z 51 331

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 Driver’s Cab 4

Basic display / explanation of colours

(Z 200 147, Z 51 331)

After switching on the ignition, the basic message ”Indicator

lights” always appears − after the company logo and control
signal. (Z 200 147)

In the basic display, the selected functions that are activated by

the corresponding switch settings are shown as symbols; e.g.
differential lock, off−road gear.
The display of the selected functions or subsequently occurring
malfunction / warning messages have different colours.
The colours are used as indicators for the influence of the
messages on the operation/traffic safety of the vehicle and
determine the order of the displayed indicator lights (from upper
left to lower right) depending on their (colour) priority. The colours
have the following meanings:

Pink: No function display possible

There is an error in the corresponding connection e.g. short

circuit, interruption. The displayed function can therefore not be
monitored.
If there is a pink−coloured message, the “Caution” (36) display
also lights up automatically.

White: Function (e.g. steering program) is

− selected, but not yet active or

− still activated, but the axles are not yet synchronised

Yellow: Function is active

The system has recognised the error when the “Caution” (36)
warning light lights up at the same time. The vehicle can still be
operated; however, determine the cause.

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4

Z 200 147

31 32 33 34 35 36 37 38 39 40

Z 51 331

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 Driver’s Cab 4

Red: Malfunction
∗ There is a malfunction when the “Caution” (36) warning light
lights up at the same time. Determine the cause of the
malfunction and remedy the problem as quickly as possible.
∗ There is a serious malfunction when the “STOP” (35) warning
light lights up at the same time. Switch off the vehicle
immediately. Continued operation is not permitted.

Risk of accidents!
As soon as a fault is displayed, stop operation, identify and
rectify fault (or have it rectified)!
Faults must be rectified by qualified specialist personnel
(customer services, for example).
If personnel who are not qualified try to rectify faults, it can
cause serious injury to people and / or damage to objects!

After remedying the fault, the warning display can be removed by

switching the ignition on and off. This is also used to check if the
fault was really remedied.

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4

61 64

62 65

63 66

60 67
Z 51 321

Z 200 147

0 25 50 75 100
FM

Z 200 148

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 Driver’s Cab 4

Main menu
(Z 51 321, Z 200 147, Z 200 148)

Pushing the “M” button (67) on the steering wheel (Z 51 321)

brings you from the “Indicator lights” (Z 200 147) basic display to
the main menu (Z 200 148).
Pushing the “M” button (67) again brings you back to the basic
display.

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4

0 25 50 75 100
FM

Z 200 148

Z 200 147

Z 200 149

42/71 140−2040−201a_en
 Driver’s Cab 4

Menu selection 1 − 2 − 3

Four menus (1, 2, 4, 5) can be selected in the main menu

(Z 200 148). The menu items 3 and 6 are not assigned:

1 “Indicator lights” menu

− identical with the basic display after “Ignition on”
Example of a possible display: (Z 200 147)

2 “Multimedia“ menu (Z 200 149)

− Reversing camera (optional)

3 not assigned

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Z 200 150 Z 200 151

Z 200 152 Z 200 153

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 Driver’s Cab 4

Menu selection 4

Output basis: Main menu (Z 200 148)

4 “Control info“ menu (Z 200 150)

1 Suspension level (Z 200 151
2 Engine data (Z 200 152)
4 Emergency pressure supply in the braking circuits 1 and
2 (Z 200 153)

* This display of the engine oil quantity (%) only serves as

additional information. The oil level may only be monitored using
the oil measuring stick.
Depending on the design, this display function is not possible for
technical reasons. The corresponding display then always
indicates 0%.
If this is the case, then B14 indicator light ”Engine oil level too low”
will also not be displayed.

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4

0 25 50 75 100
FM

Z 200 148

Z 200 154

00:00h 017

Z 200 155

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 Driver’s Cab 4

Menu selection 5 − 6

Output basis: Main menu (Z 200 148)

5 “Service / Diagnosis“ menu (Z 200 154)

− Operating hours counter: Press submenu 5.1
Display (Z 200 155) left row: Partial operating hours
1 = Superstructure (without function)
2 = Chassis
3 = Sum superstructure / chassis (without function)
Display (Z 200 155) right row: Total operating hours
4 = Superstructure (without function)
5 = Chassis
6 = Sum superstructure / chassis (without function)
− Software identification: Press submenu 5.4
Software display (only for customer service)

The partial operating hours can be deleted by holding down

(about 5 sec.) the steering wheel button (61 / 62 / 63).
The total operating hours cannot be changed.

6 not assigned

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4

A1 A11 A21

A2 A12

A3 A13

A4 A14

A5 A15

A6 A16

A7 A17

A8 A18

A9 A19

A10 A20

Z 200 157

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 Driver’s Cab 4

4.3.2 Indicator lights in the driver information system

The symbols given below as “Indicator lights” on the “Driver

information system” (43) display can be displayed.

Signal indicator lights

− the execution of manually activated functions (A row)
− or the existence of malfunctions (B row)
4.3.2.1 Indicator lights for manually activated functions
(Z 200 157)

A1 Manoeuvring operation

A2 “Manual rear−axle steering” steering program active

A3 Steering program “Close cornering” active

A4 Steering program “Driving away from the wall” active

A5 Steering program “Diagonal steering” active

A6 Release “Steering program” (for construction−site

operation)

A7 Off−road distributor gear inserted

A8 Distributor gear in neutral

A9 Longitudinal differential lock actuated

A10 Transverse differential lock actuated

A11 Suspension in the three−circuit system

A12 Suspension locked

A13 “Hold axles” actuated

A14 “Raise lift axle” actuated

A15 “Raise all axles” actuated

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4

A1 A11 A21

A2 A12

A3 A13

A4 A14

A5 A15

A6 A16

A7 A17

A8 A18

A9 A19

A10 A20

Z 200 157

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 Driver’s Cab 4

(Z 200 157)

A16 Emergency operation of the superstructure

A17 Axle that can be engaged in the function

(drive is connected with longitudinal differential lock)

A18 Speed lock effective

A19 Superstructure not locked with carrier

A20 Engine quick stop (optional) actuated

A21 Sustained−action brake cruise control activated

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4

B1 B11 B21 CHECK B31

B2 B12 B22 B32

B3 B13 B23 B33

BUS
B4 B14 B24 CAN B34
OFF

B5 B15 B25

B6 B16 B26

B7 B17 B27

B8 B18 B28

B9 B19 B29

B10 B20 B30

Z 200 158

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 Driver’s Cab 4

4.3.2.2 Indicator lights resulting from malfunctions

(Z 200 158)

B1 Suspension beyond limits

B2 Error in the electric hydraulic rear−axle steering

B3 Emergency pressure supply in braking circuits 1 below

5.5 bar

B4 Emergency pressure supply in braking circuits 2 below

5.5 bar

B5 Clutch overload (temperature too high)

B6 Transmission malfunction

B7 Hydraulic oil filter chassis clogged

B8 Steering circuit 1 no through−flow

B9 Steering circuit 2 no through−flow

B10 Steering circuit 3 (emergency steering) no through−flow

B11 Engine coolant level too low

B12 Engine oil pressure too low

B13 Coolant temperature engine too high

B14 Engine oil level too low

B15 Engine malfunction

B16 Charging current too low

B17 Charging current in the superstructure too low (not

assigned)

B18 Air filter clogged

B19 Fuel supply in the reserve

B20 (not assigned)

B21 (not assigned)

B22 Malfunction SPS

B23 Central lubricating system without grease (not assigned)

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4

B1 B11 B21 CHECK B31

B2 B12 B22 B32

B3 B13 B23 B33

BUS
B4 B14 B24 CAN B34
OFF

B5 B15 B25

B6 B16 B26

B7 B17 B27

B8 B18 B28

B9 B19 B29

B10 B20 B30

Z 200 158

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 Driver’s Cab 4

(Z 200 158)

B24 Malfunction on dolly (dolly = optional)

Stroke length exceeded, hydraulic cylinder
(if in addition to the indicator light (B24): One−time
acoustic warning signal and indicator light “Caution” (36))

or

B24 Malfunction on dolly (dolly = optional)

Critical slanted position, hydraulic cylinder
(if in addition to indicator light (B24): Repeating acoustic
warning signal and indicator light “STOP” (35))

B25 Scroll down to next mask (if no room on display)

B26 Crane operation active (not assigned)

B27 (not assigned)

B28 Malfunction exhaust brake / hydraulic retarder

B29 ABS fault, vehicle, all axles

(together with indicator light (32))

B30 ABS malfunction, dolly or additional axle or trailing axle

(together with indicator light (31))

B31 Malfunction non−return valves (electro−hydraulic rear−axle

steering)

B32 Malfunction oil supply (additional axle)

B33 Warning buzzer engine

B34 No CAN Bus connection (steering computer 1)

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56/71
31 32 33 34 35 36 37 38 39 40

43

km/h
mph

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1

Z 48 996

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 Driver’s Cab 4

4.3.3 Instrument Panel

(Z 48 996)

No. Element Designation Function

31 Lamp ABS control, dolly
32 Lamp ABS control, vehicle, circuit 1
33 Lamp Upper beam switched on
34 Lamp Flashing light − crane
35 Lamp “STOP”
36 Lamp “Attention”
37 Lamp Flashing light − dolly
38 Lamp Hydr. retarder / exhaust brake
actuated
39 Lamp Parking brake applied
40 Lamp Rear fog lamp actuated
41 Speedometer Speed display
Exterior scale: km/h
Interior scale: mph
41.1 LED Control tachograph
(when lit up, no speedometer
dial inserted)
42 LCD 7−digit display of the
(display for total distance travelled / part
ignition on) distance
43 Display “Driver information system”

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58/71
31 32 33 34 35 36 37 38 39 40

43

km/h
mph

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1

Z 48 996

140−2040−201a_en
 Driver’s Cab 4

(Z 48 996)

50 Revolution co- Engine speed display,

unter
50.1 LED Monitoring the engine speed
(with lit up: Excessive engine
speed! (> 2350 min−1)
51 Display Fuel supply
52 Reset button Reset partial mileage.
53 w/o function
54 w/o function
55 w/o function
56 w/o function
57 Taste Change brightness
58 Display Engine / coolant temperature

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4

61 64

62 65

63 66

60 67

Z 51 321

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 Driver’s Cab 4

4.3.4 Function buttons on the steering wheel

(Z 51 321)

No. Element Designation Function

60 (A 4261) “Arrow” button back one level
61 (A 4261) Button 1 Menu selection 1
62 (A 4261) Button 2 Menu selection 2
63 (A 4261) Button 3 Menu selection 3
64 (A 4261) Button 4 Menu selection 4
65 (A 4261) Button 5 Menu selection 5
66 (A 4261) Button 6 Menu selection 6
67 (A 4261) Button M to main menu / back to basic
display “Indicator lights”

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4

70 71

76 77

78 79

72 73 74 80 81

75

Z 200 160

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 Driver’s Cab 4

4.3.5 Switch on the instrument panel

(Z 200 160)

No. Element Designation Function

70 S 6114 2−step switch Parking light / lower beam
71 S 6220 Switch Rear fog lamp
72 S 6400 Switch Rotaflare light
73 S 6310 Switch Hazard flashers
74 S 6240 Switch Lights in outrigger area
75* P 2319 Display “Transmission information”
Gear display / transmission
fault message
76 S 4411 Dual Set total level (raise / lower)
switch
77 S 4424 Button Automatic activation road tra-
vel level
78 S 4413 Dual Set level, front left (raise / lo-
switch wer)
79 S 4412 Dual Set level, front right, (raise /
switch lower)
80 S 4415 Dual Adjust level, rear left, (raise /
switch lower)
81 S 4414 Dual Set level, rear right, (raise /
switch lower)

* Display layout on the (75) “Transmission information” display,

see Chap. 7.

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4

85

86 87 88 89

90

Z 200 161

64/71 140−2040−201a_en
 Driver’s Cab 4

(Z 200 161)

No. Element Designation Function

85* S 4291 Double key “Manual rear−axle steering”
steering program:
Rear wheels swing to the left
/ right
86 S 4292 Button “Close cornering” steering
program:
Axle 4+5 electrically steered
87* S 4299 Button Steering program: “Driving
away from the wall”.
88* S 4293 Button Steering program: “Diagonal
steering”: All wheel are poin-
ted in the same direction;
Steering wheel determines
the steering angles
89 Visor Not assigned
90 S 2217 Switch, Manoeuvring operation
lockable (sensitive driving at distan-
ces < 1 m;
with dragging coupling)

* Function only possible, if the (92) ”Steering program”

(construction−site operation) switch was previously actuated.

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4

92 93 94 95 96 97 98

99 100 101 102 103 104

Z 54 358

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 Driver’s Cab 4

(Z 54 358)

No. Element Designation Function

92 S 4290 Switch, Release “Steering program” (for
lockable construction−site operation)
93 S 2216 Double key press upwards: On−road gear
press downwards: Off−road
gear
(”Neutral” externally possible)
94 S 2240 Switch, Longitudinal differential lock
lockable and lift axle activation
95 S 2220 Switch, Transverse differential locks
lockable
96 S 364.1 Switch, Selector switch, hydraulic sus-
lockable pension (optional):
(operating mode selection)
OFF = axle load 12 t
ON = reduced axle load
97 S 0420 Double key Pumping fuel
actuating top side: pump ON
actuating bottom side: pump
OFF
actuating top side and keeping
pressed:
changing display (51) from sho-
wing main tank to showing addi-
tional tank
98 S 0913 Button Additional lubrication impulse
central lubricating system (optio-
nal)
99 S 4425 Switch, Suspension on three−circuit sy-
lockable stem
100 S 4401 Switch, Lock suspension
lockable
101 S 4428 Switch, Hold axles
lockable
102 S 4427 Switch, Raise lift axle *
lockable
103 S 2430 Switch, Emergency operation of the su-
lockable perstructure (optional)
104 S 4125 Button Switch ABS in tractor unit to off−
road mode

* “Raise lift axle” is done by driver in steering programs that can

be selected (for construction−site operation).

”Raise all axles” is done on the switch panel of the outrigger

controls by actuating the ”Raise axles” button, after previously
actuating the ”Raise axles” button (101).

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4

105 106 107 115

114

113

24V

112

5A

108 109 110 111

Z 53 019

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 Driver’s Cab 4

(Z 53 019)

No. Element Designation Function

105 S 5431 Switch Mirror heater
106 Visor Not assigned
107 Visor Not assigned
108 X 5412 Cigarette ligh-
ter
109 A 5111 Operating ele- Engine−independent cab hea-
ment ter arrangement (optional)
110 S 5170 Switch Air conditioning equipment on
/ off
111 Control knob Air flow
Footwell / front window
112 X 5413 Socket 24 V, 5 A *
113 Control knob Regulate engine−dependent
cab heater arrangement / A/C
equipment warm / cold
114 S 5141 Rotary switch Fan levels 0−1−2−3−4
115 Control knob Air flap fresh air / ventilation

* Socket is fused with 5 ampere; do not overload!

Voltage is always on − regardless of the ignition−starter switch
position (danger of battery drain when device is off−duty).

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4

2
1

a
1 3

Z 104 320 Z 104 321

c
3

5
b 1 4
3
1

Z 104 322 Z 104 323

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 Driver’s Cab 4

4.4 Hinged Bed (Optional)

(Z 104 320, Z 104 321, Z 104 322, Z 104 323)

If your crane is equipped with a hinged bed (1) in the crane

operator’s cab, observe the following points:

During driving, the hinged bed (1) must be folded up and

secured with a rubber strap (2).

The hinged bed (1) may only be folded down from the
passenger side, as there is not enough space on the driver’s
side.

The weight of the hinged bed is approx. 21 kg (approx. 46 lbs).

4.4.1 Procedure for Folding the Bed down

1. Hold the hinged bed (1) and release the rubber strap (2).

Risk of crushing!
When folding the hinged bed down there is a risk of crus-
hing between the dashboard and bed frame.

2. Carefully fold the hinged bed (1) down (direction of arrow “a”)
until it is resting on the dashboard.

Fold the hinged bed down carefully so that the dashboard is

not damaged (Z 104 320).

3. Raise the hinged bed (1) slightly and hang from the ceiling
of the operator’s cab using the middle chain (3) (Z 104 321).
4. Unfold the hinged component on the passenger side in the
direction of arrow “b” and attach with chain (4) (Z 104 322,
Z 104 323).
5. Now unfold the second component on the passenger side in
the direction of arrow “c” and attach it with chain (5) as well
(Z 104 322, Z 104 323).

To fold the hinged bed up, follow these instructions, but in the
reversed sequence.

140−2040−201a_en 71/71
 Engine 5

5 Engine (OM 502 LA)

Damage−prevention measures

The following safety measures must be observed, in order

to avoid injury to persons and damage to the engine, com-
ponents or cables.

− Only start the engine when the batteries are properly

connected. Never disconnect the batteries when the engine
is running.
− Only start the engine with the speed sensor fitted.
− Do not use a high−speed charger to start the engine.
Jump starting only permitted with separate batteries.
− For high−speed charging of the batteries, the battery clamps
must be removed. Follow the operating instructions for the
high−speed charger.
− In case of electric welding work, the batteries must be
disconnected and the two cables ”+” and ”−” connected firmly
together.
− The connections of the control devices may only be fitted and
removed when the electrical system is switched off.
− Reversal of the polarity for the supply voltage of the control
devices (e.g. reversal of the battery poles) can lead to the
control devices being destroyed.
− Tighten the plug connections on the injection system to the
prescribed torque.
− Remove the control units if temperatures exceed 80°C /
176°F (foundry furnace).
− Use only suitable test cables for taking measurements on
plug connections (Mercedes−Benz connector set).
− Telephones and radios that are not connected to an outside
antenna can lead to malfunctions on the vehicle electronics
and can thus endanger the operational reliability of the
engine.

Before commissioning, make sure that you have read the

operating instructions of the engine manufacturer. These
can be found in section 5 of these documents.
The following information is limited to the factors that
directly affect the crane.

140−2050−201.ildoc 1/35
5

Z 51 911 Z 51 329

12

13

Z 51 929 Z 51 346

2/35 140−2050−201.ildoc
 Engine 5

5.1 Before Starting the Engine

1. Follow the instructions in the operating manual of the engine

manufacturer (appendix in part 5 of this service literature).

2. Checking Before Starting Up:

− Fuel supply (display 51)
− Hydraulic oil level (example Z 51 911)

To avoid damage to the travelling hydraulic pumps, the engine

may no longer be started − with normal hydraulic oil filling (ATF
− Type A Suffix A) − at temperatures under −25 C (−13 F).

− Engine oil level (Z 51 329)

− Coolant level (Z 51 929):
The cooling system is filled correctly if the coolant level
reaches the marked line in the filler neck.
− Parking brake (14) closed
− Rotary switch (13) to ”N” (Z 51 346)
− Quick stop device (optional); may not be actuated.

Refer also to section 6.1 Checks Before Driving the Crane

140−2050−201.ildoc 3/35
5

2B
1B

2A
1A

4
3

Z 200 336

4/35 140−2050−201.ildoc
 Engine 5

5.2 Starting Aid with External Batteries

(Z 200 336)

If the batteries are ”weak”, the chassis engine can be started with
the aid of batteries from the superstructure engine and vice
versa.
In contrast to the specifications given in the separate engine
operating instructions (Part 5), no third−party starting aid cables
are used to jump the batteries.

Two cable couplings (consisting of 1 plug and socket each) are

attached to the chassis, on the right side (in the storage box
beneath the outrigger controls). The same connections can be
found in the engine area on the superstructure. At the same time,
”Minus” (ground) is always installed on the plugs (1A/1B) and
”Plus” is always installed on the sockets (2A/2B).
Both loose starting aid cables (3, 4) (cable cross section 95 mm2
/ 0.15 in2) included in delivery can be connected at these points;
in which − due to the different forms of the connection parts − it
is not possible to transpose the polarity.

Other crane vehicles that are equipped with these connections

from our product program can also be used as a starting aid.

We do not recommend other forms of starting aid.

Risk of injury/explosion!
− When using the starting aid, do not bend over the batter-
ies.
− Do not smoke in the vicinity of the batteries;
Avoid causing sparks and open flames.
− A discharged battery can freeze at −10°C (14°F). It must
be thawed before using the starting aid.

140−2050−201.ildoc 5/35
5

2B
1B

2A
1A

4
3

Z 200 336

6/35 140−2050−201.ildoc
 Engine 5

− To not use a starting aid with defective batteries.

− Be sure that the voltage (24 V) is the same for the flat and
the booster battery.
− Only use a starting aid with original starting aid cable.
− In no case should you use a boost charger. (Damage to
electronic parts)
− Before using the starting aid, separate mobile
communication systems from the electrical system.
− −Be sure that plugs / sockets do not come into contact
with the metal parts of the device (risk of short circuit).

Handling steps for starting aid with special cable:

1. Switch off ignition in the superstructure and chassis.
2. Connect the starting aid special cable to the cable couplings.
(connect and tighten with a short turn to the right.)
First connect the plus pole (cable 4) and then the minus pole
(cable 3).
3. Start the engine rendering assistance; let it rev up.
4. Engine receiving assistance:
Turn key to the start position in the ignition−starter switch.
Start the engine and let it run at idle speed.
5. Remove the cable, first from ”Minus” (cable 3) and then from
”Plus” (cable 4).

140−2050−201.ildoc 7/35
5

75

15

Z 51 304 Z 51 325

31 32 33 34 35 36 37 38 39 40

43

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 334

8/35 140−2050−201.ildoc
 Engine 5

(Z 51 304, Z 51 325, Z 51 334)

5.3 Ignition−starter switch (see section 4 ”Driver’s cab”)

5.4 Starting Procedure (Engine Start)

Never start the engine without the batteries connected

properly.

The engine can either be started in the driver’s cab or on the

outrigger controls (external start).

After the motor has been started, the steering performs a

self−test (see operating instructions of the crane chassis
section 9 ”Steering self−test”).

Risk of crushing!
The wheels can move back and forth independently dur-
ing the steering self−test. No−one may be in the wheel
area.

5.4.1 Starting the Engine in the Driver’s Cab

1. Insert the key into the latch contact (15) and turn (to the right)
to the driving position (position ”3”).

The electrical system performs a self−test when the ignition is

switched on; the most important signal connections to the
instrument panel are checked. At the same time, a control signal
sounds twice and all indicator lights (31−40 and 50.1) flash.
The function control is ended after the control signals go out.
Activated indicator lights may light up on the instrument panel;
e.g. item39 ”Parking brake”.
The ”CH” display appears on the (transmission information)
display (75).
The basic display ”Indicator lights” appears on the driver
information display (43). The selected functions or existing
malfunctions are shown.
For further notes, see section 4 ”Driver information system”.

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5

15
Z 51 304

Z 47 962

Z 60 982

10/35 140−2050−201.ildoc
 Engine 5

2. Start the engine

After the indicator signal goes out: Turn the key on as far as
possible (position ”4”) and start the engine, without operating
the accelerator pedal.
If required, interrupt the starting procedure after no more than
20 seconds and repeat after approx. 1 minute.

Before attempting to start the engine again, turn the key back to
the first stop.

Release the key after the engine has started.

3. If the engine fails to start after the third attempt: Search for
the cause of the fault with the help of the operating
instructions of the engine manufacturer.

5.4.2 Starting the Engine at the Outrigger Controls

(External Engine Start)

(Z 51 304, Z 47 962, Z 60 982)

1. Insert the key in the latch contact (15) (position ”2”).

2. Press the ”Caution” key (10/20) for approx. 5 secs. (ignition

on, ”Boot” data bus).

3. Press and hold the ”Caution” key (10/20) and also press the
”engine start” key (7B/17B).

4. After the engine has started release both buttons.

When the outriggers are activated, an engine speed of 1200

min −1 (rpm) is automatically set.

When the engine is started on the outrigger controls the

warning displays are not in the operator’s line of view. It is
therefore important to listen for acoustic warning signals
(buzzer).

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5

B7 B14

B11 B15

B12 B16

B13 B18

Z 62 762

31 32 33 34 35 36 37 38 39 40

43

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 324

12/35 140−2050−201.ildoc
 Engine 5

5.5 After Starting the Engine

(Z 51 328, Z 62 762)

Never disconnect the battery terminals when the engine is

running.

Keep your eye on the engine oil pressure!

If the oil pressure is too low, the B12 indicator light will
appear on the driver information display. At the same time,
the ”STOP” indicator light (35) will light up on the instrument
panel, and an acoustic warning signal (buzzer) will be
emitted.

When the ”Oil pressure” warning (B12) is shown, the

operating safety of the engine is in danger.
Stop the vehicle immediately and switch off the engine.
Determine the cause of the fault!

Do not leave the engine running at a standstill to warm it up.

Only operate the engine at full speed/full load once the

prescribed operating temperature has been reached.
− If indicator light (B18) lights up, service the air filter.
− If the indicator light (B7) lights up, service the hydraulic oil
filter (see lubricating and maintenance instructions of
chassis).

This only applies when the hydraulic oil is at operating

temperature.
At lower temperatures, it is possible that this lamp does not go out
for a short period, even though no fault is present.

Switch the engine off immediately in the case of:

− falling or heavily fluctuating oil pressure
− falling output/rpm in spite of constant operating
conditions
− heavily smoking exhaust
− excessively high coolant and oil temperature
− sudden abnormal engine noises.

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5

15
Z 51 304

Z 47 962

Z 60 982

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 Engine 5

5.6 Before Switching Off the Engine

Leave the engine running at idle speed for approx. 1−2 minutes
before switching off:
− when the coolant temperature is high (above 95 C /
203 F);
− after driving at full engine power (e.g. after driving on a slope),
to allow the exhaust turbocharger to cool down.

5.7 Switching Off (Engine Stop) in Normal Circumstances

(Z 51 304, Z 47 962, Z 60 982)

The engine can be switched off both in the driver’s cab and on the
outrigger controls.

When the ignition is ”off” the transmission automatically switches

to neutral.

When leaving the crane, remove the ignition key and close
off the cab.

5.7.1 Switching off the Engine in the Driver’s Cab

In the driver’s cab the engine is switched off with the ignition
switch (15).
The following condition ensures when the engine is started:
− If the engine is started in the driver’s cab:Turn the
ignition−starter switch (15) from driving position (position ”3”)
to position ”2”.
− When the engine is started on the outrigger control:Turn
the ignition−starter switch (15) from position ”2” to position
”1”.

5.7.2 Switching Off the Engine on the Outrigger Control

The engine is switched off on the outrigger control by pressing

button (7A/17A).
At the same time, this results in the following interaction with the
ignition−starter switch (15) in the driver’s cab:
∗ The ignition remains switched on when the ignition switch
(15) is in position ”3”.
∗ The ignition is switched off when ignition switch (15) is in
position ”1”.

140−2050−201.ildoc 15/35
5

A20

Z 47 991 Z 51 326

Z 47 992

16/35 140−2050−201.ildoc
 Engine 5

5.8 Switching Off the Engine in an Emergency

5.8.1 Switching Off Procedure ”Quick Stop” (Optional

Equipment)

(Z 47 991, Z 51 326)

On the chassis, the engines of the superstructure and chassis

can be switched off together at two central points. A mushroom
pushbutton is located on the left− and right−hand side of the
crane near the outrigger controls for this purpose. (Example Z 47
991)
Press the knob to activate the quick stop device. Once it has been
activated, the mushroom pushbutton must be released again
before an attempt is made to restart the crane (turn and unlock).

The quick stop device only functions when the handbrake is

applied and the gear is in neutral.
After the quick stop device has been activated the indicating light
(A20) lights up until the ”Locked” position is released again.

5.8.2 ”Quick Stop” with Air Shut−off Valve

(Z 47 992, example)

Using a trap between the air filter and engine the air flow is cut
off when the device is actuated.
Independently of manual activation, the quick stop device is
automatically activated when a certain speed is exceeded
(approximately 2700 U/min / rpm). At the same time the fuel
supply is interrupted. The engine is switched off.

Before the engine is restarted the trap (1) must be manually

released. Return lever (2) to the starting position.

Risk of damage!
When the trap is closed the engine cannot be started.
Repeated starting attempts lead to engine damage.
Before the restart, all air−carrying hoses − incl. the charge
air hoses between the engine and aftercooler − must be
checked to ensure that they are fitted correctly and are
completely free of blockages.

140−2050−201.ildoc 17/35
5

3
1
4
4

5
5

3
2
Z 306 015

18/35 140−2050−201.ildoc
 Engine 5

5.9 Electronic Engine Management

The chassis engine is equipped with an electronic control

system. This monitors both the engine and itself (self−diagnosis).
The control and monitoring equipment is in the cab on the
chassis.

5.9.1 Engine Control

(Z 306 015)

1 Increase idle speed,

accelerate vehicle,
store speed.

2 Reduce idle speed,

decelerate vehicle,
store speed.

3 (Sustained−action brake)

4 Switch off idle speed increase,

switch off cruise control,
switch off limiter

5 Switch on limiter:

Idle speed/intermediate speed/max. working speed

If required, the idle speed when the vehicle is stationary can be

increased from approx. 550 U/min (rpm) to max. 750 U/min (rpm).

Moreover, the engine speed (with applied handbrake) − between

idle and a parameterised maximum engine speed fixed at
1200 min −1 (rpm) − can be set to any value; e.g. when the
superstructure functions are actuated in an emergency.
When the outriggers are activated, an engine speed of 1200
min −1 (rpm) is automatically set.

When the intermediate revs are selected the engine speed can
only be changed to the max. working speed (1200 min −1) − by
pressing the accelerator pedal (18).

If the ignition switch (15) is placed in the ”Off” position, the

set intermediate speed is deleted.
It must be reset.

140−2050−201.ildoc 19/35
5

3
1
4
4

5
5

3
2
Z 306 015

20/35 140−2050−201.ildoc
 Engine 5

5.9.2 Idle Speed

(Z 306 015)

1 Hold down:

Increase idle speed.

1 Tap:

Increase idle speed by approx. 20 min −1 (rpm).

2 Hold down:

Reduce idle speed.

2 Tap:

Reduce idle speed by approx. 20 min −1 (rpm).

After releasing the lever the engine runs at the increased speed.

4 Tap:

Idle speed increase switched off.

The idle speed increase is automatically switched off after

starting off.

140−2050−201.ildoc 21/35
5

3
1
4
4

5
5

3
2
Z 306 015

22/35 140−2050−201.ildoc
 Engine 5

5.9.3 Cruise Control

Using the cruise control, the vehicle drives at a stored speed

(without actuating the accelerator pedal).
Any speed above 30 km/h (19 mph) can be stored.

RISK OF ACCIDENTS!
Do not switch on the cruise control on a slippery surface.
Risk of skidding!

Only use the cruise control when the traffic conditions enable a
constant speed. It may not be possible to hold the speed on
inclines.

Do not exceed the highest speed in the individual gears (observe

the revolution counter).

When the cruise control is switched on take your foot off the
accelerator pedal.

Switch on the cruise control:

The cruise control is switched on using the actuating lever on the

right of the steering column.
− Accelerate the vehicle with accelerator pedal (above 30 km/h
/ 19 mph)
− Lever in position

1 Hold down:

Accelerate. Release lever, the speed that has been

reached is stored.

1 Tap:

Save current speed or increase saved speed by 0.5 km/h.

2 Hold down:

Decelerate. Release lever, the speed that has been

reached is stored.

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5

3
1
4
4

5
5

3
2
Z 306 015

24/35 140−2050−201.ildoc
 Engine 5

(Z 306 015)

2 Tap:

Save current speed or reduce saved speed by 0.5 km/h.

Resume stored desired speed.

After releasing the lever the engine runs at the speed that has
been reached.

Switch off the cruise control:

Tap the lever in position 4.

The cruise control is automatically switched off:

− when the brake is activated.
− for speeds under 30 km/h (19 mph).

If the vehicle is accelerated with the accelerator pedal when the

cruise control is switched on, the stored speed is resumed once
the accelerator pedal is released.

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5

3
1
4
4

5
5

3
2
Z 306 015

26/35 140−2050−201.ildoc
 Engine 5

5.9.4 Limiter (for Limiting the Maximum Speed)

(Z 306 015)

Using the limiter the driving speed can be limited at any level
above 30 km/h (19 mph).

Switch on limiter:

− accelerate the vehicle to the desired speed.

− Press button (5). The speed limiter is activated.

Switch off limiter:

Tap the lever in position 4.

The set maximum speed is automatically deleted if the cruise

control is switched on.

To exceed the set maximum speed:

If you want to exceed the set maximum speed (e.g. when

overtaking):
press down the accelerator pedal past the acceleration point up
to the stop (kick−down).

To reduce the set maximum speed:

If you want to reduce the set maximum speed:

release the accelerator pedal (if required, brake the vehicle).
Once the desired speed has been reached, press button (5).

140−2050−201.ildoc 27/35
5

B11 B15

B12 B16

B13 B18

B14

Z 51 328

31 32 33 34 35 36 37 38 39 40

43

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1
Z 51 324

28/35 140−2050−201.ildoc
 Engine 5

(Z 51 328, Z 51 324)

5.9.5 Monitoring the Engine

5.9.5.1 Fault Display

All faults in the engine system and the engine electronic system
are collected. If a fault occurs, this is shown by the indicator light
(B15).
Regardless of this general detection/display, certain faults are
shown directly by their own indicator lights (with the
corresponding symbol).
At the same time, the indicator light (35) ”STOP” or ”Caution” (36)
will light up on the instrument panel; in some cases, an acoustic
warning signal (buzzer) will also sound.

When there is a malfunction/warning display and at the same

time the red warning light ”STOP” (35) lights up, the
operational safety of the engine is in danger. Stop the vehicle
immediately and remedy the fault.

− Speed monitor

(50.1) LED, red

When lit up: The engine speed is exceeding 2350
U/min (rpm) (excessive engine speed).

Be sure that the engine does not exceed the permissible

speed range.

At an engine speed of 2300 U/min (rpm), the exhaust brake is

deactivated to protect the engine mechanic against damage.

− Engine faults (engine system/electronic system)

(B15) Indicating light, red

When the fault indicator lights up read off the fault
code.

All faults are stored in the system and can be read off as fault
codes. Faults which are only displayed temporarily are also
stored.

140−2050−201.ildoc 29/35
5

B11 B15

B12 B16

B13 B18

B14

Z 51 328

30/35 140−2050−201.ildoc
 Engine 5

− Coolant level

(B11) Indicating light, red

The warning ”Coolant level” (B11) is displayed if the
coolant level in the compensation tank has sunk by
approx. 2 l (0.5 gal) under the norm. At the same time,
the alarm buzzer will also sound.
Switch off the engine immediately and determine the
cause of the fault.

− Oil pressure

(B12) Indicating light, red

The ”Oil pressure” warning is displayed when − while
the engine is running − the oil pressure is too low in the
engine (= depending on the speed).
At the same time − if the level continues to fall − the
alarm buzzer sounds.
Switch off the engine immediately and determine the
cause of the fault.

− Coolant temperature

(B13) Indicating light, red

The warning ”Coolant temperature” (B13) is displayed if
a coolant temperature of 104 C (219 F) is reached
during driving. Even the alarm buzzer sounds at 110 C
(230 F) and the engine performance reduces automatically.
The engine can still be used. however, the cause must be de-
termined.

− Oil level

(B14) Indicating light, red

The ”Oil level” warning (B14) is displayed when the oil
level in the engine has sunk considerably under the
minimum amount. At the same time, the alarm buzzer
will also sound.
Switch off the engine immediately and determine the
cause of the fault.

This display serves only as additional information.

Monitoring of the oil level is not to be performed except with
the dipstick.
Depending on the version, it may turn out that this display
function is not possible because of technical reasons.

140−2050−201.ildoc 31/35
5

B11 B15

B12 B16

B13 B18

B14

Z 51 328 Z 51 335

32/35 140−2050−201.ildoc
 Engine 5

(Z 51 328, Z 51 335)

− Charging current

(B16) Indicating light, red

If the ”charging current” warning is displayed when the
engine is running, switch off the engine and check the
belt drive.
Never run the engine without the belt drive. The coolant
pump is not working.

5.9.6 Reading Off the Fault Memory

When warning light (B15) lights up, the system has recognised
a fault.
The fault codes can be read off with the ”Minidiag 2”
(Mercedes−Benz) diagnosis device. This is usually done by our
customer service or in a DAIMLERCHRYSLER AG workshop.

Action steps for error diagnosis:

− Switch off the engine.
− Connect the diagnosis device to the diagnosis socket
(14−pole; in the control box ”X 300” in the driver’s cab).
(Z 47 966)
− Switch on the ignition.

Do not start the engine.

When the engine is running fault codes cannot be deleted. If no
fault codes are displayed, check the fuse and grounding of the
diagnosis socket.

− Call up the menu for reading the fault codes from the control
unit.
− Call up the fault codes.

A description of all fault codes can be found in the separate

operating instructions of the engine manufacturer (see part 5 in
this service literature).

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5

34/35 140−2050−201.ildoc
 Engine 5

5.9.7 Evaluation of the Displayed Faults

The error code has five digits; the first digit indicates the fault
group (0, 1 or 2). Depending on which fault group is displayed,
you should proceed as follows:

− Fault group 0

The fault code is stored, but only displayed when the diagnosis
instrument is connected.
The fault can, if required, be rectified during the next service.

The engine can still be used.

− Fault group 1

The fault must be rectified as soon as possible.

Risk of accidents! You must reckon with altered running

characteristics of the engine.

− Fault group 2

The fault must be rectified immediately.

Risk of accidents! The running characteristics of the en-

gine are different (emergency running programme).

140−2050−201.ildoc 35/35
 Driving the Crane 6

6 Driving the Crane

6.1 Instructions for all Types of Driving

All the control and monitoring elements required for driving the
crane are located in the driver’s cab of the crane chassis.

The pedals’ freedom of movement must not be restricted. Be

sure that there is enough room for the pedals when using
foot mats and carpets. Do not store any objects in the
driver’s foot area. Store or secure all loose objects (e.g. tins,
bottles, tools, bags, etc.) in such a way that they can’t enter
the foot area while driving. Such objects could get under the
brake pedal, block it and thereby make it impossible to brake
the crane vehicle.

6.2 Checks Before Driving the Crane

Check the capacities for all fuels and lubricants − see lubricating
and maintenance instructions for the crane chassis (part 4).

The following checks must be made every time before the crane
is driven, even when only driving short stretches.
− Driving condition of the mobile crane:
Check axle loads; Observe instructions (see under “axle
loads / speeds / tyres” and “defined driving conditions”)
− Check transport position of struts and outrigger plates (see
section 12)
− Check the engine oil level, add extra oil if required.
− Check the hydraulic oil level.
If level is too low: Determine the cause − and then top up.

Wait until the hydraulic oil has warmed up before running the
engine at speeds of over n=1600 min −1.

− Check the oil level in the transmission, add extra oil if

required.
− Check the coolant level.
If level is too low: Determine the cause − and then top up.

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6

B8

B9

B10

Z 51 300

2/179 140−2060−103b
 Driving the Crane 6

− Check the steering.

The indicator lights (B8, B9 and B10) must not light up as a
rule. (Z 51 300)

Depending on the system, in case of the fault ”No through−feed

at the emergency steering pump” (indicator light B10) , there is
a display only once driving speeds > approx. 8 km/h (5 mph) have
been reached.

Driving the crane with defective steering constitutes a major

safety hazard. Faults must be rectified before the crane is
driven.

140−2060−103b 3/179
6

Z 200 153

1 B3

2 B4

Z 51 301

31 32 33 34 35 36 37 38 39 40

Z 51 331

4/179 140−2060−103b
 Driving the Crane 6

− Check the brake system.

(Z 200 153, Z 51 301, Z 51 331)
− Emergency pressure supply in brake circuit 1 and 2:
− Driver’s information display, submenu 4.4:
emergency pressure supply is displayed.
Upper row = braking circuit 1
Lower row = braking circuit 2
− Driver’s information display, basic display:
Red indicator light, when the emergency pressure
supply is under 5.5 bar (80 psi).
Indicator light (B3) = braking circuit 1
Indicator light (B4) = braking circuit 2
− Parking brake: indicator light (39), when the parking brake
is applied.

If the emergency pressure supply is below 7 bar (102 psi), the air
tanks of the braking system must be topped up at medium revs
until a pressure of 8 bar (116 psi) is reached.

Air pressure of min. 6.2 bar (90 psi) is needed to switch gears. It
is not possible to shift gears below this mark.

Immediately after driving, test the brakes on a dry, anti−skid

road surface (service and retaining brake). When doing so,
make sure the crane brakes evenly, does not veer to the side
and that brake delay is faultless.

There must be no oil or water in the brake linings. If water has

permeated into the brake lining, lightly brake with the
service brake until the brakes are again fully functional.

− Check steering wheel/driver seat setting

Exact instructions on the steering wheel / driver’s seat settings

are in section 4 “Driver’s cab”.

− Vehicle lighting; check indicators and brake lights

140−2060−103b 5/179
6

B1

51

B19

Z 200 216 Z 200 151

99 100 101 102

A11 A12 A13 A14

Z 51 332

6/179 140−2060−103b
 Driving the Crane 6

(Z 200 216, Z 200 151, Z 51 332)

− Check the suspension system.

If a suspension circuit is outside the road travel level, the
indicator light (B1) on the driver’s information display lights
up. The exact level of individual suspension circuits can be
observed in submenu 4.1.

All suspension cylinders must be in the road travel position

(green range);
When driving on the road the suspension must be in the 4−way
system and it must not be locked. (Switch 99, 100 in the “off”
position, no displays A11, A12).

− Check the fuel level, add fuel if required.

The fuel supply is displayed on the instrument panel with
instrument (51). If the fuel supply is in the reserve area, the
indicator light (B19) lights up.

Do not fill up with fuel while the engine is running.

Other important specifications are outlined in the individual

sections.

Check the function of the vehicle lighting, warning and brake

lights and make sure that they are clean. Replace any defective
bulbs.

Check the tyre condition and air pressure. The air pressure has
a large influence on:
− The handling of the vehicle
− The running characteristics of the tyres

Tyre damage is inevitable if the tyre pressure is too low.

It is therefore essential to apply the correct air pressure.

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6

Z 36 570

Z 35 568 Z 36 571

8/179 140−2060−103b
 Driving the Crane 6

6.3 Transport Safety Locks

During transportation, the safety locks provided must be applied.

Following driving and before the superstructure is placed in

operation, the safety locks must be removed again.

− When driving with the hook block reeved, it must be fastened

to the front coupling ring of the crane chassis. (Z 36 570)
− When driving without a hook block, the hoist rope is secured
with the rope socket on the front coupling ring of the crane
chassis. (Z 36 571)
− Apply mechanical superstructure locking device.
(see section 4 of the operating instructions of the
superstructure)
− The platform on the superstructure cab must be pushed
intotransport position (switch actuation; (see section 4 of the
operating instructions of the superstructure)
− If the reeved hook block is set down on the crane chassis
when the crane is driven, it must be inserted in the holding
devices provided (optional equipment) and must be secured
accordingly. ( Example Z 35 568)
The rope must be guided over the corresponding rope
configurations on the chassis cab and chassis frame.
− Outrigger struts pinned/locked in the transport position.

140−2060−103b 9/179
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 Driving the Crane 6

6.4 Axle Loads / Speeds / Tyres

The permitted driving speed is dependent on the axle load and

the tyres. There is a direct correlation between the axle load, tyre
size and permitted speed.
With the axle loads we differentiate between the technically
possible loads and those permitted by road traffic
regulations.

All chassis parts / components are designed and approved ex

works for even axle loads of 12 t (26.4 kip) per axle.

Axle loads above and below 12 t (26.4 kip) represent a deviation

from the documented EEC approved condition.

Uneven or excessively high axle loads negatively affects the

handling of the crane in any case. Lower axle loads also have a
negative effect.

Deviation from the approved condition always means worse

handling characteristics. The larger the deviations, the
worse the driving characteristics become.
The limitations that must be observed as a result are
correspondingly larger.
Observe the relevant instructions in the following
subsections.

Before driving in public traffic the driver must be fully

conversant with the altered driving/steering/braking
behaviour (e.g. longer braking distances) of the crane −
especially where the driving condition of the crane deviates
from the standard configuration.

140−2060−103b 11/179
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12/179 140−2060−103b
 Driving the Crane 6

6.4.1 Calculating Axle Loads

Any addition or removal of components affects the vehicle /

displaces the axle loads.
Additional components can, depending on the centre of gravity
on the crane, cause an increase or decrease of weight on the
affected axles.

The section has separate tables for calculating axle loads,

alternatively using metric values or English / American units.

When using the tables, make sure to use the correct units of
measurement.

6.4.1.1 Calculated Basic Condition

The basic condition serves as the basis for all axle load
calculations. The crane then weighs 48093 kg (106027 lbs) and
is equipped with the following:

Crane with:
− Superstructure, main boom
− Locking / pinning unit in transport position (at the rear in the
main boom)
− Hoist 1
− Drive 10x8x8
− Tyres 16.00 R 25
− Central lubricating system, air conditioning equipment,
auxiliary heating
− Wooden box, empty

Crane without:
− Outriggers, front
− Outriggers, rear
− Hoist 2
− Counterweights
− Main boom extension
− Spare wheel
− Hook block

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6.4.2 Calculating Axle Loads on a Metric Basis; in

Kilograms (kg) / Tons (t)

All specifications use metric dimensions.

6.4.2.1 Weight Table (Component Weights)

Starting from the basic condition listed − using the weights listed
− the current axle loads can be calculated for different
combinations.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.

Description of the Dead Change in axle load in kg on axle

components weight
(kg) 1 2 3 4 5

Basic condition 48093 10213 10197 9362 9193 9128

2 outrigger struts, front 1428 725 697 2 2 2
2 outrigger struts, rear 1655 −518 −498 864 899 909
Wooden box rear, empty 127 −48 −46 71 74 75
Hook block holder, empty 87 57 55 −8 −9 −9
Hook block 570 kg in holder 570 375 361 −54 −56 −57
Additional tank / extra tank 300 l 294 96 92 34 36 36
Spare wheel 16.00 R 25 / holder (rear) 331 −137 −131 194 202 204
Trailer coupling D 120 (rear) 31 −11 −11 17 18 18
Hook block (1−sheave) on bumper 530 488 469 −138 −144 −145
Hook block (3−sheave) on bumper 700 645 620 −182 −190 −192
Hook block (hook) on bumper 250 230 221 −65 −68 −69
Hoist 2 1547 −661 −635 920 957 967
Main boom extension 9.1 m
1080 612 588 −39 −40 −41
(at the side in transport position)
Main boom extension 17 m
1615 767 737 36 37 38
(at the side in transport position)

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Continuation of the table:

Description of the Dead Change in axle load in kg on axle
components weight
(kg) 1 2 3 4 5

Counterweight section 1a (3.66 t /

3660 1302 1251 375 390 394
8060 lbs) set down onto the chassis
Counterweight section 1b (1.99 t /
2000 701 674 202 210 212
4390 lbs) set down onto the chassis
Counterweight section 2 (7.92 t /
7925 2779 2671 800 833 842
17455 lbs) set down onto the chassis
Counterweight section 5 (2.59 t / 5700
2600 −828 −796 1367 1422 1438
lbs) attached to the superstructure
Counterweight section 6R (1.3 t /
2915 lbs) attached to the superstruc- 1300 −408 −392 679 707 714
ture
Counterweight section 6L (1.3 t / 2915
1300 −408 −392 679 707 714
lbs) attached to superstructure
Tyres 14.00 R 25 reduced weight
−590 −118 −118 −118 −118 −118
(in place of 16.00 R 25)
Tyres 17.5 R 25 reduced weight
−305 −61 −61 −61 −61 −61
(in place of 16.00 R 25)
Tyre equipment 20.5 R 25 additional
weight 1005 201 201 201 201 201
(instead of 16.00 R 25)

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6.4.2.2 Example of an Axle Load Calculation in kg / t

The following calculation example shows how the current axle

load can be calculated with the help of the weight table.
The weights of the following components are added to the basic
condition:
− Outriggers, front and rear
− Main boom extension 17 m folded into the main boom
− Hoist 2
− Bottom hook block, 3−sheave model 63 (700 kg) at bumper
− Counterweights 1a, 1b and 2 (3.66 t + 1.99 t + 7.92 t = 13.57
t) attached to the chassis.
− Counterweights 5 and 6 L/R (2.59 t + 2 x 1.3 t = 5.19 t) pinned
to the superstructure
Description of the Dead Change in axle load in kg on axle
components weight
(kg) 1 2 3 4 5

Basic condition 48093 10213 10197 9362 9193 9128

2 outrigger struts, front 1428 725 697 2 2 2
2 outrigger struts, rear 1655 −518 −498 864 899 909
Hoist 2 1547 −661 −635 920 957 967
Hook block (3−sheave) on bumper 700 645 620 −182 −190 −192
Main boom extension 17 m
1615 767 737 36 37 38
at the side in transport position
Counterweight section 1a (3.66 t /
3713 1302 1251 375 390 394
8060 lbs) set down onto the chassis
Counterweight section 1b (1.99 t /
2000 701 674 202 210 212
4390 lbs) set down onto the chassis
Counterweight section 2 (7.92 t /
7925 2779 2671 800 833 842
17455 lbs) set down onto the chassis
Counterweight section 5 (2.59 t / 5700
2604 −828 −796 1367 1422 1438
lbs) attached to the superstructure
Counterweight section 6R (1.3 t /
2915 lbs) attached to the superstruc- 1300 −408 −392 679 707 714
ture
Counterweight section 6L (1.3 t / 2915
1300 −408 −392 679 707 714
lbs) attached to superstructure
Total 73880 14309 14134 15104 15167 15166

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Correspondingly the current weight of the crane, rounded up, is

74 t. The individual axle loads are then (rounded off):

∗ Axle 1: 14.3 t ∗ Axle 4: 15.2 t

∗ Axle 2: 14.15 t ∗ Axle 5: 15.2 t
∗ Axle 3: 15.1t

This example is equivalent to the driving mode ”Driving with an

overall weight of 74 t (Technical drivability)” described in the
subsection “Defined driving modes”.
The slight deviations are a result of rounding the individual items
up/down and/or weight tolerances.

RISK OF ACCIDENTS due to overloading of tyres!

The maximum permitted speed must be observed for the
current axle load (see section 6 under ”Possible axle
loads / permitted speeds”). The determining factor is al-
ways the axle that is under the highest load. Failure to
observe these instructions can result in the tyres being
overloaded and bursting.

Extreme risk of accidents due to extended braking di-

stances!
Axle loads exceeding 12 t result in a significantly longer
braking distance and the risk of fading.

For driving on public roads, the permitted axle loads and the
corresponding speed limits must be observed.

RISK OF ACCIDENTS!
For axle loads less than 12 t (26.4 kip), section 6.4.635(page
) ”Driving with reduced axle loads” must be observed.

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6.4.3 Calculating Axle Loads in British / American Units; in

Pounds (lbs)

All specifications use British / American measurement units.

6.4.3.1 Weight Table (Component Weights)

Starting from the basic condition listed on the previous page −

using the weights listed − the current axle loads can be calculated
for the different combinations.
Where there is a “minus” sign, there is actually a reduction in the
axle load by the specified amount.

Description of the Dead Change in axle load in lbs on axle

components weight
(lbs) 1 2 3 4 5

Basic condition 106027 22516 22481 20640 20267 20124

2 outrigger struts, front 3148 1598 1537 4 4 4
2 outrigger struts, rear 3649 −1142 −1098 1905 1982 2004
Wooden box rear, empty 280 −106 −101 157 163 165
Hook block holder, empty 192 126 121 −18 −20 −20
Hook block 570 kg (1257 lbs)
1257 827 796 −119 −123 −126
in holder
Additional tank / Extra tank 300 l
648 212 203 75 79 79
(79.3 gallons)
Spare wheel 16.00 R 25 / holder (rear) 730 −302 −289 428 445 450
Trailer coupling D 120 (rear) 68 −24 −24 37 40 40
Hook block (1−sheave) on bumper 1168 1076 1034 −304 −317 −320
Hook block (3−sheave) on bumper 1543 1422 1367 −401 −419 −423
Hook block (hook) on bumper 551 507 487 −143 −150 −152
Hoist 2 3411 −1457 −1400 2028 2110 2132
Main boom extension 9.1 m(29.5 ft) at
2381 1349 1296 −86 −88 −90
the side in transport position
Main boom extension 17 m
(55.8 ft) at the side in transport posi- 3560 1691 1625 79 82 84
tion

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Continuation of the table:

Description of the Dead Change in axle load in kg on axle
components weight
(lbs) 1 2 3 4 5

Counterweight section 1a (3.66 t /

8060 2870 2758 827 860 869
8060 lbs) set down onto the chassis
Counterweight section 1b (1.99 t /
4390 1545 1486 445 463 467
4390 lbs) set down onto the chassis
Counterweight section 2 (7.92 t /
17455 6127 5889 1764 1836 1856
17455 lbs) set down onto the chassis
Counterweight section 5 (2.59 t / 5700
5700 −1825 −1755 3014 3135 3170
lbs) attached to the superstructure
Counterweight section 6R (1.3 t /
2915 lbs) attached to the superstruc- 2915 −899 −864 1497 1559 1574
ture
Counterweight section 6L (1.3 t / 2915
2915 −899 −864 1497 1559 1574
lbs) attached to superstructure
Tyres 14.00 R 25 reduced weight
−1301 −260 −260 −260 −260 −260
(in place of 16.00 R 25)
Tyres 17.5 R 25 reduced weight
−672 −134 −134 −134 −134 −134
(in place of 16.00 R 25)
Tyre equipment 20.5 R 25 additional
weight 2216 443 443 443 443 443
(instead of 16.00 R 25)

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6.4.4 Possible Axle Loads / Permitted Speeds

Pay attention to the relation between the axle loads, the driving
speed and the tyres fitted − as shown in the following table.

The determining factor is the axle that is placed under the highest
load.

RISK OF ACCIDENTS due to overloading of tyres!

The maximum permitted speed for the actual axle load
must be observed at all times.
Failure to observe these instructions can result in the ty-
res being overloaded and bursting.

6.4.4.1 Tyres, Manufactured by Michelin (XGC)

Michelin tyres XGC tread

Tyre size 385/95 R 25 445/80 R 25 445/95 R 25 525/80 R 25
(14.00 R 25) (17.50 R 25) (16.00 R 25) (20.50 R 25)
Ply 170 E 170 E E177 E179
Tyre pressure 10.0 bar 7.0 bar 9.0 bar 7.0 bar
(145 psi) (102 psi) (131 psi) (102 psi)
Tread XGC
Maximum speed Axle loads Axle loads Axle loads Axle loads
km/h mph t kip t kip t kip t kip
80 50 12.0 26.4 12.0 26.4 12.0 26.4 12.7 28.0
70 44 12.0 26.4 12.0 26.4 14.5 32.0 14.5 32.0
60 37 13.1 28.8 13.1 28.8 15.0 33.0 15.0 33.0
50 31 14.2 31.3 14.2 31.3 16.6 36.6 16.6 36.6
40 25 14.9 32.8 14.9 32.8 17.5 38.6 17.5 38.6
30 18 15.6 34.4 15.6 34.4 19.0 41.9 19.8 43.6
20 12 17.3 38.1 15.9 35.0 20.5 45.2 21.1 46.5
10 6 22.5 49.6 20.1 44.3 26.8 59.1 26.9 59.3
5 3 25.4 56.0 22.8 50.3 32.6 71.9 30.4 67.0
2 1 29.3 64.6 26.2 57.8 36.0 79.4 35.0 77.1

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6.4.4.2 Tyres, Manufactured by Michelin (X − Crane)

Michelin tyres X − Crane tread

On Road Off Road
Tyre size 385/95 R 25 445/95 R 25 385/95 R 25 445/95 R 25
(14.00 R 25) (16.00 R 25) (14.00 R 25) (16.00 R 25)
Ply 170F 174F 170F 174F
Tyre pressure 9.0 bar
(131 psi)
Tread X − Crane
Maximum speed Axle loads Axle loads Axle loads Axle loads
km/h mph t kip t kip t kip t kip
80 50 12.0 26.4 13.4 29.5 − − − −
70 44 12.6 27.8 14.1 31.1 − − − −
60 37 13.2 29.1 14.7 32.4 − − − −
50 31 13.5 29.7 15.0 33.1 − − − −
40 25 13.8 30.4 15.4 33.9 − − − −
30 18 15.0 33.1 16.8 37.0 15.6 34.4 19.0 41.9
20 12 18.0 39.7 20.1 44.3 18.0 39.7 20.5 45.2
10 6 21.6 47.6 24.1 53.1 22.5 49.6 26.8 59.1
5 3 25.2 55.5 28.1 61.9 25.4 56.0 32.6 71.9
2 1 28.1 61.9 31.4 69.2 29.3 64.6 36.0 79.4

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6.4.4.3 Tyres, Manufactured by Bridgestone, Goodyear and

Yokohama

Bridgestone, Yokohama and Goodyear tyres

Tyre size 385/95 R 25 445/80 R 25 445/95 R 25 525/80 R 25
(14.00 R 25) (17.50 R 25) (16.00 R 25) (20.50 R 25)
Ply 170 E 170 E E177 E179
Tyre pressure 10.0 bar 7.0 bar 9.0 bar 7.0 bar
(145 psi) (102 psi) (131 psi) (102 psi)
Bridgestone VHS VGT VHS VHS
GP − 2B *
Tread Goodyear
MC − 1A − MC − 1A −
Yokohama RB 01 − RB 01 −
Maximum speed Axle loads Axle loads Axle loads Axle loads
km/h mph t kip t kip t kip t kip
80 50 9.8 21.6 9.8 21.6 12.0 26.4 12.7 28.0
70 44 12.0 26.4 12.0 26.4 14.5 31.9 14.5 31.9
60 37 13.4 29.5 13.4 29.5 15.0 33.1 15.0 33.1
50 31 14.2 31.3 14.2 31.3 16.6 36.6 16.6 36.6
40 25 14.9 32.8 14.9 32.8 17.5 38.6 17.5 38.6
30 18 15.6 34.4 15.6 34.4 19.0 41.9 19.8 43.6
20 12 17.3 38.1 15.9 35.0 20.5 45.2 21.1 46.5
10 6 22.1 48.7 20.1 44.3 26.8 59.1 26.9 59.3
5 3 25.5 56.2 23.9 52.7 31.0 68.3 32.0 70.5
2 1 28.7 63.3 26.2 57.7 35.0 77.1 35.0 77.1
* After three hours or 210 km (130 mi) of travel, you must take a 30−mi-
nute break.

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6.4.5 Driving with Uneven Axle Loads

Uneven axle loads have a negative effect on the handling of the

crane.

The braking system is designed for even axle loads of 12 t

(26.4 kip) in accordance with EC guidelines and German
road traffic regulations.

Different axle loads at the front and rear represent a

deviation from the approved crane configuration. The
vehicle handling will deteriorate to a greater or lesser
degree, depending on the amount of deviation!
The larger the differences, the more serious the
deterioration. Drive with appropriate caution and reduce the
driving speed; if necessary, walking speed must be
maintained.
React to poor road conditions by further reducing the driving
speed.

Axle load ratios, heaviest axle : lightest axle > 2:1 are not
allowed as they cannot be properly handled from a driving
perspective.
Any driving conditions that deviate from these must be listed
under “declared driving conditions” or require express
permission from case to case.

In the case of uneven axle loads, the steering can be locally

overloaded. This can result in damage to the steering.

Caution when braking!

Apply force evenly when braking. Sudden and abrupt ap-
plication of the brake pedal can cause the wheels to lock;
the vehicle could career out of control.

Caution when steering!

When driving through curves, the vehicle tends towards
the straight−ahead steering position.

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6.4.6 Driving with Reduced Axle Loads

Reduced axle loads have a negative affect on the handling of the

vehicle.

Braking:

RISK OF ACCIDENTS!
The braking system is designed and approved for axle
loads of 12 t (26.4 kip). At lower axle loads, the crane is
overbraked.

Vehicles without ABS:

Abrupt use of the brake pedal could cause all the wheels
to lock suddenly. The lower the axle loads, the greater
the risk of the axles locking.
Use the brakes therefore with care, as appropriate to the
situation!

Vehicles with ABS:

The braking effect becomes less satisfactory.

Steering:

RISK OF ACCIDENTS!
The steering behaviour is changed.
The steering system is lighter and reacts more quickly
when axle loads are reduced. It becomes less smooth.

Risk of damage!
There is a risk of damage to the steering components; e.g.
as a result of external resistance at the wheels.

Suspension system:

RISK OF ACCIDENTS!
The standard−equipped suspension system is designed
for axle loads of 12 t (26.4 kip). The suspension becomes
”harder” with lower axle loads. When axle loads are less
than 7 t (15.4 kip), the crane behaves as though the sus-
pension were blocked. The crane may begin to skid.

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There is a way to adjust the suspension system permanently to

the reduced axle loads. The preload pressure of the
accumulators must be adapted for this purpose. If this option is
available for your equipment, then you will find corresponding
information on the hydraulic circuit diagram or in the respective
Lubrication and Maintenance Instructions in the ”Hydraulics
system” section. If no information concerning this is available,
then corresponding values are obtainable upon request.

RISK OF ACCIDENTS!
If the crane is to be moved again with axle loads of 12 t
(26.4 kip), then the preliminary tension of the suspension
accumulator must be modified again accordingly.

If the crane is driven alternately with 2 axle load statuses, then

the crane can be optionally equipped for switch actuation to
change the suspension back and forth between the 12 t
(26.4 kip) axis load configuration and the axis load configuration
with reduced axle loads.
A corresponding switch is then located in the driver’s cab.
Additional information on this topic can be found then in Section
11 ”Hydraulic suspension”.

Behaviour of the driver with reduced axle loads:

Risk of accidents! Risk of skidding!

If the preload pressure of the accumulators of the sus-
pension system is not reduced, then the maximum dri-
ving speed must be reduced. The lower the axle load, the
slower the driving speed must be. For axle loads of less
than 8 t (17.7 kip), the permitted maximum speed is still
no more than 30 km/h (18 mph). The maximum speed
must be reduced even further with additional axle load
reduction and/or poor road conditions.

Risk of accidents! Risk of skidding!

For vehicles without ABS:
If the preload pressure of the accumulators of the sus-
pension system is reduced (manually or with switcho-
ver), then the maximum driving speed must be reduced
to 50 km/h (31 mph).

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6.4.7 Driving with Axle Loads Exceeding 12 t (26.4 kip)

Driving with axle loads of more than 12 t (26.4 kip) is always

an exceptional condition and is only permitted for short
stretches.
Drive extremely carefully and reduce your maximum driving
speed.
The correlation between the technically possible axle loads
and the maximum driving speed should be observed.

All travelling gear parts / components were designed in the

factory for axle loads of 12 t (26.4 kip) and approved (approved
condition see “Driving with an overall weight of 60 t (132.3 kip)”.

Axle loads of 12.5 t (27.6 kip) mean that the approved crane
condition has already been exceeded.

Axle loads exceeding 12 t (26.4 kip) mean:

− Higher loads.
− Overloading of tyres (for certain sizes).
− Extended braking distances / risk of fading.

Increased loads

Axle loads of more than 12 t (26.4 kip) lead to increased loads on

the steering, axle suspension, axles, wheel hubs, bearings,
suspension system, suspension cylinders, brakes, wheels and
tyres.
This means a considerable reduction in the life expectancy and
service life for the affected components.
Wear on brake linings is particularly increased. There is a risk of
overheating (fading).

Loading / overloading of tyres

Sudden loads (e.g. driving against kerbs), bead damage or

cutting damage must be avoided under these more exacting
operating conditions.

Damage to a tyre can result from the combination of overloading

and / or increased speed. Damage does not necessarily have to
follow a handling error. These add up over time and can result in
more serious damage following a relatively minor incident.

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RISK OF ACCIDENTS when tyres are damaged!

Damage to tyres must be rectified by professionals.

RISK OF ACCIDENTS due to overloading of tyres!

The maximum permitted speed must be observed for the
current axle load (see section 6 under ”Possible axle
loads / permitted speeds”). Failure to observe these in-
structions can result in the tyres being overloaded and
bursting.

Extended braking distances / risk of fading

The braking system for this vehicle is designed in accordance

with EC directives and German road traffic regulations for an axle
load of 12 t (26.4 kip).

Extreme risk of accidents due to extended braking di-

stances!
At axle loads above 12 t (26.4 kip) the braking decelera-
tion as required in accordance with EC partial operating
approval, can no longer be guaranteed / maintained.
The braking distances are, as a result, considerably or
even extensively extended and there is a risk of overhea-
ting (fading).

6.4.7.1 Driving with Axle Loads up to 12.5 t (27.6 kip)

RISK OF ACCIDENTS due to overloading of tyres!

The maximum permitted speed must be observed for the
current axle load (see section 6 under ”Possible axle
loads / permitted speeds”). Failure to observe these in-
structions can result in the tyres being overloaded and
bursting.

Possible driving speeds are only permitted within existing tyre

limit values; i.e. the possible maximum speed may not be driven
when the tyres are not permitted for this speed (at certain axle
loads).

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6.4.7.2 Driving with Axle Loads up to 16.5 t (36.4 kip)

This technically possible driving condition does not meet the
regulations of the German road traffic licensing regulations and
the EEC directives.
Therefore driving in this region is only permitted on private roads
and grounds. These must have a sufficient load−bearing
capacity and must be sufficiently level (e.g. no potholes).
If the crane is driven with axle loads above 12. 5 t (27.6 kip), the
following points must be observed:
− Only short driving stretches are permitted at any time.
− Before driving take the axle loads from the listed driving
condition or recalculate based on the current configuration
using the weight table.
The determining factor is always the axle that is under the
highest load.
− With the “lift axle” raised, the crane may not be driven, as
raising the “lift axle” leads to a further prohibited increase in
the axle load.
− The crane must not be steered on the spot or when on very
uneven ground.
− During driving the displayed pressures of the suspension
circuits must be observed. They should be proportionate and
must not exceed 260 bar (3771 psi).
− Calculate the maximum permitted speed based on the
current axle load and observe this maximum while the crane
is driven.
− Before driving in public traffic, the driver must be fully
conversant with the changed driving / braking behaviour of
the crane (e.g. longer braking distances).
− Reduce the maintenance intervals; carry out inspections
more often.
Risk of damage as a result of premature wear!
RISK OF ACCIDENTS as a result of worn components!
Special instructions / warnings related to this are
summarised in the subsection “Shorter maintenance
intervals for axle loads over 12.5 t (27.6 kip)”.
The information given here must be observed at all times.
The crane manufacturer shall not be held liable for damage
resulting from premature wear when driving with axle loads
above 12.5 t (27.6 kip).
Crane operators / crane drivers carry sole responsibility when the
crane vehicle is driven with axle loads > 12.5 t (27.6 kip).

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6.4.8 Shorter Maintenance Intervals for Axle Loads above

12.5 t (27.6 kip).

Even when observing the specified, axle−load−dependent

driving speeds, driving with axle loads > 12.5 t (27.6 kip) is only
permitted temporarily.

Driving with axle loads of more than 12.5 t (27.6 kip) is always
an exceptional condition and is only permitted for short
stretches. even if higher values are permitted by individual
national regulations.

The crane manufacturer shall not be held liable for damage

resulting from premature wear when driving with axle loads
above 12.5 t (27.6 kip).

Risk of damage as a result of premature wear!

If the crane is driven with axle loads above 12.5 t (27.6 kip),
steering, axle suspension, axles, wheel hubs, bearings,
suspension system, suspension cylinders, brakes, wheels
and tyres must be checked regularly − at least once every 3
months however − for damage and wear.
This applies especially to the setting of the steering
geometry and the brake linings!

RISK OF ACCIDENTS as a result of worn components!

When defects are discovered they must be dealt with
immediately in order to prevent safety risks, further wear
orirreparable damage to the component.

The steering geometry and other components relevant to the

safety of the crane may only be checked and, if necessary,
repaired by our customer service technicians or a
corresponding specialist workshop.

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6.5 Driving on Public Roads

(Z 160 015)

This crane vehicle has extraordinary dimensions and

weights.
Make sure that the vehicle is driven with caution and
foresight (avoiding regular acceleration and braking).

The maximum permitted speed for this vehicle in Germany is 80

km/h (50 mph).

When driving on public roads the crane vehicle must be in a

specific transport condition.
The transport condition of the mobile crane depends on the road
traffic regulations applicable in the country in which the crane is
to be operated.

In countries with EEC approval regulations, axle loads of

max. 12 t (26.4) are permitted when driving on public
highways.
In countries with different national regulations the permitted
axle loads may actually be lower than 12 t (26.4 kip).

The crane operator / driver must ensure that the axle loads
are within the permitted limits and that they are evenly
distributed and that any additional restrictions are
observed.
If the axle loads are exceeded or other regulations are not
followed, they carry sole responsibility.

The details in section “Axle loads / speeds / tyres” as well as

in the corresponding subsections must be strictly adhered
to.

In the interests of safety, the technically possible maxi-

mum axle loads should not be exceeded at the corres-
ponding speed indicated in the left−hand column.
Adapt the driving speed to the actual axle loads and the
route conditions.

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6.5.1 Driving with Axle Loads of 12 t (26.4 kip)

In accordance with the EEC directive and the German road

traffic licensing regulations, axle loads are permitted of up
to 12 t (26.4 kip). This is equivalent to an overall weight of 60
t (132.3 kip).
The vehicle is fully approved for this condition.

This transport condition is listed in the section “Defined transport

conditions” under “Driving with overall weight 60 t (132.3 kip)“.

6.5.2 Driving in the United Kingdom (UK Approval)

In the United Kingdom (UK) special approval regulations apply.

In the United Kingdom (UK) − as a result of a special national

regulation − other (higher) axle loads can occur.

Instructions on applying the national regulation “Special Type

General Order” can be found in the additional section 61 “Driving
in the UK”.

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Z 53 777

Z 53 778

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6.5.3 Checks Always to Be Done before Driving on the

Road

Before driving on the road, always:

− All transport locks must be fitted (see under “Transport
locks“).
− The main boom must be in the “Road travel state” (telescopic
sections pinned, locking / pinning unit must be locked in the
transport position (see part 1, section 12)).
− The suspension is not to be locked; It must be switched to the
4−way system and it must be on road travel level (see section
11).
− The steering system must be switched to “road travel” (see
section 9).
− A disc must be inserted in the tachograph.
− Emergency devices e.g. first aid box, warning triangle, fire
extinguisher must be easy to reach and complete.
− The housing cover of the outrigger controls on the side of the
chassis must be closed.
− (Z 53 777)
The ladders, which are loose (1c) must be attached to the
holders on the chassis and secured with the rubber fixtures.
− (Z 53 778)
The ladder, which is loose (2c) must be attached to the
holders under the driver’s cab and secured with the rubber
fixtures.
− No loose parts are permitted on the equipment.

This crane vehicle has extraordinary dimensions.

Pay attention in particular to the overhead clearance and
check the route in this respect.

Caution with the quick release coupling!

The equipment may be equipped with a quick release
coupling (between the superstructure and chassis).
In this case the height dimension is 4135 mm (13.6 ft).

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Z 200 235

2−EXPLICIT

Z 53 774

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(Z 200 235, Z 53 774)

Notes on the vehicle height for on−road driving:

A vehicle height of 4000 mm (13.12 ft) must be complied with.

The device can be equipped with additional rope carriers

(X) and / or a rope bracket (Y) at the boom head (on the
boom cases).
If such parts are attached, the vehicle height is 4120 mm
(13.51 ft). This is no condition for driving on−road!

Risk of damage!
In order not to exceed the maximum permitted height for
on−road driving of 4000 mm (13.12 ft), these components
must be removed.

If a quick coupling is attached, this results in an additio-

nal 135 mm (5.3 in) to the overall height.

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6.6 Defined Driving Conditions

Defined driving conditions are assigned in accordance with

national regulations or other appropriate requirements.
Driving conditions beyond these can be determined on a case by
case basis using the weight table (component weights) (see
under “axle loads / speeds / tyres”).

Counterweights that can be carried along

(Z 53 790)

The following counterweights can be installed on the crane

vehicle in different combinations, depending on driving mode:

Attached to the chassis:

(1a) − Base plate 3.66 t (8 060 lbs)

(1b) − Cover plate 1.99 t (4 390 lbs)
(2) − Counterweight section 7.92 t (17 455 lbs)

All counterweights that are installed on the chassis must be

attached correctly and secured (see operating instructions
part 1, section 9).

Attached to the superstructure:

(5) − Counterweight section 2.59 t (5 700 lbs)

(6) − Counterweight section 2.6 t (5 830 lbs)

All counterweights that are installed on the superstructure

must be attached correctly and pinned (see operating
instructions part 1, section 9).

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6.6.1 Driving with the Total Weight 60 t (132.3 kip)

(Approval Condition in Accordance with EEC
Directive)

60 t version 1:

(Z 53 791)

Crane with:
− Main boom
− Locking/ pinning unit in transport position (at the rear in the
main boom)
− Main boom extension 17 m(55.8 ft) at the side of the main
boom
− Hook block 250 kg (551 lbs)
(hook suspension gear on the bumper)
− Hoist 1
− Counterweight base plate 1a (3.66 t / 8060 lbs)
(set down/secured onto chassis)
− Counterweight section 6R, 6L (2.6 t / 5830 lbs)
(pinned to the superstructure on the left/right)
− Wooden box at rear (empty)
− Tyres 16.00 R 25

Crane without:
− Hoist 2
− Spare wheel

Axle loads:
− Axles 1 to 5: every 12 t (26.4 kip)

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1a

Z 53 792

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60 t version 2:

(Z 53 792)

Crane with:
− Main boom
− Locking/ pinning unit in transport position (at the rear in the
main boom)
− Hook block 250 kg (551 lbs)
(hook suspension gear on the bumper)
− Hoist 1
− Hoist 2
− counterweight base plate 1a (3.66 t / 8060 lbs) +
counterweight section 1b (1.99 t / 4390 lbs)
(attached to the chassis / secured)
− Wooden box at rear (empty)
− Tyres 16.00 R 25
− Spare wheel

Crane without:
− Main boom extension
− Counterweight on the superstructure

Axle loads:
− Axles 1 to 5: every 12 t (26.4 kip)

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60 t version 3:

(Z 53 791)

Crane with:
− Main boom
− Locking/ pinning unit in transport position (at the rear in the
main boom)
− Hook block, 550kg (1213 lbs) (on the bumper)
− Hoist 1
− Counterweight base plate 1a (3.66 t / 8060 lbs)
(set down/secured onto chassis)
− Counterweight section 6R, 6L (2.6 t / 5830 lbs)
(pinned to the superstructure on the left/right)
− Wooden box at rear (empty)
− Tyres 14.00 R 25

Crane without:
− Main boom extension
− Spare wheel
− Hoist 2

Axle loads:
− Axles 1 to 5: every 12 t (26.4 kip)

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Z 26 866

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6.6.2 Driving with an Overall Weight of 35.4 t (78 kip)

(without Main Boom, with Luffing Cylinder)
(Z 53 793)

Exceptional driving condition for reducing the axle loads to

meet respective national regulations.

Crane with:
− supports complete
− Superstructure position 180° (turned to the rear)
− Luffing cylinder
− Tyres 16.00 R 25

Crane without:
− Main boom
− Main boom extension
− Hoist 2
− Counterweights
− Spare wheel
− Hook block

Axle load distribution:

∗ Axle 1: 6.7 t (14.8 kip) ∗ Axle 4: 7.2 t (15.9 kip)

∗ Axle 2: 6.8 t (15.0 kip) ∗ Axle 5: 7.2 t (15.9 kip)
∗ Axle 3: 7.5 t (16.5 kip)

The braking system for this vehicle is designed in

accordance with EC directives and German road traffic
regulations for an axle load of 12 t (26.4 kip).
When the main boom is removed, the axle loads
arecorrespondingly lower; the crane is overbraked.
Use the brakes carefully, applying braking power in stages.
Abrupt use of the brake pedal could cause all the wheels to
lock suddenly.
Drive carefully and reduce the theoretically possible
maximum speed accordingly. It must not exceed max.
50 km/h (31 mph); the speed mustbe reduced further in case
of bad road conditions.

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To be observed when driving on the road:

− Lash the luffing cylinder to the support.
− Mark protruding luffing cylinder in accordance with road
trafficregulations.

The protruding luffing cylinder could present a danger

for the road users behind.
Only drive on public roads − in this condition − in accor-
dance with the applicable motor vehicle safety stan-
dards.

To remove and fit the main boom, see part 1 (operating

instructions of the superstructure).

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6.6.3 Driving with an Overall Weight of 74 t (163.1 kip)

(”Technical Drivability”)
”Technical drivability” is only permitted on construction
sites and on private roads.
Relevant instructions and warnings in section “Axle loads /
speeds / tyres” must be followed.
(Z 53 790)
Crane with:
− Main boom
− Locking/ pinning unit in transport position (at the rear in the
main boom)
− Main boom extension 17 m (55.8 ft) folded / locked on the
side of the main boom (see part 1, section 18).
− Hook block 3−sheave, model 63 (700 kg / 1543 lbs) at
bumper
− Hoist 1, hoist 2
− Counterweight 13.57 t (29905 lbs) on the chassis:
Weight plate 1a (3.66 t / 8060 lbs) + weight plate 1b (1.99 t
/ 4390 lbs) + weight plate 2 (7.92 t / 17455 lbs).
− Counterweight 5.19 t (11530 lbs) on the superstructure:
Weight plate 6R, 6L (2 x 1.3 t / 2 x 2915 lbs) + weight plate
5 (2.59 t / 5700 lbs).
− Wooden box, empty
− Tyres 16.00 R 25
Axle load distribution:
∗ Axle 1: 14.31 t (31.5 kip) ∗ Axle 4: 15.18 t (33.5 kip)
∗ Axle 2: 14.15 t (31.2 kip) ∗ Axle 5: 15.18 t (33.5 kip)
∗ Axle 3: 15.11 t (33.3 kip)
RISK OF ACCIDENTS due to overloading of tyres!
The maximum permitted speed must be observed for the
current axle load (see section 6 under ”Possible axle
loads / permitted speeds”). The determining factor is al-
ways the axle that is under the highest load. Failure to
observe these instructions can result in the tyres being
overloaded and bursting.

Extreme risk of accidents due to extended braking di-

stances!
Axle loads exceeding 12 t (26.4 kip) result in a signifi-
cantly longer braking distance and the risk of fading.

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C1
B
1a
1b
2

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A2
A3

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Overview of driving modes and axle loads (metric dimension

units)
(Z 53 794)
A1 Hook suspension gear 250 kg, lashed to the bumper 0.25 t
A2 Hook block, 1−sheave 550 kg, lashed to the bumper 0.55 t
A3 Hook block, 3−sheave 700 kg, lashed to the bumper 0.70 t
Main boom extension 17 m folded in transport position on the
B 1.62 t
main boom
C1 Locking / pinning unit in front position
C2 Locking / pinning unit in rear position
D Hoist 2, pinned on the superstructure 1.55 t
E Spare wheel 16.00 R 25 (on the rear) 0.35 t
Counterweight 3.6 t / 8060 lbs
1a 3.66 t
attached to the chassis
Counterweight 1.99 t / 4390 lbs
1b 1.99 t
attached to the chassis
Counterweight 7.92 t / 17455 lbs
2 7.92 t
attached to the chassis
5 Counterweight 2.59 t / 5700 lbsattached to the superstructure 2.59 t
Counterweight 1.3 t / 2915 lbs
6R 1.3 t
attached to the superstructure on the right
Counterweight 1.3 t / 2915 lbs
6L 1.3 t
attached to the superstructure on the left
H Front axle loads 1 and 2 (in t)
I Rear axle loads 3 to 5 (in t)
J Total weight of the crane vehicle (in t)

Axle load table with various combinations:

A1 A2 A3 B C1 C2 D E 1a 1b 2 5 6R 6L H I J
1 x − − x − x − − x − − − x x 12.0 12.0 60.0
2 x − − − − x x x x x − − − − 12.0 12.0 60.0
3 − x − − − x − − x − − − x x 12.0 12.0 60.0
4 − − x x − x x − x x x x x x 14.3 15.2 74.0

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B
1a
1b
2

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Overview of driving modes and axle loads (US dimension

units)
(Z 53 794)

A1 Hook suspension gear 250 kg (551 lbs) lashed to the bumper 0.55 kip
Hook block, 1−sheave 550 kg (1213 lbs)
A2 1.21 kip
lashed to the bumper
Hook block, 3−sheave 700 kg (1543 lbs)
A3 1.54 kip
lashed to the bumper
Main boom extension 17 m (55.8 ft)
B 3.56 kip
folded in transport position on the main boom
C1 Locking / pinning unit in front position
C2 Locking / pinning unit in rear position
D Hoist 2, pinned on the superstructure 3.41 kip
E Spare wheel 16.00 R 25 (on the rear) 0.73 kip
Counterweight 3.6 t (8060 lbs)
1a 8.06 kip
attached to the chassis
Counterweight 1.99 t (4390 lbs)
1b 4.39 kip
attached to the chassis
Counterweight 7.92 t (17455 lbs)
2 17.46 kip
attached to the chassis
Counterweight 2.59 t (5700 lbs)
5 5.70 kip
attached to the superstructure
Counterweight 1.3 t / 2915 lbs
6R 2.92 kip
attached to the superstructure on the right
Counterweight 1.3 t / 2915 lbs
6L 2.92 kip
attached to the superstructure on the left
H Front axle loads 1 and 2 (in kip)
I Rear axle loads 3 to 5 (in kip)
J Total weight of the crane vehicle (in kip)

Axle load table with various combinations:

A1 A2 A3 B C1 C2 D E 1a 1b 2 5 6R 6L H I J
1 x − − x − x − − x − − − x x 26.5 26.5 132
2 x − − − − x x x x x − − − − 26.5 26.5 132
3 − x − − − x − − x − − − x x 26.5 26.5 132
4 − − x x − x x − x x x x x x 31.5 33.5 163

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B13

58 50

Z 200 217

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6.7 Driving Downhill

− Reduce the speed and select a lower gear.

− Observe the revolution counter (50, Z 200 217) to prevent the
engine speed moving into the danger zone.
− Use non−wearing sustained−action brakes (exhaust brake,
hydraulic retarder).
− Only use the service brake briefly as an auxiliary brake.

The gear range in which the crane can be maintained at a

constant speed must be selected before the crane is
driven downhill.

When transmission is in automatic operation:

When the engine−independent sustained−action brake is
switched on, the transmission automatically adjusts the gears to
reach an optimal braking effect (engine speed faster than 1100
min−1).

The effect of the exhaust brake and the hydraulic retarder is

dependent on the engine speed.
The higher the rpm, the greater the braking effect.

When the hydraulic retarder is used, heat is created in the

transmission.
The transmission oil temperature is monitored indirectly (via
the coolant temperature of the engine) with the help of the
preheating indicator (B13) in the driver information display.

If the oil temperature rises to unauthorised values (over 1505 C

(3025 F) − which leads to a coolant temperature which is too high
− the retarder performance must be reduced until the coolant
temperature has reached a steady state of less than 955 C
(2035 F) .
If the retarder output is not regulated by the driver, the system
automatically reduces the braking effect until the permissible
temperature has been reached (again).

The service brake may only be used to brake the crane

until the speed is read at which the transmission shifts
down to the next gear.
The service brake must not be used for sustained pe-
riods under any circumstances. Risk of fading!

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94

A9
Z 200 218

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6.8 Driving over Hill Summits

(Z 200 218)

When driving over hill summits, it must be ensured that all axles
remain in contact with the ground.
The crane operator bears sole responsibility for any damage to
the crane chassis caused by ”exceeding the maximum
suspension travel” or ”block position of the suspension” and
exceeding the maximum axle loads when an axle lifts off the
ground.

When driving over hill summits, it is prohibited:

− to lock the suspension
− to exceed an axle load of 14 t (30.8 kip)
as components MAY BREAK otherwise.

If an axle should however lift off the ground, proceed as follows:

1. Stop the crane in a straight position and activate the

longitudinal differential lock by actuating switch (94) while
doing so; the indicator light (A9) lights up.

2. Driving over a hill summit at walking speed (max. 5 km/h

(3 mph).

Whilst driving over the summit:

− Avoid turning the steering
− Observe the suspension pressure continually.
If the pressure in one of the three suspension circuits
rises to 260 bar (3773 psi), then AXLES MAY BREAK !
If a pressure of 300 bar (4354 psi) is reached, then the hill
top must not be driven over.
Reverse carefully.

3. After driving over the hill summit, stop the crane immediately
and switch off the longitudinal differential lock again. Actuate
switch (94) while doing so; indicator light (A9) goes out.

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6.9 Checking the Operation Functions During the

Journey

All indicator light/display instruments are located in the driver’s

cab (see section 4).
While driving, the driver must constantly observe the display
instruments and monitoring elements.

6.9.1 Monitoring Elements in the Instrument Controls

Item Monitoring element Display Comments (measure)

Pressure gauge Pressure falls abruptly in one suspension circuit during
5
Suspension circuit, front right travel: A hazardous fault has occurred.
Pressure gauge
6/7
Suspension circuit, rear right
Pressure gauge Stop the crane, rectify the fault.
8
Suspension circuit, front left
Pressure gauge
9/10
Suspension circuit, rear left
Display of a hazardous fault
35 STOP lamp
STOP−observe order
Hydr. retarder / exhaust brake activated
38 Lamp − retarder
Pay attention to coolant temperature
Rear fog lamp switched on
40 Rear fog lamp
Only use rear fog lamp as intended
Engine speed display
50 Revolution counter
Observe in driving mode
Engine speed monitoring
50.1 LED − Excessive engine speed Lights up when engine speed excessive; at the same
time, a warning buzzer sounds. Avoid excessive engine
speed, otherwise you will cause damage to the engine.
Coolant temperature too high:
Indicator light (B13) on the display (43) is at 104° C
58 Display − coolant temperature (219° F). An additional buzzer sounds at 110° C
(230° F).
Switch off the engine immediately and rectify the fault

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B1 B11 B21 CHECK B31

B2 B12 B22 B32

B3 B13 B23 B33

B4 B14 B24 B34

B5 B15 B25

B6 B16 B26

B7 B17 B27

B8 B18 B28

B9 B19 B29

B10 B20 B30

Z 200 158

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6.9.2 Indicator Lights on the Display (43)

“Driver Information System”
(Z 200 158)

Item Indicator light Display Comments (measure)

Electric−hydraulic rear−axle Electric−hydraulic rear−axle steering fault
B2
steering Stop vehicle, read off fault code, rectify fault.
Supply pressure has dropped below 5.5 bar (80 psi),
the correct functioning of the brakes is no longer ensu-
B3 Braking circuit 1 red.
B4 Braking circuit 2
Top up the supply tank with the engine running and the
vehicle at a standstill (before driving the crane).
Clutch temperature too high
B5 Clutch overload
Change operation condition(no dragging clutch)
Fault in drive gearbox
B6 Malfunction transmission
Stop vehicle, read off fault code, rectify fault.
B8 Steering circuit 1 Steering circuit 1 no through−flow
B9 Steering circuit 2 Steering circuit 2 no through−flow
B10 Steering circuit 3 (emergency Steering circuit 3 (emergency steering pump) no flow
steering pump) see section 9 ”Steering”
If a fault is indicated during driving, stop the crane im-
mediately; Rectify fault.
Coolant level too low
B11 Engine coolant level
Switch off engine and rectify fault.
Engine oil pressure too low
B12 Engine oil pressure
Switch off the engine immediately and rectify the fault
Coolant temperature in the engine is too high (above
104° C / 219° F). An additional buzzer sounds at 110° C
B13 Engine coolant temperature (230° F).
Switch off the engine immediately and rectify the fault
Engine oil level too low
B14 Engine oil level
Switch off the engine immediately and rectify the fault
Fault display engine
B15 Engine malfunction
Read off fault codes; Rectify fault.
Charging current too low
B16 Charging current
Switch off engine, rectify fault.
Air filter clogged
B18 Air filter
Service the air filter
Fuel supply in reserve range
B19 Fuel supply
Fill up with fuel

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B1 B11 B21 CHECK B31

B2 B12 B22 B32

B3 B13 B23 B33

B4 B14 B24 B34

B5 B15 B25

B6 B16 B26

B7 B17 B27

B8 B18 B28

B9 B19 B29

B10 B20 B30

Z 200 158

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Follower axle steering circuit 1no flow

B20 Follower axle steering circuit 1 see section 9 ”Steering”
If a fault is indicated during driving, stop the vehicle im-
mediately; rectify fault.
Follower axle steering circuit 3 (emergency steering
pump)no flow
Follower axle steering circuit 3
B21 see section 9 ”Steering”
(emergency steering pump)
If a fault is indicated during driving, stop the vehicle im-
mediately; rectify fault.
Fault in the data bus system,
B22 “SPS” = data bus
Stop the vehicle, rectify the fault.
Lift exceeded at hydraulic cylinder (if in addition to the
indicator light (B24): single acoustic warning signal and
indicator light “Caution” (36))
B24 Malfunction at dolly critical inclination of the hydraulic cylinder (if in addition
to the indicator light (B24): Repeated acoustic warning
signal and indicator light “STOP” (35))
Stop the vehicle, rectify the fault.
Display overload
B25 Display
page down to next mask
Engine brake / hydraulic retar- Fault in exhaust brake / hydraulic retarder
B28
der Reduce speed, if necessary stop, rectify fault
ABS, vehicle, axles 1, 2, 3, 4 ABS malfunction
B29
and 5 while driving: Adapt driving style, rectify fault
ABS, trailer / follower axle / ad- ABS malfunction
B30
ditional axle while driving: Adapt driving style, rectify fault
Malfunction check valves
Electric−hydraulic rear−axle
B31 If a fault is displayed during the journey, stop the vehi-
steering
cle immediately, rectify fault
Oil supply steering circuits ad- Level in hydraulic oil reservoir too low
B32
ditional axle Stop vehicle immediately, rectify fault
Engine fault
B33 Warning buzzer engine
Stop vehicle immediately, rectify fault
no CAN bus connection to the steering computer
B34 CAN bus steering computer
Stop vehicle immediately, rectify fault

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6.9.3 On the Display (75)

“Transmission Information”

Item Message Display Comments (measure)

Self−check of the system
“CH” = self−check
Appears when “Ignition on”
Air pressure in the transmission system is too low (be-
low 6.2 bar (90 psi)); clutch does not open when stop-
ped − Motor is “choked”.
“AL” = Airless Transmission can stay in neutral = no auxiliary drive, no
engine braking
Stop the vehicle, rectify the fault.
“N” = Neutral Transmission status, in gear
“R” = Reverse
“1−16” = gears Further info, see Section 7
Malfunction of accelerator pedal
“FP” = accelerator pedal Put accelerator pedal in idle position; if the display does
not go out, it is not possible to drive further
Clutch is overloaded
“CL” = Clutch Change operation condition − spare the clutch; select a
75
lower gear
Clutch is worn out
“CW” = Clutch wear
Go to a specialist workshop
Communication error in the electronic gear system
“EE” = Electronic Error
Rectify fault.
Transmission temperature too high
“HT” = Gear temperature
Change operation condition
System malfunction, indicator light (B6) together with
“Spanner“ symbol “caution” (36)
Limited driving mode, go to specialist workshop
Serious system malfunction, indicator light (B6) toge-
ther with “STOP” (35)
“Spanner“ symbol
+ “STOP” Automatic driving mode deactivated, manual driving
mode possible, not permitted to continue driving, go to
specialist workshop

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6.10 Driving on the Construction Site

6.10.1 Driving in the Transport Condition

Notes on ground conditions:

The ground conditions must be suitable for the individual axle

loads as well as the overall weight.
The route must be even and the ground must be able to support
the load.

When driving with the steering program “Construction site

operation”, deviating regulations apply (see section 9).

The differential locks may only be switched on for a brief period

of time, in order to bypass obstacles when driving straight
ahead.
Driving speeds of more than 5 km/h (3 mph) overload tyres and
driving unit.
Following the obstacle the differential locks must be switched off
again immediately.

The crane must be stationary when switching the differential

locks on and off.

The hydraulic suspension of the crane chassis may not be

blocked and it must be set to level (see section 11).

When driving over hill summits or ramps, the same rules

apply as for ”driving over hill summits” on the road.
The instructions in that section must be followed.

When driving on roads which are not quite even, you can switch
to the 4−way system to enable smoother driving (for relevant
instructions, see section 11).

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6.11 Driving the Crane with the Equipment Erected

“Driving in Erect Mode” (with main boom / equipment
erected)

The crane can be equipped with another axle (trailing axle) in

addition to the normal 5−axle−chassis (basic unit).
It is connected (on the rear of the vehicle) to the basic unit using
a hydraulic pinning system. This increases the number of axles
from 5 to 6.
The crane can be ”driven in erect mode” in both versions.

There are different “driving tables” for both versions.

In order to avoid confusion, they are listed in separate sections.

The ”driving tables” for the basic unit (5−axle−chassis) are

in this section (6, “Driving”).
If you driving with a fitted trailing axle (6−axle−chassis), the
”driving tables” are in a separate additional section (62).

The following “Instructions on driving in erect mode” are valid for

every chassis version.

6.11.1 Instructions on ”Driving in Erect Mode”

“Driving in Erect Mode” always means: driving without

load on the hook!
Driving with load is prohibited!

The overall stability of the system during the procedure

“Driving while rigged” is determined by the tyres.
The tyres will be very deformed under the heavy load.
This leads to the spring movements in the flanks to sway
the rigged crane. This means there is an increased risk
of overturning!
For this reason, drive very carefully.

“Driving in the configured condition” with steering program

“construction site mode” (switch (92) actuated) is
PROHIBITED !
Driving in the configured condition is only permitted in the
4−circuit system (for instructions, see section 11).

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Z 39 851

1
90

Z 53 025 Z 52 106

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Notes on ground conditions:

The ground conditions must be suitable for the individual axle
loads as well as the overall weight.
The ground must be even and free of dips and rises, it must also
have sufficient load−bearing capacity.
“Driving in the configured condition” with steering program
“construction site mode” (switch (92) actuated) is
PROHIBITED !
Driving in the configured condition is only permitted in the
4−circuit system (for instructions, see section 11).
When driving in the erect mode:
− The gradient must not exceed the following values:
− 2 % in the forward direction
− 1 % laterally (without additional equipment)
− 0.5 % laterally (with additional equipment)
− Extend the outrigger struts and hold the outrigger feet just
above the ground.
There is a danger of overturning if the outrigger struts are not
extended!
Make sure that the outrigger struts are correctly pinned and
locked!
− The suspension system of the crane chassis must be locked
(see section 11).
− Driving speed is not to exceed walking pace.
Distributor gear: “Off−road gear” level.
Drive gearbox: 1. gear, “Manual” operating mode.
Clutch: “Starting mode”; (only for the last cm possibly
“Manoeuvring mode” with switch 90). (Z 52 106)

RISK OF ACCIDENTS!
When the warning message ’CL’ appears in the transmis-
sion display, stop immediately and let the system cool
down.
If you do not stop, the following abrupt closing of the
clutch (see section 7 ’Clutch protection’) causes the rig-
ged crane to make jerky movements.
The crane could tip over.

− Main boom to the rear − apply mechanical superstructure

locking device. Locking bolt (1) must be inserted in locking
strip (2). Make sure that this is the case (Z 39 851).
For machines with dolly equipment (optional) the locking pin (1)
can only insert in locking strip (2) when the release lock (plug) (3)
has previously been removed. (Z 53 025)

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5 6 7

8 9 10
Z 200 233

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− The hook block must be secured on the chassis e.g. on the

manoeuvring / trailer coupling, or also on the outriggers
(telescoped out) to prevent swinging movements (or it must
be raised).
− Apply the slew gear brake.

For devices with dolly equipment (option), the slewing gear brake
should not be locked open (see Driving with the dolly).

− Caution with side winds, above all if they are acting in the
same direction as a transverse gradient.
− Constantly monitor the suspension pressure on pressure
gauges (5) to (10) in the driver’s cab. (Z 200 233)

If the pressure in one of the suspension circuits rises to 300

bar (4354 psi), stop the crane immediately and extend the
supporting cylinders, until the wheels are been relieved.
Level the crane by resetting the hydraulic suspension and/or
correcting theboom position.
If the crane is driven further it may OVERTURN or the AXLES
MAY BREAK !

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The following tables concerning superstructure position, boom

angles and lengths and axle loads correspond to the following
configuration:

Basic unit with:

− Counterweight (incl. hoist 2) in accordance with
corresponding table sheet.
− Calculated hook block in accordance with the corresponding
table sheet.
− Corresponding equipment (e.g. main boom extension).

Driving the crane with other rigging configurations other

than those specified in the following table sheets (driving
tables) is PROHIBITED!

The driving tables are available using metric or British /

American dimension units in the section. When using the
tables, make sure to use the correct units of measurement.

When changing the calculated hook block, slight adjustment of

the main boom (or of the equipment) can achieve a more
balanced axle load again.

The suspension pressure when lowering the crane from the

outriggers onto the wheels can be monitored via the pressure
gauges. When this is done, 260 bar (3773 psi) must not be
exceeded.

Axle load Suspension pressure

12 t (26.4 kip) 105 bar (1524 psi)
15 t (33 kip) 140 bar (2032 psi)
20 t (44.1 kip) 190 bar (2903 psi)
25 t (55.1 kip) 240 bar (3483 psi)
27 t (59.5 kip) 260 bar (3773 psi)

In general balanced loads, as specified in the following table, are

to be aimed for.

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6.11.2 Driving Tables with Metric Dimension Units

6.11.2.1 Driving with the Main Boom

Counterweight 0 t − 39 t

(Metric Dimensions)
(Z 200 075)

Axle load table: Axle loads in relation to boom position

andconfiguration.
Counter- Super- A B RA Axle load in (t)
weight structure (m) (°) (m) Axle
(t) to (*) 1+2 3, 4, 5
0 80 0.5 10.8 10.8
6.3 75 1.6 12.1 12.0
8.3 73 2.0 12.5 12.4
10.8 71 2.4 13.0 12.9
13.5 68 3.0 13.5 13.5
18.8 64 3.7 14.6 14.5
rear 12.5
21.4 61 4.3 15.0 15.1
23.2 60 4.5 15.5 15.4
25.8 57 5.0 15.9 16.0
28.4 54 5.5 16.4 16.5
31 52 5.8 17.1 17.0
39 43 7.2 18.6 18.6

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 3−sheave, type 63 (700 kg)

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05
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C

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Z 200 079

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6.11.2.2 Driving with the Main Boom Extension 9.1 m

Counterweight 6.3 t − 39 t
(Metric Dimensions)
(Z 200 079)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (t)
weight structure (m) (°) (m) (°) (m) Axle
(t) to (*) 1+2 3, 4, 5
77 0 3.2 12.1 12.3
6.3 79 20 5.5 12.3 12.2
80 40 7.6 12.2 12.3
76 0 3.6 12.6 12.7
8.3 78 20 5.8 12.7 12.6
79 40 7.9 12.7 12.6
74 0 4.3 13.1 13.2
10.8 76 20 6.5 13.2 13.1
77 40 8.5 13.2 13.2
72 0 5.0 13.6 13.8
13.5 74 20 7.2 13.7 13.7
75 40 9.1 13.7 13.7
rear 12.5 9.1
69 0 6.1 14.8 14.7
18.8 70 20 8.5 14.7 14.8
71 40 10.3 14.7 14.8
67 0 6.8 15.3 15.3
21.4 68 20 9.1 15.2 15.3
69 40 10.8 15.2 15.3
65 0 7.4 15.5 15.7
23.2 67 20 9.4 15.7 15.6
68 40 11.1 15.7 15.6
64 0 7.8 16.2 16.1
25.8 65 20 10.1 16.2 16.2
66 40 11.6 16.2 16.2

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(Z 200 079)

Continuation of the table:

62 0 8.4 16.8 16.6
28.4 63 20 10.7 16.7 16.7
64 40 12.1 16.7 16.7
59 0 9.4 17.1 17.3
31 rear 12.5 61 9.1 20 11.2 17.3 17.2
62 40 12.6 17.3 17.2
53 0 11.2 18.8 18.8
39 54 20 13.1 18.7 18.8
55 40 14.2 18.7 18.8

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg)

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Z 55 658

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6.11.2.3 Driving with the Main Boom Extension 17 m

Counterweight 6.3 t − 39 t

(Metric Dimensions)
(Z 55 658)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (t)
weight structure (m) (°) (m) (°) (m) Axle
(t) to (*) 1+2 3, 4, 5
79 0 3.5 12.4 12.3
6.3 81 20 8.1 12.2 12.4
82 40 12.4 11.9 12.6
78 0 4.0 12.9 12.7
8.3 80 20 8.6 12.7 12.8
82 40 12.4 12.6 12.8
76 0 5.0 13.3 13.2
10.8 79 20 9.1 13.3 13.2
81 40 12.8 13.3 13.2
74 0 6.0 13.7 13.8
13.5 77 20 10.0 13.8 13.8
79 40 13.6 13.8 13.8
rear 12.5 17
71 0 7.4 14.8 14.8
18.8 74 20 11.4 14.9 14.8
76 40 14.8 14.9 14.8
69 0 8.4 15.3 15.4
21.4 72 20 12.2 15.4 15.4
74 40 15.6 15.3 15.4
68 0 8.9 15.7 15.8
23.2 71 20 12.7 15.8 15.7
73 40 16.0 15.7 15.7
67 0 9.3 16.4 16.2
25.8 69 20 13.5 16.2 16.3
71 40 16.7 16.2 16.3

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(Z 55 658)

Continuation of the table:

65 0 10.3 16.8 16.7
28.4 67 20 14.4 16.7 16.8
69 40 17.4 16.7 16.8
63 0 11.2 17.3 17.3
31 rear 12.5 66 17 20 14.8 17.4 17.3
68 40 17.7 17.4 17.3
58 0 13.4 18.9 18.8
39 60 20 17.2 18.8 18.9
62 40 19.7 18.9 18.9

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg)

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Z 55 659

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6.11.2.4 Driving with the Main Boom Extension 25 m

Counterweight 6.3 t − 39 t

(Metric Dimensions)
(Z 55 659)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (t)
weight structure (m) (°) (m) (°) (m) Axle
(t) to (*) 1+2 3, 4, 5
81 0 3.7 12.6 12.4
6.3 82 20 8.7 12.2 12.7
82 40 13.5 11.7 13.0
80 0 4.4 13.0 12.8
8.3 82 20 8.7 12.9 12.9
82 40 13.5 12.4 13.2
78 0 5.6 13.3 13.5
10.8 81 20 9.4 13.5 13.3
82 40 13.5 13.3 13.5
77 0 6.3 13.9 14.0
13.5 79 20 10.6 13.9 14.0
81 40 14.1 13.9 14.0
rear 12.5 25
74 0 8.2 14.9 15.1
18.8 77 20 11.8 15.1 14.9
78 40 15.7 14.9 15.1
73 0 8.8 15.5 15.5
21.4 75 20 13.0 15.4 15.6
77 40 16.2 15.5 15.5
72 0 9.4 15.8 15.9
23.2 74 20 13.6 15.8 15.9
76 40 16.7 15.8 15.9
71 0 10.0 16.4 16.4
25.8 73 20 14.1 16.4 16.4
75 40 17.3 16.5 16.4

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(Z 55 659)

Continuation of the table:

69 0 11.3 16.8 17.0
28.4 72 20 14.7 17.0 16.9
73 40 18.3 16.8 17.0
68 0 11.9 17.5 17.5
31 rear 12.5 70 25 20 15.9 17.4 17.5
72 40 18.8 17.5 17.5
64 0 14.2 19.1 19.0
39 66 20 18.1 19.0 19.0
68 40 20.7 19.1 19.0

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg)

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Z 55 660

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6.11.2.5 Driving with the Main Boom Extension 33 m

Counterweight 6.3 t − 39 t

(Metric Dimensions)
(Z 55 660)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (t)
weight structure (m) (°) (m) (°) (m) Axle
(t) to (*) 1+2 3, 4, 5
82 0 4.2 12.6 12.6
6.3 82 20 9.9 11.9 13.1
82 40 14.6 11.4 13.4
81 0 5.0 12.9 13.1
8.3 82 20 9.9 12.6 13.3
82 40 14.6 12.0 13.7
80 0 5.8 13.4 13.6
10.8 82 20 9.9 13.5 13.6
82 40 14.6 12.9 13.9
79 0 6.5 14.0 14.1
13.5 81 20 10.6 14.1 14.1
82 40 14.6 13.9 14.2
rear 12.5 33
77 0 8.1 15.1 15.1
18.8 79 20 12.1 15.2 15.1
80 40 16.0 15.0 15.2
76 0 8.9 15.7 15.6
21.4 78 20 12.8 15.7 15.6
79 40 16.7 15.6 15.7
75 0 9.6 16.0 16.0
23.2 77 20 13.6 16.0 16.0
78 40 17.4 15.8 16.1
74 0 10.4 16.5 16.5
25.8 76 20 14.3 16.6 16.5
77 40 18.0 16.4 16.6

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(Z 55 660)

Continuation of the table:

73 0 11.1 17.1 17.0
28.4 75 20 15.0 17.1 17.0
76 40 18.7 17.0 17.1
72 0 11.9 17.7 17.5
31 rear 12.5 74 33 20 15.8 17.7 17.5
75 40 19.3 17.6 17.6
68 0 14.9 19.1 19.2
39 70 20 18.6 19.1 19.2
72 40 21.3 19.3 19.1

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg)

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Z 200 075

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6.11.3 Driving Tableswith British / American Dimension

Units

6.11.3.1 Driving with Main Boom

Counterweight 0 − 86 kip

(US Dimensions)
(Z 200 075)

Axle load table: Axle loads in relation to boom position

andconfiguration.
Counter- Super- A B RA Axle load (kip)
weight structure (ft) (°) (ft) Axle
(lbs) to (*) 1+2 3, 4, 5
0 80 1.6 23.8 23.8
13.9 75 5.2 26.7 26.5
18.3 73 6.6 27.6 27.3
23.8 71 7.9 28.7 28.4
29.8 68 9.8 29.8 29.8
41.4 64 12.1 32.2 32.0
rear 41.0
47.2 61 14.1 33.1 33.3
51.1 60 14.8 34.2 34.0
56.9 57 16.4 35.1 35.3
62.6 54 18.0 36.2 36.4
68.3 52 19.0 37.7 37.5
86.0 43 23.6 41.0 41.0

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 3−sheave, type 63 (700 kg / 1.54 kip)

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C

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Z 200 079

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6.11.3.2 Driving with the Main Boom Extension 29.9 ft

Counterweight 13.9 kip − 86 kip

(US Dimensions)
(Z 200 079)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (kip)
weight structure (ft) (°) (ft) (°) (ft) Axle
(kip) to (*) 1+2 3, 4, 5
77 0 10.5 26.7 27.1
13.9 79 20 18.0 27.1 26.9
80 40 25.9 26.9 27.1
76 0 11.8 27.8 28.0
18.3 78 20 19.0 28.0 27.8
79 40 25.9 28.0 27.8
74 0 14.1 28.9 29.1
23.8 76 20 21.3 29.1 28.9
77 40 27.9 29.1 29.1
72 0 16.4 30.0 30.4
29.8 74 20 23.6 30.2 30.2
75 40 29.9 30.2 30.2
rear 41.0 29.9
69 0 20.0 32.6 32.4
41.4 70 20 27.9 32.4 32.6
71 40 33.8 32.4 32.6
67 0 22.3 33.7 33.7
47.2 68 20 29.9 33.5 33.7
69 40 35.4 33.5 33.7
65 0 24.3 34.2 34.6
51.1 67 20 30.8 34.6 34.4
68 40 36.4 34.6 34.4
64 0 25.6 35.7 35.5
56.9 65 20 33.1 35.7 35.7
66 40 38.1 35.7 35.7

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(Z 200 079)

Continuation of the table:

62 0 27.6 37.0 36.6
62.6 63 20 35.1 36.8 36.8
64 40 39.7 36.8 36.8
59 0 30.8 37.7 38.1
68.3 rear 41.0 61 29.9 20 36.7 38.1 37.9
62 40 41.3 38.1 37.9
53 0 36.7 41.4 41.4
86.0 54 20 43.0 41.2 41.4
55 40 46.6 41.2 41.4

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg / 1.21 kip)

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Z 55 658

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6.11.3.3 Driving with the Main Boom Extension 55.8 ft

Counterweight 13.9 kip − 86 kip

(US Dimensions)
(Z 55 658)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (kip)
weight structure (ft) (°) (ft) (°) (ft) Axle
(kip) to (*) 1+2 3, 4, 5
79 0 11.5 27.3 27.1
13.9 81 20 26.6 26.9 27.3
82 40 40.7 26.2 27.8
78 0 13.1 28.4 28.0
18.3 80 20 28.2 28.0 28.2
82 40 40.7 27.8 28.2
76 0 16.4 29.3 29.1
23.8 79 20 29.9 29.3 29.1
81 40 42.0 29.3 29.1
74 0 19.7 30.2 30.4
29.8 77 20 32.8 30.4 30.4
79 40 44.6 30.4 30.4
rear 41.0 55.8
71 0 24.3 32.6 32.6
41.4 74 20 37.4 32.8 32.6
76 40 48.6 32.8 32.6
69 0 27.6 33.7 34.0
47.2 72 20 40.0 34.0 34.0
74 40 51.2 33.7 34.0
68 0 29.2 34.6 34.8
51.1 71 20 41.7 34.8 34.6
73 40 52.5 34.6 34.6
67 0 30.5 36.2 35.7
56.9 69 20 44.3 35.7 35.9
71 40 54.8 35.7 35.9

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(Z 55 658)

Continuation of the table:

65 0 33.8 37.0 36.8
62.6 67 20 47.2 36.8 37.0
69 40 57.1 36.8 37.0
63 0 36.7 38.1 38.1
68.3 rear 41.0 66 55.8 20 48.6 38.4 38.1
68 40 58.1 38.4 38.1
58 0 44.0 41.7 41.4
86.0 60 20 56.4 41.4 41.7
62 40 64.6 41.7 41.7

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg / 1.21 kip)

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Z 55 659

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6.11.3.4 Driving with the Main Boom Extension 82.0 ft

Counterweight 13.9 kip − 86 kip

(US Dimensions)
(Z 55 659)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (kip)
weight structure (ft) (°) (ft) (°) (ft) Axle
(kip) to (*) 1+2 3, 4, 5
81 0 12.1 27.8 27.3
13.9 82 20 28.5 26.9 28.0
82 40 44.3 25.8 28.7
80 0 14.4 28.7 28.2
18.3 82 20 28.5 28.4 28.4
82 40 44.3 27.3 29.1
78 0 18.4 29.3 29.8
23.8 81 20 30.8 29.8 29.3
82 40 44.3 29.3 29.8
77 0 20.7 30.6 30.9
29.8 79 20 34.8 30.6 30.9
81 40 46.3 30.6 30.9
rear 41.0 82.0
74 0 26.9 32.8 33.3
41.4 77 20 38.7 33.3 32.8
78 40 51.5 32.8 33.3
73 0 28.9 34.2 34.2
47.2 75 20 42.7 34.0 34.4
77 40 53.1 34.2 34.2
72 0 30.8 34.8 35.1
51.1 74 20 44.6 34.8 35.1
76 40 54.8 34.8 35.1
71 0 32.8 36.2 36.2
56.9 73 20 46.3 36.2 36.2
75 40 56.8 36.4 36.2

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Continuation of the table:

69 0 37.1 37.0 37.5
62.6 72 20 48.2 37.5 37.3
73 40 60.0 37.0 37.5
68 0 39.0 38.6 38.6
68.3 rear 12.5 70 25 20 52.2 38.4 38.6
72 40 61.7 38.6 38.6
64 0 46.6 42.1 41.9
86.0 66 20 59.4 41.9 41.9
68 40 67.9 42.1 41.9

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg / 1.21 kip)

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Z 55 660

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6.11.3.5 Driving with the Main Boom Extension 108.3 ft

Counterweight 13.9 kip − 86 kip

(US Dimensions)
(Z 55 660)
Axle load table: Axle loads in relation to boom position
andconfiguration.
Counter- Super- A B C D RA Axle load (kip)
weight structure (ft) (°) (ft) (°) (ft) Axle
(kip) to (*) 1+2 3, 4, 5
82 0 13.8 27.8 27.8
13.9 82 20 32.5 26.2 28.9
82 40 47.9 25.1 29.5
81 0 16.4 28.4 28.9
18.3 82 20 32.5 27.8 29.3
82 40 47.9 26.5 30.2
80 0 19.0 29.5 30.0
23.8 82 20 32.5 29.8 30.0
82 40 47.9 28.4 30.6
79 0 21.3 30.9 31.1
29.8 81 20 34.8 31.1 31.1
82 40 47.9 30.6 31.3
rear 41.0 108.3
77 0 26.6 33.3 33.3
41.4 79 20 39.7 33.5 33.3
80 40 52.5 33.1 33.5
76 0 29.2 34.6 34.4
47.2 78 20 42.0 34.6 34.4
79 40 54.8 34.4 34.6
75 0 31.5 35.3 35.3
51.1 77 20 44.6 35.3 35.3
78 40 57.1 34.8 35.5
74 0 34.1 36.4 36.4
56.9 76 20 46.9 36.6 36.4
77 40 59.1 36.2 36.6

140−2060−103b 127/179
6

128/179 140−2060−103b
 Driving the Crane 6

(Z 55 660)

Continuation of the table:

73 0 36.4 37.7 37.5
62.6 75 20 49.2 37.7 37.5
76 40 61.4 37.5 37.7
72 0 39.0 39.0 38.6
68.3 rear 41.0 74 108.3 20 51.8 39.0 38.6
75 40 63.3 38.8 38.8
68 0 48.9 42.1 42.3
86.0 70 20 61.0 42.1 42.3
72 40 69.9 42.5 42.1

* Superstructure to: rear − Main boom to the rear

The following hook block is included in the calculation:

− 1−sheave, type 32 (550 kg / 1.21 kip)

140−2060−103b 129/179
6

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 Driving the Crane 6

6.11.4 Driving the Crane with a Load

Driving the crane while it is carrying a load is strictly pro-

hibited!

140−2060−103b 131/179
6

Z 200 226

Z 53 775

132/179 140−2060−103b
 Driving the Crane 6

6.12 Driving with Dolly

(Z 200 226, Z 53 775)

6.12.1 Important Instructions for “Dolly Operation”

“Dolly operation” means: For transporting, the boom is to the rear
(superstructure position 180°) set down on a trailer (Dolly).
There are very different “Dolly” designs and different types of
support devices.

An example of a possible construction is illustrated (not binding).

− Dolly version with hydraulic system
− Dolly version without hydraulic system

This does not necessarily represent the type of design on your

crane.

Risk of tipping, risk of skidding!

The handling of the vehicle can be seriously impaired
depending on the type of dolly used.
The reduced axle loads represent an additional negative
effect. The instructions in the section “Driving with reduced
axle loads” must be observed.

Drive with particular care when a dolly is fitted. In parti-

cular, extreme caution is required when driving through
curves (risk of swerving out, drifting sideways, displace-
ment of centre of gravity).
During driving observe the hydraulic oil pressures in the
suspension circuits. If the hydraulic pressures of the rear
axles are considerably increased on a level road surface,
the luffing cylinder must be completely retracted again.
Otherwise there is the danger that the dolly will no longer
have sufficient contact with the ground.

140−2060−103b 133/179
6

Z 53 776

11
12
13
14

15 16

Z 53 771

134/179 140−2060−103b
 Driving the Crane 6

6.12.2 Dolly Equipment for the Towing Vehicle (Optional)

6.12.2.1 Dolly Version without Hydraulic System

See notes at ”Dolly coupling / supply connections” (optional).

6.12.2.2 Dolly Version with Hydraulic System

(Z 53 771, Z 53 776)

If the dolly has a hydraulic cylinder (A), then the following

additional equipment is at the rear of the vehicle:

11 Pressure gauge for displaying the pressure in the hydraulic

system of the dolly

12 Shutoff valve between the hydraulic system of the dolly and

pressure gauge

13 Hydraulic connection

14 Shutoff valve between the hydraulic systems of the towing

vehicle and the dolly

15 Electric connection (twist union 12−pin) for supplying

thetrailer

16 Electric connection (twist union 12−pin) for filling

thehydraulic system (trailer)),actuation by remote control

140−2060−103b 135/179
6

H1

Z 53 026

136/179 140−2060−103b
 Driving the Crane 6

6.12.3 Measures for “Dolly Operation”

6.12.3.1 Measures before Driving with the Dolly

“Float position” of the superstructure

To enable the dolly system to follow the vehicle movement during

driving operation (curves / ground undulations), the
superstructure must be set to the so−called ”float position” for
”Dolly operation”.

The “float position” must be set before commencing driving and

comprises the following measures:
− Set the luffing gear.
− Open the slew gear brake and lock in this position.
− Release the superstructure locking device and safeguard the
pins.
The sequence of the steps outlined below must be followed.

Set the luffing gear:

(Z 53 026)

Procedure for “setting the luffing gear”:

1. Put the crane on outriggers (outrigger span 8.23 m x 7.5 m
(27 ft x 24.6 ft))
2. Position the dolly behind the crane and secure with wheel
chocks.

RISK OF ACCIDENTS!
Secure dolly with wheel chocks against rolling away.

3. Start the superstructure engine

4. Set down the main boom (in the longitudinal direction) on the
dolly, secure and lock.
5. Join connections between the dolly and the towing vehicle.
6. Remove the wheel chocks from under the wheels of the dolly.

140−2060−103b 137/179
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H1

Z 53 026

138/179 140−2060−103b
 Driving the Crane 6

7. Retract the luffing cylinders completely (up to the stop).

Note:
To retract the luffing cylinders up to the stop, the rear
outrigger cylinders may have to be extended further.
8. Close ball valve H1; this shuts off the bottom oil supply to the
luffing cylinder (luffing cylinder must be completely
retracted).
9. Retracting the Outriggers
10. Set the vehicle level

140−2060−103b 139/179
6

”A”

39

75B

75A 32
63
Z 53 779

”B”

65

32
63
Z 53 780

140/179 140−2060−103b
 Driving the Crane 6

Open the slew gear brake and lock open:

(Z 53 779, Z 53 780)

Risk of tipping!
When the slew gear brake is opened, the superstructure
can turn unintentionally (as a result of wind / inclination
of the crane). In this event the crane could tip over.
Therefore only open / lock open the slew gear brake
when the boom is secured on the dolly.

Whether the slew gear brake is closed or open can be determined

by the position of the shift rod (32).

The condition “Slew gear brake closed” (in operation) is

shown as position “B”.
Shift rod (32) extracted = slew gear brake in “Crane mode“;
i.e. “Dolly operation” is prohibited.

The condition “Slew gear brake opened / locked open” (not in

operation) is shown as position “A”.
Shift rod (32) inserted = slew gear brake in “Dolly mode”; i.e.
“Operation of the crane” is prohibited.

Procedure for “opening/locking open slew gear brake”:

11. Open slewing gear brake hydraulically by pressing switch
(75A); The indicator light in the switch lights up.
12. Remove the padlock (63).
13. Lock the opened slew gear brake mechanically.
To do so, push the shift rod (32) in as far as possible (position
“A“) (switching distance 26 mm (1.0 in)).
14. Lock in position “A” with a padlock (63).

15. Cut off the air pressure by pressing the switch (75B);
Indicator light in the switch goes out.

In this condition the slew gear brake is locked open and

therefore non−functioning.

16. Switch off the superstructure engine

17. Retract outrigger.

18. Set the device level

19. Adjust the dolly behind the crane in accordance with the dolly
manufacturer ’s specifications (e.g. level, etc.).

140−2060−103b 141/179
6

74

Z 53 028 Z 53 025

142/179 140−2060−103b
 Driving the Crane 6

Release the superstructure locking device and secure the

pins

(Z 53 025, Z 53 028)

Risk of tipping!
The superstructure locking device may only be released
when the boom is secured on the dolly.
If the superstructure locking device is released, before
the boom is secured on the dolly, the superstructure can
swing by itself, e.g. as a result of an inclination or the ef-
fect of the wind. In this situation the crane can tip over.

Procedure for “releasing the superstructure locking device /

securing the bolts“.
1. Release the superstructure locking device.
(When the superstructure engine is running, press switch
(74); this extends locking pin (1) out of the locking strip (2).
The indicator light in the switch lights up.)
2. Secure the locking pin (1) in the raised condition using fore
lock (3) mechanically, to prevent it being extended
unintentionally.

RISK OF ACCIDENTS!
Before driving with the dolly, the locking pin (1) of the su-
perstructure locking device must be mechanically secu-
red in the raised condition using fore lock (3).

140−2060−103b 143/179
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 Driving the Crane 6

6.12.3.2 Measures when Driving with the Dolly

The available equipment, e.g. the indicator lights / warning

buzzer, must be used to monitor “Dolly operation”.

The available devices, e.g. the suspension pressure gau-

ges, should be monitored while driving or when at a
standstill. Should it happen that the axle loads of the ba-
sic unit and thereby the suspension pressures have in-
creased while driving on level ground, then the levelling
of the dolly must be readjusted. The contact pressure on
the dolly wheels, among other things, is reduced in this
condition, so that the dolly wheels could tend to lock
while braking. This would result in a reduction of braking
power.

Hill summits may only be driven over with reduced

speed: Due to the restricted telescoping distance of the
luffing cylinder, the dolly wheels could be relieved or lift
off the road surface

The dolly should be watched in the rear vision mirror

while driving, especially when driving round a bend.

140−2060−103b 145/179
6

H1

Z 53 029

”B”

65

75B

75A 32
63
Z 53 781

146/179 140−2060−103b
 Driving the Crane 6

6.12.3.3 Measures after Driving with the Dolly

(Z 53 029, Z 53 781)

Risk of tipping when lifting off the boom!

Only lift the boom off the dolly when the slew gear brake
is closed again. Make sure that the slew gear brake is
actually closed before the boom is raised!

Unlock and close the slew gear brake following Dolly

operation

Procedure for unlocking and closing the slew gear brake after the
dolly operation:

1. Park the crane vehicle flush with the dolly.

Makes later attachment easier.

2. Secure dolly with wheel chocks.

RISK OF ACCIDENTS!
Secure dolly with wheel chocks against rolling away.

3. Put the crane on outriggers and level out (outrigger span 8.2
m x 5.4 m 26.9 ft x 17.7 ft)

4. Open ball valve H1; in doing so release the oil supply to the
luffing cylinder on the ground side. The luffing gear is in
operation.

5. Start the superstructure engine.

6. Open the slew gear brake hydraulically (not yet operating) by

pressing switch (75A); The indicator light in the switch lights
up.
7. Remove the padlock (63).

140−2060−103b 147/179
6

H1

Z 53 029

”B”

65

75B

75A 32
63
Z 53 781

148/179 140−2060−103b
 Driving the Crane 6

8. To do so, pull the shift rod out (32) as far as possible (position
“B”) (switch distance 26 mm (1.0 in)).
9. Lock in position “B” with a padlock (63).

10. Cut off the air pressure by pressing the switch (75B);
Indicator light in the switch goes out. the brake is closed.

In this condition the slew gear brake is reset to “Crane

operation”; i.e. “Dolly operation” is prohibited.

11. Connecting the boom to the dolly.

12. Raise the main boom slightly until there is clearance

between the boom and Dolly.

13. Telescope in the main boom fully.

140−2060−103b 149/179
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Z 53 031

150/179 140−2060−103b
 Driving the Crane 6

Release the superstructure locking device ”Locked”

position

(Z 53 031)

Procedure for releasing the ”Locked” position:

14. Remove the fore lock (3) from the locking pin (1)

The superstructure locking device is now set to “crane operation”

again. The locking pin remains in the raised condition, but is no
longer mechanically locked.

15. Place the main boom in the operating position

16. Release the connections between the dolly and the towing
vehicle.

17. Release the connection between the dolly and the carrier
frame (if the crane vehicle is to be moved without the dolly).

140−2060−103b 151/179
6

B24

Z 51 342

152/179 140−2060−103b
 Driving the Crane 6

6.12.4 Dolly not Contained in Crane Manufacturer’s Scope

of Supply

(Z 51 342)

If the dolly is not contained in our scope of supply, assembly,

operation and maintenance of this component remain the
sole responsibility of the crane operator. The crane operator
is responsible for careful assembly, operation and
maintenance in accordance with national regulations.
The manufacturer’s instructions must be followed.
The dolly must be attached to the crane in such a way that
no dangers arise. For instance, the axles of the dolly must be
evenly burdened, in order to achieve an optimum braking
effect.

Dolly operating conditions which are dangerous to travelling

operations must be monitored during the journey.
The crane operator must ensure, in consultation with the
dolly manufacturer, that important information is displayed
to the vehicle driver in an appropriate fashion.
A monitor lamp (17) and a warning buzzer are to be
factory−installed in the driver’s cab for this purpose.

6.12.5 Dolly Contained in the Manufacturer’s Scope of

Supply

If the dolly is part of the manufacturer’s scope of supply, detailed

instructions can be found in section 17 of these operating
instructions.

Pay attention in this case to the instructions outlined and

the regulations for operating a dolly system.

140−2060−103b 153/179
6

1 2 5 3 4

Z 53 769

154/179 140−2060−103b
 Driving the Crane 6

6.13 Dolly Coupling / Supply Connections (Optional)

(Z 53 769)

If the crane is prepared for the attachment of a trailer / dolly, then

the following equipment is at the rear of the vehicle:

1 Electric connection for dolly lighting equipment, rear

2 Compressed air connection (yellow) for braking

3 Compressed air connection (red) for supply output

4 ABS socket (7−pole)

If a dolly coupling is part of our scope of delivery:

5 Dolly coupling

Pay particular attention to the road safety of the dolly coupling (5).
Instructions on maintenance and care can be found in part 4 of
this literature.

Check the dolly coupling daily for longitudinal play.

Longitudinal play is not permitted. Risk of dolly ripping free!

6.13.1 Coupling and Uncoupling a Dolly

The coupling and uncoupling, operation and maintenance of

a dolly is exclusively the sole responsibility of the crane
operator. The crane operator is responsible for careful
performance of the coupling and uncoupling sequence,
operation and maintenance in accordance with national
regulations.
The manufacturer’s instructions must be followed.
The dolly must be attached to the crane in such a way that
no dangers arise. For instance, the axles of the dolly must be
evenly burdened, in order to achieve an optimum braking
effect.

140−2060−103b 155/179
6

1 2 5 3 4

Z 53 769

156/179 140−2060−103b
 Driving the Crane 6

Risk of crushing!
The area between towing vehicle and dolly is not visible
during the steps in which the towing vehicle is moved.
It may be advisable to assign someone the job of monito-
ring that area.

Initial situation:
− Dolly is switched off with parking brake actuated and wheel
chocks in place.

RISK OF ACCIDENTS!
Automatic braking by disconnecting the brake line is not
sufficient.

Sequence for coupling:

1. For dollys with rotating shafts:

Release front axle brake (if present).

RISK OF ACCIDENTS!
When the front axle brake is released, the fork may slam
back and forth if the wheels are standing on a smooth,
level surface.

2. Move the towing vehicle up to approximately 1 m (3 ft) from

the coupling ring, then use the height adjustment device to
set the coupling ring at the coupling height.

3. Open the coupling on the towing vehicle.

4. Step out of the danger zone between towing vehicle and
dolly!

RISK OF ACCIDENTS!
Never step between the vehicles during the coupling se-
quence!

5. Carry out the coupling by moving the towing vehicle

backward, never by using the forbidden method of having
the dolly run up to it!

RISK OF ACCIDENTS!
Because of the extreme danger of accidents, it is forbid-
den under any circumstances to allow the dolly to move
forward to couple the vehicles.

140−2060−103b 157/179
6

1 2 5 3 4

Z 53 769

158/179 140−2060−103b
 Driving the Crane 6

6. Connect the connecting lines:

6.1 disconnect the compressed air connection (yellow; 2)

for the brake line.

6.2 disconnect compressed air connection (red; 3) for the

supply output.

6.3 Connect the electric connections for trailer lighting (1)

and ABS socket (4).

RISK OF ACCIDENTS!
The connections must be made in the sequence speci-
fied.
The brakes may release if this sequence is not adhered
to.

7. Remove the wheel chocks, release the dolly parking brake,

monitor departure.

Sequence for uncoupling

Uncoupling is accomplished in the same sequence as coupling,

but in reverse, whereby the vehicles should be positioned in a
straight line if at all possible.

Risk of accidents!
− Before uncoupling, first actuate the parking brakes of
the towing vehicle and the dolly!
− Before uncoupling, first put wheel chocks in place.

Sequence for disconnecting the connecting lines:

− disconnect compressed air connection (red; 3) for the supply
output.
− disconnect the compressed air connection (yellow; 2) for the
brake line.
− disconnect the electric connections for trailer lighting (1) and
ABS socket (4).

RISK OF ACCIDENTS!
The connections must be removed in the sequence spe-
cified.
The brakes may release if this sequence is not adhered
to.

140−2060−103b 159/179
6

2
2
4

5
1
5 1

Z 53 767 Z 53 768

Z 53 770

160/179 140−2060−103b
 Driving the Crane 6

6.14 Attaching and Removing the Spare Wheel (Spare

Wheel Holder, Hoist Arrangement, Optional)
(Z 53 767, Z 53 768, Z 53 770)

In order to have a spare wheel while travelling, there is a spare

wheel holder (1, optional) to the rear of the vehicle.

In order to attach and/or remove the spare wheel from the spare
wheel holder, either one’s own crane apparatus, the optionally
available lifting device or other equipment (3) (e.g. an auxiliary
crane or similar) must be used.

To remove the spare wheel using the optionally available lifting

device, proceed as follows:
− Attach the holder (2) for the lifting device (3) to the carrier
frame.
− Attach the lifting device (3) to the holder (2).
− Uncoil lifting device (3).
− Attach spare wheel with auxiliary rope (4) to the lifting device
(3).
− Tighten the rope with the lifting device and remove the bolts
(5) on the spare wheel.
− Lower the spare wheel and set it on the ground.

Risk of crushing!
The spare wheel must be secured against tipping over
while being moved over the ground.

The spare wheel is fitted in the reverse order.

The spare wheel must be screwed firmly on to the holder.

Attachment/removal of the spare wheel is to be carried out in

corresponding fashion with one’s own crane apparatus and/or an
auxiliary crane.

The lifting device must be removed, together with the holder,

before rotating the superstructure or before moving the
crane on site.

140−2060−103b 161/179
6

ÁÁ
ÁÁ
ÁÁ
ÁÁ
ÁÁ
ÁÁ
ÁÁ

Z 58 429

162/179 140−2060−103b
 Driving the Crane 6

6.15 Reversing Check System (Optional)

(Z 58 429 Principle diagram)
6.15.1 General System Description
Using ultrasound, the reversing check system monitors the
space behind the vehicle during reversing. It warns visually and
acoustically of obstacles registered by the system.
The max. range is approx. 3 m (9.8 ft) for visual display and
approx. 1.5 m (4.9 ft) for acoustic display.
The height range for registering obstacles (over the road surface)
is approx. 1 m (3.3 ft).
When reversing you must always take great care. Critical
obstacles might not be registered or not precisely registered
due to physical reflection characteristics.

The reversing check system serves to help you when

reversing; however, it does not release the driver from taking
special care when reversing.
The system can only fulfil its purpose for slow reverse
motion (shunting speed).

When reversing, the driver must behave in such a way

excludes any danger to others.

When reversing, we recommend that you always have a

reliable person as a banksman.

Make sure that the hydraulic suspension is at road travel

level. The level setting directly affects obstacle recognition.

Keep the sensors clean. Remove snow, ice or dirt; these

affect the function.

The system does not register any components hanging over

the crane, i.e. toolboxes, ladders, trailer couplings or spare
wheels. The driver must plan ahead and take these into
consideration himself.

The system cannot recognise and therefore does not display

obstacles exceeding the registering range (approx. 1m = 3.3
ft). The driver must remember this and register obstacle
lying higher up himself.

140−2060−103b 163/179
6

A6

A5 A1 A3
A2 A4

S1 S2 S3 S4
Z 58 428

164/179 140−2060−103b
 Driving the Crane 6

6.15.2 Function Description

(Z 58 428 Principle Diagram)

The system consists of:

− sensors (S1 − S4) on the rear bumper
− dialogue unit (A) in the driver’s cab with
− display for visual distance illustration consisting of:
Digit display (A5) and
four LED columns (A1 − A4) with 6 rows each
− speakers (A6) for acoustic signals
− electronic control device at the rear of the vehicle

When reversing, the sensors

transmit ultrasound signals continuously and receive ultrasound
signals reflected by obstacles.
The distance to the obstacle is calculated by the run time of the
ultrasound signals and signalised by the speaker using a pulse
tone sequence. The closer the obstacle, the faster the tone
sequence.

The sensors must be aligned precisely horizontal.

If they face the ground, uneven ground might be displayed as
obstacles. If they face too far upwards, lower lying obstacles are
not registered.

The display
signals the position of the obstacle using LEDs in four columns
/ six rows. Each sensor has its own column.

The digit display (A5) shows the distance to the obstacle in 1 cm

steps. It is indicated in metric form.

The sensors and the dialogue unit are connected to the

electronic control device
.

140−2060−103b 165/179
6

S1 S2 S3 S4
Z4 ~0.40 m (1.3 ft)
Z3 ~0.95 m (3.1 ft)
Z2 ~1.50 m (4.9 ft)

Z1 ~3 m (9.8 ft)

Z 58 424

ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
~0.40 m

Z4 Z3
STOP

Z 58 431

166/179 140−2060−103b
 Driving the Crane 6

6.15.3 Registering Range

(Z 58 424)

The system’s registering range is divided into four zones:

∗ Zone Z1
Large objects, i.e. private cars. The distance is displayed
acoustically and using the digit display.
∗ Zone Z2
Small or badly reflected objects might not be registered.
Other objects are displayed visually and acoustically.
∗ Zone Z3
Almost all objects are displayed.
∗ Zone Z4
Almost all objects are displayed, but some could be in the
sensors’ blind spot.

6.15.4 Protruding Components

(Z 58 431)
Risk of accidents and damage
If parts have been fitted to the vehicle which protrude over
the close−up range of 0.4 m (1.3 ft), they could collide with
an obstacle before the sensors (S1 − S4) register it and issue
a STOP warning to the system.
Parts which do not protrude over the sensors more than 0.4
m (1.3 ft) are within the close−up range (Zone Z4) of up to 0.4
m (1.3 ft) in which a STOP warning will be issued and the
driver should stop.

140−2060−103b 167/179
6

Z 58 425

A
B
C

Z 58 426

168/179 140−2060−103b
 Driving the Crane 6

6.15.5 Critical Situations in the Registering Range

Risk of accidents / damage!

The registering range is limited in height; the entire vehicle
height is not monitored. Only obstacles up to approx. 1 m
(3.3 ft) over the road surface are registered.

Please observe:
The following examples show that situations can occur in which
the system does not register certain objects and does not
indicate the correct distance due to their physical composition.

Example 1 (Z 58 425)
Objects which are not in the sensors’ registering range from the
start, cannot be registered.

Example 2 (Z 58 426)
If the object has a jagged surface, the shortest distance is not
automatically indicated. In the example contour “A” is not
indicated, only “B” and “C”.

140−2060−103b 169/179
6

3
A

Z 58 427

B
Z 58 430

170/179 140−2060−103b
 Driving the Crane 6

Example 3 (Z 58 427)
If the obstacle is oblique, the shortest distance “A” is indicated.

Example 4 (Z 58 430)
The system indicates the distance “A”. When driving up to the
obstacle, once the acoustic display has gone over to the stop
range, distance ”A” will be in the blind spot if driving continues,
which means that distance ”B” is indicated instead.

As the examples show, situations can occur in which an

obstacle or the shortest distance to it is not displayed.
This is why you must always take great care when reversing.

If an object is in the area which is not monitored, the system

automatically displays the distance to the next object. This
means that the acoustic signal will jump from the fast
sequence to a slower one and that the digit display (A5) will
indicate a greater distance in the display.

In this case, always stop the vehicle immediately and check

the situation.

140−2060−103b 171/179
6

S1 S2 S3 S4
Z4 ~0.40 m (1.3 ft)
Z3 ~0.95 m (3.1 ft)
Z2 ~1.50 m (4.9 ft)

Z1 ~3 m (9.8 ft)

Z 58 424

ÁÁ
ÁÁ
ÁÁ
ÁÁ
F7 A1 A2 A3 A4
F6
F5
F4
F3
F2
F1

Z 58 435

172/179 140−2060−103b
 Driving the Crane 6

6.15.6 First Operation

(Z 58 424, Z Z 58 435)

When reversing you must always take great care. You must be
especially careful the first time you use it. The driver must
acquaint himself with the distance indication by the acoustic
signal’s various tone sequences.

6.15.6.1 Relation between Display and Tone Sequence with

Varying Distance to the Obstacle
Zone Meaning Tone sequence
The system recognises obstacles from a distance of
Z1 approx. 3 m (9.8 ft) and indicates the distance on the −
display. The blue LED lights up.
The system signals obstacles using acoustic signals
Z2 (long tone sequence) from a distance of approx. 1.5 m Bi Bi Bi Bi
(4.9 ft). The green and / or yellow LEDs light up.
The system jumps to the middle tone sequence from a
Z3 distance of approx. 0.95 m (3.1 ft). The yellow and / or Bi Bi Bi Bi Bi Bi
red LEDs light up.
The system jumps to a continuous tone from a di-
stance of approx. 0.4 m (1.3 ft). The round red LED
lights up (STOP warning).
Z4 Biiiiii.....
When this zone has been reached, the vehicle must
be stopped. If this is not followed through it will cause
damage to the vehicle and to the obstacle.

Obstacles might not be recognised in zone 4 if they are not

in the sensors’ registering range (due to their construction).

6.15.6.2 Colours of the Light−emitting Diodes (LED’s)

The different distances are assigned certain colours (F1 − F6). At
the end of the 6−row square colour scale there is a round red
warning light (F7) which is for demanding a stop.
Distance Colour
> 1.20 m (3.9 ft) blue
1.20 m − 0.80 m (3.9 ft − 2.6 ft) green
0.80 m − 0.40 m (2.6 ft − 1.3 ft) yellow
< 0.40 m (1.3 ft) red

140−2060−103b 173/179
6

A1 A2 A3 A4

Z 58 432

F7 A1 A2 A3 A4
F6
F5
F4
F3
F2
F1

Z 58 433

174/179 140−2060−103b
 Driving the Crane 6

6.15.6.3 Example of a Display:

Obstacle at a Distance of 1.20 m (3.9 ft)

(Z 58 432)

− The obstacle has been registered by both middle sensors

and is shown in the display.
− Digit display “1.20” means: obstacle at a distance of 1.20
m (3.9 ft).
− LEDs in columns A2 and A3 illuminated (blue / green)
means: the obstacle is in the registering range of both
middle sensors S2 / S3 (distance zones Z1 / Z2.
∗ Acoustic signal: long tone sequence (Bi Bi Bi Bi).

6.15.6.4 Example of a Display:

Distance to the obstacle smaller than 0.40 m (1.3 ft)

(Z 58 433)

− The obstacle has been registered by both middle sensors

and is shown in the display.
− Digit display “0.00” means: distance to the obstacle is less
than 0.40 m (1.3 ft).
− LEDs in columns A2 and A3 illuminated (blue / green /
yellow / red) means: the obstacle is in the registering range
of both middle sensors S2 / S3 (distance zone Z4).
∗ Acoustic signal: continuous tone (B i i i i i i . . . . . ).

Stop demand

If the distance to the obstacle is less than 0.40 m (1.3 ft) (zone
4) the round red LED (F7) is illuminated in each row. The acoustic
signal switches to continuous tone.

Risk of damage!
If the round red LED (F7) is illuminated − at the same time the
acoustic signal jumps to the continuous tone − the vehicle
must always be stopped and the situation must be checked.

140−2060−103b 175/179
6

A6

A5 A1 A3
A2 A4

S1 S2 S3 S4
Z 58 428

13

Z 58 434

176/179 140−2060−103b
 Driving the Crane 6

6.15.7 Activating and Using the System

(Z 58 428, Z 58 434)

The reversing check system is automatically activated once the

reverse gear has been applied if the ignition is switched on and
the engine is running.

As soon as an obstacle is in the registering range, a consistent,

repeated signal is sounded.
At the same time the display shows where the obstacle is: if the
right−hand side of the vehicle is approaching an obstacle (sensor
S4), the right−hand LED row (A4) is illuminated.
If the vehicle approaches an obstacle on the left−hand side
(sensor S1), the left−hand LED row (A1) is illuminated.
If the obstacle is within the range of one the middle sensors (S2,
S3), the corresponding one of both middle LED rows (A2, A3) is
illuminated.

When reversing, the tone sequence is changed, depending on

which zone the obstacle is in, indicating a certain distance. The
digit display (A5) of the display shows the calculated distance in
metres.

Stop the vehicle immediately and check the situation if the

following occurs:
When reversing the machine first indicates an obstacle and
the tone sequence gets faster in the usual manner (for
example, changes from the slow to the middle tone
sequence). Suddenly the tone jumps to the slow sequence
or no longer indicates an obstacle.
This means that the obstacle originally registered is no
longer in the sensors’ registering range (due to design), but
could still be in the way.

If the reverse gear is applied (rotary switch (13) to position “R”),

the standard acoustic reverse gear warning signal sounds (at an
interval). You must register this very consciously; it must not be
confused with the acoustic signal of the reversing check system.

140−2060−103b 177/179
6

A6

A5 A1 A3
A2 A4

S1 S2 S3 S4
Z 58 428

13

Z 58 434

178/179 140−2060−103b
 Driving the Crane 6

6.15.8 Testing the Function / Diagnosis Function

(Z 58 428 Principle diagram, Z 58 434)

Carry out the function test as follows:

− Apply the parking brake.
− Rotary switch to “N”.
− Activate ignition, if required start the engine; apply reverse
gear (rotary switch to ”R”).
− A short double tone sounds as a function check.
− The digit display (A5) in the display shows the distance to an
obstacle if it is within the registering range.
Diagnosis function

The system has a diagnosis function. If the sensors are faulty,

three short signals are sounded instead of the double tone if the
reverse gear is applied.
6.15.9 Fault Display
Defective sensor is displayed (three tones when applying
the reverse gear)

Proceed as follows if a defective sensor is displayed (see “Test

function”):
− Park the vehicle at a distance of approx. 1 m (3.3 ft) in front
of a large obstacle, i.e. a garage door.
− Apply parking brake, apply reverse gear (rotary switch to “R”).
∗ The slow tone sequence sounds (zone Z1) and the LEDs of
the intact sensor light up in green.
− Cover sensors one after the other (stand in front of them).
∗ The acoustic signal jumps to the fast tone sequence um.
The tone sequence does not change at the defective sensor.
Dialogue unit does not indicate any function

Check all connecting cables / plugs / contacts for correct fit

(display, sensors, control device).
6.15.10 Maintenance and Care

Occasionally clean the sensors with a damp cloth.

Do not use any abrasive or aggressive cleaning agents as
this can lead to damage of the sensors.

140−2060−103b 179/179
 Transmission 7

140−2070b 1/55
7

1 2 4 5 7 3 6

Z 200 092

35 36 B5

43
B6

35

75
36

12
18 13
19

Z 51 344

2/55 140−2070b
 Transmission 7

7 Drive gearbox / distributor gear

(Z 200 092, Z 51 344)

The drive gearbox (2) − an automatic transmission ZF−AS

TRONIC Type 16 AS 2601 (16 forward gears, 2 reverse gears)
− is flanged together with the drive motor (1) via a dry clutch. A
two−stage distributor gear (3) is rear−mounted to this
combination.

7.1 Drive gearbox:

7.1.1 Description of the System

The ZF−AS TRONIC consists of a four−speed part, a splitter unit

(GV) and a rear−mounted range unit (GP) in planetary design.
The basic gearbox is dog−clutched; splitter and planetary units
are synchronised.
Thanks to the automatic coupling (no clutch pedal), the driver no
longer needs to activate the clutch.
The actual gear switching is done by the electronic transmission
system.
The transmission actuator and the clutch actuator are the most
important components for completely automating the
transmission.
The transmission actuator consists of the electronic gear system,
shift valves, shift cylinders and sensors.
The clutch actuator is an electro−pneumatic actuator with path
sensors; it takes over the entire transmission actuation.
A hydraulic retarder (system “ZF Intarder”), a non−wearing,
functioning, hydrodynamic auxiliary brake is integrated in the
transmission.
All essential system information, e.g. neutral, gear step, clutch
overload, fault and diagnosis information are display to the driver
in the “Transmission information” display (75).
Moreover, other special indicator lights are shown in the “Driver
information system” display (43) for:
− Clutch overload (B5) and
− transmission malfunction (B6) together with “caution” (36) or
− serious transmission malfunction (B6) together with “STOP”
(35)

140−2070b 3/55
7

2.1 2

2.5

2.3
2.4

2.2

Z 51 345

43

75

12
18 13
19

Z 51 346

4/55 140−2070b
 Transmission 7

7.1.2 System Design

(Z 51 345, Z 51 346)

The transmission system consists of the transmission (2) and

components, that are required for the automation of the system.
The transmission actuator (2.1) and clutch actuator (2.2)
components are integrated into the transmission.
The driving switch (2.3), display (2.4) and e−module (2.5)
periphery components are installed in the driver’s cab.
Vehicle components such as display (75), accelerator pedal (18)
and brake pedal (19), engine electronic system, electronic
braking system with wheel speed sensors also belong to the
system.

Legend:

2 Transmission

2.1 Transmission actuator with electronic transmission control

system

2.2 Clutch actuator

2.3 Driving switch

2.4 “Transmission information” display (75)

2.5 E−module

Vehicle components:

18 Accelerator pedal

19 Brake pedal

43 “Driver information system“ display

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12

13

Z 51 346

6/55 140−2070b
 Transmission 7

7.1.3 Shifting Gears

7.1.3.1 Driving switch

(Z 51 346)

The driving switch consists of the switch lever (12) and the rotary
switch (13). It is the operating element for
− Selecting the driving range
− Selecting the gear
− Activating / deactivating the automatic mode
− Calling up the error display

Air pressure of min. 6.2 bar is needed to switch gears. It is not

possible to shift gears below this mark. Unsuccessful gear shifts
are saved as errors by the electronic system.

RISK OF ACCIDENTS!
If you shift when the air pressure is too low, thetransmis-
sion can remain in neutral, with the result that no
through drive and no engine braking effect are available.

Rotary switch

The rotary switch has three positions:

− “D” − Drive
− “N” − Neutral (no gear is engaged in the transmission)
− “R” − Reverse

If the rotary switch is in the “N” position, then the switch lever
won’t work.

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12

13

Z 51 346

8/55 140−2070b
 Transmission 7

Switch lever (12)

The switch lever is used to switch gears and change the

transmission mode (manual / automatic).

The switch lever springs back into its initial position after every
actuation.

By tapping the switch lever several time, you can shift up / down
over several gear steps.

+ Shift up by one gear

+ + Shift up by two gears

− Shift down by one gear

−− Shift down by two gears

Change transmission mode:

Manual / automatic and vice versa: press switch lever quickly to

the left.

Automatic transmission mode

Rotary switch (13) in position “D”: The shifting system

automatically selects the 3rd gear as programmed starting gear.
Rotary switch (13) in position “R”: The switching system
automatically selects the ”rapid” reverse motion as a fixed
programmed driving gear.
The shifting system automatically shifts up and down while
driving.
You can change the transmission mode from automatic to
manual at any time.

Manual transmission mode

Rotary switch (13) in position “D” or “R”: If the gear shift lever is
tilted to the left, the switching system switches to the operating
mode ”Manual”.
The driver can also select another driving gear as the
programmed driving gear.
Overrevving the engine must be avoided by the driver by shifting
gears at the right time.
If you use the accelerator pedal in too high a gear, you might stall
the engine.
You must avoid slow driving which puts stress on the clutch by
possibly driving slowly or by driving in a lower gear than is fixed
and programmed.

140−2070b 9/55
7

1 8 14

2 9 15

3 10 16

4 11 17

5 12

6 13

Z 51 348

10/55 140−2070b
 Transmission 7

7.1.4 (75) “Transmission information” display (Z 51 348)

All operating indicators (performed or preselected functions),
warning information and malfunctions / errors are shown on the
“Transmission information” display (75) with numbers and
symbols.
Malfunctions, see error code table at the end of the section.
7.1.4.1 Operating indicators
1 Self−check of the system
(during ignition, on)
2 Transmission in neutral
3 Engaged gear
4 Manual driving mode
engaged gear, possibility to shift back (two gears)
5 “Slow” reverse gear engaged
6 “Fast” reverse gear engaged
7 Automatic driving mode
is shown in the display by four bar with two arrows
(the eighth gear is engaged in the transmission)
7.1.4.2 Warning information
8 Insufficient air pressure (airless)
9 Take foot from the accelerator pedal
10 Clutch is overloaded. Select a lower gear (clutch)
11 Clutch is worn out (clutch wear)
12 Communication error to the display (electronic error)
13 Transmission temperature too high
7.1.4.3 System error
14 System malfunction. Continued operation is possible,
though limited.
15 Serious system malfunction. Continued operation is not
permitted.
16 Example: Error no. 74
17 Example: Error no. 168
Four bars are shown in addition to the number: Error no. +
100 (only for double−digit display)

140−2070b 11/55
7

35 36 B5

43
B6

35

75
36

12
18 13
19

Z 51 344

12/55 140−2070b
 Transmission 7

7.1.5 (43) “Driver information system” display

(Z 51 344)

Regardless of what is shown on the “Transmission information”

display (75), various malfunctions are also shown on the “Driver
information system” display (43) with the use of indicator lights.
− Indicator light (B5) = clutch overload
The clutch temperature is too high. Change travelling
operation (do not drive with dragging clutch).

− Indicator light (B6) + “caution” (36) = malfunction in the drive

gearbox
Stop vehicle, read off fault code, rectify fault. Continued
operation is possible, though limited.

− Indicator light (B6) + “STOP” (35) = serious malfunction in the

drive gearbox
Stop vehicle, read off fault code, rectify fault.
Continued operation is not permitted.

140−2070b 13/55
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Z 52 100 Z 52 101

14/55 140−2070b
 Transmission 7

7.1.6 Driving and Shifting Gears

You are not allowed to leave the vehicle if is the engine is

running or a gear is engaged.

7.1.6.1 Starting the Engine

(Z 52 100)

8. Apply the parking brake.

9. Rotary switch to “ N “ (transmission in neutral)

10. Switch on the ignition. (Ignition−starter switch, position “2”)

At “Ignition on”, a self−test of the shifting system is done.

After the control signal: “CH” display.

11. Starting the Engine

“N” display; Transmission is in “neutral”.

It is not possible to switch gears when the engine is at standstill.

7.1.6.2 Driving, Driving Forwards

(Z 52 101)

Starting position:
Apply parking brake, engine running, transmission in “neutral”.

1. Turn rotary switch from “N” to “D”.

Automatic drive mode is activated.

The display (75) shows the driving gear engaged.

The shifting system automatically selects the 3rd gear as

programmed starting gear.

2. Push the accelerator pedal (18) and at the same time,

release the parking brake.

The vehicle can roll away without pushing the accelera-

tor pedal (18).

3. The vehicle starts to drive (clutch engages automatically).

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12

13

Z 51 349

16/55 140−2070b
 Transmission 7

Correcting the programmed driving gear

(Z 51 349)

At road inclines or declines, you can drive with a lower or higher

gear.

The programmed driving gear (gear 3) can be corrected as

follows:
Press the switch lever (12) in the direction “ − ” or “ + ”; the
engaged driving gear is shown on the display (75).

7.1.7 Change transmission mode: Manual / automatic

The transmission mode can be changed at any time, even while

driving.

Changing the transmission mode from manual to automatic:

Push the switch lever (12) to the left.

Changing the transmission mode from automatic to manual:

− Push the switch lever (12) to the left or

− in the direction “ + “ or “ − ”.

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12

13

Z 51 346 Z 52 102

18/55 140−2070b
 Transmission 7

7.1.8 Changing Gears

A gear can be switched automatically while driving by the

automatic driving programme, or manually by the driver.

You can shift from any gear into ”neutral” using the rotary switch
(13). This gear switch has priority. (Z ›47 966‹)

The position of the accelerator pedal (18) must not be changed

while switching gears, because the engine is automatically
controlled.

A gear switch command is not executed when the max.

permissible engine speed was exceeded by the gearshift
mechanism.

RISK OF ACCIDENTS!
Shifting to “neutral” is also possible while driving. If you
shift to “neutral”, the drive train is interrupted
The engine braking effect no longer exists.

At the latest by an engine speed of 2350 rpm, the crane is to be

braked until the speed is reached at which the automatic
transmission shifts down to the next gear (possible gear range
change).

7.1.8.1 Shifting gears in the automatic transmission mode

All upshifting and downshifting is done automatically.

Shifting gears depends on various factors such as axle load,

acceleration pedal position, speed, engine speed or shift profile.

Upshifting:
When accelerating, as soon as the required speed is reached to
shift up a gear, the transmission automatically shifts into the next
higher gear.

Downshifting:
When decelerating, as soon as the required speed is reached to
shift down a gear, the transmission automatically shifts into the
next lower gear.

The gear display is shown as digits in the display (75) while

driving. (Z 52 102)

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12

13

Z 52 103

20/55 140−2070b
 Transmission 7

7.1.8.2 Shifting gears in the manual transmission mode

(Z 52 103)

Press the switch lever in the direction “ + ” or “ − ”; the engaged

gear is shown on the display (75).

When you shift gears manually, the shifting system leaves the
automatic transmission mode.

If you press the switch lever (12) to the left, the automatic
transmission mode is activated again.

Skipping gears

Skipping a gear:

Press the switch lever (12) twice quickly into the desired direction.

Skipping two gears:

Press the switch lever (12) three times quickly into the desired
direction.

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12

13

Z 200 317 Z 51 349

22/55 140−2070b
 Transmission 7

7.1.9 Reverse driving / changing the driving direction

(Z 200 317, Z 51 349)

You can only shift gear in another driving direction is the

wheels are at a standstill. Engine at idle speed!
If the vehicle is rolling, it will not shift into the reverse gear;
the transmission shifts into “neutral”.

Engage reverse gear:

1. Stop vehicle; wait for standstill; Apply the parking brake.

2. Turn the rotary switch (13) over “ N “ to “ R “.

“RH“ appears in the display (75)

(clutch remains disconnected)

The switching system automatically selects the “rapid” reverse

motion as a fixed programmed driving gear.

3. Push the accelerator pedal (18) and at the same time,

release the parking brake.
(clutch engages automatically)

4. The vehicle drive in reverse.

As soon as the rotary switch (13) is set in the “R” position, the
reverse gear warning signal sounds.

Correcting the programmed driving gear

(Z 51 349)

At road inclines or declines, you can drive with a lower or higher

gear.

The programmed driving gear (”rapid” reverse motion (display

“RH”)) can be corrected as follows:
Press gear shift lever (12) in direction “ − ”. The transmission
switches to the “slow” reverse motion (display “RL”).

Changing the driving direction

Turn the rotary switch (13) from “ R “ over “ N “ to “ D “ or reversed

from “ D “ over “ N “ to “ R “.
Remain in position “ N “ so that the gearshift is completed.

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24/55 140−2070b
 Transmission 7

7.1.10 Stopping

The vehicle can be braked in any gear to the point of standstill.

If the accelerator pedal is not actuated, the vehicle will decelerate

with the service brake to the point of standstill. Apply the parking
brake.

The clutch opens automatically before the vehicle comes to a

standstill, so that “stalling” the engine is avoided.

When engine is not in action, it is recommended to put the

transmission in neutral, because after the device has been in
standstill for a long time, the emergency pressure supply (6.2 bar)
level required for shifting gears could have sunk to a point where
it is no longer possible to shift into neutral.

RISK OF ACCIDENTS!
If the vehicle is standing with a running engine and an
engaged gear, it is enough to actuate the accelerator
pedal (18) in order to bring the vehicle into motion.

Before leaving the vehicle with the engine running, the

transmission must be in “neutral” and the parking brake
must be applied.

Applying the parking brake while driving on a smooth

surface can bring the engine to a standstill.
The hydraulic steering support is no longer available in
its previous form. A considerable amount of power is
needed for the steering wheel and the steering reacts
more slowly.

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N
D R 4

15

Z 52 105 Z 51 304

26/55 140−2070b
 Transmission 7

7.1.11 Shutting off the engine and vehicle

(Z 52 105, Z 51 304)

1. Stop vehicle; wait for standstill; Apply the parking brake.

2. Turn rotary switch (13) to “N” (neutral).

3. Shut off the engine(ignition−starter switch (15), position “1”)

4. Place wheel chocks underneath (e.g. on inclines)

After “Ignition off”, the system automatically shifts into

neutral. If no brake is actuated, the vehicle can roll away.

“Ignition off”, special case

If the ignition is switched off while driving, it is not possible to shift

into neutral. The engaged gear remains engaged, the clutch
remains engaged.
When the driving speed goes below a certain limit, the clutch and
the transmission shifts into neutral.

140−2070b 27/55
7

90

Z 52 106 Z 52 107

35 36 B5

43

75

12
18 13
19

Z 52 108

28/55 140−2070b
 Transmission 7

7.1.12 Manoeuvring (Distance < 1m)

(52 106, Z 52 107, Z 52 108)

When moving slowly and carefully (e.g. hooking up / detaching

a dolly), a manoeuvring operation is provided in the first driving
gear and in the first reverse gear. The transmission remains in
this gear; it does not upshift.
The manoeuvring operation is not effective in other gear. If it is
selected in another gear, the shift will not be executed
(transmission remains in the first gear).

In the manoeuvring operation, the clutch is switched from

“Driving mode” to “Manoeuvring mode” with the switch (90). The
clutch control is different to that for the normal “Driving mode”
(now: dragging clutch).
In this way, the vehicle can be positioned slowly and carefully
forward or backwards using the accelerator pedal (18).

During manoeuvring, the distributor gear should always be

shifted into ”Off−road gear” − because of the more favourable
transmission ratio. This prevents damage to the clutch.

The manoeuvring operation is associated with heat

development and increased clutch wear and can lead to
overloading the clutch.
The “CL” display (43) and the “Clutch overload” (B5) is
shown in the display (75) if the clutch is overloaded
(regardless of accelerator pedal position and driving speed).
The driver has to change the travelling operation now
(vehicle / stop) to prevent damage to the clutch.

In “Manoeuvring mode”, the vehicle can only be moved slightly.

The driving time is about three minutes; only a short distance (<
1 m) can be covered until the “CL” and B5 warning displays light
up as a result of heat development.
The system needs another 15 minutes or so − with stationary
vehicle and running engine − to cool off the clutch.

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Z 52 115

30/55 140−2070b
 Transmission 7

7.1.13 Towing

The towing procedure is described in detail in section 14.

Observe the procedures defined there exactly.

7.1.14 Towing start

It is not possible to start the engine by towing it along.

Jump start with external batteries, see section 5.

7.1.15 Rolling down a downhill slope

Prerequisite for this procedure: Running engine

RISK OF ACCIDENTS!
When the vehicle is rolling without an engaged gear −
rotary switch (13) is on “ N ” − there is no engine braking
effect.

Do not let the vehicle roll in the opposite direction of the

engaged gear.

If the vehicle rolls forward − when the transmission is in neutral

− after releasing the brakes and you shift from “ N “ to “ D “, then
the system selects the gear that fits to the speed. The drive train
is “closed” (positively tied). (Z 52 115; Example with third gear)

7.1.16 Exhaust brake

The engine braking effect is interrupted when switching

gears. The vehicle can speed up during downhill driving.

Manual Driving Operation

The exhaust brake is deactivated by the system when shifting.

After shifting, the exhaust brake is automatically activated again.

Automatic Driving Operation

When actuating the exhaust brake, the system shifts back to the
gear where the highest brake performance was available.

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7

Z 52 107

35 36 B5

43

75

12
18 13
19

Z 52 108

32/55 140−2070b
 Transmission 7

7.1.17 Clutch protection

(Z 52 107, Z 52 108)

Despite the automated clutch, the driver has great influence on

the service life of the clutch lining. To cut down on wear and tear,
it is recommended to always select the lowest possible gear
when driving.
See “Driving and Shifting” in this section under “Correction of the
programmed driving gear”.

To prevent damage to the mechanical parts of the clutch control,

shift the transmission to neutral for longer stops (more than 1−2
minutes, e.g. traffic jam, train crossing). In doing so, the clutch is
engaged and the clutch controller is released.

If the clutch is in danger of overloading, e.g. due to several short,

consecutive start−up procedures or crawling with dragging
clutch, the “ CL “ display will appear on the display (75) and the
indicator light (B5) on the display (43).
Put the vehicle into an operating mode where the clutch is not
overloaded; for example:
− when accelerating (to apply the clutch)
− when stopping
− when driving at a low gear
− when driving at speeds below the walking speed: switch
distributor gear to terrain driving.

If the driver ignores the warning signal, the clutch en-

gages when the accelerator pedal (18) is pushed.
In this way, further strain on the clutch is avoided.
This can lead to the “stalling” of the engine, in which
case the vehicle may roll back if on an incline.
By releasing the accelerator pedal (18), the clutch opens
again.

Further information can be found under “Manoeuvring“ in this

section.

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34/55
31 32 33 34 35 36 37 38 39 40

43

km/h
mph

41 41.1 42 51 52 53 54 55 56 57 58 50 50.1

Z 48 996

140−2070b
 Transmission 7

7.1.18 Overspeed protection

To protect the entire drive train from too high a speed, the system
allows only gearshifts that are within a certain range.
Shifting and protective measures are in conjunction with the
permissible engine speed, that can be controlled at the revolution
counter (50) in the instrument panel.

If the engine speed exceeds 2350 rpm (excessive engine speed),

the LED (50.1) lights up and the warning buzzer sounds as long
as the engine speed is excessive.

Be sure that the engine does not exceed the permissible

speed range. especially when driving downhill.

At an engine speed of 2300 rpm, the exhaust brake is

deactivated to protect the engine mechanic against damage.

7.1.18.1 Manual transmission mode

If the vehicle accelerates when going downhill, the automatic

transmission will not shift into a higher gear.

The engine can be damaged, if the vehicle accelerates when

going downhill and the engine comes in to the overspeed
range.

The − accordingly low − gear range in which the crane

can be maintained at a constant speed must be selected
before the crane is driven downhill.
When driving downhill, pay special attention to the in-
structions in section 6 regarding gear selection and brak-
ing.

7.1.18.2 Automatic transmission mode

Caution when driving downhill!

At the latest by an engine speed of 2300 rpm, the vehicle is
to be braked until the speed is reached at which the
automatic transmission shifts down to the next gear.

RISK OF ACCIDENTS!
The vehicle can accelerate when travelling downhill.
To protect the engine during excessive engine speed, the
system upshifts.

140−2070b 35/55
7

Z 52 105

36/55 140−2070b
 Transmission 7

7.1.19 Roller dynamometer

(Z 52 105)

After driving onto a roller dynamometer (brake dynamometer),

shift the transmission into “neutral”.

When rolling, the system recognises the function “Driving

vehicle”. If a gear is engaged, the clutch engages.

RISK OF ACCIDENTS!
The vehicle can drive off the roller even without the ac-
celerator pedal being pressed (18).

When rolling, it is not possible to shift into reverse gear.

7.2 Hydraulic Retarder (System “ZF Intarder”)

A hydraulic retarder (system “ZF Intarder”) isintegrated in the

transmission.

Further details about this can be found in Sect. 8 “Brakes”.

140−2070b 37/55
7

Z 52 109 Z 52 110

35 36 B5

43
B6

35

75
36

12
18 13
19

Z 51 344

38/55 140−2070b
 Transmission 7

7.3 System malfunctions / error diagnosis

7.3.1 Fault messages

The drive gearbox has a self−diagnosis system.

If the system recognises faults / errors, this will be shown to the
driver on the (75) “Transmission information“ display.
The faults are divided into fault classes 1 to 3 and entered into the
fault memory of the transmission after the ignition has been
switched off. Up to ten different errors can be stored. If the fault
memory is full, a non−active error will be overwritten.

Error class 1

Errors that even after occurring several time do not lead to a

reduced availability of the system.
Display: None
Unlimited driving mode possible.

Error class 2

If two or more class 2 errors occur, the system reacts in the same
way as with class 3 errors.
Display: “Spanner” symbol (Z 52 109)

If the ”Spanner” symbol appears on the display, there is system

malfunction. It may be that the driving mode is only possible in
limited form, e.g. only in manual.

Fault category 3

Display: “Spanner” symbol plus “STOP”

(Z 52 110)

If the “Spanner” symbol plus “STOP” appears in the display, there

is a serious system malfunction. Continued operation is not
permitted. It is necessary to bring the vehicle to the workshop.

Regardless of what is shown on the “Transmission information”

display (75), various malfunctions are also shown on the “Driver
information system” display (43) with the use of indicator lights.
(Z 51 344)

See also section 6 “Driver information display (75)” and in this

section “Transmission information display (43)”.

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7

40/55 140−2070b
 Transmission 7

Reset

It is possible to delete the fault message and the resulting error

reaction when the vehicle is at standstill using “Ignition OFF”; wait
until the display goes out.
If the display does not go out after “Ignition OFF”, switch on the
ignition again. If the fault message is still showing, it is time to
consult out customer service department.

In addition to this optical warning, the warning buzzer sounds in

the cab according to the error class.

140−2070b 41/55
7

12

13

Z 52 105 Z 52 111

Z 52 112 Z 52 113

42/55 140−2070b
 Transmission 7

(Z 52 105, Z 52 111, Z 52 112, Z 52 113)

7.3.2 Reading off the fault code

If there is an error, the error number can be called up on the

display (75). If there is a serious system error (“Spanner” symbol
plus “STOP”), stop the vehicle and switch off the engine.

Calling up the current error numbers:

1. Switch on the ignition.

2. Turn rotary switch (13) to “N”.

3. Push the switch lever (12) to the front and hold.

An error number appears on the display (43). This corresponds

to the current error; Example: Error no. 74.

Display of three−digit error numbers:

If, in addition to the display number, four bars are shown, this
means that: Error no. + 100; Example: Error no. 168.

Retrieving the errors stored in the fault memory:

While holding down the brake pedal (19) at the same time, all
(saved and active) errors are shown on the display (43) in
sequence.

7.3.3 Error list

7.3.3.1 Error list explanation

GV = transmission in GV position (splitter unit)

Even and odd gears

GP = transmission in GP position (range unit)

Slow gears (gears 1 to 8)

Fast gears (gears 9 to 16)

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7

44/55 140−2070b
 Transmission 7

7.3.3.2 Listing / explanation of possible error displays

Fault category 3 Effect

02, 03, 04, 05, 06, 07, 08, 09, 22, 34, 35, Driving: gear shifting is locked.
36, 37, 38, 39, 40, 41, 54, 61, 62, 66, 67, Standstill: Automatically shifted into neutral and the
68, 69, 70, 71, 72, 73, 77, 78, 82, 83, 84, gear shifting is locked.
85, 90, 101, 105, 117, 132, 136, 140, Continued operation is not possible.
144, 169, 170, 177, 179, 180, 181, 188, System not available.
189, 190, 191, 193
Error class 2 Effect
Driving: gear shifting locked, incl. neutral.
10, 42 Driving gear: Only when lowest gear is engaged for GP
high speed. Ignition on: System not available.
The following effects may happen:
17, 18, 19, 20, 21, 49, 50, 51, 52, 53, 97, Driving: Reduced comfort when driving, manoeuvring,
98, 99, 107, 120, 121, 122, 123, 124, shifting, increased shifting time.
164, 165 Standstill: Middle driving gear. No manoeuvring opera-
tion.
Driving: Gear shifting is locked.
81 Standstill: it is possible to engage the driving gear. Driv-
ing possible.
Driving: gear shifting is locked, including the shifting at-
110 tempts into neutral.
Standstill: Driving gears possible.
Driving: Gear shifting is locked.
118
Standstill: Engine stalls, if the clutch does not open.
Driving: clutch engages quickly. Gear shifting is locked.
119 Standstill: Automatic shifting into neutral system not
available.
Error class 1 Effect
11 Warning buzzer permanently active.
12, 44 Activation of the back−up light not possible.
23 Permanent control warning light.
25, 89 Display EE. No system reaction.
The following effects may happen:
26, 27, 28, 30, 31, 32, 33, 91, 92, 93, 94, Driving: Reduced comfort when driving, manoeuvring,
96, 113, 171, 173, 182, 183, 184, 192, shifting, increased shifting time
197, 199 Standstill: Middle driving gear. No manoeuvring opera-
tion.
43, 75 Cannot control the warning buzzer.
55, 87 Cannot control the warning light.
76 Back−up light permanently switched on.

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7

46/55 140−2070b
 Transmission 7

Fault category 3 Effect

Display cannot be switched off.
86 Driving switch does not switch off.
No restriction of the system availability.
95, 100, 104, 111, 112, 125, 127, 128, Since an isolated error, no effect on the system or on
167, 174, 195, 196, 198 certain calculations e.g. wear on clutch not possible.
Driving: gear shifting is locked, including the shifting at-
102, 163 tempts into neutral.
Standstill: Driving gears possible.
The following errors may occur:
108, 175 Driving: Gear shifting is locked.
Standstill: System not available, driving gear possible.
System function not affected. Possible loss of pressure
126
was not displayed. Higher learning time.
Driving: gear shifting is locked, shifting out of neutral
129, 130, 131
possible. Standstill: Driving gears possible.
Driving: Restricted gear selection.
133, 134, 135
Standstill: Restricted driving gear, no reverse gear.
Driving: GP shifting locked. Only gears can be engaged
in the shifted GP area.
137, 138, 139, 145, 146, 147
Reduced shifting comfort, increased shifting time.
Standstill: Driving gears possible.
Driving: Automatic gear correction (last GV position) or
shift into neutral.
141, 142, 143, 148, 149, 152
Standstill: Driving in last GV position or using driving
switch.
System not available. Renewed GV shifting attempt
150
possible.
Driving: Automatic gear correction or shift into neutral.
151 Standstill: Driving gear can only be selected using driv-
ing switch.
Driving and standstill: Automatic shift into neutral. Re-
153, 155, 156
newed shifting using driving switch.
Driving: clutch engages. Next shifting attempt using
154 driving switch.
Standstill: Driving max. lower gear, higher GP.
158, 159, 160 Automatic gear correction.
Driving: possible to shift while driving.
166
Standstill: System not available.
Driving: no system restrictions.
168
Standstill: After reset, driving is possible.

140−2070b 47/55
7

A F

B H

C I

D J

E
Z 40 589

93

A8 A7

Z 200 318 Z 52 114

48/55 140−2070b
 Transmission 7

(Z 40 589, Z 200 318, Z 52 114)

7.4 Distributor gear

The distributor gear is rear−mounted to the actual drive gearbox.

It forms a unit with the “Lift axle”.
An emergency steering pump, that secure the steering ability of
the crane in case the engine fails, is located on the intermediate
shaft. It is driven from the rolling crane.
There are two gear levels (street / off−road gear).
A = on−road gear, B = drive, C = emergency steering pump 1, D
= front drive, E = differential lock,
F = off−road gear, G = shift cylinder, H = lubricating oil pump, I =
emergency steering pump 2, (not fitted) J = rear drive

7.4.1 Operating the distributor gear

Engage the off−road gear early enough (on level surface and
before entering difficult terrain); and not after the crane vehicle
has become stuck.

On−road gear, off−road gear and the differential lock can only be
activated when the vehicle is at a standstill (dog−clutching).

On rare occasions, it is not possible to switch from on−road gear

to off−road gear in one go due to the gear teeth locking.

If the attempt to shift the distributor gear fails (locked teeth), this
will be indicated on the display (43) by an indicator light (A8). The
distributor gear will then be in neutral; i.e. the drive train is not
closed.

To change the position of the teeth in the distributor gear, carry

out the following procedure:

1. Apply the parking brake.

2. Starting position for rotary switch (13): position “ N ” .

3. Press the dual button (93) and hold it down.

4. Change rotary switch (13) from “ N ” to “ D ” and / or “ R ”.

Do not push the accelerator pedal (18) (do not give it any
”gas”).

5. Observe the display (43)

If the indicator light (A7) is shown, the gear has been
successfully shifted. The off−road gear is engaged.

6. Release the dual button (93).

140−2070b 49/55
7

93

A7

Z 52 105 Z 52 114

50/55 140−2070b
 Transmission 7

In case the off−road gear – despite carrying out the described

procedures – cannot be engaged:
Without the parking brake being engaged, turn the steering
wheel as far as it will go in one direction and then and repeat
procedures 1−6.

If the accelerator pedal was pushed at point 4 (the clutch closed),

the rotary switch (13) must be turned back to the starting position,
position “ N ”, before another attempt is made to shift the gear.
This will open the clutch again. Another gear shift attempt can be
made. (Z 52 105)

− On/off−road gear

(Z 52 114)

The switch (93) can be used to choose between two different

gear steps in the distributor gear:
The transmission ratio in the distributor gear changes when
shifting from on−road to off−road gear.
If the distributor gear is in off−road gear, only manual
transmission mode may be used in the drive gearbox in
order to avoid interruptions of tensile force.

When driving below the walking speed or during manoeuvring

operation you should always switch to the gear ”Terrain driving”
due to the more favourable transmission ratio. This prevents
damage to the clutch.

The gear shifts of the distributor gear operate independently of

the driving mode / gear mode of the drive gearbox.
A supply pressure of min. 7.0 bar is required for all distributor gear
shifts.

− Distributor gear in ”on−road gear” position:

The on−road gear is always engaged under normal
circumstances. No indicator light is shown.
− Distributor gear in ”off−road gear” position:
Press dual button (93); the indicator light (A7) lights up.

The off−road gear is primarily intended for:

− Driving on a work site
− “Driving when rigged”
− Driving with the lowest speed possible.

140−2070b 51/55
7

93

A7

Z 52 114

52/55 140−2070b
 Transmission 7

− Differential lock

The differential in the distributor gear can be locked if the drive

wheels slip in difficult ground conditions.
When locked, there is a rigid connection between forwards
output and rear output.

Further details about this can be found in section 10 of these

operating instructions.

Be sure to follow the instructions and regulations out-

lined there.

− Neutral position

If towing is required (for certain specific types of damage), the

distributor gear can also be put into the neutral position using a
manually actuated pneumatic valve.
For exact notes, see section 14 ”Tow−starting and Towing the
Crane”

When towing is finished, on/off−road gear must be reinstated in

the distributor gear by pressing dual button (93). (Z 52 114)

− Driving in reverse

Prolonged driving in reverse should be avoided. (The lubricating

oil pump does not operate!)

140−2070b 53/55
7

93

A7

Z 52 114 Z 52 115

B5

Z 52 104 Z 200 319

54/55 140−2070b
 Transmission 7

7.5 Driving stuck cranefree

(Z 52 114, Z 52 115, Z 52 104, Z 200 319)

If the crane is stuck on difficult terrain, it can be driven ”free” by

driving forwards and backwards.
Action steps for driving crane free:
1. Engage off−road gear (press dual button (93)).
2. Turn rotary switch (13) to “D”.
The driving gear is selected automatically, but can still be
changed using the switch lever (12).
3. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far forwards as possible.
4. Engage the service brake and stop the vehicle.
Engine at idle speed!
5. Wait for standstill.
6. Move rotary switch (13) from “ D ” to “ N ” and then to “ R ”).
The driving gear “RH” is automatically selected, however it
can still be modified using switching lever (12).
7. Apply careful pressure to the accelerator pedal (18).
Move the vehicle as far backwards as possible.
8. Engage the service brake and stop the vehicle.
Engine at idle speed!
9. Wait for standstill.
Repeat this procedure if the crane is getting a bit further with each
change of direction.

If the wheels are spinning, stop the attempt; the crane will have
to be towed free.
”Towing free”: see Section 14.3 of these operating instructions.

You can only shift gear in another driving direction is the

wheels are at a standstill (engine at idle speed).
If the vehicle is rolling, it will not shift gears; the
transmission shifts into “neutral”.
Keep an eye on the clutch temperature.

If the clutch is in danger of overloading, the “ CL ” display will

appear on the display (75) and the indicator light (B5) on the
display (43).

140−2070b 55/55
 Brakes 8

140−2080 1/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

Z 200 150 Z 200 153

2/25 140−2080
 Brakes 8

8 Brakes

The braking system is designed in accordance with German

road traffic regulations and European EEC directives for
axle loads of up to 12 tons.
Make sure therefore that these axle loads are observed.

Never drive with a defective brake system.

8.1 Emergency pressure supply − braking system

(Z 52 136, Z 200 150, Z 200 153)

Display of the pressure supply

The pressure supply can be called up on the display (43) “Driver

information” (to do so, see notes in section 4).

10. Call up the menu selection 4 ”Information on Checks” (Z 200

150) in the main menu.

11. Then select menu point 4 “Pressure supply in braking circuits

1 and 2” (Z 200 153).

In the top row, the pressure in braking circuit 1 and in the bottom
row the pressure in braking circuit 2 is displayed (bar display).
If the emergency pressure supply is below 7 bar, the braking
system must be topped up at medium revs, until a pressure of 8
bar has been reached.

Fault / warning displays

The following warnings are indicated on display (43), if the

pressure supply falls below 5.5 bar:
− Preheating indicator (B3) for braking circuit 1
− Preheating indicator (B4) for braking circuit 2

At the same time the preheating indicators (B3 / B4) appear, the
“STOP” display (35) lights up and the warning buzzer sounds.

If the preheating indicators (B3 / B4) light up together

with the “STOP” display (35) and the warning buzzer
sounds, the pressure supply in the braking system is too
low.
Stop the vehicle immediately; there is a serious risk of
accidents.

140−2080 3/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

4/25 140−2080
 Brakes 8

8.2 Service Brake

(Z 52 136)

The service brake (dual circuit compressed air braking system)

acts on all wheels.

To brake, press down the pedal (19) of the brake valve gently.

Immediately after driving, test the brakes on a dry, anti−skid

road surface (service and retaining brake). When doing so,
make sure the crane brakes evenly, does not veer to the side
and that brake delay is faultless.

There must be no oil or water on the brake linings. If water

has infiltrated the brake lining, lightly brake with the service
brake until the brakes are again fully functional.

The service brake must not be used for sustained peri-

ods under any circumstances. Danger of overheating
(fading)!

The service brakes may only be used when driving

downhill in order to brake the crane until a speed has
been achieved where the crane switches back to the next
gear.
This is why you must select the gear before driving
downhill with which the speed of the crane can be main-
tained when driving downhill.

Never drive with a defective brake system!

After the brakes have been used more intensely, do not switch
off the vehicle immediately but drive on for a little while in order
to allow the brakes to cool off faster from the driving wind.

140−2080 5/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

Z 200 150 Z 200 153

6/25 140−2080
 Brakes 8

8.3 Parking brake

(Z 52 136, Z 200 152, Z 200 153)

To park the crane, the parking brake (hand brake) must be

applied!
It is opened with compressed air and closed with accumulated
spring force. It is active on axles 1, 3, 4 and 5.
If the service brake fails, the parking brake can be used as an
emergency brake.

If the emergency pressure supply in the spring accumulator

brake circuit is too low, the spring accumulator parking brake can
be released mechanically in the case of an emergency (see
section 14).

As the parking brake does not work on all wheels, its braking
effect is less than that of the service brake.

Apply the parking brake:

Move lever (14) from the neutral position to the fully braked
position at the rear (lever locks in place). The indicator light
“Parking brake” (39) lights up.
With partial braking, the lever must be held in the desired position
as it otherwise returns automatically to the released (neutral)
position.

RISK OF ACCIDENTS!
Make sure that the lever (14) locks correctly in the full brake
position, as it can otherwise return automatically to the
released position.
The lever (14) must not be able to be pushed backed into the
released position (without actuating the lock).

140−2080 7/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

8/25 140−2080
 Brakes 8

(Z 52 136)

Release the parking brake:

Lift and hold the lock of the parking brake valve. Swing the lever
(14) forwards up to the stop. The indicator light “Parking brake”
(39) must go out.

The parking brake holds the crane on a max. inclination of 28 %

but not on the maximum inclination on which the crane can be
driven.

If required, additionally secure the crane with chocks to prevent

it from rolling away on downhill slopes.

When using the parking brake as an emergency brake, do not

move the lever (14) suddenly, but slowly and evenly. The braking
effect can thus be applied infinitely variable. Do not allow the
lever to lock in place!

Only use the parking brake for parking or in the case of an

emergency.

Never drive with a defective brake system.

8.4 Brake Pressure Limit

(Optional equipment / national regulations)

For special transport conditions with reduced axle loads (for

special national regulations) the vehicle can be equipped with a
brake pressure limit.

Observe the permitted axle loads and drive carefully.

Observe the information sign in the driver’s cab.

Information on exceptional driving modes can be found in section

6 of these operating instructions.

140−2080 9/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

3
0 38

I
II
III
IV
V

Z 53 048

10/25 140−2080
 Brakes 8

8.5 Retarder Brakes

(Z 52 136, Z 53 048)

The standard crane vehicle is fitted with two sustained−action

brakes (exhaust brake, hydraulic retarder).
Both are actuated using the combination switch (3). When
switching on (lever at level I) the indicator light (38) lights up.

Risk of skidding!
Do not activate the exhaust brake / retarder on a slippery
road surface. The wheels can lock.

The sustained−action brake is automatically switched off as long

as there is ABS control. However, the indicator light (38) does not
go out. Afterwards, the operating mode most recently activated
is switched on.
In switching step I, only the exhaust brake is activated; from
switching step II onward, the hydraulic retarder is activated as
well. Depending on the lever position, the brake effect is
increased steadily from the first to the last step.
Lever in position
“0” = switched off
”I” = exhaust brake
”II− V” = exhaust brake + retarder, 4 steps
Especially when driving down longer downhill stretches, use the
sustained−action brakes. Also in normal driving conditions, the
non−wearing sustained−action brakes should be used where
possible for braking.

The effect of the exhaust brake and the hydraulic retarder is

dependent on the engine speed.
The higher the rpm/speed, the greater the braking effect.

The accelerator must not be pressed when the

sustained−action brakes are in operation!

The correct gear level must be selected before a down-

hill/uphill stretch is reached at which the speed can be
held at a constant level.

The effect of a sustained−action brake is interrupted dur-

ing a gear change. The vehicle can accelerate during
downhill driving.

140−2080 11/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

3
0 38

I
II
III
IV
V

Z 53 048

12/25 140−2080
 Brakes 8

Manual Driving Operation

The exhaust brake is deactivated by the system when changing

gears. After changing gears, the exhaust brake is automatically
activated again.

Automatic Driving Operation

When activating the exhaust brake the system automatically

switches back to the gear for which there is the maximum braking
performance.

8.5.1 Engine Brake (Exhaust Brake and Constant Throttle)

The engine brake consists of a combination of exhaust brake and

constant throttle.
The constant throttle valve is closed during normal operation.
When the exhaust brake is activated, it opens constantly and
increases the braking effect by reduced compression.

When the combination switch (3) is activated (lever in position

“I”), the exhaust brake is switched on; the indicator light (38) is
illuminated.

The exhaust brake is only effective at an engine speed of more

than 900 rpm. If the engine speed falls below 900 rpm, the
exhaust brake is automatically switched off (and switched back
on again when the speed increases).
The exhaust brake is deactivated even with an engine speed
over 2300 U/min.

140−2080 13/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

3
0 38

I
II
III
IV
V

Z 53 048

14/25 140−2080
 Brakes 8

8.5.2 Hydraulic Retarder (System “ZF Intarder”)

(Z 52 136, Z 53 048)

The retarder is an additional hydrodynamic brake which is

integrated in the transmission and functions without causing
wear.
The hydraulic retarder is switched on by activating the
combination switch (3) (lever in position II−V); the indicator light
(38) is illuminated. The brake effect is increased steadily from the
first to the last step.
Using the retarder has no effect on changing speed gear.
If the clutch is applied (for switching gears), the braking force of
the retarder remains unchanged.
Depending on the engine speed, the retarder is activated with a
short time delay.

When the hydraulic retarder is used, heat is created in the

transmission.
The transmission oil temperature is monitored indirectly (via
the coolant temperature of the engine) with the help of the
preheating indicator (B13) in the driver information display.

Before and during downhill driving, make sure that the

engine speed does not fall below 1600 U/min. Otherwise,
sufficient cooling is not ensured.
You might have to switch back a gear in order to increase
speed and therefore water pump and fan performance.

If the oil temperature rises to unauthorised values (over 1505 C)

− which leads to a coolant temperature which is too high − the
retarder performance must be reduced until the coolant
temperature has reached a steady state of less than 955 C.
If the retarder performance is not regulated by the driver, the
system automatically reduces the braking effect until the
permitted temperature has been achieved (again).

When the retarder braking effect has been reduced, the indicator
light (38) starts to flash.

The reduced braking effect must be taken into consideration

and driving must be adapted (gear selection, service brake).

Following longer downhill stretches with the retarder

switched on, the engine can only be switched off when the
temperature indicator has returned to the permitted range.

140−2080 15/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

38
3 6
0

A21

I
II
III
IV
7
V
Z 53 049

16/25 140−2080
 Brakes 8

(Z 52 136, Z 53 049)

8.5.3 Function “Sustained−Action Brake Cruise Control”

Using the function “Sustained−action brake cruise control” a set

(”fixed”) speed can be kept at a constant level during a downhill
stretch − within the limits of the existing braking capacity (engine
brake torque, gear level).

The sustained−action brake cruise control is activated using the

actuating lever (3) on the right−hand side of the steering column.
The preheating indicator (A21) of the driver display (43) is
illuminated.

The sustained−action brake cruise control can only be activated

if the sustained−action brake is switched on (= lever position I−V).
The desired driving speed − according to the speedometer − can
be selected and ”fixed” (lever position 6 or 7) in any lever position.
The electronic system saves the driving speed ”set” in this way.
The saved speed is maintained when the braking effect of the
sustained−action brake is sufficient.

If the current driving speed is lower than the “set” speed, the
sustained−action brake remains without function. If speed attains
the saved value again, the sustained−action brake becomes
active again.
If speed is increased while the sustained−action brake cruise
control is activated, the vehicle returns to the saved speed after
the driving pedal has been released.

If speed is to be reduced to lower than the currently set speed

using the sustained−action brake, the ”sustained−action brake
cruise control” must be switched off first (tap gearshift position 4).
Then the driving speed can be reduced manually via the different
levels (lever positions I−V) of the sustained−action brake. To do
so, the speed must be ”set” again from lever positions 6 / 7 as
described above.

A saved speed is automatically deleted if the ignition is switched

off.

140−2080 17/25
8

31 32 35 36 38 39
B3

43
3 B4

39
38
36
35
12
18 13 32
19 14
31
Z 52 136

38
3 6
0

A21

I
II
III
IV
7
V
Z 53 049

18/25 140−2080
 Brakes 8

Activating the sustained−action brake cruise control:

− Lever (3) in position

0 = deactivated
I−V = sustained−action brake step I−V (engine
brake and retarder)
6/7 = sustained−action brake cruise control
After the lever has been released, the current
speed is saved.

After the lever has been released, the vehicle drives with the
saved brake effect (speed).

Switching off the sustained−action cruise control:

Tap actuating lever (3) in position “4”.

140−2080 19/25
8

31 32 35 36 38 39
B27

B29
43
3 104
B30

38
36
35
12
18 13 32
19 14
31
Z 52 137

20/25 140−2080
 Brakes 8

(Z 52 137)

8.6 Anti−Blocking−System (ABS)

The vehicle is equipped with the blocking protection “ABS”.

The ABS circuit covers all axles (of the vehicle) and possibly a
dolly as well.
The function is monitored as follows:
− Lamps B29 + 32 for the vehicle axles.
− Lamps B30 + 31 for possible dolly axles / additional axle /
dummy axle.

The ABS stops the wheels from blocking when the vehicle starts
driving at walking speed − independent of the surface of the road
(water, iciness).

During ABS control, the sustained−action brake is automatically

switched off. However, the indicator light (38) does not go out.
Afterwards, the operating mode most recently activated is
switched on.

RISK OF ACCIDENTS!
ABS does not free you from driving in a way that is suit-
able for traffic and road conditions. Tracking and steer-
ing of the vehicle are improved.
For example, ABS is not able to prevent the conse-
quences of keeping too small a safety distance or of in-
creased curve speeds.

140−2080 21/25
8

31 32 35 36 38 39
B27

B29
43
3 104
B30

38
36
35
12
18 13 32
19 14
31
Z 52 137

22/25 140−2080
 Brakes 8

8.6.1 ABS: Full function / off−road mode

ABS is always active, however, the driver can switch it to

”Off−road mode” using key (104).
ABS in “Off−road mode” is indicated by indicator light (32)
flashing.

The brake path can be reduced on open country or unpaved

roads (i.e. soft or extremely bumpy surfaces as well as sloping
roads) by switching ABS over to ”Off−road mode”.
The control is speed−dependent; at higher speeds the ABS
control also switches to full function when in ”Off−road mode”.

ABS can be switched over when the vehicle is at a standstill (key

in the ignition lock in driving position) or during driving.

After the engine has been switched off and started again, full
function is automatically activated. When driving off the road,
switch ABS over again.

The off−road mode may not be used in public traffic.

8.6.2 ABS Functions Check / Fault Display

Every time the ignition is switched on, the signal connections to

the instrument panel are checked again.

The indicator lights (32 / 31) must light up for a short period of
time.

The preheating indicators (B29, B30) are only displayed if there

is damage.

Once the dual control signal goes silent (approx. 30 sec.) the
function check has been completed.

The indicator lights (31, 32) must light up for a short period
of time and must have gone out after the acoustic check
signal sounds.
Blocking protection is not ensured if the displays for
functions check do not light up or do not go out after the
check signal.

The preheating indicators (B29, B30) may not be illuminated.

If they are illuminated, blocking protection is not ensured at
the individual axles.

140−2080 23/25
8

31 32 35 36 38 39
B27

B29
43
3 104
B30

38
36
35
12
18 13 32
19 14
31
Z 52 137

1 2 5 3 4

Z 53 769

24/25 140−2080
 Brakes 8

RISK OF ACCIDENTS!
If an ABS fault is displayed, (”CAUTION” (35) would light
up at the same time), the braking behaviour of the ve-
hicle can change.
Drive especially carefully.
Have the fault rectified immediately at a specialist ga-
rage.

8.6.3 Braking with ABS

− In case of danger, fully activate the brake pedal. This ensures

that all wheels are controlled and an optimum deceleration of
the vehicle is achieved.
− During ABS control, the sustained−action brake is
automatically switched off. However, the indicator light (38)
does not go out.
− If you drive with a dolly without ABS, it can overbrake if you
have to make an emergency stop. In this case, the driver
must observe the towed vehicle in the rear−view mirror. The
towing vehicle with ABS remains steerable; This means that
the driver can keep his towed vehicle steady.
− If the indicator lights (31) “ABS control, dolly” or (32) “ABS
control, vehicle” light up, ABS will not function (defective) for
the dolly or towing vehicle.
− If only the indicator light (31) “ABS control, dolly” lights up, the
dolly can overbrake. In this case, the driver must observe the
towed vehicle in the rear−view mirror. The towing vehicle
(with ABS) remains steerable; This means that the driver can
keep his towed vehicle steady.
− If indicator light (32) “ABS control, vehicle” light up, ABS is in
“Off−road mode”.

8.6.4 ABS with Dolly Operation

(Z 53 769)

If the crane vehicle has been fitted with a dolly coupling (optional)
ex works, there is a special ABS socket (4) for the transfer of the
ABS function at the rear of the vehicle rear.

4 ABS socket 7−pole)

When using a dolly, the relevant regulations must be observed

(e.g. if for example ABS is required due to the number of axles).

140−2080 25/25
 Steering 9

9 Steering

9.1 General System Description

The steering of the crane chassis consists of a hydraulic

two−circuit steering system and electro−hydraulic rear−axle
steering (auxiliary steering system).

The direction of travel is mainly determined by the rigidly

connected front axles.

The rear axles, controlled by the program, are aligned and are
steered electro−hydraulically, depending on the speed.

A computer monitors the control of the electro−hydraulic

rear−axle steering. Possible fault codes can be read out there.
(For information pertaining to this, see “Steering computer / fault
diagnosis / fault list”)

Various steering programs are available for road travel and

construction site operation.

The oil supply of the hydraulic components consists of two

engine−dependent driven steering pumps and a
driving−dependent driven emergency steering pump.
During driving the emergency steering pump which is driven by
the moving crane controls the delivery rate from the main pump
2 and deactivates it as soon as the delivery rate is sufficient to
supply steering circuit 2.

If a steering circuit fails − or in case of engine failure − during

driving, the crane vehicle can still be steered until it comes to a
standstill. It does require increased effort, however, to move the
steering wheel and the steering reacts slower.

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9

2/51 140−2090
 Steering 9

9.2 Safety Instructions

9.2.1 Safety instructions for protecting the system

Adjustments to the steering system may only be carried out

by our customer service.

Inspections / maintenance work must be carried out by

specialist personnel.

When working on the vehicle (painting, welding) suitable

measures must be put in place to protect the electronic
components (protection against overloading and static
charging).

In particular when carrying out welding work the steering

computer must be removed from the vehicle.

Never remove live plug connections.

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9

4/51 140−2090
 Steering 9

9.2.2 Safety instructions for the protection of life and limb

for maintenance / service work

Caution risk of crushing!

When working on the steering system (e.g. inspections,
maintenance / service work, manual emergency steering)
there is an increased risk of crushing in the area of the
axles, wheels and track rods.
Always ensure that you have sufficient space for safe
movement.

Unauthorised persons must stay well clear of the turning

area of axles, wheels and track rods.

For maintenance work in the turning area of axles,

wheels and track rods, it must be ensured that these are
prevented from turning (switch off engine or deactivate
steering system).

If servicing is required (e.g. balancing the angle trans-

ducers), particular caution is required.
It must be ensured that no movements can occur on
axles, wheels, or track rods. This can be achieved by
switching off the engine or removing the connector at the
corresponding non−return valves.

Caution following servicing work!

Errors in the steering system can lead to axle move-
ments. When starting the engine, keep a safe distance
from the axles; nobody should be in the turning area of
axles, wheels and track rods.

Caution with the manual emergency steering control!

Particular care is required in case of manual emergency
steering. When actuating the valves for manual emer-
gency steering, the track rods and the wheels on the af-
fected axle will turn.

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9

35 36 B2

43
B8

B9

B10

35

36
Z 52 123

6/51 140−2090
 Steering 9

(Z 52 123)

9.3 Monitoring functions for all steering programs

The most important components of the steering system (function

of the steering / emergency steering pumps and
electric−hydraulic rear−axle steering) are monitored
electronically.

Faults are displayed on the “driver’s information” screen (43) by

means of the following indicator lights:

B2 Fault electric−hydraulic rear−axle steering

B8 Steering circuit 1 no flow

B9 Steering circuit 2 no flow

B10 Steering circuit 3 (emergency steering) no flow

The indicator lights can be displayed as either pink, white, yellow

or red.
The meaning of the colours is described in detail in section 4
(Driver’s cab) “Basic display / Meaning of colours”.

Each time the ignition is switched on the electronic system

checks the signal connections to the instrument board.
Once the dual control signal goes silent (approx. 30 sec.) the
function check has been completed.

A pink−coloured massage means that the function cannot be

monitored, because of a fault concerning the relevant
connection; e.g. short circuit or interruption.
In the case of pink−coloured messages, the display “Caution”
(36) automatically lights up as well.

When an indicator light lights up at the same time as the

warning light “caution” (36) there is a malfunction.
Determine the cause of the malfunction and remedy the
problem as quickly as possible.

If an indicator light lights up at the same time as the red

warning light “STOP” (35) there is a serious malfunction.
The operational reliability of the vehicle is endangered.
Switch off the vehicle immediately and rectify the fault.

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9

35 36 B2

43
B8

B9

B10

35

36
Z 52 123

8/51 140−2090
 Steering 9

(Z 52 123)

After rectifying the fault the warning display can be reset by

switching off the ignition for approx. 10 seconds. This also serves
to check that the fault has actually been rectified.
Equally, if an indicator light lights up, the system can be reset to
try and remedy the fault. To this end, stop the vehicle, switch off
the engine (switch off the ignition approx. 10 seconds) and
restart.

9.3.1 Monitoring the steering / emergency steering pump

The steering / emergency steering pump is monitored by the
indicator lights (B8 / B9 / B10) to ensure that it is working correctly.
These have the following meaning:

B8: Steering circuit 1 (”main pump 1”) no flow

B9: Steering circuit 2 (”main pump 2”) no flow

B10: Steering circuit 3 (emergency steering pump) no flow

Depending on the system, in case of the fault ”No through−feed

at the emergency steering pump” (indicator light B10) , there is
a display only once driving speeds > approx. 8 km/h have been
reached.

The indicator lights (B8, B9 and B10) must not light up as

a rule.
If one of these indicator lights is illuminated in red (at the
same time “STOP” (36) is displayed), there is a danger-
ous fault in the steering hydraulics.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!

In the case of a pink−coloured message, a function display is not

possible as there is a faulty connection. (See Notes under
“Monitoring functions“ in this section).

Function check

Regular inspections must be carried out to ensure that all

steering units, control units and monitoring equipment are fully
functional. Check for irregularities, e.g. leaks or pink−coloured
indicator lights / changing displays.

140−2090 9/51
9

35 36 B2

43
B8

B9

B10

35

36
Z 52 123

10/51 140−2090
 Steering 9

(Z 52 123)

9.3.2 Monitoring the electro−hydraulic rear axle steering

The function of the electric−hydraulic rear−axle steering is

monitored during driving by an alarm buzzer and the indicator
light (B2).

The preheating indicator (B2) signals a fault in the

electro−hydraulic rear−axle steering of the basic unit.

The warning buzzer sounds additionally for each new fault and
in the event of faulty operation during a program change.

The indicator light (B2) must not light up.

If it lights up red (at the same time “STOP” (36) would
also be displayed), there is a dangerous malfunction in
the electro−hydraulic rear−axle steering of the basic unit.
The crane must be stopped immediately and the damage
rectified. Never drive with a defective steering system!

In the case of a pink−coloured message, a function display is not

possible as there is a faulty connection. (see Notes under
“Monitoring functions“ in this section).

Function check

Check all steering components regularly for mechanical damage,

corrosion and wear.
In particular pay attention to the angle transducers on the front
/ rear axles and their steering (fixed properly, no corrosion).
Corroded parts must be replaced.

140−2090 11/51
9

92

43

A6

Z 52 124

12/51 140−2090
 Steering 9

(Z 52 124)

9.4 Steering programs

9.4.1 Selection of the Steering Programme “Road Travel”

or
“Construction Site Operation”

With the lockable switch “Enable steering programs” (92) the

system can be set to the steering program “road travel” (switch
not actuated) or ”construction site mode” (switch actuated). For
“construction site mode” the indicator light (A6) lights up.

The system can be changed back to the ”road travel” program

from all steering programs.

For normal road travel no special measures need to be carried

out (no actuation of switch!).
Briefly, for road travel, the program “narrow curving travel” can
be used.
For the purpose of road travel, all axles must be in the
synchronous position for the steering program “road travel”
(information on this available under “synchronisation of wheels
when changing the program” in this section).

For the special construction site mode there are various

steering programs
− “Manual rear axle steering”,
− “Narrow curving travel”,
− “Driving away from the wall” and
− “Diagonal steering”,
which − using various switches / buttons − need to be selected
case by case. The driving speed is limited.
It is only possible to switch from road travel to construction site
operation (switch 92) when the speed is below the max.
permissible speed of 5 km per hour.
’Road travel’ remains active until a corresponding steering
programme is selected.

Each selected steering program is assigned to a certain display.

The display follows in the form of an indicator light on the screen
(43) “Driver’s information”. A white indicator light shows a
preselected steering program; a yellow indicator light shows the
steering program that is currently active.

140−2090 13/51
9

92

43

A6

75 B2

Z 52 125

Z 160 025

14/51 140−2090
 Steering 9

9.4.2 Steering program “road travel”

(Z 52125, Z 160 025)

Caution, the vehicle swerves out.

The steering program “road travel” must be selected for driving

on public highways.
In the program “road travel” the axles are steered as follows:

− Front axles 1 and 2 (rigidly coupled) with the steering wheel.

− Rear axles 4 and 5 using the electric−hydraulic rear−axle

steering (depending on the driving speed).
(Axle 3 cannot be steered = rigid axle).

For driving speeds < 20 km/hour, the steered rear axles steer
around the steering centre of the front axles.

For driving speeds > 20 km/h the steering lock of the rear axles
is reduced as the speed increases.

The rear axles no longer steer for driving speeds > 45 km/h.

Caution !
For road travel switch (92) “Enable steering programs” may
not be actuated and the related indicator light (A6) must not
light up.
In addition the indicator light (B2) “Error electric−hydraulic
rear−axle steering” must not light up.

When the indicator light (B2) lights up together with the

warning light “caution” (36) the system has recognised a
malfunction. Determine the cause of the malfunction and
remedy the problem as quickly as possible.

Caution RISK OF ACCIDENTS !

When one of the indicator lights (A6 or B2) lights up to-
gether with the “STOP” display (35) and the warning
buzzer sounds, the operational reliability of the steering
is no longer guaranteed.
Stop the vehicle immediately; there is a serious risk of
accidents. Never drive with a defective steering system!

140−2090 15/51
9

A6
92

3a
85

86 87 88 89
Z 160 026

16/51 140−2090
 Steering 9

9.4.2.1 “Narrow cornering” for road travel

(Z 160 026)

When turning/manoeuvring through a small radius, for example

− as in the road travel mode − the steering program ”tight
cornering” can be selected when the crane is driven at speeds of
V < 20 km/h).
With the steering program “Tight cornering”, the 4th axle turns
more sharply than during normal on−road driving (as soon as a
steering angle of >85% is reached at axle 1) .
This achieves a smaller turning radius − albeit with increased tyre
wear.

Switch on steering program “Tight cornering”:

− Reduce driving speed to < 20 km/h.
− Press button (86) (”Narrow cornering” is preselected).
The indicator light (A3) appears (first in white).
− Continue to reduce driving speed to < 5 km/h.
The selected programme is activated;
The indicator light (A3) changes from the colour white to
yellow.
If the driving speed is not reduced to < 5 km/h within 20 seconds
of the program being selected, the previously active steering
program (”road travel”) is automatically selected.

Switch off the steering program “narrow road travel”:

− Press button (86) again.
The indicator light (A3) changes from the colour yellow to
white.
− Synchronise axles (information on this under
”Synchronising the axles during programme change” in this
section).
− In a usually rolling machine, the steering angle of axle 4 is
automatically synchronised with other steering axles after
a short stretch.
− As soon as the synchronised position has been achieved,
the indicator light (A3) goes out.
When a driving speed > 20 km/h is reached, “Tight cornering” is
also automatically switched back off again; The indicator light
(A3) goes out.

140−2090 17/51
9

”A” ”B” ”C” ”D”

Z 200 276

35
B2

43
6 9 35

Z 52 128

18/51 140−2090
 Steering 9

9.4.3 Steering program “construction site mode”

(Z 200 276, Z 52 128)

Depending on the selected programme, the steered rear axles

are steered by the monitoring programme, corresponding with
the front axles (axles 1 and 2) (computer−controlled separate
hydraulic circuit).
The non−steered axle 3 (”lift axle”) can be raised by the driver
from case to case (information on this under “raising / lowering
the lift axle”). The pressure gauges assigned to the raised axle
(6) and (9) do not display pressure in this case.

Through the various steering programs the following steering

figures are possible:

− “Manual rear−axle steering” (steering figure “A”)

− “Narrow cornering” (steering figure “B”)

− “Driving away from the wall” (steering figure “C”)

− “Diagonal steering” (steering figure “D”)

Enabling of the steering program “construction site mode” is

only permitted:

− on construction sites / non−public highways

− if the crane is in the transportation state

(boom set down, axle loads max. 17 t)

The ground conditions must be suitable for driving, i.e. flat and
even ground, no dips or rises in the ground, no obstructions.
The ground must be able to support the individual axle loads (up
to 17 t) and the overall weight.

The indicator light (B2) “fault electric−hydraulic rear−axle

steering”, with which the electric−hydraulic rear−axle
steering is monitored, must not light up.
When it lights up together with the “STOP” display (35)
DRIVING IS PROHIBITED!

140−2090 19/51
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10 Z 52 134

20/51 140−2090
 Steering 9

(Z 52 134)

Observe the following when using the steering programme

“construction−site operation”:

If the “lift axle” is raised, this inevitably results in increased

axle loads on the remaining axles on the ground.

After the ”lift axle” is raised − with the vehicle stationary − a

pressure of 260 bar must not be exceeded on any of the
pressure gauges (5, 8) and (7, 10).

For reasons of stability, the suspension must be set to the

“four−circuit system”.

The differential locks must not be actuated in the steering

figures “manual rear−axle steering” and “diagonal
steering”.
With the steering figures “tight cornering” and “driving away
from the wall” switching the differential locks on must be
avoided.

The crane may only be driven at walking speed (max. 5

km/h).

140−2090 21/51
9

92

43

A6

Z 52 124

22/51 140−2090
 Steering 9

9.4.3.1 Shared characteristics of all steering programs for

the “construction site mode”

− The basic release of the various steering programmes

“Construction site operation” is done by pressing the switch
(92) at speeds < 5 km/h.
At higher speeds the switch (92) can be activated, however,
there will be no release of the steering programmes
’Construction site operation’. In this case, the buzzer
sounds.

− In steering programmes “Construction site operation” only

driving speeds up to 20 km/h can be achieved (speed lock).

− The speed lock is only effective as long as the wheels are

not synchronised (again).

− If the preselected steering programme is not active within

20 seconds, the system automatically switches back to the
previously active steering programme.

− The programmes can only be selected at low speed (V <

5 km/h); they are only activated once the axles have been
synchronised.

− Normally “lift axle” (axle 3) remains on the ground; however,

it can be raised by the driver, in order to reduce the tyre
wear. (Information on this under “Raising/lowering the lift
axle” in this section.)

− It is only possible to raise / lower the “lift axle” when the

vehicle is at a standstill, the hand brake is applied, the
vehicle is in the neutral position with activated transmission
and pressed switch (92).

− It is only possible to lower the “lift axle”, if steering / turning

angles are within the permitted range (not raised for “lift
axle” state); Otherwise reduce the steering actions, e.g. by
turning the steering wheel (wheels straight).

− When the “lift axle” is raised, speed is limited to < 20 km/h.

− If the “lift axle “ remains on the ground, the steering angles,

by which the rear axles are automatically steered, of the
steering figures are restricted; i.e. not restricted for “Manual
rear−axle steering”.

− If the axles are not synchronised to the selected steering

programme, for example when limiting the steering angles
to protect against high tyre wear, each indicator light does
not appear in yellow but in white.

140−2090 23/51
9

85 A6
92

A18

2a
86 87 88 89

Z 160 027

24/51 140−2090
 Steering 9

(Z 160 027)

9.4.3.2 “Manual rear−axle steering” (steering figure “A”)

The front axles are steered with the steering wheel.

The lifting axle (not steered) remains on the ground; can be
raised by the driver.
The rear axles steer according to the position of the front axles
and manual activation using the dual button (85). Manual
steering of the rear axles enables steering movements to the left
or right, independent of the position of the front axles.
The front and rear axles are aligned geometrically correctly
(within their combination).
The vehicle speed is limited.
There is no limit to the steering angle against increased tyre wear
(steering error); not even if the “lift axle” remains on the ground.

Switch on the steering program “Manual rear−axle steering”

− Reduce driving speed to < 5 km/h.

− Press switch (92) “Release steering programmes“.
The indicator light (A6) lights up.
Speed lock (20 km/h) is effective and indicator light (A18)
lights up.
− Press button (85) “Manual rear−axle steering”.
The indicator light (A2) appears (first in white).
After the wheels are synchronised, the selected
programme remains active.
The indicator light (A2) changes from white to yellow.

− The rear axles can now be steered using switch (85):

Turn switch to the left = moves wheel to the left
Turn switch to the right = moves wheel to the right

Switch off the steering program “manual rear−axle steering”

− Lock switch (92) in position “Off”.
The indicator light (A6) goes out.
The indicator light (A2) changes from yellow to white.
− Synchronise axles (see ”Synchronising the axles”).
− As soon as the synchronised position has been achieved,
the indicator light (A2) goes out. The steering program
“road travel “ is back in action.

140−2090 25/51
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85 A6
92

A18

3a
86 87 88 89

Z 160 028

26/51 140−2090
 Steering 9

(Z 160 028)

9.4.3.3 “Tight cornering” (steering figure “B”)

The front axles are steered with the steering wheel.

The “lifting axis” (not steered) remains on the ground; can be
rectified by the driver.
The rear axles are steered analogous to the front axles by means
of the electric−hydraulic rear−axle steering. The axle 4 then turns
more strongly towards the end than for normal road travel.

Driving speed is limited.

If the “Lift axle” remains on the ground, the steering lock is limited
to prevent excessive tyre wear (steering error).

Switch on steering program “tight cornering”

− Reduce driving speed to < 5 km/h.

− Press switch (92) “Release steering programmes“.

The indicator light (A6) lights up.
Speed lock (20 km/h) is effective and indicator light (A18)
lights up.

− Press button (86) (”Narrow cornering” is preselected).

The indicator light (A3) appears (first in white).
After the wheels are synchronised, the selected
programme remains active.
The colour of the preheating indicator (A3) changes from
white to yellow.

Switch off the steering program “tight cornering”

− Lock switch (92) in position “Off”.

The indicator light (A6) goes out.
The indicator light (A3) changes from the colour yellow to
white.

− Synchronise axles (see ”Synchronising the axles”).

− As soon as the synchronised position has been achieved,

the indicator light (A3) goes out. The steering program
“road travel “ is back in action.

140−2090 27/51
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85 A6
92

A18

A4

86 87 88 89

Z 160 029

28/51 140−2090
 Steering 9

(Z 160 029)

9.4.3.4 “Driving away from the wall” (Steering figure “C”)

The steering centre is to the rear of the vehicle; the rear does not
swing out.
The front axles are steered with the steering wheel.
The “lifting axis” (not steered) remains on the ground; can be
rectified by the driver.
The rear axles are steered analogously to the front axles by
means of the electric−hydraulic rear−axle steering.
The vehicle speed is limited.
If the “Lift axle” remains on the ground, the steering lock is limited
to prevent excessive tyre wear (steering error).

Do not lock the front axles further once the indicator light
(A4) switches from yellow to white.
The rear axles have then reached their final position − as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tyres could be separated from
the rims.

Switch on the steering program “Drive away from the wall”

− Reduce driving speed to < 5 km/h.

− Press switch (92) “Release steering programmes“.

The indicator light (A6) lights up.
Speed lock (20 km/h) is effective and indicator light (A18)
lights up.

− Press button (87) (”Driving away from the wall” is

preselected).
The indicator light (A4) appears (first in white).
After the wheels are synchronised, the selected
programme remains active.
the indicator light (A4) changes from white to yellow.

Switch off the steering program “Driving away from the wall”

− Lock switch (92) in position “Off”.

The indicator light (A6) goes out.
The indicator light (A4) changes from yellow to white.

− Synchronise axles (see ”Synchronising the axles”).

− As soon as the synchronised position has been achieved,

the indicator light (A4) goes out. The steering program
“road travel “ is back in action.

140−2090 29/51
9

85 A6
92

A18

A5
86 87 88 89

Z 160 030

30/51 140−2090
 Steering 9

(Z 160 030)

9.4.3.5 “Diagonal steering” (steering figure “D” (crab travel))

The rear axles steer in the same way and at the same angle
(parallel) as the front axles. The steering lock is determined by
the steering wheel.
The “lifting axis” (not steered) remains on the ground; can be
rectified by the driver.
The vehicle speed is limited.
If the “Lift axle” remains on the ground, the steering lock is limited
to prevent excessive tyre wear (steering error).

Do not turn front axles further, once the indicator light (A5)
changes from yellow to white.
The rear axles have then reached their final position − as
specified by the program (no further movement).
Further steering leads to a deterioration in the steering
figure / system benefits and tyres could be separated from
the rims.

Switch on the steering program “diagonal steering”

− Reduce driving speed to < 5 km/h.
− Press switch (92) “Release steering programmes“.
The indicator light (A6) lights up.
Speed lock (20 km/h) is effective and indicator light (A18)
lights up.
− Press button (88) (”Diagonal steering” is preselected).
The indicator light (A5) appears (first in white).
After the wheels are synchronised, the selected
programme remains active.
the indicator light (A5) changes from white to yellow.

Switch off the steering program “diagonal steering”

− Lock switch (92) in position “Off”.
The indicator light (A6) goes out.
The indicator light (A5) changes from yellow to white.
− Synchronise axles (see ”Synchronising the axles”).
− As soon as the synchronised position has been achieved,
the indicator light (A5) goes out. The steering program
“road travel “ is back in action.

140−2090 31/51
9

32/51 140−2090
 Steering 9

9.4.4 Synchronising the wheels when changing program

Synchronisation means that the wheels of all steered axles are

brought into one specified position in accordance with the
individual steering program.
The change to a different steering program is complete once all
axles have been synchronised.
The change between the individual steering programs can only
be carried out once all axles have been synchronised.
Synchronisation can be achieved by:
− Driving off
Moving the vehicle at speeds over 2 km/h.
While the unit is rolling, the steering angle of the rear axles
is automatically synchronised with the other steering axles
after a short stretch
or
− Operation of keys during standstill
Continuous operation of the relevant steering programme
key during standstill; the axles automatically move to the
desired position, as long as the key is pressed.
When changing back to the steering programme ’Road
travel’, synchronisation to the road travel state can be
achieved by continuously pressing the switch ’Narrow
cornering’ (E 141). To do so, the wheels of the front axles
must be aligned in the straight−ahead position.
If the adjustment force of the steering cylinders is not
sufficient to reach the desired position, e.g. if there is an
obstacle on the ground, the vehicle must be driven to another
spot.
or
− Steering movements when stationary
Larger steering movements to the front axle when stationary
by adjusting the steering wheel (right / left).
With this procedure, the so−called ”capture” of the
electric−hydraulic steered axles, these are individually
moved along with the front axles. As soon as the front axles
are moved, the rear axles begin to synchronise.

An axle that is not positioned in the specified geometry, is

automatically positioned to the value pre−set by the selected
program (synchronised) at the latest when the vehicle starts to
move.

When synchronising in a stationary position, the procedure can

be assisted by releasing the retaining brake.

140−2090 33/51
9

5
6
7
92 A6

8
9
10

102 A14
Z 52 133 Z 52 134

I II III

IV V VI

Z 160 031

34/51 140−2090
 Steering 9

9.4.5 Raising/Lowering the “Lift Axle”

(Z 52 133, Z 52 134, Z 160 031)

It is only possible to raise / lower the “lift axle“ when the vehicle
is at a standstill, the retaining brake is applied, the transmission
is switched to the neutral position and the switch (92) is pressed.
With the “lift axle” raised the speed is limited to < 20 km/h.

9.4.5.1 Raise the “Lift Axle”

12. Stop vehicle; apply parking brake; transmission in “neutral”!

13. Set the engine speed to approx. 1500 rpm .
14. Actuate switch (92) “enable steering programs“.
The indicator light (A6) lights up.
15. Actuate “Raise lift axle” (102) switch (unlock); by doing so the
“lift axle” (axle 3) is raised to the upper end position.
The indicator light (A14) lights up.
The pressure gauges 6 and 9 display no pressure.
16. Carry out a visual check to make sure that the raised wheels
of axle 3 are actually clear of the ground.

9.4.5.2 Lower the “Lift axle”

It is only possible to lower the “lift axle”, if steering / turning angles

are within the permitted range (not raised for “lift axle” condition);
Otherwise reduce the steering actions, e.g. by turning of steering
wheel (wheels straight).

1. Stop vehicle; apply parking brake; transmission in “neutral”!

2. Switch off the switch “raise lift axle” (102) (lock).
The raised “Lift axle” is lowered to the ground again.
The indicator light (A14) goes out.
3. If the “Lift axle” is on the ground, a pressure of 105 bar is built
up automatically again in the separated suspension circuits
(II / V) and they are connected again to the individual overall
suspension circuit (III or VI).
4. The overall level must be checked for road travel (re−level if
required).

140−2090 35/51
9

F1 F2 F3 F4

Z 52 116

36/51 140−2090
 Steering 9

9.5 Steering Computer / Fault Diagnosis / Fault List

The steering computers are in the floor of the driver’s cab under
the passenger seat. In order to get to the steering computers, the
entire seat − along with its baseplate − must be moved into the
most frontal position and then folded up towards the front
(against the front window).

Risk of injury!
The raised seat must be secured in place with suitable
means (e.g. wooden block, strut) to prevent it falling
backwards.

9.5.1 Operating functions

(Z 52 116)

The display (A) and the 4 function keys (F1 − F4) are directly on
the main computer.
The buttons have the following basic functions:

ESCAPE button (F1):

− Exit the current menu.
− End without saving.
− Back one entry position.

MINUS button (F2):

− Back one selection point (e. g. previous fault).
− Reduce value by 1.

PLUS button (F3):

− One selection point further (e. g. next fault).
− Increase value by 1.

ENTER button (F4):

− Activate selected menu.
− Confirm value.
− Save value.
− One entry position further.

140−2090 37/51
9

35 36
B2

43

35

36

Z 52 117

F1 F2 F3 F4

Z 52 116

38/51 140−2090
 Steering 9

(Z 52 117, Z 52 116)

9.5.2 Registration of a fault

The electric−hydraulic rear−axle steering has a self−diagnosis

system.
When the system recognises a fault, this is displayed to the driver
on the display (43) “driver’s information” by the indicator light (B2)
and additionally signalled by the warning buzzer.

Although they cannot be seen by the driver while driving, all

errors are displayed simultaneously at the relevant steering
computer (main steering computer: display A ; no display at
steering computer: at double−digit segment display)
∗ Active faults are always displayed with the indicator light (B2).
∗ If the vehicle is moving when a fault occurs, the warning
buzzer also sounds.
∗ The warning buzzer sounds whenever the crane moves off
in the faulty condition.
∗ Faults that occur remain active until the ignition is switched
off, regardless of whether the fault still exists or not.
∗ An active fault is automatically stored in the error memory.

9.5.2.1 Fault display on the display (43) “driver’s

information”

Caution !
When the indicator light (B2) lights up together with the
warning light “caution” (36) the system has recognised a
malfunction. Determine the cause of the fault and rectify as
soon as possible.
An attempt can be made to rectify the fault by resetting the
system. To this end, stop the vehicle, switch off the engine
(switch off the ignition approx. 10 seconds) and restart.

Caution RISK OF ACCIDENTS !

When the indicator light (B2) lights up together with the
“STOP” display (35) and the alarm buzzer sounds, the
operational reliability of the steering is no longer guaran-
teed.
Stop the vehicle immediately; there is a serious risk of
accidents. Never drive with a defective steering system!

See also section 6: “Driver information display (43)”.

140−2090 39/51
9

Z 52 118

Z 52 119

40/51 140−2090
 Steering 9

9.5.2.2 Fault display on screen (A) of the steering computer

Display in the fault−free condition

(Z 52 118)

In addition to the display “no error” in the second text line a “ > ”
sign moves from left to right. This moving display signals that the
steering computer is active and the software is being processed.

Display of active faults

(Z 52 119)

As soon as the system has recognised a fault, the display

changes to the fault code screen.
Faults are described according to location of fault, type of fault
and category of fault. All three individual codes are displayed.
− Example place of error: 10
− Example error type: 07
− Example error class: 01

If several faults exist at the same time, the display automatically

switches to the next fault after 2.5 seconds.

If all faults have been rectified, the display changes back to the
fault−free state (”no error”, “ >” symbol).

140−2090 41/51
9

F1 F2 F3 F4

3 sec.
Z 52 120

Z 52 121 Z 52 122

42/51 140−2090
 Steering 9

9.5.3 error memory / fault codes

Up to 32 various faults with 3 fault codes each can be stored in
the error memory of each steering computer. If the error memory
is full, the first entered fault is overwritten.
The fault codes can be read off the display of the steering
computer. They are subdivided according to the location, type
and category.

9.5.3.1 Activate / read off error memory

(Z 52 120, Z 52 121)

To read off the error memory with the display (A), first the menu
point ”error memory” must be selected in the menu for special
functions.

Select special functions menu:

The menu for special functions is activated by pressing the ESC
and ENTER keys (F1, F4) at the same time for at least 3 seconds.
The change is made when the screen switches to “i/o data
display”.

Move on to the menu item “error memory”:

The PLUS−key (F 3) switches from “i/o data display” to “error
memory”.

Activate error memory:

Use the ENTER−key (F4) to activate the error memory function.
The display changes to the first fault that is stored. (Z 52 121)

Reading Off the Error memory

Using the PLUS and MINUS keys (F2 / F3), all faults can be read
out one after the other. At the end of the error memory (fault 32)
the system automatically returns to the beginning (fault 1).

As soon as the code display “255, 255, 255” appears on the

screen, there are no additional faults in the memory.
The fault before the display “255” is the last entered fault. With
a completely deleted error memory, only code entries with “255”
are maintained. (Z 52 122)

Exit error memory function:

Using the ESC key (F1), the error memory function can be exited
at any time.

140−2090 43/51
9

F1 F2 F3 F4

Z 52 116

LCD

Z 53 001

44/51 140−2090
 Steering 9

(Z 52 116, Z 53 001)

Remote−controlled operation:
Individual steering computers of the system do not have their own
display. The faults of all steering computers are read off centrally
at the display screen (A) of the main steering computer.
To do this, the menu point ”remote control” must be selected in
the ”special functions” menu.

1. Select the ”special functions” menu (press buttons F1, F4 at

the same time for at least 3 seconds).

2. Using the ENTER button (F4) select the menu point “remote
control”.
Display text: “remote control LCD”

3. With the PLUS− and MINUS button the numbers of the

steering computer can be selected.
The display changes to select the desired steering computer.

4. Note:
When the desired steering computer is selected, the display
switches constantly between “choose SLC: ?? and the
contents of the display of the other steering computer. If the
selected computer fails to answer, “No connection” appears.

5. Using the ENTER button (F4) change to the selected

steering computer.

6. Activate / read error memory of the selected steering

computer:
Carry out “Activate / read error memory” procedure (as
described on the previous page).

7. Exit the selected steering computer:

By switching off the ignition.

9.5.3.2 Delete error memory

The error memory may only be deleted in consultation with our

customer service department.

140−2090 45/51
9

35 36
B2

43

35

75
36

12
18 13
19

Z 52 117

46/51 140−2090
 Steering 9

9.5.4 Fault categories / fault reaction

(Z 52 117)

The faults are divided into the fault categories 0 to 3 and are
entered in the error memory of the steering computer.
The fault category determines the reaction of the steering to the
fault and the subsequent effect on steering operation.

Fault category 0
Display (43) shows: No
reaction of the steering: Warning; steering behaviour is not
affected.
Effect: Unlimited driving mode possible.

Error class 1

Display (43) shows: Indicator light (B2) + “Caution” (36) + single

warning signal.
Reaction of the steering: the axle / system is steered to the next
straight position.
Effect: Speed block is partially active.

Error class 2
Display (43) shows: Indicator light (B2) + “Caution” (36) + single
warning signal or indicator light (B2) + “STOP” (35) + repeated
warning signal.
Reaction of the steering: Automatic steering in straight position.
Effect: Speed limiter active.

Fault category 3
Display (43) shows: Indicator light B2 + “STOP” (35) + repeated
warning signals.
Reaction of the steering: Self−centring / locking of the axles
(safe condition).
Effect: Speed limiter active.

If faults of categories 1, 2 and 3 are present in the error

memory, these codes must be provided to our customer
service department; they will then determine the causes of
the fault and issue suitable measures to be taken.

9.5.5 Fault list (following)

140−2090 47/51
9

Y1

X2

X1
Z 52 123

Z 200 283

48/51 140−2090
 Steering 9

(Z 52 123, Z 200 283)

9.6 Manual emergency steering

Caution, increased risk of crushing!

When the valves for the manual emergency steering con-
trol are actuated the track rods and the wheels move on
the affected axle. In the case of manual emergency steer-
ing, particular caution is therefore required.
Make sure that you have sufficient space to move in
freely.

If the steering computer fails, the electrical current is cut off to all
valves; i.e. the steered rear axles are only locked in their current
position.

To be able to adjust these axles without the computer being

active, the steering system is equipped with a manual emergency
steering control. This enables the non−return valves (Y) to be
moved from their locked position, thus releasing the axles.
Subsequently, each individual axle can be moved into a useable
position by manual actuation of the solenoid valves (X1 / X2), for
example to move the vehicle out of a hazardous area. The
requirement for this is that the steering hydraulics are available
(vehicle engine running).

Each axle has its own valve block with non−return valve (Y) and
solenoid valve (valve tappet X1 / X2) assigned to it. The valve
block is at point “A” of the undercarriage under the aluminium
cover.

Caution RISK OF ACCIDENTS !

For normal operation, the non−return valves must not be
actuated manually.
They may only be used in a case of emergency; e.g. in
order to remove the vehicle from a danger area. The
check valves must then immediately jump back to their
initial position.
If the check valves do not jump back to their initial posi-
tion, e.g. because they are stuck, then safe steering is no
longer ensured. The axles can change position in an un-
controlled fashion. Safety risk!

140−2090 49/51
9

Y1

X2

X1
Z 52 123

50/51 140−2090
 Steering 9

(Z 52 123)

Steps for positioning an axle

1. Stop vehicle; apply parking brake; secure against rolling

away; transmission in “neutral”; engine running.

2. Release axle:
Operate check valve (Y) by pressing the button (Y1) in the
blue anodised knurled nut; keep button pressed.
The axle is no longer locked as long as this button is pressed.

3. Move axle:
− to the left: valve tappet, press left (X1).
− to the right: valve tappet, press right (X2).

4. Lock axle:
If the axle is in the desired position (usually this will be the
straight ahead position):
∗ Release the valve tappet (X1 / X2).
The axle no longer moves.
∗ Let go of button (Y1); the valve anchor will jump back to its
initial position.
The axle is locked again.

RISK OF ACCIDENTS!
If the check valve is not set back to its initial position, the
relevant axle can shift in an uncontrolled manner during
driving.

140−2090 51/51
 Differential Locks 10

10 Differentials / Differential Locks

10.1 Differentials

To distribute the drive torque to the driven wheels and to adapt

the wheel speeds when driving through curves the following
differentials (drive assemblies) are fitted:
− Longitudinal differential in the distributor gear
The distributor gear forms a unit with axle 3.
− Longitudinal Differential in the Axles
The longitudinal differential is fitted in axle 4.
Activating axle 3:
Axle 3 is activated by activating the longitudinal lock in axle
4.
− Transverse Differential
A transverse differential is fitted in each drive axle.

10.2 Differential Locks

The differentials in the distributor gear and axles which work

lengthways and the transverse differentials can be locked.
In the locked condition, there is a rigid connection between the
two outputs of the differentials.

The differential locks need to be switched on in the following

circumstances:
− A wheel of a drive axle is standing on a loose surface and is
spinning:
The transverse differentials must be locked.
− Both wheels of a drive axle are spinning:
The longitudinal differentials must be locked.

Only in extreme cases may both differential locks be switched on

together.

If the differential locks are switched on, you may only drive
at walking speed.

The differential locks may not be activated in the steering

figures “Manual rear−axle steering” and “Diagonal
steering”.
You must avoid activating the differential locks during
steering figures “Narrow cornering” and “Driving away from
the wall”.

140−2100 1/7
10

2/7 140−2100
 Differential Locks 10

10.3 Activating the Differential Locks

When the differentials are locked there is a risk of parts of the

drive being overloaded. Extreme caution is always required when
driving the crane with the differentials locked.

Only use the differential locks to drive on difficult territory

(sand, mud, loose ground).

Only switch on differential locks shortly before reaching an

obstacle and switch them off immediately after the obstacle.

Only switch on and off when the crane is at a standstill. There

is an extremely high risk of the crane being damaged if the
differential locks are switched on when the drive wheels are
turning.

When the longitudinal differential is locked, the steering can

be actuated with extreme caution.
When the transverse differential is locked, the crane may
only be driven in a straight line.

Only use differential locks when the crane is in the transport

condition. Under no circumstances may they be used when
the crane is erected!

Drive carefully! Do not start or stop abruptly! Do not apply

full throttle!

When the differentials are locked, never drive on longer

stretches or on solid surfaces with good traction.

140−2100 3/7
10

94 95
A9

A10

Z 52 140

4/7 140−2100
 Differential Locks 10

10.3.1 Activating the Longitudinal Locks

(Z 52 140)

Activate the longitudinal locks as follows:

1. Stop the crane; wait for it to come to a standstill!

2. Press switch (94).

The longitudinal locks in the distributor gear and in axle 4 are
switched on and axle 3 is selected.

3. The indicator light (A9) lights up.

Switch off the longitudinal locks as follows:

1. Stop the crane; wait for it to come to a standstill!

2. Press switch (94) again.

The longitudinal locks in the distributor gear and in axle 4 are
switched off and axle 3 is cut out.

3. The indicator light (A9) goes out.

If, when switching off the longitudinal locks, display (A9) does not
go out, the lock has not disengaged.
activate the lock again and carry out small changes in direction
with the crane vehicle. At the same time turn the steering a few
times to the left and right.
At a standstill, switch off the locks again.

140−2100 5/7
10

94 95
A9

A10

Z 52 140

6/7 140−2100
 Differential Locks 10

10.3.2 Activating the Transverse Locks

(Z 52 140)

First switch on the longitudinal locks.

The transverse differentials may only be applied when it is no
longer possible to proceed even though the differential locks are
applied.

Switch on the transverse locks:

1. Stop the crane; wait for it to come to a standstill!

2. Press switch (95).

The transverse locks of the drive axles are activated
together.

3. The display (A10) lights up.

Switch off the transverse locks as follows:

1. Stop the crane; wait for it to come to a standstill!

2. Press switch (95) again.

The transverse locks of all drive axles are switched off
together.

3. The display (A10) goes out.

If, when the transverse differentials are switched off, the display
(A10) does not go out, the lock has not disengaged.
Activate the transverse lock again and carry out small changes
in direction with the crane vehicle.
When at a standstill switch off the lock again.

140−2100 7/7
 Hydraulic Suspension 11

140−2110−113a 1/25
11

99

43

A6

Z 52 145

Z 200151

2/25 140−2110−113a
 Hydraulic Suspension 11

11 Hydraulic Suspension

(Z 52 145, Z 200 151)

All axles of the crane chassis have hydraulic suspension.

During normal use (e.g. when driving on the road) the hydraulic
suspension is divided into four separate circuits.

When driving on road surfaces which are very uneven (extreme

ramps, slopes, humps), the suspension can be switched over to
a three−circuit system to improve road handling.

You switch to the three−circuit system by pressing the lockable

switch (99).
When indicator light (A6) comes on, the suspension is in the
three−circuit system.

Driving with the three−circuit system means less lateral

stability. The max. road speed should therefore not exceed
15 km/hour.

When the crane’s equipment is erected, it must be driven

with the four−circuit system.

All operating and monitoring equipment is located in the cab of

the chassis.
You can call up the current settings of the suspension circuits on
display (43) under menu point 4.1 “Suspension levels”. (Example
middle position Z 200 151)

Proceed with caution when carrying out adjustment

work! Risk of crushing!
Make sure that no−one is in the danger zone of the verti-
cally extending / retracting suspension cylinders.

140−2110−113a 3/25
11

5 6 7

8 9 10
Z 53 784

Z 53 785

4/25 140−2110−113a
 Hydraulic Suspension 11

11.1 Distribution of the suspension circuits / assignment

of the pressure gauge
(Z 53 784, Z 53 785)

11.1.1 In normal situations: Four−circuit System

− Suspension circuit I:
axle 1 to 2, front right
pressure gauge I (5)
− Suspension circuit II: *
separate suspension circuit for “Lift axle”
axle 3, right
pressure gauge II (6)
− Suspension circuit III:
axle 4 to 5, rear right
pressure gauge III (7) + II (6)
− Suspension circuit IV:
axle 1 to 2, front left
pressure gauge IV (8)
− Suspension circuit V: *
separate suspension circuit for “Lift axle”
axle 3, left
pressure gauge V (9)
− Suspension circuit VI:
axle 4 to 5, rear left
pressure gauge VI (10) + V (9)
∗ When the lift axle (axle 3) is raised, the suspension circuits
II / V assigned to this axle are automatically separated from
the other axles (separate pressure display on pressure
gauges II / V (6 / 9)) and − after it has been lowered to the
ground − switched to suspension circuits III / VI again.

11.1.2 Exception: Three−circuit System

− Suspension circuit I + IV:

axle 1 to 2, front right and left
pressure gauge I (5) / IV (8)
− Suspension circuit III:
axle 3 to 5, rear right
pressure gauge III (7) + II (6)
− Suspension circuit VI:
axle 3 to 5, rear left
pressure gauge VI (10) + V (9)

140−2110−113a 5/25
11

76 77

78 79

80 81

Z 35 554 Z 52 148

100 101 102

9/19

A12 A13 A14 A15

Z 51 302

6/25 140−2110−113a
 Hydraulic Suspension 11

11.2 Setting for Driving in the Transport Position

(Z 35 554, Z 52 148, Z 51 302)

11.2.1 General

When driving the mobile crane in the transport position

(construction site or road travel) the suspension must be at the
road travel level (all suspension cylinders in the road travel
position).
In this case, the gap of the fastening eyes on the suspension
cylinders (measurement ”X ”) is 630 mm. Only this state ensures
that there is sufficient suspension travel for driving operation.
At the road travel level the suspension travel is + 110 / −110 mm
(110 mm to the top / 110 mm to the bottom).

The hydraulic suspension can only be set if:

− ”Hold axles” is activated (display (A13) lights up).
− ”Raise axles” is activated (display (A15) lights up).

”Raise all axles” is activated on the switch panel of the outrigger

controls (button 9/19).
First “Hold axles” (button 101) must be actuated in the cab.

When the ”Lift axle” is raised (steering program “Construction site

operation”), the suspension circuits only react partially. The two
front ones can be set, the two rear ones cannot (with the
exception of axle 3).

The levels of the suspension circuits can either be set together

(dual button 76) or individually (dual buttons 78 / 79 / 80 / 81).

11.2.2 “Automatic” setting road travel level

Using the “AUTO” (77) button the road travel level is set
automatically.

The road travel level is the condition for normal driving operation.
All suspension cylinders are located in the road travel position.
The individual suspension travel movements equal − 110 / +110
mm.

The requirement for smooth functioning is a level, even road

surface (no potholes, no lateral gradient).

140−2110−113a 7/25
11

76 77

78 79
B

80 81

Z 51 303

Z 200151

8/25 140−2110−113a
 Hydraulic Suspension 11

(Z 51 303, Z 200 151)

11.2.3 “Manual” Setting of the Level

Using manual setting of the level, the individual suspension

circuits can be set independently of each other. Each level in the
entire range of the suspension movement (between 0 and 220)
can be set.
Manual level setting is only possible when standing still (parking
brake applied, transmission “in neutral”).

Starting position:
− set crane down on level and horizontal ground; apply parking
brake; transmission in “neutral”!
− Set the engine speed to approx. 1500 rpm .

11.2.3.1 Function of the dual buttons (78, 79, 80, 81)

− Press dual button on item “A”: The corresponding

suspension circuit is raised
− Press dual button on item “B”: The corresponding
suspension circuit is lowered

11.2.3.2 Setting the Suspension Circuits (Four−circuit System)

The suspension circuits can be reset using the “Raise / lower”
function of the dual buttons (78, 79, 80, 81).
To level the crane quickly and/or evenly, different (or all) circuits
must be filled or emptied at the same time.
It is not possible to set circuits in different directions (filling one
circuit while emptying another) at the same time.

Suspension circuit 1 (front right)

− Press dual button (79A):

“Raise level” (extend suspension cylinder)
− Press dual button (79B):
“Lower level” (retract suspension cylinder)

140−2110−113a 9/25
11

76 77

78 79
B

80 81

Z 51 303

Z 200151

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 Hydraulic Suspension 11

(Z 51 303, Z 200 151)

Suspension circuit 2 (rear right)

− Press dual button (81A):
“Raise level” (extend suspension cylinder)
− Press dual button (81B):
“Lower level” (retract suspension cylinder)

Suspension circuit 3 (front left)

− Press dual button (78A):

“Raise level” (extend suspension cylinder)
− Press dual button (78B):
“Lower level” (retract suspension cylinder)

Suspension circuit 4 (rear left)

− Press dual button (80A):

“Raise level” (extend suspension cylinder)
− Press dual button (80B):
“Lower level” (retract suspension cylinder)

Information for setting the overall level:

The difference with this compared to the individual settings is that
all suspension circuits can be reset together using key (76). Any
possibly existing level differences remain.
Press / hold key (76A) = raise total level
Press / hold key (76B) = lower total level.
Check: On display (43) under menu point 4.1 “Suspension
levels”.
With the manual level setting, the suspension cylinders can
be extended / retracted up to the stop (”in a block”). In this
case make sure that the pressures shown at the middle
position are not exceeded. It is prohibited to drive
suspension cylinders that are set to ”in a block”.
11.2.3.3 Setting the Suspension Circuits (Three−circuit
System)
The suspension circuits are normally set in the four−circuit
system (road travel).
However, the setting can also be made in the three−circuit
system (off−road travel).
Make sure that the two front circuits react correspondingly; even
when only one of the assigned dual buttons (78, 79) are
activated.

140−2110−113a 11/25
11

5
6
7

8
9
10

Z 52 147

B1

Z 53 786

12/25 140−2110−113a
 Hydraulic Suspension 11

11.3 Monitoring the Hydraulic Suspension

11.3.1 Monitoring the Pressure

(Z 52 147, Z 53 786)

For constant control of the pressure in the hydraulic suspension,

there are corresponding pressure gauges (items 5−10) in the
driver’s cab.

The desired value of the suspension pressure can only be

determined precisely after the suspension cylinders have been
levelled.
With a 12 t axle load, the suspension pressure should be
approximately 105 bar (average value) and can be different for
each suspension circuit.
If the suspension system is switched to ”road travel”, the
suspension pressure can fall on one side and rise on the other
side of the vehicle when driving around corners.

If the suspension pressure falls abruptly in one of the

suspension circuits during road travel, or / and the level
changes noticeably (display B1 is illuminated), the
suspension has a dangerous malfunction.
In this case you must stop the mobile crane, find the cause
of the fault and rectify it.

140−2110−113a 13/25
11

C 2 1 A

D B

Z 52 149

14/25 140−2110−113a
 Hydraulic Suspension 11

11.3.2 Level Control, Level Indicator

(Z 52 149)

Level control of the suspension circuits takes place on the display

(43) in the driver’s cab. The current level of the individual
suspension circuits is indicated with symbols under menu point
4.1 “Suspension level”.
− Symbol (A): suspension circuit I (front, right)
− Symbol (B): suspension circuit III (rear, right)
− Symbol (C): suspension circuit IV (front, left)
− Symbol (D): suspension circuit VI (rear, left)

A level indicator has been assigned to each suspension circuit

which consists of fixed vertical bars (1) and a ”piston” (2) which
moves up and down as the level goes up or down.

In the road−travel level

the bar (1) is coloured green and the “piston” (2) is in the middle
of the bar − corresponding to the road travel position of the
suspension cylinders.

In all intermediate positions

outside the road travel level the bar (1) is coloured yellow and the
“piston” (2) moves further upwards or downwards.

Carry out a level check on level, even ground with the wheels
facing straight ahead.
Deviating suspension circuits must be reset.

If constant deviations occur, the suspension must be

checked by our customer service.

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11

100 101 102

9/19

A12 A13 A14 A15

Z 51 302

16/25 140−2110−113a
 Hydraulic Suspension 11

11.4 to lock the suspension

The hydraulic suspension system must be blocked for driving in

an erect mode (see section 6).

When driving in the transport position (on the road and

construction site) the hydraulic suspension may not be
blocked.
If the suspension were blocked, it would cause great
damage to the chassis at speeds > 5 km/h!

11.4.1 Activating the Suspension Block

. . . Before Driving in an Erect Mode
(Z 51 302)

Driving in the erect condition always means driving wi-

thout load!
Driving with load is prohibited!

Before supporting the crane on outriggers:

− Align the crane horizontally (”level”).
− Activate switch ”Hold axles”(101), display (A13) is illuminated.
All axles remain in the prescribed position.
The crane can be lowered onto the wheels after it has been
supported on outriggers for driving in the erect condition by
retracting the vertical outrigger cylinders.
The crane is aligned horizontally and the suspension cylinders
are in the road travel position.

Before driving in the erect mode:

− The regulations for ground characteristics and road slope
(see section 6) must apply.
− Extend the outrigger struts and hold the outrigger feet just
above the ground.
− Before the crane is lowered onto the wheels − for driving in
the erect/configured condition, all suspension cylinders must
be in the road travel position.

This is always guaranteed if the axles which are level are set to
”Hold axles” before extending the outriggers.

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11

100 101 102

9/19

A12 A13 A14 A15

Z 51 302

76 77

78 79
B

80 81

Z 51 303

18/25 140−2110−113a
 Hydraulic Suspension 11

(Z 51 302, Z 51 303)

Place the crane in the condition ”Driving in the Erect Mode”;

Steps for the Procedure:

Starting position:
The crane is supported on outriggers.
Switch (101) ”Hold axles” is activated; display (A13) is
illuminated.

1. Retract outrigger cylinders slowly and evenly until the wheels

of all axles are pressed evenly on the ground.
Pressure check at the pressure gauge (5 to 10) in cab (see
section 12, Outriggers).

2. Switch off ”Hold axles” with switch (101).

The display (A13) goes out.

3. Switch on ”Lock suspension” with switch (100).

The display (A12) is illuminated.

4. Check the level of the crane (horizontal alignment) optically.

The suspension cylinders of all axles must be approximately

in the road travel position.
The clearance between the fastening eyes on the
suspension cylinder (dimension “X”) is then 630 mm.

If the crane is not level, extend the outrigger cylinders again

and support the crane lightly on the outriggers.
Fill up the corresponding suspension circuit by pressing
buttons (78A, 80A) for the left−hand side or (79A, 81A) for the
right−hand side.

The suspension may only be filled up to a maximum sus-

pension pressure of 270 bar.
An attempt to fill the suspension up to higher pressures
can cause the suspension to sag.

5. Afterwards, retract the outrigger cylinders until the crane is

standing free on its wheels; check for horizontal alignment.
Outrigger plates just above the ground!

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Z 35 554

20/25 140−2110−113a
 Hydraulic Suspension 11

(Z 35 554)

Repeat this procedure until the crane is horizontally aligned and

level with the outrigger cylinders retracted.
Observe the road travel position of the suspension cylinders.
The suspension cylinders must be in the road travel position.
The clearance between the fastening eyes on the suspension
cylinder (dimension “X”) is then 630 mm.

The suspension pressure should be monitored continually.

If the pressure in one of the suspension circuits rises up to
300 bar, stop the crane immediately and extend outrigger
cylinders until the load is taken off the wheels.
Make sure the crane is evened out by resetting the hydraulic
suspension and / or correcting the boom position.
If the crane is driven further there is a risk of the crane
TIPPING or of AXLE BREAKAGE !

11.5 Height Adjustment

The level of the suspension circuits can − in the context of the

suspension travel − be adjusted up or down. This can be helpful,
for example
− if the height clearance is too low;
− if more ground space is required;
− if the mobile crane is stuck on terrain;
− before retracting the outriggers.

When adjusting the height, always leave some clearance to the

final upper and lower position so that there is a degree of
suspension play remaining.
In this state the suspension is only effective in a limited capacity.

Drive with extreme caution and return the level to normal

(road travel level) once the obstacle has been passed.

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22/25 140−2110−113a
 Hydraulic Suspension 11

11.6 Raising Axles

Raise all axles when supporting on the outriggers, see section

12.

Raise “Lift axle” in the steering program “Construction site

operation”, see section 9.

11.7 Hold axles

Holding axles when supporting on outriggers, see section 12.

Driving the crane in the ”Hold axles” position leads to heavy

damage to the hydraulic suspension.

DRIVING PROHIBITED!

After every special setting:

− ”Activate suspension block”
− ”Height setting”
− ”Raise axles”

The hydraulic suspension must be reset for ”Driving in the

Transport Position”.

11.8 Lowering Brake Valves in the Basic Suspension

Block

The lowering brake valves are set ex works to ensure slow and
even lowering of the suspension.

The lowering brake valves may only be adjusted by our

customer service technicians.

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11

92 93 94 95 96 97 98

”Y”

”X”

99 100 101 102 103 104

Z 56 500

24/25 140−2110−113a
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11.9 Selecting the Operating Modes

(”Axle loads 12 t / 26.5 kip” or “Reduced axle loads”)
(Z 56 500)

Various driving configurations are possible in the operating mode

“Reduced axle loads”. Examples include:
− driving without main boom
− driving without superstructure
− driving with different axle loads < 12 t / 26.5 kip
− driving with trailer (”dolly operation”)
Risk of accidents!
The suspension must always be set to the operating mode
in which the crane vehicle is being operated. Settings are
only to be changed when vehicle is at a standstill.
Disregarding this rule can lead to an increased risk of
accidents.

When “Reduced axle loads” mode is selected, only the hydraulic

suspension is set to the changed axle loads. All other
components (e.g. brake system and steering) remain
unchanged.

A releasable switch (96) is used to select the operating mode.

If the switch is set to “OFF” (switch position “X”), the suspension

is set to “12 t / 26.5 kip axle load” mode.

If the switch is set to ”ON” (switch position ”Y”), the suspension

is set to ”Reduced axle loads” mode.
After a new operating mode has been selected, a level check
of the suspension circuit must be carried out. If necessary,
the level should be reset.

If the equipment is operated in dolly mode, it is essential to

follow the instructions contained in the section “Information
on dolly operation” in chapter 6.

The suspension can be locked in both operating modes (switch

100).

140−2110−113a 25/25
 Outriggers 12

12 Outriggers

12.1 Notes on Outriggers:

Always observe the following information, in order to ensure safe
working:
− Before stabilising:
Main boom in longitudinal direction;
Superstructure locked in transport position.
No other persons other than the crane operator are per-
mitted in the danger zone.
− Only rotate the superstructure if the crane is stabilised
on outriggers.
− Always stabilise the crane before picking up loads.
− During the stabilising procedure the outrigger pads
need some space for shifting movements to the sides.
− Always extend outrigger struts to the appropriate pin-
ning position (coloured or arrowed marking) and pin.
− For safety reasons, the outrigger struts may only be ex-
tended at the side with the corresponding switch panel.
The crane driver can thereby only extend the outrigger
struts that are always in his line of view.
− Always keep both switch panels locked.
Only the switch panel that is needed directly for opera-
ting may be opened.
In order to avoid improper use, it must be locked again,
directly after use.
− After being put on outriggers (before beginning work
with the crane), the tyres must no longer touch the
ground.
− Extend/retract the supporting cylinders only one at a
time and only at the side that can be seen from the switch
panel.
Be particularly careful when the outrigger pads are mo-
ved to the ground. Risk of crushing!
− Make sure the ground for the outrigger pads is flat and
firm; permitted inclination max. 55 (9 %)!
No foreign material (for example: stones, metal objects,
etc.) are permitted under the outrigger plates!

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12

2/79 140−2120−193a
 Outriggers 12

− The maximum surface pressure for the standard series

outrigger pads at the front (ø 600 mm/23.6 in) is approxi-
mately 260 N/cm2 (377 psi).
This is equivalent to a force of 736 kN (75 t (165 kip)).
The maximum surface pressure for the standard series
outrigger pads at the rear (ø 700 mm/27.6 in) is approxi-
mately 242 N/cm2 (350 psi).
This is equivalent to a force of 932 kN (95 t (209 kip)).
− If the load−carrying capacity of the ground is insuffi-
cient, then the ground pressure around the outrigger
pads must be reduced with the help of backup plates
(rigging mats) (see also ”Permitted ground pressure”).
− The maximum permitted support forces must be obser-
ved.
− Levelling the crane with counterweight and fitted
apparatus only to be accomplished by ”EXTENDING”
the vertical outrigger cylinders.
See section ”Notes on levelling with counterweight.”
− In order to protect the supporting cylinders from over-
loading, they must not be extended to the limit; there
should still be a residual stroke length of 2 to 3 cm (0.8
to 1.2 in) after levelling.
The remaining lift is also necessary, so that actual sup-
port pressure values can be displayed.

− Extending and retracting the supports with a load

attached is not permitted. Risk of tilting!

In order to avoid damage to the outriggers as well as

accidents in the course of driving or operating the crane,
take special care to do the following:

∗ Unlock the supports before they are extended or

retracted.
∗ Pin/secure the supports for work with the crane.
∗ Pin / secure the (retracted) supports in transport
position.
∗ Secure the outrigger pads in transport position

There is a danger of accidents, if the prescribed outrigger

span, specified in the load capacity table, is not used.
No other outrigger span is permitted − HIGH RISK OF
DAMAGE !

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12

Z 47 962

4/79 140−2120−193a
 Outriggers 12

12.2 Arrangement of Outrigger Controls

Outrigger controls are located on the chassis to the left and right
(in the direction of travel).

Switch panel left side

(Z 47 962)

Item Function
1 Rocker switch ”Outrigger cylinder, front right ”
1A: Retracting
1B: Extending
2 Rocker switch ”Outrigger cylinder, front left”
2A: Retracting
2B: Extending
3 Rocker switch ”Outrigger cylinder, rear right”
3A: Retracting
3B: Extending
4 Rocker switch ”Outrigger cylinder, rear left”
4A: Retracting
4B: Extending
5 Rocker switch ”Outrigger strut, front left”
5A: Retracting
5B: Extending
6 Rocker switch ”Outrigger strut, rear left”
6A: Retracting
6B: Extending
7 Rocker switch ”Engine start/engine stop”
7A: Engine stop
7B: Engine start
8 Rocker switch ”All outrigger cylinders together”
8A: Retracting
8B: Extending
8B with key 10: Level automatically
9 Pushbutton ”Raise all axles”
10 Pushbutton ”Caution” (safety button)
1.) ”Ramp up” data bus (press for approximately
5 sec.)
2.) before/with button (7B) for ”Engine start”
3.) before/with button (8B) for ”Automatic level-
ling”
21 Display
with crane symbol on the left−hand side

The symbols on the rocker switch determine the operation of the

outrigger cylinders.

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12

1.5?
1.5?
3?

0?

0?

3?

Z 60 982

6/79 140−2120−193a
 Outriggers 12

Switch panel right side

(Z 60 982)
Item Function
11 Rocker switch ”Outrigger cylinder, rear left ”
11A: Retracting
11B: Extending
12 Rocker switch ”Outrigger cylinder rear right”
12A: Retracting
12B: Extending
13 Rocker switch ”Outrigger cylinder front left”
13A: Retracting
13B: Extending
14 Rocker switch ”Supporting cylinder, front right ”
14A: Retracting
14B: Extending
15 Rocker switch ”Outrigger strut, rear right”
15A: Retracting
15B: Extending
16 Rocker switch ”Outrigger strut, right front”
16A: Retracting
16B: Extending
17 Rocker switch ”Engine start/engine stop”
17A: Engine stop
17B: Engine start
18 Rocker switch ”Outrigger cylinders together”
18A: Retracting
18B: Extending
18B with key 20: Level automatically
19 Pushbutton ”Raise all axles”
20 Pushbutton ”Caution” (safety button)
1.) ”Ramp up” data bus (press for approximately
5 sec.)
2.) before/with button (17B) for ”Engine start”
3.) before/with button (18B) for ”Automatic level-
ling”
22 Spirit level

The symbols on the rocker switch determine the operation of the

outrigger cylinders.

140−2120−193a
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12

21

F1 F2 F3 F4 F5 F6

M N O P Q

8 8

8 8
L

Z 60 983

8/79 140−2120−193a
 Outriggers 12

12.3 Information System for the Outrigger Controls

(Z 60 983)

The display is at the outrigger controls (to the left of the chassis).

The system on the left−hand vehicle side is described and

illustrated as an example (crane symbol ”P” to the left).

The system consists of the display (21) and the function keys F1
− F6.

Legend:

(K) Function buttons F1 − F6

F1 = Contrast
F2 = Brightness
F3 = Inversion
F4 = Not assigned
F5 = Angle
F6 = Support forces
(L) Symbols for the function buttons
(M) Support forces at the rear support
(N) Spirit level
(O) Electronic bubble
(P) Crane symbol
(Q) Support forces at the front support

140−2120−193a
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12

”A”
O P

M1 18.0t 18.0t Q1

M2 18.0t 18.0t Q2

Z 60 984

”B”

P
X 0.1
O

N
0.1 Y

L L2

Z 60 985

10/79 140−2120−193a
 Outriggers 12

12.3.1 Indicators on the Display

(Z 60 984, Z 60 985)

Diagram “A” (level indicator and supporting force)

− Basic display with electronic level indicator / bubble and
indication of supporting force.

When the supporting cylinders are operated, the moving

direction is displayed in the form of an arrow, as well as the
supports, indicated as symbols.

Diagram “B“ (inclination)

Legend:

(L) Symbols for the function buttons

L2 = Adjustment, menu−assisted (leads to figure
”F”)
(M) Support forces at the rear support
M1 = Supporting force left rear
M2 = Supporting force right rear
(N) Spirit level
(O) Electronic bubble
(P) Crane symbol
(Q) Support forces at the front support
Q1 = Supporting force left front
Q2 = Supporting force right front
(R) Retraction/extension movement of the outrigger cylin-
ders
(X) Inclination perpendicular to the direction of travel
(Y) Inclination in the direction of travel

140−2120−193a
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12

”C”
P

18.0t 18.0t Q1
M1

M2 18.0t 18.0t Q2

L L1

Z 60 986

”D”
P
S1 S3
. m . m

S2 S4
. m . m

Z 60 987

12/79 140−2120−193a
 Outriggers 12

(Z 60 986, Z 60 987)

Diagram “C” (supporting force)

Diagram ”D” (support length), menu−assisted, (optional)

Legend:

(L) Symbols for the function buttons

L1 = Support length, menu−assisted (optional)
(M) Support forces at the rear support
M1 = Supporting force left rear
M2 = Supporting force right rear
(P) Crane symbol
(Q) Support forces at the front support
Q1 = Supporting force left front
Q2 = Supporting force right front
(S) Support length (extension length of the outrigger struts
in metres)
S1 = Outrigger strut left rear
S2 = Outrigger strut right rear
S3 = Outrigger strut left front
S4 = Outrigger strut right front

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12

”E”

Z 47 972

”F”

Z 47 973

Enter PIN−Code

”G”

Z 47 974

14/79 140−2120−193a
 Outriggers 12

(Z 47 972, Z 47 973, Z 47 974)

Diagram “E” (contrast), menu−assisted

Modify contrast:
− Key F2 = darker
− Key F5 = brighter
− Key F1 (Quit) leads to View ”A” (spirit level and supporting
force)

Diagram “F” (brightness), menu−assisted

Modify brightness:
− Key F2 = darker (in accordance with bar display)
− Key F5 = brighter (in accordance with bar display)
− Key F1 (Quit) leads to View ”A” (spirit level and supporting
force)

Diagram “G” (coding; only for customer service)

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12

Z 47 962

”A”
O P

M1 18.0t 18.0t Q1

M2 18.0t 18.0t Q2

Z 60 984

16/79 140−2120−193a
 Outriggers 12

12.3.2 Functions

(Z 47 962, Z 60 984)

Starting position:
− Crane parked in transport position
− Parking brake applied
− Ignition−starter switch in position ”0” (external start
readiness)

”Boot” data bus

Press and hold “Caution” key (10 / 20) for approx. 5 sec.

External engine start:

“Caution” key (10 / 20) ahead / press ”Engine start” key (7B / 17B)
and hold until engine is running.

External engine stop:

“Caution” key (10 / 20) ahead / press ”Engine stop” key (7A / 17A)
and hold until engine has stopped.

Modify contrast:

− Call up figure ”A” (Z 60 984)

− Key F1 = figure ”E” (contrast) (Z 47 972)
− Key F2 = darker
− Key F5 = brighter
− Key F1 = Quit, return to figure ”A” (Z 60 984)

140−2120−193a
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12

Z 47 962

”A”
O P

M1 18.0t 18.0t Q1

M2 18.0t 18.0t Q2

Z 60 984

18/79 140−2120−193a
 Outriggers 12

(Z 47 962, Z 60 984)

Modify brightness:

− Call up figure ”A” (Z 60 984)

− Key F2 = figure ”F” (Brightness) (Z 47 973)
− Key F2 = darker (in accordance with bar display)
− Key F5 = brighter (in accordance with bar display)
− Key F1 = Quit, return to figure ”A” (Z 60 984)

Inversion

− Call up figure ”A” (Z 60 984)

− Key F3 = Inversion

Inclination display

− Call up figure ”A” (Z 60 984)

− Key F5 = figure ”B” (Gradient) (Z 60 985)
− Key F1 = Quit, return to figure ”A” (Z 60 984)

Support pressure display

− Call up figure ”A” (Z 60 984)

− Key F6 = figure ”C” (Supporting force) (Z 60 986)
− Key F1 = Quit, return to figure ”A” (Z 60 984)

140−2120−193a
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12

Z 47 962

O P
R
M1 18.0t 18.0t Q1
”A”
M2 18.0t 18.0t Q2
L
Z 60 984

18.0t 18.0t Q1
M1

”C”
M2 18.0t 18.0t Q2

L L1
Z 60 986

20/79 140−2120−193a
 Outriggers 12

12.3.3 Support Pressure Display

(Z 47 962, Z 60 984, Z 60 986)

The supporting force is determined via the pressure absorber at

the four supporting cylinders and indicated at the display of the
outrigger controls.

Monitor the supporting forces at every support procedure

with the help of the support pressure display.

”Boot” data bus:

Press and hold “Caution” key (10 / 20) for approx. 5 sec.

Displaying supporting force:

− Call up figure ”A”

− Key F6 = figure ”C” (supporting force)
− Key F1 = Quit, return to figure ”A”

The following supporting force values must not be

exceeded:
75 tons (165 kip) at the front supporting cylinders.
95 tons (209 kip) at the rear supporting cylinders.

Important note on complying with limit values:

The limit values to be followed are not monitored
automatically.

The support pressure display shows tolerance values. The

display value can differ from the actual value by up to
approx. 10% (plus / minus). Keep this in mind, e.g. in relation
with limited load−carrying capacity of the ground.

While the crane is in operation, the support pressure display is

supplied with power from the superstructure via an electrical
swivelling connection.

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12

Z 47 962

O P
R
M1 18.0t 18.0t Q1
”A”
M2 18.0t 18.0t Q2
L
Z 60 984

P
X 0.1
O
”B”
N
0.1 Y

L L2
Z 60 985

22/79 140−2120−193a
 Outriggers 12

12.3.4 Inclination Indicator

(Z 47 962, Z 60 984, Z 60 985)

The inclination of the crane is detected by an electronic

inclination transmitter and displayed at the switch panels of the
outrigger controls on the chassis.

The display consists of an electronic level indicator / bubble and

numerical values for the X and Y axes (one each).
Depending on the direction of a deviation, a negative value (with
a minus before the value) can also be displayed.
The level indicator is for general orientation; the numerical values
are definitely the decisive values.

”Boot” data bus

Press and hold “Caution” key (10 / 20) for approx. 5 sec.

Display gradient

− Call up figure ”A”

− Key F5 = figure ”B” (gradient)
− Key F1 = Quit, return to figure ”A”

The inclination indicator must be observed during the

levelling procedure.
Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.

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Z 47 962

3?
1.5?
0?

0?
1.5?
3?

Z 60 982

P
X 0.1
O
”B”
N
0.1 Y

L L2
Z 60 985

24/79 140−2120−193a
 Outriggers 12

12.4 Automatic Levelling

(Z 47 962, Z 60 982, Z 60 985)

The crane can also be levelled automatically (by extending the

supporting cylinders together). This is only possible when
”Extending” (not when “Retracting”) the supporting cylinders.
It is of no importance for the function, in which starting position
the supporting cylinders are.

Risk of crushing!
When levelling automatically, all supporting cylinders are
extended simultaneously; that means also those cylin-
ders that cannot be seen from the switch panel. It must
be ensured that no persons are present in the danger
zone.

Starting position:
− Crane parked in transport position
− Parking brake applied
− Outrigger struts extended/pinned/locked
− Display: diagram “B (inclination)

Automatic levelling procedure (work steps):

1. Press “Caution” key (10 / 20) and ”Extend all supporting

cylinders” key (8B / 18B) simultaneously.
Inverse display during “Automatic operation”.
The supporting cylinders are extended one after the other
until a defined supporting force has been reached. This
ensures that all supporting cylinders are on the ground
before the actual levelling procedure begins.

If supporting forces are identical, then all supporting cylinders are

extended together in this (possibly different) condition, as long as
both keys are held pressed (10 / 20) and (8B / 18B).

2. If there is sufficient clearance between wheels and the

ground (including bending after taking up a load later on), let
go of button (8B / 18B) and continue to keep “Caution” key
(10 / 20) pressed.

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12

Z 47 962

3?
1.5?
0?

0?
1.5?
3?

Z 60 982

P
X 0.1
O
”B”
N
0.1 Y

L L2
Z 60 985

26/79 140−2120−193a
 Outriggers 12

(Z 47 962, Z 60 982, Z 60 985)

3. As soon as the crane is level (angle tolerance value 0.1

degrees), the procedure is automatically stopped. The
engine’s working speed switches automatically back to idle
speed.

After the procedure, the system might change the displayed

inclination value from 0.1 to 0.2. This however has no negative
effect on the required precision.

4. Let go of key (10 B / 18 B).

Make sure there is a remaining lift (2 to 3 cm/0.8 to 1.2 inch) in

the supporting cylinders; Compare supporting forces.
The system does not automatically take the remaining lift into
consideration.

If re−levelling is necessary:
Press and hold “caution” key (10 / 20) and press ”Extend all
supporting cylinders” key (8B / 18B) briefly.
Levelling is carried out as already described.

Combined retraction of all supporting cylinders:

Press “caution” key (10 / 20) and ”Retract all supporting cylinders”
key (8A / 18A) simultaneously.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

28/79 140−2120−193a
 Outriggers 12

12.5 ”Hold Axles” / ”Raise Axles” Functions

(Z 51 302)
When the crane is on outriggers, the wheels must not touch the
ground. The functions “Hold axles“ or “Raise axles are for this
purpose.
The decision as to which function should be selected to achieve
clearance, depends on the ground conditions at the site.

If ground conditions at the site are as described in section 11.4.1

(flat, firm ground), select ”Hold axles” .

If the ground conditions at the site are not as described in section

11.4.1, then select ”Raise axles” .

12.5.1 “Hold Axles” Function

“Hold axles” is selected before the crane is stabilised.

All axles are locked in their initial position (aligned horizontally

and suspension cylinders in road traffic position).
If the crane is lowered back on to the wheels for moving (by
retracting the supporting cylinders), then it need not be
re−levelled. It is aligned horizontally and the suspension
cylinders are in road traffic position.

12.5.1.1 Switching on “Hold Axles” after

”Moving on the Road” − Suspension Is Not Locked

1. Stop the crane, switch to neutral gear, apply the parking

brake.

2. Actuate (101) “Hold axles” switch.

The display (A13) lights up.

If ”Hold axles” is switched on (display A13 lights up), the

crane may no longer be moved. RISK OF BREAKAGE!

3. Support the crane (see section ”Extend the support”)

Extend the support until no wheel is in contact with the ground.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

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 Outriggers 12

(Z 51 302)

12.5.1.2 Switching on “Hold Axles” after

”Driving in the Configured Condition“ − Suspension
Locked

1. Stop the crane, switch to neutral gear, apply the parking

brake.
− The crane is aligned horizontally,
− suspension cylinder in on−road position.

2. Extend horizontal support.

3. Extend the outrigger cylinder, until the outrigger pads are

pressed to the ground. Set the contact pressure until the
suspension pressure is still approximately 100 bar (1450
psi).
Pressure control at the pressure gauges (5, 8), (6, 7) and (9,
10).

The distance of the mounting eyelets at the suspension cylinder

is 630 mm (24.8 in.) (see Section ”Extending the outrigger”).

4. Switch off the suspension locking system by actuating switch

(100).
The display (A12) goes out.

5. Actuate (101) ”Hold axles” switch.

The display (A13) lights up.

6. The supporting cylinders are extended further and the crane

is stabilised (see section ”Extend the support”).

Extend the support until no wheel is in contact with the ground.

Keep to the sequence!

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

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(Z 51 302)

12.5.1.3 Switching off “Hold Axles” for ”Moving on the Road”

− Suspension not Locked or Switching to
”Driving in the Configured Condition“ − Suspension
Locked

1. Retract supporting cylinders, until the wheels of all axles

have light and even contact with the ground.
Pressure control at the pressure gauges (5, 8), (6, 7) and (9,
10).
Nominal value: approx. 100 bar (1450 psi)
(see Sect. ”Retracting the Outriggers”)

2. Lock “Hold axles” switch (101) in ”Off” position.

The display (A13) goes out.

For ”Driving in the configured condition”, switch on suspension

locking system with switch (100).
The display (A12) is illuminated.
For “Driving in the configured condition” the outrigger remains
just above the ground.
”Driving when rigged” is only permitted if ground conditions are
as described in section 11.4.1.

3. Continue to retract supporting cylinder / retract outrigger

entirely and lock.

4. For ”Driving the crane in transport position” (on−road driving,

axle load max. 12 t / 26.4 kip), see section 6 of the operating
instructions for the chassis.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

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(Z 51 302)

12.5.2 “Raise Axles” Function

”Raise axles” is carried out before the crane is stabilised.

Switch on “Raise axles”

Two steps are required for “Raise axles”.

Between the two steps, the crane must be stabilised.
1. Press the ”Hold axles” switch (101) in the driver’s cab. The
display (A13) lights up.
The axles remain in on−road position (on the ground).

If ”Hold axles” is switched on (display A13 lights up), the

crane may no longer be moved. RISK OF BREAKAGE!

Now the crane must be stabilised (see Stabilisation procedure).

2. Press and hold down the key (9/19) at the outrigger controls.
All axles are raised as long as the button is pressed. The
display (A15) lights up.

Switch off “Raise axles”

When the switch (101) in the driver’s cab is turned off, all wheels
are lowered back to the ground.
The indicators (A13 and A15) go out.
The crane must be re−levelled before being moved (aligned
horizontally and suspension cylinders in on−road position).

When the suspension is locked (switch 100 on, display A12

illuminated) ”Raise axles” or ”Hold axles” is not possible.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

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(Z 51 302)

12.5.2.1 Switching on “Raise Axles” after

”Moving on the Road” − Suspension Not Locked.
If the crane is in ”On−road driving” position before being
stabilised, then raise the axles as described in the following:
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Press the ”Hold axles” switch (101) in the driver’s cab. The
display (A13) lights up.
3. Support the crane (see section ”Extend the support”)
If wheels are still in contact with the ground:
4. Press and hold down the ”Raise axles” button (9/19) at the
outrigger controls. The display (A15) lights up.
All axles are raised as long as the button is pressed.
Extend the support until no wheel is in contact with the ground.

12.5.2.2 Switching on “Raise Axles” after

”Driving in the Configured Condition“ − Suspension
Locked
If the crane is in ”Driving in the configured condition” mode
(supports extended, outrigger pads on the ground) before
stabilising, then proceed as follows to raise the axles:
1. Stop the crane, switch to neutral gear, apply the parking
brake.
2. Extend the outrigger cylinder, until the outrigger pads are
pressed to the ground. Set the contact pressure until the
suspension pressure is still approximately 100 bar (1450
psi).
Pressure control at the pressure gauges (5, 8), (6, 7) and (9,
10).
3. Switch off the suspension locking system by actuating switch
(100). The display (A12) goes out.
4. Press the ”Hold axles” switch (101) in the driver’s cab. The
display (A13) lights up.
5. Keep the crane stabilised.
6. If necessary: Press and hold ”Raise axles” button (9/19) at
the outrigger controls until all wheels no longer touch the
ground. The display (A15) lights up.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

76 77

78 79
B

80 81

Z 51 303

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(Z 51 302, Z 52 303)

12.5.2.3 Switching off ”Raise Axles” for ”Driving on the Road”

− Suspension not Locked or Switching to ”Driving in
the Configured Condition” − Suspension Locked

The ”Raise axles” procedure is switched off in the driver’s cab via
the “Hold axles” button (101). All wheels are then lowered to the
ground.

1. Turn off the switch “Hold axles” (101) in the driver’s cab. The
display (A13) goes out.
When the switch (101) in the driver’s cab is turned off, all
wheels are lowered back on to the ground.

2. Actuate switch (76A). Fill all suspension circuits to

approximately 100 bar (1450 psi) (see Section 11).
Check pressure increase at the pressure gauges (5 to 10).

3. Retract supporting cylinders; Reset suspension.

Before the supporting cylinders are retracted, the wheels of

all axles must first be in contact with the ground. Then the
suspension must be readjusted (aligned horizontally and
suspension cylinder in central position; see section 11 of
these operating instructions).

If they are not readjusted, the suspension cylinders are

“locked”. Driving is not permitted in this condition. Damage
to undercarriage!

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15

Z 51 304

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12.6 Measures before Stabilising:

1. Apply the parking brake.

On sloping ground in the longitudinal direction of the

vehicle, the vehicle must be prevented from rolling away by
placing wheel chocks at the axle last released.

2. Switch to neutral gear.

3. Lock the slew gear brake in the superstructure cab.

The superstructure may only be rotated if the crane is

stabilised.

4. Start crane chassis engine.

The engine can also be started at the switch panels of the

outrigger controls. To do so, the ignition−starter switch (15) must
be in position “2” (external ignition standby). (Z 51 304)

An engine speed of 1200 U/min (rpm) is set automatically when

the outriggers are operated.

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Z 41 654

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12.7 Supporting the Outrigger Plates

The load−bearing capacity of the ground must be sufficient to

absorb the maximum support forces which can occur.
Normally, the outrigger plates would not be sufficient by surface
area to set the crane up safely on backfilled or natural ground.
If necessary, increase the support area by stacking suitable
materials under the outrigger plates.

Suitable materials (for example, timbers with the same di-

mensions, special panel constructions made of wood or
metal) must be used for the support! The crane operator
must make these available.

(Z 41 654)
The struts must be in the centre of the support and must co-
ver all supporting timbers sufficiently.

Check as well whether hollow spaces such as canals, co-

vered ditches or cellars are in the planned location of the
crane and how they run. You must also take hidden dan-
gers such as melting ice or flooding into consideration.
These dangers are often the cause for cranes falling over.

In the following segment you will find details on “Permitted ground

pressures” of various types of ground and how to determine the
required support area.

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Z 53 789

44/79 140−2120−193a
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12.7.1 Permitted Ground Pressures

(Z 53 789)

If there are doubts about the load capacity of the base at the
site, then have the ground tested.

The following load capacity values are determined according to

standard DIN 1054 for various types of ground.
Type of ground p p
(kg/ cm2) [psi]
A Backfilled, not artificially compacted ground 0−1 0−15
B Grown, obviously untouched ground
Mud, peat, marsh 0 0
Non−cohesive, sufficiently firm grounds:
− Fine to medium sand 1.5 21
− Coarse sand to gravel 2.0 28.5
Cohesive grounds:
− pulpy 0 0
− soft 0.4 5.7
− stiff 1.0 14.2
− semi−firm 2.0 28.5
− hard 4.0 56.9
Rock with hardly any cleavage in healthy, unwea-
thered condition and in convenient stratification:
− in closed succession of beds 15.0 213.4
− in massed and columnar formation 30.0 426.7

Example of non−cohesive ground with fine sand (p=1.5 kg/cm2)

(21 psi):
The values in curve 3 apply for p=1.5 kg/cm2 (21 psi) . (see table
above in the diagram at the side).
This results, e.g. for a supporting force of Fs=36 t (79.4 kip) in a
required surface area As of 2.4 m2(25.8 ft2) for the outrigger pad.
The standard outrigger pad at the front has a diameter of 600 mm
(support surface area 0.28 m2/4 ft2); the standard outrigger pad
at the back has a diameter of 700 mm (0.38 m2 /4 ft2).
The required surface area of the outrigger is to be established
with the help of suitable bases (e.g.: support mats, wooden
planks and similar objects).
Supporting forces can be looked up e.g. in the supporting force
tables.

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Z 170 688

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12.8 Safe Distance to Slopes and Pits

(Z 170 688)

Erect the crane with a sufficiently safe distance to slopes or pits.

The distance also depends on the type of ground.

The distance to the edge of a slope (X) must be at least 2 m.

A general rule is:

− if the ground is loose or filled, then the safety distance (a)
must be twice the depth of the pit (b). The slope angle a must
be < 30°.
− if the ground is firm and not loose, then the safety distance
(a) must be equivalent to the depth of the pit (b). The slope
angle a must be < 45°.

Thesafety distance is measured starting at the base of the pit (C).

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1 2

B X
5.4 m
Z 110 013

1 2

B C X
7.5 m

Z 110 014

Z 110 015

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12.8.1 Pinning positions of the outrigger struts

(Z 110 013, Z 110 014, Z 110 015)

(1) = Outrigger strut

(2) = Chassis frame
(B) = Position of outrigger struts (1) outrigger span 5.4 m
(17.7 ft) (outrigger struts partially extended)
(C) = Position outrigger strut (1) outrigger support area 7.5
m (24.6 ft) (outrigger struts completely extended)
(X) = Locking point/locking bolt on chassis frame

The supporting box is unlocked by removing the locking pin X

from transport position.

When each locking position is reached, peg/secure it with locking

pin X.

For retracting again in transport position, the locking pin X must

be removed again and then reinserted in ”transport position”.

Lock supporting box in position ”X”, as soon as it has been

retracted to transport position!

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3 2 1
2 3 1

Z 36 594 Z 36 595
1.5?
1.5?

0?
3?

0?

3?

Z 47 962 Z 60 982

50/79 140−2120−193a
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12.9 Stabilising Procedure

12.9.1 Extend support (outrigger support area 8.23 m x

7.50 m/27 ft x 24.6 ft)
(Z 36 594, Z 36 595, Z 47 962, Z 47 963)

When the crane is on outriggers, the wheels must not touch the
ground (“Hold axles” / “Raise axles” functions).

Once you are sure that no obstacles or persons are in the

extension area for the supports and that all notes on dangers in
section 12.1 have been observed, then proceed as described in
the following.

1. Placing the outrigger plates in operating position

(Z 36 594, Z 36 595)

RISK OF ACCIDENTS!
The contact surface between the outrigger cylinder’s
piston rod and the outrigger plate must be clean. In particu-
lar, no foreign matter is permitted (for example: stones,
sand, etc.).

1.1 Clean the bottom of the outrigger cylinder’s piston rod

and the top of the outrigger plate (if contaminated).

1.2 remove the forelocks (3) and the socket pins (2),

1.3 pull the outrigger pad (1) into support position.

1.4 Attach plug bolts and forelock again.

2. Remove locking pin “X” on the outrigger struts.

Open required switch panel.

Only the switch panel that is needed directly for operating

may be opened.
In order to avoid improper use, it must be locked again,
directly after use !

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Z 47 962

3?
1.5?
0?

0?
1.5?
3?

Z 60 982

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3. Extending the outrigger struts

Left side: Press rocker switch 5B or 6B (Z 47 962)
Right−hand Press rocker switch 15B or 16B (Z 60 982)
side :

The outrigger struts can only be extended / retracted

(horizontally) at the switch panel of the corresponding side.
Extend the outrigger struts one at a time up to the coloured
marking.
Hold on to the rocker switch while extending.

Risk of crushing!
Before extending the outrigger struts, make sure that no-
body is present in the danger area where the outrigger
struts are extended horizontally !

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Z 47 962

3?
1.5?
0?

0?
1.5?
3?

Z 60 982

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(Z 47 962, Z 60 982)

4. Extending the outrigger cylinders

Switch panel left side: Press rocker switch 1B, 2B, 3B or
4B.
Switch panel right side: Press rocker switch 11B, 12B, 13B
or14B.

In order to protect the supporting cylinders from

overloading, they must not be extended to the limit; a
residual stroke length of 2 to 3 cm (0.8 to 1.2 in)should still
be left.
The remaining clearance is also necessary, so that actual
support pressure values can be displayed.

Risk of crushing!
There is a risk of crushing while the outrigger cylinders
are extended.
The outrigger cylinders may only be extended at the side
that is within the crane operator’s view at the switch pa-
nel.
Extend the outrigger cylinders of the relevant side until
they have made contact with the ground.
While operating the outriggers, no corrections may be
made to the positions of the outrigger pads.

RISK OF ACCIDENTS!
When attaching the outrigger plates in this operating step,
make sure that there is no foreign matter (for example: sto-
nes, metal objects, etc.) under the outrigger plates!

If the crane is tilted visibly, then carry out a rough correction by

further extending the appropriate outrigger cylinders. When
doing so, make sure that the outrigger cylinders can be further
extended for the following levelling procedure.

5. Attach counterweight (see load capacity table and operating

instructions for the superstructure, section 9).

6. Position superstructure in the direction of travel and thereby

position counterweight above the rear outrigger.
7. Move boom to steep position.

The slew gear brake must be released at points 5 and 6.

Now reinsert it.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302
1.5?
1.5?

0?
3?

0?

3?

Z 47 962 Z 60 982

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(Z 51 302, Z 47 962, Z 60 982)

8. “Raise axles” now

”Raise axles” consists of two steps:

8.1 Press the ”Hold axles” switch (101) in the driver’s cab.
The display (A13) lights up.
The axles are still on the ground.

8.2 Press and hold down the key (9/19) at the outrigger
controls.
All axles are raised.
Raise axles until no wheel is in contact with the ground.

If ”Hold axles” was actuated before stabilising, display (A13)

lights up, then the axles do not need to be raised. However, make
sure that none of the wheels is still touching the ground.

When putting the crane on outriggers, make sure that the

ground has sufficient load bearing capacity.
The individual supporting forces are indicated at the display
of the outrigger controls (to the left and right of the chassis)
or at the PDC installation of the superstructure.
Only the current supporting forces are displayed; not those
that will occur when a load is picked up.

9. Extend rear supporting cylinder, until the lateral axis is

balanced.
Switch panel left side: Press rocker switch 3B / 4B.
Switch panel right side: Press rocker switch 11B / 12B.

10. Extend the supporting cylinders at the front, in order to also

bring the longitudinal axis in the balance.
Switch panel left side: Press rocker switch 1B / 2B.
Switch panel right side: Press rocker switch 13B / 14B.

Then use inclination indicator on the crane chassis to level

it to 0.1° (equivalent to approx. 0.2 %).

In order to achieve a most even coordination of the

supporting forces, the supporting cylinders at the front
should finally be briefly pressed further together and then
the same applies to the supporting cylinders at the rear. In
doing so, make sure that all supporting cylinders are evenly
loaded.

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11. Check the set level once more.

If the lateral axis has shifted, then the levelling procedure must
be repeated.

a.) Balance the rear lateral axis.

b.) Retract the front supporting cylinder slightly and

then balance the longitudinal axis by extending.

Retracting the supporting cylinders is only permitted if

the supporting forces specified in section 12.2 are not
exceeded.

In order to level the crane precisely, it will finally be

necessary to operate all supporting cylinders from the
switch panel on one side. In this case be particularly careful,
especially when the supporting cylinders are operated that
are not in the direct line of view.

Immediately afterwards, lock the switch panel !

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”B”

P
X 0.1
O

N
0.1 Y

L L2

Z 60 985

60/79 140−2120−193a
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12.9.2 Checking the Level at the Chassis

(Z 60 985)

After each new configuration, the level of the crane must be

rechecked (see “Inclination indicator”).

Careful levelling is essential for safe working with the crane.

Deviations must not exceed 0.1 degrees (equivalent to
approx. 0.2 %).
The numerical values X and Y are always decisive. They
show the current deviation of the crane system.

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100 101 102

9/19

A12 A13 A14 A15

Z 51 302

76 77

78 79
B

80 81

Z 51 303

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12.9.3 Retracting the Outriggers

Retracting the outrigger is carried out in reverse sequence to the

extending procedure.

Important notes on retracting the outrigger:

− Retract the outriggers separately and completely.

− Unbolt only the outrigger strut to be retracted.

− As soon as a support is in the transport position, insert

the transport lock.

− When retracting the outrigger struts, reeving and crus-

hing movements around the retracting parts and the car-
rier frame are possible.
It must be ensured that no persons are present in the
danger zone.

− Extending and retracting the supports with a load

attached is not permitted. Risk of tipping!

12.9.3.1 Retracting the Supports

. . . for ”Driving in transport position”
(Z 51 302, Z 51 303)

1. Lower main boom to transport position.

2. Remove counterweight (see operating instructions for the

superstructure, section 9).

Risk of crushing!
When lowering the suspension / retracting the suppor-
ting cylinders, crushing movements between tyres and
ground space are possible. Watch your feet !
It must be ensured that no persons are present in the
danger zone.

3. Lock ”Hold axles” switch (101) in ”Off” position. The wheels

are lowered to the ground. The display (A13) goes out.

The following step “Pressing down the wheels” applies only if

“Raise axles” (switch 9 / 19) was also actuated.

4. Pressing down the wheels

Actuate switch (78A/79A/80A/81A) or switch (76A), until the
wheels of all axles are pressed on the ground.

140−2120−193a
63/79
12

1.5?
1.5?

0?
3?

0?

3?

Z 47 962 Z 60 982

Z 110 015

64/79 140−2120−193a
 Outriggers 12

(Z 47 962, Z 60 982, Z 110 015)

5. Retracting the supporting cylinders:

Switch panel left side: Press rocker switch 1A, 2A, 3A or
4A.
Switch panel right side: Press rocker switch 11A, 12A, 13A
or 14A.
Retract all supporting cylinders completely!

When retracting the supporting cylinders on slopes in the

longitudinal direction of the vehicle, the vehicle must be
secured with support blocks at the axle that is to touch the
ground first.

6. Retracting the outrigger struts:

Left side: Press rocker switch 5A or 6A
Right−hand side : Press rocker switch 15A or 16A

Retract all outrigger struts completely, one by one!

Extending and retracting the supports with a load attached

is not permitted.− RISK OF OVERTURNING !

Risk of crushing and reeving !

When retracting the outrigger struts, reeving and crus-
hing movements around the retracting parts and the car-
rier frame are possible.
Make sure that no persons are present in the danger
area!

Lock the supporting boxes in position ”X”, as soon as they

have been retracted to transport position!

140−2120−193a
65/79
12

3 2 1
2 3 1

Z 36 594 Z 36 595

76 77

78 79
B

80 81

Z 51 303

66/79 140−2120−193a
 Outriggers 12

(Z 36 594, Z 36 595, Z 51 303)

7. Move outrigger pads to transport position.

Remove flap plug (3) and socket pin (2), pull outrigger pad
(1) to transport position.
Attach plug bolts and forelock again.

8. If ”Raise axles” was actuated:

By actuating switch (76) level all axles. See section 11
”Settings for driving in transport position”.

Or,

9. If ”Hold axles” was actuated:

Lock ”Hold axles” switch (101) in ”Off” position. The display
(A13) goes out.

Driving in the “Hold axles” condition is prohibited. Damage

to undercarriage!

12.9.3.2 Retracting the Supports

. . . . for “Driving in the configured condition”
See section 11.4, ”Switching on suspension locking − . . . . Before
”Driving in the configured condition”.

Before lowering the crane on to the wheels (for subsequent

“Driving in the configured condition”), always pay attention
to the permitted axle loads relating to rigging mode,
counterweights, superstructure position, main boom length
and angle (see section 6 ”Driving in the configured
condition”).
When lowering the crane on to the wheels, check the
suspension pressure at pressure gauges (5) to (10) in the
driver’s cab. It may not exceed 300 bar (4.351 psi).

140−2120−193a
67/79
12

Z 53 787

68/79 140−2120−193a
 Outriggers 12

12.10 Levelling with the Counterweight

Before attaching the counterweight, the crane must be

on outriggers and levelled.

After attaching the counterweight, the crane must be re−

levelled in the range of 3605 (in steps of 905) .

Starting position:
− Crane on outriggers; outrigger span 8.23 m x 7.50 m (27 ft x
24.6 ft).
− Superstructure position 180 degrees = main boom to the rear.

Procedure for levelling with counterweight:

1. Check the supporting forces at the support pressure display

on the crane chassis (see “Support pressure display”).
Make sure that the supporting forces are symmetrically
balanced (left / right).

2. By adjusting the inclination of the main boom or by extending

telescope 1, distribute the load moment of the counterweight
in such a way, that the outrigger pressure on all 4 supports
is roughly identical. (Z 53 787)

3. Check the levelling of the crane, if necessary repeat the

procedure (see “Checking the levelling of the chassis”).

RISK OF ACCIDENTS!
− The levelling can be done by extending or retracting the
supporting cylinders, up to a maximum supporting force
of 50 t (110 kip).
− If the supporting force of one of the 4 supports exceeds
50 t (110 kip), then the levelling procedure may only be
carried out by extending the supporting cylinders (no
longer by retraction).
However, this is only possible, if the supporting force of
the support to be extracted does not exceed 50 t (110
kip).
Therefore the supporting forces must first be shifted by
a light adjustment / rotation of the superstructure / main
boom / equipment.

4. Rotate superstructure by 180° .

5. Repeat steps 2 and 3.

140−2120−193a
69/79
12

2
1

B C X
7.5 m

Z 110 014

2
1

B X
5.4 m

Z 110 013

70/79 140−2120−193a
 Outriggers 12

12.11 Supporting Spans

12.11.1 Normal Outrigger Span

Outrigger span 8.23 m x 7.50 m (27 ft x 24.6 ft).

(Z 110 014)

For the outrigger support area 8.23 m x 7.50 m (27 ft x 24.6 ft),
the outrigger strut (1) is completely extended and pinned at point
X/C.

Working with the crane is permitted only with the load

capacity tables supplied with the crane. The crane’s
construction number is noted on the load capacity tables.
If there are no specifications for the outrigger span in the
load capacity tables, then the outrigger struts must be
extended completely and pinned.

12.11.2 Reduced Outrigger Span

Outrigger span 8.23 m x 5.40 m (27 ft x 17.7 ft).

(Z 110 013)

For the outrigger support area 8.23 m x 5.40 m (27 ft x 17.7 ft),
the outrigger strut (1) is partially extended and pinned at point
X/B.

The extension length is marked in colour on the outrigger struts

(1).

If the outrigger span is reduced, then only certain

counterweights / main boom lengths / equipment are
permitted.
Details of these can be found in the corresponding load
capacity tables. Only the combinations specified there are
permitted.

140−2120−193a
71/79
12

2
1

B C X
7.5 m

Z 110 014

Q
E R P

6
7
8
5

Z 53 788

72/79 140−2120−193a
 Outriggers 12

(Z 110 014, Z 53 788)

12.12 Removal and installation of the outrigger struts with

auxiliary crane
(optional)

12.12.1 Notes on removing and installing the outrigger struts

An auxiliary crane is required for removing and installing the

outrigger struts.

One entire outrigger strut weighs around 0.85 t (1874 lbs).

The lifting tackle must be selected and calculated in
accordance with this weight.

Danger risk of crushing!

There is a risk of being crushed at all work related to the
installation and removal of the supports!

Quick connection couplings

The quick connection couplingsat the hydraulic lines ”R”, ”E” and
”P” are marked with labels.
Connection ”R” = Extending the horizontal cylinders.
Connection ”E” = Retracting the horizontal cylinders and
the vertical cylinders:
Connection ”P” = Extending the vertical cylinders

Observe designations/coloured markings provided; do not mix

up the lines.
Take care to ensure that the chassis engine has been turned off.
The hydraulics connections are then depressurise and easier to
mount.
In order to avoid damage to the threads, make sure that their
initial engagement is clean; particularly when pliers are used to
connect the quick connection coupling.

Make sure that the coupling pieces are completely screwed

in (up to the stop), otherwise it causes damage to the
hydraulic system.

If there are no labels on the quick assembly hose couplings,

mark them before disconnecting.

140−2120−193a
73/79
12

2
1

B C X
7.5 m

Z 110 014

Q
E R P

6
7
8
5

Z 53 788

74/79 140−2120−193a
 Outriggers 12

(Z 110 014, Z 53 788)

12.12.2 Removing the outrigger struts with the auxiliary crane

Starting position:
− suspension (in position for driving on normal roads) locked.
− boom secured in folded position (retracted).
− superstructure locking device inserted

Risk of tipping!
The superstructure locking device may only be detached
again when the crane is on outriggers (outrigger span
8.23 m x 7.50 m/27 ft x 24.6 ft).
If the superstructure locking device is detached before
the crane is on outriggers, the superstructure can swivel
on its own, for example, due to sloped positioning or the
effect of wind. In this situation the crane can tip over.

Procedure (action steps) for removing the outrigger struts

1. Supporting cylinder and outrigger strut (1) are in transport

position (completely retracted).
Remove locking pin at position ”C”.

2. Extend outrigger strut (1) entirely, as far as possible.

3. Disconnect the quick release couplings for the hydraulic

lines ”R”, ”E” and ”P”.
Release the outrigger pressure display connection (plug
”Q”).

When the quick release couplings are released/connected,

none of the switches at the switch panel may be actuated.

4. Remove flap plug (8) and attach pin (5) on the piston rod of
the horizontal cylinder (6).

5. Connect the extension hoses to the quick release couplings

for the hydraulic lines ”R” and ”E”.
Check the connecting components for cleanliness and also
check the seal rings (O−rings); Check that the extension
tubes are not impeded.

6. Retract the horizontal cylinder. Release the extension hoses

to the quick release couplings for the hydraulic lines ”R” and
”E”.

140−2120−193a
75/79
12

2
1

B C X
7.5 m

Z 110 014

Q
E R P

6
7
8
5

Z 53 788

76/79 140−2120−193a
 Outriggers 12

(Z 110 014, Z 53 788)

7. Attach the outrigger struts (1) to the auxiliary crane with

suitable lifting gear.

8. Disconnect the extension hoses at the quick release

couplings for the hydraulic lines ”R” and ”E”.
Attach dust guard caps to all quick release couplings.
Load outrigger struts on an adequate transport vehicle and
secure.

12.12.3 Installation of the outrigger struts

Starting position:
− suspension (in position for driving on normal roads) locked.
− boom secured in folded position (retracted).
− superstructure locking device inserted

Risk of tipping!
The superstructure locking device may only be detached
again when the crane is on outriggers (outrigger span
8.23 m x 7.50 m/27 ft x 24.6 ft).
If the superstructure locking device is detached before
the crane is on outriggers, the superstructure can swivel
on its own, for example, due to sloped positioning or the
effect of wind. In this situation the crane can tip over.

Procedure (action steps) for installing the outrigger struts

1. The outrigger struts are folded together (transport position)
on the transport vehicle.

2. Using the auxiliary crane, pick up the outrigger struts from

the transport vehicle and move them to their individual
supporting boxes in a horizontal, aligned insertion position.
Clean and grease the slide faces.

3. Before inserting the hooked outrigger strut: Push the

extension hoses through the supporting boxes in the
direction of the quick release couplings.

4. Insert the outrigger struts (1) horizontally (approx. 700

mm/27.5 inches).

140−2120−193a
77/79
12

2
1

B C X
7.5 m

Z 110 014

Q
E R P

6
7
8
5

Z 53 788

78/79 140−2120−193a
 Outriggers 12

(Z 110 014, Z 53 788)

5. Connect the extension hoses to the quick release couplings

”R” and ”E”.
Check the connecting components for cleanliness and also
check the seal rings (O−rings); Check that the extension
tubes are not impeded.

6. Extend horizontal cylinder; Retract piston rod (6) in bearing.

In doing so, observe the extension hoses in the supporting
box and protect from damage.

7. Use socket pin (5) to connect piston rod (6) to frame bracket
(7) and secure with flap plug (8).

8. Disconnect the extension hoses from the quick release

couplings ”R” and ”E”.

9. Connect all hydraulics connections (”R”, ”E” and ”P”) to the

hoses at the frame side.

10. Join outrigger pressure display connection (plug ”Q”).

11. Detach lifting tackle.

12. When all 4 outrigger struts are installed, stabilise the crane.

140−2120−193a
79/79
 Parking 13

13 Parking

The crane vehicle must be made completely safe before it is left.

The following basic instructions should be observed.

13.1 Crane in the Transport Condition

1. Apply the parking brake (14) of the crane chassis.

The retaining brake cannot hold the mobile crane at every slope
or descent that it can drive!
If you must park on a slope or descent, the wheels must be
secured additionally using chocks.

2. Switch the transmission to the neutral position using rotary

switch (13).

3. Switch off the engine.

4. Switch off the heating if necessary (in case of

engine−independent heating).

5. The main boom must be in the “road travel

condition”(telescopic sections pinned, locking−pinning unit
locked in the transport position (see part 1, section 12)).

6. Place all control levers in the off or middle position (”O”

position).

7. Pull out the ignition key (superstructure and crane chassis).

If the crane is equipped with an engine−independent heater,

wait one or two minutes before switching off the ignition
switch.
(After−run time of the heater fan for cooling off the heating).

8. Lock the driver’s cab and crane operator’s cab.

140−2130 1/3
13

2/3 140−2130
 Parking 13

13.2 Crane in Erect Condition and Supported on

Outriggers

1. Set the crane load down on the ground and detach

(whenever the crane operator leaves the crane operator’s
cab).

2. Lock the slew gear brake (see ”Operating instructions for the
superstructure”, part 1, section 8).

3. Retract and pin lock the telescopic sections.

4. Put all control levers in the off or middle position (”O”

position).

5. Switch off the engine.

6. Switch off the heating if it is on.

7. Pull out ignition key (superstructure and crane chassis).

If the aircraft warning light is to remain switched on while parking,

the ignition key in the crane operator’s cab of the superstructure
must not be pulled out, but must be switched to “parking position”.
In this case, make sure that the radio, fan and any additional
ventilators are switched off.
The batteries will run down if the aircraft warning lights are
switched to constant operation and the engine is switched off.
To avoid this, the crane operator must provide a secondary power
source (e.g. charging set).

If the crane is equipped with an engine−independent heater,

wait one or two minutes before switching off the battery
switch or ignition key (after−run time of the heater fan for
cooling off the heater).

8. Lock the driver’s cab and crane operator’s cab.

Observe the permitted wind speeds!

If necessary, the boom or equipment must also be lowered!

140−2130 3/3
 Tow−starting and Towing the Crane 14

140−2140 1/15
14

1 2 4 5 7 3 6

Z 200 092

2/15 140−2140
 Tow−starting and Towing the Crane 14

14 Tow−starting and Towing the Crane

(Z 200 092)

14.1 Towing start

The engine cannot be started by tow−starting the crane.

If the batteries are dead the engine can be started with the help
of jump−start cables and the batteries of another vehicle. (see
also section 4)

14.2 Towing

14.2.1 Important General Instructions

The trailer coupling on the front frame is designed for manoeu-

vring and towing the crane.

The towing vehicle must be sufficiently dimensioned (brakes, en-

gine output).

Use only a permitted towbar to tow the crane. Lock the coupling
bolts to safeguard against them falling out.

Avoid oblique pull under all circumstances.

Voice contact must exist between the towing machine and the
crane vehicle.

14.2.2 Recovering from a Hazardous Area

As a rule, certain joint shafts must be removed before the crane

is towed.
The only exception: Neutral position of the distributor gear for
towing with damage to the engine / transmission

Further details about this can be found in sect. 14. 2. 6.

Failure to observe this regulation will unavoidably result in

damage to the crane.

140−2140 3/15
14

1 2 4 5 7 3 6

Z 200 092

M16x1.5

1 ”L”
B3
3 ”R”

B4

35

Z 51 301 Z 200 320

4/15 140−2140
 Tow−starting and Towing the Crane 14

14.2.3 Towing with Engine Damage

(Z 200 092, Z 51 301, Z 200 320)

First option:

− Remove drive shaft (4) from between drive gearbox (2) and
distributor gear (3).
− Ignition on.
− Drive gearbox in neutral position.
− Distributor gear in road travel position.

Second option:

Under certain conditions (max. 30 km at 30 km/h), you can avoid

removing the universal joints for towing. In this case, the distribu-
tor gear must be switched to neutral position instead (for more in-
formation see “Neutral position of the distributor gear” in this sec-
tion).
− Ignition on.
− Drive gearbox in neutral position.
− Drive gearbox in neutral position.

For both options the following applies:

− The braking system of the mobile crane must be supplied with

pressurised air using a hose from the towing vehicle. For this
purpose there is a combined external filling and tyre filling
connection with M 16 x 1.5 thread on the right side of the
crane base.
The connection for the filling hose must only be screwed on
to the combined connection in such a way, that the cylindrical
component is pressed in by approx. 1 mm (position L: exterior
filling). (Information: on filling up the tyres: screw filling tube
on so that the cylindrical component is pressed in approx. 3
mm (position R).

If the air pressure in the supply tanks falls below 5.5 bar (indi-
cator lights B3 / B4 and “STOP” display (35) are illuminated),
the crane must be stopped immediately.

If the pressure in the braking system falls to such an extent that

the spring accumulators − brake cylinder close of their own ac-
cord, the spring tension can be released again mechanically.
To do this, unscrew the release bolts on the spring accumulators
− brake cylinder using an SW 27 wrench until they move freely.

140−2140 5/15
14

1 2 4 5 7 3 6

Z 200 092

35 36 B4

B3
43 B8

B9

B10

35
36
Z 52 142

6/15 140−2140
 Tow−starting and Towing the Crane 14

The spring accumulator brake cylinders may only be re-

leased once the vehicle has been secured to prevent it
from rolling away.

(Z 200 092, Z 52 142)

Following towing with the spring accumulators − brake cylinders

released, the braking action of the parking brake must be re-
stored before the crane is placed back in operation.
The compressed air must first be raised to a pressure of 8 bar with
the engine running. The displays (B3 / B4) go out at 5.5 bar.
Then − with the parking brake released − the release bolts on the
spring accumulator brake cylinders must be fully screwed into the
cylinders and tightened.
Once you have done this, check the free travel of the brake cylin-
der and adjust as necessary.

To ensure the road safety of the vehicle, this work may only
be carried out by trained and qualified personnel.

Important note on steering while engine is at a standstill:

When the engine is at a standstill, the main steering circuits
1 and 2 do not function. Only when the vehicle is in motion
does the emergency steering pump, which is connected to
the drive train (distributor gearbox), rotate and supply (de-
pending on speed) the steering circuit 3. This means:

∗ The joint shafts 5 AND 6 may not be removed at the same

time. One of the shafts must always be fitted so that the
emergency steering pump will pump.
∗ Much greater effort is required to move the steering
wheel.
∗ The steering times for the vehicle being towed are in-
creased 3− to 4−fold.
∗ In tight bends the vehicle may need to be manoeuvred in
the area of the bend.
∗ The steering circuits 1 and 2 do not function at the mo-
ment. This is indicated while towing by red indicator
lights (B8, B9) in combination with “Caution” (36).
∗ While towing the indicator light (B10) must be observed.

140−2140 7/15
14

35 36 B4

B3
43 B8

B9

B10

35
36
Z 52 142

1 2 4 5 7 3 6

Z 200 092

8/15 140−2140
 Tow−starting and Towing the Crane 14

(Z 52 142)

The indicator light (B10) may not light up.

If these indicator lights are illuminated in red (“STOP”
(35) would be displayed at the same time), the crane
must be stopped immediately. It is no longer possible to
steer the crane.

Depending on the system, in case of the fault ”No through−feed

at the emergency steering pump” (indicator light B10) , there is
a display only once a driving speed > approx. 8 km/h has been
reached.

14.2.4 Towing with Damage to the Drive Gearbox

(Z 200 092)

First option:

− The drive shaft (4) must be disconnected between the drive

gearbox (2) and the distributor gear (3).
− Drive gearbox in neutral position.
− Distributor gear in road travel position.

Second option:

Under certain conditions (max. 30 km at 30 km/h), you can avoid

removing the universal joints for towing. In this case, the distribu-
tor gear must be switched to the neutral position instead (for more
information see “Neutral position of the distributor gear” in this
section).
− Drive gearbox in neutral position.
− Drive gearbox in neutral position.

For both options the following applies:

− Start the engine of the chassis and set the speed to 1200 rpm.
This speed must be maintained during the towing procedure.

If the chassis engine should stop running for some reason,

follow the towing regulations outlined for towing the crane
in the case of engine damage.

140−2140 9/15
14

1 2 4 5 7 3 6

Z 200 092

B8

B9

B10

36

Z 51 300

10/15 140−2140
 Tow−starting and Towing the Crane 14

14.2.5 Towing with Damage to the Distributor Gear

(Z 200 092, Z 51 300)

− The drive shaft (4) must be disconnected between the drive

gearbox (2) and the distributor gear (3).
− The drive shaft (5) must be removed between the distributor
gear (3) and front axles.
− The drive shaft (6) must be removed between the distributor
gear (3) and rear axles.
− Start the engine of the chassis and set the speed to 1200 rpm.
This speed must be maintained during the towing procedure.

If the warning lights (B8, B9) light up during towing, the

crane must be stopped immediately. It is no longer pos-
sible to steer the crane.

When towing with damage to the distributor gear the drive

motor must always run; otherwise the vehicle cannot be
steered.

In this case, the indicator light (B10) which controls the function
of the emergency steering pumps is also illuminated during tow-
ing (red together with ”Caution” (36)) as there is no connection to
the emergency steering pump due to the missing drive shafts.
Depending on the system, the message is only shown at driving
speeds > approx. 8 km/h.

140−2140 11/15
14

A8

1
2

Z 52 143

93 A7

Z 52 144 Z 200 321

12/15 140−2140
 Tow−starting and Towing the Crane 14

14.2.6 Neutral Position of the Distributor Gear for Towing

with Damage to Engine / Transmission

(Z 52 143, Z 52 144, Z 200 321)

The neutral position of the distributor gear is meant to ease the

driver’s job, so that the universal joints do not have to be removed
if there is damage to the engine / transmission.

It is only permitted to tow with the distributor gear in neutral posi-

tion if the journey is no longer than 30 km and speeds do not ex-
ceed 30 km/h.
Avoid longer towing journeys (the lubricating oil pump does not
work).

If the max. towing distance (30 km) and / or the max. towing
speed (30 km/h) is not adhered to, it will always lead to dam-
age.

The neutral position is switched on via a manually activated

pneumatic valve (1) (key function). In order to carry out a switch-
ing procedure, a pressure supply of 7 bar is required.

The button is on the right−hand side of the machine in the outer

covering under the rubber sheeting (Z 200 321).

Steps for neutral position of the distributor gear

1. Stop vehicle; apply parking brake; secure against rolling

away; transmission in “neutral”.

2. Switch to neutral position in the distributor gear by pressing

the button (2). The indicator light (A8) is displayed in the
driver display (43).

3. After towing is completed (wait for the vehicle to come to

a standstill), road travel must be activated again in the distrib-
utor gear by pressing the dual button (93). The indicator light
(A8) goes out.
No resetting is required at the actual pneumatic valve.

Make sure that the dual button (93) is not pressed during tow-
ing (not even by accident).

140−2140 13/15
14

14/15 140−2140
 Tow−starting and Towing the Crane 14

14.3 Towing Free From Rough Terrain

Towing the crane free (pulling out) if the wheels have become
stuck in the ground is only allowed with extreme caution.

It is prohibited to pull it out using the trailer coupling at the front

frame, as it is only for towing on a firm surface.

The crane vehicle may only be towed backwards using the rear
trailer clutch or long steel ropes, fastened to the rear outrigger
beams. The crane should then be towed along the track that it
has already made.

Sudden, jerking movements and oblique pull are prohibited, as

these could result in damage to the chassis.

If it is not possible to pull the crane out in a straight line, a deflec-

tion point may need to be set up between the crane and the re-
covery vehicle. Make sure that there is sufficient air in the braking
system.

140−2140 15/15
 Heating and Ventilation 15

140−2150−103 1/25
15

105 106 107 115

114

113

24V

112

5A

108 109 110 111

Z 53 019

2/25 140−2150−103
 Heating and Ventilation 15

15 Heating and Ventilation

15.1 Cab Heater Arrangement (Dependent of Engine)

(Z 53 019)

This heating system is dependent on the temperature of the en-

gine coolant.

When the engine coolant is warm, the temperature in the cab can
be regulated via control knob (113).

A fan can also be switched on with rotary switch (114) in order to

accelerate the air circulation in the driver’s cab or to bring more
warm air into the cab when the crane is standing still.

Using control knob(111) for air circulation windscreen or driver‘s

cab.

Using rotary button (115) an air flap can be set to fresh air or circu-
lating air.

140−2150−103 3/25
15

8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

4/25 140−2150−103
 Heating and Ventilation 15

15.2 Hot Water Heater Arrangement with Preheating for

coolant (independent of engine), Optional Equipment
(Z 35 590)

The crane is equipped with the Eberspächer D 9 W hot water

heater arrangement.
With low ambient temperatures (up to −20° C) it makes starting
the engine easier. With temperatures lower than −20° C the cool-
ant must be preheated.
For operating the heater there is a timer (109) in the cabin.

1. Clock time

2. Preselection

3. Heating

4. Back

5. Forward

6. Memory display

7. Symbol for radio remote control

8. Weekday or preselected day

9. Actual clock time or preselected time

10. Temperature display

11. Operating display

If the coolant has been replaced or topped up considerably,

the vehicle engine must be brought up to an operating tem-
perature of approx. 80° C (activation point of the coolant ther-
mostat) before the independent heater is switched on so that
the coolant circuit and the circuit for the independent heater
can be bled automatically.

When the heater is switched on, the lower fan level is automati-
cally switched on when the water temperature reaches approx.
55° C − measured on the independent heater.

140−2150−103 5/25
15

8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

6/25 140−2150−103
 Heating and Ventilation 15

(Z 35 590)

The following operating conditions can be preselected:

− cab pre−heating only, via preset time

Set the heater control (control knob 113) to the desired tempera-
ture and using the timer (9), program the time when the heater is
to begin operation.

This heating procedure is fast and saves electricity.

− cab and engine pre−heating via preset time

Set the heater control (control knob 113) to the desired tempera-
ture and using the timer (9), program the time when the heater is
to begin operation.
− engine pre−heating only, via preset time

Set the heater control (control knob 113) to the temperature posi-
tion 0, and using the timer (9), program the time when the heater
is to begin operation.

If the power supply is interrupted, the display on the heating

timer flashes.
The clock must then be completely reset.

To do this, proceed as follows:

1.) Setting the time and weekday for the first time

Press push button 1 briefly.

12:00 flashes on the display.
Set the clock time with push button 4 or 5.
The time is stored as soon as it stops flashing.
Then the weekday flashes. Set the current weekday with push
button 4 or 5. It is stored as soon as is stops flashing.
When the ignition is switched on, the clock time and weekday are
displayed continuously. When the ignition is switched off, the dis-
play goes out after 10 seconds.

140−2150−103 7/25
15

8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

8/25 140−2150−103
 Heating and Ventilation 15

(Z 35 590)

2.) Changing the clock time and weekday

Press push button 1 and hold it down until the clock time flashes.
Proceed as described under point 1.).
If you only want to change the clock time, press the push button
1 twice after setting the clock time to skip weekday adjustment.
After changing the weekday, flashing on the weekday can be re-
duced by pressing the push button 1.

3.) Heating without preselection when ignition is “OFF”

Heating symbol (11) = Observe operating display

Switching on heater

Press push button 3 briefly.

Operating display (11) appears and the heating duration is dis-
played (120 Min).
The heating duration is factory−preset to 120 min., and can be
changed once only or permanently.

Changing the heating duration once only

After power−on:
To reduce heating duration (to min. 1 min.): Press push button 4.
To increase heating duration (to max. 120 min.): Press push but-
ton 5.

Changing the heating duration permanently

Do not switch on push button 3.

Press the push button 4 and hold it down (approx. 3 seconds)
until the display appears and flashes.
Release push button briefly.
Then set the heating duration using the push button 4 or 5 (on 10
to 120 min.).
The new heating duration is set when the display disappears.

Switching off heater

Press push button 3 briefly.

Operating display 11 disappears.
The blower automatically continues to operate to cool the heater
down.

140−2150−103 9/25
15

8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

10/25 140−2150−103
 Heating and Ventilation 15

(Z 35 590)

4.) Heating without preselection when ignition is “ON”

Switch on the heater

Press push button 3 briefly.

The operating display (11) and time and weekday.
The heating stays in operation until the ignition is switched off.
If the ignition is switched off, a residual heating period of 15 min.
remains. This can be extended to max. 120 min. by pressing the
push button 5 or reduced by pressing the push button 4.

Switching off heater

Press push button 3 briefly.

Operating display (11) disappears.
The blower automatically continues to operate to cool the heater
down.

5.) Heating operation preselection

3 switch−on times within the following 24 hours or one switch−on

time in 7 days can be programmed.

Only one switch−on time can be activated at a time.

5.1. Heating via preset time

∗ Selecting and activating memory:

(starting from neutral status with display visible)

First memory − press push button (2) once

Memory display: 1 (default setting 12 00)

Second memory − press push button (2) twice

Memory display: 2 (default setting 12 00)

Third memory − press push button (2) three times

Memory display: 3 (default setting 12 00)

Neutral status − no memory activated.

Press push button 2 repeatedly until the memory display dis-

appears.

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15

8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

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 Heating and Ventilation 15

(Z 35 590)

5.2. Start of heating within 24 hours

∗ Set the program day:

The correct program day is automatically displayed − no ad-
justment necessary.

Set the program time:

Press push button 2 repeatedly until the desired memory dis-
play (1, 2, 3) begins to flash.
Briefly press and then release push button 4 or 5. the program
time flashes.
Then set the program time for heating using push button 4 or
5.
Setting is only possible if the program time is flashing.
To select another memory: press push button 2.

5.3. Start of heating after 24 hours (max. 7 days)

∗ Set the program time:

Press push button 2 repeatedly until the desired memory dis-
play (1, 2, 3) begins to flash.
Briefly press and release push button 4 or 5.
The program time flashes.
Then set the program time for heating using push button 4 or
5.

Set the program day:

The program day begins to flash approx. 5 seconds after the
program time has been set.
Then set the program day for heating using push button 4 or
5.

The program time and program day are stored when the time
display disappears or when the current time appears.
The memory display indicates the activated memory.
The flashing heating−on symbol (3) also indicates that a
memory has been activated.

6.) Checking activated memory:

The program time of the displayed memory is displayed for ap-

prox. 5 seconds. The display then disappears or the current time
is displayed (if the ignition is “ON”).
The program time display together with the program day can then
be called up by pressing push button 2 once for 5 seconds.

140−2150−103 13/25
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8 9 10 11

7 MO ºC

6 3 20:30
P

1 2 3 4 5

Z 35 590

14/25 140−2150−103
 Heating and Ventilation 15

(Z 35 590)

7.) Attention !

When the ignition is switched on, the clock time and weekday are
displayed continuously. When the ignition is switched off, the dis-
play goes out after approx. 15 seconds.

Radio remote control operation is possible with the appropriate

accessory.

If a fault occurs, with the heater switched on and a diagnosis line

connected, operating display (11) flashes and the fault code No.
is displayed (contact repair workshop).

8.) If faults occur, we recommend the following:

Switch off and on again (max. twice)

Check the main fuse
Check the air channels for blockages
Consult a workshop.

140−2150−103 15/25
15

2 A
1 B
C
3

Z 27 544

16/25 140−2150−103
 Heating and Ventilation 15

15.3 Petrol Gas Heating (independent of engine), Optional

Equipment
(Z 27 544)

Heating

Switch on the heater as follows:

1. Remove the cap (if there is one) from the heater.

2. Open the steel cylinder valve and quick lock valve in the gas
pipe.

3. Set the desired temperature on control knob (4) of the oper-

ating panel.

4. Set switch (3) to ”heating” (position ”A”) and switch (2) to the
desired output (”FULL, high flame” or ”1/2, low flame”). With
low ambient temperatures leave the heater running on
”FULL”.

Ventilation

Switch on the fan as follows:

1. Set switch (3) to ”ventilation” (position ”C”).

2. Set switch (2) to the desired level (”FULL” or ”1/2”).

When switch (3) is in position ”B”, the system is switched off.

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15

2 A
1 B
C
3

Z 27 544

18/25 140−2150−103
 Heating and Ventilation 15

Notes on operating the heater

(Z 27 544)

If switch (3) is set on ”heating” (position ”A”) or ”ventilation” (posi-

tion ”C”), the green indicator lamp under control knob (4) must be
on. The fan is in operation.
If the indicator lamp is not on, the fuse in the electrical control unit
must be renewed (see lubrication and maintenance instructions
for the crane chassis, Part 4, Sect. 19).

If, after a while, the heater is switched off, the green light means
that the fan is continuing to run to cool down the heater. The igni-
tion switch must therefore not be switched off until the fan has
gone off.

When filling up the tank and in enclosed spaces (garage etc.) the
heater must not be switched on.

If the red indicator lamp (1) comes on and is not flickering, this
can, amongst other things, mean the gas is low, there is air in the
gas pipe, the blower is badly clogged or there’s a defect in a
safety part.
The malfunction is cleared each time by switching the heater off
and on again.

If the red indicator lamp (1) is flickering, this indicates that the op-
erating voltage is too low for the heater.

Make sure that the heater is always free from dirt (slush, leaves
etc.) for gas emission and for the combustion air supply.

The heater cap must always be replaced when the heater is not
in operation.

For operation and maintenance of the heater also see the operat-
ing instructions from the manufacturer, Part 5.

Before carrying out any welding the corresponding breaker must

be switched off.

140−2150−103 19/25
15

105 106 107 115

114

113

24V

112

5A

108 109 110 111

Z 53 019

20/25 140−2150−103
 Heating and Ventilation 15

15.4 Air conditioner, Optional Equipment

(Z 53 019)

The air conditioner operates with the refrigerating agent R 134a

and is therefore without florchloride−carbonhydrogen.
To operate the air conditioner, there are two control buttons either
in the cabin.

1. control button air conditioner (110) (on/off)

2. blower switch, 3−settings (114)
The air conditioner only operates by running motor.
The air conditioner is switched off if the control button air condi-
tioning (110) is in position “out”.
To switch on the air conditioner, you have to turn the blower
switch (114) in clockwise direction to setting 1 at least. The cool-
ing temperature can be chosen with the control button tempera-
ture (113). By turning the button in clockwise direction, you can
reach a higher efficiency of the air conditioner. The room temper-
ature in the cabin decreases.
The higher you chosen the cooling temperature of the air condi-
tioner with the control button temperature, the higher you should
put the blower setting.
Should the efficiency the air conditioner noticeably decrease by
same speed and normal adjustment there is the possibility that
the evaporator is frozen. In that case, switch off the air conditioner
by running evaporator about 3 minutes. The ice on the evapora-
tor defreezes.

To obtain the most effective cooling in the cabin, you have to....
− turn control button temperature in clockwise direction as far
as it will go
− switch on the highest blower setting
− turn off the heater
− keep close the windscreens.
On cold and damp days the air conditioner can dehumidify the air
in the cabin. With the vehicle’s heater, the cooling is compen-
sated again. An agreeable climate of the cabin is obtained and
the steaming up of the windscreens is prevented.
The air conditioner should be switched on for a short time one
time every month a least. The operate is necessary so that all run-
ning parts will be lubricated.

Servicing the air conditioning system see part 3 (Lubrication and

Maintenance Manual of the Superstructure) .

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 Heating and Ventilation 15

15.5 Instructions for Winter Operation

Starting the Engine at Ambient Temperatures below −16° C

If the crane does not have an engine oil or engine coolant pre-
heating system, the engine can be equipped with a flame start
system for very low ambient temperatures.
Information is available from any DAIMLERCRYSLER service
station.

Fuel

Refer to the engine manufacturer’s operating instructions.

Engine oil for low temperatures

Refer to the engine manufacturer’s operating instructions.

Coolant for low temperatures

Refer to the engine manufacturer’s operating instructions.

Batteries

At ambient temperatures below −15° C the batteries must be

heated or removed when the vehicle is at a standstill for a pro-
longed period outdoors (e.g. overnight). Always ensure that bat-
teries are well charged in the winter.
Discharged batteries will freeze at −10° C.

Transmission

With ambient temperatures below −20° C start the engine and

allow the transmission to warm up.
With the crane at standstill and the parking brake applied, the en-
gine must be operated for at least 10 minutes until the trans-
mission oil is warmed up.

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Z 2542 Z 22 699

24/25 140−2150−103
 Heating and Ventilation 15

Draining the Air Tanks

(Z 2542)

All tanks with a manual valve are to be drained regularly. By pull-

ing or pushing the pin on the drain valve sideways, the tilting valve
opens and the condensation water can escape.

Windscreen Washing Assembly

(Z 22 699)

The windscreen washing assembly should be checked at least

once a week to ensure that it is functioning correctly. The supply
tank should always be filled with water. At low temperatures, an
amount of antifreeze appropriate to the temperature should be
added to the water.

140−2150−103 25/25
 Central Lubricating System 16

140−2160 1/15
16

Z 42 271

7
8

6 9

10

Z 29 548

2/15 140−2160
 Central Lubricating System 16

16 Central Lubricating System (Optional Equipment)

(Z 29 548, Z 42 271)

16.1 Components
(1) Lubricating nipple for manual lubrication
(2) Grease container
(3) Safety valve
(4) Filler nipple
(5) Plug

After removing plug (5) the control board with the following items
can be seen:

(6) Light−emitting diode ”live battery voltage”

(7) Rotary switch ”set the pause time”
(8) Rotary switch ”set the operational time”
(9) Light−emitting diode ”display of a lubricating procedure”
(10) Button for additional lubricating pulse

140−2160 3/15
16

Z 42 271

7
8

6 9

10

Z 29 548

4/15 140−2160
 Central Lubricating System 16

16.2 Function
(Z 42 271, Z 29 548)

The central lubricating system automatically supplies the

connected lubricating points via local sub−distributors with
grease.

It works according to preprogrammed cycles, i.e. there are pause

times and operating times. These begin to run as soon as the
ignition on the chassis is switched on.

Pause time: Period in which no lubrication is carried out

(exception possible if the additional lubricating
pulse is used)

Operating time: Period in which lubrication is carried out.

An exact description of the pause and operating times can be

found in section 16.3.

If there is a blockage in the system, lubricant is emitted from the

safety valve (3) of the pump.

An exact description of how to proceed in the event of faults can

be found in section 16.7.

To check that the system and controls are functioning correctly,

a test run can be carried out.

1. Switch on the ignition:

Light−emitting diode (6) must light up.

2. Press button (10) for additional lubrication for approx. 2

seconds (or button “98” in the dashboard).
The pause time is then abbreviated and the usual lubrication
procedure is carried out; light−emitting diode (9) and
indicator light in button (98) light up.

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7
8

6 9

10

Z 29 548

6/15 140−2160
 Central Lubricating System 16

16.3 Setting the Pause and Operating Time

(Z 29 548)

16.3.1 General

The pause and operating times are electronically regulated.

As soon as the ignition is switched on, the pause time begins.
Once the pause time is completed, the operating period begins,
the actual lubrication procedure.

If, for example, a pause time of 6 hours has been set, the time that
has already run when the ignition is switched off (e.g. 4 hours) is
stored. When the ignition is switched back on, a further two hours
pause time remain.

If the battery voltage is disconnected − for more than four days

− a complete pause cycle will run again (6 hours).

An operating cycle will run as long as the ignition is switched on.

If the operating cycle is interrupted by switching off the ignition −
it continues where it left off once the ignition is switched back on.
The individual cycle periods are stored electronically.
Example: Operating time already run 3 min. −
Remaining operating time 3 min.

The duration of the lubricating cycle is dependent on the amount

of lubricant required by the system. The pause / operating times
of the chassis are set ex works as follows:
− Pause cycle: 6 hours
Position of rotary switch (7) = 6
− Operating cycle:
6 min.
Position of rotary switch (8) = 3

That means that every 6 hours a lubricating procedure of 6

minutes is carried out.

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7
8

6 9

10

Z 29 548

8/15 140−2160
 Central Lubricating System 16

16.3.2 Setting the Pause Time

(Z 29 548)

The pause time is set on rotary switch (7) in 15 increments.

Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

The pause time set ex works is 6 hours.

For normal operating conditions this setting must be maintained.

16.3.3 Setting the Operating Time/Cycle

(Z 29 548)

The operating time can be set using 15 settings on rotary switch

(8).
Switch 1 2 3 4 5 6 7 8 9 A B C D E F
position
Minutes 2 3 6 8 10 12 14 16 18 20 22 24 26 28 30

The operating time set ex works is 6 minutes.

For normal operating conditions this setting must be maintained.

140−2160 9/15
16

7
8

6 9

10

Z 29 548

4
98
5

Z 42 271 Z 53 751

10/15 140−2160
 Central Lubricating System 16

(Z 29 548, Z 42 271, Z 53 751)

16.4 Additional Lubricating Pulses

In addition to the automatic lubricating cycles, it is possible to end
the pause time early and to carry out additional lubricating cycles.
These can be carried out either by pressing (approx. 2 seconds)
the following buttons:

1. Button (98) in the dashboard;

the indicator light lights up in the button.

Or

2. Button (10) on the control board of the lube pump;

light−emitting diode (9) lights up on the control board.

The ignition must be switched on!

Once the additional lubrication has been carried out, the usual
pause time begins again from the start.

16.5 Manual Lubrication in Case of an Emergency

If the lube pump fails, the lubrication points can also be supplied
manually with grease.
The grease is then fed into the system using a grease gun via
lubricating nipple (1).

16.6 Filling the Grease Container (Lube Tank)

The grease container or lube tank (2) is filled up to the ”max.”
marking using filler nipple (4). This is carried out using a standard
grease pump or a hand−lever press.
During filling, the pump must be set in motion (by first activating
the additional lubricating pulse).

The grease that has been added must be free of impurities

and and must not change in consistency with time.

Pay attention to the instructions on the prescribed lubricants in

the ”lubricating / maintenance instructions of the chassis” (part 4).

140−2160 11/15
16

12/15 140−2160
 Central Lubricating System 16

16.7 Troubleshooting

Fault: The engine of the pump is not running

Cause Remedy
Power supply interrupted. Check power supply / fuses. Rectify fault / re-
place fuses if necessary.

Fault: Pump is not delivering

Cause Remedy
Container empty. Fill up the container with clean grease, allow
the pump to run (additional lubrication) until
the lubricant is emitted at all lubricating points.
Note: Depending on the ambient temperature
and/or lubricant the pump elements require up
to 10 minutes run time in order to reach their
full delivery capacity.
Air pockets in the lubricant. Carry out an additional lubricating pulse.
Loosen the outlet plug on the safety valve.
The lubricant must be emitted without bubbles.
Unsuitable lubricant used. Replace the lubricant, see lubricants table (lu-
bricating and maintenance instructions of the
chassis”, part 4).
Suction hole of the pump element is clogged. Remove the pump element, check the suction
hole for impurities/blockages and clean.
Pump pistons worn. Replace the pump element.
Non−return valve in the pump element defec- Replace the pump element.
tive or clogged.

Fault: Different lube quantities at the lubricating points

Cause Remedy
Corresponding valve body is fitted without Remove the valve body and check whether a
clamping ring. clamping ring is fitted. If not, fit a clamping
ring.

140−2160 13/15
16

Z 29 549

14/15 140−2160
 Central Lubricating System 16

Fault: Blockage in the connected progressive system (Z 29 549)

Cause Remedy
Bearing, leads or distributor Find and rectify the blockage − as described in the following
clogged. example.
The fault can be recognised by 1. Leave the pump running (additional lubricating pulse).
the following characteristics: 2. Individually release all main lines (G) from the main dis-
a) Grease emitted at the safety tributor (B) to the sub distributors. If, for example, grease
valve. is emitted under pressure from outlet (1) of the main dis-
b) The check pins on the distrib- tributor (B), the blockage must be looked for in the lubri-
utor pistons (if fitted) are not cating circuit of the sub−distributor (D).
moving. 3. Leave the pump running.
4. Individually release all lubricating lines (E) of the sub−dis-
tributor (D) one after the other. If, for example, grease is
emitted under pressure from outlet (3) of distributor (D),
the blockage must be looked for in the line of outlet (3) or
in the connected bearing.
5. Replace safety valve A.
Note: To check the individual outlets, leave each outlet
loose for a longer period of time, as only one piston
stroke is carried out for each rotation of the pump. Sev-
eral piston strokes are required, however, to carry out a
complete run through all distributors.
c) If a distributor is blocked, lu- Pump out the blocked line / bearing using a hand pump.
bricant is not emitted at any Replace the distributor or clean as described below:
outlet. 1. Remove all pipe connection screws.
2. Unscrew the piston sealing plugs.
3. Drive out the pistons, if possible, with a small soft mandrel
(ø smaller than 6 mm).
Caution: The pistons are fitted flush in the distributor bores.
After removing, mark the pistons to make sure they are
fitted again in the right position and direction. They must
not be mixed up when refitting.
4. Clean the distributor body in grease−dissolv-
ing cleaner and blow off with compressed air.
5. Press through the cross channels (ø 1.5 mm) on the
thread ends of the piston bores with a pin.
6. Clean the distributor again and blow out.
7. Assemble the distributor.
8 Replace the copper washers.
9. Before screwing in the pipe connectors, pump through the
distributor several times with oil using a manual pump. The
pressure in the distributor must not exceed 25 bar ( 362.8
psi) when doing this.
If this is the case, replace the distributor.

140−2160 15/15
 Index

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Personnel selection and qualifications . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Particular types of hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Risk of crushing / shearing / collisions . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Risk of snagging and dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Risk of slipping, tripping, falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.4 Risk of thermal effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.5 Risk of residual energy in the hydraulic system . . . . . . . . . . . . . . . . 7
1.4 Before commencing lubrication and maintenance work . . . . . . . . . 9
1.4.1 Cleaning the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.2 Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Carrying out lubrication and maintenance work . . . . . . . . . . . . . . . . 15
1.6 Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2 Consumables and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Lubrication and Maintenance Schedule . . . . . . . . . . . . . . . . . . . 3

4.1 Initial Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Regular Routine Lubrication and Maintenance . . . . . . . . . . . . . . . . 3
4.3 Tips for Maintaining the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Measures to Maintain the Crane: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

200−1−3000−587_en 1
 Index

5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1 Engine Quick Stop: Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 Slew Ring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6.1 Lubricating the Slew Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2 Lubricating the Toothed Rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.3 Lubricating the Mechanical Superstructure Locking Device . . . . . 5

7 Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1 Slew gear mechanism, checking the oil level . . . . . . . . . . . . . . . . . . 3
7.2 Slew gear mechanism, changing the oil . . . . . . . . . . . . . . . . . . . . . . 3
7.3 Lubricating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.4 Checking and Re−tightening the Screw Connections if Necessary 5
7.5 Visual and Noise Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.6 Maintenance of the Slew Gear Brake . . . . . . . . . . . . . . . . . . . . . . . . 7

8 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1 Hoist 1 and 2 − check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.2 Hoist Gear − Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.3 Check screwed connection, tighten if required. . . . . . . . . . . . . . . . . 7
8.4 Lubricating the Rope Drum Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.5 Calculating the Percentage Used of the Theoretical Service Life . 9
8.6 General Overhaul of the Hoist Gear Winches . . . . . . . . . . . . . . . . . 9
8.7 Lower Limit Switch − Checking the Proper Function . . . . . . . . . . . 9
8.8 Hoist limit switch − check that it functions properly . . . . . . . . . . . . . 11
8.9 Lubricating Erection Cylinder Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . 11

9 Luffing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1 Lubricating the Luffing Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

200−1−3000−587_en 2
 Index

10 Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 Lubricating the Boom Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.2 Lubricating the Locking and Pinning Unit (LPU) . . . . . . . . . . . . . . . 11
10.3 Locking and Pinning Unit − Carrying Out a Visual Check . . . . . . . 15
10.4 Locking and Pinning Unit − Checking the Proximity Switches and
Sliding Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.5 Locking and Pinning Unit −
Checking the Preliminary Gas Tension of the Accumulators . . . . . 17
10.6 Checking the Rope of the Length Transducer Drum . . . . . . . . . . . . 21
10.7 Lubricating the Foot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.8 Lubricate the main boom head axles . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.9 Check the main boom for weld cracks . . . . . . . . . . . . . . . . . . . . . . . 21
10.10 Checking the Roller Bearings of the Sheaves . . . . . . . . . . . . . . . . . 23
10.11 Exchanging Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.12 Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

11 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Main Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1.1 Checking the draw shackles (depending on the version) . . . . . . . . 3
11.1.1.1 Check for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.1.2 Checking the Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11.1.1.3 Check the wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.1.1.4 Check the Paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.1.1.5 Check for plastic deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.1.2 Lubricating the Spindle (Depending on the Design) . . . . . . . . . . . . 7
11.2 Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.1 General Notes on Handling and Assembly . . . . . . . . . . . . . . . . . . . . 9
11.2.1.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2.1.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.2.1.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.2.2 Lubricating the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.2.3 Cleaning the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.2.4 Checking the Cables and Replacing as Necessary . . . . . . . . . . . . 27
11.3 Lubricating the Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.4 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.4.1 Checking the Roller Bearings of the Sheaves . . . . . . . . . . . . . . . . . 43
11.4.2 Exchanging Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.4.3 Checking the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

200−1−3000−587_en 3
 Index

12 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 Replacing the Filter Elementsin the Return Flow Filter . . . . . . . . . 3
12.2 Replacing the Ventilation Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.3 Cleaning / Replacing the Filter Element of the High−pressure Filter /
Leak Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
12.3.1 Cleaning the HP Filter (1)
(Type ”LF BN/HC 60”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.3.2 Clean the Overflow Oil Filter (3)
(Type ”HD 062−171”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.3.3 Cleaning the HP Filter (2)
(Type ”HD 069−171”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.4 Hydraulic Pump − Changing the Add−On Filter . . . . . . . . . . . . . . . . 21
12.5 Hydraulic Tank − Checking the Oil Level / Topping up . . . . . . . . . . 23
12.6 Checking the Hydraulic Oil Tank Return Filter for Contamination . 25
12.7 Changing Oil in the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.8 Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.9 Checking the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.10 Checking the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.11 Replace the hose lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.12 Checking the Accumulator Initial Gas Pressure . . . . . . . . . . . . . . . 33
12.13 Using Biological Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

200−1−3000−587_en 4
 Index

13 Heating and Air Conditioning Equipment . . . . . . . . . . . . . . . . . . 3

13.1 Checking the System is Functioning Correctly . . . . . . . . . . . . . . . . 3
13.1.1 Checking the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13.1.2 Fault Diagnosis with the Heating Timer . . . . . . . . . . . . . . . . . . . . . . 5
13.2 Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.3 Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.4 Bleeding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.5 Air Conditioning Equipment (optional) . . . . . . . . . . . . . . . . . . . . . . . . 19
13.5.1 Switching on the Air Conditioning Equipment . . . . . . . . . . . . . . . . . 19
13.5.2 Servicing the Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . . 19
13.5.3 Having the Air Conditioning Equipment Checked . . . . . . . . . . . . . . 19

14 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Checking the Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Servicing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.4 Checking the Slip Ring Contacts on the Winches and the
Rotary Joint of the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14.5 Preventative Measures Against Cable Fires . . . . . . . . . . . . . . . . . . 11

15 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Checking the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Cooling, Intake and Exhaust System . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Cleaning or Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . 3
16.1.1 Dry Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.2 Wet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.3 Testing the Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2 Replacing the Safety Cartridge (Optional) . . . . . . . . . . . . . . . . . . . . 9
16.3 Air Filter Preseparator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.5 Checking the Coolant Level and Topping up as Necessary . . . . . . 13
16.6 Replacing the Coolant with Anti−freeze . . . . . . . . . . . . . . . . . . . . . . 15
16.7 Diesel Particle Filter Huss (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 21
16.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16.7.2 Checking and Emptying Condensate Separator . . . . . . . . . . . . . . . 23
16.7.3 Blowing out Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
16.7.4 Changing the Filter Element of the Fuel Filter . . . . . . . . . . . . . . . . . 25
16.7.5 Having a Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

17 Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17.1 Exposed Chrome Surfaces − Applying Protective Grease . . . . . . 1

200−1−3000−587_en 5
 Index

18 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

18.1 Lubricate the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.2 Check the windscreen washing assembly . . . . . . . . . . . . . . . . . . . . 5
18.3 Fill up the supply tank of the windscreen washing assembly . . . . 5
18.4 Lubricating the Guide Rail of the Sliding Door . . . . . . . . . . . . . . . . . 5

19 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19.1 Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

20 Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1 Central Lubricating System (option) . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.1 Filling up the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.2 Checking the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1.3 Cleaning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

22 Examinations of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22.1 Recurrent Inspections of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22.1.1 Inspection of Load−bearing Steel Constructions . . . . . . . . . . . . . . . 15
22.1.2 Inspection of the Disc Wheels (Rims) . . . . . . . . . . . . . . . . . . . . . . . . 49
22.1.3 Inspection of the Winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22.1.4 Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
22.1.5 Inspection of the Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
22.1.6 Inspection of the Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
22.1.7 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

200−1−3000−587_en 6
 Foreword

Foreword

Part 3: Lubrication and Maintenance Instructions for the Su-

perstructure

For you,

This instruction manual is provided for the benefit of personnel

carrying out maintenance work, and includes information requi-
red for maintenance and lubrication of the machine and all spe-
cial equipment.

The information contained in this manual is correct with regard to

the equipment at the time of publication. Data, diagrams and di-
mensions are subject to change as a result of technical develop-
ment.
No liability can be accepted for damage resulting from incorrect
maintenance.

In these lubrication and maintenance instructions you will find the

titles or the respective symbols ”Danger”, ”Caution” and ”Note”
used as follows:

DANGER!

”Danger” is used if a maintenance procedure, NOT per-

formed according to the prescriptions given, may cause
death or injury to persons.

CAUTION !

”Caution” is used if a maintenance procedure, NOT perfor-

med according to the instructions given, may cause damage
to the crane or the crane equipment.

NOTE:

”Note” is used for identifying an important maintenance proce-

dure as well as for additional information.

200−1−3002 1/3
2/3 200−1−3002
 Foreword

General Recommendations Regarding Lubrication and

Maintenance Tasks

− Thoroughly clean all nipples, caps and plugs before grea-

sing.
− Refill the fuel tank at the end of each working day, in order to
prevent condensation.
− Renew the gaskets for drain, filler, inspection plugs and fil-
ters, before replacing the screws or filter.
− The oil can be drained more easily from individual units if it is
drained at operating temperature.
− Ensure that the crane is kept clean at all times, i.e. free of
flammable substances. In particular, the crane must be clea-
ned thoroughly following maintenance work on the hydraulic
system, the engine or the fuel system. Cleaning is best car-
ried out with a steam cleaner.
− After cleaning the crane, grease all lubricating points.
When dry, spray the slew gear teeth with the recommended
grease.
− Never carry out welding repairs without first consulting our
Customer Service Department responsible for cranes.
Repair work carried out incorrectly may cause serious da-
mage, resulting in extensive repairs at considerable cost.

Please contact the Customer Service Department immediately if

you discover cracks in the steelwork of your crane.
Describe the course of the crack as closely as possible (enclose
photograph, page from spare parts catalogue etc.).

200−1−3002 3/3
 Safety Instructions 1

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1

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 Safety Instructions 1

1 Safety Instructions

1.1 General

This section ”Safety instructions” gives a concentrated and

general overview of the dangers and risks involved when carrying
out lubrication and maintenance work on the crane
superstructure and crane chassis.
In the corresponding sections of the maintenance and lubrication
instructions, these safety instructions are cross−referenced and
outlined in more detail as required.

In the maintenance and lubrication instructions of the crane

chassis (part 4 of this documentation), section 1 ”safety
instructions” simply refers back to this section of the manual.

Carry out the prescribed setting and maintenance work at the

specified times and observe the instructions regarding the
replacement of parts!

Keep all grips, steps, rails, platforms, stages and ladders free
from dirt, snow and ice.

Wear safety clothing, goggles, face mask and other safety

equipment when required by the working conditions.

Make sure that there are no unauthorised persons on the crane

when carrying out lubrication and maintenance work.

Spare parts must satisfy the technical specifications prescribed

by the manufacturer. Therefore only use our original spare parts.
A new examination and authorisation may be required.

The safety instructions listed for lubrication, maintenance

and setting work must also be observed for all maintenance
and repairs.

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1

Z 30 300

Z 29 801

4/21 200−1−3010e
 Safety Instructions 1

1.2 Personnel selection and qualifications

The crane equipment may only be serviced and calibrated by

specialist personnel.

This especially applied to work on the electrics, hydraulics, travel

gear and brake and steering systems.

1.3 Particular types of hazard

At certain points, where specified risks during operation of the

crane are safeguarded by safety clearances or covers, particular
care must be taken when carrying out lubrication and
maintenance work.
Follow the specific instructions that are given in the
corresponding sections of the lubrication and maintenance
instructions.

1.3.1 Risk of crushing / shearing / collisions

(Safety Signs: Z 30 300)

The affected areas are:

− Main boom
− Slew Ring Connection
− slew gear pinion

1.3.2 Risk of snagging and dragging

(Safety Signs: Z 29 801)

The affected areas are:

− ropes to winches / all sheaves / hook blocks / fixed and flying
bridle

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1

Z 29 803

6/21 200−1−3010e
 Safety Instructions 1

1.3.3 Risk of slipping, tripping, falling

(Safety Signs: Z 29 803)

Only the walkways and ladders described may be used. These

provide sufficient gripping points to hold on to and the walkways
are slip−free in design (e.g. sanding, chequer plate etc.).

1.3.4 Risk of thermal effects

The affected areas are:
− engine with exhaust system
− parts of the hydraulic system under covers

1.3.5 Risk of residual energy in the hydraulic system

In certain situations, e.g. damage to the hydraulic components
such as tubes, hoses, valves etc. the machine can come to a
standstill. Part of the system then remains under pressure.
It is not always possible to release this pressure (e.g. opening the
lowering brake valves on the telescoping cylinders).
In such cases an auxiliary crane must be used to dismantle the
crane.
Such work may only be carried out by our customer service
department.

200−1−3010e 7/21
1

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 Safety Instructions 1

1.4 Before commencing lubrication and maintenance

work

Inform the operating personnel and appoint a supervisor.

Switch off the diesel engine.

The component group, on which maintenance work is to be
carried out, must be switched off and free of load.
The only exception to this requirement is for parts that need to be
powered up for lubrication and maintenance work to be carried
out.

Work must never be performed when a load is suspended.

Secure the working equipment by placing it on the ground, setting

on outriggers (ensure that the ground has sufficient load−bearing
capacity) or similar measures to ensure that there is no
subsequent movement.

Make sure that the crane cannot be started up by unauthorised

persons (e.g. lock the cab doors, remove the battery switch
and/or ignition key) and fix corresponding warning signs in place.

Before carrying out lubrication and maintenance work on the

electrical system, remove the battery switch and/or ignition key.

1.4.1 Cleaning the vehicle

When commencing maintenance, clean the crane, and in
particular all connections and bolts and screws, to remove oil,
fuel or preserving agents. Do not use aggressive cleaners. Use
non−fibrous cleaning cloths.

Before cleaning the crane with water or steam cleaner

(high−pressure cleaner) or other cleaners, cover/tape together
all openings that need to remain free of water, steam or cleaning
agents for safety or functional reasons (e.g. switch cabinets)

Rubber components, such as tyres etc. must be cleaned

particularly carefully. In this case, see the instructions in the
sections ’Wheels and tyres’ in the chassis lubrication and
maintenance manual.

For further instructions on cleaning the crane with water or steam

jet (high−pressure cleaner) see the next page.

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1

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 Safety Instructions 1

Minimum clearance between high−pressure nozzle and object to

be cleaned for all cleaning work:
− circular spray nozzles: approx. 700 mm (27.6 inches)
− 25°−flat spray nozzles and dirt milling cutters: approx. 300 mm
(11.8 inches)
− steam sprays: 800 mm (31.5 inches)
− temperature maximum 60 °C (140 °F)

To avoid damage, do not point the water jet directly at door

gaps, hoses, electric components (control devices, starters,
alternators, spotlights) and electric leads (socket
connections, cable lead−ins or fuses).

During cleaning, always keep the water jet moving.

The steam or water jet should be applied across a large surface
area.
The vehicle should be rinsed off with a good quantity of water.
Scouring agents must not be used.

If air−cooled components are fitted on your crane (e.g. retarder),

these must be regularly cleaned in winter or in dusty operating
conditions.
The equipment must be cleaned when it is cold and without
adding solvents.
Dirt and salt residues must be removed. Electric connections
must be cleaned particularly carefully.

In addition, the operating instructions for the steam jet (or

high−pressure cleaner) must be followed.

Sound absorption mats must not be cleaned using

high−pressure cleaners.
Sound absorption mats that are contaminated with fuel or oil are
combustible and flammable and must be replaced immediately.

After cleaning, particularly when using steam jets, the crane must
be lubricated, in particular the slewing rim and joint shafts.

The inside of the cabs may only be cleaned with warm water, with
a little washing−up liquid added.
All surfaces, in particular the fittings and switches, should only be
wiped down with a damp cloth.

200−1−3010e 11/21
1

Z 18 094

12/21 200−1−3010e
 Safety Instructions 1

After cleaning, remove the covers/any tape completely and carry

out a visual inspection to ensure that water has not entered any
prohibited areas.

After cleaning, check all fuel, engine oil and hydraulic oil lines for
leaks, loose screw connections, shearing points and damage.
Rectify any damage immediately.

As oil can be emitted during maintenance and assembly work,

suitable containers and binding agents must be kept available
and ready.

1.4.2 Fire prevention

(Z 18 094)

Preventative measures against the risk of fire

Keep the crane clean, in particular making sure that there is

no combustible material around. Following maintenance
work on the hydraulic system, engine and fuel system, clean
the crane thoroughly.
Remove any residues of oil, fuel or cleaning agents.

 Remove the plug cap unscrew the hexagonal nut M 4 and

take out the plug cable.
− Fuel lines
− engine oil lines
− hydraulic oil lines

for leaks, loose connections, shear points and damage.

Rectify any damage found immediately.

 Check all electric lines, plug connections and terminals for

loose connections and damage.
Rectify any damage found immediately.

 Check the turbocharger fixing

Check the exhaust and air inlet lines and lube oil feed and
return lines for any leaks. Rectify any damage found
immediately.

 Fire extinguishers must be filled and ready for use.

200−1−3010e 13/21
1

14/21 200−1−3010e
 Safety Instructions 1

1.5 Carrying out lubrication and maintenance work

To carry out lubrication and maintenance work, suitable

workshop equipment is required.

Please observe the regulations and instructions specified in the

operating instructions.

The expression ”operating instructions” includes the operating

instructions and the lubrication and maintenance instructions.

Cordon off the required area, leaving sufficient safety clearance.

Individual components and larger component groups must be

attached to suitable lifting equipment and secured when
replacing them, to ensure that all risks are avoided. Only suitable
and fully functional lifting devices and load−handling devices with
sufficient load capacity may be used. Do not stand or work
underneath suspended loads.

Only assign experienced personnel to attach loads and act as

banksmen for crane operators! The banksman must remain
within view of the operator or must remain in communication with
him (see in particular section 1 ”Safety instructions” in the
operating instructions of the superstructure, part 1 of this
documentation) !

When carrying out assembly work above head height, use

suitable climbing aids and operating platforms. Do not use
machine components as climbing aids. Wear safety harnesses
when carrying out maintenance work at height.

When carrying out maintenance work, always tighten up loose

screw connections!

If you are required to dismantle safety equipment to carry out

maintenance work, the equipment must be refitted and checked
immediately upon completion of the maintenance work.

Make sure that all fuels and lubricants and used parts are
disposed of properly and in an environmentally friendly manner.

Oily rags and highly flammable materials must be stored away to

prevent the risk of fire or disposed of properly.

200−1−3010e 15/21
1

16/21 200−1−3010e
 Safety Instructions 1

The electrical equipment of the crane must be

inspected/checked regularly. Faults such as loose connections
or scorched cables must be removed immediately.

Only electric specialists or trained persons under the su-

pervision and guidance of an electric specialist may work
on electric systems or operating equipment and only in ac-
cordance with the electrotechnicalregulations.

Use only original fuses with the prescribed amperage. Switch the
crane off immediately if there are faults in the electric energy
supply!

Check all lines, hoses and screw/bolt connections on the

hydraulic and pneumatic systems regularly for leaks and
externally visible damage! Rectify (have rectified) any damage
immediately.

In particular, observe the detailed instructions in part 4,

lubrication and maintenance instructions for the crane chassis for
the areas of the steering, suspension and brakes.

Work on the hydraulic equipment may only be carried out

by persons with specialist knowledge and experience in
hydraulics (the system must be depressurised)

Spraying oil can lead to injuries and fires.

When handling oil, grease and other chemical substances,

observe the relevant safety regulations for the product.

Caution when handling hot fuels and lubricants (risk of

burns/scalding).

Make sure not to forget any tools on the crane after comple-
ting lubrication and maintenance work or after repair. All
parts (trims, etc.) must be reattached properly.
Falling or flung tools or parts can cause risk to life and limb!

200−1−3010e 17/21
1

18/21 200−1−3010e
 Safety Instructions 1

Complete all regular checks at the prescribed intervals (see

section 22)!

All components that hold or brace the main boom or fly jib
(bracing rods and draw bars) must be checked at least once a
year by a specialist engineer (in accordance with the accident
prevention regulations ”Load lifting equipment for hoisting
operations (VBG 9)”). In addition they must be checked by a
specialist between these intervals as and when required by the
operating and site conditions.
The inspection intervals are generally determined by the
operating and site conditions. That means that the more often the
crane is operated, the shorter the intervals should be.
All checks and inspections should be documented (e.g. in the
examination log book for the crane).

The following checks should be made:

∗ Checking for Cracks
∗ Checking the Length
∗ Checking for Wear
∗ Checking the Paint
∗ Checking for Plastic Deformation
∗ Check of weld seams

Which components are affected by these measures and

information on how the test is to be carried out can be found in
section 11 of these lubrication and maintenance instructions

200−1−3010e 19/21
1

20/21 200−1−3010e
 Safety Instructions 1

1.6 Repair work

General repair work is not included in the scope of these

lubrication and maintenance instructions.
Please contact our customer service department.

However, the following general safety instructions should be

observed at all times.
− Welding, firing and grinding work may only be carried out on
the crane if express permission has been given to do this (e.g.
there may be a risk of fire and explosion)
− Before carrying out welding, firing or grinding work, make
sure that the crane and its immediate environment are free
of dust and combustible materials and ensure that there is
sufficient ventilation (risk of explosion) !
− When carrying out work on the hydraulics, system sections
that need to be opened must first be depressurised before
work is commenced.
− Do not carry out any changes, fit additional parts or make
modifications to the crane that could affect its safety without
first obtaining permission from the manufacturer. This also
applies to the fitting and adjustment of safety equipment and
valves and the welding of load−bearing components.

200−1−3010e 21/21
 Consumables and capacities 2

200−1−3020−120−1a
1/9
2

2/9 200−1−3020−120−1a
 Consumables and capacities 2

2 Consumables and Capacities

The initial filling is for the normal temperature range.

Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US gall.)
See regulations on consumables in the operating and maintenance
Section 5
instructions of the engine OM 904 LA
Drive motor
as well as the Mercedes−Benz regulations
With filter change min. 13,00
− ACEA E3 CD 15 W − 40
max. 16,00 Engine oil
in exceptional cases Sheet 228.1 / 228.3
(min. 3.5 gal) 15W − 40
− API CE, CF−4 or 228.5
(max. 4.3 gal)
Section 6.1 High−pressure lu-
DIN 51825, part 3
Roller bearing slew- − bricant “Shell Alvania EP 2”
KP2K
ing rim NLGI grade 2
Section 6.2 Spray grease Order from
Slew ring toothing − (special adhesive − Terex Demag
grease) SP no. 500 893 98
Section 6.3 Order from
Grease paste
Superstructure lock- − − Terex Demag
NLGI class 1
ing SP no. 634 758 40
Section 7.2
Transmission Gear oil API−GL 4 oder 5 Shell Spirax
6,00
Slew gear SAE 80W−90 (MIL−L 2105 B) SAE 80W−90
(1.6 gal)
Section 7.3 High−pressure lu-
DIN 51825, part 3
Bearings − bricant “Shell Alvania EP 2”
KP2K
slewing gear NLGI class 2
Section 8.2
3.60 each Hydraulic oil
Hoists, DIN 51524.3 − HVLP “Shell Tellus T 100”
(0.95 gal) ISO VG 100
oil change
Section 8.4
High−pressure lu-
Hoists, DIN 51825, part 3
− bricant “Shell Alvania EP 2”
− Lubricating nipple: KP2K
NLGI class 2
Rope drum bearing
Kap. 8.8
High−pressure lu-
Hoist 2 (Option) DIN 51825, Teil 3
− bricant “Shell Alvania EP 2”
− Lubricating nipple: KP2K
NLGI−Klasse 2
Erection cylinder

The specified capacities are approximate values. For an accurate measurement, service
and operating personnel must carry out checks using the inspection points, inspection
plugs, dipsticks and inspection windows provided.
Further consumables specifications on request. If consumables are used which do not
meet these specifications, damage to the engine may result, which will not be covered
by warranty.

200−1−3020−120−1a
3/9
2

4/9 200−1−3020−120−1a
 Consumables and capacities 2

Continued: Consumables and capacities

Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US gall.)
Section 9.1
Luffing cylinder High−pressure lu-
DIN 51825, part 3
− Lubricating nipple: − bricant “Shell Alvania EP 2”
KP2K
Luffing cylinder NLGI grade 2
bearings
Section 10.1 Order from
Adhesive lubricant DIN 51502
Main boom − Terex Demag
NLGI class 1 MLE 1 N − 40
Sliding surfaces SP no. 022 029 12
Section 10.2 Order from
Adhesive lubricant
Locking and pinning − Terex Demag
NLGI class 0
unit SP no. 155 936 12
Section 10.7
High−pressure lu-
Main boom DIN 51825, part 3
− bricant “Shell Alvania EP 2”
− Lubricating nipple: KP2K
NLGI class 2
Foot bearing
Section 11.2 Spray grease Order from
Ropes − (special adhesive Terex Demag
grease) SP no. 083371
Section 11.3 High−pressure lu-
DIN 51825, part 3
Lubricating nipple, − bricant “Shell Alvania EP 2”
KP2K
hook blocks NLGI class 2
Section 11.4 High−pressure lu-
DIN 51825, part 3
Sheave roller bear- − bricant “Shell Alvania EP 2”
KP2K
ings NLGI class 2

The specified capacities are approximate values. For an accurate measurement, service
and operating personnel must carry out checks using the inspection points, inspection
plugs, dipsticks and inspection windows provided.

Further consumables specifications are available on request. If consumables are used

which do not meet these specifications, damage to the engine may result, which will not
be covered by warranty.

200−1−3020−120−1a
5/9
2

6/9 200−1−3020−120−1a
 Consumables and capacities 2

Continued: Consumables and capacities

Filling point Capacities Filling agent Quality regula- Initial filling

in litres tions
(in US gall.)
Section 12.7
Hydraulic system min. 780 Hydraulicöl
(Tank) max. 830 ISO VG 46 DIN 51524.3 −
“Shell Tellus TX 46”
(min. 206 gal) (−15°C − +30°C) HVLP
(max. 219 gal) (+5 5F − +86 5F)

The specified capacities are approximate values. For an accurate measurement, service
and operating personnel must carry out checks using the inspection points, inspection
plugs, dipsticks and inspection windows provided.
Further consumables specifications on request. If consumables are used which do not
meet these specifications, damage to the engine may result, which will not be covered
by warranty.

Hydraulic oil must be suitable for the individual surrounding temperature / temperature
in use. If these deviate from the normal temperature range for standard filling
(−15°C / +30°C) / ( +55 F / +865 F), the hydraulic oil must be replaced in accordance with
the following table:

Prescribed hydraulic oil Surrounding / operating

for deviating surroun- Classifica- temperature
Viscosity
ding / operating tempe- tion
ratures °C °F
Shell Tellus Arctic 32 −40 / +10 −40 / +50
ATF Dexron
Shell Donax TX −25 / +40 −13 / +104
III G 34077
Shell Tellus TX 32 ISO VG 32 HVLPD −20 / +20 −4 / +68
Shell Tellus TX 68 ISO VG 68 HVLPD −10 / +40 +14 / +104

It is only permitted to replace the hydraulic oil if the surrounding temperatures are
within the indicated limits. Otherwise there is a risk that safety−relevant compo-
nents are either limited in function or become damaged.

When replacing the hydraulic oil from the normal temperature range to a deviating
temperature range (and vice versa), system components which have no flow−
through (such as cylinders, for example) must be rinsed.

200−1−3020−120−1a
7/9
2

8/9 200−1−3020−120−1a
 Consumables and capacities 2

Continued: Consumables and capacities

Filling point Capacities Filling agent Quality regula- Initial filling

in litres tions
(in US gall.)
Section 14.3 Order from
Slip ring contacts, − Contact spray − Terex Demag
rope drum SP no. 174 427 40
Section 16
16,00 (4.3 gal) See regulations on consumables in the operating 50% water/
Cooling system cpl.
8.50 (2.3 gal) and maintenance instructions of the engine, 50 % glysantine
− Engine
7,50 (2.0 gal) sheet 310 Sheet 325.2
− Compensation tank
Section 17
Piston rod of the Fuchs company :
− Protective grease
hydraulic cylinder CTP D 350
of the outriggers
Kap. 18.1
Crane Operater’s cab:
− Lubricating nipple: High−pressure lubricant DIN 51825, Teil 3
− “Shell Alvania EP 2”
Tilt cylinder NLGI−Klasse 2 KP2K
bearings

Kap. 18.3
Windscreen wahing
cleaning agent /
assembly: 3,5 (0.9 gal cleaning agent −
− Supply tank 50% antifreeze

Kap. 20.3
Central lubrication sy-
Order from
stem (Option): Grease paste
2,0 (0.5 gal) − Terex Demag
− Lubricant’s NLGI class 1
SP no. 634 75840
container

The specified capacities are approximate values. For an accurate measurement, service
and operating personnel must carry out checks using the inspection points, inspection
plugs, dipsticks and inspection windows provided.
Further consumables specifications on request. If consumables are used which do not
meet these specifications, damage to the engine may result, which will not be covered
by warranty.

200−1−3020−120−1a
9/9
 Lubrication and Maintenance Schedule 4

200−1−3040−120−1 1/14
4

2/14 200−1−3040−120−1
 Lubrication and Maintenance Schedule 4

4 Lubrication and Maintenance Schedule

4.1 Initial Lubrication and Maintenance

Lubrication and maintenance work which occurs before the regu-

lar routine work is identified by ”1X” on the maintenance sched-
ule.
The work must be undertaken once at the time specified.

4.2 Regular Routine Lubrication and Maintenance

Regular routine lubrication and maintenance work is identified by

”X” on the maintenance schedule.
The work must be undertaken once at the interval specified and
then regularly repeated at this interval.
A ”X” in the column entitled 250 operating hours thus means that
the corresponding work must be undertaken every 250 operat-
ing hours, i.e. after 250, 500, 750 operating hours, etc.

The following details on maintenance intervals are applicable to

cranes which are subject to normal operating and environmental
influences. For certain applications, the maintenance intervals
must be adapted according to the operating conditions.

For more infrequent maintenance work, e.g. ”Every 1000 operat-

ing hours”, all those maintenance tasks which are required at
shorter intervals and which coincide with this time must of course
also be undertaken.

This means that for the above example, the maintenance tasks
occurring ”Every 500 operating hours” and those required at
even shorter intervals must also be undertaken.

200−1−3040−120−1 3/14
4

4/14 200−1−3040−120−1
 Lubrication and Maintenance Schedule 4

4.3 Tips for Maintaining the Crane

The purpose of maintaining the crane is to:

− safeguard operational reliability
− maintain efficiency
− prevent downtimes
− maintain the crane’s value
− reduce repair costs

4.4 Measures to Maintain the Crane:

1. Inspections of the Condition

Inspections of the condition are visual inspections undertaken by

the crane operator at regular intervals in accordance with the lu-
brication and maintenance schedule.

For example:
− Checking oil levels and oil grade
− Checking displays and monitors
− Checking the functioning and clogging of the tank and filter
systems
− Checking the tubing systems for leaks and damage
− Checking bearings for adequate lubrication and abnormal
bearing clearance
− Checking the drive mounts (transmission, motors, valves)
− Checking the ropes for lubrication, dirt and wear

As a result of these regular visual inspections, damage can often

be recognised and eliminated in good time.
This means downtimes are prevented during crane operation.

200−1−3040−120−1 5/14
4

6/14 200−1−3040−120−1
 Lubrication and Maintenance Schedule 4

2. Preventative maintenance

Preventative maintenance includes measures which may be un-

dertaken within the framework of an ”inspection of the condi-
tion of the crane”.
The inspection of the condition thus serves to recognise and
eliminate any wear, damage or defects in good time.
In this way, operational downtimes and repairs can be prevented
during crane operation.

The tasks involved in the inspection of the condition include

visual and performance inspections of the superstructure and un-
dercarriage assemblies and a comparison of the desired and ac-
tual values of all measurable quantities.
These tasks must be undertaken by an appropriately trained
specialist.

Various measures are thus required.

For example:
− Checking the safety devices
− Comparing the desired/actual values in the hydraulic and
electrical system.
− Checking the hydraulic and electrical system is functioning
correctly.
− Checking the nitrogen boost pressure of the accumulator
fitted.
− Analysis of the grade of the hydraulic and transmission oil.
− Checking the individual drives for noises and vibrations.
− Checking the bearings for damage and wear.
− Checking the crane equipment for damage and wear.
− Checking the ropes for damage and wear.

The exact visual and performance inspections and their corre-

sponding results are listed in the ”crane inspection sheet “.

A log is created for this inspection of the condition. This inspec-

tion log then forms the basis for any repair measures which may
be required.

Of importance to the success of any such measures is their

correct implementation, their regular repetition and full docu-
mentation of the inspections.

Our ”Mobile Crane Engineering” customer service department in

Zweibrücken is there to help with any information regarding this
matter.

200−1−3040−120−1 7/14
4

8/14 200−1−3040−120−1
200−1−3041−120−1

4.5 Maintenance List

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
5 Engine
Engine: MERCEDES BENZ (OM 904 LA) see engine operating instructions
6 Slew Ring Connection
6.1 Lubricating the slew ring x x
6.2 Lubricating the ring gear x
6.3 Checking the screwed connections x2)
6.4 Lubricating the mechanical superstructure locking device x
7 Slew Gear
7.1 Checking oil level / topping up x
7.2 Changing the oil 1x x2
7.3 Lubricating the bearings 1x x2
7.4 Checking the screw connections and tightening as re- x
quired
7.5 Visual inspection and noise check x

Lubrication and Maintenance Schedule 4

7.6 Maintenance of slew gear brake x2)
8 Hoist
8.1 Checking oil level / topping up x
8.2 Changing the oil 1x 2x x2)
8.3 Checking the screw connections and tightening as re- x
quired
8.4 Lubricating the rope drum bearing x1)
8.5 Calculation of spent share of the theoretical service life At least once a year
8.6 General overhaul of hoist gear winch x5)
8.7 Checking proper functioning of lowering limit switch x
8.8 Hoist limit switch − checking for correct function x
8.9 Erection cylinder hoist 2 − lubrication x2)
1* − daily before beginning work 2* − when required 1) − at least every 6 months
2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years
9/14

5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week

8) − every 800 operating hours
200−1−3041−120−1

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
9 Luffing Gear
9.1 Lubricating the luffing cylinders x
10 Main Boom
10.1 Lubricating the boom linings x
10.2 Lubricating the locking and pinning unit (LPU) Every six months
10.3 Visual inspection of locking and pinning unit Every six months
10.4 Locking and pinning unit − checking the proximity switches Every six months
and sliding contacts
10.5 Checking the initial gas pressure in the accumulator on the x2)
locking and pinning unit
10.6 LPU − checking the rope length sensor drum Once a year
10.7 Lubricating the main boom foot pins x
10.8 Check the main boom for weld cracks x
10.9 Checking the roller bearings of the sheaves Once a year
10.10 Replacing sheaves x4)
10.11 Checking the sheaves x1)
1* − daily before beginning work 2* − when required 1) − at least every 6 months

Lubrication and Maintenance Schedule 4

2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years
5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week
8) − every 800 operating hours
10/14
200−1−3041−120−1

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
11 Equipment
11.1 Main boom extension
11.1.1 Checking the draw shackles Once a year
11.1.2 Lubricating the spindle x
11.2 Ropes
11.2.1 General information on operation and assembly see section 11.4.1
11.2.2 Lubricating the ropes x
11.2.3 Cleaning the ropes x
11.2.4 Checking the cables and replacing as necessary Once a year
11.3 Lubricating the hook blocks
11.4 Sheaves
11.4.1 Checking the roller bearings of the sheaves Once a year
11.4.2 Replacing sheaves x4)
11.4.3 Checking the sheaves x1)
1* − daily before beginning work 2* − when required 1) − at least every 6 months
2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years

Lubrication and Maintenance Schedule 4

5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week
8) − every 800 operating hours
11/14
200−1−3041−120−1

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
12 Hydraulic System
12.1 Replacing the filter elementsin the return flow filter 1x 1x x x
12.2 Replacing the aeration filter 1x x2)
12.3 Cleaning/replacing the filter element of the high−pressure 1x 1x x2)
filter / oil leakage filter
12.3.1 Cleaning the high−pressure filter (1) x x x
12.3.2 Cleaning the oil leakage filter (3) x x
12.3.3 Cleaning the high−pressure filter (2) x x x
12.4 Hydraulic pump − changing the add−on filter x x
12.5 Hydraulic tank − checking oil level / topping up x x
12.6 Checking the hydraulic tank return oil filter for contamina- 1x x
tion
12.7 Changing oil in hydraulic tank x
12.8 Bleeding the hydraulic system x x
12.9 Checking the hydraulic system Once a year
12.10 Checking the hose lines x
12.11 Replacing the hose lines Every 6 years

Lubrication and Maintenance Schedule 4

12.12 Checking the initial gas pressure in the accumulator x2)
13 Heating and Air Conditioning
13.1 Checking function Once a month
13.2 Replace heat exchanger Every 10 years
13.3 Replacing the fuel filter x
13.4 Bleeding the system x
13.5 Air Conditioning
13.5.1 Switching on the air conditioning equipment Once a month
13.5.2 Service air conditioning equipment Beginning, middle and end of the cooling period
13.5.3 Having the air conditioning equipment checked Once a year
1* − daily before beginning work 2* − when required 1) − at least every 6 months
2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years
5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week
8) − every 800 operating hours
12/14
200−1−3041−120−1

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
14 Electrical System
14.1 Checking the lighting system x
14.2 Service batteries x
14.3 Fuses x
14.4 Checking the slip ring contacts x
15 Fuel System
15.1 Checking the fuel system Once a year
16 Cooling, Intake and Exhaust System
16.1 Clean and replace filter element of air filter x3)
16.2 Replace the safety cartridge (optional) x
16.3 Cleaning the air filter preseparator (optional) x
16.4 Cleaning the cooling system x
16.5 Checking the coolant level and topping up as necessary x
16.6 Replacing the coolant with anti−freeze x3)
16.7 Diesel particle filter Huss (optional)
16.7.1 General

Lubrication and Maintenance Schedule 4

16.7.2 Checking and emptying condensation filter x
16.7.3 Blowing out filter after approx. 600−800 operating hours of the engine
16.7.4 Changing the filter element of the fuel filter in accordance with the fuel filter of the drive motor x
16.7.5 Having a service x8)
1* − daily before beginning work 2* − when required 1) − at least every 6 months
2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years
5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week
8) − every 800 operating hours
13/14
200−1−3041−120−1

Interval (operating hours)

Fuels 1* 50 100 150 250 500 10 15 30 50 2*
Section Task
Section 2
x100
17 Piston Rods
17.1 Exposed chrome surfaces − applying protective grease x
18 Crane Operator’s Cab
18.1 Lubricating the tilt cylinder x
18.2 Checking the windscreen washing assembly x
18.3 Filling up the supply tank of the windscreen washing as- x
sembly
19 Superstructure
19.1 Visual check x
20 Optional Equipment
20.3 Central lubricating system (optional)
20.3.1 Filling up reservoir x
20.3.2 Checking the system x1
20.3.3 Cleaning the system x
1* − daily before beginning work 2* − when required 1) − at least every 6 months
2) − at least 1 x a year 3) − at least every 2 years 4) − at least every 5 years
5) − at least every 10 years 6) − every 900 operating hours 7) − at least 1 x a week

Lubrication and Maintenance Schedule 4

8) − every 800 operating hours
14/14
 Engine 5

200−1−3050b 1/5
5

6 2

1 7

3 Z 51 703

2/5 200−1−3050b
 Engine 5

5 Engine
(Z 51 703)

Risk of injury!
Maintain safety distance to hot, rotating and moving
components.

Danger of burning or scalding.

Before carrying out maintenance work in the engine area,
allow a cooling period of 60 minutes.

Please follow the notes and instructions concerning mainte-

nance of the engine in the operating instructions of the engine
manufacturer. The operating instructions for the engine and a
maintenance book are included in Part 5 of this service literature.

The description of the engine is on the bearing plate.

The location of the bearing plate can also be found in the opera-
ting instructions of the engine manufacturer.

Assembly of the Engine

(1) Oil dipstick

(2) Oil filler
(3) Oil drain valve
(4) Oil filter
(5) −
(6) Fuel filter
(7) Hand pump
(8) −

Starter

When cleaning the starter it must always be ensured that,

− when in the fitted position the starter is not sprayed with the
water jet and
− when dismantled the starter is cleaned with the bearing fa-
cing downwards, that is, suspended downwards,

so that moisture does not enter the magnetic switch.

200−1−3050b 3/5
5

Z 200 411 Z 47 991

Z 58 696

4/5 200−1−3050b
 Engine 5

5.1 Engine Quick Stop: Function Test

(Z 200 411, Z 47 991 principle drawing, Z 58 696)

Both engines (drive motors in the chassis and in the superstruc-

ture engine) can be switched off by pressing the engine quick
stop button in the crane operator’s cab and the optional additio-
nal engine quick stop button in the outrigger control area (exam-
ple Z 47 991) on the left− and right−hand side of the crane chassis
vehicle (for instructions, see part 1, section 5 “Engine”).

During the function test you must check that the engines are swit-
ched off by pressing each existing push button.

If the engines are equipped with an air shutoff flap (Z 58 696,

optional equipment), you must also check that it has closed du-
ring the function test.

If the engines are started again, the air shutoff flaps (1) of both
engines must be unlocked manually. Return lever (2) to the star-
ting position.

Risk of damage !
When the shutoff flap is closed the engine cannot be started.
Repeated starting attempts result in engine damage.
Before restarting, all air−carrying hoses − incl. the charge air
hoses between the engine and charge air cooler − must be
checked to ensure that they are fitted correctly and are com-
pletely free of blockages.

200−1−3050b 5/5
 Slew Ring Connection 6

200−1−3060 1/5
6

Z 35 741

Z 0148 Z 29 081

2/5 200−1−3060
 Slew Ring Connection 6

6 Slew Ring Connection

When maintenance work is carried out, there is a danger

of dragging at the slew gear pinion (Z 29 081) − in spite of
the protective covering.
Observe the warning sign which is attached.

Danger of crushing/shearing !
When carrying out the tasks described below, ensure
that no maintenance personnel, with the exception of the
crane operator (in the cab), are situated in the danger
areas between the main boom, superstructure and chas-
sis or between the superstructure and chassis once the
engine has been switched on to carry out the necessary
slewing and luffing movements.

6.1 Lubricating the Slew Ring

(Z 35 741)

Grease the central lubrication.

Lubricating procedure

First grease the nipples on the slew ring, then turn the superstruc-
ture twice through 360° before greasing the nipple a second time.
After the second lubricating procedure, the grease must be
emitted around the circumference of the slew ring, forming a col-
lar of grease.

This lubricating procedure must be carried out

− every 100 operating hours
− following cleaning with steam jets
− before and after a long operating lay off.

6.2 Lubricating the Toothed Rim

(Z 0148)

Any blank areas which may appear on the teeth edges must be
sprayed with special adhesive grease.

200−1−3060 3/5
6

Z 46 546

4/5 200−1−3060
 Slew Ring Connection 6

6.3 Lubricating the Mechanical Superstructure Locking

Device
(Z 46 546)

Apply grease to the pins of the superstructure locking device

using a brush.

200−1−3060 5/5
 Slew Gear 7

200−1−3070−401a 1/7
7

4
5 3

Z 55 932 Z 55 933

2/7 200−1−3070−401a
 Slew Gear 7

7 Slew Gear
(Z 55 932, Z 55 933)

When maintenance work is carried out, there is a risk of

being dragged in at the slew gear pinion (Z 55 932) − in
spite of the protective covering.
Observe the warning sign.

Shift rod (5, Z 55 933) only for slew gear with dolly (”Driving with
Dolly”).

7.1 Slew gear mechanism, checking the oil level

(Z 55 933)

Always perform the oil level check when the when the transmis-
sion is at a standstill and the oil has cooled down.

The oil level is correct if it is in the middle of the gauge glass (3).
If oil level too low − add new oil until oil level reaches the middle
of the gauge glass.

7.2 Slew gear mechanism, changing the oil

(Z 55 933)

It is easier to change the oil when the gear oil is at operating tem-
perature.

Caution ! Risk of scalding.

We recommend that you wear goggles, protective gloves
and protective clothing.

1. Screw out the filler plug (4).

2. Unscrew the drain screw (2) and drain the oil into a suitable
tank.

Dispose of the used oil in an environmentally−friendly manner.

3. Clean the gear mechanism with flushing oil before adding

new oil.

4. Clean the drain screw (2), replace the 3/8” seal ring and
screw the drain screw back in firmly.

5. Add new oil until the oil level reaches the middle of the gauge
glass (3).
6. Screw filler plug (4) back in firmly.

200−1−3070−401a 3/7
7

4
5 3

Z 55 933

Z 55 934

4/7 200−1−3070−401a
 Slew Gear 7

7.3 Lubricating Bearings

(Z 55 933)

Lubricate bearing of the pinion using lubricating nipples (1,

Z 55 933).

7.4 Checking and Re−tightening the Screw Connections

if Necessary
(Z 55 934)

Using a torque key, regularly check the torque of the exterior

screwed connections (Z 55 934).

If required, tighten screws in accordance with the following ta-

bles.
Screw
Property class Torque
No. Size
63 / 73 Nm
1 M 10 x 30 10.9 / 12.9
(46.5 / 53.9 lbf−ft)
49 Nm
2 M 10 x 140 8.8
(36.2 lbf−ft)
49 Nm
3 M 10 x 50 8.8
(36.2 lbf−ft)
86 Nm
4 M 12 x 70 8.8
(63.4 lbf−ft)
265 Nm
5 M 16 x 55 10.9
(195.5 lbf−ft)

When fitting new screws, lubricate the thread and head support
using roller bearing grease KP2K.

7.5 Visual and Noise Inspections

Carry out visual and noise inspections on the transmission on a
weekly basis.
You must especially check the seals of the transmission. Listen
for unusual noises.

200−1−3070−401a 5/7
7

6/7 200−1−3070−401a
 Slew Gear 7

7.6 Maintenance of the Slew Gear Brake

The slew gear brake is maintenance−free.

If there are malfunctions, thermal overload or whenever car-

rying out repairs on the retaining disc brakes,
− discs
− springs
− sealing elements
must be replaced.

200−1−3070−401a 7/7
 Hoists 8

200−1−3080d 1/11
8

Z 29 082

Z 46 297

2/11 200−1−3080d
 Hoists 8

8 Hoists

Measures to achieve safe operating periods:

In accordance with the accident prevention regulations for
winches, hoist and traction equipment, VBG 8, the operator of the
crane is responsible for ensuring that a crane inspection is
carried out at least once a year (see also ISO 9927−1).
The spent share of the theoretical service life for the winches
must also be determined. The crane operator must employ an
expert for the purpose if necessary.
This regulation is legally binding within the scope of the accident
prevention regulations of the trade association.
Outside of this realm, the crane manufacturer recommends that
the procedure listed is also observed.
See Section 1.8, ”Safety Instructions”, of these lubrication and
maintenance instructions
Risk of snagging!
When carrying out maintenance, inspection and
mounting work, special care must be taken in this area
as there is a risk of being caught and dragged into the
equipment between the winches and hoist ropes.

8.1 Hoist 1 and 2 − check the oil level

(Z 46 297)
Check the oil level on the inspection opening. This should
generally be done when the transmission is at a standstill and the
oil has cooled down.
During operation a considerable amount of oil is distributed
around the inside of the gearbox case. We recommend
therefore that the oil level be checked and any oil added
immediately after starting up the system and with the
transmission at a standstill.
If the level is below the ’min.’ marking, proceed as follows:
1. Remove the oil filler plug (1) from the top end of the inspection
glass.
2. Using the funnel or hose, add oil until the marker ’max.’ on the
inspection glass has been reached.
Make sure that you use the correct types of oil as listed in section
2 ”Consumables and Capacities”.
3. Screw the oil filler plug back in (1).
If, when checking the oil, you find a continual loss of oil,
operation must be stopped and the system dismantled.

200−1−3080d 3/11
8

Z 46 298

4/11 200−1−3080d
 Hoists 8

8.2 Hoist Gear − Changing the Oil

(Z 46 298)

Use the oil grade given in section 2 ”Consumables and

Capacities” or on the serial plate. It is preferable to use an oil of
a higher viscosity rather than using a thinner oil.
Different oil types should not be mixed, even if they come from
the same manufacturer.

Fully synthetic oils may only be used with acid−proof seals and
a sufficiently resistant inner coating. Please check with customer
services.

The oil should be warm when it is changed, i.e. following a longer

period of operation:

Risk of burns and scalding!

Both the surface of the transmission and the oil that is
being drained off have high temperatures.
Avoid any contact and wear protective clothing!

1. Remove the oil filler plug (1) from the top end of the inspection
glass.

2. Remove the oil drain plug (2) at the bottom of the inspection
glass and drain the oil off into a suitable container.

3. Screw the oil filler plug back in (2).

4. Add new oil as described in section 8.1

5. Screw the oil filler plug back in (1).

During operation a considerable amount of oil is distributed

around the inside of the gearbox case. We recommend
therefore that the oil level be checked and any oil added
immediately after starting up the system and with the
transmission at a standstill.

200−1−3080d 5/11
8

2
3

Z 51 706

6/11 200−1−3080d
 Hoists 8

8.3 Check screwed connection, tighten if required.

(Z 51 706)

Check the torque of the outer screw connections regularly using

a torque wrench.
Loose, broken off or defective screws must be removed and
replaced with new ones where necessary.

Torques of the gear housing screws:

No. Size Property Torque

class
3 M 16 10.9 290 Nm (214 lbf−ft)

Torques of the fixing bolts for the hydraulic motor and gear
mount:

No. Size Property Torque

class
1 M 10 8.8 43 Nm (32 lbf−ft)
2 M 20 10.9 510 Nm (376 lbf−ft)
4 M 10 10.9 63 Nm (46 lbf−ft)

When new screws are fitted, the thread and head should be
smeared with KP2K roller bearing grease.

200−1−3080d 7/11
8

Z 46 547

8/11 200−1−3080d
 Hoists 8

8.4 Lubricating the Rope Drum Bearing

Lubricate the rope drum bearing via the lubricating nipple on the
top. (Z 46 547)

8.5 Calculating the Percentage Used of the Theoretical

Service Life

A detailed description is given in the section on safety instructions

under 1.8.4.

8.6 General Overhaul of the Hoist Gear Winches

Depending on the remaining service life or when the service life

”D” is reached (see explanation in section 1.8.4 of these
maintenance instructions) the winches must be subjected to a
general overhaul.

In any case, a general overhaul must be carried out at the

latest 10 years after the crane is placed in operation for the
first time.
The maximum time period between two general overhauls
may only exceed 10 years in exceptional cases.

8.7 Lower Limit Switch − Checking the Proper Function

The lower limit switch is best checked when a large number of

ropes are reeved and when the main boom is in its highest
position.

Telescope out the main boom and lower the hook block by means
of the hoist until the lower limit switch shuts off the movement for
the corresponding hoist.

Check to make sure that there are at least three turns of the rope
remaining on the rope drum.

Carry out this check at regular intervals whenever the crane is in

the suitable configuration.

200−1−3080d 9/11
8

Z 51 507

10/11 200−1−3080d
 Hoists 8

8.8 Hoist limit switch − check that it functions properly

Approach the hoist limit switch daily and check that it functions
properly.
To do so, lift the hook block with the hoist accordingly until the shift
weight is relieved. The ”Raise hoist” movement must then be
switched off.

8.9 Lubricating Erection Cylinder Hoist 2

Lubricate the two lubricating nipples every time before fitting
hoist 2 (Z 51 507).

200−1−3080d 11/11
 Luffing Gear 9

200−1−3090 1/3
9

1 A

RA
Z 51 708

2/3 200−1−3090
 Luffing Gear 9

9 Luffing Gear

9.1 Lubricating the Luffing Cylinders

(Z 51 708)

Danger of crushing / danger due to shearing.

As soon as the engine is started up to carry out the ne-
cessary slewing and luffing movements, ensure, when
the following work is carried out, that there are no main-
tenance personnel other than the crane operator (in the
cab) in the danger area between the main boom, super-
structure and chassis, and superstructure and chassis.

Lubricate the four nipples on the foot bearing (1).

Lubricate the four nipples on the piston rod bearing (2).

200−1−3090 3/3
 Main Boom 10

200−1−3100−140a 1/25
10

T0 T1 T2

LK 95

T2 T3

LK 96

T3 T4

LK 97

T4 T5

LK 98

Z 160 614

2/25 200−1−3100−140a
 Main Boom 10

10 Main Boom

10.1 Lubricating the Boom Linings

(Z 160 614)

On the upper (inner) sliding surfaces of basic boom section (T0)

and telescopic sections 1 − 4 (T1 − T4) and the lower (outer) slid-
ing surfaces of telescopic sections 1 − 5 (T1 − T5) grease must
be applied with a brush. To this end the main boom must be ex-
tended horizontally to the specified ”lubricating lengths”.

Starting point: Crane in transport position.

Proceed as follows:

6. Support the crane on outriggers as specified and align. Start

the superstructure engine and fit the specified counter-
weight.
Observe the corresponding specifications on the IC−1 dis-
play screen for the longitudinal codes for lubricating the main
boom (Z 60 177, see the following page), i.e. in this instance:
Minimum counterweight 21.4 t (47.2 kip), outrigger support
area 7.5 m (24.6 ft).

For information on navigating around the IC−1 and subse-

quent telescoping procedures, please refer to section 12
“Telescoping” and in particular the section “Telescoping
procedure” and “length code”.

200−1−3100−140a 3/25
10

Z 60 176

17 18 19

Z 60 177

4/25 200−1−3100−140a
 Main Boom 10

(Z 60 176, Z 60 177)

7. On the “Tele mode” screen (Z 60 176) select the lubricating

symbol. Screen (Z 60 177) appears with the selection
list for the length codes for lubricating the main boom.
Instead of details on load capacities and radii, values for the
counterweight combination and outrigger support area are
indicated here, which must at least be fulfilled:
(17) − Minimum counterweight
(18) − Minimum outrigger support area
(19) − Key:back to “Tele mode” screen.

Risk of tipping !
Only when the actual crane configuration satisfies the
minimum requirements with regard to the counterweight
combination and outrigger support area is it safe to tele-
scope and lubricate the main boom.

8. Select longitudinal code for the first lubricating length (here:

LK 95) and exit the screen by pressing ”save”.

If the configuration of the crane that is currently stored in the

control system does not satisfy the specified minimum re-
quirements for the counterweight and outrigger support
area, the corresponding value is displayed in red. The
screen cannot be exited by pressing the ”save” button. The
desired telescoping procedure cannot be carried out.

200−1−3100−140a 5/25
10

LK 95

T0 T1 T2

90% 90%

Z 160 617

LK 95

T0 T1 T2

Z 160 618

6/25 200−1−3100−140a
 Main Boom 10

9. Telescope out the main boom with the selected length code
“LK 95”. The achieved extended state (100/100/0/0/0)
means that telescopic sections 1 and 2 are each fully ex-
tended (100%) and all the others remain completely re-
tracted (0%).

10. Once the telescoping procedure has been completed switch

off the superstructure engine and exit and lock the crane op-
erator’s cab.

Risk of crushing!
With the following lubricating procedures on the main
boom, it must be ensured that the main boom cannot be
telescoped! Otherwise there is a risk of crushing for the
service personnel.

(Z 160 617)
11. Lubricate the upper (inner) sliding surfaces of basic boom
section (T0) and telescopic section 1 (T1). Insert a suitable
brush through the 90% pinning hole and apply a thick coat
of grease to the opposite upper sliding surface. This proce-
dure must be carried out in sequence from both sides.
The grease that is applied is subsequently distributed along
the linings when the system is telescoped.

As the basic boom section is always accessible from the

outside, all openings are closed off with covers to avoid the
risk of crushing. For this reason, the lid over the 90% pin-
ning hole must be removed first before the lubricating pro-
cedure can be carried out in the interior of the basic boom
section. Immediately after the lubricating procedure has
been completed, the lid must be fitted onto the pinning hole
again.
Otherwise there is a risk of crushing!

(Z 160 618)
12. Lubricate the lower (outer) slideways of the telescopic sec-
tions 1 and 2 with grease.

200−1−3100−140a 7/25
10

T0 T1 T2

LK 95

T2 T3

LK 96

T3 T4

LK 97

T4 T5

LK 98

Z 160 614

8/25 200−1−3100−140a
 Main Boom 10

(Z 55 774)

13. One after the other select the remaining lubricating length
codes (LK 96, LK 97 and LK 98) and lubricate the remaining
inside and outside telescopic sections / sliding surfaces.
Proceed in the same way as detailed on the previous page
for the length code “LK 95” and basic boom section and tele-
scopic sections 1 and 2.

The following table shows and overall view of all permissible

length codes (LK) for lubricating the main boom, with the resulting
main boom lengths, extension statuses of the telescopic sections
and the minimum requirements for the counterweight and out-
rigger support area.

Extension state of the

Main boom telescopic sections (%) Minimum coun- Outrigger sup-
LK
length terweight port area
T1 T2 T3 T4 T5
95 100 100 0 0 0
96 31.5 m 0 100 100 0 0 24.1 t 7.5 m
97 (103.4 ft) 0 0 100 100 0 (47.2 kip) (24.6 ft)
98 0 0 0 100 100

200−1−3100−140a 9/25
10

Z 60 178

10/25 200−1−3100−140a
 Main Boom 10

10.2 Lubricating the Locking and Pinning Unit (LPU)

(Z 60 178)

1. Support the crane and attach the counter weight so that LK 2

can then be extended at (45/0/0/0/0).

Risk of accidents!
See the valid load capacity table with the corresponding
specifications for the necessary extension sequence, e.g.
outrigger support area, counterweight, etc.

2. Luff up the completely retracted main boom to an angle of

approx. 60° .

Select a main boom angle that allows the assembly opening on

the underside of the basic case to be easily accessed.

3. Extend the main boom with the selected LK 2 (45/0/0/0/0).

4. Remove the cover from the assembly opening on the under-

side of the basic case.

Risk of crushing!
Do not reach into the opened assembly opening while the
locking and pinning unit is moving.

5. Reposition the locking and pinning unit until it is positioned

just in front of the assembly opening.
To do this, you must switch to “Manual telescoping”.

While carrying out this procedure, you must also observe

the corresponding section “Manual telescoping” and the fol-
lowing section “Teaching...” in section 12 “Telescoping” of
the operating manual for the superstructure.

200−1−3100−140a 11/25
10

Z 60 178

12/25 200−1−3100−140a
 Main Boom 10

(Z 60 178)

6. Switch off the drive motor and safeguard to prevent it from

being switched on again unintentionally by removing the key
and locking the empty crane operator’s cab. Attach a warn-
ing plate to the latch of the crane operator’s cab.

Risk of crushing!
You must ensure that the LPU cannot be actuated while lu-
brication procedures are being carried out inside the basic
case on the LPU.

7. Lubricate all moving parts with the lubricants described in

section 2, “Oils, lubricants and capacities”. While doing this,
pay particular attention to the sliding surfaces indicated by
arrows.

The LPU state is “unlocked / pinned”. This means that, contrary

to the illustration “Z 60 178”, the locking pins (1) are retracted and
the grippers are extended.

8. Leave the hazardous area (assembly opening or the inside

of the basic case).

Risk of crushing!
Before actuating the LPU, be sure that neither persons nor
body parts are in the LPU area or inside of the basic case.

9. Return to the cab and put the LPU in the “locked / unpinned”
state. The locking pins (1) are then extended as seen in the
illustration (Z 60 178).

200−1−3100−140a 13/25
10

Z 60 178

14/25 200−1−3100−140a
 Main Boom 10

(Z 60 178)

10. Resecure the cab − as described in point 6. − Lubricate the

LPU in the area of the extended locking pins (1) and leave
the hazardous area.

Risk of crushing!
Before actuating the LPU, be sure that neither persons nor
body parts are in the LPU area or inside of the basic case.

11. Return to the cab and actuate the LPU lock / unlock or pin
/ unpin. This evenly distributes the lubrication.

12. Resecure the cab − as described in point 6. − and check that

the LPU has sufficient lubrication.
Repeat the lubrication procedure if necessary.

13. Lock the assembly opening using the cover.

10.3 Locking and Pinning Unit − Carrying Out a Visual

Check

Check the following components to make sure that they are

seated properly and check for damage and leaks.
− Plugs (in particular on the solenoid valves)
− Solenoid valves
− Hoses and cables

10.4 Locking and Pinning Unit − Checking the Proximity

Switches and Sliding Contacts

Check the proximity switches and sliding contacts

− to make sure they are properly seated; they must not be loose
or be able to move around in their housing.
− to make sure that they are undamaged;
− to make sure that they move freely, i.e. that the spring return
is working correctly.

200−1−3100−140a 15/25
10

Z 51 711

Z 30 194

16/25 200−1−3100−140a
 Main Boom 10

10.5 Locking and Pinning Unit −

Checking the Preliminary Gas Tension of the Accu-
mulators
(Z 30 194; Z 51 711)

The accumulators used in the hydraulics of the main boom are

diaphragm or bubble accumulators with nitrogen.
The corresponding component can only function correctly when
the installed accumulators are charged with the correct prelimi-
nary gas tension.
A loss in preliminary gas tension or a defect in the accumulator
is indicated by
− very slow completion of the pinning and locking processes
− frequent and long recharging intervals of the feeder valve.
This initial gas pressure must be checked at regular intervals.
To check the preliminary gas tension a filling and testing device
for bubble accumulators is needed.
The test may only be carried out by a technician who is fully
conversant with use of the filling and testing equipment.
Please contact our customer service department if you do
not have such a technician and/or this type of testing and fill-
ing equipment.

To test or to fill the accumulator please proceed as follows:

1. Switch off the drive motor on the superstructure and switch

the ignition key to position ”0”.

2. Release the pressure from the hydraulic system.

The accumulator (2) must be completely emptied of hydrau-
lic oil.
Check this on a pressure gauge if a test nipple is available

or
gently loosen the union nut on the hydraulic line on the oil
connection for the accumulator.

If there is no pressure reading on the pressure gauge or if no hy-

draulic oil is emitted at the loosened union nut, the system is with-
out pressure.

3. Remove the safety guard (1) on the gas valve of the accumu-
lator (2) and screw the filler and test device (3) in place.

200−1−3100−140a 17/25
10

Z 51 711

5
4

Z 40 074

18/25 200−1−3100−140a
 Main Boom 10

(Z 40 074; Z 51 711)

4. Open the gas valve via the screwed−on filler and test device
and read off the charge pressure on the pressure gauge of
the test device.
Preliminary pressure of the accumulators:

2 accumulator (MP 4) 3 bar (44 psi)

1 accumulator (MP 3) 60 bar (870 psi)

5. If the preliminary pressure is insufficient fill the accumulator

with nitrogen by means of the filler device (3) until the re-
quired preliminary tension is reached.
After initial filling, wait for approximately two to three minutes,
check the preliminary tension again and top up as necessary.

Check the pressure gauge at the test nipple ”X” when topping up
the initial gas pressure on the accumulator.
The pressure in the corresponding hydraulic circuit must not rise.
If this occurs, the diaphragm in the accumulator is defective. The
accumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

If, when checking for the first time, there is a heavy fall (approx.
60%) in the preliminary pressure, check the accumulator again
after approx. 3 to 4 weeks.
If a second measurement shows a fall in pressure again, the ac-
cumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

A pressure reducer (5) must be fitted on the nitrogen cylinder
(4, Z 40 074).
Accumulators may only be repaired by the manufacturer or
its approved workshops.
The accumulator must be officially passed by an approved
specialist following completion of repairs.
A new test certificate must be drawn up for the accumulator.

200−1−3100−140a 19/25
10

Z 51 712

Z 46 549 Z 550 102

20/25 200−1−3100−140a
 Main Boom 10

10.6 Checking the Rope of the Length Transducer Drum

(Z 51 712)

Check rope (1) to make sure that it is undamaged.

10.7 Lubricating the Foot Bearing

(Z 46 549)

Lubricate the nipple on each side of the main boom base bearing.

10.8 Lubricate the main boom head axles

(Z 550 102, principle diagram)

Lubricate the lubricating nipples on both sides of the main boom

head axles.

10.9 Check the main boom for weld cracks

To avoid fractural damage, the weld seams on the main boom

must be inspected once a year during crane inspections for weld
seam cracks.

If crack formations are found, Demag service repair instructions

must be requested to carry out repair welding.
In this case, as precise a description as possible of the crack
formation should be supplied (corresponding page from the
spare parts catalogue, photos, sketches etc.).

Repair welding work may only be carried out by a suitably

qualified welder.

200−1−3100−140a 21/25
10

1
2
3

Z 51 713

22/25 200−1−3100−140a
 Main Boom 10

10.10 Checking the Roller Bearings of the Sheaves

(Z 51 713)

Risk of snagging!
Extra care is required when carrying out maintenance,
inspection and assembly work in this area, as there is a
risk of becoming entangled and dragged into the equip-
ment between the sheaves and ropes.

Check all sheaves annually for:

− Grease emission
− Correct seating of bearing seals
− Correct seating of sealing rings
− Running noises, rolling resistance
− Bearing play

If any deficiencies are detected, the roller bearing (2) of the corre-
sponding sheave (1) must be replaced. In this case, notify our
customer service department.

If the inspection reveals a damaged circlip (3), the circlip must be

replaced.

Use only original DEMAG circlips with a chamfered opening.

10.11 Exchanging Sheaves

We recommend that all sheaves be replaced after 10 000 operat-

ing hours or every 5 years crane operation.

To do so, notify our customer service department.

200−1−3100−140a 23/25
10

1
2
3

A−A
“Y” “Y”

“X”

Z 51 715

24/25 200−1−3100−140a
 Main Boom 10

10.12 Checking the Sheaves

(Z 51 715)

Check all sheaves for damage, for example cracks, indentations

or similar damage.

Sheaves with this type of damage must be replaced immedi-

ately.

Also check all sheaves for wear:

− Tread bottom “X” max. 3 mm (0.12 in)
Dimension “X” = Difference between ∅ new lower tread and
∅ actual lower tread.
− Side tread “Y” “Y” max. 5 mm (0.2 in)
Dimension “Y” measured between rope (S) and tread of rope
sheave.

If the sheave is worn up to the wear limit, it must be replaced.

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 Equipment 11

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73

Z 51 716

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 Equipment 11

11 Equipment

11.1 Main Boom Extension

11.1.1 Checking the draw shackles (depending on the

version)
(Z 51 716)

The draw bars for setting the 20°− or 40° working angle 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)). Depending on the operating
conditions and the applications for which they are used, they
should also be checked by a specialist between these
prescribed inspections where necessary.
Since the inspection intervals are normally based on the
operating conditions, they should be correspondingly
shortened if the crane is operated more frequently.
This inspection must be documented when it is carried out
(e.g. in the examination log book for the crane).

It may be necessary to dismantle the draw bars (73) in order to

inspect them properly.
The draw bars must be inspected in their entirety, i.e. all hidden
surfaces and bores must also be inspected.

The following checks must be carried out:

− Check for cracks
− Check the length
− Check the wear
− Check the Paintwork
− Check for plastic deformation

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74 73

74

73
59

Z 51 718

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 Equipment 11

11.1.1.1 Check for cracks

The draw bars should be inspected regularly for cracks. A surface

crack test (e.g. magnaflux test) must be carried out at least once
every year. If cracks are detected during inspection of a bar, it
must be replaced. Modification work is not permitted.

11.1.1.2 Checking the Length

The draw bars are dimensioned so that, even under test load,
there can be no permanent expansion. No measurable change
in length is permitted as this would create problems in mounting
the bars.
The length of the draw bars must be measured to ensure that
they have not become overloaded or damaged.
The upper limit for serviceability (equals the ”replacement state
of wear for ropes”) is a change in length of 0.05 %. For example,
a maximum of 0,5 mm (0.02 in) for a draw bar length of 1 000 mm
(39.37 in).

If a change in length is detected, our customer service

department should be informed.

(Z 51 718)
The nominal measurement as well as the parts no. of the tension
bars and of the guide to the tension bar for bracing the main boom
extension to the main boom head can be found in the crane
inspection logbook.

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Z 51 717

6/45 200−1−3110−140_en
 Equipment 11

11.1.1.3 Check the wear

Pin locks, pins and bores must be checked for signs of wear. It
must be ensured that the pin locking mechanism is functioning
correctly.

11.1.1.4 Check the Paintwork

The paintwork must be checked regularly for signs of corrosion.

Damaged areas must be repaired.
The draw bars must not be stored in aggressive media (e.g. sea
water).

11.1.1.5 Check for plastic deformation

If plastic deformation occurs (e.g. bending) the draw bar may no

longer be used. It must be replaced.

11.1.2 Lubricating the Spindle (Depending on the Design)

(Z 51 717)

Whenever fitting the main boom extension, the thread of the

spindle must be lubricated using multipurpose grease.

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Z 30 316

Z 29 084 Z 29 085

8/45 200−1−3110−140_en
 Equipment 11

11.2 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!
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
− between the sheaves on the fixed bridle / flying bridle

Proceed with special caution!

Danger due to friction and scraping!

11.2.1 General Notes on Handling and Assembly

11.2.1.1 Transport
(Z 29 084, Z 29 085)

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.

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

(Z 29 085)
A reel is best raised by means of a rod placed through its central
axis.

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10/45 200−1−3110−140_en
 Equipment 11

11.2.1.2 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 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.

11.2.1.3 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.

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Z 29 086

Z 29 087

12/45 200−1−3110−140_en
 Equipment 11

(Z 29 086)
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.

Assembly procedure

The best way to mount cables 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.

Re−reeling
(Z 29 087)

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 beneath the reel and vice versa.

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11

14/45 200−1−3110−140_en
 Equipment 11

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.

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Z 29 088

Z 29 089

16/45 200−1−3110−140_en
 Equipment 11

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.

(Z 29 088)
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 29 089)
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.

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Z 29 090 Z 29 091

Z 29 092

18/45 200−1−3110−140_en
 Equipment 11

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 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.

(Z 29 090, Z 29 091)
This can be achieved, for example, by braking 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 29 092)
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.

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.

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Z 29 093

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 Equipment 11

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
8 mm (0.31 in), 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.

(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 placed on either side of the cutting
point.

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y
Z 29 094

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 Equipment 11

11.2.2 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, for operational reasons, it is not possible to
relubricate the rope, a shorter service life is to be expected and
the ropes must be monitored accordingly. The effects of
lubrication and relubrication on the life expectancy of the rope
can be seen in figure (Z 29 094):
x Number of reversed bending stresses (%)
y Tensile stress (N/mm2)
a greased and regreased
b greased
c without grease

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24/45 200−1−3110−140_en
 Equipment 11

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 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.

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.

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Z 38 119

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 Equipment 11

11.2.3 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.

11.2.4 Checking the Cables and Replacing as Necessary

(Z 38 119)

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 38
119).

General Notes

A cable is a basic consumer item with a limited life span. Many

characteristics of a cable change throughout its period of use. For
example, its breaking force initially increases slightly with
accrued operating time before falling rapidly once a maximum
value has been reached.

This breaking force decrease is due to an increased loss of the

metal percentage caused by wear and corrosion which occur with
wire breakage and structure changes of the cable.

In the cable, the load−bearing elements are connected in

parallel. This is why a cable can still be safe for operation even
if a large number of wires have broken.

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.

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28/45 200−1−3110−140_en
 Equipment 11

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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Criteria for removal

A rope must be removed when one or several of the following

points are fulfilled. See also the relevant DIN standards.

a) Wire breakage

A cable must be removed when the permitted wire breakage

number is in accordance with DIN 15 020 or exceeds it.

The cable must be removed if there are wire breakage clusters

or if a cord breaks.

b) Rope wear

If the rope diameter in cables is decreased by 15 % or more

during longer journeys compared to the nominal value, the cable
must be removed.

c) Corrosion

You can determine corrosion of the outer rope wires with a visual
inspection. However, it is difficult to determine corrosion on wires
that cannot be seen externally.

Corrosion can lead to a decrease of the static breaking force of

the cable due to reduction of the metallic rope average as well as
a decrease of the operational stability due to corrosion pits.

d) Abrasion

Abrasion of the rope wires can be ”interior abrasion” which is

caused by movements of the cords and wire against each other
when bending the cable up and down or ”external abrasion”
which is caused by movements between the cable and the
sheave or by dragging the cable on the ground or over the
material to be conveyed.

Abrasion is encouraged if lubrication is insufficient or lacking or

by the existence of dust. If the rope diameter is decreased by 10
% or more compared to the nominal value, the cable must be
removed even if no wire breakage was discovered.

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Z 1367

Z 1368

Z 1369

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 Equipment 11

e) Rope deformation

Deformation of the cable is visible change to the rope structure.

Deformation generally also causes the rope configuration to
loosen in the area of the deformation. Depending on the
appearance, there is the following differentiation of the most
important deformations:
− corkscrew−type deformation
− ”basketwork” formation (deformation)
− loop formation of the wires
− loosening of individual wires or cords
− knots
− contraction
− flattening
− curl−type deformation
− Kinks and bends

Corkscrew−type deformation (Z 1367)

With the corkscrew−type deformation, the axle of the unloaded

cable becomes a corkscrew.

Remove cable, if the deformation ”X” has become 1/3 d

larger or more (d = rope nominal diameter).

”Basketwork” formation (deformation) (Z 1368)

”Basketwork” formation (deformation) can occur in cables with

steel inserts if the outboard bearing of the wires is loosened or the
external cords are longer than the internal ones.
If the external wire or cord positions slip in comparison to the
interior ones, the excessive length share is shifted in one place.

If there is ”basketwork” formation (deformation), the cable

must be removed.

Loop formation of wires (Z 1369)

If there is loop formation of the wires, individual wires or wire

groups poke out of the rope structure like little hairs on the rope
side facing the sheave.

If there is a significant change to the rope structure due to

wire loop formation, the cable must be removed.

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Z 1370

Z 1371

Z 1372

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 Equipment 11

Loosening of individual wires or cords (Z 1370)

If individual wires or cords loosen, the exterior wires of the loaded

cable or individual cords can be shifted.

This means that they do not assume the share of then tension
force assigned to them, which overloads the other wires or cords.

If the cable runs over sheaves, it can cause increased bending

tension which causes premature wire breakage.

If the wires become loose due to rust and abrasion, the cable
must be removed. If there is another cause for the loosening,
the wire breakage occurring as a consequence determine
the aptitude for removal.

Knots (Z 1371)

A knot is defined as a thickening of the wires which repeatedly

occur over longer periods. Often the inlay pokes out of the cable
at the point of thickening.
At the thinner points in the cable, the cords push against each
other, forming arches, which causes wire breakage.

Cables with several knots must be removed.

Contraction (Z 1372)

Contraction is when the cable’s diameter is decreased on short

stretches.
Cable components immediately in front of end fastenings must
be carefully checked for contraction, which can be difficult to see
at these points.

Cable with a lot of contraction must be removed.

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Z 1373

Z 1374

Z 1375

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 Equipment 11

Flattening (Z 1373)

Flattening is defined as permanent deformation of the cable,

which is caused by crushing.

Flattening causes increased wire breakage.

Curl−type deformation

Curl−type deformation is caused when a loaded cable is pulled

over an edge.

Cables with curl−type deformation must be removed.

Kinks (Z 1374)

A kink is a deformation of the cable caused by pulling an

eyelet−shaped rope loop straight without the cable being able to
balance out the deformation by rotating around its axle.

Cables with one or more kinks must be removed.

Bends (Z 1375)

A bend is a deformation of the cable which is caused by forceful

external influences.

Cables with bends must be removed.

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 Equipment 11

Effects of heat

Cables which have been subject to 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.

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40/45 200−1−3110−140_en
 Equipment 11

11.3 Lubricating the Hook Blocks

Risk of snagging!
When carrying out maintenance, inspection and
assembly work, special care must be taken in this area
as there is a danger of becoming entangled and dragged
into the equipment between the hook block pulleys and
ropes.
Use the hand grips located on the hook blocks!

Lubricate all lubricating nipples of the hook blocks, as well as

those of the hook suspension gear.

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Z 39 123

42/45 200−1−3110−140_en
 Equipment 11

11.4 Sheaves

11.4.1 Checking the Roller Bearings of the Sheaves

(Z 39 123)

Risk of snagging!
Extra care is required when carrying out maintenance,
inspection and assembly work in this area, as there is a
risk of becoming entangled and dragged into the
equipment between the sheaves and ropes.

Check all sheaves annually for:

− Grease emission
− Correct seating of bearing seals
− Correct seating of sealing rings
− Running noises, rolling resistance
− Bearing play

If any damage or problems are found, the roller bearing of the

corresponding sheave must be replaced. In this case, please
contact our customer service department.

If inspection reveals a damaged circlip, the circlip must be

replaced.

Use only original DEMAG circlips with a chamfered opening.

11.4.2 Exchanging Sheaves

We recommend that all sheaves be replaced after 10 000

operating hours or every 5 years crane operation.

In this case, please contact our customer service department.

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“Y” “Y”

“X”

Z 33 646

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 Equipment 11

11.4.3 Checking the Sheaves

(Z 33 646)

Check all sheaves for damage, for example cracks, indentations

or similar damage.

Sheaves with such damage must be replaced immediately.

Also check all sheaves for wear:

− Bottom tread “X” max. 3 mm (0.12 in)
Measure “X” = difference between ∅ new bottom tread and
∅ bottom tread is !
− Side tread “Y” max. 5 mm (0.2 in)
Measure “Y” measured between rope (S) and tread of the
sheave.

If the sheave is worn up to the wear limit, it must be replaced.

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 Hydraulic System 12

200−1−3120b 1/37
12

7 1 6

Z 51 719

2
3

Z 51 728 Z 7 809

2/37 200−1−3120b
 Hydraulic System 12

12 Hydraulic System

Danger of burns !
Please note that particularly parts of the hydraulic
system can be exposed to very high temperatures under
the coverings.
Allow therefore sufficient cooling time or wear
appropriate clothing etc.

12.1 Replacing the Filter Elementsin the Return Flow Filter

To replace the elements, the filter units must be removed.

Proceed as follows:

1. Lower the suspended load to the ground, retract the

telescopic sections and switch off the superstructure engine.
The system must be depressurised.

2. Loosen the nuts (6) on the filter cover (1) and remove both
the filter cover and the O−ring. (Z 51 719, Z 51 728)

3. Remove the filter unit (2, Z 7 809) and place on a clean

surface. Ensure that the O−ring is not damaged.

200−1−3120b 3/37
12

Z 27 827 Z 27 828

Z 27 829

4/37 200−1−3120b
 Hydraulic System 12

4. Wash the bayonet catch (3, Z 27 827) and the valve

connected to it in diesel oil or petroleum ether and place on
a clean surface.

5. Remove and dispose of the filter element (4) from the filtering
tube (2) (Z 27 828).

6. Drain the remaining oil from the filtering tube (2) into the
container for old oil and wash out the filtering tube using
diesel oil or petroleum ether.

7. Insert new filter element (4) in the filtering tube (2). (Z 27 828)

8. Insert filtering tube in the hydraulic tank. If necessary,

replace the O−rings. (Z 27 829)

9. Start the superstructure engine and check the tank for leaks.

The filters should be replaced 50 hours after repair work has been
carried out on the hydraulic system.

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12

7 1 6

Z 51 719

6/37 200−1−3120b
 Hydraulic System 12

12.2 Replacing the Ventilation Filter

(Z 51 719)

1. Unscrew the filter (7).

2. Screw on new filter (7) and tighten by hand.

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12

89

Z 200 415

8/37 200−1−3120b
 Hydraulic System 12

12.3 Cleaning / Replacing the Filter Element of the

High−pressure Filter / Leak Oil Filter
(Z 200 415)

The HP filter for the double pump and the HP filter for the gear
pump are fitted in the pressure line to the pump. The leak oil filter
is located in the return line. The add−on filter is fitted to the
hydraulic pump. The indicator light (89) on the dashboard is
assigned to these filters and to the return oil filters in the hydraulic
oil reservoir.

If this indicator light (89) comes on, it means that one or more filter
elements must be cleaned or changed.

In order to find out which filter must be cleaned or changed, you

must remove the plugs on the pressure switch of the filter one
after another and observe the indicator light (89) in the
dashboard. The filter element of the filter on which they go out
must be cleaned or replaced.

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12

10

Z 51 721

10/37 200−1−3120b
 Hydraulic System 12

12.3.1 Cleaning the HP Filter (1)

(Type ”LF BN/HC 60”)
(Z 51 721)

1. Lower the suspended load to the ground, retract the

telescopic sections and switch off the superstructure engine.
The system must be depressurised.

2. Place a suitable container beneath the filter to catch any oil

that might run off.

3. Remove the filter barrel (5) using wrench SW27 by turning

to the left at hexagonal nut (6).
Ensure that the O−ring (7) is not damaged.

4. Remove and dispose of the paper element (8) by gently

moving it from side to side and pulling it downwards from the
holder (9).

5. Drain the remaining oil from the filter barrel (5) into the
container for old oil and clean the filter barrel with diesel oil
or petroleum ether. Place the filter barrel (5) on a clean
surface.

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12

10

Z 51 721

12/37 200−1−3120b
 Hydraulic System 12

(Z 51 721)

6. Check the O−ring (7) is in good condition.

Replace the O−Ring if damaged.

7. Push the new paper element (8) onto holder (9).

Only use original DEMAG spare parts.

8. Carefully push the filter barrel (5) over the paper element (8),
screw in up to the stop on the head piece (10) and tighten
using wrench SW 27.

9. Turn back the filter housing a forth of a turn.

10. Start the superstructure engine and check the filter for leaks.

If, after 1000 operating hours, the respective indicator light

has not come on, we recommend the paper element be
replaced.

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12

Z 46 524

14/37 200−1−3120b
 Hydraulic System 12

12.3.2 Clean the Overflow Oil Filter (3)

(Type ”HD 062−171”)
(Z 46 524)

1. Lower the suspended load to the ground, retract the

telescopic sections and switch off the superstructure engine.
The system must be depressurised.

2. Place a suitable container beneath the filter to catch any oil

that might run off. The filter is located at the side of the
hydraulic tank.

3. Remove socket housing (3) using wrench SW 27.

4. Drain the remaining oil from the filter barrel (3) into the
container for old oil and clean the filter barrel with diesel oil
or petroleum ether.

5. Remove the clogged filter element (4) and dispose of it in an

environmentally friendly manner.

If there is a limited amount of space available for disassembling

the filter barrel (3), the filter element (4) should be pulled off the
drain socket (3) and removed together with the socket housing
(3).

6. Check that the O−Ring (2) is in perfect condition.

Replace the O−Ring if damaged.

7. Push the new filter element (4) onto the drain socket (5).

Only use original DEMAG spare parts.

8. Carefully push the socket housing (3) over the filter element
(4), screw in up to the stop on the head piece (1) and tighten
using wrench SW 27.

If there is a limited amount of space available for fitting the filter

element (4), the element should first be placed in the filter barrel
(3). The socket housing and the filter element are then screwed
in up to the stop on the head piece (1) and tightened using wrench
SW 27.

9. Start the superstructure engine and check the filter for leaks.

If after 1000 operating hours, the respective indicator light

has not come on, we recommend the filter element be
replaced.

200−1−3120b 15/37
12

Z 46 522

16/37 200−1−3120b
 Hydraulic System 12

12.3.3 Cleaning the HP Filter (2)

(Type ”HD 069−171”)
(Z 46 522)

1. Lower the suspended load to the ground, retract the

telescopic sections and switch off the superstructure engine.
The system must be depressurised.

2. Place a suitable container beneath the filter to catch any oil

that might run off.

3. Remove the filter barrel (4) using wrench SW36 by turning

to the left at hexagonal nut (6).
Ensure that the O−ring (2) is not damaged.

4. Remove and dispose of the paper element (5) by gently

moving it from side to side and pulling it downwards from the
holder (3).

5. Drain the remaining oil from the filter barrel (4) into the
container for old oil and clean the filter barrel with diesel oil
or petroleum ether. Place the filter barrel (4) on a clean
surface.

200−1−3120b 17/37
12

Z 46 522

18/37 200−1−3120b
 Hydraulic System 12

(Z 46 522)

6. Check that the O−Ring (2) is in perfect condition.

Replace the O−Ring if damaged.

7. Push the new paper element (5) onto holder (3).

Only use original DEMAG spare parts.

8. Carefully push the filter barrel (4) over the paper element (5),
screw in up to the stop on the head piece (1) and tighten
using wrench SW 36.

9. Turn back the filter housing a forth of a turn.

10. Start the superstructure engine and check the filter for leaks.

If, after 1000 operating hours, the respective indicator light

has not come on, we recommend the paper element be
replaced.

200−1−3120b 19/37
12

Z 51 727

89

Z 200 415

20/37 200−1−3120b
 Hydraulic System 12

12.4 Hydraulic Pump − Changing the Add−On Filter

(Z 51 727, Z 200 415)

When the indicator light (89) in the crane operator’s cab lights up,
the add−on filter must be checked.
By removing the plug from the electrical contamination indicator
you can determine whether the add−on filter or the leak oil filters
or one of the high pressure filter has to be cleaned. If indicator
light (89) goes out, this filter has to be replaced.

If the indicator light (89) remains lit up, even though the plug has
been removed, or the leak oil filters or one of the high pressure
filter must be serviced (see section 12.3).

Changing the add−on filter.

(Z 51 727)

Unscrew the clogged filter (X).

Screw on a new filter with O−ring.

200−1−3120b 21/37
12

Max.

Z 51 723

22/37 200−1−3120b
 Hydraulic System 12

12.5 Hydraulic Tank − Checking the Oil Level / Topping up

(Z 51 723)

1. Fully retracted all hydraulic cylinders.

2. Position the crane on level, flat ground.

3. Switch off the engine.

4. Check the oil level on the level indicator.

The oil level in the stand pipe must come up to the ”max”
marker on the hydraulic tank.

5. The oil should be topped up if it is below this marker.

6. Investigate the cause of the oil loss and rectify immediately.

If oil must be added, the return oil filters must subsequently

be checked or replaced at the prescribed intervals. See
section 4 “Lubrication and Maintenance Schedule”.

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12

89

Z 200 415

24/37 200−1−3120b
 Hydraulic System 12

12.6 Checking the Hydraulic Oil Tank Return Filter for

Contamination
(Z 200 415)

Each time the oil is topped up or changed, check that the return
oil filters have not become clogged within a short period of time
(e.g. through contaminated oil).
This is what the indicator light (89) in the dashboard is for. If it is
lit up, the filter elements must be exchanged.
This inspection must be carried out approx. 50 operating hours
after repair work on the hydraulic system or after an oil change.

If the return oil filters are clogged, the filter elements must be
replaced.
Filter elements are removed and installed as described in section
12.1 of these maintenance instructions.

200−1−3120b 25/37
12

Z 51 725

6 2
Z 51 726

26/37 200−1−3120b
 Hydraulic System 12

12.7 Changing Oil in the Hydraulic Tank

1. Position the crane on level, flat ground and set down the
suspended load.

2. Retract all hydraulic cylinders.

3. Turn the superstructure in such a way that the draining oil
can be caught in containers which have been placed in
position.

The oil should be at operating temperature.

4. Switch off the superstructure engine.

5. Unscrew protection cap (4) from the coupling (5) on the

underside of the hydraulic tank (Z 51 725).

6. Screw the drain hose onto the coupling (5).

This effects the release of the through−flow cross−section. There

is no need to activate any shut−off valves.

7. Drain off the old hydraulic oil into a suitable container.

8. Release the coupling and remove the drain hose. Screw

back in the protection cap (4).

The hydraulic tank is now sealed tight.

(Z 51 726)

9. Open the cover (2) of the filler neck, fill up with new hydraulic
oil.

Pour oil into the hydraulic tank up to the upper marker on the oil
level gauge (6). This marker is valid at room temperature (approx.
20° C / 68 5F) and when all cylinders are retracted.

10. Bleed the hydraulic system (see section 12.8).

200−1−3120b 27/37
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28/37 200−1−3120b
 Hydraulic System 12

12.8 Bleeding the Hydraulic System

The hydraulic system is bled via the bleeder nozzles provided in

the pipework and vent screws on the hydraulic cylinders and
hydraulic motors.
At points where no vent fittings are provided, the connection
fitting (union nut) can be loosened slightly.
While bleeding the system, with the engine running at slow idling
speed, the vent fittings should be kept open until oil which is free
from air bubbles escapes from the fittings.

In order to avoid damage to seals and hydraulic elements, the

system should be bled while depressurised.

12.9 Checking the Hydraulic System

In addition to the visual inspections (e.g. when checking the oil

level), the hydraulic system in the engine compartment should be
inspected once a year. Ensure that all the connection fittings are
not leaking and are sufficiently tight.

Lines and/or hoses damaged due to mechanical, thermal or

other effects must be replaced.
Ensure that all lines and hoses are at a sufficient distance
from hot engine parts (e.g. turbocharger) and are laid so that
they do not chafe.

200−1−3120b 29/37
12

Z 35 446

4 SH

20 ∅

NNNNNN 4SH 20 DIN 20 023 3Q94

1 2 3 4 5
Z 30 193

30/37 200−1−3120b
 Hydraulic System 12

12.10 Checking the Hose Lines

(Z 35 446)

Check all hose lines regularly for damage.

If this visual inspection of the hose lines reveals even the slightest
damage, the defective hose must be replaced immediately.
Examples of possible defects on the hose lines:

1. Damage to the outer layer (1) (areas of abrasion, cuts,

cracks, etc.).

2. Ageing of the material of the outer layer (1) (formation of

cracks).

3. Deformations which do not correspond to the natural form of

the hose line (layers coming away, blistering, crushed points,
kinks, torsioning).

4. Leakage points.

5. Requirements regarding installation and positioning not

observed (see DIN 20 066 part 4 ”Installation of Hose Lines).

6. Fixture on the hose fitting (2) is damaged.

7. Hose fitting (2) corroded, deformed or damaged.

8. Storage time or duration of use exceeded

(see point 12.11).

12.11 Replace the hose lines

Even if no damage is detected, the hose lines must be replaced
at the latest after 6 years, including a storage time of, at most,
2 years.

Identification of hydraulic hoses

(Z 30 193)

− (1) Manufacturer
− (2) Hose type (classification)
− (3) Rated width
− (4) DIN standard designation
− (5) Date of manufacture (quarter and year of production)
For the operating or storage life go by the date of manufacture
on the hydraulic hose.

200−1−3120b 31/37
12

Z 30 194

Z 51 729

32/37 200−1−3120b
 Hydraulic System 12

12.12 Checking the Accumulator Initial Gas Pressure

(Z 51 729)

The accumulators used in the hydraulic system of the crane are

diaphragm−type pressure or bubble reservoir accumulators with
nitrogen filling.
They are fitted in the slew gear control equipment of the crane.
The corresponding components will only function properly if the
accumulators fitted are charged with the pre−set gas pressure
specified.
This initial gas pressure must be checked at regular intervals.

In order to check the initial gas pressure a filling and testing

device is required for the bubble reservoir.

This check may only be carried out by a specialist who

knows how to work with a filling and inspection device of this
type. Please contact our service department if a specialist
and for the corresponding equipment is not available.

To test or to fill the accumulator please proceed as follows:

1. Switch off the drive engine on the superstructure and put the
ignition switch into position ”0”.

2. Depressurise the hydraulic system.

The accumulator (2, Z 30 194) must be completely emptied
of hydraulic oil.
Check this on a pressure gauge if a test nipple is available

or
loosen the union nut of the hydraulic line slightly at the oil
connection of the accumulator.

The system is depressurised when no pressure is shown on the

pressure gauge or when no hydraulic oil escapes from the
loosened union nut.

3. Remove the safety guard (1) on the gas valve of the

accumulator (2) and screw on the filling and testing device
(3).

200−1−3120b 33/37
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Z 51 729

2
5
4

Z 40 155 Z 40 157

34/37 200−1−3120b
 Hydraulic System 12

4. Open the gas valve via the screwed−on filler and test device
and read off the charge pressure on the pressure gauge of
the test device.
Pretension pressure of the accumulator (2, Z 51 729):
15 bar (218 psi).

5. If the preload pressure is insufficient, the accumulator must

be filled with nitrogen to the corresponding preload pressure
via the filling device (3).
After initial filling, wait for approximately two to three minutes,
check the preliminary tension again and top up as necessary.

When recharging the preliminary gas tension on the accumulator,

pay attention to the pressure gauge on test connection ”X”.
The pressure in the corresponding hydraulic circuit must not rise.
If this is the case, the diaphragm in the accumulator is defective.
The accumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

If a considerable fall in pressure (approx. 60%) in the preload

pressure is observed during the initial check, the accumulator
must be checked again after approx. 3 to 4 weeks.
If a second measurement shows a fall in pressure again, the
accumulator must be replaced.

Only NITROGEN may be used to fill the accumulator.

A pressure reducer (5) must be fitted on the nitrogen cylinder
(4, Z 40 074).
Accumulators may only be repaired by the manufacturer or
in approved workshops.
The accumulator must be officially accepted by an approved
specialist following completion of repairs.
A new test certificate must be drawn up for the accumulator.

200−1−3120b 35/37
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36/37 200−1−3120b
 Hydraulic System 12

12.13 Using Biological Hydraulic Oils

− When changing the hydraulic fluid, you must check the tank
for residue.
− It is not permitted to mix other bio−degradable oils
(unsaturated synthetic ester oils and / or rape oil).
− The biological hydraulic fluid must be checked at regular
intervals for serviceability by a lab which is authorised by the
manufacturer of the hydraulic fluid.
With normal use the hydraulic fluid must be inspected at least
after 500 operating hours, after 1000 operating hours and
then every 1000 operating hours; however, it must be
checked at least once a year.
If conditions are more extreme the operating hours are
halved.
− The remaining mineral oil percentage may not exceed 8 % of
the total filling when filling new and used machines with
biological hydraulic fluid.
The hydraulic system must be rinsed with the new hydraulic
fluid with which it is to be filled.

200−1−3120b 37/37
 Heating and Air Conditioning Equipment 13

200−1−3130a 1/19
13

37.2 41.1 37.1

41.2

42

Z 51 730

6 99

1 2 3 4 5

Z 39 292

2/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

13 Heating and Air Conditioning Equipment

13.1 Checking the System is Functioning Correctly

The manufacturer’s operating instructions for the hot water-

heater D 5WS must be followed.

Briefly switch on the heating (for approx. 10 seconds) approxima-

telyonce a month, even outside of regular heating periods.This-
prevents the water pump and the burner motor from seizing up.

Do not operate the heating in enclosed spaces.

If the heater assembly does not start after switching on, procee-
das follows:

1. Check the fuel level.

2. Check the components for mechanical damage.

3. When switching to winter operation, check to see if there

isany summer diesel remaining in the fuel line.

4. Check the exhaust and combustion air lines.

5. Check the fuses in the fuse panel (Z 51 730).

Replace blown fuses if necessary.
(see Section 13.1.1 ”Checking the Fuses”.)

6. Switch the heating off and on again. Not more than twice. If-
the heating still fails to start, have the fault repaired in a work-
shop.

7. Check to see if a fault code is indicated in the display (6,

Z 39 292) of the heater (99, Z 39 292) (fault code table see
from page 11).

200−1−3130a 3/19
13

37.2 41.1 37.1

41.2

42

Z 51 730

6 99

1 2 3 4 5

Z 39 292

4/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

13.1.1 Checking the Fuses

The fuses inserted in the fuse panel are allocated as follows:

(Z 51 730)

Pos. 42 − Fuse 25 A: main fuse for heater assembly

Pos. 37.1 − Fuse 10 A: Control (e.g. heater timer)

Pos. 37.2 − Fuse 10 A: Control (e.g. heater timer)

Pos. 41.1 − Fuse 25 A: for cab fan

Pos. 41.2 − Fuse 10 A: for cab fan

If the 25 A fuse has blown, the heater assembly will start but no-
warm air will be circulated.

The blown fuse must be replaced by a new one after the inspec-
tion.

13.1.2 Fault Diagnosis with the Heating Timer

(Z 39 294)

If the control unit recognises a fault when the heater is switche-

don or during operation of the heater, the fault is displayed wit-
hin15 seconds by the heating timer with a letter F and 2−−digit
number.
Indication in the display: e.g. F 64 (current fault)
and flashing heater symbol

200−1−3130a 5/19
13

5
4
3
2
1

Z 39 294

6/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

(Z 39 294)

Calling up the faultmemory in the control unit with the hea-

tertimer

The electronic control unit can save up to 5 faults which are then
read off and displayed using the heater timer. The current fault is
always written in memory position F1.
Previous faults are stored in positions F2 − F5, the content of me-
mory position F5 is overwritten as required.

Calling up the fault memory

Condition: The heater is switched off.

Press button 3 − the heater is switched on − then press button 1,

hold pressed down and press button 2 within 2 seconds.
The heater flashes and the current fault is displayed.

Using buttons 4 and 5, the faults stored in memory positions F1

and F5 can be called up.

Fault code, fault description, comments are described on page

11.

Please note!

Not only the defective component, but also a defective current-

path leads to a fault display.

200−1−3130a 7/19
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5
4
3
2
1

Z 39 294

8/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

(Z 39 294)

Disabling the control unit

D Overheating
If the heater overheats 10 x in sequence − fault F12 − F15 is
indicated in the display, i.e. the control unit is disabled.

D Too many start attempts

If the heater at tempts 10 starts without success − fault F50
− F50 is indicated in the display, i.e. the control unit is disa-
bled.

Reverse the disabling of the control unit by deleting the fault-

memory − after the cause of the fault has been

Condition: There is an electrical connection fromthe 12−pin

plug,terminal 10 of the heater timer to terminal 15 (ignition). Press
button 3 − the current fault F15 or F50 is displayed
− thenpress button 1, keep pressed down and press button 2 wit-
hin 2 seconds.
The heater timer is now in the program ”call up fault memory”.
Continue operation: (Bedienung fortsetzen):
Switch off ignition (terminal 15).
Press buttons 1 and 2 at the same time, keep pressed down, in-
addition switch on the ignition (terminal 15) and wait until the follo-
wingis shown in the display.
Display on scree- Display flas-
nafter ignition “ON” hing,heater symbol
notflashing

After 3 seconds the control unit is enabled, the heater then start-
sup.
Display on scree- Display flas-
nafter heater has hing,heater symbol
started notflashing

200−1−3130a 9/19
13

10/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

Fault code table

Fault- Fault description Comment
code
010 Overvoltage − shut−−off Overvoltage for at least 20 sec. uninter-
ruptedon the control unit −−> heater wi-
thoutfunction.
011 Low voltage − shut−−off Voltage too low for at least 20 sec. unin-
terruptedon the control unit −−> heater
without function.
012 Overheating (software − threshold value) Temperature on overheating sensor
>125 °C (257 5F).
014 Possible overheating recognised (evalua- Difference in the temperature levels of the
tionof difference) overheating sensor and the temperature
sensor > 25K.
Condition for this fault code display is that
the heater is in operation and the water-
temperature on the overheating sensor
has reached at least 80 °C (176 5F).
015 Operation disabled − system has overhea- The control unit is disabled.
tedmore than the permitted 10 times
017 Overheating detected − EMERGENCY Temperature on overheating sensor
OFF (hardware threshold value) >130 °C (266 5F).
020 Glow plug interruption
021 Glow plug failure − short circuit, overloa-
dor short circuit to ground
030 Speed of the combustion air fan motor Fan wheel or combustion air fan motor-
outside the permitted range blocked (frozen, clogged, restricted, ca-
blestrand brushing against end of shaft
...).
031 Combustion air fan motor interruption
032 Combustion air fan motor − short cir- Fan wheel or combustion air fan motor
cuit,overload or short circuit to ground blocked (frozen, clogged, restricted, ca-
blestrand brushing against end of shaft
...).
038 Relay control of the vehicle fan − interrup-
tion
039 Relay control of the vehicle fan − short cir-
cuit, overload or short circuit to ground

200−1−3130a 11/19
13

12/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

Fault- Fault description Comment

code
041 Water pump − interruption
042 Water pump − Glow plug failure − short
circuit, overloador short circuit to ground
047 Metering pump − short circuit, overload
orshort circuit to ground
048 Metering pump − interruption
050 Operation disabled as too many start at- Too many start attempts, the control devi-
temptshave been made (10 start at- ceis disabled.
tempts,in addition to a start repeat foreach
start attempt)
051 Time out − cold blowing During the start the flame probe detects a
temperature >70 °C (158 5F). for longer
than 240 seconds.
052 Safety time exceeded
053 Flame shut−off at control level “high” Warning
056 Flame shut−off at control level “low” If the flame is shut off from the ”high” or
”low” setting and more start at tempts are
permitted, the heater automatically at-
tempts a new start, if necessary with a
start repeat.
If the new start or the start repeat was
successful, the fault code display is dele-
ted.
Fault (because a further start at tempt is
not permitted).

060 Temperature sensor − interruption

061 Temperature sensor − short circuit, over-
load or short circuit to ground
064 Flame probe − interruption

200−1−3130a 13/19
13

14/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

Fault- Fault description Comment

code
065 Flame probe − short circuit, overload or
short circuit to ground
071 Overheating sensor − interruption
072 Overheating sensor − short circuit, over-
load or short circuit to ground
090 / Control unit defective External interference voltage
092 −
103
091 External interference voltage Malfunction of the control unit as a result
of interference voltages from the onboard-
power supply, possible causes: Poor bat-
teries, charging set, other fault sources;
remedy interference voltages.

200−1−3130a 15/19
13

”X”

14

14

Z 51 731

Z 51 732

16/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

13.2 Replacing the Heat Exchanger

The heat exchanger has a life span of 10 years and must be re-
placed after this period with an original spare by themanufacture-
ror by an approved workshop. The heater assembly should
thenbe labelled with the purchase date of the heat exchanger
and the words ”original spare part”.

13.3 Replacing the Fuel Filter

1. Pinch off the fuel hose between the tank and the fuel filter.

2. Release the two hose clips on the fuel filter (14).

(Z 51 731)

3. Pull the hoses from the fuel filter (”X”).

4. Insert the new filter.

13.4 Bleeding the System

The entire cooling system, including the heater assembly,

mustbe bled to ensure that no air bubbles remain following any
servicing of the system (repairs, changing the coolant). Allow the
superstructure engine to run until air bubbles no longer form in
the expansion tank
(Z 51 732).
All water connections (clamps) must be tightened to ensure they
are perfectly watertight and must be re−tightened after 20 opera-
ting hours.

200−1−3130a 17/19
13

4
Z 51 733

Z 51 734

18/19 200−1−3130a
 Heating and Air Conditioning Equipment 13

13.5 Air Conditioning Equipment (optional)

The details in the manufacturer’s (Woelfe company) docu-

mentation must be adhered to.
This can be found in part 5 of this documentation.

13.5.1 Switching on the Air Conditioning Equipment

To lubricate the compressor, the air conditioning equipmentmust

be switched on for at least 10 minutes every month.

13.5.2 Servicing the Air Conditioning Equipment

Legend:
1 Inspection glass on the dryer/fluid container (Z 51 734)
2 Vaporiser/heat exchanger (Z 51 733)
3 Filter (Z 51 733)
4 Fan (Z 51 733)
5 Capacitor (Z 51 734)

At the beginning, in the middle and at the end of a cooling period,

the following servicing work must be carried out:

1. Check the V−−belt tension and compressor mounting.

2. Check the coolant fill−−up.

The coolant must flow bubble−free through the inspection glass

(1, Z 51 734) of the fluid reservoir when the engine is running and
the airconditioning equipment is at its highest setting (control
knob in the cab for temperature selection and fan level at maxi-
mum setting). After switching off, the fluid level in the reservoir
should sink again. This is the only way to ensure that the reservoir
is not over−filled.

The air conditioning equipment may only be filled by a spe-

cialist workshop.

13.5.3 Having the Air Conditioning Equipment Checked

In order to ensure that the air conditioning equipment remains-

fully operational, an inspection must be carried out at least once
a year by a specialist workshop. We recommend that this be car-
ried out at the beginning of the cooling period.

200−1−3130a 19/19
 Electrical System 14

200−1−3140−120−1 1/15
14

Z 46 535

Z 51 735

2/15 200−1−3140−120−1
 Electrical System 14

14 Electrical System

14.1 Checking the Lighting System

(Z 46 535)

Check that the system is functioning correctly and repair any

faults immediately. (Example: aircraft warning light, rotaflare
light, position light)

14.2 Servicing Batteries

The batteries (1) are located on the left side behind the crane
operator’s cab (Z 51 735).

Observe the fluid level of the batteries. It may fall rapidly

because the batteries are close to heat radiating crane
components.

You can find the maintenance instructions for the batteries in the
operating instructions of the engine manufacturer.

14.3 Fuses

Fuses are located:

− In the main electrical unit of the cab.
− In the battery compartment.

Before you replace a fuse, first identify the cause of the fault and
rectify it.
The fuse numbers are indicated on the fuse boxes.

A blown fuse must always be replaced by a fuse with the

same number of amps (as stated on the fuse label).

Remove the covering in order to reach the fuses.

200−1−3140−120−1 3/15
14

4/15 200−1−3140−120−1
 Electrical System 14

− Superstructure (fuses)

BMK Val- Fitting Page.Path Potential Function

ue/A location
F0001 50 Battery 5.1 30 Main fuse OW
A0303−F1 25 5.4 2 Ignition lock superstructure
A0303−F2 10 5.7 6 Battery check, engine quick stop, tank
filling level OW
A0303−F3 10 7.10 25 Power supply diagnosis ignition and
KI50 ADM
A0303−F4 10 7.13 34 Power supply engine control unit (Mer-
cedes ADm2FR) battery plus
A0303−F5 10 7.3 23 Power supply engine control unit (Mer-
cedes MR) ignition
A0303−F6 10 7.8 20 Electricity supply engine diagnosis,
quick stop
A0303−F7 25 7.15 28 Power supply engine control unit (Mer-
cedes ADm2FR) ignition
A0303−F8 25 7.2 21 Power supply battery plus engine con-
trol unit (Mercedes MR)
A0303−F9 15 11.2 60 Cigarette lighter, horn, rotaflare lights,
ZE OW clearance lights, cab support
A0303−F10 10 12.5 66 Instrument illumination
A0303−F11 10 13.6 287 Adjustment sot light
A0303−F12 10 12.8 71 Dome light, radio, doubled obstruction
light
A0303−F13 10 15.3 335 Magnetic clutch compressor, capacitor
fan
A0303−F14 10 15.8 92 Control device air conditioning equip-
ment, load relay engine running
A0303−F15 10 16.2 101 Wipers front window, roof window,
washer pump
A0303−F16 10 17.10 116 Cab up/down, IPC, pilot control sensor,
SPS A0701,A0702
A0303−F17 10 18.4 126 Visualisation computer
A0303−F18 10 17.11 117 SPS A0703, A0704
A0303−F19 10 17.12 118 SPS A0705, A0706
A0303−F20 2 44.4 376 Position sensor counterweights

BMK = Operating equipment code

ZE OW = Central electrical unit superstructure

200−1−3140−120−1 5/15
14

Z 60 272

6/15 200−1−3140−120−1
 Electrical System 14

BMK Val- Fitting Page.Path Potential Function

ue/A location
A0303−F21 10 28.3 154 OW pinned unpinned, outriggers, steer-
ing, main boom extension
A0303−F22 10 34.2 185 HA sensor system, pumps and LS
pressure surveillance, lower limit
switches; erect HW2
A0303−F23 10 14.14 298 Step switch fan
A0303−F24 10 14.8 73 Heater timer
A0303−F25 10 14.12 299 Fan
A0303−F26 10 17.4 114 Bus supply A0701,A0703, A0705,
chassis, angle sensor
A0303−F27 10 18.11 127 Battery supply A0701, A0703, A0705
ZE OW
A0303−F28 25 42.2 247 Oil cooler
A0303−F29 10 44.2 263 GGW cylinder up / down
A0303−F30 10 14.9 334 Electricity supply timer, prop control
control valve
A0303−F31 10 13.2 340 Spotlights
A0303−F32 10 15.1 357 Pilot control pressure switch−off, suc-
tion flap
A0303−F33 2 17.6 153 CAN sensors, pressure contacts luffing
cylinder, WG HA.head
A0303−F34 15 28.2 378 Outrigger lighting
A0303−F35 10 14.6 74 Control unit heater

(Z 60 272)

−F38 5 Diesel soot particle filter company Huss

(optional) Ignition
−F39 5 ZE OW Diesel soot particle filter company Huss
(optional) Control voltage (30)
−F40 20 Diesel soot particle filter Huss company
(optional) 24V
−F41 20 Diesel soot particle filter Huss company
(optional) 24V

BMK = Operating equipment code

ZE OW = Central electrical unit superstructure

200−1−3140−120−1 7/15
14

8/15 200−1−3140−120−1
 Electrical System 14

14.4 Checking the Slip Ring Contacts on the Winches and

the Rotary Joint of the Chassis.

Condensation in the housing can cause the contacts to become

contaminated and corroded.

1. Unscrew the housing cover.

2. Check the slip ring contacts and clean if required. Spray

contacts with contact spray (spare parts no. 174 247 40).

3. Completely remove all condensation.

4. Screw housing cover in place and do a test run of the

corresponding functions.

200−1−3140−120−1 9/15
14

10/15 200−1−3140−120−1
 Electrical System 14

14.5 Preventative Measures Against Cable Fires

Cable fires in electric components and systems do not start due

to technical faults but as a result of carelessness or
manipulation of components or the circuit. Furthermore, it is
required that you use original parts when exchanging
components in the case of repair work.
It is very difficult to foresee the results of using non−original
parts on the electric equipment. This can cause malfunctions
in the individual circuit.
Electric currents can only be recognised by their effects.

One effect is heat.

Usually, each lead with currents only heats up minimally. If

currents are prohibited and high, high temperatures and fires
can be the result.
In order to prevent this, fuses have been fitted in the individual
circuits. These fuses interfere with the electric current if it is
above the maximum permitted value.

Fuses protect the cables of the electric equipment if there is

a short circuit!
They may not be bridged, even for a short period of time!
Under no circumstances may larger fuses (higher Ampere
value) be used!

As a result, faulty fuses are one of the main reasons for cable
fires.

200−1−3140−120−1 11/15
14

12/15 200−1−3140−120−1
 Electrical System 14

Other causes can be :

− non−permissible or defective cables or cable connectors,
(not sufficient cable cross sections)
− non−permissible or defective consumers or operating
elements (relays, engines, switches, lamps, etc.),
− connecting additional consumers to a fuse (cable and fuse
overload),
− installation of a larger−sized or differently constructed battery
(fitting measurements of the battery box are exceeded, risk
of a short circuit due to ground contact at the +−pole),
− penetration of damp in components of the electric equipment
after cleaning with water or a steam jet,
− bad state of the electric equipment due to faulty maintenance
and inspections.

All these points mentioned − either individually or several

points together − can cause scorching or an open cable fire.

You will achieve effective protection by following the measures

listed in the following.

Precautionary measures :
− The electric equipment of the crane must be inspected /
checked regularly.
Faults such as loose connections or scorched cables must be
removed immediately. Their causes must be identified and
rectified.
− All electric leads, plug−in connections and terminals must be
checked for loose mountings and damage (to be recognised
by the oxidation on clips or at battery poles).
Rectify identified faults immediately.

Only electric specialists or trained persons under the su-

pervision and guidance of an electric specialist may
work on electric systems or operating equipment and
only in accordance with the electric technical regula-
tions.

200−1−3140−120−1 13/15
14

14/15 200−1−3140−120−1
 Electrical System 14

− Only use original spare parts and original fuses with the
prescribed electricity strength! (See the spare parts
catalogue or electrical circuit diagram.)
Switch off the crane immediately if there are faults in the
electric power supply!
− Do not modify or add or convert any part of the electric system
without the authorisation of the manufacturer!
− Check the electric equipment in accordance with the
conditions of use and the operating conditions as required;
however, it must at least once a year by a specialist!
For example:

Components:
Generator, mountings, state,
starter, starting aid for function, insulation,
diesel engine,
lighting equipment, must be protection against di-
leads, collectors, slip checked for: rect contact of active
rings, parts
heating, switches, re- protection for indirect
lays, fuses, contact of active
parts
batteries.

200−1−3140−120−1 15/15
 Fuel System 15

200−1−3150 1/3
15

2/3 200−1−3150
 Fuel System 15

15 Fuel System

15.1 Checking the Fuel System

In addition to the visual inspections (e.g. checking the oil level),

the fuel system in the engine compartment should be inspected
once a year. The following points must then be checked:
− All system fittings must be free of leaks and sufficiently tighte-
ned.
− With re−usable fittings, the hose on the connection to the
hose nipple must be a tight fit. If in doubt, secure the hose ad-
ditionally with a hose clamp or replace the hose completely.

Lines and/or hoses damaged due to mechanical, thermal or

other effects must be replaced.

Ensure that all lines and hoses are an adequate distance

from hot engine parts (e.g. turbo charger) and are laid so that
they do not chafe.

The fuel system of the crane is connected with that of the crane
chassis. Only the fuel system of the crane chassis is filled (see
section 15 in part 4).

200−1−3150 3/3
 Cooling, Air Intake and Exhaust System 16

200−1−3160−120−1 1/25
16

87

Z 200 420 Z 51 736

1 2

Z 42 107 Z 4 965

2/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16 Cooling, Intake and Exhaust System

16.1 Cleaning or Replacing the Air Filter Element

Never service the air filter with the engine running.

Clean filter element as soon as the indicator light (87) lights up

with the engine running (Z 200 420).

1. Undo the spring−loaded latches (1) and remove cover (2)

from the housing (Z 51 736 and Z 42 107).

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

3. Clean and check filter cartridge (4). Replace the filter

cartridge if required.

After having been cleaned 3 times, or if it becomes

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

200−1−3160−120−1 3/25
16

Z 0 406 Z 0 125

Z 0 126 Z 0 129

4/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.1.1 Dry Cleaning

− Temporarily by Tapping out

If the filter cannot be cleaned using compressed air or water, the

dirt in the element can be shaken out.

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

Try to avoid damaging the filter element. Clean the surface of the
seals.

− With compressed air

Compressed air − max. 5 bar (73 psi)

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
approx. 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.

200−1−3160−120−1 5/25
16

Z 0 130 Z 0 131

6/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

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 (73 psi).

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.

200−1−3160−120−1 7/25
16

Z 27 837 Z 27 838

Z 501 336

8/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.2 Replacing the Safety Cartridge (Optional)

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 housing of dirt which may be present, but do

not blow it out with compressed air.

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 Preseparator (Optional)

(Z 501 336)

The air filter preseparator 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).

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

200−1−3160−120−1 9/25
16

Z 51 737

10/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.4 Cleaning the Cooling System

(Z 51 737)

Danger 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
completely 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.

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

operating instructions.

The radiator guard must be removed to clean the cooling

elements.

200−1−3160−120−1 11/25
16

Z 51 738

12/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.5 Checking the Coolant Level and Topping up as

Necessary

Only open cover of engine cooling system when cooled

down. Otherwise the system is under pressure. RISK OF
ACCIDENTS!

1. Turn the cap (Z 51 738) on the expansion tank to the first

notch and release excess pressure.

2. Continue to turn to the second notch and remove the cap.

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

antifreeze.
− See also the engine manufacturer’s operating
instructions.

200−1−3160−120−1 13/25
16

Z 51 738

14/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.6 Replacing the Coolant with Anti−freeze

(Z 51 738)

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

throughout the year (see operating instructions for the engine).
The anti−freeze does not have any negative effect on the refined
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! RISK OF
ACCIDENTS!

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.

200−1−3160−120−1 15/25
16

Z 46 539

16/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

3. Drain the engine and the radiator (Z 46 539).

− To drain the engine, the drain plug on the crankcase and,
if fitted, the drain plug on the oil heat exchanger should be
opened.
− To drain the radiator, open the radiator drain plug.

4. When the cooling system has been drained, all the drain
plugs should be screwed back in again.

200−1−3160−120−1 17/25
16

Z 51 738

18/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

5. Fill the cooling system with fresh coolant.

When filling the cooling system, ensure that air pockets do

not form. 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
coolant 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
(Z 51 738).

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

with the expansion tank open. If necessary, top up the
coolant.

7. Replace the cover and close the heating valves.

200−1−3160−120−1 19/25
16

20/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.7 Diesel Particle Filter Huss (Optional)

16.7.1 General

It must be ensured that the diesel engine functions faultlessly and

is operated and serviced in accordance with the operating
instructions of the engine manufacturer to guarantee proper
function of the filter.
Even small deviations from the regulations for engine operation
can cause an increase in the emission of sooty particles (higher
smoke spot number), resulting in reduced filter standstill time.

Important!
Using additive fuels can have a negative effect on the exhaust
emission, also effecting the standstill time of the diesel particle
filter, depending on the additives.
For this reason, you must consult HUSS before using additives.

Blue exhaust gas plume from the filter:

A blue exhaust plume from the filter is a clear indication that the
diesel engine is ”spraying” oil, i.e. there is unburned lube oil in the
engine exhaust fumes, which is partially deposited in the diesel
particle filter, and partially escapes as blue smoke.
In this case, the engine must be serviced immediately so that the
diesel particle filter is not damaged. A diesel particle filter which
is laden with too much oil (or fuel residue) reaches relatively high
temperatures during regeneration, which reduces its lifespan.

Grey or brownish exhaust gas plume from the filter:

This indicates that there are unburned carbon residue or ferric
sulphates in the exhaust gas. The fuel injection system of the
engine must be checked.

Recommendation:
Use engine lubricants with low white ash formation.
The quality of the engine’s lubricants is very important for the
service life and continuous use in the field. For this reason, ask
your dealer, manufacturer or maintenance and service centre for
engine lubricants which contain very little white ash or have none
at all.

200−1−3160−120−1 21/25
16

11

Z 160 625

12

Z 61 439

22/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

The following maintenance work can be carried out by trained

and qualified crane manufacturer personnel while observing the
warranty regulations of the filter manufacturer.

16.7.2 Checking and Emptying Condensate Separator

(Z 160 625)

The condensate separator (11) is behind the driver seat in the

superstructure cab.
If condensate fluid can be found there, drain it by pressing the
drain valve at the bottom end of the condensate separator.

16.7.3 Blowing out Filter

(Z 61 439, principle depiction)

After approx. 600−800 operating hours of the diesel engine, the

filter must be blown back.
To do so, module A (12) must be removed from the filter in order
to blow pressure air through the filter against the normal direction
of flow (6−10 bar / 87−145 psi), until no more ash or soot comes
out.

During this procedure, the residue coming out must be picked up

by an industrial hoover. Then module A (12) is fitted back onto the
filter with a clamp (do not forget the seal!).
It would be sensible to carry out the entire procedure outside.
Request a maintenance recommendation from HUSS.

It is harmful to health to breath in diesel soot particles!

200−1−3160−120−1 23/25
16

Z 58 819

24/25 200−1−3160−120−1
 Cooling, Air Intake and Exhaust System 16

16.7.4 Changing the Filter Element of the Fuel Filter

(Z 58 819)

The filter element of the particle filter fuel supply can normally be
changed with reference to the service interval of the crane
engine.

1. Switch off the engine and the ignition.

The regeneration of the particle filter cannot be carried out
currently.

2. Shut off the fuel hose between the tank and the fuel filter.

3. Change the filter element of the particle filter fuel supply.

16.7.5 Having a Service

Usually, servicing must be carried out with reference to the

crane’s service interval. The service interval of the particle filter
must be reduced depending on application (difficult operating
conditions, dusty environment, an indication for this could be the
service interval of the crane / engine). For applications in
environments with high dust concentration, a pre−separator
must be used to protect the fan.

The date of the maintenance work is shown in the display of the

“HUSS Control”. The HUSS service team must be requested in
order to carry out maintenance work.
The maintenance work can also be carried out by personnel
trained by the Huss company.

200−1−3160−120−1 25/25
 Piston Rods 17

17 Piston Rods

17.1 Exposed Chrome Surfaces − Applying Protective

Grease

Despite being of the highest quality, surfaces may be susceptible

to corrosion in an aggressive environment. If the crane is out of
operation for more than one day, exposed surfaces should be
protected against corrosion by applying acid free protective
grease (Recommended: ”Decordyn 350”, Order No. for spray
can: 604 106 40).

200−1−3170 1/1
 Crane Operator’s Cab 18

200−1−3180a_en 1/5
18

Z 40 175

2/5 200−1−3180a_en
 Crane Operator’s Cab 18

18 Crane operator’s cab

18.1 Lubricate the tilt cylinder

Grease the foot bearing and piston rod bearing on the tilt cylinder
(5) of the crane operator’s cab via the lubricating nipple on each
(Z 40 175).

200−1−3180a_en 3/5
18

Z 46 540

4/5 200−1−3180a_en
 Crane Operator’s Cab 18

18.2 Check the windscreen washing assembly

Check at least once a week that the windscreen washing assem-

bly is functioning properly.

18.3 Fill up the supply tank of the windscreen washing as-

sembly

The supply tank of the windscreen washing assembly must al-

ways be filled with water and if necessary with a little cleaning
agent (Z 46 540).

Before the onset of winter, a suitable amount of antifreeze

(depending on the temperature) must be added to the water.

18.4 Lubricating the Guide Rail of the Sliding Door

Using a paintbrush, lightly cover the guide rail of the sliding door
at the top and the bottom with grease.

200−1−3180a_en 5/5
 Superstructure 19

200−1−3190 1/3
19

F A

H
D

c
B

G
Z 51 739

2/3 200−1−3190
 Superstructure 19

19 Superstructure

19.1 Visual Inspections

(Z 51 739)

A − Check slew ring − external toothing for intact lubricating

film.
B − Check hydraulic system for leaks and damage as well as
the oil level.
C − Check cover and coverings for damage, check loose or
missing screws.
D − Check engine for oil and fuel leaks and contamination.
E − Check cooler for contamination.
F − Check instruments and displays for damage.
G − Check ropes for intact lubricating film and damage.
H − Battery (for maintenance, see operating instructions of
the engine)

200−1−3190 3/3
 Special Equipment 20

200−1−3200−401_en 1/3
20

11

Z 55 938

2/3 200−1−3200−401_en
 Special Equipment 20

20 Special Equipment

20.1 Central Lubricating System (option)

(Z 55 938)

20.1.1 Filling up the container

Always fill the container (1) of the central lubricating system regu-
larly up to the ”Max.” mark using the filling nipple (5). To do so, use
a commercial grease pump or lever press.

The grease must not be contaminated and may not change

its consistency throughout the course of time.
Never exceed the max. level.

Switch the pump on several times during filling by activating the

key (11).

The lubricants container (1) is filled with high pressure grease

(see section 2 of these maintenance and lubrication instructions).
The pump may require up to 10 minutes running time after it has
been completely emptied in order to achieve the full pump perfor-
mance.

20.1.2 Checking the system

Activate one or several additional lubrication processes and then

check:
− the sealing of the leads
− lubricants leakage at all lubricating points
− time setting of the control system

20.1.3 Cleaning the system

Use petroleum ether or kerosene to clean the system.

The plastic material of the pump container (1) can be dama-

ged if it comes into contact with triethylene dichloride, ace-
tone or other similar cleaning and diluting fluids.

200−1−3200−401_en 3/3
 Examinations of the Crane 22

22 Examinations of the Crane

In order to keep the crane in a safe operating condition, the ope-

rator must take the relevant precautions. An important tool is re-
gular inspections. These inspections may only be carried out by
specialised employees (ISO 9927−1), i.e. “technical experts” or
“appraiser”.

A technical expert is someone who due to his / her professional

training and experience has sufficient knowledge of cranes and
is familiar enough with the appropriate governmental health and
safety regulations, accident prevention regulations and the ge-
nerally recognised regulations of the technology to ascertain the
operational safety of cranes (BGG 905, section 3.2).

An appraiser is someone authorised by the employer’s liability in-

surance association or an authorised expert of the technical sur-
veillance (BGG 905, section 3.1).

22.1 Recurrent Inspections of the Crane

It is the responsibility of the crane operator to have the crane in-

spected according to the applicable international and national re-
gulations at regular intervals. This responsibility is described in
several national regulations regarding the prevention of acci-
dents (in Germany: BGV D6 and BGV D8) and in International
Standards (for example ISO 9927, ISO 12480, BS 7121, CSA
Z150, ASME B30.5 or others).
The following applies for Germany: Inspections to be performed
yearly by a technical expert, and at least every four years by an
appraiser (yearly, after 12 years of operation).

During this inspection the remaining theoretical service life

of the winches (in accordance with BGV D8, ISO 12482−1,
annex A). To do so, observe the instructions in the relevant
section 22.1.3.1, from page 53.

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The following information is based upon the regulations of the ac-

cident prevention regulations ”Crane” (BGV D6) with regard to re-
gular routine crane inspections.

The section 22.1.7 contains a check list for the repeated inspec-
tions of TEREX−Demag vehicle and crawler−mounted cranes to
help the inspector.
This check list is only a general guide. It is not type−related and
does not cover the complete range of all designs.

Inspections according BGV D6 do not replace the applicable

national regulations.

Carrying out the inspection

The routine inspection is primarily a visual and functional check,

mainly comprising:
− Checking the identity of the crane with the information in the
inspection book (crane log book).
− Checking the condition of the components and equipment
with regard to damage, wear, corrosion or other changes.
− Checking the safety equipment and the brakes for complete-
ness and effectiveness.
− Checking the state of the carrying equipment with regard to
damage, wear, corrosion or other changes.
− Checking to ensure there are decals and that they are com-
plete and legible.

The results of these inspections must be recorded in the log

book and must be certified by the inspector.

Specialists and trained personnel inspect the crane as matter of

their own responsibility.

After any major changes to the crane or after repair work on

carrying parts, the operator must authorise an inspection by
a technical expert before resuming operation.

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The following must be checked:

1. Frameworks

1.1 Chassis and Superstructure

Components: Checking for:
Frame, cracks,
outriggers, deformation,
slewing rim, wear,
axles, mountings and locks of removable
axle suspension, parts,
wheels corrosion and corrosion protection,
warning paint,
assignment of cables and hoses

1.2 Crane equipment

Components: Checking for:
Boom, cracks,
frame, deformation,
erecting struts, wear,
guides, mountings and locks of removable
braces, parts,
overextension lock, easy movement of the supports and
stay bars, guides,
bracing rod assembly and rope reeving,
corrosion and corrosion protection,
elongation,
plastic deformation,
paint,
assignment of cables and hoses

1.3 Counterweight
Components: Checking for:
Counterweight sec- to make sure all parts are complete
tions, and properly attached.
base plate

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2. Engines
2.1 Drives
Components: Checking for:
Final drive mountings and locks of removable
slew gear drive parts,
crane drive state, function and noises,
winch drive jerk−free driving and stopping,
idling,
wear of coupling and brakes,
effectiveness of reverse locks,
wear of the spline shaft connection,
assignment of cables and hoses

2.2 Rope drives

Components: Checking for:
Rope drums, configuration and storage of rope
rope sheaves, sheaves, rope guide rollers and rope
rope guide rollers sheaves (sheave grooves, flanged
wheels, wear).

2.3 Hydraulic equipment

Components: Checking for:
Hydraulic pumps, attachment,
hydraulic motors, condition,
cylinders, function,
valves, noises,
cases, leaks,
hydraulic accumula- hydraulic oil condition and quantity
tor, filling pressures
leads,
filters

2.4 Pneumatic equipment

Components: Checking for:
Compressors, attachment,
engines, condition,
cylinders, function,
valves, noises,
pressure tanks, leaks.
leads,
filters,

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2.5 Electrical equipment

Components: Checking for:

Alternators, motor, attachment,
resistors, condition,
brake vents, function,
lighting equipment, insulation,
heating, guard against direct contact with ac-
leads, collector, tive components,
switches, protectors, guard against indirect contact
fuses, installation
batteries,
lines
warning devices

2.6 Actuating equipment final drive

Components: Checking for:

Coupling state,
shifting function,
adjustable engine idling,
steering bringing to a standstill,
brakes easy movement,
play of linkage and cables (dead
gear),
display of the monitors, lamps and si-
gnals,
designation,
brake tests

2.7 Actuating equipment crane drive

Components: Checking for:

Slew gears state,
hoist gears function,
boom derricking ge- idling,
ars bringing to a standstill,
brakes easy movement,
play of linkage and cables (dead
gear),
display of the monitors, lamps and si-
gnals,
designation,
brake tests with load (inspection load
in the range of the load capacity)

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2.8 Other actuating equipment

Components: Checking for:
Outriggers condition,
additional equipment function.
axle interlock

3. Lubrication

3.1 Oil baths

Components: Checking for:
Transmissions adequately filled,
oil loss.

3.2 Lubricating points

Components: Checking for:
Lubricating nipple accessibility,
recognisibility, markings.

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4. Ladders, safety guards, safety equipment, decals

4.1 Steps
Components: Checking for:
Ladders attachment and condition.

4.2 Safety guards

Components: Checking for:
Panels, attachment and condition
covers, completeness,
guides, effectiveness.

4.3 Safety devices

Components: Checking for:
Load limit device, mountings and condition,
emergency limit completeness,
switch equipment, function
warning devices,
locking devices,
radius indicator,
tilt indicator,
air speed indicator,
wind safeguard,

4.4 Decals
Components: Checking for:
Signs completeness and legibility.

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22.1.1 Inspection of Load−bearing Steel Constructions

The load−bearing steel constructions must be carefully checked

at least during the prescribed repeated crane inspection (at
least1 x a year).
It is important to check the welded seams in particular.

The principle drawings listed in the following are examples for

load−bearing welded constructions. Inspections must be carried
out at the connections / zones around the points / welded seams
marked by arrows.

The inspector is personally responsible for carrying out the

inspection, as well as for content and extent. The following
principle depictions only serve as examples and additional
aids to the inspector. They make no claim to completeness.

The service life of load−bearing steel constructions are governed

on the one hand by the number of load cycles pursuant to DIN
15018, Part 3, and on the other hand to the loads (load collective)
that arise during periods of operation.

TEREX−Demag cranes are dimensioned for erection operation;

the following calculated values are the basis for the dimensioning
(DIN 15018, part 3):
Load collective: So (light)
Number of load cycles: 25 000.

If the crane was subjected to excessive stress during operation,

e.g. due to an exceptional hit, there must be an immediate in-
spection of the load−bearing components.

If damage, e.g. cracks, are found anywhere in the steel construc-

tion, the extent of the damage must be determined by suitable
specialists using recognised material examination methods (for
example: magnetic powder, ultrasound or x−ray inspections) −
with a subsequent decision on the possibility and type of repair
work.

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Z 54 326

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Frame chassis
(Z 54 326)

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Z 56 212

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Front frame of the carrier

(Z 56 212)

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Z 54 327

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Outriggers
(Z 54 327)

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Z 59 730

Z 59 731

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Frame superstructure 1
(Z 59 730)

Frame superstructure 2
(Z 59 731)

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Z 59 732

Z 59 733

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Frame superstructure 3
(Z 59 732)

Frame superstructure 4
(Z 59 733)

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Z 61 472

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Main boom
(Z 61 472)

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Z 61 473

Z 61 474

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Main boom extension − basic boom

(Z 61 473)

Main boom extension − tip section

(Z 61 474)

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Z 61 475

Z 61 476

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Main boom extension − intermediate sections

(Z 61 475, Z 61 476)

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Z 61 477

Z 61 478

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Fly jib − foot section

(Z 61 477)

Fly jib − reducer

(Z 61 478)

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Z 61 479

Z 61 480

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Fly jib − intermediate sections

(Z 61 479, Z 61 480)

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Z 61 481

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Fly jib − top piece

(Z 61 481)

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Z 61 482

Z 61 483

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Fly jib − head connecting piece

(Z 61 482)

Fly jib − luffing mast connecting piece

(Z 61 483)

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Z 61 484

Z 61 485

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Fly jib − luffing masts

(Z 61 484, Z 61 485)

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Z 61 486

Z 61 487

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Fly jib − flying bridle

(Z 61 486)

Fly jib − bracing rods

(Z 61 487)

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Z 61 488

Z 61 489

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Head roller
(Z 61 488)

Runner
(Z 61 489)

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Z 61 470

Z 61 471

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Superlift
(Z 61 470, Z 61 471)

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Z 51 910

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22.1.2 Inspection of the Disc Wheels (Rims)

(Z 51 910)

The rim of a wheel is an important component of the mobile crane

which is relevant to safety.
In addition to the annually prescribed inspection of the crane,
there must be a crack inspection of the rims. If it is determined that
cracks are starting to form or if cracks are discovered, the affec-
ted rims must be replaced immediately.
After a running stretch of max. 40 000 km (24 000 mi), the crane
operator must carry out a running observation.
Especially the rims should be inspected for cracks in the basic
material and in the zones marked with arrows.

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22.1.3 Inspection of the Winches

An external visual inspection is not sufficient. The service life of

the winches can be reduced by bad servicing, defective seals,
unprofessional operation or overloading. For this reason a spe-
cialist must carry out inspections in accordance with the following
regulation.

Inspections

− Inspections interval − every 1000 operating hours, at least

once a year
− Check the oil level
− Check for colouring of oil
− Check for solid foreign materials − this check must be carried
out by a qualified lab
− Visual inspection
− Check of the brakes on the transmission of the winches
− Check of the spline fitting “engine/brake/transmission”

During the annual crane inspection, the used portion of the

theoretical period of use of the winches must also be determi-
ned. The crane operator must employ a specialist for the purpose
if necessary.

Where accident prevention regulations of the German em-

ployer’s liability insurance association apply, this is requi-
red by law.
Outside of the validity period, the crane manufacturer re-
commends that the procedures listed also be observed.

Risk of accidents! Risk of fatalities!

Not complying with these standard settings for determi-
ning the remaining period of use of the winch may result in
unnoticed expiration of the winch and sudden, unexpected
winch failure. This could result in property damage acci-
dents and fatalities!

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22.1.3.1 Theoretical Service Life

The design engineer has assumed certain operating conditions

in calculating and dimensioning the winches on your crane.
The winches of your crane are graded as follows (ISO 4301/1,
FEM 1.001, DIN calculation parameters for drives):
Power unit group: M........
Load spectrum: Q....... (L.......)
Load spectrum factor: km = ..........

A theoretical service life, D, is thus calculated.

The individual values can be taken from the table ”Monitoring the
winches” in the crane log book.

The theoretical service life must not be equated with the real
(actual) service life of a winch.
The real period of use of a winch is additionally influenced
by many external conditions, for example:
− Overloading through not using the crane as intended.
− Insufficient maintenance: the oil is not changed in good
time.
− Maloperation such as extreme acceleration or decelera-
tion of the load or the load falling into the ropes.
− Maintenance mistakes such as using the wrong oil, in-
correct oil fill or contamination when changing the oil.
− Mounting mistakes when undertaking repairs or mainte-
nance.
− Leaks not taken into consideration.
− Incorrectly adjusted safety equipment.
− Concealed damage caused by accidents.
− Extreme ambient conditions such as low or high tempe-
ratures, aggressive atmosphere, dust and dirt.

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Z 29 551 Z 29 552

Z 29 553 Z 29 554

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22.1.3.2 Actual Operating Conditions

Before the spent share of the theoretical service life of the win-
ches can be determined, the actual operating conditions (load
spectrum) and the operating hours of the hoists per inspec-
tion interval must be determined.

22.1.3.3 Determining the Operating Conditions (Load

Spectrum)
The load collective of the crane is divided into groups (see also
ISO 4301/1, FEM 1.001).
From knowledge of the actual operating conditions, one of the
load spectrums listed below must be selected and recorded in the
crane log book for the relevant inspection interval.
Load Definition Shares of operating time Load
spec- spec-
trum trum
class factor
(Km)
light Power units or parts thereof 10% of operating time under
Q1 subject to highest loading highest load (dead load +
L1 only as exception but routi- 1/1 load capacity)
nely only subject to very low 40% of operating time under
loading dead load + 1/3 load cap.
0.125
50% of operating time only
under dead load
see figure Z 29 551
me- Power units or parts thereof 1/6 of operating time under
dium subject to highest loading highest load (dead load +
Q2 quite often but routinely only 1/1 load capacity)
L2 subject to low loading 1/6 of operating time under
dead load + 2/3 load cap.
1/6 of operating time under
0.25
dead load + 1/3 load cap.
50% of operating time only
under dead load
see figure Z 29 552
heavy Power units or parts thereof 50% of operating time under
Q3 often subject to highest loa- highest load (dead load +
L3 ding and routinely subject to 1/1 load capacity)
medium loading 50% of operating time only
0.5
under dead load
see figure Z 29 553
very Power units or parts thereof 90% of operating time under
heavy regularly subject to loading highest load (dead load +
Q4 in the realm of highest loa- 1/1 load capacity)
L4 ding 10% of operating time only
1
under dead load
see figure Z 29 554

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22.1.3.4 Operating Hours of the Hoists per Inspection Interval

Determine the effective number of operating hours per inspection

interval (Ti). This must be recorded in the crane log book for the
relevant inspection interval.

As a rule, the hoist winch share of the total operating hours for the
superstructure is 20% for mobile cranes used for erection opera-
tion.

If hoist rope reevings are correspondingly reduced for loads

beneath the maximum loads of the selected load table, and
the permitted rope load therefore almost completely used,
this must be taken into consideration when calculating the
winch load.

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22.1.3.5 Determining the Spent Share of the Theoretical

Service Life of the Winches

For an inspection interval i (max. 1 year in accordance with ISO

9927−1 or BGV DB) the used proportion of the theoretical service
life of the winches is calculated according to the following for-
mula:
Kmi
Si = x Ti
km
Si = spent share of theoretical service life
Kmi = factor of the load collective in the inspection interval
”i” in accordance with section 22.1.3.3
Km = load spectrum factor which formed the basis of
calculation for the winch
(here: Km = 0.125)
Ti = effective operating hours in the inspection interval ”i”
in accordance with section 22.1.3.4

This used proportion is deducted after each inspection interval

from the remaining theoretical service life (see example in section
22.1.3.6). Observe the following:
− If a theoretical service life remains which is insufficient
for the next operating period, a general overhaul of the win-
ches must be carried out.
− If the theoretical service life, D, is achieved, the winch must
only be continued to be operated following a general
overhaul.

In each case a general overhaul is required at the latest 10

years after the crane is placed in operation.

The general overhaul must be arranged by the operator and

carried out by the manufacturer (or persons authorised by
the manufacturer) and must be entered in the crane book.

A new theoretical service life is then declared by the manu-

facturer or persons authorised by the manufacturer follo-
wing the general overhaul.

The max. time period until the next general overhaul is, ho-
wever, at the most 10 years.

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22.1.3.6 Documentation
(Z 60 292)

The crane operator is responsible for documenting how the spent

share of the theoretical service life for the winches has been de-
termined.

The forms required for this purpose are enclosed in the crane log
book:
− Sample tables (Z 60 292)
− Tables for each winch.
The theoretical remaining service life of each winch must be
documented using these tables.

The crane user is liable for the correctness of the informa-

tion!

The specimen table is clarified by the following example:

Inspection No. 1 (year 1)

The crane has been used for erection purposes for the past year:
Load spectrum L 1, i.e. Km1 = 0.125

800 h are recorded on the superstructure hour meter. The winch

has been in operation for approx. 20% of this time, i.e T1 = 160 h.

The spent share S1 of the theoretical service life for the first in-
spection is thus:

km1 0.125
S1 = x T1 = x 160 h = 160 h
km 0.125

The value for the load spectrum factor (here: Km = 0.125) and the
theoretical service life (here: D = 3200 h) are recorded at the top
of the relevant table.

Theoretical remaining service life after the first year :

D1 = D − S1 = 3200 h − 160 h = 3040 h

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Z 60 292

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(Z 60 292)

Inspection No. 2 (year 2)

The crane has been used for harbour unloading operation:
Load spectrum L 3, i.e. Km2 = 0.5.
2000 h are recorded on the superstructure hour meter, i.e. during
this period: 2000 h − 800 h (used in first year of operation) =
1200 h.
The winch has therefore been in operation for approx. 40% of this
time, i.e. T2 = 480 h.
The spent share S2 of the theoretical service life for the second
inspection interval is thus:
km2 0.5
S2 = x T2 = x 480 h = 1920 h
km 0.125

Theoretical remaining service life after the second year :

D2 = D1 − S2 = 3040 h − 1920 h = 1120 h

Inspection No. 3 (year 3)

The crane has been used for erection operation and occasionally
for harbour unloading operation:
Load spectrum L 2, i. e. Km3 = 0.25.
3000 h are recorded on the superstructure hour meter, i.e. during
this period: 3000 h − 2000 h (used in the first two years of opera-
tion) = 1000 h.

The winch has been in operation for approx. 30 % of this time, i.e.
T3 = 300 h.
The spent share S3 of the theoretical service life for the third in-
spection interval is thus:
km3 0.25
S3 = x T3 = x 300 h = 600 h
km 0.125

Theoretical remaining service life after the third year :

D3 = D2 − S3 = 1120 h − 600 h = 520 h
Calculations must now be carried out to determine whether the
remaining theoretical service life is sufficient for the next opera-
ting period. If this is not the case, a general overhaul must be un-
dertaken (see section 22.1.3.5).

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22.1.4 Hooks
(Z 54 325)

The hooks must be checked by a specialist once a year. This

should prevent accidents because faults will be determined early
on. Any faults that are discovered must be documented as well
as their rectification. Then you must check whether the determi-
ned faults have been rectified.

Inspection and Surveillance Measures

Check for deformation, localised cold forming and compression

in the pincer mouth, cracks, wear, rusting.
Lock fitting of the hook nuts.

Deformation

If the hook jaw expands more than 10 % compared to the starting

dimension “y” or “y1”+”y2”, the hook must be replaced.

The starting dimension “y” or “y1”+”y2” is recorded on the hook.

It is measured from grain to grain.

Corrosion

Threads and the operated shaft smut be checked for corrosion

and wear. To do so, the hook nut must be unscrewed from the
shaft.

If aftertreatment is needed to remove the corrosion, the thread

core diameter may not be exceeded by more than 5 % by this pro-
cess. Otherwise, the hook must be replaced.

With older hooks the main dimensions must be compared with

the data in DIN 687, 689, 699, newer hooks with the data in
DIN 15401 and 15402 with regard to jaw width, main bending
cross−section, thread core diameter.

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“Y” “Y”

“X”

Z 33 646

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22.1.5 Inspection of the Sheaves

(Z 33 646)

Check all rope sheaves for damage as for example notches or si-
milar damage, and check if the bearings are properly seated (run-
ning smoothly).

Sheaves with such damage must be replaced immediately.

All check all plastic sheaves for wear:

− Bottom tread “X” max. 3 mm (0.12 in)
Measure “X” = difference between ∅ new bottom tread and
∅ bottom tread is !
− Side tread “Y” max. 5 mm (0.2 in)
Measure “Y” measured between rope (S) and tread of the
sheave.

If the sheave is worn up to the wear limit, it must be replaced.

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22.1.6 Inspection of the Ropes

General

A cable is a basic consumer item with a limited life span. Many

characteristics of a cable change throughout its period of use. For
example, its breaking force initially increases slightly with ac-
crued operating time before falling rapidly once a maximum value
has been reached.

This breaking force decrease is due to an increased loss of the

metal percentage caused by wear and corrosion which occur with
wire breakage and structure changes of the cable.

In the cable, the load−bearing elements are connected in paral-

lel. This is why a cable can still be safe for operation even if a large
number of wires have broken.

One of the purposes of a cable inspection is to monitor the con-

tinuous increase in the amount of wire breakage, so that the ca-
ble 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 influen-
ces.
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.

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Intervals

Standard ISO 4309 recommends the following:

− daily visual check of the cables and rope end fastenings for
any possible damage
− regular check of the cables by trained specialists to ensure
an operationally safe condition
− Special inspections:
− after exceptional loading or supposed invisible damage
− after longer periods of standing still
− when lifting devices have been removed for a change in lo-
cation, before beginning operation at the new operating lo-
cation
− after every accident or case of damage occurring in con-
nection with rope operation.

Scope of the inspection

Wear from friction, rust markings, rusting, crushing points, loose-

ning of outer wire threads, clustering of ropes, formation of loops
from cords or wires, twisting, corkscrew formation, kinks, number
of visible wire breakages, clusters of broken wires, cord brea-
kage.
Determine the rope diameter in relation to the condition of the
sheaves on the drums and rollers.
Fasten to ensure the rope does not spring out.
Check the condition of the fastening of the ends of the rope.
Protect against the effects of heat from fire operations.

It may be necessary to dismantle components before an accu-

rate assessment of the load−bearing equipment can be made.
Ropes must be inspected over their entire length during inspec-
tion which includes those sections normally concealed, e.g. bea-
ring surfaces on compensating sheaves, pressure points under
rope clamps and fastening devices at the ends of ropes.

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Criteria for removal

A rope must be removed when one or several of the following

points are fulfilled. See also the relevant DIN standards.

a) Wire breakage

A cable must be removed when the permitted wire breakage

number is in accordance with DIN 15 020 or exceeds it.

The cable must be removed if there are wire breakage clusters

or if a cord breaks.

b) Rope wear

If the rope diameter in cables is decreased by 15 % or more du-

ring longer journeys compared to the nominal value, the cable
must be removed.

c) Corrosion

You can determine corrosion of the outer rope wires with a visual
inspection. However, it is difficult to determine corrosion on wires
that cannot be seen externally.

Corrosion can lead to a decrease of the static breaking force of

the cable due to reduction of the metallic rope average as well as
a decrease of the operational stability due to corrosion pits.

d) Abrasion

Abrasion of the rope wires can be ”interior abrasion” which is cau-

sed by movements of the cords and wire against each other when
bending the cable up and down or ”external abrasion” which is
caused by movements between the cable and the sheave or by
dragging the cable on the ground or over the material to be con-
veyed.

Abrasion is encouraged if lubrication is insufficient or lacking or

by the existence of dust. If the rope diameter is decreased by 10
% or more compared to the nominal value, the cable must be re-
moved even if no wire breakage was discovered.

200−1−3220b 73/109
22

Z 1367

Z 1368

Z 1369

74/109 200−1−3220b
 Examinations of the Crane 22

e) Rope deformation

Deformation of the cable is visible change to the rope structure.

Deformation generally also causes the rope configuration to loo-
sen in the area of the deformation. Depending on the appea-
rance, there is the following differentiation of the most important
deformations:
− corkscrew−type deformation
− ”basketwork” formation (deformation)
− loop formation of the wires
− loosening of individual wires or cords
− knots
− contraction
− flattening
− curl−type deformation
− Kinks and bends

Corkscrew−type deformation (Z 1367)

With the corkscrew−type deformation, the axle of the unloaded

cable becomes a corkscrew.

Remove cable, if the deformation X has become 1/3 d larger

or more (d = rope nominal diameter).

”Basketwork” formation (deformation) (Z 1368)

”Basketwork” formation (deformation) can occur in cables with

steel inserts if the outboard bearing of the wires is loosened or the
external cords are longer than the internal ones.
If the external wire or cord positions slip in comparison to the in-
terior ones, the excessive length share is shifted in one place.

If there is ”basketwork” formation (deformation), the cable

must be removed.

Loop formation of wires (Z 1369)

If there is loop formation of the wires, individual wires or wire

groups poke out of the rope structure like little hairs on the rope
side facing the sheave.

If there is a significant change to the rope structure due to

wire loop formation, the cable must be removed.

200−1−3220b 75/109
22

Z 1370

Z 1371

Z 1372

76/109 200−1−3220b
 Examinations of the Crane 22

Loosening of individual wires or cords (Z 1370)

If individual wires or cords loosen, the exterior wires of the loaded

cable or individual cords can be shifted.

This means that they do not assume the share of then tension
force assigned to them, which overloads the other wires or cords.

If the cable runs over sheaves, it can cause increased bending

tension which causes premature wire breakage.

If the wires become loose due to rust and abrasion, the cable
must be removed. If there is another cause for the loosening,
the wire breakage occurring as a consequence determine
the aptitude for removal.

Knots (Z 1371)

A knot is defined as a thickening of the wires which repeatedly

occur over longer periods. Often the inlay pokes out of the cable
at the point of thickening.
At the thinner points in the cable, the cords push against each
other, forming arches, which causes wire breakage.

Cables with several knots must be removed.

Contraction (Z 1372)

Contraction is when the cable’s diameter is decreased on short

stretches.
Cable components immediately in front of end fastenings must
be carefully checked for contraction , which can be difficult to see
at these points.

Cable with a lot of contraction must be removed.

200−1−3220b 77/109
22

Z 1373

Z 1374

Z 1375

78/109 200−1−3220b
 Examinations of the Crane 22

Flattening (Z 1373)

Flattening is defined as permanent deformation of the cable,

which is caused by crushing.

Flattening causes increased wire breakage.

curl−type deformation

Curl−type deformation is caused when a loaded cable is pulled

over an edge.

Cables with curl−type deformation must be removed.

Kinks (Z 1374)

A kink is a deformation of the cable caused by pulling an eyelet−

shaped rope loop straight without the cable being able to balance
out the deformation by rotating around its axle.

Cables with one or more kinks must be removed.

Bends (Z 1375)

A bend is a deformation of the cable which is caused by forceful

external influences.

Cables with bends must be removed.

200−1−3220b 79/109
22

80/109 200−1−3220b
 Examinations of the Crane 22

Effects of heat

Cables which have been subject to 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 ad-
vance 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 re-

placement 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 in-
spection.
The description of the regular inspections goes beyond the
bounds of the lubrication and maintenance instructions.
It is contained in corresponding national regulations.

200−1−3220b 81/109
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 Examinations of the Crane 22

22.1.7 Documentation

Instructions for repeated inspections on TEREX crawler−moun-

ted and mobile cranes in accordance with § 26 sections 1 and 2
of the UVV “Crane” (BVG D6)

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

1st inspection group: Crane document

Test component A B C D E Remarks
Inspection log book for the crane
Operation / assembly instructions
Load tables

2nd inspection group: Notices / markings

Test component A B C D E Remarks
Factory sign
Load / stress details
Notice of operating regulations
Prohibition and regulation notices
Other safety markings

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

200−1−3220b 83/109
22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

3rd inspection group: Travel gear 1)

Test component A B C D E Remarks

Axles
Wheels
Tyres
Bearing
Distributor gear
Cardan shaft
Leaf springs / springs
Shock dampers
Brakes
Hydraulic axle suspension

4th inspection group: Chassis 1)

Test component A B C D E Remarks

Frame 2)

Axle suspension
Axle interlock
Outriggers 2)

Covering
Steeping surfaces
Steps
Counterweight holding devices 2)

Holding device for block 2)

Boom support 2)
Attachment device

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

200−1−3220b 85/109
22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

5th inspection group: Chassis / crane operator’s cab 1)

Test component A B C D E Remarks

Doors
Windows / glass
Wipers
Mirrors
Seat
Heater
Ventilation
Noise absorption
Tachograph
First−aid kit
Replacement bulbs
Hazard warning triangle
Warning jacket

6th inspection group: Chassis / drive 1)

Test component A B C D E Remarks
Combustion engine
Exhaust system / combustion protection
Fuel tank
Fuel lines
Filter
Engine suspension
Oil / coolant levels

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

7th inspection group: Chassis / hydraulics 1)

Test component A B C D E Remarks

Oil tank
Filter
Pumps
Engines
Valves
Lines
Hoses
Cylinders
Pressure relief valves

8th inspection group: Chassis / air pressure system 1)

Test component A B C D E Remarks
Compressor
Filter
Air tank
Valves
Lines
Hoses
Cylinders

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

9th inspection group: Chassis / electric system 1)

Test component A B C D E Remarks

Engines
Alternators
Batteries
Switch
Lines
Fuses
Resistors
Lighting equipment
Braking lights
Indicators
Tail lights
Flood lights
Signalling devices
Indicator lights
Battery switch
Limit switch:
transmission, steering, drive
Support pressure gauge 2)

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

200−1−3220b 91/109
22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

10th inspection group: chassis / control devices 1)

Test component A B C D E Remarks

Engine control
Transmissions
Clutches
Circuits
Steering
Control displays
Engine stop pull
Control of the outriggers 2)

Axle suspension
Crane levelling
Rear−axle steering

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

200−1−3220b 93/109
22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

11th inspection group: Superstructure

Test component A B C D E Remarks
Frame
Coverings
Steeping surfaces
Bearing
Counterweights
Back−stroke safety device
Slewing rim: fastening screw
Slewing rim: toothing
Slew gear: fastening screws
Slew gear: toothing
Slew gear: Drive
Slew gear: lock
Slew gear: Covering

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

12th inspection group: Superstructure / cab

Test component A B C D E Remarks
Doors
Windows / glass
Wipers
Mirrors
Seat
Heating / air conditioning equipment
Ventilation
Mufflers
Control lever for operating functions
Transmission switches
Safety device: points of crushing /
shearing

13th inspection group: Superstructure / retaining devices and safety guards

Test component A B C D E Remarks
Handles and ladders
Coverings
Covers
Flaps

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

14th inspection group: Superstructure / drive

Test component A B C D E Remarks
Combustion engine
Exhaust system / combustion protec-
tion
Fuel tank
Fuel lines
Filter
Engine suspension
Noise absorption
Oil / coolant levels

15th inspection group: Superstructure / hydraulic system

Test component A B C D E Remarks
Oil tank
Filter
Pumps
Engines
Valves
Lines
Hoses
Cylinders
Pressure relief valves
Lowering brake valves

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

16th inspection group: Superstructure / electric system

Test component A B C D E Remarks
Engines
Alternators
Batteries
Switch
Lines
Fuses
Resistors
Lighting equipment
Switch cabinet
Indicator lights

17th inspection group: Superstructure / control devices

Test component A B C D E Remarks
Engine control
Transmissions
Elastic clutches
Circuits
Engine stop
Control displays
Slew brake

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

18th inspection group: Superstructure / rope drives

Test component A B C D E Remarks
Winch H1 3)

Winch H2 3)
Winch W1/H3 3)

Winch W2 3)
Winch E 3)
Winch R 3)
Sheaves
Rope end fixture
Rope for winch H1
Rope for winch H2
Rope for winch W1/H3
Rope for winch W2
Rope for winch E
Rope for winch R
Bracing ropes

19th inspection group: Superstructure / hooks / hook blocks

Test component A B C D E Remarks
Sheaves
Protecting clamps on the sheaves
Axle stirrups
Hooks
Hook fastenings
Lock−on hook

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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22

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

20th inspection group: Superstructure / safety and switching devices

Test component A B C D E Remarks
Hoist emergency limit switch H1
Hoist emergency limit switch H2
Lowering emergency limit switch H1
Lowering emergency limit switch H2
Boom emergency limit switch E1
Boom emergency limit switch E2
Top section:
Boom emergency limit switch W1
Top section:
Boom emergency limit switch W2
Load limit device
Length display: working radius, boom
length
Angle display: boom
Angle display: top section
Angle display: slew gear
Safety device: control
Operating range limits
Tilt indicator
Support pressure gauge
EMERGENCY OFF

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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 Examinations of the Crane 22

Company: Inspector: Date:

Crane manufacturer: Crane type: Construction number:
TEREX−Demag
Construction year: Inventory no.: Signature

21st inspection group: Boom

Test component A B C D E Remarks
Welded construction
Sheaves
Boom support
Boom pinning
Bracing rods / ropes
Retaining cylinders
Luffing cylinders
Telescoping cylinders
Extension ropes
Pull ropes

22nd inspection group: Optional Equipment

Test component A B C D E Remarks

A: existing / complete B: state / servicing C: function

D: repair / replacement E: subsequent inspection required
fulfilled = x not fulfilled = − not required = 0

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 Examinations of the Crane 22

Remarks

1) It is considered that an inspection of the traffic safety status

of the mobile crane has been carried out if there is a fault−
free result of expert inspection in accordance with the road
traffic licensing regulations. The expert must carry out an in-
spection of the traffic safety status on mobile cranes which
are not authorised for travel on public roads (see also UVV
“Vehicles” BGV D29).

2) The expert must still carry out these inspections even if

there is a fault−free result from an expert inspection in ac-
cordance with the road traffic licensing regulations.

3) Inspection of the winches with regard to the used portion of

the theoretical period of use

200−1−3220b 109/109
 Index

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Consumables and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Lubrication and Maintenance Schedule . . . . . . . . . . . . . . . . . . . 1

4.1 Initial Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.2 Regular Routine Lubrication and Maintenance . . . . . . . . . . . . . . . . 1
4.3 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1 Engine Quick Stop: Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 Automatic and Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6.1 Checking the Automatic and Distributor Gear for Leaks . . . . . . . . 3
6.2 Automatic Transmission (ZF), Checking and Topping Up the
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.3 Automatic transmission (ZF), change the oil and exchange the
filter element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.4 Distributor Gear, Checking and Topping Up the Oil Level . . . . . . . 13
6.5 Distributor Gear, Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.6 Distributor Gear Shift, Checking the Air Pressure System . . . . . . 17
6.7 Distributor Gear, Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7 Joint Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1 Flange Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.1 Checking the Axle Fixings and Tightening as Necessary . . . . . . . 3
8.2 Lubricating the Steered Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.3 Driven Axles − Checking the Oil Level and Topping Up
as Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.3.1 Axles without Drive Differentials (Axle 2 and 5 or Axle 2 and 6) . . 7
8.3.2 Axles with Drive Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.4 Wheel Hub Drive −− Checking and Topping up Oil Level
as Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.5 Wheel Hub Drive − Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.6 Check Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.6.1 Checking the Axial Play of the Wheel Bearing . . . . . . . . . . . . . . . . . 15
8.6.2 Checking the Lock Fitting of the Wheel Locking Nut . . . . . . . . . . . 15
8.7 Driven Axles − Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.7.1 Axles without Drive Differentials (Axle 2 and 5 or Axle 2 and 6) . . 17
8.7.2 Axles with Drive Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.8 Suspension Cylinder − Lubricating the Swing Bearing . . . . . . . . . . 23
8.9 Wheel hub bearing − change the grease . . . . . . . . . . . . . . . . . . . . . 23

200−1−4000d 1
 Index

9 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.1 Checking the Tightness of the Steering Components . . . . . . . . . . . 3
9.2 Lubricating the Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.3 Lubricating the Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.4 Checking the Axial Play in the Steering Arm Bearing and Adjusting as
Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.5 Checking the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.6 Replacing the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.7 Electro−Hydraulic Additional Rear Axle Steering . . . . . . . . . . . . . . . 7

10 Brake and Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . 3

10.1 Check brake linings for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.2 Renew brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.3 Perform brake function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.4 Check expanding cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.5 Replace brake drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.6 Replace other brake parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.7 Draining the Air Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.8 Two−chamber − Air Dryer − Replacing the Cartridges . . . . . . . . . . 9
10.9 Checking the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.10 Replacing the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

11 Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11.1 Re−tightening the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.2 Tyres − checking inflation pressure, tread depth and tyre damage 3
11.3 Inspection of Disc Wheels (Rims) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.4 Cleaning the Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

12 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 Hydraulic tank − check oil level / top up . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Hydraulic oil reservoir − check filter inserts of the return oilfilter,
exchange if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12.3 Hydraulic oil reservoir − clean and replace barrel and
filterinserts of the return oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.4 Hydraulic oil reservoir − clean the filler filter . . . . . . . . . . . . . . . . . . . 11
12.5 Hydraulic tank − replace the aeration filter . . . . . . . . . . . . . . . . . . . . 11
12.6 Change oil in hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.7 Bleed the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12.8 Inspecting the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12.9 Check hoses of the suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.10 Replace hoses of the suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.11 Checking the Pre−Set Gas Pressure in the Accumulators . . . . . . 17
12.12 Using Biological Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

200−1−4000d 2
 Index

13 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1 Lubricating the Sliding Surfaces of the Outriggers . . . . . . . . . . . . . 3
13.2 Checking the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.3 Replacing the Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.4 Greasing the Slide Rails of the Support Plates . . . . . . . . . . . . . . . . 3
13.5 Lubricating the castors of the outriggers . . . . . . . . . . . . . . . . . . . . . . 3

14 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Check the Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Service the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.3 Lighting Equipment: Replacing a Bulb . . . . . . . . . . . . . . . . . . . . . . . 3
14.4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

15 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Fuel Tank − Draining Off Water and Sediment . . . . . . . . . . . . . . . . 3
15.2 Checking the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.3 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.4 Maintaining the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.4.1 Draining the Preliminary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.4.2 Changing the Preliminary Fuel Filter Filter Element . . . . . . . . . . . . 9
15.5 Additional Tank 300 l (79.3 gal) (optional) . . . . . . . . . . . . . . . . . . . . 11
15.5.1 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15.5.2 Maintenance of the Preliminary Fuel Filter . . . . . . . . . . . . . . . . . . . . 13

200−1−4000d 3
 Index

16 Cooling, Air Intake and Exhaust System . . . . . . . . . . . . . . . . . . . 3

16.1 Cleaning and Replacing the Air Filter Element . . . . . . . . . . . . . . . . 3
16.1.1 Dry Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.2 Wet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.1.3 Testing the Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2 Air filter prefractionator (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.3 Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.4 Checking the Coolant Level and Topping Up as Necessary . . . . . 11
16.5 Replacing the Coolant with Anti−Freeze . . . . . . . . . . . . . . . . . . . . . . 13

17 Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17.1 Exposed Chrome Surfaces − Applying Protective Grease . . . . . . 1

18 Driver’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
18.1 Checking the Windscreen Washing Assembly . . . . . . . . . . . . . . . . . 3
18.2 Filling Up the Supply Tank of the Windscreen Washing Assembly 3

19 Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19.1 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.1 Lubricating the Dolly Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20.2 Servicing the Dolly Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20.3 Central Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20.3.1 Filling the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20.3.2 Checking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20.3.3 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20.4 Auxiliary Heating System ”D9W” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
20.4.1 Checking the System is Functioning Correctly . . . . . . . . . . . . . . . . 9
20.4.2 Replacing the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
20.4.3 Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
20.4.4 Bleeding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
20.5 Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
20.5.1 Switching On the Air Conditioning Equipment . . . . . . . . . . . . . . . . . 15
20.5.2 Servicing the Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . . 15
20.5.3 Having the Air Conditioning Equipment Checked . . . . . . . . . . . . . . 15

200−1−4000d 4
 Foreword

Foreword

Part 4: Lubrication and Maintenance Instructions for the

Crane Chassis

For you,

This instruction manual is provided for the benefit of personnel

carrying out maintenance work, and includes information requi-
red for maintenance and lubrication of the machine and all spe-
cial equipment.

The information contained in this manual is correct with regard to

the equipment at the time of publication. Data, diagrams and di-
mensions are subject to change as a result of technical develop-
ment.
No liability can be accepted for damage resulting from incorrect
maintenance.

In these lubrication and maintenance instructions you will find the

titles or the respective symbols ”Danger”, ”Caution” and ”Note”
used as follows:

DANGER!

”Danger” is used if a maintenance procedure, NOT per-

formed according to the prescriptions given, may cause
death or injury to persons.

CAUTION !

”Caution” is used if a maintenance procedure, NOT perfor-

med according to the instructions given, may cause damage
to the crane or the crane equipment.

NOTE:

”Note” is used for identifying an important maintenance proce-

dure as well as for additional information.

200−1−4002 1/5
2/5 200−1−4002
 Foreword

General Recommendations Regarding Lubrication and

Maintenance Tasks

− Thoroughly clean all nipples, caps and plugs before grea-

sing.
− Refill the fuel tank at the end of each working day, in order to
prevent condensation.
− Renew the gaskets for drain, filler, inspection plugs and fil-
ters, before replacing the screws or filter.
− The oil can be drained more easily from individual units if it is
drained at operating temperature.
− Ensure that the crane is kept clean at all times, i.e. free of
flammable substances. In particular, the crane must be clea-
ned thoroughly following maintenance work on the hydraulic
system, the engine or the fuel system. Cleaning is best car-
ried out with a steam cleaner.
− After cleaning the crane, grease all lubricating points.
When dry, spray the slew gear teeth with the recommended
grease.
− Never carry out welding repairs without first consulting our
Customer Service Department responsible for cranes.
Repair work carried out incorrectly may cause serious da-
mage, resulting in extensive repairs at considerable cost.

Please contact the Customer Service Department immediately if

you discover cracks in the steelwork of your crane.
Describe the course of the crack as closely as possible (enclose
photograph, page from spare parts catalogue etc.).

200−1−4002 3/5
4/5 200−1−4002
 Foreword

Central lubrication system

If the crane is equipped with a central lubrication system, the fol-

lowing components do not require manual lubrication:
− Steering arm bearing
− King pin bearing
− Steering cylinder bearing
− Suspension cylinder bearings

These bearing points are connected to the central lubrication sy-

stem which is driven by an electronic control unit (Central lubrica-
tion system, see operating instructions for the crane chassis, Part
2, Sect. 16).

200−1−4002 5/5
 Notes on Safety 1

1 Notes on Safety

All hazards which may arise in connection with lubrication and

maintenance work on the crane chassis are listed in part 3 of the
lubrication and maintenance instructions for the superstructure,
Section 1 ”Notes on Safety”.

Therefore carefully read this Section before starting to perform

maintenance and lubrication jobs at the crane chassis.

200−1−4010 1/1
 Consumables and Capacities 2

200−1−4020−166c 1/7
2

2/7 200−1−4020−166c
 Consumables and Capacities 2

2 Consumables and Capacities

Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US−gall.)
See regulations on consumables in the operating and maintenance
Sect. 5
instructions of the engine OM 502 LA
Drive motor
as well as the Mercedes−Benz regulations
with filter change min. 32 l
Mercedes−Benz
max.40 l Engine oil
− ACEA E4 Sheet 225.6 / 228.5 or
(min. 8.5 gal 5 W − 30
228.51
max. 10.6 gal)
Sect. 6.
Gear oil ZF TE−ML 02 synthetic gear oil
Automatic Gear 23 l
SAE 75W−85 02C/02D/02H/02L 02L
(6 gal)
Sect. 7.
High−pressure
Lubricating nipple
lubricant DIN 51825
(manual lubrication, − “Shell Alvania EP 2”
NLGI−class 2 KP2K − 20
central lubricating
system)

The specified capacities are approximate values. For an

accurate measurement, service and operating personnel must
carry out checks using the inspection points, inspection plugs,
dipsticks and inspection windows provided.

Further consumables specifications on request. If consumables

are used which do not meet these specifications, damage to the
engine may result, which will not be covered by warranty.

200−1−4020−166c 3/7
2

4/7 200−1−4020−166c
 Consumables and Capacities 2

Continued: Consumables and Capacities

Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US−gall.)
Sect. 8.
Axles
Axle 2
− Axle housing 20 l
(5.3 gal)
− Wheel hub drive 1.2 l each
(0.3 gal)
Axle 3
− Distributor gear 11,5 l
(3 gal)
− Axle housing 21 l
(5.5 gal)
− Wheel hub drive 1.3 l each
(0.34 gal) Gear oil API GL − 5
Axle 4 SAE 90 MIL − L − 2105 B
− Axle housing 22 l
(5.8 gal)
− Wheel hub drive 1.2 l each
(0.3 gal)
− Idler shaft 1,1 l
(0.29 gal)
Axle 5
− Axle housing 20 l
(5.3 gal)
− Wheel hub drive 1,2 l
(0.3 gal

The specified capacities are approximate values. For an

accurate measurement, service and operating personnel must
carry out checks using the inspection points, inspection plugs,
dipsticks and inspection windows provided.

Further consumables specifications on request. If consumables

are used which do not meet these specifications, damage to the
engine may result, which will not be covered by warranty.

200−1−4020−166c 5/7
2

6/7 200−1−4020−166c
 Consumables and Capacities 2

Continued: Consumables and Capacities

Filling point Capacities Filling agent Quality regulations Initial filling

in litres
(in US−gall.)
Sect. 12 Hydraulic oil
Hydraulic system ISO VG 32
incl. steering 370 l (−25 °C to +25 °C)
(97.8 gal) (−13 5F to 77 5F);
of which: ISO VG 46 DIN 51524.3 −
Shell Tellus TX 46
− Hydraulic oil 190 l (−10 °C to +30 °C) HVLP
reservoir (50.2 gal) (14 5F to 86 5F);
ISO VG 68
− Steering gear 2,4 l (−5 °C to +40 °C)
(0.6 gal) (23 5F to 104 5F)
alternative: (for instructions, see section 12)
46.1 mm 2/s (cSt) at
40 °C (104 5F); “Panolin HLP Synth
BIO hydraulic oil
Solidifying point 46”
−58 °C (−72.4 5F)
Sect. 13 Order from Terex−
Grease paste
Pin surfaces/ − − Demag
NLGI class 1
Outrigger SP no. 634 758 40
Sect. 15 Chassis =
Fuel system (main tank)
for crane and 500 l
chassis together (132.1 gal)
(auxiliary tank) Mercedes−Benz
Diesel fuel Diesel fuel
300 l Sheet 132.3
(79.3 gal)
Crane =
50 l
(13.2 gal)
Sect. 16 50% water/
Mercedes−Benz
Cooling system 110 l Coolant 50 % glysantin
Sheet 310
(29.1 gal) Sheet 325.2
Sect. 17 Order from Terex−
Protective grease
Exposed chrome − Demag
(Spray)
surfaces SP no. 604 106 40

The specified capacities are approximate values. For an

accurate measurement, service and operating personnel must
carry out checks using the inspection points, inspection plugs,
dipsticks and inspection windows provided.
Further consumables specifications on request. If consumables
are used which do not meet these specifications, damage to the
engine may result, which will not be covered by warranty.

200−1−4020−166c 7/7
 Lubrication and Maintenance Schedule 4

4 Lubrication and Maintenance Schedule

4.1 Initial Lubrication and Maintenance

Lubrication and maintenance work which occurs before the regu-

lar routine work is identified by ”1X” on the maintenance sche-
dule.
The work must be undertaken once at the time specified.

4.2 Regular Routine Lubrication and Maintenance

Regular routine lubrication and maintenance work is identified by

”X” on the maintenance schedule.
They must be carried out once at the given interval and repeated
regularly in accordance with the schedule.
For example, an ”X” in the column for 500 kilometres means that
the corresponding work has to be carried out every 500 kilome-
tres i.e. after 500, 1000, 1500 etc. kilometers.

The following service intervals apply to cranes operated under-

normal ambient and operating conditions.
Adjustment should be made to the servicing intervals when the-
crane is operated under abnormal conditions.

When carrying out more comprehensive maintenance work

i.e.”after 1000 km”, such work which is carried out at shorter inter-
vals and which coincides with the present interval should natu-
rally also be carried out.In this instance, maintenance work which
needs to be carried out ”after 50 km” as well as all maintenance
work required ”after500 km” must also be included at this interval.

200−1−4040−001c 1/8
4

2/8 200−1−4040−001c
200−1−4041−001c_en

4.3 Maintenance List

Fuels Interval (kilometres travelled)
Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
5 Engine
MERCEDES BENZ (OM 502 LA) see the Operating Instructions of the Manufacturer
Engine: Check oil level & top up as nec. x x
Engine: Change oil and oil filter for oil quality: in accordance with Mercedes−Benz x3)
fuel regulations 228.5 5)

for differing oil quality:

see the Operating Instructions of the Manufacturer
other maintenance works see the Operating Instructions of the Manufacturer
5.1 Engine Quick Stop: Function Test 1 x year

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁ
ÁÁÁ
6 Automatic transmission and distributor gear
6.1 Check automatic transmission and distributor gear forleaks 1x

ÁÁÁÁ
6.2
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ ÁÁ
ÁÁÁ
Automatic transmission (ZF),check oil level, fill up if neces-

ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
sary x1)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ ÁÁ ÁÁÁ ÁÁ
ÁÁÁ
6.3 Automatic transmission (ZF),change the oil
x4)

Lubrication and Maintenance Schedule 4

6.4 Distributor gear,check oil level, fill up if necessary x
6.5 Distributor gear,change oil and clean breather 1x x3)
6.6 Distributor gear switches,check the air pressure system x3)
6.7 Distributor gear, visual check x
7 Joint Shafts
7.1 Check the flange connections for proper fitting 1x 1x x3) x
1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
3/8
200−1−4041−001c_en

Fuels Interval (kilometres travelled)

Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
8 Axles
8.1 Check axle mounting bolts for proper fitting, tighten as re- 1x 1x x
quired
8.2 Lubricate steered axles 1x 1x x
8.3 Driven axles − check and top up oil level as required x1)
8.4 Wheel hub drive − check and top up oil level as required x1)
8.5 Wheel hub drive − change the oil 1x 1x x
8.6 Check wheel bearing 1x x
8.7 Axle drive − change the oil 1x x3)
8.8 Suspension cylinder − lubricate the swing bering x
8.9 Wheel hub bearing − change the grease x3)
9 Steering
9.1 Check steering components for proper fitting 1x 1x x3)
9.2 Lubricate steering lever x
9.3 Lubricate steering cylinder 1x x
9.4 Steering lever bearing − check axial play 1x x
9.5 Check the hose lines x

Lubrication and Maintenance Schedule 4

9.6 Replace the hose lines every 2 years
9.7 Rear axle additional steering − steering sensor x
1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
4/8
200−1−4041−001c_en

Fuels Interval (kilometres travelled)

Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
10 Brake and air pressure system
10.1 Check brake lining for wear 1x x1)
10.2 Renew brake linings x
10.3 Perform brake function check x
10.4 Check expanding cylinder x4)
10.5 Replace brake drums x
10.6 Exchange other brake components x4)
10.7 Drain water from the air tank x daily in winter
10.8 Air drier − replace granulate cartridge x4)
10.9 Check the hose lines 1x x
10.10 Replace the hose lines every 2 years
11 Wheels and Tyres
11.1 Tighten wheel nuts 1x 1x 1x x x
11.2 Check tyre pressure, check tread depth and look for signs x
of damage
11.3 Clean tyres x
11.4 Check rim x x3)

Lubrication and Maintenance Schedule 4

1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
5/8
200−1−4041−001c_en

Fuels Interval (kilometres travelled)

Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
12 Hydraulic system
12.1 Hydraulic tank − check oil level / top up x
12.2 Hydraulic oil reservoir − check filter inserts of the return 1x x
oilfilter, exchange if necessary
12.3 Hydraulic oil reservoir − clean and replace barrel and filte- 1x 1x x3)
rinserts of the return oil filter
12.4 Hydraulic oil reservoir − clean the filler filter x
12.5 Hydraulic tank − replace the aeration filter x2)
12.6 Change oil in hydraulic tank x
12.7 Bleed the hydraulic system x
12.8 Check the hydraulic system x
12.9 Check hoses of the suspension x
12.10 Replace hoses of the suspension every 2 years
12.11 Check the preliminary gas tension of the accumulators x3)
13 Outriggers
13.1 Lubricate sliding surface on outrigger struts x
13.2 Check the hose lines x

Lubrication and Maintenance Schedule 4

13.3 Replace the hose lines every 6 years
13.4 Grease sliding tracks of the support plate x
13.5 Lubricate outrigger sliding rollers x
1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
6/8
200−1−4041−001c_en

Fuels Interval (kilometres travelled)

Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
14 Electrical system
14.1 Check the lighting system x
14.2 Service the batteries x
14.3 Lighting equipment − replace bulb x
14.4 Check the fuses x
15 Fuel system
15.1 Fuel tank − drain off sediment and water x
15.2 Check the fuel system x
15.3 Refuel x
15.4 Maintenance of the fuel filter see operating instructions of the diesel engine
15.5 Additional Fuel Tank 300 l (optional) x x
16 Cooling, intake and exhaust system
16.1 Clean/replace the filter element in the air filter x4)
16.2 Cleaning the air filter prefractionator (optional) x
16.3 Cleaning the cooling system x
16.4 Check the coolant and top up as necessary x
16.5 Change the coolant and anti−freeze x4)

Lubrication and Maintenance Schedule 4

17 Piston rods
17.1 Exposed chrome surfaces − apply protective grease x
1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
7/8
200−1−4041−001c_en

Fuels Interval (kilometres travelled)

Chap. Work to be carried out Sect. 2 1* 50 500 1 2 5 10 20 40 100 2*
x1000
18 Driver’s cab
18.1 Check the windscreen washing assembly x1)
18.2 Fill up the supply tank of the windscreen washing assem- x
bly
19 Crane chassis
19.1 Visual inspection x
20 Optional equpment
20.1 Lubricate the dolly coupling x
20.2 Service the dolly coupling x
20.3 Central lubrication system
20.3.1 Fill up reservoir
20.3.2 Check the system x1
20.3.3 Clean the system x
20.4 Auxiliary heating system “D9W”
20.4.1 Check the system is functioning correctly x
20.4.2 Replace the heat exchanger every 10 years x
20.4.3 Replace fuel filter x

Lubrication and Maintenance Schedule 4

20.4.4 Bleed the system x
20.5 Air conditioning x
20.5.1 Switch on the air conditioning equipment once a month
20.5.2 Service the air conditioning equipment At beginning, middle and end of cooling period
20.5.3 Have the air conditioning equipment checked 1 x year
1* − daily before driving 2* − as required
1) at least 1 x per week 2) at least every 5000 hours 3) at least 1 x year 4) at least every 2 years
5) every 40000 km
8/8
 Engine 5

200−1−4050b 1/5
5

2 1

3
Z 51 740

Z 46 543

2/5 200−1−4050b
 Engine 5

5 Engine
(Z 51 740, Z 46 543)

Risk of injury!
Maintain safety distance to hot, rotating and moving
components.

Danger of burning or scalding.

Before carrying out maintenance work in the engine area,
allow a cooling period of 60 minutes.

For information and instructions on the maintenance of the en-

gine, please refer to the engine manufacturer’s operating instruc-
tions.
This can be found along with a maintenance manual in part 5 of
this service literature.

The description of the engine is on the bearing plate.

The location of the bearing plate can also be found in the opera-
ting instructions of the engine manufacturer.

Assembly of the Engine

1 Dipstick

2 Oil filler

3 Oil drain

Starter

When cleaning the starter it must always be ensured that,

− when in the fitted position the starter is not sprayed with the
water jet and
− when dismantled the starter is cleaned with the bearing fa-
cing downwards, that is, suspended downwards,

so that moisture does not enter the magnetic switch.

200−1−4050b 3/5
5

Z 47 991 Z 58 696

4/5 200−1−4050b
 Engine 5

5.1 Engine Quick Stop: Function Test

(Z 47 991 principle drawing, Z 58 696)

Both engines (drive motors in the chassis and in the superstruc-

ture engine) can be switched off by pressing the optional additio-
nal engine quick stop button in the outrigger control area (exam-
ple Z 47 991) on the left− and right−hand side of the crane chassis
vehicle (for instructions, see part 2, section 5 “Engine”).

During the function test you must check that the engines are swit-
ched off by pressing each existing push button.

If the engines are equipped with an air shutoff flap (Z 58 696,

optional equipment), you must also check that it is closed during
the function test.

If the engines are to be restarted, the shutoff flaps (1) of both en-
gines must be unlocked. Return lever (2) to the starting position.

Risk of damage !
When the shutoff flap is closed the engine cannot be started.
Repeated starting attempts result in engine damage.
Before restarting, all air−carrying hoses − incl. the charge air
hoses between the engine and charge air cooler − must be
checked to ensure that they are fitted correctly and are com-
pletely free of blockages.

200−1−4050b 5/5
 Automatic and Distributor Gear 6

200−1−4060a 1/19
6

13

13

Z 51 741 Z 51 742

Z 51 743

2/19 200−1−4060a
 Automatic and Distributor Gear 6

6 Automatic and Distributor Gear

6.1 Checking the Automatic and Distributor Gear for
Leaks
(Z 51 741 and Z 51 743)

1. Park the crane on horizontal ground.

2. Apply the parking brake and place sprags in front of the

wheels to prevent any rolling movement.

3. Check the automatic transmission (2) and the distributor

gear (3) for possible leaks (so−called sweat or leakage
points).

The visual inspection may only be carried out when the en-
gine is switched off. There must be no−one in the chassis
cab and the cab must be locked.

6.2 Automatic Transmission (ZF), Checking and Topping

Up the Oil Level

The crane can suddenly and unexpectedly be set in motion.

Therefore, before carrying out the oil level check, make sure
that the parking brake has been correctly applied and that
chocks have been placed in front of the wheels or the crane
has been supported on outriggers.

− Check the oil level daily before driving or operating the crane.
The oil level must be checked with the crane in a horizontal
position.
− The oil level inspection must not be carried out immediately
after driving (incorrect result). Only carry out the inspection af-
ter the transmission oil has cooled down (< 40 5C / 104 5F).

Oil level inspection

Having too little oil in the transmission causes damage to the

transmission.
Accidents may occur.

1. Shift the gearshift to position ”N” (neutral) (Z 51 742) and ap-

ply the parking brake.

200−1−4060a 3/19
6

1
4 2

Z 51 744

4/19 200−1−4060a
 Automatic and Distributor Gear 6

2. Remove oil filler screw(4, Z 51 744).

3. If the oil level has sunk beneath the oil filler opening, the oil
must be filled up again.

6.3 Automatic transmission (ZF), change the oil and ex-

change the filter element.
(Z 51 744)

The intarder may NOT be activated immediately after the mo-

bile crane has been switched off!
This ensures that the correct oil change quantity is in the
transmission.

To change the oil the gear oil should be at operating temperature.

Place the mobile crane in operation before changing the oil, or
change the oil after the crane has been driven.

Park the mobile crane on even horizontal ground.

Before the oil is changed, the crane must be secured with
chocks to prevent it rolling or should be supported on outrig-
gers.

To change the oil in the automatic transmission proceed as

follows:

1. Set the mobile crane on outriggers, place the gear shift in the
neutral position ”N” and switch off the engine.

2. Unscrew plug (1) from the transmission drain hose and un-
screw the plugs (2) from the drain hose for the intarder.

Drain oil into a suitable container and dispose of in environmen-

tally suitable manner.

Risk of burning with hot transmission oil.

3. Screw in drain hoses’ plugs again.

200−1−4060a 5/19
6

1
4 2

Z 51 744

6/19 200−1−4060a
 Automatic and Distributor Gear 6

4. Unscrew oil filler screw (4, Z 51 744).

5. Fill up transmission until oil runs over.

6. Screw in oil filler screw (4, Z 51 744). Torque 60 Nm

(44 lbf−ft).

7. Test drive: journey of 2 − 5 km (1.2 − 3 miles).

Do NOT activate intarder during test drive.

8. At the end of the test drive, bring the mobile crane to a stand-
still WITHOUT using the intarder

9. At the end of the test drive, bring the mobile crane to a stand-
still WITHOUT using the intarder

10. Check oil level again and if necessary, fill up oil.

11. Screw in oil filler screw (4, Z 51 744). Torque 60 Nm

(44 lbf−ft).

New oil must be used to fill up for the first filling or after repairs
once the oil filler screw (9, Z 51 744) has been removed!

200−1−4060a 7/19
6

3 2
1 10

Z 51 745 Z 51 746

3 8 7 6 5

Z 51 747 Z 51 748

8/19 200−1−4060a
 Automatic and Distributor Gear 6

Use a new oil filter for every oil change.

To change the filter, the gear oil should be at operating tempera-

ture.
Place the mobile crane in operation first or change the filter ele-
ment after the crane has been driven.

To change the filter on the automatic transmission proceed

as follows: (Z 51 745; Z 51 746; Z 51 747; Z 51 748)

1. Park the crane on horizontal ground.

Before changing the filter, secure the crane with chocks to

prevent it rolling or set on the outriggers.
The filter should only be changed when the engine has been
switched off. There must be no−one in the chassis cab and
the cab must be locked.

Risk of burning with hot transmission oil!

2. Support the crane on outriggers or secure with chocks to pre-

vent it rolling.

3. Place the gear shift in the neutral position ”N”, apply the par-
king brake and switch off the engine.

4. Unscrew screw (10, Z 51 746) from the oil filter housing lid
(3, Z 51 746).

5. Pull out oil filter housing lid (3, Z 51 747) with inserted filter.

There is remaining oil in the oil filter housing.

6. Check O−ring (8, Z 51 748) on the oil filter lid for damage and
exchange and lubricate if necessary.

7. Attach magnet (5, Z 51 748) safely to the new filter (6,

Z 51 748).

8. Lubricate O−ring (7, Z 51 748) on the new filter (6, Z 51 748).

9. Insert oil filter housing lid (3, Z 51 746) on the new filter (6,
Z 51 748).

10. Insert unit into the filter housing up to the stop.

11. Fit oil filter housing lid (3, Z 51 746) using screw (10,
Z 51 746).

200−1−4060a 9/19
6

Z 51 749

Z 0147

10/19 200−1−4060a
 Automatic and Distributor Gear 6

12. Start the chassis engine and leave running for approx. 2 to
3 minutes at idle speed.

13. Carry out an oil level check and add oil as necessary. For
more information on fuels and lubricants and capacities,
please refer to section 2 of these lubricating and mainte-
nance instructions.

14. Check the filter barrel for leaks.

Cleaning the breathers

(Z 51 749, Z 0147)

When the crane is driven, the oil in the converter and in the trans-
mission warms up. This increases the pressure, which is relieved
continually via the breathers. The breathers should be cleaned
at regular intervals to make sure that they can function properly
at all times.

These breathers on the automatic transmission (5) must be clea-

ned after every oil change.

The breathers are cleaned by blowing them out with compressed

air from the inside outwards (Z 0147).

If the breathers are still fitted with a plastic protection cap,

which are fitted before painting, the cap MUST be removed.

200−1−4060a 11/19
6

Z 51 900

2
Z 51 901

12/19 200−1−4060a
 Automatic and Distributor Gear 6

6.4 Distributor Gear, Checking and Topping Up the Oil Le-

vel
(Z 51 900; Z 51 901)

Check the oil level every 1000 km (600 miles), but at least 1 x
month before the crane is driven.
The oil level must be checked with the crane in a horizontal posi-
tion.

Before carrying out the check, the crane should be secured

with chocks to prevent it rolling or secured on outriggers.
The check may only be carried out when the engine is swit-
ched off. There must be no−one in the chassis cab and the
cab must be locked.

Carry out the check before commencing driving as follows:

1. Park the crane on horizontal ground.

2. Support the crane on outriggers or secure with chocks to pre-

vent it rolling.

3. Place the gear shift in the neutral position ”N”, apply the par-
king brake and switch off the engine.

4. Unscrew the plug from the inspection opening (1, Z 51 901)

on the distributor gear (3, Z 46 473).

5. The gear oil must come up to the lower edge of the inspection
opening (1, Z 51 901).

If the oil does not come up to the lower edge of the inspection
opening (1), you must add oil via the filler neck (1) or, if the level
is too high, drain off oil.

200−1−4060a 13/19
6

Z 51 900

2
Z 51 901

14/19 200−1−4060a
 Automatic and Distributor Gear 6

6.5 Distributor Gear, Changing the Oil

(Z 51 900; Z 51 901)

To change the oil the gear oil should be at operating temperature.

Place the crane in operation first, or change the oil after the crane
has been driven.

Before the oil change the crane should be secured with

chocks to prevent it rolling or should be supported on outrig-
gers.
The oil should only be changed when the engine is switched
off. There must be no−one in the chassis cab and the cab
must be locked.

To change the oil in the distributor gear proceed as follows:

1. Park the crane on horizontal ground.

2. Support the crane on outriggers or secure with chocks to pre-

vent it rolling.

3. Place the gear shift in the neutral position ”N”, apply the par-
king brake and switch off the engine.

4. Unscrew the plug (2, Z 51 901) of the oil drain opening on the
distributor gear (3, Z 51 900):

5. Clean the magnet on the plug (2, Z 51 901) to remove any

abrasion which has become attached to it.

6. Screw the plug (2) of the oil drain opening back in. Replace
the sealing ring.

7. Unscrew the check plug (1) and add gear oil up to the lower
edge of the inspection opening hole (1).
For more information on fuels and lubricants and capacities,
please refer to section 2 of these lubricating and mainte-
nance instructions.

200−1−4060a 15/19
6

5 3 2
1
6

Z 51 902

43

13

A38

13

Z 51 903

16/19 200−1−4060a
 Automatic and Distributor Gear 6

6.6 Distributor Gear Shift, Checking the Air Pressure Sy-

stem
Legend: (Z 51 902)
1 pneumatic connections − distributor gear shift
2 pneumatic connections − distributor gear shift
3 pneumatic connections − distributor gear shift
4 compressed air connection − differential lock
5 electric connection − road gear (2nd gear)
6 electric connection − off−road gear (1st gear)
7 electric connection − differential lock
8 shift cylinder (road, off−road, neutral)

Before carrying out the visual check, make sure that the
crane is secured with chocks to prevent rolling or is suppor-
ted on outriggers.
The check may only be carried out when the engine is swit-
ched off.
The transmission may only be shifted from off−road to road
gear in the driver’s cab by a trained and reliable person.

Carry out the inspection as follows:

1. Park the crane on horizontal ground.
2. Set the crane on outriggers or secure with chocks to prevent
rolling.
3. Place the gear shift in the neutral position ”N”, apply the par-
king brake and switch off the engine (Z 51 903).

Make sure that there is enough air pressure in the supply tank.
Observe the display on the screen (43, Z 51 903).

Check the air pressure system on the distributor gear for:

− loose screw connections,
− loose and/or defective electric cable connections (5, 6, 7,
Z 51 902),
− pressure lines for signs of leaking and shearing points (4),
− leaks on the shift cylinder (8) of the road / off−road gear and
the pressure lines (1, 2, 3),
− solenoid valve for abrupt venting,
− function of the switches and indicator lights.
Any faults should be rectified immediately.
If faults or shortcomings are found which impair the operational
reliability of the vehicle, these must be rectified before the
crane is used again.

200−1−4060a 17/19
6

5 3 2
1
6

Z 51 902

43

13

A38

13

Z 51 903

18/19 200−1−4060a
 Automatic and Distributor Gear 6

6.7 Distributor Gear, Visual Check

(Z 51 902)

Before carrying out the visual check, make sure that the
crane is secured with chocks to prevent rolling or is suppor-
ted on outriggers.
The visual check may only be carried out with the engine
switched off. There must be no−one in the chassis cab and
the cab must be locked.

Carry out the check as follows:

1. Park the crane on horizontal ground.

2. Set the crane on outriggers or secure with chocks to prevent

rolling.

3. Place the gear shift in the neutral position ”N”, apply the par-
king brake and switch off the engine (Z 51 903).

Check the distributor gear for:

− loose screw connections,
− loose and/or defective electric cable connections,
− clogging of the transmission ventilation,
− loose, damaged or leaking oil lines,
− leaks on the transmission.

Any faults should be rectified immediately.

If faults or shortcomings are found which impair the operational
reliability of the vehicle, these must be rectified before the
crane is used again.

200−1−4060a 19/19
 Joint Shafts 7

200−1−4070a 1/3
7

Einzelheit Z
Detail Z
1

Z 51 904

2/3 200−1−4070a
 Joint Shafts 7

7 Joint Shafts

7.1 Flange Connections

(Z 51 904)

Check the nuts and bolts of the flange connections for signs of
damage and to make sure that they are fitted properly, and retigh-
ten as necessary.

The following values apply for the tightening torques:

− Bolts (1): All flange connections on the joint shafts
and idler shafts (Z 40 764)
M14x1,5; 10.9 MA = 187 Nm (138 lbf−ft)
lubricate the thread and head support
with roller bearing grease KP2K

Missing or defective bolts must be replaced.

Only bolts of the specified size and strength may be used.

200−1−4070a 3/3
 Axles 8

200−1−4080b 1/23
8

Z 21 526

2/23 200−1−4080b
 Axles 8

8 Axles

8.1 Checking the Axle Fixings and Tightening as Neces-

sary
(Z 21 526)

− Check bolts (1) on the axle brace collars and tighten if neces-
sary. The tightening torque is 70 to 80 Nm (52 to 59 lbf−ft).
− Tighten fixing screws (2) on the axle braces using a torque
wrench. The tightening torque is as follows:
∗ Bolts M 18 : 410 Nm (302 lbf−ft)
When changing these bolts the following is to be observed:
∗ Do not use any striking tools
∗ Before inserting each bolt, coat the bolt support and thread
in oil or grease.

Do not use MoS2

200−1−4080b 3/23
8

Z 21 527 Z 21 529

4/23 200−1−4080b
 Axles 8

8.2 Lubricating the Steered Axles

Grease the steering−swivel bearing (Z 21 527, Z 21 529) and

double joint shaft of the steering axles.

If the crane is equipped with a central lubrication system (optional

equipment), the lubricating points of the steering−swivel bearing
are supplied with grease by the central lubricating pump.

200−1−4080b 5/23
8

Z 21 530

6/23 200−1−4080b
 Axles 8

8.3 Driven Axles − Checking the Oil Level and Topping

Up as Necessary

8.3.1 Axles without Drive Differentials (Axle 2 and 5 or Axle

2 and 6)
(Z 21 530)

Check the oil level as follows:

1. Unscrew bolt (2) from the inspection or filler opening.

The oil level must come up to the lower rim of the inspection
opening.

2. If this is not the case, the oil must be topped up.

The oil level should be checked after 500 km (300 miles), but
at the latest, after one week.

200−1−4080b 7/23
8

Z 21 531

Z 21 532

8/23 200−1−4080b
 Axles 8

8.3.2 Axles with Drive Differentials

(Z 21 531 and Z 21 532)

− Axle 4 or 5

Check the oil level as follows:

1. Unscrew bolt (2) for the axle drive or (4) for the idler shaft
from the inspection and filler opening.
The oil level must come up to the lower rim of the inspection
openings.

2. If this is not the case, the oil must be topped up.

For axles with drive differentials, it is advisable, if oil needs to be

topped up, to first of all fill up oil in the differential (idler shaft). Any
overflow of oil actually runs into the axle housing.

The oil level should be checked after 500 km (300 miles), but
at the latest, after one week.

200−1−4080b 9/23
8

1
Z 60 465

10/23 200−1−4080b
 Axles 8

(Z 60 465)

− Axle 3

Check the oil level as follows:

1. Unscrew bolt (2) from the inspection and filler opening.

The oil level must come up to the lower rim of the inspection
opening.

2. If this is not the case, the oil must be topped up.

The oil level should be checked after 500 km (300 miles), but
at the latest, after one week.

200−1−4080b 11/23
8

Z 21 533

12/23 200−1−4080b
 Axles 8

8.4 Wheel Hub Drive −− Checking and Topping up Oil Le-

vel as Required
(Z 21 533)

Drive the crane forwards or backwards until the oil drain plug (2)
is at the lowest point. Remove the oil inspection plug (1). The oil
level must come up to the rim of the inspection opening, top up
if necessary.

The oil level should be checked after 500 km (300 miles), but
at the latest, after one week.

8.5 Wheel Hub Drive − Changing the Oil

(Z 21 533)

1. Drive the crane forwards or backwards until the oil drain plug
(2) is at the lowest point.

2. Open the oil drain plug and the oil inspection or filler plug (1)
and drain off the old oil.

3. Screw on the oil drain plug having replaced the oil seal with
a new one.

4. Fill new oil up to the bottom edge of the inspection opening

and screw in filler and inspection screw. Replace the old seal
with a new one.

200−1−4080b 13/23
8

Z 27 961 Z 27 962

Z 27 963

14/23 200−1−4080b
 Axles 8

8.6 Check Wheel Bearing

When the oil is changed in the wheel hub drive or the grease is
changed in the wheel hub bearing, the axial play of the wheel
bearing must be checked and the lock fitting of the wheel locking
nut tested.

8.6.1 Checking the Axial Play of the Wheel Bearing

If axial play is detected in the wheel bearing, an adjustment must

be made. To do so, consult our customer service department.

8.6.2 Checking the Lock Fitting of the Wheel Locking Nut

In order to check this lock fitting:

− for drive axles, (Z 27 961)
∗ the oil must be drained off,
∗ the brake drum (1) must be removed,
∗ the planetary housing (2) must be unscrewed;
− for steered and rigid axles, (Z 27 962)
∗ the wheel hub cap (3) must be unscrewed.
The lock fitting of the wheel locking nut must be checked to en-
sure that it is firmly tightened and is not damaged (Z 27 963).
− If the wheel locking nut is designed as a shaft nut (4) the cylin-
der screw (5) must be checked to ensure that it is firmly tighte-
ned.

Do not use a wrench to perform this check as the cylinder

screw is secured with ”Loctite 270”.

− If the wheel locking nut is designed as a groove nut (6), the

locking plate (7) must be checked for any signs of damage.
If the locking tongue has been sheared off, the locking plate
must be replaced. The lock nut (6a) must then be secured
with ”Loctite 242”.

200−1−4080b 15/23
8

Z 21 530

16/23 200−1−4080b
 Axles 8

8.7 Driven Axles − Changing the Oil

8.7.1 Axles without Drive Differentials (Axle 2 and 5 or Axle

2 and 6)
(Z 21 530)

1. Unscrew drain plug (1) and filler and inspection screw (2).

2. Drain off the old oil, clean the plugs and fit new sealing rings.

3. Screw in the oil drain plug (1). Add fresh oil into the axle hou-
sing until it flows out from the inspection hole. After this,
screw filler plug (2) back in.

The oil in the axle drive should be changed after 10 000 km

(6000 miles), but at the latest, after one year.

200−1−4080b 17/23
8

Z 21 531

Z 21 532

18/23 200−1−4080b
 Axles 8

8.7.2 Axles with Drive Differentials

(Z 21 531 and Z 21 532)

− Axle 4 or 5

1. To change the oil, unscrew the oil drain plug and the oil filler
or inspection plugs (1), (2), (3) and (4).
Drain off the old oil, clean the plugs and fit new sealing rings.
Screw in oil drain plugs (1) and (3).

2. When filling up with fresh oil, first pour it into the idler shaft
until it flows out from inspection hole (4).
Thereafter, pour oil into the axle housing until it flows out from
inspection hole (2).

3. Screw in filler plugs (2) and (4).

The oil in the axle drive should be changed after 10 000 km

(6000 miles), but at the latest, after one year.

200−1−4080b 19/23
8

1
Z 60 465

20/23 200−1−4080b
 Axles 8

(Z 60 465)

− Axle 3

1. To change the oil, unscrew the oil drain plug and the oil filler
or inspection plugs (1) and (2).
Drain off the old oil, clean the plugs and fit new sealing rings.
Screw in oil drain plug (1).

2. In the axle housing, fill up with oil using the oil filler opening
(2) until it runs out of the check hole (2).

3. Screw in filler plug (2).

The oil in the axle drive should be changed after 10 000 km

(6000 miles), but at the latest, after one year.

200−1−4080b 21/23
8

Z 14 048

Z 21 534 Z 9796

22/23 200−1−4080b
 Axles 8

8.8 Suspension Cylinder − Lubricating the Swing Bearing

Lubricate the swing support of the suspension cylinders via the

lubricating nipples (Z 14 048).

If the crane is equipped with a central lubrication system (optional

equipment), the lubricating points of the suspension cylinders are
supplied with grease from the central lubricating pump.

8.9 Wheel hub bearing − change the grease

1. Remove wheel hub (Z 21 534).

2. Clean the wheel hub on the inside and outside thoroughly.

Remove all traces of old grease. Clean the roller bearing and
check to see if it can be used again.

3. Fill the hub cap 3/4 full with grease (Z 9796) and screw on.

The grease should be changed after 10 000 km (6000 miles)

but at the latest,after one year.

200−1−4080b 23/23
 Steering 9

200−1−4090a 1/7
9

a
b

Z 51 906

2/7 200−1−4090a
 Steering 9

9 Steering

9.1 Checking the Tightness of the Steering Components

Check that all screws of the steering transmission components

are fitted snugly (if required, tighten loosened screwed connec-
tions) and check especially for corrosion.

The inspection should be carried out after 10 000 km

(6000 miles), but at the latest, after one year.

9.2 Lubricating the Steering Arm

(Z 51 906)

Grease all lubricating nipples on the steering arm. Clean the lubri-
cating nipples beforehand. Inject fresh grease into the lubricating
nipple until all the old grease is completely replaced by the new.

If the crane is equipped with a central lubrication system (optional

equipment), the steering arm lubrication points are supplied with
grease from the central lubricating pump.

200−1−4090a 3/7
9

Z 14 050

4/7 200−1−4090a
 Steering 9

9.3 Lubricating the Steering Cylinders

If a lubricating nipple is available, grease the swing bearing

(Z 14 050).

If the crane is equipped with a central lubrication system (optional

equipment),the steering cylinder lubrication points are supplied
with grease from the central lubricating pump.

At the same time check the steering cylinders for leaks. The
piston rods of the cylinders can be coated with a thin film of oil.
However, no beads of oil must be allowed to form.

200−1−4090a 5/7
9

Z 29 199

Z 51 907

6/7 200−1−4090a
 Steering 9

9.4 Checking the Axial Play in the Steering Arm Bearing

and Adjusting as Necessary

If axial play is detected in the steering arm, necessary adjust-

ments must be made.

Adjustment procedure:
(Z 29 199)

1. Remove steering rods (3).

2. Undo threaded pins (2) (2 per bearing).

3. Tighten groove nut (1) until the steering arm cannot be mo-
ved any further by hand.

4. Loosen groove nut (1) again until the steering arm can be
moved slightly (Ma = 960 Nm / 708 lbf−ft)

5. Secure groove nut using the threaded pin (2) (Ma = 4 Nm /

3 lbf−ft).

6. Attach steering rods (3) again.

9.5 Checking the Hose Lines

Check all hose lines regularly for damage.

If, during these visual checks, even the slightest damage is disco-
vered, the defective hoses should be replaced immediately.

9.6 Replacing the Hose Lines

Even if no damage is detected, the hose lines must be replaced

at the latest after 2 years.

9.7 Electro−Hydraulic Additional Rear Axle Steering

(Z 51 907)

Check daily that the steering angle sensors of axles 4 and 5 or

4, 5 and 6 (right−hand side) for correct fitting, damage and corro-
sion.

200−1−4090a 7/7
 Brake and Compressed Air System 10

200−1−4100a 1/11
10

Z 21 539

2/11 200−1−4100a
 Brake and Compressed Air System 10

10 Brake and Compressed Air System

Safety instructions

The brakes are a paramount safety system; the brake sy-

stem may fail if work has not been carried out properly.

Service and repair work require specialised knowledge

and may only be carried out by appropriately trained per-
sonnel.
We recommend that an authorised specialist workshop
be used in such cases (e.g. brake repair service)

Vehicles requiring authorisation

The traffic regulations of the land in question must be observed

by those vehicles which are authorised to use public roads. For
this, a special brake check with an internal inspection of the indivi-
dual parts must be undertaken, which entails removing the brake
drum.

Vehicles not requiring authorisation

are to be inspected at least once a year by a specialist in accor-

dance with the appropriate accident prevention regulations.

Repair sets

Various repair sets are available for maintenance purposes.

Only original parts may used.

Wear in brake linings (Z 21 539)

Each new brake lining must be worn in so that it achieves maxi-

mum braking efficiency. This is achieved by interval braking at low
to medium speed; sudden braking is not acceptable for this pur-
pose. The maximum brake drum temperature of 200 °C (392 °F)
may not be exceeded during this procedure. The temperature
rise resultant from any one brake actuation may not exceed 15 %
of the maximum value.
When wearing in new linings, protracted braking and repeated
sudden braking at high speeds are to be avoided.

200−1−4100a 3/11
10

Z 36 580
d

Z 38 189

4/11 200−1−4100a
 Brake and Compressed Air System 10

10.1 Check brake linings for wear

Drum brakes:

1. Remove plug (Z 36 580).

Brake lining wear can be ascertained by looking through the in-

spection holes in the cover plate.

2. Check thickness of brake linings (Z 38 189)

− Changing brake linings: after reaching the wear edge.
− Minimum lining thickness: d = 4.5 mm (0.18 inch).
(Minimum thickness for overlarge brake linings − (neces-
sary for re−lathed drums: d = 5.5 mm (0.22 inch))

The thickness of the brake shoe linings should be checked

every month.

10.2 Renew brake linings

For worn or oiled brake linings always replace both brakes on an
axle and always use a consistent quality of lining per axle.
Ensure that only linings cleared for release are used.

10.3 Perform brake function check

Press brake pedal slowly and check if brake shoe connects with
drum an by means of the inspection holes. The brake shoe must
return to its original position immediately that the brake pedal is
released.

The brakes should be checked every month for proper func-

tion.

10.4 Check expanding cylinder

Every 40 000 km (24 000 miles) the complete expanding cylin-

der assy. should be dismounted.
Clean all parts with spirit or a suitable cleaning agent at the latest
two years after being put into service, replacing all defectives and
spring washers.
Assemble using Paragon EP 2 (DEA) lubricant or equivalent.
At the same time, renew the bellows.

This inspection is to be carried out after 40 000 km

(24 000 miles) or, at the latest, after two years.

200−1−4100a 5/11
10

Z 38 190 Z 3552

Z 14 052 Z 14 053

6/11 200−1−4100a
 Brake and Compressed Air System 10

10.5 Replace brake drums

The brake drums (Z 38 190) may only be worn down to the mini-
mum permitted thickness.
Brake drums may only be re−lathed to a value of max. 0.75 % of
the nominal diameter.

10.6 Replace other brake parts

Compression springs, draw springs and sealing rings, protective

caps and bellows must be replaced at least every two years.

10.7 Draining the Air Tanks

The air tanks need not be drained if they are equipped with an
automatic drain valve (1, Z 3552).

To check that the automatic drain valves are functioning correctly,

the outlet can be opened by pressing in the pin situated in the out-
let.

The valve should be cleaned from time to time, e.g. during the
special brake inspection.

Air tanks equipped with a manual drain must be drained by the

operator (Z 14 052, Z 14 053).

The flip valve opens by pulling or pushing the pin on the drain
valve to the side. Condensed water can then escape from the
tank.

In winter, the air tanks should be drained of water every day.

200−1−4100a 7/11
10

Z 51 908

Z 29 512

8/11 200−1−4100a
 Brake and Compressed Air System 10

10.8 Two−chamber − Air Dryer − Replacing the Cartridges

The air dryer is located in the tub on the right side (driving direc-
tion) of the crane chassis (Z 51 908)

The air system must be depressurised while maintenance

work is carried out.

Unscrew the cartridge (1, Z 29 212) by turning it to the left (if ne-
cessary use strap wrench ø 160 mm (6.3 inch)).

Before screwing in a new cartridge, grease the ring seal lightly

(replace a damaged seal).

The torque of the cartridge is 15 Nm (11 lbf−ft).

200−1−4100a 9/11
10

Z 35 446

4 SH

20 ∅

NNNNNN 4SH 20 DIN 20 023 3Q94

1 2 3 4 5

Z 30 193

10/11 200−1−4100a
 Brake and Compressed Air System 10

10.9 Checking the Hose Lines

(Z 35 446)

Check all hose lines regularly for damage.

If this visual inspection of the hose lines reveals even the slightest
damage, the defective hose line must be replaced immediately.
Examples of possible defects on the hose lines:
1. Damage to the outer layer (1) (areas of abrasion, cuts,
cracks, etc.)
2. Ageing of the material of the outer layer (1) (formation of
cracks)
3. Deformations which do not correspond to the natural form of
the hose line (layers coming away, blistering, crushed points,
kinks, torsioning).
4. Leakage points
5. Requirements regarding installation and positioning not ob-
served (see DIN 20 066 Part 4 ”Installation of Hose Lines))
6. Fixture on the hose fitting (2) damaged.
7. Hose fitting (2) corroded, deformed or damaged.
8. Storage time or duration of use exceeded
(see point 10.10).

10.10 Replacing the Hose Lines

Even if there is no sign of damage, the hose lines must be repla-

ced at the latest after 2 years.

Identification of hydraulic hoses

The hydraulic hoses are marked as follows: (Z 30 193)
− (1) Manufacturer
− (2) Hose type (classification)
− (3) Rated width
− (4) DIN standard designation
− (5) Date of manufacture (quarter and year of production)

200−1−4100a 11/11
 Wheels and Tyres 11

200−1−4110a 1/5
11

Z 21 546

Z 51 910

2/5 200−1−4110a
 Wheels and Tyres 11

11 Wheels and Tyres

11.1 Re−tightening the wheel nuts

(Z 21 546)

The wheel nuts must be re−tightened 50 km (30 miles) after

a wheel change has taken place.

The torque for wheel nuts with pressure discs (M 22 x 1.5) is

600 Nm (443 lbf−ft).

When mounting new wheel nuts ensure that wheel nuts and
wheel bolts are in the same condition as when delivered, i.e.
coated with just a light anti−corrosive oil film.
Oiling and greasing the thread and the supporting surface
(nut / pressure disc) at the above torque leads to overtighte-
ning of the wheel bolts and should therefore be avoided.

11.2 Tyres − checking inflation pressure, tread depth and

tyre damage

Tyre dimension Inflation pressure

14.00 R 25 10 bar (145 psi)
16.00 R 25 9 bar (131 psi)
20.50 R 25 7 bar (102 psi)

11.3 Inspection of Disc Wheels (Rims)

(Z 51 910)

You must carry out a check for cracks at least during the annual
inspection of the crane. If signs of possible cracks or actual
cracks are discovered, the rims affected must be exchanged im-
mediately. These rims should be checked especially for cracks in
the basic material and in the zones marked with arrows.

200−1−4110a 3/5
11

Z 23 373

4/5 200−1−4110a
 Wheels and Tyres 11

11.4 Cleaning the Tyres

(Z 23 373)

Dirt can be removed from tyres using a brush or a jet of water.

Cleaning the wheels using high−pressure cleaners may cause

tyre damage.
This does not depend on the water temperature.
The sides of the tyres are particularly prone to such damage.
The pulsating jet of water causes tyre vibration at the effected
point. The ensuing frictional heat cannot be dissipated suffi-
ciently quickly, resulting in localised overheating and melting.

Omnidirectional nozzles must not be used as they may

cause tyre damage after less than one operational second at
a spraying distance of less than 700 mm (27.56 inch).

In the case of 25° flat jet nozzles and of dirt cutters a mini-
mum spraying distance of 300 mm (11.81 inch) should be
observed. The jet of water should be moved continually to
and fro and not be concentrated upon a single point for any
length of time or directly upon tyre surfaces.

Always replace damaged tyres.

200−1−4110a 5/5
 Hydraulic System 12

200−1−4120b 1/23
12

max

min

Z 51 911

2/23 200−1−4120b
 Hydraulic System 12

12 Hydraulic System

Danger of burns !
Please note that particularly parts of the hydraulic
system can be exposed to very high temperatures under
the coverings. Allow therefore sufficient cooling time or
wear appropriate clothing etc.

12.1 Hydraulic tank − check oil level / top up

(Z 51 911)

The hydraulic tank serves as the common oil supply for the
hydraulic steering component, the outriggers and the hydraulic
suspension.

When checking the oil level:

1. Park the crane on horizontal, level ground.

2. Switch off the engine.

3. The outriggers must be fully retracted.

4. The oil level in the pipe must come up to the marker on the
hydraulic tank.

5. If the oil level is below the marker, the oil must be topped up.

6. Investigate the cause of the oil loss and rectify immediately.

If oil must be added, the return oil filters must subsequently

be checked or replaced at the prescribed intervals. See
section 4, Lubrication and Maintenance Schedule.

200−1−4120b 3/23
12

max

min

Z 51 911

4/23 200−1−4120b
 Hydraulic System 12

12.2 Hydraulic oil reservoir − check filter inserts of the

return oilfilter, exchange if necessary
(Z 51 911)

Each time the oil is topped up or changed, check that the return
oil filters do not become clogged within a short period of time (e.g.
through contaminated oil).
For this, check either the filter elements or the oil grade. This
inspection must always be carried out after approx. 500 km
(300 miles) have been driven.

If the return oil filters are clogged, the filter elements must be
replaced.
Filter elements are removed and fitted as described in
maintenance point 12.3.

200−1−4120b 5/23
12

Z 51 912

Z 7809 Z 7810

6/23 200−1−4120b
 Hydraulic System 12

12.3 Hydraulic oil reservoir − clean and replace barrel and

filterinserts of the return oil filter
(Z 51 912)

The filter units must be removed before the filter barrel can be
cleaned and the filter elements replaced.

Removal

1. Switch off the hydraulic system. The hydraulic system must

be depressurised.
2. Loosen the cover (1) using an auxiliary tool and unscrew.
Take care not to damage the O−ring (5) (Z 32 308).
3. After opening the cover, allow the oil in the filter barrel (7) to
flow into the tank over the filter elements as much as possible
and then pull filter unit (2) on the spring clip (3) from the head
piece. Take care not to damage the O−ring (6) (Z 7809 and
Z 32 308).
4. Press spring clip (3) together until it has disengaged from the
barrel (7) (Z 7810).

200−1−4120b 7/23
12

Z 26 805 Z 7808

8/23 200−1−4120b
 Hydraulic System 12

5. Remove spring clip and valve. Remove filter elements (8)

from barrel (7) and dispose of them observing environmental
protection regulations.
6. Pour the remaining oil from the filter barrel (7) into container
for old oil and rinse the barrel using diesel oil or petroleum
ether (Z 26 805).

Fitting
(Z 7808)

1. Check that O−rings (5) and (6) are in perfect condition.

Replace any damaged parts.

2. Insert new filter elements (8) in the filter barrel (7). Ensure
that the filter elements sit perfectly on top of one another.
Only use original spare parts for filter elements. See the
relevant spare parts catalogue.

3. Place spring clip (3) and valve on the filter element and press
together until it engages in the filter barrel (7) again.

4. Slide the filter unit into the head piece. Take care not to
damage the O−ring (6).

5. Screw on the filter cover (1) by hand. Ensure that O−ring (5)
is perfectly positioned in the groove of the filter cover.
Tighten the filter cover using a suitable auxiliary tool.

Check the filter for leaks by undertaking a trial run of the system.

The filter elements should be changed regularly at the

stipulated intervals, or at the latest, after one year.

200−1−4120b 9/23
12

Z 51 913

Z 29 508

10/23 200−1−4120b
 Hydraulic System 12

12.4 Hydraulic oil reservoir − clean the filler filter

(Z 51 913)

Strainer (2) of the filler can be cleaned as necessary.

12.5 Hydraulic tank − replace the aeration filter

(Z 51 913)

1. Unscrew and remove filter (1).

2. Attach new filter and screw on.

Observe the details given in the Lubrication and

Maintenance Schedule, Sect. 4 regarding intervals for
replacing the filter. The filter must, however, be replaced at
the latest after 5000 operating hours. In the event of
particularly unfavourable environmental conditions, the
aeration filter must be changed more frequently.

12.6 Change oil in hydraulic tank

(Z 29 508)

The crane should be parked horizontally with the engine

switched off. The outriggers must be fully retracted.

1. Unscrew the protection caps (1) from the hose couplings (2)
on the underside of the hydraulic tank.

2. Screw the drain hoses onto the hose couplings.

This releases the cross−sectional through−flow. There is no need
to activate any shut−off valves.

3. Drain off the old hydraulic oil into a suitable container.

4. Clean the hydraulic oil tank.

5. Loosen the hose couplings and remove the drain hoses.

Screw the protective caps back on.
The hydraulic tank is now sealed tight.

6. Pour in fresh hydraulic oil.

Following an oil change, the return oil filters must be

checked and replaced at the prescribed intervals. See
section 4, ”Lubrication and Maintenance Schedule”.

200−1−4120b 11/23
12

Z 16 661

12/23 200−1−4120b
 Hydraulic System 12

12.7 Bleed the hydraulic system

The hydraulic system is bled via the bleeder nozzles provided in

the pipework or the vent screws on the hydraulic cylinders and
hydraulic motors (e.g. Z 16 661).

At points where no vent fittings are provided, the connection

fitting (union nut) can be loosened slightly.

While bleeding the system, with the engine running at slow idling
speed, the vent fittings should be kept open until oil which is free
from air bubbles escapes from the fittings.

In order to avoid damage to seals and hydraulic elements, the

system should be bled while depressurised.

12.8 Inspecting the Hydraulic System

In addition to the visual inspections (e.g. when checking the oil

level), the hydraulic system in the engine compartment should be
inspected once a year. Ensure that all the connection fittings are
not leaking and are sufficiently tight.

Lines and hoses, damaged due to mechanical, thermal or

other influences, must be replaced.

Ensure that all lines and hoses are an adequate distance

from hot engine parts (e.g. turbo charger) and are laid so that
they do not chafe.

200−1−4120b 13/23
12

Z 35 446

4 SH

20 ∅

NNNNNN 4SH 20 DIN 20 023 3Q94

1 2 3 4 5

Z 30 193

14/23 200−1−4120b
 Hydraulic System 12

12.9 Check hoses of the suspension

(Z 35 446)

Check all hose lines regularly for damage.

If this visual inspection of the hose lines reveals even the slightest
damage, the defective hose line must be replaced immediately.
Examples of possible defects on the hose lines:
1. Damage to the outer layer (1) (areas of abrasion, cuts,
cracks, etc.)
2. Ageing of the material of the outer layer (1) (formation of
cracks)
3. Deformations which do not correspond to the natural form of
the hose line (layers coming away, blistering, crushed points,
kinks, torsioning).
4. Leakage points
5. Requirements regarding installation and positioning not
observed (see DIN 20 066 Part 4 ”Installation of Hose Lines))
6. Fixture on the hose fitting (2) is damaged.
7. Hose fitting (2) corroded, deformed or damaged.
8. Storage time or duration of use exceeded
(see point 12.10).

12.10 Replace hoses of the suspension

Even if there is no sign of damage, the hose lines must be

replaced at the latest after 2 years.

Identification of hydraulic hoses

The hydraulic hoses are marked as follows: (Z 30 193)
− (1) Manufacturer
− (2) Hose type (classification)
− (3) Rated width
− (4) DIN standard designation
− (5) Date of manufacture (quarter and year of production)

200−1−4120b 15/23
12

2
6

Z 51 914

16/23 200−1−4120b
 Hydraulic System 12

12.11 Checking the Pre−Set Gas Pressure in the

Accumulators

The pre−set gas pressure in the accumulators should be

checked at ambient temperatures and oil temperatures of
between 10 °C (50 °F) and 30 °C (86 °F).

Before commencing work on systems with pressure

accumulators, the pressure in the hydraulic system must
be released.
Ensure that the systems are definitely depressurised
before commencing work.

The pressure accumulators used in the hydraulic suspension of

the undercarriage are diaphragm−type accumulators with
nitrogen filling.
The corresponding components will only function properly if the
accumulators fitted are charged with the pre−set gas pressure
specified.
This pre−set gas pressure must be checked at regular intervals
(once a year).

In order to check the pre−set gas pressure, a filling and testing

device for bladder and diaphragm−type accumulators is
required.

This check may only be carried out by a specialist who

knows how to work with a filling and inspection device of this
type. Please contact our Service department if a specialist
and for the corresponding equipment is not available.

To test or fill the accumulators, proceed as follows:

1. Start the chassis engine and support the crane on outriggers

with the engine running.

2. Once the crane has been supported properly on the

outriggers, switch the ignition key to the “0” position until the
engine comes to a standstill.

3. Now turn ignition key clockwise up to the first notch to switch

on the ignition, charge control light (B16) must come on.

Once the ignition is switched on, control voltage is available on

the solenoid valves (Z 51 914) in the suspension circuits.

200−1−4120b 17/23
12

43

78 79

80 81

A12 A13 A14

Z 51 915

2
6

Z 51 914

18/23 200−1−4120b
 Hydraulic System 12

4. Depressurise the hydraulic system.

Before depressurising the system, make sure:

− the suspension is not locked (indicator light A12 on display
43, Z 51 915 is out).
− “Retain axles” is not switched on (indicator light A13 in the
display 43, Z 51 915 has gone out).
− “Raise Lift−axle” is not switched on (indicator light A14 in
the display 43, Z 51 915 has gone out).

Press and hold the buttons (78, 79, 80, 81) to relieve all
suspension circuits, the accumulators (2, Z 51 914) must be
completely emptied of hydraulic oil.

5. Now check to make sure that the hydraulic system is actually

depressurised.
To this end, attach pressure gauge (0 to 10 bar) (0 to 145 psi)
to the test nipple (6, Z 51 914).
If there is no pressure reading on the pressure gauge, the
system is depressurised.

If pressure is still displayed, press and hold buttons (78,

79, 80, 81, Z 51 914) again, if necessary loosen the union
nut on the oil connection of the accumulators slightly
and wait until no more hydraulic oil is emitted.

200−1−4120b 19/23
12

Z 30 194

2
6

5
4

Z 39 931 Z 51 914

20/23 200−1−4120b
 Hydraulic System 12

6. Remove the protection cap (1) on the gas valve of the

accumulators (2) and screw on the filling and testing device
(3, Z 30 194).

7. Open the gas valve of the accumulator via the filling and
testing device and read off the charging pressure from the
pressure gauge of the testing device.
The pre−set gas pressure of the accumulators is 55 bar (798 psi)
for an axle load of 12 t (26.4 kip).

8. If the pre−set pressure is insufficient, the accumulator must

be topped up with nitrogen via the filling device (3) up to the
corresponding pre−set pressure (55 bar) (798 psi).
After initial filling, wait for approximately two to three minutes,
check the preliminary tension again and top up as necessary.

When topping up the pre−set gas pressure on the accumulator,

observe the pressure gauge on the test nipple (6, Z 51 914).
The pressure in the corresponding hydraulic suspension circuit
must not increase.
If this is the case, the diaphragm in the accumulator is defective.
The accumulator must be replaced.

Driving with insufficient pre−set gas pressure or defective

accumulators can damage the wheel suspension or axles.
If the initial test reveals a larger decrease (approx. 30 %) in
pre−set pressure, the accumulator must be checked again after
approx. 3 to 4 weeks. If a second measurement shows a fall in
pressure again, the accumulator must be replaced.

− Only NITROGEN must be used for filling the

accumulators. A pressure reducer (5) must be fitted on
the nitrogen cylinder (4, Z 39 931).
− Accumulators must only be repaired by the manufacturer
or an approved workshop.
The accumulator must be officially accepted by an
approved specialist following completion of repairs. A
new test certificate must be drawn up for the
accumulator.

200−1−4120b 21/23
12

22/23 200−1−4120b
 Hydraulic System 12

12.12 Using Biological Hydraulic Oils

− When changing the hydraulic fluid, you must check the tank
for residue.
− It is not permitted to mix other bio−degradable oils
(unsaturated synthetic ester oils and / or rape oil).
− The biological hydraulic fluid must be checked at regular
intervals for serviceability by a lab which is authorised by the
manufacturer of the hydraulic fluid.
With normal use the hydraulic fluid must be inspected at least
after 500 operating hours, after 1000 operating hours and
then every 1000 operating hours; however, it must be
checked at least once a year.
If conditions are more extreme the operating hours are
halved.
− The remaining mineral oil percentage may not exceed 8 % of
the total filling when filling new and used machines with
biological hydraulic fluid.
The hydraulic system must be rinsed with the new hydraulic
fluid with which it is to be filled.

200−1−4120b 23/23
 Outriggers 13

200−1−4130 1/3
13

2 3

Z 32 309 Z 40 775

Z 34 311

2/3 200−1−4130
 Outriggers 13

13 Outriggers

13.1 Lubricating the Sliding Surfaces of the Outriggers

(Z 32 309)

Lubricate the upper guide brackets and the underside of the ou-
trigger struts.

Risk of crushing and shearing !

When extending and retracting the outrigger struts, ob-
serve the procedural instructions given in the operating
instructions for the crane chassis, Section 12 ”Outrig-
gers”
Ensure that there is nobody standing the in the hazar-
dous area.

13.2 Checking the Hose Lines

Check all hose lines regularly for damage.

If, during these visual checks, even the slightest damage is disco-
vered, the defective hoses should be replaced immediately.

13.3 Replacing the Hose Lines

Even if no damage is detected, the hose lines must be replaced

at the latest after 6 years, including a maximum 2 years in sto-
rage.

13.4 Greasing the Slide Rails of the Support Plates

(Z 40 775)

Grease the slide rails of the support plates at the support plate
holders.

This makes pushing the support plates into operating or transport

position easier.

13.5 Lubricating the castors of the outriggers

(Z 34 311)

Lubricate at each outrigger both castors at the respective nipple.

200−1−4130 3/3
 Electrical System 14

200_1_4140b 1/11
14

Z 51 916

Z 32 311

2/11 200_1_4140b
 Electrical System 14

14 Electrical System

14.1 Check the Lighting System

Check that the system is functioning correctly and repair any

faults immediately.

14.2 Service the Battery

The batteries are located on the right side (driving direction)

behind the pneumatic system below the covering (Z 51 916).

Observe the fluid level of the batteries. It may fall rapidly

because the batteries are close to heat radiating crane
components.

For maintenance instructions, see the engine manufacturer’s

operating instructions.

14.3 Lighting Equipment: Replacing a Bulb

Proceed as follows:

1. Remove the appropriate glass and diffusing glass.

2. Remove the defective bulb by turning to the left or by pulling

off the lamp bracket.

3. Fit a new bulb and replace the glass.

Avoid touching the glass in the bulb with your fingers.

Legend: (Z 32 311)
(1) Headlights
(2) Front indicator light
(3) Front indicator light (on the side)
(4) Rotaflare light
(5) Tail light
(6) Plate light

200_1_4140b 3/11
14

4/11 200_1_4140b
 Electrical System 14

14.4 Fuses

The fuses are located in the chassis driver’s cabin in the box of
the central electrics.

Before you replace a fuse, first identify the cause of the fault and
rectify it.
The fuse numbers are indicated on the fuse boxes.

A blown fuse must always be replaced by a fuse with the

same number of amps (as stated on the fuse label).

200_1_4140b 5/11
14

6/11 200_1_4140b
 Electrical System 14

− Carrier (fuses)
A0203
OEC Value/A Location Potential Function
F1 10 15 Ignition steering computer A4200
F2 10 30 Ignition lock
F3 15 30 Lighting stabilizers
F4 10 15 Power supply SPS
F5 10 215 Ignition engine control MR
F6 10 15 Diagnosis plug; control cruise control; ABS; all−terrain
travel; road travel; engine control; optional dolly;
retarder; hand brake signal;
F7 15 30 Horn; hazard switch, reversing light, cabin light;
buzzer; stop light
F8 25 30 Main fuse parking light
F9 15 30 Rotaflare light
F10 15 15 Wiper; flasher; cabin ventilation carrier; rotaflare light;
horn control
F11 10 30 Power supply ADM2−FR
F12 10 15 Ignition gearbox electronics A2110;
F13 10 15 Ignition moki; tachograph
F14 10 30 Power supply retarder
F15 10 CEU CR 15 Ignition retarder lock; diagnosis plug retarder
F16 10 15 Control rear axle steering; raise / lower axle 3; hold axle;
pull up axles; emergency lowering superstructure
F17 10 15 Control fog tail light; back−up fuse for lower beam;
lighting equipment outrigger area; upper beam
F18 5 30 Rear fog light
F19 5 58 Illumination for the dashboard instruments
F20 10 73 Low beam left
F21 25 430 Activation air conditioning compressor
F22 10 91 Power supply steering computer A4200
F23 10 15 Power supply SPS
F24 3 49 Power supply in CAN−BUS cable
F25 10 73 Low beam right
F26 10 79 High beam left
F27 10 79 High beam right
F28 25 30 ABS trailer socket
F29 10 15 Ignition steering computer A4201
F30 10 430 Power supply gearbox electronics A2110

OEC = Operating equipment code

CEU CR = Central electrical unit on carrier

200_1_4140b 7/11
14

8/11 200_1_4140b
 Electrical System 14

A0203
OEC Value/A Location Potential Function
F31 10 15 Ignition SPS − electronics
F32 5 15 Power supply ECU−ABS A4123
F33 10 430 Fan cab for auxiliary heating system
CEU CR
F34 10 91 Power supply steering computer A4201
F35 10 30 Rotaflare light superstructure when controlled from the
chassis

A0204
OEC Value/A Location Potential Function
F1 15 30 Main fuse low beam light
F2 10 58 Parking light; side lamps
F3 10 58 Parking light; license plate light; side lamps
F4 10 430 MOKI central computer; MOKI; combination board
moki; tachograph; diagnosis socket
F5 5 430 Auxiliary heating system clock
F6 15 30 Power supply ABS
F7 15 430 Auxiliary heating system D9W
F8 10 CEU CR 15 Mirror heater; mirror adjustment; seat heating
F9 10 430 Cigarette lighter; radio: free customer connection
F10 5 430 Plug; illumination wiring box
F11 10 91 Air conditioning unit
F12 10 91 Longitudinal differential locks; transverse differential
lock; quick stop; engine running signal; pinning
afterrunning axle
F13 10 91 Suspension locked; switch−over 4−point/3−point
Y4425

OEC = Operating equipment code

CEU CR = Central electrical unit on carrier

200_1_4140b 9/11
14

10/11 200_1_4140b
 Electrical System 14

OEC Value/A Location Potential Function

F0201 2 x 50 CEU CR 430 Main fuse alternator circuit
F0202 2 x 50 Bat 30 Main fuse battery circuit

F0211 10 15 Ignition steering computer axle 7 AC 200−1 PT

F0212 10 91 Electricity supply steering computer axle 7 AC 200−1
PT
F0213 10 15 Ignition steering computer axle 7 AC 200−1 PT
F0214 10 CEU CR 91 Electricity supply steering computer axle 7 AC 200−1
PT
F0215 5 215 Ignition ABS axle 7 AC 200−1 PT
F0216 15 30 Electricity supply ABS axle 7 AC 200−1 PT
F0217 5 15 Electricity supply CAN repeater axle 7 AC 200−1 PT

OEC = Operating equipment code

CEU CR = Central electrical unit on carrier

200_1_4140b 11/11
 Fuel System 15

200−1−4150b 1/15
15

17
Z 51 917

2/15 200−1−4150b
 Fuel System 15

15 Fuel System

From the fuel system of the crane chassis the diesel engine in the
crane superstructure and the heater are also supplied.

15.1 Fuel Tank − Draining Off Water and Sediment

(Z 51 917)

To drain off the water, remove the drain plug (17) and drain off at
least 1 l (0.26 gal) of fuel.

In winter this procedure should be carried out every week after

an 8 hour lay off of the crane.

200−1−4150b 3/15
15

15

17

15 2
Z 51 918

18 2 17 15 3 4 5 8

8
17
Vorlauf zum OW−Tank

2
15

0,1bar
3

4 5
6
7

7
Rücklauf vom OW−Tank

18
6
13
0,25bar

9
14
0,1bar

10
15

11

16
1

12
Motorkreislauf

14 1 15 16 9 10 13 11 12

Z 51 919

4/15 200−1−4150b
 Fuel System 15

15.2 Checking the Fuel System

In addition to the visual inspections (e.g. checking the oil level),

the fuel system in the engine compartment should be inspected
once a year. The following points must then be checked:
− All system fittings must be free of leaks and sufficiently tighte-
ned.
− With re−usable fittings, the hose on the connection to the
hose nipple must be a tight fit. If in doubt, secure the hose ad-
ditionally with a hose clamp or replace the hose completely.

Lines and hoses, damaged due to mechanical, thermal or

other influences, must be replaced.
Ensure that all lines and hoses are at a sufficient distance
from hot engine parts (e.g. turbocharger) and are laid so that
they do not chafe.

Fuel system schematic (Z 51 919)

Legend:
1 fuel tank with strainer
2 preliminary filter separator with manual fuel pump
3 telligent engine control unit (cooled with fuel)
4 fuel pump
5 fuel filter
6 plug−in pumps
7 high−pressure lines
8 injection nozzles
9 pressure regulating valve
10 return to tank via throttle bore with permanent ventilation
11 leakage fuel of the injection nozzles
12 flushing amount of plug−in pumps
13 Zusammenführung Rücklauf (einschl. Filterleerlaufleitung)
14 return to tank
15 throttle check valve 0.1 bar (1.45 psi) (tank outlet safety)
16 fuel drainage for filter change
17 Electric fuel pump for superstructure tank
18 pressure limit superstructure fuelling

200−1−4150b 5/15
15

43

Z 51 920

Vorlauf zum OW−Tank

17
2 7
8

3
15
6
4 5
2 0,1bar
Rücklauf vom OW−Tank

18
13
0,25bar

9
14
0,1bar
10

16 1
15

16
11

12
Motorkreislauf

2
16

3
5

10 6

7
8
Z 51 921

6/15 200−1−4150b
 Fuel System 15

15.3 Refuelling
(Z 51 920)

The tank level can be checked on the fuel level indicator in the
display of the multiple function display (43).
If necessary, refill the fuel tank at the nozzle after removing the
filler cap (1).

In order to avoid contact with harmful substances, it may

be necessary to wear protective clothing when filling the
diesel tank.
Ensure that there is sufficient ventilation.

If an additional tank is fitted on the crane chassis, the crane chas-

sis is refuelled using the filler necks of the additional tank of the
crane chassis (see section 15.5).

15.4 Maintaining the Fuel Filter

(Z 51 921)

2 preliminary fuel filter with separator

5 fuel filter

16 shut−off valve

The fuel filter in the diesel engine must be drained by open-

ing the shut−off lever (16) before it can be changed.
Once all the fuel has been drained off, carefully close the
shut−off lever. Pull the lever off the shut−off valve and place
in the toolbox.

15.4.1 Draining the Preliminary Fuel Filter

Water is heavier than diesel fuel, you can see it at the bottom of
the inspection glass (7) as a differently coloured liquid. The in-
spection glass (7) must be drained before the bottom of the filter
element (6) gets contaminated. Drain the water collected in the
inspection glass (7) daily

1. Open the drain valve (8) and activate the feed pump (3).
Then close the drain valve again.

200−1−4150b 7/15
15

16
3

10

8
Z 51 922

8/15 200−1−4150b
 Fuel System 15

15.4.2 Changing the Preliminary Fuel Filter Filter Element

(Z 51 922)

The filter element of the preliminary fuel filter may only be

changed when the fuel tank has been either fully or partially
drained.

The changing intervals for the filter element depend on the conta-
mination of the fuel. Clogging of the filter leads to decreased fuel
feed , resulting in loss of performance and starting difficulties.
The element must be replaced if there is a marked loss of perfor-
mance.

We recommend you always have a substitute filter as just one

tank of heavily contaminated fuel can clog a filter up.

1. Open shut−off lever (16) and drain fuel into a prepared con-
tainer. Then close the shut−off lever again.

2. Open the drain valve on the fuel filter and drain some fuel.

3. Twist the filter element (6) with the inspection glass (7) from
the filter head (10). Remove the filter element (6) and clean
the sealing surfaces of the O−ring.

4. Coat the O−ring with fresh fuel or some grease. Screw the
inspection glass (7) onto the new filter element (6) and screw
both hand−tight onto the filter head (10). Do not use any
tools for tightening.

5. Activate the feed pump (3) with open vent screw (5) until the
fuel flows out of the vent screw. Close the vent screw, start
the engine and look out for leaks. If necessary, make any cor-
rections with the engine switched off.

200−1−4150b 9/15
15

1 2 5
7
8
9
6

Z 51 923

105106107

92 93 94 95 96 97 98

99100101102103104

Z 51 924 Z 51 925

10/15 200−1−4150b
 Fuel System 15

15.5 Additional Tank 300 l (79.3 gal) (optional)

15.5.1 Refuelling
(Z 51 924)

The crane chassis is filled up using the filler necks (9, Z 51 924)
of the additional tank.

You can check how much is in the chassis tank on the fuel gauge
in the display of the multi−function display (43).
If necessary, refill the fuel tank at the nozzle after removing the
filler cap (9).

In order to avoid contact with harmful substances, it may

be necessary to wear protective clothing when filling the
diesel tank.
Ensure that there is sufficient ventilation.

Refuelling procedure (Z 51 923; Z 51 925)

1. Fill up the additional tank(6).

2. Switch on the fuel pump “2” (7) using switch (97).

The fuel pump “2” only starts pumping once there is enough fuel
in the additional tank (6) and the main tank (1) is empty enough.

3. The refuelling procedure is automatically completed when

the additional tank is empty and / or the main tank is full.

However, the refuelling procedure can also be started or finished

at any time by pressing switch (97).

200−1−4150b 11/15
15

5
6
10

Z 51 926

12/15 200−1−4150b
 Fuel System 15

15.5.2 Maintenance of the Preliminary Fuel Filter

(Z 51 926)

Draining the Preliminary Fuel Filter

Water is heavier than diesel fuel, you can see it at the bottom of
the inspection glass (7) as a differently coloured liquid. The in-
spection glass (7) must be drained before the bottom of the filter
element (6) gets contaminated. Drain the water collected in the
inspection glass (7) daily

1. Open the drain valve (8) and activate the feed pump (3).
Then close the drain valve again.

Changing the Preliminary Fuel Filter Filter Element

(Z 51 926)

The filter element of the preliminary fuel filter may only be

changed when the additional fuel tank is empty.

The changing intervals for the filter element depend on the conta-
mination of the fuel. Clogging of the filter leads to decreased fuel
feed, resulting in loss of performance and starting difficulties. The
element must be replaced if there is a marked loss of perfor-
mance.

We recommend you always have a substitute filter as just one

tank of heavily contaminated fuel can clog a filter up.

1. Open the drain valve on the fuel filter and drain some fuel.

2. Twist the filter element (6) with the inspection glass (7) from
the filter head (10). Remove the filter element (6) and clean
the sealing surfaces of the O−ring.

3. Coat the O−ring with fresh fuel or some grease. Screw the
inspection glass (7) onto the new filter element (6) and screw
both hand−tight onto the filter head (10). Do not use any
tools for tightening.

200−1−4150b 13/15
15

14/15 200−1−4150b
 Fuel System 15

4. Activate the feed pump (3) with open vent screw (5) until the
fuel flows out of the vent screw. Close the vent screw, start
the engine and look out for leaks. If necessary, make any cor-
rections with the engine switched off.

200−1−4150b 15/15
 Cooling, Air Intake and Exhaust System 16

200−1−4160b 1/15
16

Z 51 927

1 2

Z 42 107 Z 4965

2/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

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.

Clean the filter elements as soon as the maintenance switch (1)

for the running engine is in the red field (Z 51 927).

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.

200−1−4160b 3/15
16

Z 0 406 Z 39 941

Z 39 942

4/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

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 (73 psi)

To this end, a pipe should be connected to the compressed air

pistol, the end of which is bent through approx. 90°. It must be
long enough for it to reach the cartridge floor (Z 39 941).
Blow out the cartridge with dry compressed air (max. 5 bar /
73 psi) from the inside outwards by moving the pipe up and down
in the cartridge until there is no further sign of dust.

16.1.2 Wet Cleaning

First soak the filter element in hand−hot water with a non−foa-

ming detergent additive (Mann detergent 053) for 10 minutes.
Then agitate the element in the washing solution for approx. 5 mi-
nutes.

Rinse well in clear water, shake and allow to dry at room tempera-
ture (Z 39 942).

Under no circumstances should petrol, alkaline solutions

or hot liquids be used for cleaning.

200−1−4160b 5/15
16

Z 0130 Z 0131

Z 501 336

6/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

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 (73 psi).

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.

16.2 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.

200−1−4160b 7/15
16

7 1

Vehicle
heating

Th.

Engine OM502LA
Aufuell/Ausgleichsltg
Water cooler
Charge cooler

6 2 5 3 4
Z 51 928

Z 51 932

8/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

16.3 Cleaning the Cooling System

Risk of burning and scalding.

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

Legend (Z 46 490):
1 Expansion tank
2 Water cooler
3 Transmission
4 Gear heat exchanger
5 Diesel engine
6 Charge cooler
7 Vehicle heating

Pass compressed air through the cooling system (Z 51 932)

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 completely 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.

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.

200−1−4160b 9/15
16

Z 51 929

10/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

16.4 Checking the Coolant Level and Topping Up as Ne-

cessary
(Z 51 929)

Open the cap of the engine cooling system only when the
engine has cooled down. Otherwise the system is under
pressure. Accidents may occur.

1. For safety reasons, turn cover (1) on the expansion tank up

to the first lock and if required, let off any overpressure.

2. Continue to turn to the second notch and remove the cap.

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 antifreeze.

See also the engine manufacturer’s operating instructions.

200−1−4160b 11/15
16

Z 51 929

12/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

16.5 Replacing the Coolant with Anti−Freeze

(Z 51 929)

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.

2. To be on the safe side, turn the cap on the expansion tank (1)
slowly to the first notch so that any excess pressure can be
released. Only then turn the cap further to the 2nd notch and
remove.

200−1−4160b 13/15
16

2
Z 51 930

5
4
Z 51 931 Z 39 946

14/15 200−1−4160b
 Cooling, Air Intake and Exhaust System 16

3. Empty engine (5) and cooler (2 Z 51 930).

− To drain the engine the drain plug on the crankcase on the
right−hand side (Z 39 946) and on the oil cooler should be
opened.

The position of the drain plugs on the engine is shown in the en-
gine manufacturers operating instructions supplied, in Section
“Replacing Coolant” .

− To drain the cooling system, the following drain plugs must be

opened:
∗ Water drain plug on the heat exchanger (4, Z 51 931)
∗ Drain plug on the water cooler (3, Z 51 930)
4. When the cooling system has been drained, all the drain
plugs should be screwed back in 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 coolant
level is able to penetrate and settle. Any trapped air can also
escape.

Add coolant until the expansion tank (1, Z 39 944) is filled com-
pletely.

6. Start the engine and allow to run at idling speed for one mi-
nute with the expansion tank (1) open. If necessary,
7. Switch off the engine and top up the coolant to the max. posi-
tion in the expansion tank (1).
8. Start the engine again and allow to run at idling speed for one
minute with the expansion tank open. Check the coolant le-
vel and top up if necessary.
Replace the cover on the expansion tank.
Check the engine temperature during the warm−up phase. If
the operating temperature is reached, check the coolant le-
vel and top up if necessary.

200−1−4160b 15/15
 Piston Rods 17

17 Piston Rods

17.1 Exposed Chrome Surfaces − Applying Protective

Grease

Despite being of the highest quality, surfaces may be susceptible

to corrosion in an aggressive environment. If the crane is out of
operation for more than one day, exposed surfaces should be
protected against corrosion by applying acid free protective
grease (Recommended: ”Decordyn 350”, Order No. for spray
can: 604 106 40).

200−1−4170 1/1
 Driver’s Cab 18

200−1−4180 1/3
18

Z 51 933

2/3 200−1−4180
 Driver’s Cab 18

18 Driver’s Cab

18.1 Checking the Windscreen Washing Assembly

Check at least once a week that the windscreen washing assem-

bly is functioning properly.

18.2 Filling Up the Supply Tank of the Windscreen Was-

hing Assembly

The supply tank of the windscreen washing assembly must al-

ways be filled with water and if necessary with a little cleaning
agent (Z 51 933).

Before the onset of winter, a suitable amount of antifreeze

(depending on the temperature) must be added to the water.

200−1−4180 3/3
 Crane Chassis 19

19 Crane Chassis

19.1 Visual Checks

The following points should be checked every day before the

crane is driven:
− Check the hydraulic system for leaks and damage and check
the oil level.
− Check all covers and panels for damage, loose or missing
screws.
− Check the engine for oil and fuel leaks and for clogging.
− Check the oil cooler for clogging.
− Check the instruments and displays for damage.
− Check the lighting system for damage.

200−1−4190 1/1
 Optional Equipment 20

200−1−4200a 1/15
20

Z 26 829

Z 27 501

2/15 200−1−4200a
 Optional Equipment 20

20 Optional Equipment

20.1 Lubricating the Dolly Coupling

”ROCKINGER”
(Z 26 829)

The dolly coupling should be lubricated in the uncoupled position,

i.e. with the pins up, to avoid the pins being greased.

”RING SPRING”
(Z 27 501)

The dolly coupling should be lubricated via the lubricating nipple

at the lock (2) in the uncoupled position.

200−1−4200a 3/15
20

Z 27 502

Z 7232 Z 7233

4/15 200−1−4200a
 Optional Equipment 20

20.2 Servicing the Dolly Coupling

”ROCKINGER”

If, when disengaging the coupling and engaging the second

lock−in position, the release gear does not automatically lock in
the receiving jaw, the jaw should be moved into its centreline po-
sition. The centreline position can be set correctly by releasing
the three bolts (1, Z 7232) on the base and re−tightening them
when the release gear locks in the notch of the jaw.

By thoroughly shaking the coupling (holding the complete cou-

pling head and not just the jaw), check that the rubber springs are
sufficiently pretensioned to ensure that the coupling is firmly sea-
ted. If necessary, the coupling can be re−tightened by replacing
the two rubber springs and the two taper adapters.

Ensure that the castel nut is well greased to protect it from rust.
If necessary, completely grease the castel nut (Z 7233).

”RING SPRING”

To restrict wear on the coupling bolt (3) and the coupling ring (4),
we recommend that these parts be kept constantly clean and well
greased (Z 27 502).

The bearing of the towing bar is maintenance free.

200−1−4200a 5/15
20

Z 38 287

6/15 200−1−4200a
 Optional Equipment 20

20.3 Central Lubrication System

(Z 38 287)

20.3.1 Filling the Tank

Fill up the container (2) of the central lubricating system regularly

up to the ”max” mark, always using filling nipple (4). To do so, use
a commercial grease pump or lever type hand gun.

The grease must be free of impurities and must not change

its consistency over a period of time.
Never fill above the maximum level.

Let the pump run while filling up (see part 2, section 16.4 ”Additio-
nal Lubrication”).

The lubrication container is filled up with high pressure lubricating

grease (see section 2 of these lubrication and maintenance in-
structions). The pump can need up to 10 minutes running time
after it has been fully emptied in order to achieve the full feed ca-
pacity.

20.3.2 Checking the System

Activate one or more additional lubrications and then check:

− the lines for leakages
− the lubricant emission at all lubricating points
− time setting of the control

20.3.3 Cleaning the System

To clean the system use petroleum ether or kerosene.

The synthetic material of the pump tank (2) may be damaged

if it comes into contact with trichloroethylene, acetone or
other similar cleaning agents and thinners.

200−1−4200a 7/15
20

F 33
F5 F7

Z 51 934

Z 39 948

8/15 200−1−4200a
 Optional Equipment 20

20.4 Auxiliary Heating System ”D9W”

It is vital to observe the manufacturer’s operating instruc-

tions for the Eberspächer hot water heater D9W.

20.4.1 Checking the System is Functioning Correctly

Even outside of the winter months, switch on the heater briefly

(for approx. 10 seconds) roughly once a month. This prevents the
water pump and burner motor from seizing up.

Do not use the heater in enclosed spaces.

If the heater assembly fails to start when switched on, proceed

as follows:

1. Check the fuses

− F 7 = 15 A
− F5=5A
− F 33 = 10 A
in the central electric system between the seats in the dri-
ver’s cabin (Z 51 934).

2. Check the glow plug (5, Z 39 948).

Replace the glow plug if necessary (”Checking the Glow
Plug”, see Sect. 20.4.1.2).

3. Switch the heater system on and off again

But not more than twice. If the heater still fails to work, have
the fault repaired in a workshop.

200−1−4200a 9/15
20

2
Z 51 935

30

28
32 11
17
10 30 14

Z 40 050

10/15 200−1−4200a
 Optional Equipment 20

20.4.1.1 Checking the Fuses

(Z 51 935)

The fuses used in the central electric system are arranged as fol-
lows:

1. Fuse 15 amp: for heater assembly

2. Fuse 5 amp: for operation

3. Fuse 10 amp: for fan in cab

If the 10 amp fuse is faulty, the heater assembly starts but no

warm air is circulated.

After checking, the defective fuse must be changed.

20.4.1.2 Checking the Glow Plug

(Z 40 050)

1. Remove control device (28).

2. Remove plug cap (14), release hexagonal nut M 4 (11) and

remove spark cable (32).

3. Unscrew glow plug (10) with a wrench SW 19 across flats.

4. Check and clean the glow plug, replace if necessary.

− Before fitting the glow plug, unblock the plug bore in the plug
connector with an angle hook and clean.
− With the glow plug removed, blow through the fuel connection
and the plug ventilation with compressed air (less than 5 bar
/ 73 psi).

5. Screw in glow plug (10).

6. Screw spark cable (32) back in and screw on plug flap (14).

7. Stick new seal (17) on the control device (28).

8. Fit the control device (28) with seal (17) on the heater assem-
bly and tighten with screws (30).

200−1−4200a 11/15
20

14

Z 40 771

12
Z 40 052 Z 51 929

12/15 200−1−4200a
 Optional Equipment 20

20.4.2 Replacing the Heat Exchanger

The heat exchanger (12, Z 40 052) has a life span of ten years
and must be replaced after this period with an original spare by
the manufacturer or by an approved workshop. The heater as-
sembly should then be labelled with the purchase date of the heat
exchanger and the words ”original spare part”.

20.4.3 Replacing the Fuel Filter

1. Release the two hose clips from the fuel filter

(Z 40 771).

2. Remove the hoses from the fuel filter.

3. Insert the new filter.

If the fuel tanks are full, the hose between the fuel filter and the
fuel tanks should be disconnected before releasing the hose
clips.

20.4.4 Bleeding the System

After any work on the cooling system (repairs, changing the coo-
ling water), the entire cooling system including the heater assem-
bly must be bled free of any air bubbles. For this, allow the engine
of the crane chassis to run until air bubbles no longer form in the
expansion tank (1, Z 51 929).

All water connections (clamps) must be tightened so that they are

sealed completely and re−tightened after approx. 100 kilometres
(60 miles).

200−1−4200a 13/15
20

Z 46 542

14/15 200−1−4200a
 Optional Equipment 20

20.5 Air Conditioning Equipment

20.5.1 Switching On the Air Conditioning Equipment

To lubricate the compressor, the air conditioning equipment must

be switched on at least once a month for approx. 10 minutes.

20.5.2 Servicing the Air Conditioning Equipment

At the beginning, in the middle and at the end of the summer

months, the following maintenance work must be carried out:

1. Check the V−belt tension and compressor mounting.

2. Check the refrigerant level.

Here, with the engine running and the air conditioning equipment
on full (control knob, located in the cab, for temperature selection
and fan level moved to maximum), the refrigerant must flow wi-
thout air bubbles through the inspection glass (1) of the liquid
tank (Z 46 542).
After switching off, the liquid level should drop back into the tank
again. This is the only way to ensure that the system has not been
overfilled.

The air conditioning equipment may only be filled by a spe-

cialist workshop.

The electrics for the air conditioning equipment are located in the
main distributor box ”X300” of the driver’s cab.

20.5.3 Having the Air Conditioning Equipment Checked

To ensure that the air conditioning equipment functions correctly,

it must be inspected at least once a year by a specialist workshop.
We recommend that this is done at the beginning of the summer
period.

200−1−4200a 15/15