Working Instructions 11

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91
90
90 91

Z 40 601

0 1. 5 80
WSE m/s
Z 40 602

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 Working Instructions 11

11 Working Instructions

11.1 wind speeds

The permitted wind speeds MUST be observed. To check the

wind speed, the crane is equipped with an air speed indicator
(anemometer).

This consists of two elements:

1. the rotor (90, Z 40 601) on the head of the main boom, main
boom extension or fixed or luffing fly jib

and

2. the digital display (80) in the crane operator’s cab.

The rotational movement of the rotor caused by the wind is
converted into an electric signal which is displayed on the in-
dicator (80) in the crane operator’s cab. The crane operator
can read off the wind speed in m/s (Z 40 602).

The rod and fitted rotor (90) and possibly aircraft warning light
(91) must be secured with the bracket provided on the head of the
main boom, main boom extension or fixed/luffing fly jib (Z 40
601).

For technical reasons, a value of 1.5 m/s is displayed on the

display (62) even if there is no air current. This display does
not automatically mean that the system is functioning. This
must be checked and guaranteed before work is com-
menced or the equipment is raised.
You can see if the system is working if the value on the dis-
play changes in relation to the rotation of the rotor.
If there is no wind, it has to be simulated by manual rotation
of the rotor.

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The wind speeds specified below are maximum values.

National regulations must also be observed.

11.1.1 Maximum Permitted wind speeds during Erection

For all crane configurations the boom system may only be

erected (raised from the ground) if the expected wind speeds
(weather forecast) are also permitted for operation of the crane
(see Sect.11.1.2).

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11.1.2 Maximum Permitted wind speeds for Operation of the

Crane

Before the crane is operated, the local weather authority

should be contacted for information on expected wind con-
ditions during the entire operation of the crane!

For the wind speed allowed in the load tables of 9.8 m/s (dynamic
pressure 60 N/m2) a surface area of the load exposed to the wind
of 1.0 m2/t and a wind resistance coefficient cw of 1.2 is calcu-
lated.

For loads with a larger wind surface area, please contact the
crane manufacturer.

11.1.2.1 Permitted wind speeds for Main Boom Operation (HA)

The maximum permitted wind speeds for operation of the crane

on the main boom are dependent on the main boom length.

For a main boom length of:

-- HA = 15.5 m : Vmax = 15,0 m/s
-- HA = 20.5 m to 35.5 m : Vmax = 12.5 m/s
-- HA = 40.5 m to 60.0 m: Vmax = 9,8 m/s

The specified wind speeds are valid both for normal and for Su-
perlift crane operation.

Operation of the crane on the main boom with the main boom
extension (MBE) fitted in the operating position or the fixed
fly jib fitted (LF) is permitted independent of the system
length up to a maximum wind speed of 9.8 m/s.

11.1.2.2 Permitted wind speeds for Operation of the Crane on

the Main Boom Extension (MBE) or on the Fixed Fly
Jib (LF)

Operation of the crane on the main boom extension and on the

fixed fly jib is permitted up to a wind speed of maximum 9.8 m/s,
regardless of the system length.

The specified wind speeds are valid both for normal and for Su-
perlift crane operation.

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WIHI (m) / WIHISSL-- 0°

--
--

Z 49 819

WIHI (m) / WIHISSL-- 0°

-
-

Z 49 820

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 Working Instructions 11

11.1.2.3 Permitted wind speeds for Operation of the Crane on

the Luffing Fly Jib (WIHI / WIHISSL-- 0°)

For operation of the crane on the luffing fly jib the permitted maxi-
mum wind speed is dependent on the system length. This system
length is made up of the main boom and fly jib length and from
the 4 m adapter (Z 49 819).
* HA = main boom
* AD = Adapter
* WIHI = luffing fly jib
* WIHISSL--0° = Luffing fly jib with lateral Superlift / arms
folded in
* Vmax = max. permitted wind speeds

The adjacent table (Z 49 820) contains the maximum permitted

wind speeds in m/s. These are valid for fly jib operation without
Superlift bracing and with Superlift bracing with fully folded arms
(SSL--0°).

Examples:
-- When HA = 35.5 m and WIHI = 60.0 m: Vmax = 9.8 m/s
-- When HA = 25.5 m and WIHI = 84.0 m: Vmax = 7.0 m/s
-- When HA = 45.5 m and WIHI = 72.0 m: Vmax = 5.0 m/s

The data given in the load tables must be observed at all

times.

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Z 49 821 Z 49 822

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 Working Instructions 11

11.1.2.4 Permitted wind speeds for Operation of the Crane on

the Luffing Fly Jib with lateral Superlift Bracing (WI-
HISSL-- 60°)

For operation of the crane on the luffing fly jib the permitted maxi-
mum wind speed is dependent on the system length. This system
length is made up of the main boom and fly jib length and from
the 4 m adapter (Z 49 821).
* HA = main boom
* AD = Adapter
* WIHI = luffing fly jib
* WIHISSL--60° = Luffing fly jib with lateral Superlift / arms
folded in 605
* Vmax = max. permitted wind speeds

The adjacent table (Z 49 822) contains the maximum permitted

wind speeds in m/s. These wind speeds are only valid for fly jib
operation with the Superlift bracing with the arms fully folded out
(SSL--60°).

Examples:
-- When HA = 35.5 m and WIHI = 60.0 m: Vmax = 9.8 m/s
-- When HA = 40.5 m and WIHI = 66.0 m: Vmax = 9.0 m/s
-- When HA = 45.5 m and WIHI = 72.0 m: Vmax = 7.0 m/s

The data given in the load tables must be observed at all

times.

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11.1.3 Prohibited wind speeds

If the wind speeds outlined below or listed in the wind

speed tables are reached, crane operation is no longer
permitted.
The crane must be placed in a non--operational condi-
tion. This depends on the current and the expected wind
speed. For this reason a weather forecast must be ob-
tained from the weather office responsible.

If the crane is to be left unattended for a longer period of

time, e.g. overnight, the main boom must be telescoped
in and any additional equipment which is fitted set down
on the ground.

At the work site make sure that sufficient space is left in

the vicinity of the crane so that the main boom can be
telescoped in and the additional equipment placed on the
ground, if a (strong) wind suddenly occurs.

If site conditions do not allow the boom system to be

lowered to the ground, a weather forecast must be ob-
tained for the whole of the work period.
A suitable and safe contingency plan must be put in
place to lower the boom system in the event of (strong)
winds.

In addition the following rules apply:

11.1.3.1 Main boom operation

In relation to the main boom length operation of the crane on the

main boom is permitted up to a maximum wind speed of 15 m/s
(see section 11.1.2.1). The main boom -- without load -- can ini-
tially remain telescoped out.

Above 15 m/s the main boom must remain telescoped in and

lowered into the transport position.

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HAV

Z 49 823

Z 49 824

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11.1.3.2 Operation with the Main Boom Extension or Fixed Fly

Jib

-- Above 9.8 m/s operation of the crane is no longer permitted

on the main boom extension and on the fixed fly jib (see sec-
tion 11.1.2.2).
If the main boom and auxiliary equipment is without load, the
main boom can initially remain telescoped out.
If possible, the boom system must be positioned into the
wind.
The permitted highest values for the crane out of operation
are dependent on the length of the fitted auxiliary equipment.
When the wind speeds in the adjacent tables are reached,
the main boom must be lowered to the ground with the addi-
tional equipment.
-- Maximum permitted wind speeds with the main boom ex-
tension fitted (MBE): 15 m/s bzw. 12m/s (Z 49 823).
-- Maximum permitted wind speeds with the fixed fly jib fitted
(LF): 15 m/s bzw. 12m/s (Z 49 824).

Pay attention to the procedures for lowering the correspond-

ing additional equipment as described in the corresponding
sections of the operating instructions.

Examples:
-- When main boom extension length = 18 m: Vmax = 15 m/s
-- When main boom extension length = 30 m: Vmax = 12 m/s
-- When fixed fly jib length = 26 m: Vmax = 15 m/s
-- When fixed fly jib length = 32 m: Vmax = 12 m/s

The specified wind speeds are valid both for normal and for Su-
perlift crane operation.

If it is expected that the wind speed will exceed 15 m/s or

12 m/s, the boom must be lowered to the ground in good
time with the additional equipment. If possible, the equip-
ment must be lowered against the direction of the wind.
Above 15 m/s or 12 m/s the boom system must be low-
ered to the ground. The lowering procedure must be
introduced in good time.

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Z 49 825 Z 49 826

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11.1.3.3 Operation with Luffing Fly Jib

For crane operation on the luffing fly the prohibited wind speeds
are dependent on the system length.
This system length is made up of the main boom and fly jib length
as well as the 4 m adapter (Z 49 825).
* HA = main boom * WIHI = luffing fly jib
* AD = Adapter * Vmax = max. permitted wind
speed
-- For operation with the luffing fly jib the values outlined in the
table in section 11.1.2.3 and 11.1.2.4
If the values in the table are exceeded, the main boom can
initially remain telescoped out, if there is no load on the main
boom and fly jib.
Where possible, the boom system should be positioned into
the wind.
-- When the wind speeds in the adjacent table are reached
(Z49 826), the main boom and the fly jib must be lowered to
the ground.

Pay attention to the procedures outlined for lowering the luf-

fing fly jib in section 19.9 and 27.6 of these operating instruc-
tions.

Examples:
-- When HA = 35.5 m and WIHI = 60.0 m: Vmax = 15 m/s
-- When HA = 25.5 m and WIHI = 84.0 m: Vmax = 11 m/s
-- When HA = 45.5 m and WIHI = 72.0 m: Vmax = 8 m/s

The specified wind speeds are valid both for normal-- and also for
Superlift operation.

If it is expected that these wind speeds will be reached or

exceeded, the boom and additional equipment must be
lowered to the ground in good time. If possible, the
equipment should be lowered against the direction of the
wind. If these wind speeds are reached, the boom system
must already be lowered to the ground. The lowering pro-
cedure must be introduced in good time.

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”S511”
2

”S512”

Z 40 668

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 Working Instructions 11

11.2 Crane operation

Before starting the engine or starting crane movements

the crane operator must sound the horn to warn persons
who are in the vicinity of the crane.

- The crane may only be placed in operation when:

∗ the engine of the crane chassis is switched off.

∗ the cab of the crane chassis is closed.
∗ the control panels of the outriggers are closed.
∗ the manhole cover (1) on the main boom basic case is
screwed in place (Z 40 668).

If the manhole cover is missing, a gearshift rail is not avail-

able in the area of the manhole. When telescopic section 1
is extended there is a risk of the proximity switches “S511”
and “S512”, which are responsible for the bolting procedure,
initiating an undesired bolting procedure.
The locking bolt (2) on the telescopic section 1 is extended.
Risk of damage for the basic case and locking pin ! (Z 40 668)

- Use great care when initiating and completing the slewing

procedure!
Select a low slewing speed! Brake carefully with the control
lever (1)!
This applies in particular to operation of the crane with the
main boom extension and fly jib or special local conditions.

- To increase the operating speed, two crane movements can

be carried out simultaneously and independently of one
another in addition to the slewing procedure.

- Before each load case, the corresponding limit switches must

be checked to make sure that they are functioning correctly.

- The crane can only be operated when it is supported on out-

riggers.
If no information is given in the load tables with regard to the
support base area, the crane must be operated with the out-
riggers fully extended (outrigger support area: 12 x 12.20 m).

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Z 40 669

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 Working Instructions 11

- Simultaneous raising of the load on the main boom extension

or on the fly jib and on the main boom is not permitted (Z 40
669).

- There is one load capacity table that only allows operation of

the crane with the superstructure in the 180° position, i.e. the
superstructure to the rear. In this case:

∗ the superstructure may not be rotated.

∗ the mechanical superstructure locking device must be ap-
plied.
∗ a central support is required (”central support”: see operat-
ing instructions of the crane chassis, part 2, section 12.8).

- The specified reevings in the lifting capacity Tables supplied

are not less than double. If single reeving is required, then the
lifting capacities listed in the Tables is to be reduced by 20%.
This also applies if the lifting capacity falls below the maxi-
mum permitted rope traction of 13.7 t per fall.

- The standard hoist rope lengths are as follows:

-- Rope of hoist 1: 550 m

-- Rope of hoist 2: 770 m

If hoist rope 1 is reeved, the hook block may not reach the
ground. Such load cases are marked in the load capacity
table with “#”. In this case, for operation with the main boom
and main boom with lateral Superlift, hoist 2 should be
reeved.

- When the main boom has been extended to its final operating
length and bolted, the locking and bolting unit must be com-
pletely retracted. This is required:

-- in order to reduce the head weight.

-- in order to keep the hydraulic oil temperature as low as
possible.

- If a counterweight of more than 100 t is fitted, rotation of the

superstructure and operation of the crane with a reduced
support base area of ”8.45 x 9.02 m” is not permitted. Risk of
tipping!

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Z 37 682 Z 37 683

Z 37 684

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 Working Instructions 11

- The weights of hook blocks (Z 37 682) hook suspension gear

(Z 37 683), heavy--duty suspension gear (Z 37 684), lifting
tackle etc. must be subtracted from the lifting capacities of the
tables.
∗ Heavy--duty suspension gear ”type 550”:8800 kg / 19404
lb
∗ Hook block ”type 320” (13 sheaves): 4000 kg / 8820 lb
∗ Hook block ”type 250” (9 sheaves): 2800 kg / 6174 lb
∗ Hook block ”type 200” (7 sheaves): 2600 kg / 5733 lb
∗ Hook block ”type 160” (5 sheaves): 2200 kg / 4851 lb
∗ Hook block ”type 100” (3 sheaves): 1800 kg / 3969 lb
∗ Hook block ”type 40” (1 sheave): 1200 kg / 2646 lb
∗ Hook suspension gear ”type 12.5”: 650 kg / 1433 lb
- To raise the maximum load and for simultaneous reeving of
”hoist rope 1” and ”hoist rope 2” a double hook block must be
used. For work with this hook block, synchronous regulation
of hoist 1 and hoist 2 -- or a balance indicator for the hook
block is required.
- Telescoping out loads which are higher than the specified lev-
els is prohibited (”telescoping loads”: see section 12 of these
operating instructions).

Risk of crushing !
In spite of the use of automatic safety devices, the load
cannot always be prevented from swinging out when a
movement is switched off.
This can only be avoided by suitable acceleration /
speeds for all crane movements.

- The main boom must be in the high position for crane opera-
tion with the luffing fly jib (boom at the upper stop / 83°) or in
the 65°-- or 73° position (see corresponding load tables).
In order to reach these tilted positions of 65° and 73° under
load, the main boom must be adjusted without load to the cor-
responding angle +2° (e.g. 73° operating position with load,
set main boom without load to 75°).

Risk of accidents!
Before lowering the luffing fly jib or changing the main
boom length (telescoping) the main boom must be
moved into the high position (83°).

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32

42

Z 47 343

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- To allow for immediate reaction if the crane is subjected to

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

-- An exception is only permitted in emergency situa-

tions. To avoid hazardous situations, as a last option
the drive source (diesel engine) can be switched off
using the emergency off button in the crane operator’s
cab. First, where possible, any movements which
have been started should be completed using the con-
trol lever.
-- When configuring the Superlift bracing support or
when moving to the configuration and operating
length of the main boom in Superlift operation, with
the telescopic section unpinned, the engine must
never be switched off using the ”emergency stop” but-
ton. The brake of the bracing winch does not close,
there is a risk of the bracing support falling back-
wards!

- The erected crane may only be left without the supervision of

an experienced crane operator if certain conditions are satis-
fied (see operating instructions of the crane chassis, section
14 ”Parking”).

- In order to prevent crane movements being activated unin-

tentionally, both control levers are equipped with an addi-
tional button (dead man’s switch).
A crane movement can only be carried out as long as one of
these buttons is pressed.

- For operation of the crane with the Superlift set down on the
main boom in the transport position, the roller (32) must be
fitted on the erecting lever (42) of the bracing support (Z 47
343). If this is not done, there is a risk of damage to the hoist
rope and Superlift!

- During operation of the crane, observe display (14). The tem-

perature of the hydraulic oil must not exceed 85° C.

This applies to the oil filled ex works. For oils with a different
viscosity, observe the corresponding characteristic curves
or get in touch with the crane manufacturer.
If this value is exceeded, operation of the crane should be
stopped temporarily. Leave the diesel engine running at low
revs so that the hydraulic oil can be cooled down via the oil
cooler.

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Z 47 324

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11.2.1 Main Boom Operation with Additional Equipment

Fitted

11.2.1.1 Main Boom Operation with Fixed Fly Jib Fitted

When raising a load on the main boom with a fixed fly jib fitted in
the operating position, minimum loads must be calculated. These
minimum loads -- in relation to the main boom length, fly jib length
and angle -- can be taken from the adjacent table (Z 47 324). The
minimum loads include the weight of the 1--sheave hook block of
1200 kg / 2646 lb.

Legend:
-- HA = main boom
-- LF = fly jib

The reduced loads specified in the table (lb x 1000) must be taken
from the corresponding load capacity tables of the main boom.

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Z 42 343

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11.2.1.2 Main Boom Operation with Main Boom Extension

Fitted

When raising a load on the main boom with the main boom exten-
sion fitted in the operating position, minimum loads must be cal-
culated. These minimum loads -- in relation to the main boom
length and the length and angle of the main boom extension --
can be taken from the adjacent table (Z 42 343). The minimum
loads include the weight of the 1--sheave hook block of 1200 kg
/ 2646 lb.

Legend:
-- HA = main boom
-- HAV = main boom extension

The reduced loads specified in the table (lb x 1000) must be taken
from the corresponding load capacity tables of the main boom.

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24
25

Z 40 672

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11.3 Cab adjustment

To allow work with the crane to be followed better, the superstruc-

ture cab can be tilted backwards.

This occurs by cylinder (5) extending. To this end, press and hold
button (25) in the console of the crane operator’s cab for the en-
tire procedure (Z 40 672).

The crane operator’s cab can be adjusted infinitely up to a maxi-

mum angle of 18° to 20° to the rear.

To return the cab to the horizontal position, press and hold button
(24) in the console. The cylinder (5) is retracted (Z 40 672).

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11.4 Operation Planning / Monitoring Safety Measures

Before commencing work, i.e. before taking up a load, the condi-

tions described below must be fulfilled!

11.4.1 General

For every crane operation, the crane operator / operations plan-

ner must provide the crane that is suitable for the work at hand,
for example with regard to lifting capacity, lifting height and work-
ing radius. The weight of the load must be known.

Move the load as low above the ground as possible.

Avoid excessive operating speeds which could cause the load to

swing. Large loads must be guided from the ground with ropes.

11.4.2 Condition of the Crane

-- correctly supported on outriggers and horizontally aligned.

-- all four outriggers extended to the support base area speci-
fied in the corresponding load capacity table.
-- all four outriggers locked with bolts to prevent movement.
-- all four vertical outrigger cylinders extended so that all axles
are relieved of load, i.e. so that all wheels are free of the
ground.
-- Support plates locked.
-- Suspension system of the crane chassis switched to “raise
axles” or “hold axles”.

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11.4.3 Condition of the Environment

Load--bearing capacity of the ground

The ground must have sufficient load--bearing capacity to take

the maximum support pressures which occur. If necessary, in-
crease the support area by stacking suitable materials under the
outrigger plates.

Details on the maximum support pressures which occur can be

found in section 12 “Outriggers” of the operating instructions for
the crane chassis.

The permitted load on the ground is determined by the type and

condition of the ground. Information on permitted ground pres-
sures can be found for example in the standard DIN 1054 on per-
mitted ground loads (a roughly translated excerpt is contained in
the following table, please refer to the actual DIN standard).

Permitted
ground
Type of ground
pressures
(N/cm2)
1. Organic ground in general:
peat, sapropel, marshy ground 0
2. Non--compacted bulk refuse: rubble etc. 0 -- 10
3. Non--cohesive ground:
Sand, gravel, stones and their mixtures 20
4. Cohesive ground:
a) coarse clay, mixed with for example native soil 12
b) clay, consisting of weathered and hanging loam 13
c) fertile clay comprising clay and filling
rigid 9
semi--hard 14
hard 20
d) mixed grain soil: clay to sand,
gravel and stone areas
rigid 15
semi--hard 22
hard 33
5. Rock in even firm condition:
brittle, with weather traces 150
not brittle 400

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If doubts exist with regard to the load--bearing capacity

of the ground, an examination of the ground must be car-
ried out (e.g. with a pile sensor).

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Z 41 654

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Calculation example for the required stacking surface area for

insufficiently supportive ground for standard outrigger plates:

-- max. support pressure approx. 1815 kN

-- Diameter of the outrigger plates is 80 cm.

Specific support pressure (per support)

= (maximum support pressure): (outrigger pad surface)
= 1,815,000 N: 5027 cm2
= 361 N/cm2

The specific support pressure must be equal to or less than the

permitted ground pressure. If this crane is to be used on gravel
for example (permitted ground pressure 20N/cm2), the outrigger
support surface area must be increased using the following for-
mula:

Surface area of the outrigger = (max. support pressure) : (permis-

sible ground pressure)
= 1,815,000 N : 20 N/cm2
= 90750 cm2 = 9,08 m2.

The outrigger plates must be stacked with suitable materials to

create a surface area of 9.08 m2 .

(Z 41 654)
The plates must be positioned at the centre of the supports and
all supporting wood must be sufficiently covered.

You should also check to see if there are any channels, covered
ditches or cellars in the area where the crane is to be operated
and in what direction they are running. In addition, watch out for
hidden hazards such as melting ice or scouring.
These hidden hazards are often the cause of cranes falling over.

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Z 41 655

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Safety clearance from slopes or ditches

(Z 41 655)

A sufficient safety clearance must be maintained from slopes or

ditches. This depends on the type of ground.
This clearance can be defined precisely in accordance with
DIN 4124. As a general rule:
-- the gap “a” from the outside edge of the outrigger plate (or
stacked support) to the edge of the slope must never be less
than 2m.
-- for grown, binding soils the gap “b” between the ditch and out-
side edge of the outrigger plate (or stacked support) must
equal at least dimension “t” (ditch depth).
The slope angle α must not exceed 45° .
-- for filled--up soil and loose soils the gap “b” between the foot
of the ditch and the outside edge of the outrigger plate (or
support) must equal at least 2 x t (ditch depth).
The angle of the slope α must not exceed 30° .

If the safety clearance cannot be maintained, the slope or

ditch must be additionally sectioned off.

-- no live wires or cables in the operating area of the crane.

-- no obstacles which hinder the necessary crane movements.
Maintain sufficient safety clearances in order to prevent the
risk of crushing (e.g. on the counterweight).
-- Location selected so that the crane operation can be carried
out with as low a working radius as possible.
-- In case of poor visibility or darkness, the immediate surround-
ings of the crane operator’s cab, the outriggers and the
winches must be lit up using the spot lights fitted on the ma-
chine (outside lighting rear, outside lighting front, outside
lighting side).
Additional surroundings (load, load path, slewing range, driv-
ing area etc.) must be lit with suitable lighting which is inde-
pendent of the crane. The crane operator is responsible for
this.

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