CC2800 62151 Part1 - en

Manufacturers Specifications
The operating, lubricating and maintenance instructions and

mounting manual included here are valid for the mobile crane de-
tailed below.
A quality management system as per DIN EN ISO 9001 forms the
basis of this cranes construction and its manufacture.
Crane classification Mobile crane

(as per DIN 15018)
(as per DIN 150012)
Crane type CC 2800
Construction number 62 151
Maximum load 600 t
Manufacturer Demag Mobile Cranes
0621001151 1/1
Foreword
Foreword
For you,
the owner of this crane manufactured by us, we have summa-

rised the most important instructions for the operation, lubrica-
tion and maintenance of the machine in this manual.
These instructions enable you to familiarise yourself with your
crane and to use the operating applications as intended. The
instructions must always be kept at hand at the operating site.
Hand over this manual to the crane operator and to the special-
ised personnel responsible for the maintenance of the crane
with the request that they read the instructions before working on
or with the crane for the first time and later at regular intervals.
Important instructions are included which ensure that the crane
is operated safely, correctly and economically.
Your observation of these instructions helps to both avoid dan-
gerous situations, repair costs and downtimes and to increase
the reliability and service life of your crane.
Periodic preventive inspection and maintenance are the surest

way to keep your crane in good operating condition at all times.
The early recognition and elimination of minor irregularities and
the immediate replacement of worn and damaged parts prevents
downtimes and their associated costs. Also replace any dam-
aged signs or symbols.
You will appreciate that we can accept no claims for damage or

malfunctions attributable to improper use and operation and/or
inadequate maintenance.
Please note that the information contained in this manual corre-
sponds to the state of machine engineering at the time the litera-
ture was drawn up. Deviations in the technical specifications, fig-
ures and dimensions are therefore possible.
Should you discover any mistakes when reading this manual or
if you have further suggestions and hints, please contact:
Demag Mobile Cranes
Abt. 8333
Postfach 1552
D 66465 Zweibrcken
Fax: (49)06332/831639
The editors are looking forward to your cooperation under the slo-
gan
Putting practice into practice
0621002151_en 1/11
2/11 0621002151_en
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.
Any blank parts are protected by preserving wax.
If the crane is supplied from the works with a paint protection
coating (preserving wax), this does not necessarily have to be re-
moved. It provides added protection against corrosion.
The preserving agent can be removed using:
Washing thinners, e.g. Conrad thinners RV 5339 E 45430;
Cold cleaners, e.g. Allpur 150 X or Purtex 65;
Steam spray gun.
Before commissioning
you should subject the crane to a thorough inspection by our ser-

vice 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 Demag spare and wear parts.
0621002151_en 3/11
Z 35 020e
4/11 0621002151_en
Foreword
Service
Please contact the service department if you have any questions

about your crane. Always quote the type designation and
construction number of your crane in all correspondence.
Tel: (49)06332/830
Fax: (49)06332/16715
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.
Warranty
(Z 35 020)
Observe here the information on the opposite page.
0621002151_en 5/11
6/11 0621002151_en
Foreword
...and you can find your way around this manual as follows:
From the example given here see how fast and accurately I arrive
at the required information.
WHAT do I want to know ?

I would like to know, for instance, what control elements are
provided for the Electronic Crane Information System
(ECIS).
WHERE do I find the information required ?

The complete documentation comprises 4 parts:
Part 1 operating instructions
Part 2 lubrication and maintenance instructions
Part 3 mounting instructions
Part 4 various
These parts are divided by index sheets. I need part 1 since the
load limit device are part of the operating instructions.
1. I look for the index sheet 1 (for part 1) and open the operat-
ing instructions at this point.
2. I skip over the foldout table and foreword and find the con-
tents for part 1.
3. I glance over the bold headings of the sections until I come

to Section 8, Operating the safety equipment.
4. In Section 8, I then find, Electronic Crane Information

System (ECIS) under 8.1.2.
The page details on the righthand side of the page refer to
the number of pages within the section.
0621002151_en 7/11
Z 26 350
8/11 0621002151_en
Foreword
HOW do I find the page in Section 8 ?
1. I take the pages of part 1 as shown in (Z 26 350) and flick

through the pages.
Whilst doing this, I always keep the top righthand side
(1, Z 26 350) in view.
As soon as the required section number appears, I stop flick-
ing through the pages.
The name and number of the section are on the top righthand
side (1, Z 26 350) of each page.
2. Then, with the help of the page number on the bottom right
hand side, I decide whether I must flick backwards or for-
wards in order to reach the page number required.
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 with
reference to the total number of pages in the section. This
means, for instance, that 5 is given as the page number in the
contents and the page itself is numbered 5/47. This makes for
better orientation within a section.
Please note that the option of targeted access for specific in-
formation described above does not exempt you from read-
ing the instructions carefully and in full before the crane is
operated for the first time and at regular intervals afterwards.
0621002151_en 9/11
10/11 0621002151_en
Foreword
In this operation manual you will find the titles or the respective
symbols Danger, Caution and Note used as follows:
DANGER !
Danger is used if performing an operation, a mounting

procedure etc. NOT according to the prescriptions given
may cause death or injuries of human beings.
CAUTION !
Caution is used if performing an operation, a mounting

procedure etc. NOT according to the prescriptions given
may cause damages of the crane or parts of it.
NOTE:
Note is used for marking an important operation or mounting

procedure as well as for additional information.
There are two foldout panels for the cab.

You should fold out these panels when reading the operating
instructions.
Information such as left and right of the crane must always be

understood as looking in the direction of travel.
0621002151_en 11/11
Contents
Folding Table Crane Cab
Foreword
Contents
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Operating Conditions and Computed Design of the Crane . . . . . . 5
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.3 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.4 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.5 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.6 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 11
1.3.7 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4.2 Selection and Qualifications of Personnel . . . . . . . . . . . . . . . . . . . . 17
1.4.3 Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.3.1 Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.3.2 Gas, Dust, Steam, Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.3.3 Crushing / Collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.3.4 Snagging / Dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.3.5 Crushing / Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.3.6 Hazards due to Slipping, Stumbling, Falling . . . . . . . . . . . . . . . . . . . 23
1.4.4 Combination of Hazards with Combined Operation of Two or
More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.4.1 Operating Areas of Several Cranes Overlap . . . . . . . . . . . . . . . . . . 27
1.4.4.2 Raising a Load Using More than One Crane . . . . . . . . . . . . . . . . . . 29
1.4.5 Before Operating the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4.6 During Operation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.4.7 After Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.4.8 When Mounting and Dismantling Crane Components . . . . . . . . . . 43
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 51
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 53
1.6 Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Structure of the Crawlermounted Crane . . . . . . . . . . . . . . . . . . 3

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Boom Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0621003151_en 1
Contents
2.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.5.1 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.2 Pump Distributor Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.3 Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.4 Slew Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.5 Winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.6 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.7 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.8 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.9 Drive Gearbox (Undercarriage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Crane Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Addon Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.1 Attachment console PDCDisplay . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.1 Lefthand Console D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.2 Multifunction Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Engine and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.1.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2 Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Starting Up, Operating and Shutting Down the Power Units . . . . . 9
5.2.1 Checks before Starting the Diesel Engines . . . . . . . . . . . . . . . . . . . 9
5.2.2 Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.1 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.2 To be observed following starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3.3 Warming Up the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3.4 Warmingup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3.5 Checks with the Diesel Engine Running . . . . . . . . . . . . . . . . . . . . . . 19
5.3.6 Notes on Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.7 Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Driving the Crawlermounted Crane . . . . . . . . . . . . . . . . . . . . . . 3

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.1 Main Direction of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.1.2 Requirements for the Road Surface . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1.3 Regulations for Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.2 Steering the Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.1 Steering Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.2 Option for Regulating the Driving Speed and the Drive Force . . . 11
6.3 Driving without Load on Horizontal and Sloping Ground . . . . . . . . 15
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Driving the Crane without Load
Application SH, SH/LH, SSL, SSL/LSL . . . . . . . . . . . . . . . . . . . . . . . 17
0621003151_en 2
Contents
6.5 Driving the Crane without Load Application SW . . . . . . . . . . . . . . 19

6.6 Driving the Crane without Load Application SWSL . . . . . . . . . . . 23
6.7 ....................................................... 27
6.8 ....................................................... 27
6.9 ....................................................... 27
6.10 ....................................................... 27
6.11 Driving with Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.11.1 Driving with Load, Boom Along the Longitudinal Axis of the
Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.11.2 Driving with Load, Boom Not Along the Longitudinal Axis of the
Crawlers
(Positioning Loads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 Slewing and Braking the Superstructure . . . . . . . . . . . . . . . . . . 3

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.1.1 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2 Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Braking the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.4 Mechanical Locking of the Parking Brake in the Open Position . . 7
8 Operating the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.2 Electronic Crane Information System (ECIS) . . . . . . . . . . . . . . . . . . 5
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.2.2 Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2.3 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2.4 Description of displayed pictures and buttons . . . . . . . . . . . . . . . . . 19
8.3 Operating the Electronic Crane Information System (ECIS) . . . . . 41
8.3.1 Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.2 Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.3 Entering the Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3.4 Setting the Configuration Programs for the self assembly of
the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3.5 Entering the Reeving Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.3.6 Synchronous Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.3.7 Entering the Load on the 2nd Hook
(Twohook Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3.8 Load Monitoring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.3.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3.10 Tilt Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.11 Relative Working Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.4 Bridging the Load Limit Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.4.1 Bridging the ShutOff Function for Movements Which Reduce
the Load Moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.4.2 Bridging the ShutOff Function for all Movements . . . . . . . . . . . . . 89
8.5 Limit Switches for Switching Off Various Crane Functions . . . . . . 91
8.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.5.2 Functions of the Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.5.3 Crane Functions Which Are Shut Down When the Limit Switches
Are Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
0621003151_en 3
Contents
9 Working with the Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . 3

9.1 Simultaneous Crane Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.2 Operating Hoist 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.2.2 Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.2.3 Operating at Level 1 (Normal Speed) . . . . . . . . . . . . . . . . . . . . . . . . 7
9.2.4 Operating at Level 2 (High Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.5 Crane Operation with Double Hook Block, Hoist 1 and Hoist 2 in
Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.6 Operating the Derricking Gear (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.6.2 Operating the Derricking Gear (E) when Erecting and Lowering
a Boom Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.6.2.1 Simultaneous Operation of Derricking Gear (E) and Luffing Gear 1
(W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.6.2.2 Simultaneous Operation of Derricking Gear (E) and Luffing Gear 2
(W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.6.3 Operating the Derricking Gear (E) during Crane Operation . . . . . 35
9.6.3.1 Simultaneous Operation of Derricking Gear (E) and
Hoist 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hoist 2 (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hoist 3 (H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.6.4 Operating Range of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.7 Operating Luffing Gear 1 (W1 = OE) . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.7.2 Operating Luffing Gear 1 (W1) when Erecting and Lowering a
Boom Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.7.2.1 Simultaneous Operation of Luffing Gear 1 (W1) and Derricking
Gear (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.7.2.2 Simultaneous Operation of Luffing Gear 1 (W1) and Luffing
Gear 2 (W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
0621003151_en 4
Contents
9.7.3 Operating Luffing Gear 1 (W1) during Crane Operation . . . . . . . . 51

9.7.3.1 Simultaneous Operation of Luffing Gear 1 (W1) and
Hoist 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hoist 2 (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hoist 3 (H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.7.4 Operating Range of the Fly Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.8 Operating Luffing Gear 2 (W2 = OE) . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.8.2 Operating Luffing Gear 2 (W2) when Erecting and Lowering a
Boom Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.8.2.1 Simultaneous Operation of Luffing Gear 2 (W2) and Derricking
Gear (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.8.2.2 Simultaneous Operation of Luffing Gear 2 (W2) and Luffing
Gear 1 (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.8.3 Operating Luffing Gear 2 (W2) during Crane Operation . . . . . . . . 63
Hoist 1 (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hoist 2 (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hoist 3 (H3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.8.4 Operating Range of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.9 Operating the Reeving Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.10 Working with the Superlift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.10.2 Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.10.3 Measuring the Derricking Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.10.4 Operating the Crane without a Superlift Counterweight . . . . . . . . . 79
9.10.5 Operating the Crane with the Superlift Counterweight . . . . . . . . . . 81
9.10.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.10.5.2 Raising, Slewing and Setting Down the Load with the Working
Radius Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.10.5.3 Raising, Extending the Working Radius and Setting Down the
Load without Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . 87
9.10.5.4 Raising, Reducing the Working Radius and Setting Down the
Load without Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . 93
9.10.6 Safety Instructions for Working with the Superlift . . . . . . . . . . . . . . 99
9.11 Working Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.11.2 Positioning the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.12 Wind Speeds Dynamic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.12.2 Crane under Load (Crane Operation) . . . . . . . . . . . . . . . . . . . . . . . . 109
9.12.3 Parking the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.12.4 Lowering the Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
0621003151_en 5
Contents
10
11 Operation of the Heating and Ventilation . . . . . . . . . . . . . . . . . . 3

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.2 Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.1 Setting the Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
11.2.2 Heater Operation without Preselection with Ignition OFF . . . . . . 9
11.2.3 Heater Operation without Preselection with Ignition ON. . . . . . . 11
11.2.4 Heater Operation with Preselection . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.2.5 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12
13
14 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Preparations for Assembly using the Radio Remote Control . . . . 3
14.3 Table Outline of the Assembly Procedures . . . . . . . . . . . . . . . . . . . 11
14.3.1 Assembly Procedures on the Superstructure . . . . . . . . . . . . . . . . . 11
14.3.2 Assembly Procedures on the Chassis . . . . . . . . . . . . . . . . . . . . . . . 11
14.3.3 Assembly Procedures on the Counterweight Dolly . . . . . . . . . . . . . 13
14.3.4 Assembly Procedures on the JackUp System . . . . . . . . . . . . . . . . 13
14.4 Assembly Procedures in Case of Failure on the Radio of Remote
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14.5 Table Outline of the Assembly Procedures in Case of Remote
Control Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
14.5.1 Assembly Procedures on the Superstructure . . . . . . . . . . . . . . . . . 17
14.5.2 Assembly Procedures on the Chassis (UW) . . . . . . . . . . . . . . . . . . 17
14.5.3 Assembly Procedures on the Counterweight Dolly (GW) . . . . . . . 19
14.5.4 Assembly Procedures on the JackUp System . . . . . . . . . . . . . . . . 19
Folding Table Dashboard
0621003151_en 6
Safety Instructions 1
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1 Safety Instructions
1.1 General
This section on safety instructions gives a concise and general

overview of hazards which can occur during operation of the
crane.
Where necessary, these safety instructions are referred to and
dealt with in further detail in the corresponding sections of the op-
erating instructions.
The safety instructions for lubrication, service and maintenance
work are contained in part 2 of this documentation.
The safety instructions for assembling the crane are contained in

part 3 of this documentation.
1.2 Intended Use
The crane is designed exclusively for assembly operation. Any

other type of use or 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 which results. The operator carries full re-
sponsibility for this type of use.
It is prohibited to use the crane to pull free fixed loads !
The crane operator is responsible for the operation of additional

equipment which is not included in the manufacturers scope of
supply (e.g. personnel cages), under observation of the applica-
ble safety and accident prevention regulations.
The use of two hoists for raising loads (2hook operation) is only
permitted following consultation with the crane manufacturer.
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 spec-
ifications.
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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. Neverthe-
less, its use can lead to hazards for the life and limb of the opera-
tor and third parties, and/or damage to the machine and other ob-
jects.
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 par-
ticular have any malfunctions which might impair safety rectified
immediately.
The term operating instructions refers to the operating instruc-

tions and the lubrication and maintenance instructions.
The design engineers have assumed certain operating condi-

tions when calculating and designing the winches of your crane.
The winches of your crane are classified as follows (ISO 4301/1,
FEM 1.001, DIN basic calculation principles for drive machinery):
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.
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 assem-
bly crane. More exacting operating conditions necessarily lead to
a shorter life expectancy for the crane.
Operating conditions or types of use other than assembly opera-

tion require the permission of the manufacturer and normally lead
to a reduction in the lifting capacities.
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Z 32 352
6/55 0621010151_en
1.3.2 Workplace Ergonomics
The following noise levels can occur near the crane operators
seat in the cab of the superstructure:
Engine at idle speed (1000 rpm) < 75 dB(A)
Engine max. revs without load (2200 rpm) < 85 dB(A)
Engine speed at highest engine torque
without load (1400 rpm) < 80 dB(A)
Measurements were taken using a noise level measuring unit

with the test microphone at the ear position of the crane operator.
The Aassessed equivalent permanent sound level at the opera-
tors seat measured over the shift duration of 8 hours is below 70
dB(A). For this purpose, measurements were taken during op-
eration 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 operators seat offers infinite adjustment options for the
seat height and tilt, backrests and armrests. This means that the
seat can be adjusted to the optimum working position for any
crane operator.
Crane operators seat

(Z 32 352)
(1) Hand wheel for adjusting the weight
(2) Lever for horizontal adjustment of the seat (top)
(3) Lever for horizontal adjustment of the seat (bottom)
(4) Lever for adjusting the backrest
(5) Lever for adjusting the height of the seat
The weighted effective value of acceleration to which the upper

body is exposed is below 2.5 m/s2.
The weighted effective value of acceleration to which the lower
body is exposed (feet and seat) is below 0.5 m/s2.
Both values are therefore below the statutory specifications.
1.3.3 Load and Utilisation of the Crane

The load capacity tables supplied with the crane specify limit val-
ues which may 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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1.3.4 Required Ambient Conditions
The permitted temperature range for operating the crane is

20C to +40C, if the maximum or minimum temperature occurs
only a few days a year.
Optional equipment for other operating conditions can be sup-

plied.
The crane can be operated under full load up to a height of 1000

m above mean sea level. It is not hazardous to operate the crane
up to an operating height of 2000 m 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, steel works etc.) combined with high relative air mois-
ture can require an adapter kit / optional equipment.
High levels of dust require the filter to be changed more regu-

larly. 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, part 2.
With oncoming wind the crane operator must observe the stipu-
lations laid down in the operating instructions. Please refer to the
operating instructions for the crane, section 9.11 Wind Speeds.
The ground, on which the crane is standing or across which the

crane is driven under load must have sufficient loadbearing
capacity.
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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1.3.5 Service Life
To calculate the service life of a crane for assembly operation the

following operating conditions are required:
The crane is operated for approximately equal amounts of
time under high, medium and low load.
The number of lifts is approximately 5 10 per day.
The crane is operated on average 210 days a year.
Under these conditions, assuming that maintenance work is car-

ried out properly, the theoretical service life can be more than 20
years.
The load capacity tables specified for the crane are for assembly
operation only. General cargo handling or grab operation can
only be permitted following express permission from the
manufacturer under suitable conditions.
For the winches, the regulations for calculating the remain-

ing theoretical service life should be observed, as listed in
part 2, lubrication and maintenance instructions, section
1.8.
The same service life naturally also results if the number of oper-
ating hours per day is higher, but the number of work days in the
year correspondingly lower.
Under no circumstances may the operating conditions be similar

to those for general cargo handling or grab operation. This can
lead to rapid wear and failure, especially on drive components
(power unit, winches etc.).
1.3.6 Standards and Calculation Regulations
The information given above on service life, loading and utilisa-

tion of the crane is taken from DIN standards DIN 15018/part 3
and DIN 15020 or the corresponding FEM standards.
For countries in which other standards and calculation regula-

tions apply, extra service life calculations can be carried out. If re-
quired, the crane operator must place an order for these calcula-
tions to be carried out. The operating conditions for the crane are
not altered, however it may be necessary to limit the lifting capaci-
ties.
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1.3.7 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, in particular in the vicinity of airports, landing
areas and air traffic control areas (socalled protected zones),
the crane may only be operated with the permission of the author-
ities in charge.
For Germany, its compulsory to obtain the permission of the au-

thorities. For other countries do obserce the corresponding na-
tional regulations.
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1.4 Safety Regulations
1.4.1 Organisational Measures
In addition to the operating instructions, applicable national regu-

lations and any other binding regulations on the prevention of ac-
cidents 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 preven-

tion 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 report-
ing duties for any special operating occurrences, for example
with regard to work organisation, operating procedures, allo-
cated personnel etc.
Keep a complete and legible set of all safety and hazard instruc-
tions on the crane at all times.
Provide instructions on the location and use of fire extinguishing

equipment.
The fire extinguisher supplied is located next to the drivers seat

in the crane operators cab.
In case of poor visibility or darkness, the immediate area in front

of the crane operators cab, the outriggers and the winches
should be illuminated using the spot lights on the crane.
The extended area (load, load path, slewing range, driving route
etc.) is to be illuminated using suitable equipment, separate from
the crane. You the crane operator are responsible for provid-
ing this lighting.
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1.4.2 Selection and Qualifications of Personnel
To make optimum use of a crane, without overloading it or failing

to use it to its full potential, the crane operator and the mainte-
nance, assembly and dismantling engineers must be thoroughly
trained.
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 operation, configuration and maintenance.
for the machine driver, also with regard to responsibility for
observing road traffic regulations. Allow him to refuse instruc-
tions 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 supervi-
sion 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 Hazards
1.4.3.1 Electrical Energy
High voltage
Keep a safe distance between the crane and overhead power

cables. When working near electric power cables, the boom
equipment must be kept well away from the power lines. Risk to
life and limb!
Keep a clearance of at least 10 m. 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.
If, however, the crane accidentally comes into contact with high
voltage power lines:
Do not leave the crane.
Slew or drive the crane out of the hazardous area.
Warn anyone in the vicinity against approaching or touching
the crane.
Arrange for the power in the cable to be switched off.
Leave the crane when the power in the cable which has been
touched/damaged has been switched off.
Highfrequency radiation
The risk of the load limit device being influenced by highfre-

quency radiation is minimised by state of the art technology
(shielding). It cannot however be fully exluded under extreme
conditions, for example in the vicinity of powerful transmitters.
For this reason, observe the instructions outlined in section 8 on

safety equipment.
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Lightning
If bad weather and storms appear imminent, lower the crane

equipment where possible and leave the crane.
If this is not possible, lower and unhook the load, switch off the
engine and leave the crane.
Only remain in the crane operators cab if you cannot carry out
these measures in good time.
Under no circumstances must the crane operator ap-

proach the crane or its immediate vicinity during the
storm. Warn any other people in the vicinity of the crane.
If you suspect that lightning has struck the crane, check the fol-
lowing:
Load limit device; if it is defective a fault message appears on
the display.
Limit switches; to see if they are functioning.
Inductive proximity switches; to see if they are functioning.
Air speed indicator; to see if it is functioning.
1.4.3.2 Gas, Dust, Steam, Smoke
Only operate combustion engines and fueloperated heaters in

sufficiently ventilated spaces. Make sure that sufficient ventila-
tion is provided before operating in restricted spaces.
Follow the applicable regulations for the operating site.
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Z 29 802 Z 29 803
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1.4.3.3 Crushing / Collision

(Z 29 800)
For the points listed below, please also refer to the more detailed
description in the corresponding sections of the operating in-
structions.
During assembly of the main boom, fly jib and Superlift mast.
Hook block when rotating the superstructure
1.4.3.4 Snagging / Dragging

(Z 29 801)
structions.
Head sheaves and deflection rollers
Hook blocks
Winches
1.4.3.5 Crushing / Shearing

(Z 29 802)
structions.
Outriggers
Counterweights
Additional equipment
Load (with uncontrolled movements)
Slewing the crane operators cab
Assembling and dismantling the boom system
Assembling and dismantling the superstructure
1.4.3.6 Hazards due to Slipping, Stumbling, Falling

(Z 29 803)
Only the catwalks and ladders described may be used. These

provide sufficient places to hold on to and the catwalks are de-
signed to prevent slipping (e.g. sanding, checker plate etc.).
0621010151_en 23/55
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1.4.3.7 Wind
The crane may only be operated up to specific wind speeds, de-

pending on the boom length, equipment fitted and dynamic pres-
sure.
If these are exceeded ACCIDENTS CAN OCCUR!
In this respect, please refer to section 9.12 Wind Speeds .
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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 sequence in advance.
make sure that the crane operators can communicate with
each other .
If the crane operators are unable to communicate verbally or by

giving visible signs, suitable means must be used, for example
walkietalkies, spotters etc.
If spotters are used, the exact signals given must be agreed be-
tween the crane operators and the spotters. Please refer to sec-
tion 1.5 on Safety Instructions.
The crane operators must operate their cranes carefully and in

a restrained manner to make sure that collisions cannot occur as
a result of uncontrolled movements.
They must receive suitable training and instructions to this end.
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1.4.4.2 Raising a Load Using More than One Crane
If a load is to be raised using more than one crane, the operating

procedure must be laid down in advance by the operator or his
agent and carried out in the presence of a foreman designated
by the operator.
Special care should be taken in the following instances:

Cranes do not have the same lifting capacities.
In this instance, the component to be raised must be attached so

that each crane is loaded within the limits of its loadbearing ca-
pacity.
The component to be raised is not symmetrical or the location

of the centre of gravity is not clear. If necessary, use only 75%
of the permissible load.
Dynamic influences may act on the load once raised.
The load must not be dragged at an angle under any

circumstances.
Note that an individual crane can also become over-

loaded when lowering the load.
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1.4.5 Before Operating the Crane
Before commencing work on site, take time to survey the operat-

ing area. This includes, for example, obstructions to operations
and traffic, loadbearing capacity of the ground and the neces-
sary safety measures to isolate the construction site from general
traffic.
The crane may only be operated when the crane itself, the load
and the load path can be seen clearly.
The necessary measures should be taken to ensure that the

crane is operated in a safe and fully functional condition.
The crane may only be operated when all safety devices and
equipment are fitted and in full working order.
Note that all mobile jib cranes may be used on firm ground only.
Check the effectiveness of the brakes, steering, signal and light-

ing equipment, limit switches and the overload cutoff device
daily, or before starting work (or driving) in the case of cranes in
infrequent use.
Before starting work, ensure that noone is standing in the dan-

ger zone of the crane. Give a warning signal if necessary (sound-
ing the horn is recommended before starting the engine ).
Before starting work, check that all crane movements are func-
tioning correctly.
Always have a suitable container and binding agent to hand

when carrying out maintenance and assembly work, as oil may
sometimes leak.
Where necessary and in accordance with the regulations, per-

sonnel must use individual protective equipment (e.g. safety har-
nesses, safety clothing, goggles, face masks, etc.).
Even protective equipment cannot provide 100% protec-

tion. A helmet can perhaps provide protection against
small falling objects, but not against a falling load.
Always remain fully alert and safety conscious.
Before driving the crane, always check that the accessories are
stored safely.
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1.4.6 During Operation of the Crane
Only the crane operator is permitted on the crane during

powerdriven operating, erection or assembly proce-
dures (and only in the crane operators cab). No other
personnel are permitted on the crane or in the danger
zone of the crane.
An exception is only permitted when erecting the coun-
terweight with the aid of a slinger. This must, however,
leave the slewing range as soon as the erection proce-
dure is completed.
To allow rapid reaction to outside influences working on the

crane, the drive mechanism of the crane must never be switched
off, nor the crane operators cab be left unoccupied, when a load
is still attached to the crane.
An exception is only permitted in an emergency. In order

to prevent dangerous situations, the drive (diesel engine)
can, as a last resort, be switched off using the emer-
gency stop button in the crane operators cab. If pos-
sible, any movements already started should be com-
pleted using the control levers beforehand.
The erect crane must not be left with a load if not supervised by
a trained crane operator.
Only hook blocks referred to by Demag Mobile Cranes may be

used.
The use of other hook blocks is only permitted after consulting
Demag Mobile Cranes and obtaining the appropriate authoriza-
tion.
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Transportation of persons on the load or the loadhandling

equipment is prohibited.
Transportation of persons on personnelcarrying equipment and

the carrying out of work from this equipment is permitted only if
the operator gives written notice in advance to the Employers Li-
ability Insurance Association, detailing the work planned and the
safety measures to be undertaken (see for instance the Safety
Regulations for Extendable PersonnelCarrying Equipment, ZH
1/461).
The crane may only be boarded or left once the crane operator
has been informed and whilst the crane is stationary.
Observe all safety and warning signs on the crane.
Fixed, mechanical safety guards must not be opened or removed

while the crane is in operation.
Do not carry out any operation which may be unsafe (e.g. opera-
tions which may endanger the stability of the crane).
Keep the crane operators cab and drivers cab windscreens

clean to ensure good visibility.
No personnel are permitted in the slewing range of the crane.

Work should be stopped if persons fail to leave the danger zone
in spite of warnings.
Only start the crane engine from the operators seat. Only oper-
ate control lever from the cab.
Keep the control levers within reach whilst a load is suspended

from the crane or the crane is being driven under load.
If operation of the equipment (or danger zone) cannot be ob-

served from the crane operators cab (or drivers cab), a banks-
man should be employed (see Section 1.5).
This also applies when normal communication by speech is not
possible due to an increased noise level.
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1
Z 27 796
36/55 0621010151_en
Particular attention should be paid to the load during all crane op-
erations, and to the loadhandling equipment and the boom top
section when raising without load. Also monitor the swing of the
counterweight etc.
It is prohibited to use the crane to pull loads at an angle or to drag

loads.
Do observe the rope drums in order to avoid wrongdirection

reeling of the hoist ropes !
Do not jump from the crane. Use the ladders and handrails.
Secure the doors to prevent them flying open or slamming shut.
Check the crane for any externally visible damage or shortcom-

ings at least once during a shift period. Inform the authority / per-
son in charge immediately of any changes which arise (including
the operational behaviour of the crane). If necessary, stop work
immediately and secure the crane.
In the case of maloperation, shut down the crane immediately

and secure it safely. Have any faults rectified immediately.
Observe the procedure for starting and switching off the crane
and the function of the indicator displays as laid out in the operat-
ing instructions.
Always switch on the exterior lighting on the crane when visibility

is poor or when in darkness. The interior lighting should then be
switched off to ensure that the load and the area surrounding the
crane can be seen clearly.
Always keep the operating instructions at hand at the operating

site in the retainers provided. These are located on the rear wall
of the crane cab (Z 27 796).
Observe the availability of fire warning and fire fighting equip-

ment.
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Keep a safe distance from banks and ditches.
Do not park the crane on embankments or near the edges of

ditches.
Set the computer of the load limit device in accordance with the
load tables provided.
Observe the permissible wind speeds.
It is generally prohibited to slew the superstructure in the over-

load range (load limit device has shut down).
When driving downhill, always drive the crane at a speed suitable

for the prevailing ground conditions.
Always ensure that enough clearance is available when passing

under underpasses, bridges, tunnels, overhead power lines,etc.
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1.4.7 After Crane Operation
When leaving the crane, ensure that:

the load has been detached from the crane hook or placed
on the ground;
the engine is switched off and all control levers are returned
to the Off or Locked position;
the heating is switched off;
the crane is locked to prevent unauthorized use of the crane
and to prevent the crane from rolling.
If the crane is parked on a slope, the chassis must be secured by

chocks, the slew brake must be applied.
Always lock all control stands which are equipped with a lock
when they are not in use or when the control is being operated.
When parking the crane, please observe the permissible wind

speeds. If necessary, set down the boom.
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1.4.8 When Mounting and Dismantling Crane Components
In addition to the instructions already given in this section, the

instructions detailed below apply specifically to mounting and dis-
mantling operations.
These operating instructions describe the standard mounting se-

quence.
The reverse of the mounting procedure must be followed exactly

when dismantling (unless otherwise specified).
The crane components must not be mounted or dismantled by

untrained personnel under any circumstances.
Incorrect mounting would lead to extremely dangerous situa-
tions.
Owing to the hazard of slipping, stumbling and falling, the boom

and corresponding equipment or components must not be
walked on.
All assembly work must be carried out with the help of suitable
aids (ladders, work platforms, scaffolding, auxiliary crane etc.).
Exceptions are only permitted where provision is made for

personnel to climb on the equipment. In this case, however,
additional safety gear must be used.
Standard mounting requires that all component parts which are

transported separately are transported close to the ground by
means of suitable auxiliary cranes and loadhandling equipment
(ropes) and are secured reliably to the basic crane.
Before mounting personnel approach suspended loads such as

counterweights, outriggers, intermediate sections, boom foot
sections and top pieces, luffing masts or fly jibs, these loads
must be lowered onto the ground or onto trestles or other sup-
ports of sufficient loadbearing capacity.
Any persons standing in the vicinity of suspended loads

may be jolted or crushed when loads move laterally !
During the mounting procedure, personnel must never stand in

areas into which loads might fall or under suspended loads be-
fore the loads have been secured in accordance with the speci-
fied procedure.
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A securing procedure is not completed until the suspended load

has been secured firmly to the stable part of the crane, e.g. by
driving home pins into an intermediate section or by tightening all
bolts of a threaded connection to the specified torque, etc.
A safe distance must be kept from areas where crushing and

shearing may be unavoidable, in particular between the super-
structure and the crane chassis, near cylinders, on the main
boom, on the fly jib and on the superlift mast while any part is sus-
pended in the air during mounting and / or is not firmly secured
or the engine of the crane or the mounting auxiliary crane is still
running.
Connecting pins for the mounting of main boom,fly jib and super-
lift mast must be driven home from the outside inwards unless
otherwise expressly stated in the operating instructions. Guard-
ing using auxiliary pins and clip pins can be carried out once all
pins of a component have been driven home.
When boom components or other parts are being dismantled,

connecting pins may only be driven out when all individual com-
ponents are reliably supported symmetrical to the component
centre of gravity. Before components can be released, the shift
foreman must establish the likelihood of components falling or
folding unexpectedly as a result of their being released. A Demag
Mobile Cranes customer service representative must be con-
sulted if in any doubt.
The driving out of pins must be planned with particular care. It

must be ensured that no persons are standing within the main
boom, fly jib or superlift mast where they may be at risk of being
crushed. Suitable measures must be planned and taken to pre-
vent pins from falling when driven out, ropes from falling when re-
leased or any other component falling.
Ensure that no tools are left behind once work has been com-
pleted, as tools which fall or are flung from the crane can prove
extremely dangerous.
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1.5 Hand Signals
If the crane operator cannot observe operation of the equipment

(or danger zone) from the crane operators cab (or drivers cab),
a banksman should be employed.
This also applies when normal communication by speech is not
possible due to an increased noise level.
Only reliable persons who are familiar with the sym-

bols may be employed as banksmen.
The banksman should stand in a safe position from

which he can SEE THE LOAD and BE SEEN clearly
by the crane operator.
The operator must be able to identify the banksman

easily. The banksman must use one or more suitable
identification markings, e.g. jacket, helmet, cuffs,
armbands, signalling discs.
These identification markings should be of a
distinctive colour, preferably uniform, and must be
reserved for the banksman.
Should the operator not understand a signal fully, he should

not carry out any movement with the crane. The operator and
the banksman should agree a suitable means of commu-
nication for such an instance before starting work.
0621010151_en 47/55
1
1 2
3 4
Z 26 024
48/55 0621010151_en
1.5.1 General Hand Signals

(Z 26 024)
1. START
Attention, hand signals follow.
Arms extended horizontally each side, palms forwards.
2. STOP !
Interruption, end of a movement.
Right arm raised, palm of right hand forwards.
3. END
of a movement.
Hands clasped at chest level.
4. DANGER !
Emergency stop.
Both arms raised, palms forwards.
RAPID MOVEMENT
Coded hand signal for movements carried out rapidly.
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1 2
3 4
Z 29 352
50/55 0621010151_en
1.5.2 Hand Signals for Working Movements

(Z 26 026)
1. RAISE load
Right arm pointing upwards, palm of the right hand facing for-
wards, make slow circular movements with the index finger.
2. LOWER load
Right arm pointing downwards, palm of the right hand facing
inwards, make slow circular movements with the index fin-
ger.
3. RAISE boom
Signal with one hand. Right arm stretched out, thumb point-
ing upwards.
4. LOWER boom
Signal with one hand. Right arm stretched out, thumb point-
ing downwards.
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1 2
3 4
Z 26 025
52/55 0621010151_en
1.5.3 Hand Signals for Driving Movements

(Z 26 025)
1. Drive FORWARDS
Arms bent; palms facing inwards; forearms move slowly to-
wards body.
2. Drive BACKWARDS
Arms bent; palms facing outwards; forearms move slowly
away from body.
3. Drive to the RIGHT (as seen by banksman)

Right arm stretched out more or less horizontally, palm of
right hand facing downwards, small movements in the direc-
tion indicated.
4. Drive to the LEFT (as seen by banksman)

Left arm stretched out more or less horizontally, palm of left
hand facing downwards, small movements in the direction
indicated.
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1.6 Power Failure
General
In case of power failure, all movements are stopped. Movements

cannot be started up again unintentionally. When the diesel en-
gine stops, the driven hydraulic pumps are stopped automati-
cally. The oil contained in the circuit also stops. As soon as the
control pressure reaches zero, all sliders return, springloaded,
to the neutral position irrespective of the position of the pilot con-
trol lever on the associated control device.
In those hydraulic circuits which affect the safety of the crane, the
winches and cylinders can be additionally braked by bringing
them into the locked position or by applying the retaining brake.
Winches and cylinders
The oil column on the raising side of the winch motors and cylin-
ders is protected by brake valves which are independent of the
load (lowering brake valves). Winches and cylinders can no
longer be moved following power failure. The lowering brake
valves are fitted directly onto the winch motors and cylinders (no
hoses).
As the case described is extremely rare, there is no way in which

a load suspended on the hook can be lowered. In this instance,
the Customer Service Dept. must be contacted.
A burst oil pipe or hose will not therefore cause any hazardous
crane movements.
In addition, the hydraulically released disc brake for the slew gear
is applied.
0621010151_en 55/55
Structure of the Crawlermounted Crane 2
0621020151_en 1/21
2
25
16
14
2 5
Z 38 063
2/21 0621020151_en
2 Structure of the Crawlermounted Crane
2.1 Overview
Legend:
(Z 38 063)
1 Superstructure
2 Undercarriage
5 Counterweight
8 Main boom
14 Aframe
25 Hoist 3 (H3)
26 Luffing gear 1 (W1)
0621020151_en 3/21
2
8
14
9
10
6
21
17
5
13
4
3
24
20
1 2
23
Z 40 510
4/21 0621020151_en
2.2 Superstructure
Legend:
(Z 40 510)
1 Frame
2 Hoist H1
3 Derricking gear
4 Drive
5 Counterweight
6 Roller set, superstructure
8 Hoist H3
9 Luffing gear W1
10 Main boom foot section
11
12
13 Air filter
14 Aframe
15
16
17 Oil cooler
18
19
20 Hoist H2
21 Main boom back stops
22
23 Cab
24 Pinlocking unit for main boom
0621020151_en 5/21
2
Z 29 702
6/21 0621020151_en
2.3 Undercarriage
Legend
(Z 29 702)
1 Middle section
2 Track frame righthand side, assy.
3 Track frame lefthand side, assy.
4 Track group
5 Track roller
6 Idler
7 Drive sprocket
8 Drive gearbox
9 Drive motor
10 Idler
11 Track shoe
12 Track frame
13 Slewing rim support
14 Rotary joint
15 Fixing points for outriggers
16
17
0621020151_en 7/21
2
1 2 Z 38 066
8/21 0621020151_en
2.4 Boom Variants

(Z 38 066)
1. Variant SH (type 2724)
Main boom lengths 24 84 m, consisting of:

Main boom foot section 10.50 m (prepared for fitting winch
W1)
Intermediate section 6.00 m (type 27241701)
Intermediate section 12.00 m (type 27241701; x 2)
Intermediate section 12.00 m (type 27241401; x 2
Reducer 12.00 m (type 2724/2421)
Connecting head 1.50 m
Roller set 600 t
2. Variant SH/LH (type 2724/2421)

The heavy basic length of type 2724 equals 60 m. Further
extension is made with type 2421 and the top piece of the
fly jib.
Main boom lengths 66 102 m (heavy basic length HBL

= 60 m), consisting of:
W1)
Reducer 6.00 m (type 2724/2421)
Top piece 7.50 m)
0621020151_en 9/21
2
3 Z 38 667
10/21 0621020151_en
(Z 38 067)
3. Variant SW (type 2724 and 2421)
The fly jib SW is fitted on the main boom SH.
Main boom lengths SH 30 66 m consisting of:
W1)
Reducer 12.00 m (type 2724/2421)
Roller set 600 t
Fly jib lengths SW 24 84 m consisting of:

Fly jib foot section 4.50 m
Top piece 7.50 m
4.
5.
0621020151_en 11/21
2
6 7 Z 38 069
12/21 0621020151_en
(Z 38 069)
6. Variant SSL (type 2724)

The mast radius equals 11 m, 13 m or 15 m.

Main boom foot section 10.50 m (prepared for fitting
winch W1)
Reducer 12.00 m (type 2724/2421)
Mast length 30 m, consisting of:
Foot section MA 5.50 m (prepared for fitting winch W2)
Mast point 6.50 m
7. Variant SSL/LSL (type 2724/2421)

The heavy basic length of type 2724 equals 82.5 m. Further
extension is made with type 2421 and the top piece of the
fly jib. The mast radius equals 11 m, 13 m or 15 m.

Main boom foot section 10.50 m (prepared for fitting
winch W1)
Reducer 12.00 m (type 2724/2421)
Top piece 7.50 m
Mast point 6.50 m
8.
9.
0621020151_en 13/21
2
10 Z 38 071
14/21 0621020151_en
(Z 38 071)
10. Variant SWSL (type 2724 and 2421)

The fly jib SW is fitted on the main boom SSL. The mast ra-
dius equals 11 m, 13 m or 15 m.

W1)
Reducer 12.00 m (type 2724/2421)

Mast point 6.50 m
Fly jib lengths SW 24 84 m consisting of:

Foot section HI 4.50 m
Intermediate section 12.00 (type 24211001)
Top piece 7.50 m
0621020151_en 15/21
2
1(2) 3 4
8 5 6 7
Z 38 072
16/21 0621020151_en
2.5 Technical Data

2.5.1 Drive Motor
Manufacturer: Mercedes Benz
Type: OM 502 LA
Design: 8cylinder diesel engine with charged air cooling
and exhaust turbocharger
Nominal
speed: 2000 min1
Output: 390 kW at 1800 min1
2.5.2 Pump Distributor Gear
Design: Distributor gear with:
Pump combination 1:
variable displacement axial piston pump (P1.1)
Pump combination 2:
(only with a driven counterweight dolly)
Pump combination 3:
gear pump (P3.3)
2.5.3 Hydraulic Pumps
(Z 38 072)
On the pump distributor gear (8) a total of 7 hydraulic pumps are
fitted.
Item Pump Model Max. Max. de- Remarks
pres- livery rate
sure (l/min)
(bar)
1 P 1.1 Variable displacement 340 452 H1, left crawler, W2
pump
2 P 1.2 Variable displacement 300 169 Slew gear, reeving winch
pump
3 P 2.1 Variable displacement 340 452 EW, H2, right crawler H3
pump
4 P 2.2 Variable displacement 350 260 Optional equipment for counterweight
pump
5 P 3.1 Variable displacement 330 452 W2, W1, EW, Trailing
pump
6 P 3.2 Variable displacement 270 67 Main boom pinlocking. Pump dynamic pressure,
pump H1 + H2 pin locking Aframe mounting cylin-
der, counterweight locking, fifth wheel, chassis
centre section, pinlocking, outriggers, locking
for quickdisconnect, cabin inclination, support
for main boom and mast
7 P 3.3 Gear pump 70 54 Oil cooler circuit
0621020151_en 17/21
2
18/21 0621020151_en
2.5.4 Slew Gear

Design: Twostage planetary gear with hydrauli-
cally ventilated springoperated brake and
additional nonwearing hydraulic brake.
Superstructure slewing speed infinitely
variable 00.7 min1
2.5.5 Winches
The following winches are fitted in the superstructure, the main
boom and the Superlift mast of the crane:
Hoist H1 Rope diameter: 28 mm
Rope length: 900 m
Perm. rope traction: 158 kN
Rope speed: max. 120 m/min
Rope length: 900 m
Perm. rope traction: 158 kN
Derricking gear Rope diameter: 30 mm
E Rope length: 2 x 230 m
Luffing gear W1 Rope diameter: 28 mm
(optional equip- Rope length: 800 m
ment)
Luffing gear W2 Rope diameter: 28 mm
ment)
ment)
Reeving winch Rope diameter: 10 mm
EW Rope length: 320 m/min
Luffing gear W1 is required for boom variants SW and SWSL.

Luffing gear W2 is required for boom variants SSL, SSL / LSL and
SWSL.
0621020151_en 19/21
2
20/21 0621020151_en
2.5.6 Safety Equipment
Design: Electronic crane information system (ECIS)
2.5.7 Heater
Type: D5WS
2.5.8 Cab
To improve visibility, in particular for crane work at great heights,

the cab can be hydraulically tilted backwards. During transporta-
tion the cab can be slewed in front of the superstructure.
Design: Comfort cab with sliding door and large, front

window,
safety glass all round,
cushioned and adjustable operators seat,
control and monitoring units for the crane and
driving functions,
nonenginedriven heater,
wipers for front and roof window with windscreen
washing assembly.
2.5.9 Drive Gearbox (Undercarriage)
Design: Each track group is driven by two hydraulic mo-

tors by means of a closed, splashlubricated
planetary gear. Each side can be controlled infi-
nitely and in opposite directions.
0621020151_en 21/21
Crane Operators Cab 4
0621040151 1/21
4
10 11 10 12 12
9 9 9 9
13
3 1 2
Z 40 511
2/21 0621040151
4 Crane Operators Cab
4.1 Cab
(Z 40 511)
D = Side panel
KW = Option
Item Element Designation Function

1 B 215 Control lever with Hoist H1:
Dead mans han- H 1 lower
dle H 1 raise
Hoist rotation indi- For crane operation with double
cator hook block, hoist H1 + H2:
H1 + H2 lower
H1 + H2 raise
Luffing gear W2:
W2 Lower
W2 Raise
Chassis:
left track forwards
left track backwards
2 B 216 Control lever with Hoist H2:
Dead mans han- H 2 lower
dle H 2 raise
Hoist rotation indi- Hoist H3 (KW):
cator H3 lower
H3 raise
Derricking gear E:
Derricking gear Lower
Derricking gear Raise
Chassis:
right track forwards
right track backwards
3 B 217 Control lever with Derricking gear E:
dead mans han- Derricking gear lower
dle Derricking gear raise
hoist rotation indi- Slew gear:
cator Rotate to left
button Rotate to right
Luffing gear W1 (OE):
W1 lower
(button for increas- W1 raise
ing the pressure of Luffing gear W2 (OE):
the slew gear) W2 lower
W2 raise
Travel gear:
both crawlers forwards
both crawlers backwards
Reeving winch (KW): EW
EW lower
EWraise
0621040151 3/21
4
10 11 10 12 12
9 9 9 9
13
3 1 2
Z 40 511
4/21 0621040151
Cab continued
(Z 40 511)
7 B 105 Pedal (accelerator Speed adjustment of the engine
pedal)

9 Button Dead mans handle
10 Winch rotation indicator
11 B217 Button Pressure increase on slewing gear
12 B215/B216 Button Slew gear may slew free
13 S 201 Footoperated Bridging the load moment limiter
switch (enabling erection); see also push
button, pos. 23
0621040151 5/21
4
57 58 53 36 33 108 121 100 71

52 104 34 44 37 106 101 77
73
55
59 32 45 38 76
56 31 35 70
54 72
50 103
51 102
95 20 110
Z 40 512
6/21 0621040151
4.2 Addon Console

(Z 40 512)
The position of the switches, lamps and displays may be different

on your crane than the one shown here.
The symbol attached to the switch, the lamp or display deter-

mines its exact function.

20 N 312 Fitted console Display and control console with
PDCDisplay CPU load limit device system:
(Description of Control Superlift counterweight
chapter 4.2.1 and dolly
8) Display tilt superstructure
Slew gear speed
Wind speed
Pump pressures
31 H 123 Indicator light, red Coolant level too low
32 H 103 Indicator light, red Coolant temperature too high
33 H 125 Indicator light, red Hydraulic filter pumpe 1.2 clogged
34 H 107 Indicator light, red Battery charge indicator
35 H 102 Indicator light, red Engine oil pressure too low
36 H 114 Indicator light, red Air filter clogged
37 H 124 Indicator light, red Hydraulic oil level too low
38 H 100 Indicator light, red ADM check
44 H Indicator light, red Hydraulic oil temperature too high
45 H Indicator light, red
50 S 217 C Luminous switch Preselection control lever 3:
W2 = Luffing gear 2 (P3.1)
51 S 222 E Luminous switch Luffing gear 2:
Hydraulic engine adjustment
52 S 217 E Luminous switch Slew gear parking brake
53 Control knob Slew speed
54 S 222 D Luminous switch Luffing gear 1:
55 S 217 D Luminous switch High speed derricking gear
(pump circuit P3.1 + P2.1)
56 S 217 B Luminous switch Preselection control lever 3:
W1 = Luffing gear 1 (P3.1)
0621040151 7/21
4
57 58 53 36 33 108 121 100 71

52 104 34 44 37 106 101 77
73
55
59 32 45 38 76
56 31 35 70
54 72
50 103
51 102
95 20 110
Z 40 512
8/21 0621040151
Cab continued
(Z 40 512)
57 S 217 A Luminous switch Preselection control lever 3:
E = derricking gear (P3.1)
58 S 217 F Luminous switch Preselection control lever 3:
both crawlers forwards (P3.1)
both crawlers backwards (P3.1)
59 S 217 G Luminous switch Operation of reeving winch R1
70 S 216 B Luminous switch Preselection control lever 2:
H3 = Hoist 3 (P2.1)
71 S 216 A Luminous switch Preselection control lever 2:
H2 = Hoist 2 (P2.1)
72 S 222 C Luminous switch Hoist 3:
73 S 222 B Luminous switch Hoist 2:
76 S 222 A Luminous switch Hoist 1:
77 S 215 Luminous switch Changeover:
operation hoist H1
synchronous operation H1 + H2
95 S 100 Emergencyoff Shutdown of power supply for the en-
switch tire crane
100 S 219 A Luminous switch Operation travel gear chassis
101 S 219 B Luminous switch High speed travel gear chassis
102 S 218 B Luminous switch Preselect control lever 1
W2 = luffing gear 2 (P1.1)
103 S 218 A Luminous switch Preselect control lever 2
E = derricking gear (P2.1)
104 R 223 A Rotary switch Pump adjustment P3.1 (E, W1, W2)
adjustment of the delivery rate
106 R 222 A Rotary switch Pump adjustment P2.1
108 R 221 A Rotary switch Pump adjustment P1.1
110 R 100 Rotary switch Manual speed adjustment for the die-
sel engine
121 S 219 C Luminous switch High range counterweight dolly
0621040151 9/21
4
20 40 41 42 43
44
47
46
45 21
39
22 23 24 26
Z 40 513
10/21 0621040151
4.2.1 Attachment console PDCDisplay

(Z 40 513)
The PDCdisplay (20) consists of the following components:
21 Keypad Numerical input of parameters
22 Keypad Function keys for menu selection
23 S 300 A Key switch Bridging load limit device (E, W1, W2
lower; H1 H3 raise)
24 S 300 B Key switch Bridging load limit device, raise der-
ricking gear, luffing gear 1 and luffing
gear 2
26 S 202 Key switch Release hoist limit switch erect
39 Monitor Status display
Display
Function display
40 Indicator light Overload prewarning
41 Indicator light Overload signal (load limit device
shutdown)
42 Indicator light Hoist limit switch triggered
43 Indicator light System test
0621040151 11/21
4
96 97 116 92 122
99 117 98 91 74
93
94
115 114 112 111

30 119 28 113
Z 40 514
12/21 0621040151
4.3 Side Panel

(Z 40 514)
The position of the switches, lamps and displays may be different

on your crane than the one shown here.
The symbol attached to the switch, the lamp or display deter-

mines its exact function.
4.3.1 Lefthand Console D

28 S 327 Luminous switch Bridging: accelerator pedal manual /
automatic
30 P 100 Multifunction dis- Digital display instrument:
play for super- Fuel level
structure engine Engine oil pressure
(description in Engine temperature
section 4.4.2) Hydraulic oil temperature
Engine speed
Hour meter
Battery voltage
Time
74 S 258 Luminous switch Cab adjustment cylinder
91 S 103 B Luminous switch Roof window wiper
92 S 118 Luminous switch Windscreen washing assembly, front
window
93 S 103 A Luminous switch Front window wiper
94 S 200 Key switch Power supply:
2position control / PDCdisplay
96 R 803 Rotary switch Air conditioning equipment:
Temperature setting
97 S 801 Luminous switch Air conditioning equipment:
Condenser fan
98 S 800 Luminous switch Heater:
Multiple contact switch additional fan
for heater
99 P 801 Timer Heater:
Programming of switchon time
0621040151 13/21
4
96 97 116 92 122
99 117 98 91 74
93
94
115 114 112 111

30 119 28 113
Z 40 514
14/21 0621040151
Continued: Side panel

(Z 40 514)

111 S 101 Ignition switch Power supply assy.
112 S 102 B Luminous push- Diesel engine stop
button
113 S 102 A Luminous push- Diesel engine start
button
114 S 104 Luminous push- Horn
button
115 S 106 Luminous switch Rotaflare light
116 S 115 Luminous switch Aircraft warning light
117 S 111 Luminous switch Instrument illumination
119 S 109 Luminous switch Outside lighting cab front
122 X 101 Cigarette lighter
0621040151 15/21
4
30
30.9
30.10 30.10
30.1
30.4
30.3
30.2
30.8
30.5
30.6 30.10 30.7
30.10 30.10
Z 40 515
16/21 0621040151
4.3.2 Multifunction Display

(Z 40 515)
The multifunction display (30) consists of the following compo-

nents:
Item Designation Function
30.1 Button Fuel level display:
Display 0...230 l (= 0...2300 l; display x10).
Warning: LED (lightemitting diode) flashes if
level falls below 10% = 230 l
(display reads 23 l).
30.2 Button Engine oil pressure display:
Display 0...5 bar.
Warning: LED flashes if level falls below 0.5
bar (with engine running and minimum speed
500 rpm).
30.3 Button Coolant temperature display:
Display 20...120 C.
Warning: LED flashes if 102 C is exceeded.
Special feature: Display begins at 20 C even
if this temperature has not yet been reached.
30.4 Button Hydraulic oil temperature display:
Display 40...120 C.
Warning: LED flashes if 90 C is exceeded.
Special feature: Below 40 C the display
reads .
30.5 Button Engine speed display:
Display 0...3000 rpm.
Warning: LED flashes if 2600 rpm is ex-
ceeded.
30.6 Button Engine operating hour display:
Display of the operating hours of the engine
at a speed above 500 rpm. Can only be
called up when the engine is running.
30.7 Button Board voltage display.
Display 0...32VDC.
Warning: LED flashes at less than 18V.
30.8 Button no function
30.9 Display Digital display:
Display two digits, 4/6 digits, illuminated.
30.10 LED Function display:
(LED) LED lights up when button is pressed.
Fault display (limit values reached):
LED flashes. Warning deleted by pressing
the corresponding button (3 seconds).
0621040151 17/21
4
30
30.9
30.10 30.10
30.1
30.4
30.3
30.2
30.8
30.5
30.6 30.10 30.7
30.10 30.10
Z 40 515
18/21 0621040151
Continued: Multifunction display

(Z 40 515)
The abovementioned information can be called up on the multi

function display (30) at the press of a button. The LED allocated
to the button then lights up.
When the ignition is switched off the time appears in the display
(30.9) (bottom).
If a button is not pressed when the ignition is switched on, the time
is still shown on the display (30.9) (bottom).
If the gear oil temperature or coolant temperature is too high, or

if the power supply or engine oil pressure is too low, this informa-
tion flashes on the display (30.9), even if it has not been selected
at this point in time. At the same time the corresponding light
emitting diode (LED) flashes. These warning messages can be
acknowledged, i.e. deleted by pressing the corresponding button
(3 seconds).
Setting the time:

press buttons (30.6) and (30.7) simultaneously for 5 seconds
time flashes on the display
press the buttons repeatedly (30.5, (30.6) and (30.7), until the
desired time setting is shown
the corresponding time unit jumps by one digit value
Saving the time:

press buttons (30.6) and (30.7) simultaneously until the time
no longer flashes.
0621040151 19/21
4
130.1 130.2 130.3
130.4 130.5 130.6
130.7 130.8 130.9
130.10 130.11 130.12
130.13 130.14 130.15
130.16 130.17 130.18
Z 38 078
20/21 0621040151
4.4 Radio Remote Control

(Z 38 078)
The radio remote control can be used to operate all assembly

procedures remotely.
For how to operate the radio remote control see chapter 14.
0621040151 21/21
10 11 10 12 12
9 9 9 9
13
3 1 2
Z40 511
0621040151_A3
57 58 53 36 33 108 121 100 71
52 104 34 44 37 106 101 77
73
55
59 32 45 38 76
56 31 35 70
54 72
50 103
51 102
95 20 110
Z 40 512
0621040151_A3
Engine and Drive 5
0621050151_en 1/21
5
38
Z 40 516
2/21 0621050151_en
Engine and Drive 5
5 Engine and Drive
5.1 General
(Z 40 516)
The engine OM 502 LA is particularly low in pollutant emissions

(EURO 2). It has a fully electronic control system which regulates
the injection amount and time via solenoid valves.
This control system consists of the two control devices FMR and
PLD and the corresponding sensors.
Control device FMR Control device PLD

(Vehicle engine control) (Pump line nozzle)
Function Carries out various control tasks Continual evaluation of all en-
of the vehicle for the engine gine data of the sensors (start
electronics. of injection, ambient condi-
Control tasks: tions, etc.) as well as the data
of the driver (e.g. accelerator of the FMR electronics. Inter-
pedal) nally this data is compared
stored in the control device with stored characteristic
(e.g. idle speed). fields, the optimum injection
time and quantity is calculated
and the injection pumps
(plugin pumps) of the individ-
ual cylinders correspondingly
activated.
Malfunction Indicator light FMR (38) lights Indicator light PLD (38) lights
up. up.
0621050151_en 3/21
5
4/21 0621050151_en
Engine and Drive 5
Safety measures for engines with electronic control units
The following safety measures must be observed to prevent in-

jury to persons and damage to the engine, components or
cables.
Only start the engine when the batteries are connected prop-
erly. Do not disconnect the batteries when the engine is run-
ning.
Only start the engine when the speed sensor is connected.
Never use a boost charger to start the engine.
Jump starting only with separate batteries.
For rapid charging of the batteries, the battery terminals must
be removed. Follow the operating instructions for the boost
charger.
The batteries must be disconnected when electric welding
work is carried out , and the + and cables connected to
one another.
The lines of the control units may only be disconnected and
connected when the electrical system is switched off.
Switching the poles of the supply voltage for the control units
(e.g. by connecting the poles of the batteries incorrectly) can
lead to the destruction of the control units.
Tighten the plug connections on the injection system to the
prescribed torque.
For temperatures of higher than 80 C (e.g. foundry stove) the
control units must be removed.
Use only suitable test lines for taking measurements on plug
connections (MercedesBenz connector set).
Telephones and radio equipment which are not connected to
an external antenna can cause malfunctions to the vehicle
electronics and endanger the operating safety of the engine.
Before commissioning, make sure that you have read the op-
erating instructions of the engine manufacturer for the die-
sel engine OM 502 LA. These are enclosed in part 5 of this
documentation.
The following points are primarily limited to information
which specifically affects the crane.
0621050151_en 5/21
5
1(2) 3 4
8 5 6 7
Z 38 072
6/21 0621050151_en
Engine and Drive 5
5.1.1 Cooling System
The cooling system of the diesel engine consists of two cooling

units (radiator and aftercooler). The fan for the two cooling units
is thermostatically controlled (switchon point approx. 83).
The hydraulic oil cooler is thermostatically controlled (switchon
point approx. 45 C).
5.1.2 Hydraulic Pumps

(Z 38 072)
A total of 7 hydraulic pumps are mounted on the pump gearbox

(8).
Pos. Pump Hydraulic Functions supplied
no. block
1 P 1.1 Block 1 Lefthand crawler
Hoist H1
Luffing gear W2
2 P 1.2 Reeving winch
Slew gear
3 P 2.1 Block 2 Righthand crawler
Hoist H2
Hoist H3 / jack up cylinder at
Aframe
Derricking gear
4 P 2.2 Dolly
Outriggers
Final drive
5 P 3.1 Block 3 Luffing gear W1
Luffing gear W2
Derricking gear
Lefthand / righthand crawlers
6 P 3.2 Main boom back stops
Mast support
Aframe mounting cylinder
Pin locking H1
Pin locking H2
Main boom pin locking
Inclination cylinder, cab
Counterweight dolly
Locking cylinder
Mounting cylinder for connecting
frame
Chassis
Outriggers, pin locking,
intermediate section,
quick release
7 P 3.3 Hydraulic oil cooler
0621050151_en 7/21
5
Z 38 080
Z 38 081
30.1
Z 38 082 Z 40 517
8/21 0621050151_en
Engine and Drive 5
5.2 Starting Up, Operating and Shutting Down the Power

Units
5.2.1 Checks before Starting the Diesel Engines
On the crane
Required action Check point Picture

Check the engine oil level, Oil dipstick (1). Z 38 080
add engine oil as required.
Check the coolant level, Filler neck (2) on Z 38 081
add coolant as required the expansion
tank.
If the coolant level is too Coolant pipes and

low, check the coolant cir- hoses, radiator.
cuit for leaks. *
Oil level in the pump dis- Oil level check Z 38 080
tributor gear. plug (3).
If the oil level has fallen, Pump distributor

check for leaks. gear, oil cooler,
lube oil circuit out-
side the transmis-
sion.
Check the hydraulic oil Oil level display. Z 38 082
level.
Pipes and valves,
If the oil level has fallen, oil cooler, hydrau-
check for leaks in the hy- lic oil tank.
draulic system.
Check the fuel system for Fuel lines
leaks. *
In the crane operators cab after the power supply has been
switched on.
Required action Check point Picture

Check the fuel level in the Button (1) on the Z 40 517
tank of the superstructure. multifunction dis-
play (30.1) in the
cab.
* )= measure is not required for every startup.
0621050151_en 9/21
5
10/21 0621050151_en
Engine and Drive 5
5.2.2 Starting the Diesel Engine
Only operate the diesel engine in sufficiently ventilated spaces.

Before starting in closed spaces, make sure that sufficient ven-
tilation is available.
Before starting, sound the horn to warn people to leave the haz-
ardous area.
To improve the cold start procedure and the warmup phase, the
engine of the crane is equipped with a flame starting system. It
is ready for operation at a coolant temperature below 15C.
If the ignition is switched on with ignition switch (111), indicator

light (33) lights up for approximately 20 seconds, indicating that
the glow plug of the flame starting system is being preheated.
When it goes out, the engine can be started.
For a coolant temperature above 15C the flame starting system

does not come on. Indicator light (33) lights up for 2 seconds
when the ignition is switched on to check that it is functioning cor-
rectly. The engine can be started immediately.
The flame starting system is controlled and monitored electroni-

cally. It switches off automatically:
as soon as the coolant temperature has reached 23C.
if the engine is not started within 30 seconds of the indicator
light (33) going out.
if the engine is started before indicator light (33) goes out.
If the indicator light (33) fails to go out after approx. 20 seconds,

there is a fault in the flame starting system. In this case, have the
flame starting system checked by MercedesBenz Service.
0621050151_en 11/21
5
12/21 0621050151_en
Engine and Drive 5
5.3 Starting
5.3.1 Starting Procedure

Before starting, always check that all control levers are in the
Off position.
1. Prepare the electrical system for operation by switching on

the battery switch.
2. Insert the ignition key in the ignition lock and turn to the sec-
ond notch in the clockwise direction.
The charge control light (34) and engine indicator lights (PLD)
and (FMR) must light up.
The key switch of the ignition lock is designed as a fourposi-

tion switch:
Position 0: Off position. The key can only be removed
in this position.
Position P: Parking position. Voltage supply for radio,
fan.
Position 1: On position. The ignition is switched on.
Position 2: Momentary contact position start. The en-
gine switches on.
3. Place the accelerator pedal (7) and knob (110) in idle posi-
tion.
4. Turn the ignition key further up to the stop and hold in this
position until the engine starts. If required, interrupt the start-
ing procedure after a maximum 20 s and repeat after approx.
60 s.
When the engine is running the charge control light (34) and
engine indicator lights (PLD) and (FMR) must go out.
Release the ignition key as soon as the engine starts. Do not,

under any circumstances, actuate the starter when the en-
gine is running.
If indicator light (34) does not go out, there is a fault in the
power supply.
Observe the corresponding instructions in the operating in-
structions of the engine manufacturer.
If one of the indicator lights fails to go out, there is a fault in
the engine control. This is identified by a fault code. Fault
codes can only be read off at the diagnosis socket in the
switch box using a Mercedes diagnosis unit. If a diagnosis
unit is not available, please contact the customer service de-
partment. Operation of the crane is prohibited !
0621050151_en 13/21
5
14/21 0621050151_en
Engine and Drive 5
5.3.2 To be observed following starting
Directly after the start, display the oil pressure on the multi
function display (30.1) by pressing button (30.2).
Do not rev up the engine until oil pressure is displayed. If oil

pressure is not displayed after approx. 10 seconds, switch
off the engine and determine the cause.
If the indicator light (36) lights up, service the air filter or the
hydraulic oil filter (see lubricating and maintenance instruc-
tions of the superstructure).
Shortly after starting, do not place the engine under full load
or at its highest speed. Do not apply full throttle either in the
loaded or unloaded condition.
Leave the engine running for some time at no more than 2/3
of the maximum speed (approx. 1400 min1).
The engine may only be run at full power once a coolant tem-
perature of approx. 70 C has been reached.
The coolant temperature can be read off the multifunction dis-

play (30.1).
The fans for the radiator and oil cooler must remain at a
standstill as long as the engine, the hydraulic oil and the lube
oil in the pump distributor gear are cold.
The idle speed should not fall below 800 min1 . At a lower idle
speed turn rotary switch (110) for the speed control to the
right, to position 1, and regulate the idling speed using foot
operated switch (7).
At extreme minus temperatures do not place the cold engine
under full load.
Switch off the engine immediately in case of:

abnormally low or strongly fluctuating oil pressure.
falling output and speed when the accelerator pedal (7)
or knob (110) are held constant.
strongly smoking exhaust.
abnormally high coolant and oil temperature.
sudden abnormal noises on the engine or turbocharger.
0621050151_en 15/21
5
(2) (1)
Temperature
Z 35 203
16/21 0621050151_en
Engine and Drive 5
5.3.3 Warming Up the Hydraulic System
It is only necessary to warm up the hydraulic system if the oil vis-

cosity is between 1000 and 1600 cSt, depending on the ambient
temperature.
These values are reached for a hydraulic oil with the nominal vis-
cosity ISO VG 46 at a hydraulic temperature of 8C or 11C.
Other temperature values apply for hydraulic oils with another

nominal viscosity (see table Z 35 203).
5.3.4 Warmingup Procedure

1. First make sure in table (Z 35 203) that the correct hydraulic
oil has been used for the prevailing temperatures. The vis-
cosity of the oil must be below 1600 cSt.
2. Start the diesel engine.
This is described in detail in Sect. 5.2.2.
Standard hydraulic oil filling for medium temperatures

Oil temper- Oil viscosity Speed of diesel
ISO VG 46
ature (C) (cSt) engine (min1)
Starting without load below 1000
11 1600
(1) (idle)
min 8 1000
Operation (2) max
max + 85 10
As soon as the diesel engine is running initially in idle , the hy-

draulic pumps are automatically activated. This causes the hy-
draulic oil to be circulated without pressure and heated up.
The hydraulic system must be allowed to warm up until the vis-

cosity of the oil is below 1000 cSt.
With a running time of 30 minutes and approx. 1000 (min1) the

hydraulic oil is warmed by 4 to 5 C.
3. After this carefully carry out all movements repeatedly for

approximately 10 to 15 minutes without load. The system is
then warmed up.
0621050151_en 17/21
5
36 33
31
Z 40 518
30.9
30.10
30.2
30.3
30.5
Z 40 519
18/21 0621050151_en
Engine and Drive 5
5.3.5 Checks with the Diesel Engine Running

(Z 40 518, Z 40 519)
When the diesel engine is running the monitoring instruments

must be checked regularly.
Engine oil pressure
The oil pressure for the diesel engine can be called up on the mul-
tifunction display by pressing the button (30.2, Z 40 519) on the
display (30.9). The oil pressure should not fluctuate strongly at a
constant speed.
If the oil pressure in an engine is too low (less than 0.3 bar at a
minimum speed of 500 rpm) the LED indicator (30.10) flashes
and the buzzer signal sounds. The engine must be switched off
immediately. Determine the cause using the faultfinding chart in
the engine operating instructions.
Air filter
If the indicator light (36, Z 40 518) lights up, the air filter is clogged
and the filter element must be replaced.
Hydraulic oil filter
If the indicator light (33, Z 40 518) lights up, the filter cartridge at
the hydraulic pump (1.2) is clogged. The filter cartridge must be
replaced by a new one.
Coolant
The indicator light (31) lights up if the coolant level is too low. The
coolant temperature of the engine at operating temperature must
lie between 70 C and 95 C and can be shown on the display
(30.9) by pressing button (30.3, Z 40 519).
If the coolant temperature is too high (above 103 C), the LED in-
dicator (30.10) lights up and the buzzer signal sounds. The en-
gine must be switched off immediately. Determine the cause of
overheating using the faultfinding chart of the engine operating
instructions.
Idle speed
The idle speed should not fall below 800 min1. The idle speed
can be regulated using footoperated switch (7). The speed for
the engine can be displayed by pressing button (30.5) on the dis-
play (30.9).
0621050151_en 19/21
5
20/21 0621050151_en
Engine and Drive 5
5.3.6 Notes on Operation
Avoid long idling times.They are detrimental to the engine.

Pay attention to the fuel gauge. Do not allow the tank to run
dry.
The alternator must always be connected to the batteries
when the diesel engine is running. The cable connections
may therefore not be disconnected during operation.
5.3.7 Switching Off
1. Place the knob (110) and accelerator pedal (7) in the idle
position.
Following operation with full engine output or high coolant

temperature, leave the engine running without load for 1 2
minutes at idle speed.
2. Turn the ignition key in an anticlockwise direction (to posi-

tion 0) and remove the ignition key.
When leaving the crane, remove the ignition key and lock the
cab.
0621050151_en 21/21
Driving the Crawlermounted Crane 6
0621060151_en 1/31
6
1 1
Z 38 085
2/31 0621060151_en
6 Driving the Crawlermounted Crane
6.1 General
Drive:
Each crawler is driven by two hydraulic motors via a planetary
gear. Each side can be controlled progressively, individually and
in opposite directions.
Brakes:
The driving movement is braked using a nonwearing, hydraulic
service brake.
For operation mode Tailing (driving and lifting simulta-

neously) the crane may only be driven on level ground as
the hydraulic operation brake does not work in this op-
eration mode.
Each crawler is equipped with a hydraulic motor with a springac-

tuated and hydraulically vented retaining brake.
Counterweight dolly (Optional equipment):

The crawlermounted crane can be operated with or without
counterweight dolly. For a description of the counterweight dolly
and information on setting the different parameters for driving
with the counterweight dolly, please refer to section 10.
When driving the crawlermounted crane with a counterweight

dolly, the slew gear brake must be opened using luminous switch
(73).
6.1.1 Main Direction of Travel
The control levers (1 + 2 or 3) for operating the crawlers only

cause analogous driving movements if the superstructure and
undercarriage are standing parallel and the counterweight of the
superstructure is positioned above the final drive (1) (Z 38 085).
The forwards direction of travel for this superstructure position

is the main direction of travel.
There is no relation between the load bearing capacity of the

crane and the main direction of travel.
0621060151_en 3/31
6
4/31 0621060151_en
6.1.2 Requirements for the Road Surface
The ground on which the crane is driven must have sufficient

loadbearing capacity and must be even. When the crane is
driven with various configurations, certain uphill and downhill gra-
dients in the direction of travel as well as lateral ground gradients
may not be exceeded. Dips and bumps in the road surface must
be compensated for, at least in the area of the tracks. (Use of
sand or gravel; excavation of earth and subsequent levelling.)
6.1.3 Regulations for Driving Operation
Make sure that the crane has sufficient driving clearance and
is kept away from overhead power cables, if necessary en-
gage a banksman.
When driving on uneven terrain near overhead power cables,
keep a clearance of at least 10 m to allow for lateral move-
ment of the boom system.
The driving direction of the crane may only be reversed when
the crane is at a standstill.
The temperature of the hydraulic oil, the driving gears and the
bottom rollers must be monitored.
When driving without the counterweight dolly lock the super-
structure using the slew brake (press luminous switch 73).
Where possible, always drive the crane with the drive at the
rear, as seen in the direction of travel (particularly on steep
ground).
Before driving across a bridge, check to make sure that the
bridge is strong enough to support the operating weight of the
crane.
Keep a safe distance from slopes and ditches.
To avoid damage to the track groups, you must avoid rotation
of the tracks above ditches and troughs.
0621060151_en 5/31
6
Z 40 520 Z 40 521
Z 40 522 Z 40 523
6/31 0621060151_en
In order to avoid damage to the drives, the following points

should be observed when driving on ramps or slopes:
As a basic rule, only ever drive at a right angle to the ramp

(Z 40 520).
Driving on or off the ramp at an oblique angle is prohib-
ited! (Z 40 521)
The access and exit route to and from the ramp must be
set up so that a change in the angle of 0.55/m is not ex-
ceeded (Z 40 522).
The ramp surface must be smooth and even. The maxi-

mum transverse tilt of 1.55 may not be exceeded.
A change in direction when driving on and off ramps is

strictly prohibited ! (Z 40 523)
A change in direction when the vehicle is already on the

ramp is only allowed when all links of the track group are
on clear ground and the drive sprockets and idler are
free. The maximum transverse tilt of 1.55 may not be ex-
ceeded.
0621060151_en 7/31
6
Z 00 025
8/31 0621060151_en
6.2 Steering the Undercarriage
6.2.1 Steering Movements

(Z 00 025)
Control levers (1 and 2) are used to carry out the steering move-
ments shown in figure Z 00 025.
The following driving movements are carried out in the different

positions:
No. Movement of the Movement of Movement of

control levers (1 + 2) the track the undercar-
groups riage
left (1) right (2) left right
1 forwards forwards for- for- forwards
wards wards
2 back- backwards back- back- backwards
wards wards wards
3 back- forwards back- for- turning left on
wards wards wards the spot
4 forwards backwards for- back- turning right on
wards wards the spot
5 forwards for- left curve
wards forwards
6 forwards for- right curve
wards forwards
7 back- back- right curve
wards wards backwards
8 backwards back- left curve
wards backwards
When driving in a straight line forwards or backwards, while one

of following movements may bee carried out simultaneously (tail-
ing):
Hoist 1 (H1) raise / lower (P1.1) with control levers (1)
Derricking gear (E) raise / lower (P2.1) with control levers (2)
Luffing gear 2 (W2) raise / lower (P1.1) with control levers (1)
The crawlers are then steered after the luminous switch (74) has
been switched on using control lever (3).
0621060151_en 9/31
6
10/31 0621060151_en
6.2.2 Option for Regulating the Driving Speed and the

Drive Force
The travel gear has two speed levels. normal speed and high
speed.
Switching on the speed levels:
Normal speed:
Rocker switch (5 or 11) not pressed in control levers 1, 2 or

3.
High speed:
Rocker switches (5 and 11) pressed and held down in control

levers 1, 2 or 3.
The travel gear can move at any speed level from 0 up to maxi-
mum speed. Normal speed must always be selected for turning
movements, driving on difficult terrain, on inclines and with
loads. The speed level should always be selected when the
crane is at a standstill.
Varying the pump flow rate:
If the thrust of normal speed is not sufficient in particular cases

(engine stalls), the pumps should be switched to a lower flow rate
by adjusting the rotary switches (63 + 64).
Rotary switches (63 + 64) to the left: increases thrust.
Rotary switches (63 + 64) to the right: decreases thrust.
0621060151_en 11/31
6
12/31 0621060151_en
Brakes:
During normal driven operation, the crane is braked by throttling

the oil which flows back from the engines. The braking effect is
greater in normal speed than in high speed .
When stationary, the travelling gear is braked by the hydraulically

locked engines.
At standstill and during crane operation, always switch to normal

speed as all the hydraulic motors of the tracks are then used for
braking.
0621060151_en 13/31
6
14/31 0621060151_en
6.3 Driving without Load on Horizontal and Sloping

Ground
6.3.1 General
The positions of the boom shown in the following tables enable

an optimum centre of gravity to be achieved, guaranteeing even
distribution of the ground pressures.
The boom angles are measured with an attached angle sensor

and can be read off the screen in the drivers cab.
The screen in the cab always specifies the angle to the horizon-
tal. This allows the crane to be driven in both the forward and re-
verse directions of travel with the boom at the same angle.
In addition to the slope (incline) specified, the lateral gradient of

the ground must also be taken into consideration.
Attention must be paid to dips and bumps in the ground even if

the crane is not carrying the load.
Sudden shifts in the position of the centre of gravity as a result

of the crane tilting must be prevented to avoid the hook block
swinging and impacting with the boom construction.
This danger is particularly accute when the boom is in a steep
(high) position.
Bei ebener Fahrbahn kann der Kran unabhngig von der Ausle-
gervariante im Schnellgang gefahren werden.
With a stepped main boom (variants SH/LH and SSL/LSL) the

heavy basic length (HBL) of the main boom must be specified.
Only when driving straight without load a simultaneous move-

ment is possible (tailing).
0621060151_en 15/31
6
Table: Application SH, SH/LH, SSL, SSL/LSL
HA WA STW STP FQW FQP

(m) () () (%) () (%)
24 ... 36
3.0 5.2
42 ... 54 8.5 15.0
60 ... 72
78 ... 90 75 6.8 12.0
96 ... 108 5.1 9.0 2.0 3.5
114 ... 126 3.4 6.0
132 ... 138 2.0 3.5
16/31 0621060151_en
6.4 Driving the Crane without Load

Application SH, SH/LH, SSL, SSL/LSL
Legend:
HA Main boom length
WA Angle of the main boom to the horizontal
STW Permissible climbing angle (in degrees)
STP Permissible incline (as a percentage)
FQW Permissible lateral gredient of the ground (in degrees)
FQP Permissible lateral gredient of the ground
(as a percentage)
The main boom must be adjusted to the angle WA given in the

table using the derricking gear.
The angle of the main boom to the horizontal is displayed on the
monitor (39).
If the angles given in the table are maintained, the crane can be
driven on the horizontal with the optimum centres of gravity.
When the crane is driven uphill and downhill, the angle given un-
der WA in the table can be maintained.
The maximum permissible angle of inclination (in degrees) is
given in the table under STW.
The maximum permissible inclination (as a percentage) is given
in the table under STP.
When the crane is driven on an incline, the boom must al-

ways be positioned up the slope !
0621060151_en 17/31
6
Table: Application SW
HA HI WA WI STW STP FQW FQP

(m) (m) () () () (%) () (%)
24 2.0 3.5
30
8.5 15.0
36
42
48
30 54 85 65 6.8 12.0
1.5 2.6
60
66
72 5.1 9.0
78
84 3.4 6.0
24
30 8.5 15.0
36
42
48 6.8 12.0
36 54 85 65 1.5 2.6
60
66 5.1 9.0
72
78
3.4 6.0
84
24
8.5 15.0
30
36
42 6.8 12.0
48
42 54 85 65 1.5 2.6
60 5.1 9.0
66
72
78 3.4 6.0
84
18/31 0621060151_en
6.5 Driving the Crane without Load Application SW
Legend:
HA Main boom length
HI Fly jib length
WI Angle of the fly jib to the horizontal
(as a percentage)

monitor (39).
The fly jib must be moved to the angle WI given in the table
using luffing gear W1.
The angle of the fly jib to the horizontal is shown on the monitor
(39).
When the crane is driven uphill and downhill, the angles given un-
der WA and WI in the table can be maintained.
given in the table under STW:

0621060151_en 19/31
6
Table: Application SW

(m) (m) () () () (%) () (%)
24 8.5 15.0
30
36 6.8 12.0
42
48
48 54 85 65 5.1 9.0 1.5 2.6
60
66
72 3.4 6.0
78
84 2.0 3.5
30
6.8 12.0
36
42
48 5.1 9.0
54
54 85 65 1.5 2.6
60
66 3.4 6.0
72
78
2.0 3.5
84
36
42 5.1 9.0
48
54
60 60 85 65 3.4 6.0 1.5 2.6
66
72
78 2.0 3.5
84
20/31 0621060151_en
Continued: Driving the Crane without Load Application SW
Legend:
HA Main boom length
HI Fly jib length
(as a percentage)

monitor (39).
(39).
given in the table under STW:

0621060151_en 21/31
6
Table: Application SWSL

(m) (m) () () () (%) () (%)
24
30 8.5 15.0
36
42
48 6.8 12.0
54
36 60 85 65 1.5 2.6
66 5.1 9.0
72
78
84 3.4 6.0
90
96 2.0 3.5
24
8.5 15.0
30
36
42 6.8 12.0
48
54
42 60 85 65 5.1 9.0 1.5 2.6
66
72
78 3.4 6.0
84
90
2.0 3.5
96
24 8.5 15.0
30
36 6.8 12.0
42
48 85 65 1.5 2.6
48
54 5.1 9.0
60
66 3.4 6.0
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6.6 Driving the Crane without Load Application SWSL
Legend:
HA Main boom length
HI Fly jib length
(as a percentage)

monitor (39).
(39).
If the weight of the hook block is less than that listed in the table,
the boom should, if possible, be tilted further forwards.

0621060151_en 23/31
6

(m) (m) () () () (%) () (%)
72
3.4 6.0
78
48 84 85 65 1.5 2.6
90 2.0 3.5
96
30
6.8 12.0
36
42
48 5.1 9.0
54
60
54 85 65 1.5 2.6
66 3.4 6.0
72
78
84 2.0 3.5
90
96 1.0 1.7
30 6.8 12.0
36
42 5.1 9.0
48
54
60 3.4 6.0
60 85 65 1.5 2.6
66
72
78 2.0 3.5
84
90
1.0 1.7
96
36
5.1 9.0
42
66 48 85 65 1.5 2.6
54 3.4 6.0
60
24/31 0621060151_en
Continued:
Driving the Crane without Load Application SWSL
Legend:
HA Main boom length
HI Fly jib length
(as a percentage)

monitor (39).
(39).


0621060151_en 25/31
6

(m) (m) () () () (%) () (%)
66
72 2.0 3.5
78
66 85 65 1.5 2.6
84
90 1.0 1.7
96
42
48 3.4 6.0
54
60
66 2.0 3.5
72 85 65 1.5 2.6
72
78
84
1.0 1.7
90
96
48 3.4 6.0
54
60 2.0 3.5
66
78 72 85 65 1.5 2.6
78
84 1.0 1.7
90
96
54
2.0 3.5
60
66
72
84 85 65 1.5 2.6
78
1.0 1.7
84
90
96
26/31 0621060151_en
Continued:
Driving the Crane without Load Application SWSL
Legend:
HA Main boom length
HI Fly jib length
(as a percentage)
monitor (39).
(39).


6.7
6.8
6.9
6.10
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6
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6.11 Driving with Load
General
The crane can be driven with load with all boom combina-
tions.
When the crane is driven with load, the load capacity tables
and the notes on the load capacity tables apply.
As a basic rule, loads should be moved using as small a ra-
dius as possible and near to the ground.
Das Verfahren mit Last darf grundstzlich nur im Normalgang
erfolgen. Fahrtrichtungsnderungen sind so langsam wie
mglich vorzunehmen.
Swinging of the load must be avoided at all times (if required,
the load should be tied with ropes).
The ground must be level and must have sufficient load
bearing capacity (compare ground pressure values).
If the ground on which the crane is to be driven is sloping, the
loads must be reduced:
Slope 0.5 1.5 .... by 15%,
Slope 1.5 2.5 .... by 25%.
When driving the crane under load on slopes of greater than

2.5 the manufacturer must first be consulted.
The crane can be driven under load at wind speeds of up to

a maximum of 9.8 m/sec.
Lower wind speeds specified in the corresponding load capacity

tables must be observed.
When the crane is driven with the Superlift, it must be ensured

that the Superlift counterweight is raised.
The limit switches on the basic frame of the Superlift coun-

terweight only function when the crane is in operation and
have no effect on the travel gear. For this reason, the clear-
ance between the basic frame and the ground must be moni-
tored continually.
Minimum clearance: 100 mm
Max. clearance: 400 mm
It must be possible to set down the load evenly and safely in
the case of any faults which might occur. If required, the
ground must be levelled as appropriate.
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6
30/31 0621060151_en
6.11.1 Driving with Load, Boom Along the Longitudinal Axis

of the Crawlers
When the crane is driven under load with the boom facing along
the length of the crawlers, the following points must be observed:
The load must be in the drivers direct line of vision.
No additional crane movements are permitted while the
crane is being driven.
Pay attention to the temperatures (see Sect. 6.1.3).
6.11.2 Driving with Load, Boom Not Along the Longitudinal

Axis of the Crawlers
(Positioning Loads)
When driving the crane under load with the boom not facing along
the length of the crawlers, the following points must be observed:
The load must be held close to the ground.
The driving movement can, if absolutely required, be carried
out simultaneously with another crane movement.
The travel speed may not exceed 0.1 m/sec.

Acceleration and braking procedures must be carried out
gently and smoothly.
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Slewing and Braking the Superstructure 7
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7
2/7 0621070151_en
7 Slewing and Braking the Superstructure
7.1 General
The slew gear is driven by a hydraulic motor via a closed splash

lubricated planetary gear.
The slew gear is equipped with a springoperated, hydraulically

released holding brake.
The deceleration of the slewing movement is effected exclusively

by actuating control lever (3) according by.
7.1.1 Speed control
The slewing speed of the superstructure must be reduced for cer-

tain operating conditions. The reductions depend on the height
of the crane equipment and the load moment.
The maximum slewing speed may be limited using rotary switch

(62). Control lever (3) always controls the slewing speed from
zero up to the formerly adjusted maximum slewing speed.
The lower the maximum slewing speed, the finer the slewing
movement may be controlled.
The maximum possible superstructure speed equals 0.77 min1.

The diesel engine runs with maximum revs.
Adjustment levels for rotary switch (62):

Height of crane equipment Adjustment level
Below 50 m
Between 50 m and 102 m
Above 102 m
0621070151_en 3/7
7
L R
Z 38 086
4/7 0621070151_en
7.2 Slewing
Standard operation
Release the parking brake by actuating luminous switch (73),

the integral indicator light must come on.
Slew to the left (L, Z 38 086): move lever (3) to the left.
Slew to the right (R, Z 38 086): move lever (3) to the right.
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7
Z 38 087
6/7 0621070151_en
7.3 Braking the Superstructure
Service brake
Move control lever (3) slowly into the Off position
The superstructure should not be braked by switching it to

slew in the opposite direction.
Parking brake
Operate luminous switch (73) the integral indicator light must

go out. The parking brake is applied.
7.4 Mechanical Locking of the Parking Brake in the Open

Position
In order to enable the crane superstructure to position itself auto-

matically in the direction of the wind during prolonged stoppages
in work, the parking brake must be released, particularly when a
fly jib is attached.
Ensure that the slewing range is free from any obstacles

before carrying out these measures.
With Superlift attachment mounted the slew brake must
not be locked in the open position.
Release the parking brake by pressing luminous switch
(52) the integral indicator light must come on.
Push in lever (A, Z 38 087) when the brake is released.
Relieve the parking brake by pressing switch (52) the in-
tegral indicator light must go out.
0621070151_en 7/7
Operating the Safety Equipment 8
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8
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8 Operating the Safety Equipment
8.1 General
The crane is equipped with numerous safety monitoring and

measurement devices to monitor operational reliability, particu-
larly in the area of the superstructure, the boom and the counter-
weight dolly.
The central unit is the electronic crane information system PDC

which is described in section 8.2. This system provides informa-
tion on the current load moment as well as a large number of im-
portant operating parameters.
The information is displayed on the computer screen in the cab.
The controls of the counterweight dolly are described in section

10 of these operating instructions.
The combined operation of PDC and the radio remote control

is described in chapter 14 of these operating instructions.
The separate operating instructions as well as the fault code

table of the load limit device manufacturer PAT explain how the
measurement data is broken down as well as providing the crane
operator with instructions on how to use the screen and key-
board.
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8
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8.2 Electronic Crane Information System (PDC)
8.2.1 General
The instruction manual of the manufacturer (PAT) in part 4 of

this documentation must be observed.
The electronic crane information system PDC combines several

devices which supply the crane operator with a large amount of
information for the purpose of operating the crane within the pa-
rameters specified by the manufacturer:
Overload cutoff device (load limit device ).
Monitoring the limit switches.
Display of numerous crane functions, for example support
pressure, inclination, crane configuration, loads etc.
Warning (optical and acoustic) in case of prohibited condi-
tions.
Control of the counterweight dolly (see Sect. 10).
Preselection remote control for mounting the crane (see
Sect. 14).
The crane information system (incl. load limit device) is an oper-

ating aid. It provides the crane operator with important informa-
tion on crane data, such as length and angle of the boom, height
of the sheave head, nominal payload, total load suspended on
the boom etc. and provides a warning if an overload condition is
imminent or if the hook block approaches the boom head.
This safety device is not a replacement for the judgement

and experience of the crane operator, nor does it replace
safe procedures for operation of the crane.
The crane operator still carries full responsibility for safe op-
eration of the crane.
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8
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If, when raising a load or lowering the boom when laden, the per-
missible load moment / permissible load is exceeded, all move-
ments which increase or reduce the load moment along with the
raising action of the load on the hook will be shut down.
The load limit device should only be triggered in an emer-

gency situation. It may not, under any circumstances, be
used for regular operation of the crane.
Before a load is raised, its weight must be known. The safety de-
vice may not be used to determine the weight of the load (see
Sect. 8.6).
The load limit device must be set to the corresponding crane

configuration by the crane operator. This means that if the
crane configuration is changed, the crane operator must
also change the load limit device.
The load limit device only operates automatically after it has
been correctly set.
Following the shutdown of an overload condition by the load

limit device, movements which reduce the load moment can be
carried out in order to move a freely suspended load out of the
overload range back into the normal operating range. In this
case, key swtich (24) and footoperated switch (13) must be
pressed. These movements which reduce the load moment are
only allowed if they are not dangerous in any way. Make sure that
this is the case before actuating the key switch (24) and footop-
erated switch (13).
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8
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The load may only be taken up using the hoist in hook

operation.
If the load is still in contact with the ground and the func-
tion for raising the hoist has been switched off, the load
is too heavy. The movement raise main boom and fly
jib may not be enabled.
It may not, under any circumstances, be used to raise the

load.
It is essential for the operational reliability of the crane that

the load limit device functions in its original condition. If the
seal on the central unit of the load limit device is damaged,
the General operating permit is rendered invalid.
Risk of crushing!
In spite of the use of automatic safety devices, swinging

of the load cannot be fully avoided when the system is
shut down.
This can only be achieved by the use of suitable accel-
eration and speeds for all crane movements.
Pay attention to the continual display of the load moment
with advanced warning at 90 % of the permitted load mo-
ment before shut down.
The risk of the load limit device being affected by high

frequency radiation is minimised by stateoftheart
technology (shielding). It cannot, however, be fully ex-
luded under extreme conditions, for example in the vicin-
ity of powerful transmitters.
0621080151_en 9/107
8
20 40 41 42 43
47
44
46
45
21
39
22 23 24
Z 40 777
10/107 0621080151_en
8.2.2 Controls and Displays

(Z 40 777)
(20) Console PDC
(21) Input keypad

The crane operator is guided by menu prompts which in-
dicate the inputs required in this field.
(22) Function keypad

These function keys are used to select the functions dis-
played by symbols in the bottom line of the display.
This means that the allocation of these keys depends on
the symbols in this line of the display.
(23) Key switch (Load moment increasing movements)

This key switch is used to bridge the load limit cutoff de-
vice for the functions lower E, W1, W2, raise H1, H2, H3.
The indicator light above the key switch lights up when
the load limit device is bridged.
(24) Key switch (Load moment decreasing movements)

This key switch is used to bridge the load limit cutoff de-
vice for the functions raise E, W1 and W2. The indicator
light above the key switch lights up when the load limit
device is bridged.
(39) LCD (see Sect. 8.2.3).
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8
20 40 41 42 43
47
44
46
45 21
39
22 23 24
Z 40 777
Z 38 780
12/107 0621080151_en
Continued: Controls and Displays

(Z 40 777)
(40) Lamp advanced warning

This yellow warning light lights up if the load on the crane
is between 90 % and 100 % of the permitted load, indi-
cating that an overload condition is imminent.
(41) Lamp overload

This red warning light lights up if the load on the crane
exceeds 100 % of the permitted load. At the same time,
all movements which reduce or increase the load mo-
ment are shut down and the acoustic transmitter sounds.
(42) Lamp hoist limit

This red warning light lights up when the hoist limit switch
contacts open, indicating that a hoist limit condition has
occurred (to prevent the hook block coming into contact
with the boom head).
(43) Lamp standby

This lamp lights up when the system is ready for opera-
tion.
(44) Light RAM/ROM memory fault
(45) Light load limit device (LMB) fault
(46) Light bus fault
(47) Light flashes and alarm sounds simultaneously
8.2.3 LCD Display

(Z 38 780)
A Opening Screen
B Status line
C Operating modes
K Function line
0621080151_en 13/107
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Z 38 781
14/107 0621080151_en
Structure of the screen displays

(Z 38 781)
Item Screen contents Accessed by activating
function taste
1 Opening screen Automatic, after the power
supply is switched on
2 Main menu Appears automatically after
the opening screen has been
displayed for 10 seconds
K1.1 Load table Press function key 22c on the
main menu screen
K1.2 Operating mode / Press function key 22h on the
reeving main menu screen
K1.2.1 Operating mode Press function key 22c on the
configure of the operating mode / reeving
previously se- menu screen
lected crane con-
figuration
K1.2.2 Operating mode Code number entered in the
configure of the mask of the menu screen op-
crane configura- erating mode / reeving
tion
SMAB 1
SMAB 2
RG 0
K1.2.2.1 Configure chas- Press function key 22d on the
sis menu screen RG 0
K1.2.2.2 Configure super- Press function key 22e on the
structure menu screen RG 0
K2 Main menu with Press function key 22 a on the
function key level main menu screen
K2
K2.1 Counterweight Press function key 22d on the
dolly selection main menu screen at func-
tion key level K2
K2.1.1 Rear travel op- Press function key 22a on the
eration menu screen counterweight
dolly selection
K2.1.2 Circular travel Press function key 22b on the
operation menu screen counterweight
dolly selection
K2.1.3 Parallel travel Press function key 22c on the
operation menu screen counterweight
dolly selection
K2.1.4 Counterweight Press function key 22 e on the
dolly switched off menu screen counterweight
dolly selection
0621080151_en 15/107
8
Z 38 781
16/107 0621080151_en
Item Screen contents Accessed by activating

function task
K2.2 Tilt / rotational Press function key 22e on the
angle (reduced menu screen main menu at
image) function level K2
K2.3 Relative working Press function key 22g on the
radius (reduced main menu screen at func-
image) tion level K2
K2.4 Large view of the Press function key 22h on the
current reduced main menu screen at func-
image tion level K2
K3 Main menu with Press function key 22b in
function key level menu screen main menu 2 x
K3 if starting from function level
K1
K3.1 Bus system over- Press function key 22d in
view menu screen main menu at
function level K3
K3.1.1 Bus information Press function key 22b on the
menu screen bus system
overview
K3.1.2 Bus information Press function key 22a in
modular couplers menu screen bus system
overview
K3.2 Service screens Press function key 22e in
menu screen main menu at
function level K3
K3.2.1 Overview of ana- Press function key 22b in
logue inputs menu screen service screens
K3.2.2 Overview of digital Press function key 22d on the
outputs menu screen service screens
K3.2.3 Overview of digital Press function key 22e on the
inputs menu screen service screens
K3.2.4 Pump pressure Press function key 22a on the
monitor menu screen service screens
K3.2.5 After data group A Press function key 22g on the
menu screen service screens
K3.3 Language selec- Press function key 22f on the
tion menu screen service screens
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8
Z 38 760
Z 41 020
18/107 0621080151_en
8.2.4 Description of displayed pictures and buttons
8.2.4.1 Opening Screen

(Z 38 760)
Once the system has been switched on using key switche (111)
menu screen 1 (Z 38 760) appears on the display.
After approximately 10 seconds, the display automatically

switches to main menu.
8.2.4.2 Language Selection

(Z 41 020)
Main menu (Z 38 761) allows you to select the language of your

choice for subsequent text outputs by changing to function level
K3 (see Section 8.3.2).
After the language has been selected the display automatically

returns to the main menu display.
0621080151_en 19/107
8
B
C
E F
A G
Z 41 021
20/107 0621080151_en
8.2.4.3 Main Menu
Example: Operating mode SWSL

(Z 41 021)
(A) Display of the current crane configuration and geometry.
(B) Symbols status line
(C) Symbols for operating modes
(D) Continually changing display of the load moment with

the advanced warning range (90 %) and the overload
range (100 %) marked.
When the advanced warning range is reached, lamp (40) also

lights up.
When the overload range is reached, the load limit device shuts
down all movements which increase or reduce the load moment.
Lamp (41) lights up and a warning buzzer sounds.
(E) Display of the attached load (net load) following a taring

process (see Sect. 8.5 load monitoring assembly).
(F) Display of the maximum load for the current crane con-
figuration.
(G) Display of the attached total load (gross load).

This contains the load, hook block, hoist rope and all
loadhandling devices.
(H) Display setting of the rotary switch 63/64/65 for the

speed limit of the pump displacement.
(J) Balance indicator for the double hook block
(K) Function display.
(I) Inclination indicator
0621080151_en 21/107
8
Z 41 022
Z 41 023
Z 41 024
22/107 0621080151_en
Continued: Main menu
Example: Operating mode SWR

(Z 41 022)
(L) Display of the load suspended on the runner
Example: Operating mode SSL + LF

(Z 41 023)
(M) Display of the suspended load for twohook operation
Example: Operating mode SH/LH

(Z 41 024)
(I) Balance indicator of the double hook block
0621080151_en 23/107
8
C B
F
E
G
A
Z 41 025
24/107 0621080151_en
Symbol Status Line B

(Z 41 025)
The symbols in the status line B have the following meaning:
Bus error.
More detailed information on the bus screen.
Fault display load limit device.
Display of the system time.
Operating mode display.

00000104
Reeving display.
12
Actual force in derricking gear below min. force.
Max. permitted force according to table exceeded in the

derricking gear.
Swivelling bolster S1 counterweight dolly unlocked
Chassis against the forward direction of the superstruc-

ture cab
Fault in plug connection
Display control error

S 016C
Slewing angle for counterweight operation exceeded
0621080151_en 25/107
8
C B
F
E
G
A
Z 41 025
26/107 0621080151_en
Continued: Symbols status line B

(Z 41 025)
The symbols in the status line B have the following meaning:
Correct all swivelling bolsters.
Outrigger counterweight dolly extended
Mast radius outside the defined area.
Configuration operation activated
Synchronous display initialised and switched off
Synchronous display activated, limit value exceeded
No operating mode defined for counterweight dolly
Slew gear brake and parking brake not opened for opera-
tion with the counterweight dolly
Twohook operation activated
0621080151_en 27/107
8
1 2 3 4 5 6 7 8 9 10 11
E
G
Z 41 026
28/107 0621080151_en
Symbols of Operating Modes C

(Z 41 026)
The symbols of the operating modes C have the following

meaning:
(C1) Type of device in accordance with the load table.
(C2) Main boom length.
(C3) Fly jib length (luffing or fixed).
(C4) Angle of the fly jib for LF / SFSL / SFVL
(C5) Runner (1.5 m)
(C6) Counterweight on superstructure.
(C7) Superlift counterweight.
(C8) Central ballast.
(C9) Reeving of the hook block.
(C10) Angle of the main boom for operation with luffing fly jib.
(C11) Operating radius of the Superlift counterweight.
(C12)
0621080151_en 29/107
8
A B C D E F G H 22
A B C D E F G H
K1
K2
K3
Z 41 027
30/107 0621080151_en
Function Display K
(Z 41 027)
The function display line (K) has 3 levels. It changes in relation

to the corresponding level.
The displayed function is activated via the corresponding key on
the keypad (22), e.g. function (K1f) via key (22f).
Function Display K Level 1 (K1)

(Z 38 699)
(K1a) Switch from level 1 to level S with key (22a) (current level
(here 1) is underlined black).
(K1b) Switch from level 1 to the next highest level with key
(22b) (current level is underlined black).
(K1c) Idle.
(K1d) Idle.
(K1e) Switch to load table.
(K1f) Switch off warning buzzer.

The alarm buzzer is reactivated for any subsequent
warnings.
(K1g) Tare key.

Checking the net load to be raised (for a detailed de-
scription see Sect. 8.5).
(K1h) Change operating mode / reeving (for a detailed de-

scription see Sect. 8.4).
0621080151_en 31/107
8
A B C D E F G H 22
A B C D E F G H
K1
K2
K3
Z 41 027
32/107 0621080151_en
Function Display K Level 2 (K2)

(Z 41 027)
(K2a) Switch to the next lowest level with key (22a) (current
level is underlined black).
(K2b) Switch to the next highest level with switch (22b) (current
level is underlined black).
(K2c) Idle.
(K2d) Switch to counterweight selection.
(K2e) Small display of tilt / angle of rotation
(K2f) Idle.
(K2g) Small display of the relative working radius.
(K2h) Selection of large view (zoom) of the current reduced

image
0621080151_en 33/107
8
A B C D E F G H 22
A B C D E F G H
K1
K2
K3
Z 41 027
34/107 0621080151_en
Function Display K Level Service 3 (K3)

(Z 41 027)
(K3a) Idle.
(K3b) Switch to level 1 with key (22b) (current level is under-

lined in black).
(K3c) Idle.
(K3d) Switch to overview of bus system.
(K3e) Switch to service images.
(K3f) Change language.
(K3g) Set time.
(K3h) Idle.
For a detailed description of the functions (K3g) (K3h) and the

corresponding screens, please refer to the manual of the com-
pany PAT (see part 4 of this documentation).
0621080151_en 35/107
8
22
a b c d e f g h
Z 41 028
22
a b c d e f g h
Z 41 029
36/107 0621080151_en
8.2.4.4 Menu Operating Mode Selection

(Z 41 028)
(22a) enter operating mode
(22b) actuate menu selection
(22c) configure
(22d) enter reeving for single hook block
(22e) enter reeving for double hook block
(22f) horn off
(22g) not assigned
Operation with Runner:
(22g) activate / deactivate runner operation

enter reeving of runner
Operation with dual hook operation:
(22g) activate / deactivate dual hook operation

2H enter reeving of runner
(22h) return to main menu
8.2.4.5 Menu Counterweight Dolly Selection

(Z 41 029)
(22a) operating mode rear travel
(22b) operating mode circular travel
(22e) operating mode parallel travel
(22d) correction
(22e) counterweight dolly switched off
(22f) horn off
(22g) not assigned
0621080151_en 37/107
8
22
a b c d e f g h
Z 41 030
22
a b c d e f g h
Z 41 031
38/107 0621080151_en
8.2.4.6 Bus System Overview

(Z 41 030)
(22a) bus information
(22b) bus information coupler
(22c) not assigned
(22d) not assigned
(22e) not assigned
(22f) horn off
(22g) not assigned
8.2.4.7 Service Screen

(Z 41 031)
(22a) overview of pumps
(22b) overview of analogue inputs
(22c) overview of digital inputs
(22d) overview of digital outputs
(22e) Bus (multisensorborad)
(22f) horn off
(22g) after data group A
0621080151_en 39/107
8
93
111
Z 41 032 Z 38 760
22a
22e
K3
Z 41 033 Z 41 034
40/107 0621080151_en
8.3 Operating the Electronic Crane Information System

(PDC)
8.3.1 Switching On
1. Insert key switch (111, Z 41 032).
2. Menu image 1 opening screen appears.
After approx. 10 seconds the display automatically switches to

the display of the main menu
8.3.2 Language Selection

Main menu (Z 41 033) allows you to select the language of your
choice for subsequent text outputs.
The default setting is German.
Press key 22a to activate function display level K3.

Press key 22e to select the language selection menu screen.
Select the language by entering the language code (Z 41 034).
The information is not input as normal using the function keys,

which remain idle in this case, but rather using the numerical key-
pad (21, Z 41 034) on the righthand side of the screen.
After the language has been selected the display automatically

returns to the main menu display.
0621080151_en 41/107
8
42/107 0621080151_en
8.3.3 Entering the Operating Mode
To make sure that the load limit device functions correctly, it must:
be set by the crane operator in accordance with the crane
configuration before work is commenced (as soon as the con-
figuration is achieved) after the ignition/engine is switched
on.
reset by the crane operator in accordance with the new oper-
ating mode once the crane configuration has been changed.
It can only function automatically when the load limit device

has been correctly set by the crane operator in accordance
with the corresponding operating mode.
The operating mode can be set using two methods:
1. Directly with the help of the DS code
2. Using menu selection
Direct selection by inputting the DS code is recommended for

the configuration programs RGO, SMAB1 and SMAB2 and al-
ways when the load capacity table which is to be used is known,
as the corresponding DS code can be read off there.
0621080151_en 43/107
8
B
K
G
J
O
C
Z 38 677
44/107 0621080151_en
8.3.3.1 Selecting the operation mode directly selecting the

DSCode
1. Select the load table (paper) which corresponds with the cur-
rent crane configuration.
The following example shows where to find the relevant data
in the load table:
The adjacent load table (Z 38 677) is only a specimen copy.

To operate the crane, only the load tables supplied with the
crane may be used.
(A) Code no. of the desired load table DS: 000 001 02
(B) Device type in accordance with load table: SH
(C) Main boom length: 30 m
(D)
(E)
(F)
(G) Counterweight on the superstructure: 180 t
(H)
(J) Central ballast on the undercarriage: 60 t
(K) Permitted slewing range: 360
(L) Reeving number of the hoist rope: 17fold
(M)
(N)
(O) Track width: 8.40 m
(P)
0621080151_en 45/107
8
22h 22a
Z 41 035 Z 41 036
21
Z 41 037
46/107 0621080151_en
2. Enter the code no. from the selected load table to identify the
current operating mode.
3. You access the main menu by pressing the button 22h (Z 41

035) (Z 41 036).
4. Once the button 22a has been pressed in the operating

mode selection menu (Z 41 036) an input field appears in
which the desired DS code can be entered via the keys of the
numerical keypad (21, Z 41 037).
All the parameters displayed must correspond with the data

in the load table.
5. The input is ended by pressing key C in the numerical key-

pad (21, Z 41 037).
0621080151_en 47/107
8
21
22h
22b
Z 41 038
Z 41 039
48/107 0621080151_en
6. Once the function key 22h (Z 41 038) has been pressed, an

input window appears to confirm the selected operating
mode.
Before confirming, make sure that the code number of the

desired operating mode has been set correctly.
If no change is desired for the operating mode, the entry is
confirmed by pressing the key 0 in the numerical keypad
(21, Z 41 038).
7. Following confirmation with key C in the numerical keypad

(21, Z 41 038) the system switches back to the main menu
and the operating mode which has been entered appears in
the status line B (Z 41 039).
8.3.3.2 Menu Selection
If the DS code is unknown, it can be determined with the help of

menu selection.
Menu selection is activated using key 22b in the operating mode

selection menu (Z 41 038). The menu point which is to be se-
lected is then highlighted in black in the operating mode selection
menu.
Using the arrow keys in the numerical keypad (21, Z 41 038)
the desired setting can now be carried out and confirmed using
the C key. The system then automatically jumps to the next
selection option. The key (21, Z 41 038) in the numerical key-
pad is used to jump to the previous entry, the current selection is
reset to the last operating mode which was selected.
Only important settings are offered for selection.
0621080151_en 49/107
8
22h 22b
Z 41 035 Z 41 040
21
Z 41 041
50/107 0621080151_en
Below is an example of operating mode selection SH:
1. Press key 22h in the main menu (Z 41 035) to switch to the

operating mode selection menu (Z 41 040).
2. Menu selection is activated by pressing key 22b in the oper-

ating mode selection menu (Z 41 040).
3. As a first selection type is offered.
4. Using the keys in the numerical keypad (21, Z 41 041)

the crane configuration is selected.
5. Press key C in the numerical keypad (21, Z 41 041) to con-

firm the selection which has been made.
0621080151_en 51/107
8
Z 41 042 Z 41 043
Z 41 044 Z 41 045
52/107 0621080151_en
6. After the C key has been pressed, the system automatically

switches to the menu option counterweight (Z 41 042).
7. After selecting the counterweight and confirming the selec-

tion by pressing key C, the system automatically switches
to the menu option central weight (Z 41 043).
8. After selecting the central weight and confirming the selec-

tion by pressing the key C, the system automatically
switches to the menu option main boom length (Z 41 044).
Once all the required parameters have been set, the correspond-
ing DS code nummer is displayed and a blackedout field no lon-
ger indicated.
0621080151_en 53/107
8
22h
Z 41 046
54/107 0621080151_en
9. Press key 22h (Z 41 046).

An input field appears to confirm the selected operating
mode.
10. Following confirmation with the C key, the system switches

back to the main menu and the operating mode which has
been entered appears in the status line B.
0621080151_en 55/107
8
56/107 0621080151_en
8.3.4 Setting the Configuration Programs for the self as-

sembly of the crane
For self assembly of the crane, various configuration programs
have to be set for the different crane configurations. The configu-
ration programs and their use are listed below.
1. Configuration program SMAB 1 without track frame:
Assembling the track frame with the Aframe (see Sect.
8.3.3.1).
2. Configuration program SMAB 2 without track frame:
Assembling the crane equipment with the Aframe (see
Sect. 8.3.3.2).
3. Configuration program RG 0:
Erecting with a partially assembled crane (e.g. moving the
Aframe; see Sect. 8.3.3.3).
0621080151_en 57/107
8
DS
22
A B C D E F G H
Z 38 089
01 00EEEE
SMAB1 10
11099801
SMAB1
10
A B C D E F G H 22
Z 38 090
58/107 0621080151_en
8.3.4.1 Configuration Program SMAB1 without Track Frame
When selfassembling the crane with the Aframe the configura-

tion program operation SMAB1 without track frame must be set
for assembling the first track frame.

Setting the configuration program:

Enter the code no. 000 009 90 for the configuration program
SMAB1 without track frame to identify the current operating
mode.
Press key (22h, Z 38 089). The mask appears on the display
(Z 38 090).
Press key (22a, Z 38 090). A field appears in which the code
no. 000 009 90 has to be entered for the desired operating
mode using the input keypad on the righthand side next to
the display.
Confirm the input. This is carried out using a menu prompt.
Before activating, make sure once again that the code no. for
the desired operating mode has been entered correctly.
Make selection with key (22h, Z 38 090) . Subsequent con-

firmation is menuprompted.
The following values are shown on the display (Z 38 089):

Angle of the Aframe
Load in the derricking gear
max. Load
an approximate value for the load via the bars
0621080151_en 59/107
8
DS
22
A B C D E F G H
Z 38 091
01 00EEEE
SMAB2 10
11099801
SMAB2
10
22
A B C D E F G H
Z 38 092
60/107 0621080151_en
8.3.4.2 Configuration Program SMAB 2 with Track Frame
When selfassembling the crane with the Aframe the configura-

tion program operation SMAB 2 with track frame set for assem-
bling the crane equipment frame.


SMAB 2 with frame to identify the current operating mode.
(Z 38 092).
the display.


Angle of the Aframe
0621080151_en 61/107
8
22
DS
22
A B C D E F G H
Z 38 093
000008
RG0 10
00000900
RG 0
10
22
A B C D E F G H
Z 38 094
62/107 0621080151_en
8.3.4.3 Configuration Program RG 0
When erecting the partially assembled crane (e.g. for moving the
Aframe) the configuration program RG 0 must be set.
With the exception of the limit switches stated in the follo-

wing all limit switches are without function when having the
erection program RG0:
S009C = final position of rear Aframe

S027 = final position of front Aframe
S024 = oblique pull of derricking gear
B305 = max. force of derricking rope < 352 kN


RG 0 as an identification for the current operating mode.
(Z 38 094).
the display.


0621080151_en 63/107
8
A B C D E F G H A B C D E F G H
22 22
Z 39 273 Z 39 274
22 22
Z 39 275 Z 39 276
64/107 0621080151_en
8.3.4.4 Erection Operation
To erect the selected crane equipment erection operation must

be switched on.
Switching on erection operation
1. Switch on the operation mode selection menu
2. Press the function key 22c to select the erection operating

mode assigned to the current operating mode (Z 39 273).
3. The symbol displays that the operating mode
erect has been selected (Z 39 274).
4. Use function key 22h to return to the main menu.
5. Before the main menu screen appears, the input must first
be confirmed by pressing the key C.
6. The symbol in the main menu indicates that the erection con-
figuration has been switched on (Z 39 276).
Switching off erection operation
1. Switch off the operation mode selection menu
2. By pressing the function key 22c the erection operation

mode is deactivated.
3. The Symbol is switched off.
4. Switch back to main menu using function button 22h.
5. Before the main menu appears your choice must be confir-

med by actuating button C.
0621080151_en 65/107
8
22h
Z 41 035 Z 41 047
21
22f 22h
22d
Z 41 048
66/107 0621080151_en
8.3.5 Entering the Reeving Number
1. Press key 22h in the main menu (Z 41 035) to access the op-
erating mode selection menu (Z 41 047).
2. Press key 22d or 22f to display an input field to confirm the

entry (Z 41 048).
3. Press key C in the numerical keypad (21, Z 41 048) to con-

firm the entry.
4. Press key 22h to switch back to the main menu (Z 41 048).
0621080151_en 67/107
8
22 22
Z 41 049 Z 41 100
22 22
Z 41 101 Z 41 102
68/107 0621080151_en
8.3.6 Synchronous Display
The synchronous display function is started when operation

with double hook block is set.
8.3.6.1 Switching On the Synchronous Display
1. To switch from the main menu to the operating mode selec-

tion menu, press key 22 h (Z 41 049).
2. After key 22 e is pressed, the setting is made for the reeving

number of the double hook block via the input keyboard to
the right of the display and confirmed with key C (Z 41 100,
Z 40 101).
3. You can return to the main menu again by pressing key 22 h.

The synchronous display 1 now appears in the main menu
(Z 41 102).
The bar which indicates the deviation from the desired value
is still faded out and the symbol (1, Z 40 102) in the status line
shows that the synchronous display has not yet been acti-
vated.
4. Press key 22 b to move to level K2 of the function display.
0621080151_en 69/107
8
22 22
Z 41 103 Z 41 104
22 22
Z 41 105 Z 41 106
70/107 0621080151_en
5. The synchronous display is activated od deactivated by

pressing key 22 c, the symbol in the status display disap-
pears and bar 2 for displaying the deviation from the desired
value becomes visible (Z 41 103).
8.3.6.2 Working with the Synchronous Display
Bar 1 for displaying the deviation from the desired value moves
to the left when hoist 1 is moved down more quickly than hoist 2
and to the right when hoist 2 is moved down more quickly than
hoist 1.
When the double hook block has reached maximum tilt (bar 2 is
positioned completely to the left or to the right in the display field),
symbol 3 appears in the status line (Z 41 104).
Symbol 3 also appears for invalid counter values (communication
failure with counter board) and bar 2 is also deleted (Z 41 105)
and the control of both hoists (H1 and H2) is blocked.
By actuating button 22c the control of both hoists (H1 and H2) is
activated again.
8.3.6.3 Monitoring the Counter Status
1. Press key 22 a to switch to the function display, level K3.
2. You can access the service screen by pressing key 22 e.

When operating with the double hook block, this is where the
line status is displayed for hoist 1 and hoist 2 (Z 41 105).
0621080151_en 71/107
8
22h
Z 41 035 Z 41 047
21
22g
Z 41 107
72/107 0621080151_en
8.3.7 Entering the Load on the 2nd Hook

(Twohook Operation)
All operating modes with a fixed fly jib type LF in the 305 position
can be operated using twohook operation.
The load limit device is internally programmed so that only certain

operating modes can be authorised for twohook operation.
If the operation mode is enabled the display is also activated.
1. Press key 22h in the main menu (Z 41 035) to switch to the

operating mode selection menu (Z 41 047).
2. Set the operating mode.
If twohook operation is possible for this selected operating

mode, key 22g is indicated in the operating mode selection menu
(Z 41 107).
3. When key 22g (Z 41 107) is displayed, an input field appears

in which the second reeving number is entered.
4. Press key C to confirm the entry (Z 41 107).
0621080151_en 73/107
8
22h
Z 41 108
22f Z 41 109
22e Z 41 110
74/107 0621080151_en
5. Once the entry has been confirmed, the reeving number

which has been selected is indicated in the operating mode
selection menu (Z 41 108).
If twohook operation has already been activated, it is now

switched off. The display in the operating mode selection menu
is deleted.
6. Press key 22h (Z 41 108) to transmit the setting to the load

limit device and to switch to the main menu (Z 41 109).
In the status display B, when twohook operation is activated,

the symbol 2H is displayed (Z 41 109).
Load display (Z 41 109) in the main menu. Key 22f can be used
to display the separately calculated loads on the main boom and
fly jib.
Press key 22e to return to the main menu and display the slewing
angle, inclination etc. (Z 41 110).
0621080151_en 75/107
8
E
F
G
22
A B C D E F G H
Z 41 111
76/107 0621080151_en
8.3.8 Load Monitoring Assembly

(Z 41 111)
With the help of the load limit device computer it is possible to

check the weight of the raised load (net load).
The load monitoring assembly may not be used to calculate

the weight of the load, rather it is used to check the weights
of loads which have been previously and independently cal-
culated. This helps to estimate the load hoist and to avoid
possibly hazardous situations.
Before the load is raised, the maximum load corresponding to the

operating condition must be specified. This is displayed in rela-
tion to the operating mode selected on the display in the MAX (F)
field.
Load monitoring
1. With the hook block suspended freely (without load, with

loadhandling device) press and hold down button (22g).
The lifting tackle is tared, in order to display the net load.
2. Release the button again after a short period of time.
3. Raise the load with the hoist.

The TARE (E) display now shows the net load (actual load
on the hook without loadhandling device).
Taring is automatically switched off if the position of the boom is

moved by 2.5 or the ignition is switched off/on, and the gross
load displayed again on the load display (G).
The gross load includes in addition to the weight of the load it-
self the weight of the hook block, the hoist rope and all load
handling devices. The net load is the actual load on the hook
block without the loadhandling device. Display errors are pos-
sible due to external factors, such as wind acting on the crane
and load.
The load may only be raised using the hoist. Raising the load
by luffing up the fly jib or derricking the main boom is prohib-
ited.
0621080151_en 77/107
8
22
A B C D E F G H
A B C D E F G H
K1
K2
K3
Z 41 112
78/107 0621080151_en
8.3.9 Troubleshooting
The crane information system PDC also provides information

on errors and faults which occur in the transmission system be-
tween the measuring units (sensors, pressure contacts, angle
transmitters) and the central unit.
Errors which occur in the measuring and tranmission range of the

load limit device are displayed directly in the status display of the
screen by means of corresponding fault codes.
The appendix of the PDC instructions contains a list, in which the

displayed error/fault codes are explained.
The malfunctions can, in some case, be rectified by the measures

suggested. If this is not successful and if repairs or the replace-
ment of defective components is required, trained service per-
sonnel must be used.
As well as displaying fault codes in the area of the load limit de-
vice, checks of the remaining parameters can also be carried out.
This is carried out by means of an PDC databus.
In the case of transmission faults, an acoustic signal is given and

an error message appears in the status line on the screen.
Press key (22b, Z 41 112) (switch to level K3).
By pressing key (22d in level K3, Z 41 112; BUS informa-
tion) all the consumers connected to the PDC databus and
their respective condition are displayed on the screen.
0621080151_en 79/107
8
D
F
E G
I
A B C D E F G H 22
A B C D E F G H
K1
K2
K3
Z 41 113
Y +1
+2
22
c d e f g h
Z 38 787
80/107 0621080151_en
8.3.10 Tilt Display

(Z 41 113, Z 38 787)
Before work is carried out, the crane must be aligned horizon-

tally.
The current tilt of the crane can be checked continually on the

main menu and using the following procedure on the LCD:
(Z 41 113, Z 38 787)
Press function key (22e) in level K2. A crosshair appears on
which the current angle of tilt is displayed by means of a bar dis-
play.
The maximum permitted angles of tilt are:
0.3 for crane operation
2.5 when driving the crane
Risk of tipping!
If the permitted tilt is exceeded you must:
1. Set down the load.
2. Realign the crane.
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D
F
E G
I
A B C D E F G H 22
A B C D E F G H
K1
K2
K3
Z 41 113
22
a b c d e f g h
Z 38 788
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8.3.11 Relative Working Radius

(Z 41 113, Z 38 788)
In order to allow the same point (radius) to be selected repeatedly

without having to remember the radius value each time, the de-
sired radius can be set as the zero value.
Example: Several components have to be lifted from the

same point
After the ignition or engine has been switched on, first switch to
level K2 on the PDC display and then press key (22g, Z 41 113).
Image (Z 38 788) appears, on the right side of which a reduced
image of the relative working radius is displayed:
Value B: 0.0 m, as a zero point has not yet been defined.
Value A: Current radius.
When the required radius has been selected, this value also ap-
pears in display field A.
Switch to fullscreen view by pressing key (22h).
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B C
22d 22h
Z 38 789
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(Z 38 789)
Press key (22d) to define the radius 11.7 m as the zero value.
The value B then shows the radius value of the set zero point.
The value A shows the deviation from the zero point (display
can be positive or negative).
The value C displays the current total radius.
Return to main menu using key (22h).
The required radius can then be repeatedly selected in the main

menu by selecting the value 0.0 m in field A.
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8.4 Bridging the Load Limit Device
8.4.1 Bridging the ShutOff Function for Movements Which

Reduce the Load Moment
If a prohibited overload condition has occurred, all movements

which reduce the load moment are also shut down by the load
limit device. The only function which is still available is lowering
the load on the hook.
Following the shutdown of an overload condition by the load

limit device, movements which reduce the load moment can be
carried out in order to move a freely suspended load out of the
overload range back into the normal operating range. To do so
in this case keyoperated switch (24) and footoperated switch
(13) must be actuated for general enablement.
These movements which reduce the load moment are

only allowed if they are not dangerous in any way. Make
sure that this is the case before pressing key switch (24).
If the load is still in contact with the ground and the func-
tion for raising the hoist has been switched off, the load
is too heavy. The movement raise main boom and fly
jib may not be enabled.
It may not, under any circumstances, be used to raise the

load.
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8.4.2 Bridging the ShutOff Function for all Movements
For this purpose, key swtich (23) must be turned and the footop-
erated switch (13) must be actuated.
The load moment limiter is bridged during operation

mode RG0.
This may only be carried out by authorised personnel
who are fully conversant with operation of the crane.
The load limit device may never be bridged in order to
increase the load moment.
Raising the load when the load limit device is bridged is
prohibited.
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8.5 Limit Switches for Switching Off Various Crane

Functions
8.5.1 General
The limit switches are electrical switches which interrupt the cur-
rent circuit when the crane is in a certain condition, thus prevent-
ing prohibited movements.
The functions of the limit switches are listed in section 8.10.2 in

a table.
The effect of the limit switches on the winch functions is described

in Sect. 8.10.3 in a table.
The assigned item numbers (e.g. S 001) correspond with the des-
ignations in the electrical circuit diagram.
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Z 15 611
Z 38 684 Z 38 685
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8.5.2 Functions of the Limit Switches
Designa- Diagram Unit / Function Switching point

tion no. location
S 002 A Z 15 611 Pull switch / Prevents the hook block coming too Depending on the
S 002 B sheave head HI near to the sheave head when the size of the hook
(top piece HA/HI) hook block has reached its highest block 3.03.5 m
position. When the switching point is clearance between
reached, the hook block raises the the sheave head
frame (3, Z 15 611), the ropes (2) are HI and the hook on
relieved of strain, the limit switches (1) the hook block.
open the electrical circuit.
S 001 B roller set on the con- near the roller set when the hook block size of the hook
necting head has reached its highest position. When block 2.53.5 m
the switching point is reached, the hook clearance between
block raises the frame (3, Z 15 611), the roller set in the
the ropes (2) are relieved of strain, the connecting head
limit switches (1) open the electrical cir- and the hook of
cuit. the hook block.
S 003 B sheave head LF (top near to the sheave head when the size of the hook
piece LF) hook block has reached its highest block 3.03.5 m
position. When the switching point is clearance between
reached, the hook block raises the the sheave head
frame (3, Z 15 611), rope (2) is relieved and the hook of
of strain, the limit switch (1) opens the the hook block.
electrical circuit.
S 003 C Z 15 611 Pull switch / Prevents the hook block coming too Approx. 2.0 m
runner near the runner when the hook block clearance between
has reached its highest position. When the sheave in the
the switching point has been reached, runner and the
the hook block raises the shift weight hook of the hook
(3, Z 15 611), the rope (2) is relieved of block.
strain, the limit switch (1) opens the
electrical circuit.
S 004 Z 38 684 Camkey / Prevents excessive lowering of the fly 110 between the
connecting head HA jib. When the switching position has main boom and fly
been reached, a control cam of the limit jib (roller set on
switch (E, Z 38 684) is activated which main boom).
opens the circuit.
S 005 Z 38 685 Camkey / Prevents excessive lowering of the fly 60 between the
connecting head HA jib. When the switching position has main boom and fly
been reached, a control cam of the limit jib (without roller
switch (E, Z 36 685) is activated which set on the main
opens the circuit. boom).
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Z 29 755 Z 29 756
X X
Z 40 778 Z 40 779
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Continued: Functions of the limit switches

tion no. location
S 006 A Z 29 755 Camkey / Prevents a prohibited high position of 13 between the fly
connecting head HA the fly jib. When the switching position jib and main boom
has been reached, a control cam of the longitudinal axis.
limit switch (E, Z 29 755) is activated
which opens the circuit.
S 006 B Z 29 756 Camkey / Prevents a prohibited high position of 17 between the fly
connecting head HA the fly jib. When the switching position jib and main boom
has been reached, a control cam of the longitudinal axis.
limit switch (E, Z 29 756) is activated
which opens the circuit.
The limit switch position is bridged us-
ing roller lever limit switch (1) on the
pan of the back stroke cylinder when
the back stroke cylinders are in the
correct position.
S 007 A Z 40 778 Inductive switch / Prevents the highest (steepest) per- Main boom angle
S 007 B HA back stop, left mitted position of the main boom being 87 degrees to the
hand side exceeded. When the switching position horizontal.
has been reached, the limit switch (1, Z
40 778) is activated by piston rod (2)
and opens the electrical circuit.
S 009 A Z 40 779 Inductive switch / Prevents the highest (steepest) per- Mast angle
mast support, left mitted position of the mast being ex- 127 degrees to the
hand side ceeded. When the switching position horizontal.
has been reached, the limit switch (1, Z
40 779) is activated by piston rod (2)
and opens the electrical circuit.
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Z 29 759 Z 40 780
2 1
1
Z 40 781 Z 40 782
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tion no. location
S 013 Z 29 759 Tumbler switch / Prevents the superstructure rotating When the Superlift
Superlift counter- when the Superlift counterweight is in counterweight
weight contact with the ground. When the comes into contact
switching position has been reached with the ground.
the limit switch (1, Z 29 759) is actu-
ated and opens the electrical circuit.
S 017 A Z 40 780 Tumbler switch / The limit switch (1, Z 40 780) monitors With engagement
connecting head if the back stop cylinder is engaged. If of the lefthand
lefthand side the limit switch (1) is activated, the back stop cylinder
electrical circuit is closed. HI.
S 017 B Z 40 780 Tumbler switch / The limit switch (1, Z 40 780) monitors With engagement
connecting head, if the back stop cylinder is engaged. If of the righthand
righthand side the limit switch (1) is activated, the backstop cylinder
electrical circuit is closed. HI.
S 018 Z 40 781 Tumbler switch / Prevents a prohibited high position of When the switch-
Back stroke cylin- the fly jib. When the switching position ing position of the
ders has been reached (10 mm ahead of the back stop cylinder
block position of the back stop cylinder HI is reached (10
HI), the limit switch (1, Z 40 781) is ac- mm ahead of the
tuated, the circuit is opened. block position of
Emergency switch if camswitch S006A the cylinder).
13 position between axis of the main
boom and fly jib fails.
S 024 Z 40 782 Induction switch / Prevents the highest permitted inclina- 22 degree inclina-
Derricking gear tion of the derricking gear rocker arm tion of the rocker
rocker arm being exceeded. When the switching arm.
position has been reached, the limit
switch (1, Z 40 782) is actuated by a
control cam on the rocker arm (2), the
circuit is opened.
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1
2
Z 40 783 Z 40 784
Z 40 785
98/107 0621080151_en

tion no. location
S 025 A Z 40 783 Inductive switch / Prevents the rope being unreeled from With three turns on
S 025 B winch hoist 1, the drum completely. If the rope is un- the drum.
S 025C winch hoist 2 reeled from the winch, switch (1, Z 40
winch hoist 3 783) opens the electrical circuit. The
slip ring (2) maintains the electrical
connection when the rope drum is ro-
tated.
S 026 A Z 40 783 Inductive switch / Prevents the rope being unreeled from With three turns on
S 026 B winch luffing gear 1, the drum completely. If the rope is un- the drum.
winch luffing gear 2 reeled from the winch, switch (1, Z 40
783) opens the electrical circuit. The
slip ring (2) maintains the electrical
connection when the rope drum is ro-
tated.
S 091 A Z 40 784 Inductive switch / The limit switch (1, Z 40 784) monitors When the rota-
Winch hoist 1, right the rotational movement of the winch of tional movement is
hoist 1. The rotational movement is dis- started.
played on the control lever in the cab.
S 091 B Z 40 784 Inductive switch / The limit switch (1, Z 40 784) monitors When the rota-
S 091 C Z 40 784 Inductive switch / The limit switch (1, Z 40 784) monitors When the rota-
S 092 A Z 40 784 Inductive switch / The limit switch (1, Z 40 784) monitors When the rota-
Winch luffing gear 1, the rotational movement of the winch of tional movement is
right luffing gear 1. The rotational movement started.
is displayed on the control lever in the
cab.
S 092 B Z 40 784 Inductive switch / The limit switch (1, Z 40 784) monitors When the rota-
Winch luffing gear 2, the rotational movement of the winch of tional movement is
right luffing gear 2. The rotational movement started.
is displayed on the control lever in the
cab.
S 093 Z 40 785 Inductive switch / The limit switch (1, Z 40 785) monitors When the rota-
winch derricking the rotational movement of the winch of tional movement is
gear, righthand the derricking gear. The rotational started.
side movement is displayed on the control
lever in the cab.
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2
1
Z 40 786
100/107 0621080151_en
Fortsetzung: Funktionen der Endschalter
Schalt- BildNr. Gert / Funktion Schaltpunkt

planbez. Einbauort
S 027 Z 40 786 Induction switch / Prevents, that Aframe is lowered furt- 14 towards hori-
Afrane, lefthand her as permitted. If the switching posi- zontal to the front
side at superstruc- tion is reached, the electrical circuit is
ture opened and lowering the Aframe is
interrupted.
S 009 C Z 40 786 Induction switch / Prevents, that Aframe is lowered furt- 8 towards hori-
Afrane, lefthand her as permitted. If the switching posi- zontal to the front
side at superstruc- tion is reached, the electrical circuit is
ture opened and lowering the Aframe is
interrupted.
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8.5.3 Crane Functions Which Are Shut Down When the

Limit Switches Are Actuated
R = raise; L = lower
Designation Switches for Crane functions shut down (x) Reset the switch
of the
switch Hoist Luffing gear Derricking
1 and 2, 3 1 and 2 gear
R L R L R L
Load limit de- Permitted load ex- With button (23) (see
X X X
vice ceeded. Sect. 4).
Hoist limit Highest permitted By lowering the
switch con- hook position on hook block.
necting head the connecting
X X X
HA head HA ex-
S 001 A ceeded.
S 001 B
switch sheave hook position on hook block.
head HI sheave head HI X X X
S 002 A exceeded.
S 002 B
switch sheave hook position on hook block.
head LF sheave head LF X X X
S 003 A exceeded.
S 003 B
switch runner hook position on X X X hook block.
S 003 C runner exceeded.
Limit switch Angle between By raising the fly jib
lowest position main boom and fly using luffing gear 1
fly jib jib < 110 (down-
X X X
S 004 wards) with roller
set fitted on the
main boom.
Limit switch Angle between By raising the fly jib
lowest position main boom and fly using luffing gear 1
fly jib jib < 60 (down-
X X X
S 005 wards) without
roller set fitted on
main boom.
Limit switch Angle between By lowering the fly
highest posi- main boom and fly jib with luffing gear 1
tion of the fly jib < 13 (up- X X
jib wards).
S 006 A
Limit switch Angle between By lowering the fly
highest posi- main boom and fly jib with luffing gear 1
tion of fly jib jib < 17 (up-
S 006 B wards) with the fly X X
jib back stop in-
correctly posi-
tioned.
Limit switch Main boom angle By lowering the der-
main boom 87 > 87. ricking gear.
degrees X X By lowering the luf-
S 007 B fing gear 2 during Su-
perlift operation.
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Continued: Winch functions switched off when the limit

switches are actuated
Designation Switches for Crane functions switched off (x) Reset the switch
of the
1 and 2, 3 1 and 2 gear
R L R L R L
Limit switch Ground contact of By increasing the
SL cweight SL counterweight. Slewing of superstructure shut down. working radius of the
S 013 load.
Limit switch Fly jib back stop By lowering the fly
foot section fly cylinder not en- jib with luffing gear 1
X
jib gaged.
S 017A
Limit switch Fly jib back stop By lowering the fly
foot section fly cylinder not en- jib with luffing gear 1
X
jib gaged.
S 017B
Limit switch Back strocke cyl- By lowering the fly
highest posi- inder of the fly jib jib with luffing gear 1
X
tion fly jib fully retracted
S 018 (block position).
Limit switch Inclination of the By actuating bridging
rocker arm in rocker arm > 22. switch (4). The tilted
derricking gear position must then be
X X
S 024 rectified immediately
(see assembly in-
structions).
Lower limit Only three turns By raising hoist 1 or
switch hoist 1 remaining on the by means of the limit
S 025 A rope drum of hoist X switch when lowering
1 the main boom below
27 degrees.
S 025 B rope drum of hoist X switch when lowering
27 degrees.
S 025 C rope drum of hoist X switch when lowering
27 degrees.
Lower limit Only three turns By raising luffing
switch luffing remaining on the gear 1 or by means of
gear 1 rope drum of luf- the limit switch when
X X
S 026 A fing gear 1 lowering the main
boom below 27 de-
grees.
Lower limit Only three turns By raising luffing
switch luffing remaining on the gear 2 or by means of
gear 2 rope drum of luf- the limit switch when
X X
S 026 B fing gear 2 lowering the main
boom below 27 de-
grees.
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Continued: Winch functions switched off when the limit

switches are actuated
Designation Switches for Crane functions switched off (x) Reset the switch
of the
1 and 2,3 1 and 2 gear
R L R L R L
Limit switch Mast support cyl- By lowering the der-
mast support inder not in correct ricking gear.
X
cylinder position.
S 009 A
Inductive Recording of rota- Indication of the rotational movement of
switch winch tional movement hoist 1 on the control lever in the cab.

hoist 1 on hoist 1.
S 091 A

hoist 2 on hoist 2.
S 091 B

hoist 3 on hoist 3.
S 091 C
switch winch tional movement luffing gear 1 on the control lever in the

luffing gear 1 on luffing gear 1. cab.
S 092 A
switch winch tional movement luffing gear 2 on the control lever in the

luffing gear 2 on luffing gear 2. cab.
S 093 B
Inductive Recording rota- Rotational movement of the derricking
switch winch tional movement gear is indicated on the control lever in

derricking gear on the derricking the cab.
S 093 gear.
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Working with the Crane Equipment 9
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9 Working with the Crane Equipment
9.1 Simultaneous Crane Movements

The crane movements marked in the table can be carried out si-
multaneously.
H1/H2/H3 = Hoist H1 / Hoist H2 / Hoist H3
W1/W2 = Luffing gear W1 / Luffing gear W2
E = Derricking gear
DW = Slew gear
LR = Left crawler
RR = Right crawler
P1.1 = Pump circuit P1.1
Simultaneous crane movements
Control lever 1 2 3
Configura- H1 W2 LR H2 H3 E RR E W1 W2 DW LR + RR
tion P1.1 P1.1 P1.1 P2.1 P2.1 P2.1 P2.1 P3.1 P3.1 P3.1 P1.2 P3.1
x x x
x x x
x x x
x x x
x x x
Hakenbetrieb
x x x
x x x
x x x
x x x
x x x
x x x
x x x
Fahrbetrieb
x x x
x x x
x x
x x
Rstbetrieb
x x
x x
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9.2 Operating Hoist 1 (H1)
9.2.1 General
Hoist 1 (H1) can either be operated individually or in combination

with hoist 2 (H2) and the double hook block, depending on lifting
capacity (see Sect. 9.5).
The winch of the hoist is driven by a hydraulic motor with variable

rates of flow, which is supplied by a hydraulic pump P1.1 with a
variable delivery rate.
If the hydraulic motor control is activated (luminous switch, 76)
the rate of flow of the hydraulic motor can be infinitely varied using
control lever (1). (Control lever moved more smaller motor
angle faster hoist)
If the control pressure is exceeded the hydraulic motor automati-

cally readjusts to a larger rate of flow.
However, to exploit the maximum rope speed, high speed should

only be selected for a load of up to 60 kN per rope line.
The control elements specified in the instructions are shown in
the foldout tables.
9.2.2 Preparing for Operation

Switch on luminous switch (77), the integrated indicator light
lights up.
Switch luminous switch (28) to automatic, the integrated in-
dicator light lights up.
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9.2.3 Operating at Level 1 (Normal Speed)

Switch off luminous switch (76), the integrated indicator light
goes out.
RAISE load:
Push control lever (1) backwards, at the same time pressing
button (9) for the dead mans handle.
The winch rotation indicator (10) shows whether the drum of hoist
H1 is rotating.
LOWER load:
Push control lever (1) forwards, at the same time pressing
The final rope speed is altered using rotary switch (108). The
deflection range for the control lever (1) always spans from 0 to
the selected final rope speed. This feature allows individual pre-
cise control of the hoist in the selected rope speed range. The
lower the final rope speed selected, the greater the precision con-
trol for the control lever (1).
H1 is rotating.
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9.2.4 Operating at Level 2 (High Speed)
High speed must be selected before the load is raised with

the drum at a standstill.

lights up.
RAISE load:

H1 is rotating.
LOWER load:

H1 is rotating.
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9.3.1 General
Hoist 2 (H2) can either be operated individually or in combination

with hoist 1 (H1) and the double hook block, depending on lifting
capacity (see Sect. 9.5).
The winch of the hoist is driven by a hydraulic motor with variable

rates of flow, which is supplied by a hydraulic pump P2.1 with a
variable delivery rate.
angle faster hoist)


the foldout tables.

lights up.
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goes out.
RAISE load:
H2 is rotating.
LOWER load:
H2 is rotating.
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lights up.
RAISE load:

H2 is rotating.
LOWER load:

H2 is rotating.
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9.4.1 General
The winch of the hoist H3 is driven by a hydraulic motor with vari-

able rates of flow, which is supplied by a hydraulic pump P2.1 with
a variable delivery rate.
angle faster hoist)


the foldout tables.

lights up.
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goes out.
RAISE load:
H2 is rotating.
LOWER load:
H3 is rotating.
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lights up.
RAISE load:

H3 is rotating.
LOWER load:

H3 is rotating.
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9.5 Crane Operation with Double Hook Block, Hoist 1 and

Hoist 2 in Combined Operation
9.5.1 General
The synchronism of the hoist winches is displayed on the LCD.

Corrections must be made by the crane operator.
Two speeds can be selected by changing the rate of flow of the
hydraulic motors.

lights up.
lights up.
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Switch off luminous switches (73) and (76), the integrated in-
dicator light goes out.
RAISE load:

H1/H2 is rotating.
LOWER load:

H1/H2 is rotating.
The final rope speed is altered using rotary switch (106 + 108).
The deflection range for the control lever (1) always spans from
0 to the selected final rope speed. This feature allows individual
precise control of the hoist in the selected rope speed range. The
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Switch on luminous switches (73 and 76), the integrated indi-

cator light lights up.
RAISE load:

H1 is rotating.
LOWER load:

H1 is rotating.
The final rope speed is altered using rotary switch (106 + 108).
The deflection range for the control lever (1) always spans from
0 to the selected final rope speed. This feature allows individual
precise control of the hoist in the selected rope speed range. The
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9.6 Operating the Derricking Gear (E)
9.6.1 General
The derricking gear is used for boom variants (SH; SH/LH, LF and
SW) for erecting and adjusting the main boom and for Superlift
boom variants (SSL; SSL/LSL and SWSL) for erecting and hold-
ing or adjusting the Superlift mast.
The allocation of the hydraulic circuits for the winches allows the
derricking gear (E) to be used in conjunction with other winches.
Derricking gear (E) + luffing gear 1 (W1)
Derricking gear (E) + luffing gear 2 (W2)
Derricking gear (E) + hoist 1 (H1)
For crane operation, the derricking gear (E) is actuated using

control lever (3).
For configuration operation, the derricking gear (E) is actuated
using control lever (2).
The derricking gear (E) has two speed levels. Level 2 is selected
using luminous switch (55).
At speed level 1, the derricking gear (E) is driven using working

circuit 3.1 or 2.1.
At speed level 2, the derricking gear (E) is driven using working
circuits 2.1 and 3.1.
Speed level 1 is recommended for crane operation, as the work-

ing circuits are available for the hoists in this case.
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9.6.2 Operating the Derricking Gear (E) when Erecting and

Lowering a Boom Combination

Luffing Gear 1 (W1)
The derricking gear (E) can only be operated at speed level 1.
Use luminous switch (103) to switch on derricking gear E,

the integrated indicator light lights up.
Use luminous switch (56) to switch on luffing gear W1, the
integrated indicator light lights up.
goes out.
RAISE main boom or mast:

The winch rotation indicator (10) shows whether the drum of the
derricking gear E is rotating.
LOWER main boom or mast:

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Luffing Gear 2 (W2)
Operation of the derricking gear (E) only possible at level 1.
Operation at level 1:

Use luminous switch (50) to switch on the luffing gear W2,
goes out.
RAISE main boom or mast:

LOWER main boom or mast:

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9.6.3 Operating the Derricking Gear (E) during Crane Op-

eration

Hoist 1 (H1)
The derricking gear (E) can be operated at speed levels 1 and 2.
Use luminous switch (57) to switch on derricking gear E, the
goes out.
Use luminous switch (77) to switch on hoist 1, the integrated
indicator light lights up.
RAISE main boom:
LOWER main boom:
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lights up.
RAISE main boom:
LOWER main boom:
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Hoist 2 (H2)

Use luminous switch (71) to switch on hoist H2, the inte-
grated indicator light lights up.
goes out.
RAISE main boom:

LOWER main boom:

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Hoist 3 (H3)

goes out.
RAISE main boom:

LOWER main boom:

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9.6.4 Operating Range of the Main Boom
Steepest position:
85 to the horizontal (observe load tables).
Lowest position:
Radius in accordance with the load table
When operating with the luffing fly jib (hook block on the fly jib)
the main boom remains positioned in its steepest position, in line
with the information given in the load table!
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9.7 Operating Luffing Gear 1 (W1 = OE)

(OE = Optional equipment)
9.7.1 General
The winch in the main boom is used for boom variants SW and
SWSL as luffing gear 1 (W1) for adjusting the fly jib.
use of luffing gear 1 (W1) together with other winches.
Luffing gear 1 (W1) + derricking gear (E)
Luffing gear 1 (W1) + luffing gear 2 (W2)
Luffing gear 1 (W1) + hoist 1 (H1)
Luffing gear 1 (W1) is actuated using control lever (3).
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9.7.2 Operating Luffing Gear 1 (W1) when Erecting and


Derricking Gear (E)
The luffing gear 1 (W1) can only be operated at speed level 1.

goes out.
RAISE fly jib:

The winch rotation indicator (10) shows whether the drum of luf-
fing gear W1 is rotating.
LOWER fly jib:

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Luffing Gear 2 (W2)
Operation of the luffing gear 1 (W1) only possible at level 1.

RAISE fly jib:

LOWER fly jib:

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9.7.3 Operating Luffing Gear 1 (W1) during Crane Opera-

tion

Hoist 1 (H1)

Use luminous switch (77) to switch on hoist 1.
RAISE fly jib:

LOWER fly jib:

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Hoist 2 (H2)

RAISE fly jib:

LOWER fly jib:

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Hoist 3 (H3)

RAISE fly jib:

LOWER fly jib:

9.7.4 Operating Range of the Fly Jib
Steepest position:
Radius in accordance with the load table.
Lowest position:
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9.8 Operating Luffing Gear 2 (W2 = OE)

(OE = Optional equipment)
9.8.1 General
The winch in the Superlift mast is used for boom variants SSL,
SSL/LSL and SWSL as luffing gear 2 (W2) for adjusting the main
boom.
use of luffing gear 2 (W2) together with other winches.
Luffing gear 2 (W2) + derricking gear (E)
Luffing gear 2 (W2) + luffing gear 1 (W1)
Luffing gear 2 (W2) is actuated using control lever (3).
Only if during erection luffing gear 1 and luffing gear 2 shall

be operated simultaneously, luffing gear 2 must be controlled us-
ing control lever (1).
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9.8.2 Operating Luffing Gear 2 (W2) when Erecting and


Derricking Gear (E)

goes out.
RAISE main boom:

LOWER main boom:

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Luffing Gear 1 (W1)

RAISE main boom:

LOWER main boom:

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9.8.3 Operating Luffing Gear 2 (W2) during Crane Opera-

tion

Hoist 1 (H1)

Use luminous switch (77) to switch on hoist H1.
RAISE main boom:

LOWER main boom:

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Hoist 2 (H2)

RAISE main boom:

LOWER main boom:

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Hoist 3 (H3)

RAISE main boom:

LOWER main boom:

9.8.4 Operating Range of the Main Boom
Steepest position:
85 to the horizontal radius (observe the load table).
Lowest position:
When operating with the luffing fly jib (hook block on the fly jib)
the main boom remains positioned in its steepest position, in line
with the information given in the load table!
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2
1
Z 16 288
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9.9 Operating the Reeving Winch
9.9.1 General
The reeving winch (EW, Z 38 750) is used during assembly of the
crane for reeving the ropes of hoist 1, hoist 2, luffing gear 1 and
luffing gear 2.
The hydraulic system of the reeving winch is coupled with the hy-
draulic system of the slew gear. You can switch between the two
by alternately releasing the brakes.
The auxiliary reeving rope of the reeving winch must be reeved

in accordance with the reeving diagrams, however in the reverse
order, i.e.
with the hoist ropes between the sheaves in the boom head
and the sheaves of the hook block,
with luffing rope W1 between the sheaves of the two luffing
masts,
9.9.2 Operation
Use luminous switch (82) to release the brake of the reeving
winch.
Luminous switch (83) may not be actuated at the same time.
DRAW IN auxiliary reeving rope:

Move control lever (3) to the right, at the same time button (6)
must be pressed for the dead mans handle.
LET OUT auxiliary reeving rope:
Move control lever (3) to the left, at the same time button (6)
must be pressed for the dead mans handle.
If the rope drum of the hoist or luffing gear is moved in the
lifting direction, the reeving winch must be moved at the
same time in the lowering direction to prevent the brake on
the reeving winch being overloaded.
Use luminous switch (59) to apply the brake of the reeving
winch.
If the ropes of the hoists and luffing gear are not reeved, they
have to be secured during transportation with a rope clamp
(1, Z 16 288) on the edge of the drum (2). This helps to protect
the rope ends (3) against damage as a result of uncontrolled
movement of the winches.
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9.10 Working with the Superlift
9.10.1 General
(Z 38 751)
Lattice mast cranes of the type CC 2800 can, in addition to the

standard crane equipment, also be operated in combination with
a Superlift (abbreviation SL).
The Superlift consists of:

3 Basic frame
4 Weights
5 Connecting ropes
8 Mast
17 Bracing ropes
18 Stay ropes
The basic frame (3) and the weights (4) combine to make up the
Superlift counterweight.
The basic frame (3) is connected to the mast (8) by means of the
stay ropes (18). The Aframe (6) is connected to the mast (8) by
means of the bracing ropes (17).
The Superlift counterweight is connected to the superstructure

by means of horizontal connecting ropes (5).
These must be taut when the crane is under load and the Superlift
counterweight is raised so that the Superlift counterweight can-
not swing backwards.
As a result of the larger radius of the mast point compared with

the radius of the Superlift counterweight, the stay ropes (18) must
be pulled outwards, creating tension in the connecting ropes (5).
The weights (4) must be stacked symmetrically and secured in

place using stops on each plate or by inserting wooden wedges
to prevent them from slipping.
If are placed too far to one side, the basic frame will be unevenly
loaded. This can cause the system to be overloaded in an ex-
treme case.
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Z 44 499
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The Superlift is used primarily for large individual loads. The Su-
perlift increases the load capacity of the crane, but primarily the
load moment.
With small working radii, the increase in the load moment is lim-
ited by the strength of the components.
With medium and large working radii, the load moment can be
doubled or even tripled.
When the Superlift is fitted it is still possible to use the crane with-
out the Superlift counterweight (= 0 t Superlift counterweight).
Once the Superlift mast has been erected, the rope protec-
tion (1, Z 44 499) must be bolted on the superstructure roller
set (2) before the crane is operated with the Superlift.
Before lowering the Superlift mast with the derricking gear,
this rope protection (1) must be removed again to prevent
damage to the derricking rope and the rope protection.
The rope protection (1) is secured on the lefthand side of
the superstructure frame (3) for storage.
If the crane is in a tilted position or positioned on a float-

ing base, use of the Superlift is prohibited.
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SLG
L
A B
Z 29 739
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9.10.2 Operating Principle

(Z 29 739)
The additional load moment of the crane L x A (load x working ra-

dius) is increased by the opposing moment of the Superlift coun-
terweight (SLG x B).
The equipment acts like a balance arm, whereby the load mo-
ment (L x A) is greater.
The difference for the state of equilibrium is achieved by the mast
bracing (17). The bracing force stabilises the system.
If a load is to be raised and slewed, the Superlift counterweight

must be raised with sufficient ground clearance (more than
100mm).
It is not possible to slew the Superlift counterweight without load

on the boom, as the Superlift counterweight does not lift off the
ground even with a wider working radius and long boom within
the range of the load table, depending on the size of the Superlift
counterweight.
To maintain the state of equilibrium the size of the Superlift coun-

terweight must be adjusted to the load moment. The clearance
(B) of the Superlift counterweight remains constant.
Minimal differences in the working radius are possible for the

same Superlift counterweight.
Operation of the crane with the Superlift fitted is also possible

without the Superlift counterweight, in accordance with the lifting
capacity for 0 t counterweight (see load table).
Special case
If a load is to be moved simply by increasing the radius (A) without

slewing the superstructure, the Superlift counterweight does not
have to be raised.
The size of the Superlift counterweight must in this case equal at
least the value specified in the table for the largest working radius
for that operating condition.
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9.10.3 Measuring the Derricking Force

(Z 38 752)
The crane is equipped with a measuring device which operates

independently of the load limit device to record the force in the
derricking rope.
The lifting beam (2) fitted in the superstructure roller set (1) is con-
nected to the end of the derricking ropes by means of two draw
bars.
The axis (3) in the lifting beam is designed as a torsion shaft

B305.
The torsion caused by the derricking rope force is measured. This

torsion is converted into direct voltage by means of strain gauges,
amplified and compared with the limit value which has been set.
The rope force which is measured is displayed on the screen in

the crane operators cab.
The maximum permitted derricking force for the corresponding

configuration is set when the load table codes are entered.
When the specified limit value is reached, all subsequent move-
ments which may be dangerous are shut down.
Raise hoist 1, 2 and 3,
lower / raise derricking gear,
lower / raise luffing gear 1 and 2.
Monitoring of the derricking force by the torsion shaft B

305 (3) is no substitute for the load limit device, but rather
an additional measuring device to help prevent overloading
of the superstructure.
The torsion shaft may not be used as a single monitoring
system for continued operation of the crane when the load
limit device is defective or the codes have been entered in-
correctly.
Before continuing operations, check the load limit device
and rectify any faults.
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9.10.4 Operating the Crane without a Superlift Counter-

weight
(Z 29 741)
When working without a Superlift counterweight the stay ropes

(18) must be detached from the basic frame (3).
The stay ropes on the rear end of the basic frame must be con-
nected to the stay ropes on the front end of the basic frame to pre-
vent them dangling from the head of the mast.
The front stay ropes are connected to the superstructure by
means of the connecting ropes (5).
Detach the stay ropes (18) from the basic frame (3).
Connect stay ropes (18) with hemp ropes.
Disconnect the electric cable between the superstructure
and basic frame.
Insert a dummy plug in the socket.
When working with the Superlift without the Superlift counter-

weight, the corresponding load tables are to be used for the 0 t
Superlift counterweight.
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9.10.5 Operating the Crane with the Superlift Counterweight
9.10.5.1 General
The size of the Superlift counterweight is selected according to

the load which is to be lifted and the required working radius.
To guarantee the required balance of equilibrium and to make

sure that the Superlift counterweight is raised for slewing, the val-
ues may only deviate from those specified in the tables by a mini-
mal amount.
If the values do not match, the next largest Superlift counter-

weight must be selected. By increasing the working radius ac-
cordingly, the balance of forces can be restored again.
Example:
(Z 38 753)
Boom length: 54 m
Mast length: 30 m
Superlift radius: 15 m
Counterweight: 180 t
Central counterweight: 60 t
Track width: 8.40 m
Working radius: 18 m
Load: 190 t
Required
Superlift counterweight: 100 t
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9.10.5.2 Raising, Slewing and Setting Down the Load with the
Working Radius Constant
(Z 29 743)
Before commencing work with the Superlift equipment

the crane is placed in the operating position. The hook block
(13) is suspended free above the load and the Superlift coun-
terweight (4) is beneath the stay ropes (18).
if the weight of the Superlift counterweight (4) has been se-
lected in accordance with the load to be raised pursuant to
the load table (see example in Sect. 9.10.5.1) and has been
placed on the basic frame (3).
Secure the weights to prevent them from slipping.
Operating sequence:
Secure the load to the hook block (13).

Secure stay ropes (18) to the basic frame (3).
Switch on derricking gear (see Sect. 9.6).
Unreel derricking ropes (22) for adjusting Superlift mast (8)
from the rope drum by moving lever (3) forwards.
The stay ropes (18) on the Superlift counterweight (4) are ten-
sioned by the dead weight of the main boom (7).
Unreel the derricking ropes (22) until they are relieved of load, set
a residual force of approx. 10 kN per strand.
Check the derricking rope force display (x0 t) in the LCDDis-
play.
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24.1
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4
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(Z 29 744)
Reel hoist rope H1 or H2 (24.1) onto the rope drum by press-

ing lever (2) backwards. When hoist rope H1, H2 (24.1) is ten-
sioned, the Superlift counterweight (4) is raised from the
ground by approx. 20 to 30 cm.
In addition, by taking up the hoist rope H1, H2 (24.1) on the

rope drum, the bracing ropes (17) of the SL mast (8) and the
derricking ropes (22) for adjusting the SL mast (8) are ten-
sioned.
The load is raised by reeling the hoist rope (24.1).
The condition is now reached where the superstructure of the
crane can be slewed.
The load is set down on the ground by pushing lever (2) for-
wards.
The load can only be set down if the ground on which the Su-
perlift counterweight (4) is to be set down is even and of suffi-
cient loadbearing capacity.
Pull the Superlift mast (8) backwards by pulling lever (1) back-
wards until the stay ropes (18) can be detached from the Su-
perlift counterweight (4).
Release the stay ropes (18) from the Superlift counterweight
(4).
If another lifting movement is to be carried out, the Superlift coun-

terweight (4) must be moved back to its initial position using a
transport vehicle.
The Superlift counterweight (4) can also be moved with the

crane, depending on the size, boom length and minimum working
radius.
To this end, the code for lifting forces with 0t Superlift counter-
weight must be entered in the computer of the load limit device.
Once the Superlift counterweight (4) has been moved into the re-
quired position and after the superstructure has been slewed
back, it may be necessary to adjust the mast (8), in order to reat-
tach the stay ropes (18) to the Superlift counterweight (4).
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9.10.5.3 Raising, Extending the Working Radius and Setting

Down the Load without Slewing the Superstructure
If a load is to be moved out to an extended radius with the Super-

lift without slewing the superstructure, the Superlift counter-
weight required for the widest working radius must be selected.
Example:
(Z 38 754)
Boom length: 54 m
Mast length: 30 m
Central counterweight: 60 t
Track width: 8.40 m
Load: 190 t
Working radius 1: 18 m
Required
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(Z 29 743)

(13) hangs free above the load and the Superlift counter-
weight (4) is positioned beneath the stay ropes (18).
the weight of the Superlift counterweight (4) is selected in
relation to the load which is to be lifted (see example) and
Operating sequence:

Unreel derricking ropes (22) until a remaining force of approx. 10

kN per strand results.
play.
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24.1
18
22
4
Z 29 746
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(Z 29 746)
Reel hoist rope H1, H2 (24.1) onto the rope drum by pressing
lever (2) backwards.
The load on the stay ropes (18) increases continually until the
load is lifted off the ground. As a result of the stay ropes (18)
stretching, the position of the mast point is changed, causing
the bracing ropes (17) and the derricking ropes (22) to be
loaded correspondingly.
The force in the derricking ropes (22) can be read off the mon-
itor in the crane operators cab.
The Superlift counterweight (4) must remain on the ground.
Switch on luffing gear 2 (see Sect. 9.8).

Lower the main boom (7) by pushing lever (3) forwards until
the desired working radius has been reached.
While the working radius is being extended, the Superlift counter-

weight (4) must remain on the ground.
The load is lowered to the ground by moving lever (2) for-

wards.
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9.10.5.4 Raising, Reducing the Working Radius and Setting

Down the Load without Slewing the Superstructure
If a load is to be brought closer with the Superlift without slewing

the superstructure, the Superlift counterweight required for the
widest working radius must be selected.
Example:
(Z 38 755)
Boom length: 54 m
Mast length: 30 m
Central ballast: 60 t
Track width: 8.40 m
Load: 190 t
Required
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22
4
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(Z 29 743)

(13) hangs free above the load and the Superlift counter-
weight (4) is positioned beneath the stay ropes (18).
the weight of the Superlift counterweight (4) is selected in
relation to the load which is to be lifted (see example) and
Operating sequence:

Unreel derricking ropes (22) until a remaining force of approx. 10

kN per strand results.
play.
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24.1
22
4
Z 29 747
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(Z 29 747)
Reel hoist rope H1, H2 (24.1) onto the rope drum by pressing
lever (2) backwards.
In addition the bracing ropes (17) of the Superlift mast (8) and
the derricking ropes (22) for adjusting the Superlift mast (8)
are tensioned by reeling in hoist rope H1, H2 (24.1) on the
rope drum.
By reeling hoist rope H1, H2 (24.1) further onto the rope
drum, the last is raised.
The force in the derricking ropes (22) can be read off the mon-
itor in the crane operators cab.
Depending on the size, the Superlift counterweight (4) remains

on the ground or is lifted off the ground.
Switch on luffing gear 2 (see Sect. 9.8).

Raise the main boom (7) by moving lever (3) backwards until
the working radius reaches the desired value.
The load is lowered to the ground by moving lever (2) for-
wards.
If the force in the derricking gear reaches the minimum limit value
as a result of the working radius being decreased, continued der-
ricking is prevented. The following movements are then shut
down:
raise derricking gear,

raise luffing gear 1 and 2.
The symbol is displayed in the LCD display (39) in the status line.
The load can be set down using the hoist or the working radius
increased again using luffing gear 2, to reactivate the move-
ments.
This switching prevents:
swinging: of the load backwards when the Superlift counter-

weight (4) is already standing on the ground,
uncontrolled lowering of the previously raised Superlift coun-
terweight (4) when the working radius is reduced.
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9.10.6 Safety Instructions for Working with the Superlift
Use of the Superlift is reserved for special operations and re-

quires particular care and attention from the crane person-
nel with regard to the function and possible hazards of the
equipment.
The crane must be standing on level, horizontal ground with

sufficient loadbearing capacity when the Superlift equip-
ment is fitted.
Please observe the regulations for erecting and supporting the

crane in Sect. 9.11.
For work with Superlift equipment, the crane is supplied with

special load tables with additional data which is not required
(e.g. max. force in the reeving rope for adjusting the Superlift
mast and total weight of the Superlift counterweight).
The crane and Superlift can also be operated without the Su-
perlift counterweight; again the Superlift load tables contain
the required data.
The advantages of the Superlift are particularly well demon-
strated when large loads have to be moved once.
Use of the crane with Superlift for frequent and repetitive load
movements is not recommended, as operation of the crane
with the Superlift requires more time than operation without
the Superlift.
To enable the Superlift counterweight to be lifted clearly and
therefore the superstructure to be slewed, the values speci-
fied in the load tables must be adhered to.
When the working radius is reduced, the force in the derrick-

ing gear is reduced, which in an extreme case can lead
to unintentional lowering of the Superlift counterweight and
backward sagging of the boom system.
To minimise this danger, the derricking gear force is mea-
sured with a torsion shaft B305 in the lifting beam of the
derricking gear.
If a set limit value is below level (minimum derricking gear
force) further derricking of the load is shut down.
The load must then be lowered or the working radius in-
creased again using luffing gear 2 or luffing gear 1 (depend-
ing on the boom variant).
If in doubt, please contact the manufacturer for more detailed in-

formation!
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For loads which can be lifted without a Superlift counter-

weight 0 t in accordance with the Superlift load capacity table,
a Superlift counterweight may not be used.
The lifting capacity, which depends on the boom length, the
type of boom head, the size of the attached Superlift counter-
weight and the working radius, must be adhered to.
Slewing with the Superlift counterweight hanging free is only
permitted if ground clearance is guaranteed in the slewing
area.
The derricking gear is used to return the SL mast to its operat-
ing position before crane operations are begun.
The Superlift mast is no longer adjusted once crane opera-
tions have begun.
The working radius may only be changed if the Superlift coun-
terweight can be set down.
The working radius may only be changed on the main boom

with the rope from the rope drum luffing gear 2.
The working radius may only be changed on the fly jib with
the rope from the rope drum luffing gear 1.
A person outside the cab who is in visual and verbal contact
with the crane operator must observe the Superlift counter-
weight.
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9.11 Working Instructions
9.11.1 General
The loads specified in the load tables are valid under the follow-
ing conditions:
The crane is standing on horizontal, even ground ( 0.5%)
If the crane is tilted, or if it is driven across uneven terrain, the

boom lengths and load must be reduced.
The ground must have sufficient loadbearing capacity for

the surface pressures that occur.
Max. occurring surface pressure:
Variant SH: 320 N/cm2
Variant SH/LH: 183 N/cm2
Variant SW: 190 N/cm2
Variant SSL: 269 N/cm2
Variant SSL/LSL: 68 N/cm2
Variant SWSL: 148 N/cm2
All crane movements must be carried out at a suitable speed
without sudden jerking and in accordance with the configura-
tion and the load case.
The weight of the hook blocks and the loadhandling devices
is part of the rated load and must be deducted from the pay-
load.
The maximum permitted rope load of hoist 1 equals 158 kN.
The maximum reeving number required is programmed in the
load limit device. If a smaller reeving number is selected, this
reeving number must be entered in the load limit device.
Handle the slew gear and slew brake carefully, particularly
when operating the crane with the fly jib fitted.
Select a low slewing speed.
Brake carefully.
Simultaneous lifting of loads on the main boom and fly jib

(twohook operation) is only permitted in consultation
with the crane manufacturer.
Oblique pull and prohibited extension of the working ra-
dius must be avoided at all times.
Because of danger of collision it is prohibited to lift loads
simultaneously of runner and main boom.
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9.11.2 Positioning the Crane
Before starting work with the crane, you must make sure that the
ground has the required loadbearing capacity. For crawler
mounted cranes, the ground must also be flat and horizontal, and
it must be well compressed.
You can check to see if the crane is level using the spirit level on
the superstructure (next to the cab).
Before starting work with the crane you should check that this
level is correctly calibrated. This can be done using the following
simple visual check.
Visual check:
Use the unloaded hook block as a freeswinging pendulum. This

must be positioned in the centre of the boom when the crane is
correctly positioned, as seen from the front of the crane.
With a short main boom (42 m) there must be no visible lateral
deviation from the centre of the system (deviation of less than
0.1 m)
With a long main boom and fly jib the hook block is allowed
to deviate from the central position by half the boom width, in-
cluding the effect of a side wind.
If there is a visible deviation in the position of the hook block, a

precisely calibrated spirit level must be used on a finished surface
of the slewing rim to measure the tilt. The rotating surface must
not deviate from the horizontal plane by more than 0.5 % (
0.3).
0621090151_en 105/117
9
106/117 0621090151_en
9.12 Wind Speeds Dynamic Pressure
9.12.1 General
If wind speeds are anticipated which are higher than the safe per-
mitted level for parking the crane, the boom system must be low-
ered and secured in good time.
Accordingly, the crane operator must request the expected wind

conditions from the competent met office before commencing as-
sembly of the crane and before starting work with the crane, and
must monitor the weather conditions using an anemometer.
The anemometers fitted on the crane must be checked with a cal-

ibrated anemometer during the crane inspection, or at least once
a year.
Since the stability and strength limits of the crane are allimpor-
tant when lowering certain boom combinations, information
about the wind direction is an equally important aspect.
Wind conditions which exceed the permitted limit values can lead
to hazardous situations due to the additional static loads, swing-
ing of the load and / or dynamic influences (e.g. windinduced
vibration of crane components). Therefore the (peak) maximum
wind speed must be taken as the limit value. This wind limit is the
average value of a gust of wind over the duration of three sec-
onds or the maximum value recorded on the anemometer.
If vibrations of crane components are detected when wind condi-

tions are excessively high, an inspection must be carried out by
Demag Mobile Cranes.
0621090151_en 107/117
9
108/117 0621090151_en
9.12.2 Crane under Load (Crane Operation)
For the wind speeds of 9.8 m / sec specified in the load tables
(equals a dynamic pressure of 60 N / m2) a load surface area ex-
posed to the wind (wind surface area) of 1.2 m2 /t is calculated
(including form factor 1.2).
Higher or lower permitted wind speeds (dynamic pressure levels)

apply for other wind surface areas, however the maximum per-
mitted wind speeds and dynamic pressures listed in the tables
may not be exceeded.
Permitted wind speeds and dynamic pressures for crane op-

eration with main boom:
Main boom length Permitted wind Permitted

speed dynamic pressure
(m) ( m / sec ) ( N / m2 )
up to 36 15.0 140
4266 13.8 120
7284 11.3 80
above 84 9.8 60
Permitted wind speeds and dynamic pressure levels for

crane operation with a fly jib:
Main boom length/ Permitted wind Permitted

fly jib length speed dynamic pressure
(m) ( m / sec ) ( N / m2 )
up to 48 / 13.8 120
up to 42
up to 48 / 11.3 80
48 72
54 84 / 10.6 70
up to 42
above 54 / 9.8 60
above 48
0621090151_en 109/117
9
110/117 0621090151_en
In the following examples the permitted surface area of the load ex-
posed to the wind at a dynamic pressure of 60 N/m2 is assumed
to be 1.0 m2/t for reasons of safety.
Example 1: given: load 200 t, dynamic pressure 145 N / m2

sought: permitted wind surface area AWperm.
The permitted wind surface area in accordance

with DIN at 60 N / m2 is 200 m2.
200m2 x 60 N / m2
AWperm. = = 82.7 m2
145 N / m2
Example 2: given: load 200 t, wind surface area 100 m2
sought: permitted dynamic pressure Pperm.

permitted wind speed Vperm.
The permitted wind surface area in accordance

with DIN at 60 N / m2 is 200 m2.
200m2 x 60 N / m2
Pperm. = = 120 N / m2
100 m2
Vperm. = p(Pperm. x 1.6) = 13.8 m / sec
This example only applies however, if the main boom is no longer

than 66 m for main boom operation, or if the main boom and fly
jib are no longer than 48 m and 42 m for fly jib operation.
If loads with greater surface areas exposed to the wind than 1.2
m2 / t are lifted, either the load moment must be reduced if the
maximum permitted wind speed applies (9.8 m / sec), or the load
must be lifted when the wind force is lower.
To evaluate and authorise individual load cases, precise

data is required. This data must be made available to Demag
Mobile Cranes before the crane is operated.
For special cases the permitted minimum and maximum wind

speeds are to be taken from the special load tables.
0621090151_en 111/117
9
112/117 0621090151_en
9.12.3 Parking the Crane
If the crane is parked with the boom erected following operation

of the crane, the maximum forecast wind speeds must be taken
into consideration for the crane (in the parked condition).
Main boom crane without load

e.g. SH, SH/LS, LF, SH/LH+LF, SSL, SSL/LSL, SSL+LF, SSL/
LSL+LF
Crane Track Main boom HA max. wind

type (m) (Superlift) ( speed
CC (m) (5) ( m/s )
2800 8.0 up to 132 75 15
Main boom and fly jib crane without load

e.g. SW, SWSL
HA 85 (65) / HI 45
Crane type Total length HA HA max. wind

CC (m) ( ( speed
(5) (5) ( m/s )
2800 up to 180 85 65 15
Check to make sure that the slewing range is free of ob-

stacles before releasing the slew brake.
The slew brake must be released and the hook block must
hang free. For longer pauses or at the end of work, the slew
brake must be locked in the open position (see Sect. 7.4).
With the Superlift the crane equipment must be slewed so that
the wind acts along the length of the crane equipment from
behind. The slew brake must be applied (closed). The Super-
lift counterweight must be fitted in accordance with the erect-
ing regulations (Sect. 10 in part 3) and set down. If the Super-
lift counterweight is deposited on the counterweight carriage,
this must stand on the ground. The stay ropes of the Superlift
counterweight must be tensioned.
0621090151_en 113/117
9
Z 39 467
114/117 0621090151_en
If higher winds are expected than are permitted (following

consultation with the weather authorities) the boom system
must be lowered in good time.
With the fly jib lowered
jib top section is lying on the ground
boom system is positioned against the wind
the slew brake is closed
the wind speeds apply in accordance with the main boom
table.
Wind direction
If the crane is to be taken out of operation for a longer period of
time (e.g. on the weekend), the crane superstructure and boom
must be turned in a direction which would mean that possible
storms would approach the crane from behind.
Boom position
The crane is at its most stable against the effects of wind from all
directions when the centre of gravity of the entire crane is near
the centre of the undercarriage (rotating axis). The position of the
centre of gravity can be affected by the angle of the main
boom and fly jib.
Back stroke safety devices
Two hydraulic cylinders prevent both the main boom and fly jib
from sagging backwards. When the crane is out of operation, the
boom must be tilted so far forwards that it cannot be pushed from
the front to the back, even under heavy storm conditions, thus
avoiding sudden and abrupt activation of the mechanical stops.
Counterweight carriage (Optional equipment)
After end of operation the support cylinders of the counterweight
carriage with the superlift counterweight deposited on it must be
extended until the wheels are free.
To prevent the support cylinders from retracting by leak-

ages, do set the shutoff valves (1, Z 39 467) at the individual
cylinders into position locked.
0621090151_en 115/117
9
116/117 0621090151_en
9.12.4 Lowering the Boom System
If the wind conditions could possibly exceed the limit values for
parking of the crane, the boom must be lowered to the ground in
good time.
If local conditions allow, the boom system should be lowered
against the wind direction (oncoming wind). Therefore the boom
must be turned into the wind, to reduce the wind loads when low-
ering the boom. The parking brake of the slew gear must be
closed.
Changing wind forces and direction must be taken into consider-
ation in good time; information should be collated in advance.
The entire Superlift counterweight required in accordance with
the erection table must be fitted and positioned correctly, to en-
able lowering of the boom system without delay, should this be
required as a result of heavier winds.
0621090151_en 117/117
Operation of the Heating and Ventilation 11
0621110151_en 1/17
11
93 91
92 94
97
107 95
106
105
99 100
102
104
101 103
98 96
Z 42 416
2/17 0621110151_en
11 Operation of the Heating and Ventilation
11.1 General
(Z 42 416)
The crawlermounted crane is equipped with a nonengine

driven heater. The heating is switched on by means of the rotary
switch (97) and the timer (95).
The fuel tank for the heater is located on the rear of the crane op-
erators cab.
The heater starts automatically. Starting takes up to 1 minute, de-

pending on the ambient temperature.
When the heater is switched off, the heater fan continues to run
for a further 2 to 3 minutes to cool down. The battery switch must
not therefore be switched off until the heater fan has stopped.
The heating system must not be operated in enclosed

areas such as garages and workshops without the use of
exhaust extraction equipment. DANGER OF POISONOUS
FUMES
At garages and filling stations, the heating system must
be switched off.
When electric welding is being carried out on the vehicle,
the main electric cable must be removed from the vehicle
battery and connected to the ground (to protect the elec-
tronic control unit).
The storage temperature must not exceed 85 C in the vi-
cinity of the control unit (e.g. when painting work is being
carried out on the vehicle).
If the exhaust system backfires or visible carbon depos-
its appear in the exhaust, the air intake and exhaust line
apertures should be cleared if necessary.
Operation is not permitted where combustible gases or
dust can accumulate (e.g. near storage points for fuel,
coal, wood dust, grain, etc.).
Briefly switch on the heating (for approx. 10 seconds)
approximately once a month, even outside of regular
heating periods. This prevents the water pump and the
burner motor from seizing up.
Before unscrewing the overheating fuse, release the
coolant cap to release the pressure from the system.
0621110151_en 3/17
11
99
A 6
B
C
1 2 3 4 5
Z 38 778
4/17 0621110151_en
(Z 38 778)
If a sensor is connected, the temperature is shown continu-

ously if button (1) is pressed once; if the ignition is switched
off, the temperature is displayed for 10 seconds when button
(1) is pressed twice.
If a heating time of 0 mins. is stored, the heater can no longer
be switched on.
Voltage dips and temporary cutoff from the battery voltage
are bridged by the heating timer. The display (6) then flashes
all signals: The system must then be reset.
With the ignition switched on, time and day are displayed
constantly. With the ignition switched off, the display disap-
pears after approx. 10 seconds.
Recommended action if malfunctions occur:
Switch off and on again (not more than twice).

Check the main fuse.
Check that the air flow is not blocked.
Take the vehicle to a workshop.
0621110151_en 5/17
11
99
A 6
B
C
1 2 3 4 5
Z 38 778
6/17 0621110151_en
11.2 Heater Operation
11.2.1 Setting the Timer

(Z 38 778)
When the power supply is switched on, all signals appear flashing
on the display (6). The timer must be set. The heater cannot be
switched on in this condition.
To switch on the timer, proceed as follows:
Calling up the time:
Press button (1).
Setting the time:
Press button (1), at the same time pressing button (4) or but-
ton (5).
Setting the day:
Press button (1), at the same time pressing button (2) (sev-
eral times if necessary).
Calling up the time and day:
Press button (1).
When the timer has been set, time and day are shown on the dis-
play (6).
0621110151_en 7/17
11
95
97
Z 42 641
99
A
6
B
C
1 2 3 4 5
Z 38 778
8/17 0621110151_en
11.2.2 Heater Operation without Preselection with Ignition

OFF
Switching on the heater:

Switch the thermostat to the desired position (1 to 5) with the
rotary switch (97, Z 42 641).
Press button (3, Z 38 778) on the timer to switch on the heater
(the duration of heating is set to 120 minutes by the factory.
A different duration can be selected each time or perma-
nently).
Display:
Heating duration, Heater symbol = Heater in operation.
Changing the duration of heating each time:
After switching on:

To reduce the duration of heating: Press button (4, Z 38 778).
To increase the duration of heating: Press button (5, Z 38
778).
Changing the duration of heating permanently:
Press button (3, Z 38 778) and hold down, at the same time press-
ing button (4) to reduce the duration of heating or button (5) to
increase the duration of heating. (When button (3) is released,
the original duration of heating appears on the display (6). To call
up the altered duration of heating, press button (3) twice, i.e.
switch off and on again).
Switching off the heater:
Press button (3, Z 38 778). The heater automatically runs on for

2 to 3 minutes in order to cool down.
0621110151_en 9/17
11
95
97
Z 42 641
99
A
6
B
C
1 2 3 4 5
Z 38 778
10/17 0621110151_en
11.2.3 Heater Operation without Preselection with Ignition

ON.
Switching on the heater:

Switch the thermostat to the desired position (1 to 5) with
rotary switch (97, Z 42 641).
Press button (3, Z 38 778) on the timer to switch on the heater.
The heater remains in operation until the ignition is switched
off. When the ignition is switched off, the heater continues to
operate for 5 minutes. This afterrun time can be extended
up to a maximum of 4 hours by pressing button (5).
Display:
Time, day, heater symbol = Heater in operation
Switching off the heater:
Press button (3, Z 38 778). The heater automatically runs on for

2 to 3 minutes in order to cool down.
0621110151_en 11/17
11
99
A 6
B
C
1 2 3 4 5
Z 38 778
12/17 0621110151_en
11.2.4 Heater Operation with Preselection

(Z 38 778)
Three starting times for the heating system can be selected for
the following 24 hours or one starting time can be selected for
the following 7 days.
Only one starting time can be activated at any one time.
Select memory:
Select memory, thus activating selection (commencing from neu-

tral setting as long as the display is visible).
Press Indication Basic setting

button (2)
First memory 1x A 111
setting
Second memory 2x B 222
setting
Third memory 3x C 333
setting
Neutral setting 4x
The display of the stored time goes out after 10 seconds.
Recall:
Press button (2) once.
11.2.4.1 Starting the Heater within 24 Hours
Adjusting the preselected day:
The day is selected automatically. No setting is necessary.
Adjusting the preselected time:

Select the desired memory with button (2).
Release button (2).
Set the time with button (4) or (5).
Adjustment can only be made while the display is shown.
Recall:
Press button (2) once.
0621110151_en 13/17
11
99
A 6
B
C
1 2 3 4 5
Z 38 778
14/17 0621110151_en
11.2.4.2 Starting Heating Later than 24 Hours Ahead (up to 7

Days Ahead)
(Z 38 778)
If the startup time is set for a week day outside of the next 24
hours, this setting must remain activated, i.e. the setting can no
longer be left (in the meantime the heater can only be used im-
mediately, 3, or the time, 1, can be displayed). If another
memory or the neutral setting is selected (even if only for check-
ing), the memory is automatically reset to the next setting option
(within 24 hours).
Adjusting the preselected day:

Select the desired memory with button (2).
Hold down button (2) and select the preselected day with but-
ton (5).
Adjusting the preselected time:

Release button (2).
Set the time with button(4) or (5).
Checking the activated

memory setting:
The preselected time of the selected memory setting will be dis-
played for approx. 10 seconds. It then disappears or, with the
ignition switched ON, the time is displayed. The preselected
time and preselected day can then be called up again (for 10 se-
conds, as described above) by pressing button (2) once.
0621110151_en 15/17
11
10 7
Z 24 632
10
Z 25 776
16/17 0621110151_en
11.2.5 Safety Equipment

(Z 24 632 and Z 25 776)
The flame is monitored by the flame probe (7), the maximum per-
missible temperature by the overheat fuse (8), or by the overheat
switch (9) as preferred. The overheat fuse and overheat switch
both activate the control device (10),which switches off the heater
in the event of a fault.
1. If the heater does not ignite within 90 seconds of the fuel be-
ing supplied, the starting procedure must be repeated.
If the heater fails to ignite after a further 90 seconds, the sys-
tem is shut down.
2. If the flame goes out of its own accord during operation, the
ignition is initially restarted.
If the heater fails to ignite within 90 seconds of fuel flow being
switched on, or if it ignites but goes out again within 3 min-
utes, the system is shut down.
This automatic cutout can be cancelled by switching off
briefly and then switching on again.
Do not switch on more than twice. If the heater still fails to

ignite after three attempts, have the fault rectified in a work-
shop.
0621110151_en 17/17
Radio Remote Control 14
0621140151_en 1/19
14
Z 40 789 Z 40 790
130.19
130.1 130.2 130.3
130.4 130.5 130.6
130.7 130.8 130.9
130 130.10 130.11 130.12
130.13 130.14 130.15
130.16 130.17 130.18
Z 38 078
2/19 0621140151_en
14 Radio Remote Control
14.1 General
The radio remote control can be used to operate all assembly

procedures remotely.
If the radio remote control fails, the valves must be actuated by

hand for the assembly procedures (see Sect. 14.4).
14.2 Preparations for Assembly using the Radio Remote

Control
You must be positioned in such a way that you have direct visual
contact to the radio receiver at the rear side of the operators
cabin.
1. Switch on the power supply of the crane.
2. Start the drive motor.
3. Prepare the transmitter (130, Z 38 078) for operation, i.e.

push the rechargeable battery into the battery holder (Z 40
789).
switch on the power supply by activating the emergency off
switch (130.19, Z 38 078) (Z 40 790).
The green LED (130.16, Z 38 078) must flash in sequence
when the transmitter is switched on.
4. By pressing the buttons (130.1, 130.17; Z 38 078) at the

same time, set the remote control to zero.
When the LED at the receiver lights up, the radio remote con-
trol is ready for operation.
Every time the radio remote control is switched on again, it oper-

ates at the frequency used last.
If the radio remote control now does not start properly the fre-
quency must be changed until proper operation is possible.
For changing the frequency keep pressed button 130.17 and

press simultaneously button 130.18. If the receiver lockes on to
a new frequency the horn sounds a signal. The radio remote con-
trol is now ready for operation.
0621140151_en 3/19
14
22a
Z 40 791
22d
Z 40 792
4/19 0621140151_en
5. Set the operating mode RG0 or SMAB1 on the PDC

(Z 40 791).
6. Select level 3 using button 22 a.
7. Press button 22 d (Z 40 792).
0621140151_en 5/19
14
Z 40 793
21
Z 40 794
6/19 0621140151_en
8. The options for the assembly function are now displayed on

the load limit device screen (Z 40 793).
9. Using the arrow keys and on the keypad (21), the desired
function can now be selected (Z 40 794).
Assemble chassis
Assemble winch frame
Assemble main boom foot section
Aframe folding
Outriggers
Position cylinders slewing rim
Off
0621140151_en 7/19
14
21
Z 40 795
Z 40 796
8/19 0621140151_en
10. The selected function is activated by pressing button C in

the keypad (21, Z 40 795). The function which is activated is
displayed in the status line.
In the operating mode SMAB1 there is only one selection option

available (Z 40 796).
Ending assembly using the remote control

by activating the function OFF all assembly functions are de-
activated.
when the remote control function is ended, all assembly func-
tions are deactivated by pressing the key
in the third level of keys on the load limit
device screen and the display of
the current assembly option on the LLD screen is deleted.
When a new operating mode for the load limit device is se-
lected, all functions of the remote control are deleted.
0621140151_en 9/19
14
130.19
130.1 130.2 130.3
130.4 130.5 130.6
130.7 130.8 130.9
130
130.10 130.11 130.12
130.13 130.14 130.15
130.16 130.17 130.18
Z 38 078
10/19 0621140151_en
14.3 Table Outline of the Assembly Procedures

14.3.1 Assembly Procedures on the Superstructure
(Z 38 078)
Desired function Keys
Assemble winch frame H1
Unbolt frame 130.1 + 130.10
Bolt frame 130.2 + 130.10
Unbolt frame 130.1 + 130.11
Bolt frame 130.2 + 130.11
Aframe adjustment
Extend Aframe cylinder 130.1 + 130.8
Retract Aframe cylinder 130.2 + 130.8
Unbolt boom foot section, lefthand side 130.1 + 130.10
Bolt boom foot section, lefthand side 130.2 + 130.10
Unbolt boom foot section, righthand side 130.1 + 130.11
Bolt boom foot section, righthand side 130.2 + 130.11
14.3.2 Assembly Procedures on the Chassis

(Z 38 078)
Unbolt lefthand track frame 130.1 + 130.10
Bolt lefthand track frame 130.2 + 130.10
Unbolt righthand track frame 130.1 + 130.11
Bolt righthand track frame 130.2 + 130.11
Extend all outriggers 130.1 + 130.3
Retract all outriggers 130.2 + 130.3
Retract front left outrigger 130.1 + 130.6
Extend front left outrigger 130.2 + 130.6
Retract front right outrigger 130.1 + 130.12
Extend front right outrigger 130.2 + 130.12
Retract rear left outrigger 130.1 + 130.9
Extend rear left outrigger 130.2 + 130.9
Retract rear right outrigger 130.1 + 130.15
Extend rear right outrigger 130.2 + 130.15
Extend tension cylinder slewing rim 130.1 + 130.7
Retract tension cylinder slewing rim 130.2 + 130.7
Extend position cylinder slewing rim 130.1 + 130.8
Retract position cylinder slewing rim 130.2 + 130.8
0621140151_en 11/19
14
130.19
130.1 130.2 130.3
130.4 130.5 130.6
130.7 130.8 130.9
130
130.10 130.11 130.12
130.13 130.14 130.15
130.16 130.17 130.18
Z 38 078
12/19 0621140151_en
14.3.3 Assembly Procedures on the Counterweight Dolly

(Z 38 078)

Swivelling bolster 1 left rotate 130.4 + 130.13
Swivelling bolster 1 right rotate 130.5 + 130.13
Swivelling bolster 2 left rotate 130.4 + 130.14
Swivelling bolster 2 right rotate 130.5 + 130.14
Unlock swivelling bolster 1 130.1 + 130.10
Lock swivelling bolster 1 130.2 + 130.10
Unlock swivelling bolster 2 130.1 + 130.11
Lock swivelling bolster 2 130.2 + 130.11
Extend lift cylinder connecting frame 130.1 + 130.7
Retract lift cylinder connecting frame 130.2 + 130.7
14.3.4 Assembly Procedures on the JackUp System

(Z 38 078)

Retract front left outrigger 130.1 + 130.6
Extend front left outrigger 130.2 + 130.6
Retract front right outrigger 130.1 + 130.12
Extend front right outrigger 130.2 + 130.12
Retract rear left outrigger 130.1 + 130.9
Extend rear left outrigger 130.2 + 130.9
Retract rear right outrigger 130.1 + 130.15
Extend rear right outrigger 130.2 + 130.15
Extend front position cylinder 130.5 + 130.7
Retract front position cylinder 130.4 + 130.7
Extend rear position cylinder 130.5 + 130.8
Retract rear position cylinder 130.4 + 130.8
0621140151_en 13/19
14
14/19 0621140151_en
14.4 Assembly Procedures in Case of Failure on the Radio

of Remote Control
If the remote control fails, the valves for the individual assembly
procedure must be activated manually.
All valves are marked with plates.
For all assembly procedures on the superstructure, chassis,

counterweight dolly and jackup system the solenoid valve
Y 256B (highpressure pump P3.2) must be actuated.
The valve Y 256B is secured on the assembly frame. A 24 V volt-

age can be connected to the valve to facilitate manual assembly.
Following assembly, the valve Y 256B must be replaced in its
original position.
0621140151_en 15/19
14
16/19 0621140151_en
14.5 Table Outline of the Assembly Procedures in Case of

Remote Control Failure
14.5.1 Assembly Procedures on the Superstructure

Desired function Valve Fitting location of the valve
Bolt frame Y223A Assembly frame
Unbolt frame Y223B Assembly frame
Bolt frame Y223C Assembly frame
Unbolt frame Y223D Assembly frame
Aframe
Lower Aframe (8 cutoff) Y234B Assembly frame
Bolt boom foot section, lefthand side Y260A Near slew gear motor
Unbolt boom foot section, lefthand side Y260B Near slew gear motor
Bolt boom foot section, righthand side Y260C Near slew gear motor
Unbolt boom foot section, righthand side Y260D Near slew gear motor
14.5.2 Assembly Procedures on the Chassis (UW)

Bolt lefthand track frame Y060A Chassis intermediate section
Unbolt lefthand track frame Y060B Chassis intermediate section
Bolt righthand track frame Y060C Chassis intermediate section
Unbolt righthand track frame Y060D Chassis intermediate section
Extend rear left outrigger Y061C Gate on chassis intermediate
section
Retract rear left outrigger Y061D Gate on chassis intermediate
section
Extend front left outrigger Y061A Gate on chassis intermediate
section
Retract front left outrigger Y061B Gate on chassis intermediate
section
Extend rear right outrigger Y061G Gate on chassis intermediate
section
Retract rear right outrigger Y061H Gate on chassis intermediate
section
Extend front right outrigger Y061E Gate on chassis intermediate
section
Retract front right outrigger Y061F Gate on chassis intermediate
section
Extend tension cylinderslewing rim Y062B Chassis intermediate section
Retract tension cylinderslewing rim Y062A Chassis intermediate section
Extend position cylinder slewing rim Y062D Chassis intermediate section
Retract position cylinderslewing rim Y062C Chassis intermediate section
0621140151_en 17/19
14
18/19 0621140151_en
14.5.3 Assembly Procedures on the Counterweight Dolly

(GW)
For all assembly procedures on the counterweight dolly the

solenoid valves Y 243 and Y 256D must be actuated.
The valve Y 256D is secured on the control block on the bottom

of the counterweight dolly. The valve Y 243 is secured on the bot-
tom of the counterweight dolly.
Manual assembly can be made easier by connecting a 24 V volt-
age to both valves.
Following assembly, however, both valves must be returned to
their original position.

Lock swivelling bolster 1 Y244B Valve bank on bottom of CW
Unlock swivelling bolster 1 Y244A Valve bank on bottom of CW
Lock swivelling bolster 2 Y244D Valve bank on bottom of CW
Unlock swivelling bolster 2 Y244C Valve bank on bottom of CW
Extend all outriggers Y280A Control block bottom of CW
Retract all outriggers Y280B Control block bottom of CW
Extend lift cylinder connecting frame Y246A Valve bank on bottom of CW
Retract lift cylinder connecting frame Y246B Valve bank on bottom of CW
14.5.4 Assembly Procedures on the JackUp System

Extend front right outrigger cylinder Y235D Valve bank front bridge
Retract front right outrigger cylinder Y235C Valve bank front bridge
Extend front left outrigger cylinder Y235B Valve bank front bridge
Retract front left outrigger cylinder Y235A Valve bank front bridge
Extend front displacement cyl. Y236B Valve bank front bridge
Retract front displacement cyl. Y236A Valve bank front bridge
Extend rear left outrigger cylinder Y235F Valve bank rear bridge
Retract rear left outrigger cylinder Y235E Valve bank rear bridge
Extend rear right outrigger cylinder Y235H Valve bank rear bridge
Retract rear right outrigger cylinder Y235G Valve bank rear bridge
Extend rear displacement cyl. Y236D Valve bank rear bridge
Retract rear displacement cyl. Y236C Valve bank rear bridge
0621140151_en 19/19

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Manufacturers Specifications

The operating, lubricating and maintenance instructions and

Crane classification Mobile crane

Crane type CC 2800

Construction number 62 151

Maximum load 600 t

Manufacturer Demag Mobile Cranes

the owner of this crane manufactured by us, we have summa-

Periodic preventive inspection and maintenance are the surest

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

Handover of the crane

you should subject the crane to a thorough inspection by our ser-

Please contact the service department if you have any questions

Modifications to the crane

After modifications or repairs to parts which affect the safety of

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

Observe here the information on the opposite page.

WHAT do I want to know ?

WHERE do I find the information required ?

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

4. In Section 8, I then find, Electronic Crane Information

HOW do I find the page in Section 8 ?

1. I take the pages of part 1 as shown in (Z 26 350) and flick

Danger is used if performing an operation, a mounting

Caution is used if performing an operation, a mounting

Note is used for marking an important operation or mounting

There are two foldout panels for the cab.

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

Folding Table Crane Cab

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

2.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Crane Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 Engine and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6 Driving the Crawlermounted Crane . . . . . . . . . . . . . . . . . . . . . . 3

6.5 Driving the Crane without Load Application SW . . . . . . . . . . . . . . 19

7 Slewing and Braking the Superstructure . . . . . . . . . . . . . . . . . . 3

8 Operating the Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9 Working with the Crane Equipment . . . . . . . . . . . . . . . . . . . . . . . 3

9.7.3 Operating Luffing Gear 1 (W1) during Crane Operation . . . . . . . . 51

11 Operation of the Heating and Ventilation . . . . . . . . . . . . . . . . . . 3

14 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Folding Table Dashboard

This section on safety instructions gives a concise and general

The safety instructions for assembling the crane are contained in

1.2 Intended Use

The crane is designed exclusively for assembly operation. Any

It is prohibited to use the crane to pull free fixed loads !

The crane operator is responsible for the operation of additional

1.3 Operating Conditions and Computed Design of the

The term operating instructions refers to the operating instruc-

The design engineers have assumed certain operating condi-

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

All important components of the crane are designed and

Operating conditions or types of use other than assembly opera-

1.3.2 Workplace Ergonomics

Measurements were taken using a noise level measuring unit

The crane operator is protected against mechanical vibrations by

Crane operators seat

The weighted effective value of acceleration to which the upper

1.3.3 Load and Utilisation of the Crane

1.3.4 Required Ambient Conditions

The permitted temperature range for operating the crane is

Optional equipment for other operating conditions can be sup-