AC140 14193 Part1 - en PDF

140−0000 1/1
Index
Manufacturer’s Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Operating Conditions and Computed Design of the Crane . . . . . . 7
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.2 Classification of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.3 Classification of the Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.5 Load and Utilisation of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.6 Required Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.7 Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.8 Standards and Calculation Regulations . . . . . . . . . . . . . . . . . . . . . . 17
1.3.9 Dangers to Air Traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4.1 Organisational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4.2 Selection and Qualifications of Personnel . . . . . . . . . . . . . . . . . . . . 25
1.4.3 Particular Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4.4 Combination of Hazards with Combined Operation
of Two or More Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4.5 Driving Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4.6 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4.7 Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.4.8 When Assembling and Dismantling Crane Components . . . . . . . . 65
1.5 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.5.1 General Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5.2 Hand Signals for Working Movements . . . . . . . . . . . . . . . . . . . . . . . 75
1.5.3 Hand Signals for Driving Movements . . . . . . . . . . . . . . . . . . . . . . . . 77
140−1000−193 2
Index
2 Structure of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Safety−relevant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.1 Ladders and safety harnesses/guards . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.2 Spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.3 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Signs and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.1 Signs in the Crane Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.2 Signs and Symbols on the Superstructure . . . . . . . . . . . . . . . . . . . . 19
2.5.3 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.4 Safety signs ( US only ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.1 Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.2 Entering / Exiting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4 Workplace Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4.1 Adjusting the Crane Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4.2 Sun Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.3 Lighting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.4 Open / Close Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
140−1000−193 3
Index
5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.1 Engine control/monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.2 Starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.3 To be observed after starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.4 Warming up the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.4.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.4.2 Warming up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.5 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.5.1 Motor Quick Stop (Emergency stop) . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.5.1.1 Motor Quick Stop (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 Operating hour display (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Automatic driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Coolant preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Supporting the Crane on Outriggers from the

Superstructure Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 Slewing the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.2 Initiating a Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Braking the Slewing Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.4 Regulating the Slewing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5 Preparation for Dolly (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
140−1000−193 4
Index
9 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 Important Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.3 Load Capacity Tables for Fitting and Removing the
Counterweight Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9.4 Counterweight Combination 0 t / 0 lbs . . . . . . . . . . . . . . . . . . . . . . . 7
9.5 Counterweight Combination 6.3 t (13 900 lbs) . . . . . . . . . . . . . . . . . 7
9.5.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.5.2 Fitting the Counterweight Combination 6.3 t (13 900 lbs)
to the Superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9.6 Counterweight Combination 8.3 t (18 300 lbs) . . . . . . . . . . . . . . . . . 11
9.6.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.7 Counterweight Combination 10.8 t (23 800 lbs) . . . . . . . . . . . . . . . 15
9.7.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.8 Counterweight Combination 13.5 t (29 800 lbs)
“US−Variant / 1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.8.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
to the Superstructure, ”US−Variant / 1” . . . . . . . . . . . . . . . . . . . . . . . 21
“US−Variant / 2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.9.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
to the Superstructure, ”US−Variant / 2” . . . . . . . . . . . . . . . . . . . . . . . 25
9.10.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
to the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.11.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
to the Superstructure, ”US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . 37
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.13.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.14.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
140−1000−193 5
Index

9.15.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
“US−Variant” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.16.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.17.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.17.3 Fitting and Removal of the Counterweight Combination
39.0 t (86 000 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.17.3.1 Setting Down the Counterweight Combination on the
Crane Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.17.3.2 Fitting and Removing the Counterweight Combination on the
Superstructure Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.17.3.2.1 Manual Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.17.3.2.2 Manual removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.17.3.2.3 Automatic fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.17.3.2.4 Automatic removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.17.3.3 Removing the Counterweight Combination from the
Crane Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
140−1000−193 6
Index
10 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1 IC−1 crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10.1.1 Load limit device (LLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10.1.2 Control and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.1.3 Operating the IC−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.1.4 System start/Switching the system off . . . . . . . . . . . . . . . . . . . . . . . 21
10.1.5 ”Crane operation” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1.6 ”Main menu” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1.7 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1.7.1 ”System”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1.7.2 Background illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.7.3 ”Crane operation” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1.7.4 ”TableViewer”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.7.5 ”Error messages” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1.7.6 ”Control lever configuration” screen . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.1.7.7 ”Hour meter” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.1.7.8 ”Parameter” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.1.7.9 ”Info” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.7.10 ”Emergency operation” screen (optional) . . . . . . . . . . . . . . . . . . . . . 89
10.1.7.11 ”Operating area limit” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.7.12 ”Joystick”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1.7.13 ”I/O”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.1.7.14 ”CAN”screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1.7.14.1 CAN Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1.7.15 ”LS” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.1.7.16 ”Datalogger” screen (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.1.7.17 ”Function diagnosis” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.1.7.18 ”Main menu” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.1.7.19 ”Telescoping information system” screen . . . . . . . . . . . . . . . . . . . . . 125
10.1.7.20 ”Support pressure/tilt display” screen . . . . . . . . . . . . . . . . . . . . . . . . 127
10.1.7.21 Keys for ”Operating mode of the hydraulic pumps” . . . . . . . . . . . . 131
10.1.7.22 ”Active operating range limits” screen . . . . . . . . . . . . . . . . . . . . . . . . 133
10.1.7.23 ”Engine display” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.1.7.24 ”Configure counterweight” screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
10.1.8 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.1.9 Load Monitoring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.1.10 Dead man’s handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.1.11 Malfunction procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.11.1 Malfunction−free operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.1.11.2 Failure of the display ”touchscreen” feature . . . . . . . . . . . . . . . . . . . 145
10.1.11.3 Display screen failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
10.1.11.4 Failure of the crane control (CAN stop) . . . . . . . . . . . . . . . . . . . . . . 151
10.2 Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2.1 Hoist limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.2.2 Lower limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.3 Electric safety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.1 Main boom operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.2 Operation “Main Boom Extension” . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
140−1000−193 7
Index
11 Working Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.1 Wind Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11.2 Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.3 Operation Planning / Monitoring Safety Measures . . . . . . . . . . . . . 19
11.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.2 Condition of the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11.3.3 Condition of the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.4 Conversion of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12.2 Locking and Pinning Unit (LPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.1 Functional Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.2.2 Supply of the LPU with hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 11
12.3 Telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12.3.2 Telescoping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12.3.3 Telescoping display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.3.4 Length code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.3.4.1 Selection of length code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.3.4.2 Selection of the Length Code for Lubrication of the Main Boom . . 35
12.3.5 Automatic telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.3.6 Manual telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3.7 Teaching the extension status of the telescopes . . . . . . . . . . . . . . . 59
12.3.8 Locking and Pinning Positions of the
Telescopic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12.4 Lifting Capacities in the Unpinned Condition . . . . . . . . . . . . . . . . . . 65
12.4.1 Lifting Capacities in Intermediate Positions . . . . . . . . . . . . . . . . . . . 67
12.4.2 Lifting capacities that can be telescoped . . . . . . . . . . . . . . . . . . . . . 73
12.5 Main boom state to move the crane in
transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13 Luffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.1 Luffing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13.2 Regulating the luffing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
14 Hoist 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.1 Hoist Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
14.2 Regulating the hoist speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
140−1000−193 8
Index
15 Hoist 2 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1 Fitting and removing Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15.1.1 when fitting and removing Hoist 2with the auxiliary crane . . . . . . . 5
15.1.1.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
15.1.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
15.2 when fitting and removing Hoist 2with your own crane . . . . . . . . . 9
15.2.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15.2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15.3 Fitting and removing the additional top rollers . . . . . . . . . . . . . . . . . 15
15.4 Rope guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.5 Hook Operation with Hoist 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15.5.1 Pilot control assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15.5.2 Hoist speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16 Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16.1 Engine−Dependent Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.2 Engine−Independent Heating with Coolant Preheating System . . 5
16.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
16.2.2 Operating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
16.2.3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.2.4 Heating Operation without Preselection . . . . . . . . . . . . . . . . . . . . . . 11
16.2.5 Heating Operation with Preselection . . . . . . . . . . . . . . . . . . . . . . . . . 13
16.2.6 Rectifying Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16.3 Air Conditioning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
17 Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
17.2 Load Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
17.2.1 Hoist Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17.2.2 Hook blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
17.3 Reeving the Hoist Rope on the Main Boom Head . . . . . . . . . . . . . . 31
17.4 Reeving the Hoist Rope on the Main Boom Head
with Auxiliary Sheaves (HD attachment, optional) . . . . . . . . . . . . . 33
17.4.1 Fitting and Removal of “One−Sided” Fitted HD Attachment . . . . . 33
17.4.2 Fitting and Removal of “Mutual” Fitted HD attachment . . . . . . . . . 35
140−1000−193 9
Index
18 Main Boom Extension (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

21.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21.2 Assembly and dismantlement of head roller during
separate transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21.3 Folding in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
140−1000−193 10
Index
31 Dismantling and Assembly of the main boom (optional) . . . 1

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

36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
36.2 Connecting the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
36.3 Recovering a Small Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 Runner (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
41.2 Fitting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41.3 Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
41.3.2 Electric safety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
41.4 Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
41.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
41.4.2 Folding in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
41.4.3 Folding in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
41.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
46 Central lubricating system (optional) . . . . . . . . . . . . . . . . . . . . . 3

46.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
46.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
46.3 Setting the interval and operating times . . . . . . . . . . . . . . . . . . . . . . 9
46.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.3.2 Time setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
46.4 Auxiliary lubrication impulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.5 Manual lubrication in the case of an emergency . . . . . . . . . . . . . . . 11
46.6 Filling the grease container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
46.7 Malfunctions/Elimination of malfunctions . . . . . . . . . . . . . . . . . . . . . 13
140−1000−193 11
Manufacturer’s Specifications
Manufacturer’s Specifications
The operating, lubricating and maintenance instructions included

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

(as per DIN 15001,15018 T3)
Crane type AC 140
Construction number _______________
Maximum capacity 140 t / 308.6 kip

(with additional equipment)
Manufacturer Terex−Demag
140−1001a 1/1
Foreword
Foreword
For you,
as owner of a crane manufactured by us, we have produced this

manual, comprising the most important instructions for its opera-
tion, lubrication and maintenance.
These instructions should enable you to familiarise yourself with
your crane and to use the operating applications as intended.
The instructions must always be kept to hand at the operating
site.
The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
Part 3 − Lubrication and maintenance instructions for the
superstructure
Part 4 − Lubrication and maintenance instructions for the crane
chassis
Part 5 − Various
Please note that the information contained in this manual corres-

ponds to the state of machine engineering at the time the litera-
ture was drawn up. Deviations in the technical specifications, fi-
gures and dimensions are therefore possible.
In such cases we make every effort to bring your documentation

up to date by sending you modified pages.
But we must ask for your kind cooperation. For it is only you who
can ensure, that such modifications will be included into your ori-
ginal documentation.
This has to be applied also and especially for the part of the docu-
mentation that is permanently with the crane.
140−1002b_en 1/13
2/13 140−1002b_en
Foreword
Pass this manual on to your crane operator and driver and to

the specialised personnel responsible for the maintenance of
the crane with the request that they read the instructions carefully
before the crane is operated for the first time and later at regular
intervals.
Important instructions are included which ensure that the crane
is operated safely, correctly and economically.
Observing these instructions will help to avoid dangerous situa-
tions, repair costs and downtimes as well as to increase the relia-
bility and service life of your crane.
Periodic, preventive inspection and maintenance are the surest
way to keep your crane in good operating order. The early reco-
gnition and elimination of minor irregularities and the immediate
replacement of worn and damaged parts prevents downtimes
and the associated costs. Replace any damaged signs or sym-
bols.
You will appreciate that we can accept no claims for damage or

malfunctions attributable to improper use and operation and/or
inadequate maintenance.
Should you discover any mistakes when reading this manual or

if you have further suggestions and hints, please contact:
Terex − Demag GmbH & Co. KG

Dept. 1160
Postfach 1552
D−66465 Zweibrücken
The editors would welcome your involvement.
”Putting experience into practice”
140−1002b_en 3/13
4/13 140−1002b_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.
If the crane is delivered from the works with a protective coating

(preserving wax), this does not necessarily have to be removed.
It provides added protection against corrosion.
The protective coating can be removed using:
Washing thinners, e.g. Conrad thinners RV 5339 E 45430

Cold cleaners, e.g. Allpur 150 X or Purtex 65
Stream spray gun
Before commissioning
you should inspect the crane thoroughly together with our service
engineer.
Spare parts
When ordering spare parts, please refer to the first page of our
spare parts catalogue:
”Instructions on using the catalogue”
Use only original spare and wear parts authorized by the crane
manufacturer.
140−1002b_en 5/13
6/13 140−1002b_en
Foreword
Service
Please contact the service department if you have any questions

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

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

Tel: (49)06332/83−0
Fax: (49)06332/16715
E−Mail: info@terex−demag.com
or do contact the TEREX−Demag−partner in your area.
Modifications to the crane
We would point out that any modifications to the crane (e.g. the
purchase of boom parts, etc.) may invalidate the information in
these operating instructions or make it insufficient.
After modifications or repairs to parts which affect the safety of

the crane, the crane must not be returned to operation until it has
been inspected and approved by a safety inspector where this
has been stipulated in national legislation.
For this reason, please notify us without delay of any modifica-

tions which you carry out or have carried out on your crane.
140−1002b_en 7/13
8/13 140−1002b_en
Foreword
...and you can find your way around this manual as follows:
From the example given here, you can see how fast and accura-
tely I can arrive at the required information.
WHAT do I want to know ?
I would like to know for instance what control elements are pro-
vided for outriggers.
WHERE do I find the information required above ?
The complete manual comprises 5 parts:

Part 1 − Operating instructions for the superstructure
Part 2 − Operating instructions for the crane chassis
superstructure
crane chassis
Part 5 − Various
These parts are divided by index sheets. I need Part 2 because
the outriggers are part of the crane chassis.
1. I look for the index sheet ”1” (for Part 1), and open the super-
structure operating instructions at this point and find the
Contents of Part 1.
2. I glance over the bold headings of the sections until I come

to Section 11, Working Instructions”.
3. In this Section11 I then find ”Wind speeds” as item 11.1.

The page details on the right−hand side of the page refer to
the page number within the section.
140−1002b_en 9/13
Z 26 350
10/13 140−1002b_en
Foreword
HOW do I find the page in Section 11 ?
1. I take the pages of Part 1 and flick through the pages as

shown in (Z 26 350).
Whilst doing this, I always keep the top, right−hand edge
(1, Z 26 350) in view.
As soon as the required section number appears, I stop flik-
king through the pages.
The name and number of the section are on the top right−hand
edge (1, Z 26 350) of each page.
2. Then, with the help of the page number on the bottom right−
hand edge (2, Z 26 350), I decide whether I must flick back-
wards or forwards in order to reach the page number requi-
red.
The page number within the section is given on the bottom right−
hand side (2, Z 26 350) of each page. This number is given along
with the total number of pages in the section. This means, for in-
stance, that 3 is given as the page number in the contents and
the page itself is numbered 3/39. This makes for better orienta-
tion within a section.
Please note that this option of fast and accurate access to

specific information as described above does not exempt
you from reading the instructions carefully and in full before
the crane is operated for the first time and at regular intervals
afterwards.
140−1002b_en 11/13
12/13 140−1002b_en
Foreword
The headings and corresponding symbols ”Danger”, ”Caution”

and ”Note” are used in these operating instructions as follows:
DANGER !
”Danger” is used for operation procedures, mounting se-

quences etc. where failure to observe the stipulations
made may result in death or injury.
CAUTION !
”Caution” is used for operating procedures, mounting se-

quences etc. where failure to observe the stipulations made
may result in damage to the crane or equipment.
NOTE:
”Note” is used to indicate an important operation or mounting pro-

cedure or to draw attention to further information.
Information such as “left” and “right” of the crane must always be

understood as looking in the direction of travel.
140−1002b_en 13/13
Safety Instructions 1
1 Safety Instructions
1.1 General
This section ”Safety Instructions” provides a compact and

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

work can be found in part 3 of this documentation.
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1.2 Intended Use
The crane is designed for lifting loads.
It is prohibited to transport people with personnel carrying

equipment!
In many cases, there have been serious injuries when peo-
ple have been transported using personnel carrying equip-
ment (or even on the hook or on loads). In these cases, they
have no control over crane movements and are not protec-
ted against bumps or falls. Even the smallest of errors can
have fatal consequences.
In exceptional cases (for example, the use of personnel ca-
ges which were not supplied by the crane manufacturer),
please consult the responsible authorities / agencies con-
cerning relevant permits, fixed special conditions, safety
regulations, additional tests and demands on the crane and
similar issues. In Germany, the authority / institution
concerned in the first place is the Berufsgenossens-
chaft.
The use of such additional devices is then the responsibi-
lity of the crane operator following the valid safety and acci-
dent prevention regulations!
Risk of death!
It is expressly forbidden to use the crane for jumps with
rubber ropes (bungee jumping)!
Using the crane for such jumps represents a misuse of the
crane and entails extreme danger for life and limb!
The crane is designed exclusively for assembly operation.

Any other type of use which goes beyond the limits specified, for
example handling of general cargo or grab operation, are not
classified as intended use. The manufacturer shall not be held
liable for any damage that results. The operator carries full
responsibility for this type of use.
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Intended use also includes the observation of all load tables, the
operating instructions − in particular with regard to the specified
assembly sequence − and the lubrication and maintenance
specifications.
If operation of the crane for part−load handling or another type

of use is required, please contact the crane manufacturer.
The use of two hoists to raise the load (2−hook operation) is not
permitted.
Special load cases are however permitted in consultation with the
crane manufacturer.
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1.3 Operating Conditions and Computed Design of the

Crane
1.3.1 General
The crane has been constructed using state of the art technology
and in accordance with recognised safety regulations.
Nevertheless, its use can lead to hazards for the life and limb of
the operator and third parties, and/or damage to the machine and
other objects.
Use the crane only when it is in full working order and only for its
intended use, paying attention at all times to safety and potential
hazards, and in observance of the operating instructions. In
particular have any malfunctions which might impair safety
rectified immediately.
The term ”operating instructions” refers to the operating

instructions and the lubrication and maintenance instructions.
1.3.2 Classification of the Crane
The crane is classified as follows (ISO 4301−2 and FEM 1.001):

− Operating class => U1
− Load class => Q2
− Crane group => A1
All important components of the crane are designed and

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

operation require the permission of the manufacturer and
normally lead to a reduction in the lifting capacities.
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1.3.3 Classification of the Engines
The power units are also classified in accordance with ISO

4301−2 and FEM1.001. They have been calculated and
designed based on specific operating conditions which are laid
down in European standards.
The winches of your crane are classified as follows:

Power unit group: M........
Load collective: Q....... (L.......)
Factor of the load collective: Km = ..........
Please refer to the table on monitoring the winches in the crane

identification papers for the corresponding values.
The classification of the power units is the basis for their

evaluation during the annual inspection (see part 3, Lubrication
and Maintenance Instructions for the Superstructure).
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1.3.4 Workplace Ergonomics
The following noise levels can occur near the crane operator’s
seat in the cab of the superstructure:
− Engine idle speed (550 rpm) < 75 dB(A)
− Max. engine speed without load (2750 rpm) < 85 dB(A)
− Engine speed at maximum engine torque
without load (1300 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 A−assessed equivalent permanent sound level at the
operator’s seat measured over the shift duration of 8 hours is
below 70 dB(A). For this purpose, measurements were taken
during operation on construction sites using dosimeters.
The crane operator is protected against mechanical vibrations by

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

body is exposed is below 2.5 m/s2 (8.2 ft/s2).
The weighted effective value of acceleration to which the lower
body is exposed (feet and seat) is below 0.5 m/s2 (1.6 ft/s2).
Both values are therefore below the statutory specifications.
1.3.5 Load and Utilisation of the Crane

The maximum permitted load changes in relation to the
configuration, boom length and working radius. It is specified by
the crane manufacturer in the load capacity tables.
The load capacity tables supplied with the crane specify limit
values which must not be exceeded.
The load limit of the winches is effectively reached when the rope
force has reached its permitted value. Low loads with a small
amount of reeving can place the winch under just as much load.
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1.3.6 Required Ambient Conditions
The permitted temperature range for operating the crane is

−20°C to +40°C (−4°F bis +104°F), if the maximum or minimum
temperature occurs only a few days a year.
Optional equipment for other operating conditions can be

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

1000 m (3281 ft) above mean sea level. It is not hazardous to
operate the crane up to an operating height of 2000 m (6562 ft)
above mean sea level.
The crane can also be operated without danger with high / low
relative air moisture.
Continuous operation in aggressive air (e.g. harbours, chemicals

industry, steelworks etc.) combined with high relative air moisture
can require an adapter kit / optional equipment.
High levels of dust require the filter to be changed more

regularly. Dust concentration levels of up to 35 mg/m3 are
permitted for a short period of time.
Observe the corresponding regulations in the lubrication and

maintenance instructions, parts 3 and 4.
With an oncoming wind the crane operator must follow the rules
outlined in the operating instructions. Please refer to section 11
on operating rules and instructions in the operating instructions
of the superstructure.
The ground, on which the crane is supported − or driven with load

− must be strong enough to support the load.
Use of the crane in a potentially explosive atmosphere or in

operating conditions where combustible gas can be drawn in is
only permitted following corresponding conversion.
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1.3.7 Service Life
Classification of the crane is based on a total operating life

(service life) of 20 years under the following conditions:
− the crane is operated as an assembly crane.
The load capacity tables that are authorised for the crane are
based on assembly operation only. General cargo handling
or grab operation can only be permitted following express
permission from the manufacturer under suitable
conditions.
− the total number of load cycles in this period is less than

32000 (e. g. 5 − 10 lifts / day on 200 days / year).
A “LOAD CYCLE” encompasses processes which begin when a

load is raised and end when the crane is ready to raise the next
load.
− the type of load (load collective) of the entire crane shows

values no worse than the following:
∗ for 1/10 of the load cycles the crane is placed under max.
load
∗ for 4/10 of the load cycles with 44 % of the max. load
∗ for 5/10 of the load cycles with 16 % of the max. load
“Load” in this context refers to the sum of the load, load−handling

devices and lifting tackle (e.g.: load + hook block + sling ropes).
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Under these conditions, assuming that maintenance work is

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

remaining theoretical service life must be observed, as
outlined in part 3, Lubrication and Maintenance Instructions,
section 1.8.
Some components (e.g. ropes) are not designed for the

entire service life of the crane, but must be replaced after a
certain amount of time.
Information on this can be found in the lubrication and
maintenance instructions for the superstructure.
1.3.8 Standards and Calculation Regulations
The specifications contained in section 1.3.7 on service life,

loading and utilization of the crane are taken from the European
standards ISO 4301−2 and FEM 1.001, FEM 5.004 and
ISO 9927−1.
The proof of stability for the framework, the components and

parts of the crane is based on the standards: FEM 5.004,
ISO 4301−1, ISO 4301−2, FEM 1.001 and ISO 4308−2.
The ropes are selected and calculated in accordance with ISO

4308−2.
All required proofs of stability (buckling and bending) were

carried out in accordance with DIN 18800. The minimum safety
factors are taken from FEM 5.004.
The proof of standing stability for the crane is based on ISO 4305.
For countries in which different standards and calculation

regulations apply, special calculations or proofs can be carried
out.
If required, these calculations must be specially ordered by the
crane operator. This does not alter the operating conditions for
the crane. If necessary the lifting capacities must be limited.
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1.3.9 Dangers to Air Traffic
As considerable heights are reached when the crane is operated,

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

Deutsche Flugsicherung GmbH (DFS)
Kaiserstraße 29−35
D−63067 Offenbach a. M.
Tel. 069/8054−0
These regulations apply in Germany. In other countries, the

corresponding national regulations must be observed.
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1.4 Safety Regulations
While carrying out power−driven erection and assembly

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

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

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

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These means of identification should be in a distinctive co-
lour and where possible of an identical design and must be
exclusive to the fitter.
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11 7 1 5 6 7 8 1
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Z 54 018
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1.4.1 Organisational Measures

In addition to the operating instructions, applicable national
regulations and any other binding regulations on the prevention
of accidents and protection of the environment must be followed
and passed on. These should be added to the operating
instructions.
Such stipulations may involve, for example, handling hazardous
substances, making available / wearing personal protective
equipment or road traffic regulations.
In addition to the operating instructions and the accident
prevention regulations valid in the country and on the operating
site where the crane is in use, the recognised technical
regulations pertaining to safe and correct working procedures
must also be observed.
The operating instructions should be supplemented by any other
instructions that are necessary, including supervisory and
reporting duties for any special operating occurrences, for
example with regard to work organisation, operating procedures,
allocated personnel etc.
(Z 54 018)
Keep a complete and legible set of all safety and hazard
instructions on the crane at all times.
Safety guards on the crane must not be opened or removed
during crane operation.
Provide instructions on the location and use of fire extinguishing
equipment.
The fire extinguishers which are supplied are located near the
passenger seat in the cab of the crane chassis.
First aid boxes − and other accessories in accordance with road
traffic licensing regulations − must be taken by the crane operator
from the pallet supplied and placed in the cab of the crane
chassis.
In case of poor visibility or darkness, the immediate area in front

of the crane operator’s cab, the outriggers and the winches must
be illuminated by the spot lights, which are fitted on the crane
(rear outside lighting, front outside lighting, side outside lighting).
The side outside lighting can be switched from the crane
operator’s cab or from the driver’s cab.
The extended area (load, load path, slewing range, driving route
etc.) is to be illuminated using suitable equipment, separate from
the crane. The responsibility for this belongs to the crane
operator.
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1.4.2 Selection and Qualifications of Personnel
In order to operate a crane optimally within its proper parameters,

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

on and with the crane.
Make sure that only authorised personnel are allowed to carry out
work .
Pay attention to the minimum working age.
Clearly specify all areas of responsibility:

− for operating, erecting and servicing.
− for the crane driver, also with regard to his responsibilities as
a result of road traffic regulations. Allow him to refuse
instructions from third parties which contravene safety
regulations !
Personnel who are still being trained and instructed in the use of
the crane, or who are completing a general apprenticeship, may
only be allowed to work on the crane under the constant
supervision of an experienced member of staff .
Personnel who are responsible for work on the crane must have
read the operating instructions before commencing work, and
in particular the section on ”safety instructions”.
It is too late in the middle of crane operations.
This applies especially to personnel who only work on the crane
occasionally − e.g. for configuration or maintenance work.
Check − at least now and then − to make sure that all personnel
are working safely and are following the operating instructions.
Personnel are not allowed to wear their hair long, wear loose
clothing or jewellery, including rings. There is a risk of injury, e.g.
as a result of being caught or dragged by moving parts.
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1.4.3 Particular Hazards
1.4.3.1 Electrical Energy
High voltage
With high voltage lines, any direct contact with the boom or the
hoist rope is always dangerous.
With high voltage lines above 1000 V current can be transferred
even as the lines are approached.
This hazard should be prevented by the following measures:

− Switch off the power to the lines.
− Cover or cordon off the danger zone.
Both measures may only be carried out by qualified

electrical specialists.
If these measures cannot be carried out, a sufficient safety

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

are very difficult to judge. To be on the safe side, increase the
safety clearance to 20 m (65.6 ft).
The safety clearance must still be available for unfavoura-

ble crane or load positions.
Allow for possible swinging of the load or swinging out of
the free line as a result of the wind.
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If, however, the crane accidentally comes into contact with high
voltage power lines:
− Move the crane out of the danger zone: drive out, swing away,
adjust the boom!
If this is not possible:

− Do not leave the crane or driver’s cab.
− Warn those outside not to approach or touch the crane.
If the crane operator leaves the crane or if another person

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

− Only leave the crane when you are sure that the
touched/damaged line has definitely been disconnected
from the power source.
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High−frequency radiation / operating in vicinity of

transmitters
Charging
It can cause dangerous electrical charging if track−free mobile

cranes are used in the vicinity of transmission systems (e.g. radio
transmitters).
In this case, the following measures must be taken:

− agreement with the operator of the transmitter (possibly
switching off the transmitter).
− grounding (of the track−free mobile crane).
In order to protect the rotating connection the grounding
cable must be fastened directly to the superstructure of the
crane or to the boom.
Risk of injury!
If the prescribed measures are not taken the persons con-
necting the charged components to ground will be violently
and painfully electrified at touch.
Interference with the crane electrics
At the same time, the crane electrics, especially the load limit
device, cannot be considered function safe, depending on the
strength and frequency of the transmitter.
The danger of the load limit device being influenced by

high−frequency radiation has been minimised with up−to−date
technology (shields). However, it cannot be fully discounted,
especially under extreme circumstances.
This is especially valid if the crane is used in the close

vicinity of high−frequency radiation sources (e.g. radar
stations, radio transmission stations, radio and television
stations).
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Lightning
If storms are approaching, if possible lower the crane equipment

and leave the crane.
If this is not possible, lower the load from the hook, switch off the
engine and leave the crane.
Only remain in the crane operator’s cab if you cannot carry out
these measures in good time.
Under no circumstances must the crane operator approach

the crane or its immediate vicinity during the storm. Warn
any other people in the vicinity of the crane.
The general functions of the crane must be checked if it is

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

sufficiently ventilated spaces. Make sure that sufficient
ventilation is provided before operating in restricted spaces.
Follow the applicable regulations for the operating site.
Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth de-
fects, and other reproductive harm.
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Z 29 802
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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
instructions.
− Hook block / load when slewing the superstructure
1.4.3.4 Snagging / Dragging

(Z 29 801, Z 29 802)
instructions.
− Head− and deflection roller
− Hook blocks
− Winches
− Slew ring toothing (slew pinion)
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1.4.3.5 Crushing / Shearing

(Z 29 800)
instructions.
− when extending and retracting the main boom
− when lowering the main boom on the foot bearing of the
superstructure frame
− when slewing the superstructure
− when extending and retracting outriggers and cylinders
− when releasing the suspension locking following the
outrigger procedure in the vicinity of the wheels
− in the vicinity of the hook block and load in case of
uncontrolled movements
− when stacking the counterweights
− when fitting and removing hoist 2
− when fitting and removing the main boom and superstructure
− when tilting the crane operator’s cab
− when fitting and removing / erecting additional equipment
(optional), as, e. g., main boom extension.
1.4.3.6 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
designed to prevent slipping (e.g. sanding, checker plate etc.).
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1.4.4 Combination of Hazards with Combined Operation

of Two or More Cranes
1.4.4.1 Operating Areas of Several Cranes Overlap
If the operating areas of several cranes overlap, there is a risk of

collisions.
The operating company or its representative must:
− specify the working procedure in advance!
− make sure that there is a clear line of communication with the
crane operator !
If the crane operator does not have spoken or visual contact,

suitable measures must be taken, e.g. use of radios,
spotters/banksmen etc.
If spotters are used, suitable signals must be agreed between the

spotters and the crane operators. In this regard, please refer to
section 1.5 of this chapter ”Safety Instructions”.
Crane operators must operate the crane in such a way that

uncontrolled movements and subsequent collisions are avoided.
They must receive suitable training and instructions to this end.
1.4.4.2 Combined Raising of a Load by More Than One Crane
If a load is to be raised by more than one crane, the operator of

the crane or his representative must first set up a working
procedure and appoint a supervisor, in whose presence the
operations are carried out.
The most important requirement for this type of operation is,

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

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

manufacturer should be consulted to see whether the crane can
be fitted with any additional safety devices (e.g. limiters) or
whether the lifting capacity needs to be restricted additionally for
the operation in question.
Avoid pulling a load sideways or at an angle!
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1.4.5 Driving Operation
1.4.5.1 Before Driving
Check the correct function of the brakes, steering and signal and
lighting equipment daily, for cranes that are seldom used − every
time that they are driven.
Before driving the crane, always make sure that there is no−one
in the danger zone of the crane. If necessary give a warning sign
(actuate the horn before starting the engine for example! ).
If you cannot see the hazardous area from the driver’s cab, a
spotter (or banksman) must be used (see section 1.5) !
This also applies if normal voice communication is not possible
as a result of an increased noise level.
Keep the windscreens of the driver’s cab clean to guarantee

good visibility.
Make sure that all accessories are stored safely and cannot
cause an accident.
When driving on public roads, highways and precincts observe

the relevant traffic safety regulations and make sure that the
crane is properly equipped for road travel.
In the case of the axle loads a differentiation is made between

the technically possible load (technical driveability) and the load
permitted in accordance with the road traffic regulations.
”Technical driveability” is only permitted on construction sites or
private roads (with the exception of countries which permit axle
loads over 12 t / 26.4 kip).
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Axle loads above 12 t (26.4 kip) are not permitted in countries

which have regulations in accordance with the EEC (or reduced
axle loads) for road travel. If the crane is driven with axle loads
above 12 t (26.4 kip), the crane operator carries full responsibility.
All components and systems are designed and calculated for a
12 t (26.4 kip) axle load at maximum speed.
If the 12 t (26.4 kip) axle load is exceeded, the life expectancy
(service life) of the axles, wheel hubs, bearings, suspension
cylinders and brakes is reduced. In particular wear to the brake
linings and the risk of the brakes overheating and fading are
increased.
Deceleration for the brakes (EEC: 50 %) reduces in proportion to
the increase in the axle load or the transport weight of the crane.
1.4.5.2 During Travel
When driving on the road in the transport position, the boom must
be placed in the travel rest and the telescopic sections bolted.
On a slope always adapt the speed of the crane to the local

conditions. Never shift gear once on the slope, but change to a
lower gear before reaching the slope.
When passing flyovers, bridges, tunnels, electric lines etc. make

sure that there is sufficient overhead clearance.
When towing, follow the towing regulations with respect to the

prescribed transport position, permitted speed and distance
travelled.
Passengers may only travel in the cab of the crane chassis on the
proper passenger seats provided.
In an emergency the passenger door can be used as an exit.
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1.4.6 Crane Operation
1.4.6.1 Before Crane Operation
Check the load conditions again before commencing crane

operation: Is the mass (the weight) of the load and the operating
procedure known and is there sufficient lifting capacity, working
radius and lifting height? Compare the values with the load
capacity table.
Check whether outside conditions such as wind, snow, poor

visibility, unfavourable temperatures etc. could limit crane work.
Make sure that the ground has sufficient load−bearing capacity

when supporting the crane on outriggers.
For more detailed information, see section 11 “Working

Instructions” in the operating instructions of the superstructure
and section 12 “Outriggers” in the operating instructions of the
crane chassis.
Maintain a safe distance between the supported crane and

slopes and ditches.
For more detailed information, see section 11 “Working

Instructions” in the operating instructions of the superstructure.
Before commencing work at the operating site, familiarise

yourself with the working environment. The working environment
includes, for example, obstructions in the operating and traffic
areas, the load−bearing capacity of the ground and the
necessary safety precautions required to cordon off the
construction site from public traffic areas.
To operate the crane, unhindered sight of the crane, load and
load path must be ensured.
Carry out the necessary measures to ensure that the crane is

operated in a safe and functional condition.
Before commencing work, check that all crane movements are

functioning correctly and safely.
Operate the crane only if all safety guards and equipment are
fitted and functional.
140−1010a 47/77
1
48/77 140−1010a
Check the correct function of the brakes, signal and lighting

equipment, limit switches and overload cut−off device daily, for
cranes that are seldom used − every time that they are operated.
Before commencing work with the crane make sure that no−one
is in the hazardous area. If necessary give a warning sign
(actuate the horn before starting the engine for example! ).
As oil can be emitted during maintenance and assembly work,

suitable collecting vessels and binding agents must be kept
ready.
Wherever required or stipulated the personnel must wear

personal protective gear (e.g. safety harnesses, safety clothing,
goggles, face mask etc.) !
Remember that protective equipment does not offer 100%

protection! A helmet can protect you against small falling
objects, but not against falling loads!
You should therefore remain attentive and safety−con-
scious at all times!
140−1010a 49/77
1
50/77 140−1010a
The weight of the load must be known.
It is difficult to calculate the load weight during dismantling

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

dismantled, never utilise the full values allowed in the load
capacity tables of the crane, but allow for a safety buffer.
Select the correct boom length and reeve the hoist rope in
accordance with the individual load case.
Select the lifting tackle in accordance with the weight of the load,
the type of attachment and the angle of inclination.
Only hook blocks supplied by the crane manufacturer may be

used.
The use of other hook blocks is only allowed following permission
from the crane manufacturer.
Pay attention to the rules and regulations for working with load
handling equipment (attachment ropes etc.). Never use lifting
tackle if there is any doubt as to its lifting capacity. Check to make
sure that the lifting tackle is in perfect condition.
140−1010a 51/77
1
52/77 140−1010a
1.4.6.2 During Operation of the Crane
When carrying out power−driven working procedures

(raise / lower load) only the crane operator is allowed on the
crane (and he must be in the crane operator’s cab). Remai-
ning personnel must remain clear of the hazardous area on
and around the crane.
The crane operator must give a warning signal when starting the
drive motor and before starting crane movements (horn).
Stop work immediately if persons fail to leave the hazardous area
in spite of the warning.
The crane operator may only start movements if he has good

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

good visibility at all times.
In order to allow immediate reaction when 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 operator’s cab.
Exceptions are only permitted in emergency situations. To

avoid hazardous situations, in the final instance the drive
source (diesel engine) can be switched off using the quick−
off−button in the crane operator’s cab. First − where possi-
ble − movements that have been started should be comple-
ted using the control levers.
Before raising a load, you must always make sure that the hook
block is positioned vertically over the load’s centre of gravity.
140−1010a 53/77
1
54/77 140−1010a
The crane (superstructure) may only be placed in operation when

the crane chassis engine is switched off, the driver’s cab closed
and the control panels of the outriggers locked.
The erected crane without load may only be left without the
supervision of a trained crane operator if certain conditions are
met (see operating instructions of the crane chassis, section 14
”Parking”).
The carrying of persons with the load or the load handling

equipment is prohibited.
The crane may only be accessed and left following agreement

with the crane operator and only when the crane is at a standstill .
Observe all safety and hazard warnings on the crane .
Avoid any actions which may impair safety (e.g. risk to the
stability of the crane).
Never slew loads over people.
140−1010a 55/77
1
56/77 140−1010a
Only start the crane engine from the driver’s seat. Only actuate
the control lever from the cab.
Keep the controls lever within reach as long as a load is

suspended on the crane or the crane is driven.
To prevent the unintended activation of crane movements, both

control levers are equipped with an additional button (dead man’s
button).
The crane movement can only be carried out as long as one of
these buttons is pressed.
The dead man’s switch may only be actuated (pressed and
released) and the limit switches in the instrument panel bridged,
when the corresponding control lever is in the ”O” position and/or
the working movement that is underway has been completed.
RISK OF ACCIDENTS!
Actuation of one of these buttons when the control lever is
fully deflected leads to an abrupt activation or braking of
the corresponding movement.
For all crane movements, pay particular attention to the load, for
unladen operation the load−handling device, and the boom tip !
Watch the slewing radius of the counterweight etc.
Watch out for obstacles (on the crane and on the operating site)
which could lead to a collision.
The load must never come into contact with the framework of the
crane (boom system, superstructure, crane chassis, outriggers
etc.).
140−1010a 57/77
1
58/77 140−1010a
Dragging and scraping of the load is prohibited during crane

operation.
It is prohibited to pull loads free that have become lodged.
Do not jump off the crane! Do not jump from the crane.Use the
ladders and the handrails provided.
Secure the doors with the available locks to prevent them

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

immediately and secure it. Have any faults rectified immediately !
Pay attention to the procedures for switching equipment on and

off as well as the behaviour of the indicator lights as outlined in
the operating instructions.
In case of poor visibility and darkness always switch on the

outside lighting. The inside lighting should be switched off to
enable proper sight of the load and the immediate environment
of the crane.
Always keep the operating instructions at the crane operating site

in the storage compartments provided. These are located on the
superstructure on the back wall of the cab and on the crane
chassis on the driver’s door.
Be aware of the location and availability of fire warning and fire

fighting equipment.
Pay attention to the weight and surface area of the load exposed
to the wind.
Loads that are in water are lighter for the crane than those in air
(due to buoyancy). When the load leaves the water it becomes
heavier. If this results in the crane being overloaded the load limit
device would be triggered.
There is a risk to the lifting tackle, however, if this is not measured
for the actual load weight.
140−1010a 59/77
1
60/77 140−1010a
Set the computer of the load limit device in accordance with the
load capacity tables supplied.
Observe the permitted wind speeds.
The superstructure may only be slewed when the crane is

supported on outriggers. Note that slewing is only permitted for
certain crane configurations (e.g. with regard to outrigger support
area, counterweight etc.). Always observe the specifications of
the load capacity tables.
Slewing of the superstructure in the overload range (load limit
device has shut off) is generally prohibited.
In an emergency the wide−opening front window can be used as

an exit.
1.4.6.3 Following Crane Operation
When you leave the crane:

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

additionally secured with chocks, the slew brake applied and the
boom secured.
Close all control panels that are fitted with a lock when they are
not being used.
When parking the crane pay attention to the permitted wind

speeds (also for the time when the crane is at a standstill). If
necessary telescope in and set down the boom.
140−1010a 61/77
1
62/77 140−1010a
1.4.7 Power Supply Failure
General
If the power supply fails, all movements are stopped. An

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

is redundant braking of the winches and cylinders as a result of
the locked position or additional retaining brake.
Winches and cylinders
The oil column on the lever side of the winch motors and cylinders
is safeguarded by means of load−independent brake valves
(lowering brake valves). The winches and cylinders can no longer
be moved in the event of a failure to the power supply. The lower
brake valves are directly fitted to the winch motors and cylinders
(no hose lines).
As the described case is extremely seldom, there is no in−built

option for lowering a load on the hook. In this event the customer
service department must be informed.
If hoses or pipes should burst, therefore, there will be no

dangerous crane movements as a result.
In addition, in the case of a standstill the hydraulically actuated

disc brake of the slew gear is applied.
Driving the crane in the erect (configured) condition
When the crane is driven in the configured position, the load rests
on the suspension cylinders. These are not equipped with pipe
burst valves, in order to guarantee problem−free suspension
behaviour during driving of the crane. To avoid hazardous
situations, the regulations outlined in the operating instructions
for the crane chassis, section 6, ”Driving in the Configured
Condition” must be strictly observed.
140−1010a 63/77
1
64/77 140−1010a
1.4.8 When Assembling and Dismantling Crane

Components
Although all possible protective and safety measures have

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

sequence is described.
The equipment must be dismantled exactly in the reverse order

(unless otherwise described).
Crane equipment must under no circumstances be assembled

and dismantled by untrained personnel. This also applies to staff
providing temporary help.
Incorrect assembly can result in danger to life and limb.
As a result of the risk of slipping, stumbling and falling, it is

prohibited to walk on the boom and equipment − or parts thereof.
All assembly work is to be carried out with the help of suitable
accessories (ladders, hoist platforms, scaffolding, auxiliary crane
etc.).
Exceptions are only permitted if access areas are provided.

This requires additional safety measures however.
Normal assembly prescribes that all component parts which are

transported separately are transported near to the ground with
suitable auxiliary cranes and lifting tackle (ropes) − and are safely
connected to the basic crane.
140−1010a 65/77
1
66/77 140−1010a
Before assembly personnel approach suspended loads, for

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

the danger of being hit or crushed by loads swinging side-
ways.
During the assembly procedure, or at any other time, personnel

must never walk or stand beneath loads, especially before the
load has been properly attached.
If, during assembly work, certain crane movements have to be

carried out, the crane operator must ensure that no−one is in the
hazardous area affected.
A load is properly attached when the suspended load is firmly

connected to the lowered component of the crane, e.g. following
fixation with the bolts of an intermediate section or the tightening
of all the bolts of a bolted connection to the prescribed tightening
torque etc.
A safe distance should be kept from unavoidable crushing

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

during the assembly of fly jibs, unless the operating instructions
expressly state otherwise.
Only when all bolts of a component have been inserted may the
component be secured using auxiliary bolts and clip pins.
140−1010a 67/77
1
68/77 140−1010a
Connecting bolts may only be knocked out during the dismantling

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

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

work. Falling or flung tools can cause risk to life and limb!
Often it is necessary to bridge limiters (e.g. limit switches) during

assembly and dismantling work. This can also lead to additional
hazards. The systems may therefore only be bridged if this is
required in the operating instructions for a certain piece of work.
140−1010a 69/77
1
70/77 140−1010a
1.5 Hand Signals
If the crane operator cannot oversee the operation and working

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

bols may be employed as spotters.
The spotter should be in a safe position, from where he can

SEE THE LOAD and can himself be clearly SEEN BY THE
CRANE OPERATOR.
The spotter must be easily recognisable for the crane oper-

ator. The spotter should wear one or more suitable means
of identification e.g. jacket, helmet, collars, armbands, sig-
nalling discs.
These signs of identification must be in a distinctive colour
and uniform in design and must be worn exclusively by the
spotter.
If the load is attached by several people, only one person

may give the signals. These must be made known to the
crane operator.
If the crane operator does not fully understand a signal, he

should not carry out any movement with the crane. Before
commencing work the crane operator and spotter must work
out a signal for this scenario.
140−1010a 71/77
1
Z 26 024
72/77 140−1010a
1.5.1 General Hand Signals

(Z 26 024)
1. START
Attention, pay attention to the following signals
Arms stretched out horizontally sideways, palms of the

hands facing forwards.
2. STOP !
Interruption, end a movement
Right arm raised, palm of the right hand facing forwards.
3. END
of a movement
Hands folded at chest height.
4. DANGER !
Emergency stop
Both arms raised, palms of the hand facing forwards.
RAPID MOVEMENT
Coded hand signals for movements, carried out rapidly.
140−1010a 73/77
1
Z 26 026
74/77 140−1010a
1.5.2 Hand Signals for Working Movements

(Z 26 026)
1. RAISE load
Right arm raised, palm of the right hand facing forward,
moving slowly in a circle.
2. LOWER load
Right arm down, palm of the hand facing inwards, moving
slowly in a circle.
3. RAISE boom
Signal with one hand. Right arm stretched outwards, thumb
pointing upwards.
4. LOWER boom
Signal with one hand. Right arm stretched outwards, thumb
pointing downwards.
5. TELESCOPE OUT boom

Signal with both hands. Thumbs pointing outwards.
6. TELESCOPE IN boom
Signal with both hands. Thumbs pointing inwards.
140−1010a 75/77
1
Z 26 025
76/77 140−1010a
1.5.3 Hand Signals for Driving Movements

(Z 26 025)
1. Drive FORWARDS
Arms angled upwards; palms facing inwards; lower arms
making slow movements towards the body.
2. Drive BACKWARDS
Arms angled upwards; palms facing outwards; lower arms
making slow movements away from the body.
3. Drive to the RIGHT (seen from the spotter)

Right arm stretched out more or less horizontally, palm of the
right hand facing downwards, small movements in the
direction indicated.
4. Drive to the LEFT (seen from the spotter)

Left arm stretched out more or less horizontally, palm of the
left hand facing downwards, small movements in the
direction shown.
140−1010a 77/77
Structure of the Crane 2
140−1020−103a_en 1/45
2 14180
max. 4000
2572 (14.00R25)
max. 3000
Z 54 010
2/45 140−1020−103a_en
2 Structure of the Crane
2.1 Technical data

(Z 54 010)
All dimensions and figures apply only to the standard design

(e.g. tyres 14.00 R 25).
Length 14 180 mm (46.5 ft)

Height 4000 mm (13.1 ft)
Width 3000 mm (9.8 ft)
Max. load capacity 140 t (308.6 kip) with 3 m
(9.8 ft) working radius (with
optional equipment)
120 t (264.5 kip) with 3 m
(9.8 ft) working radius (with
optional equipment)
Max. main boom length 60 m (196.9 ft)
Max. system length with main
93 m (305.2 ft)
boom extension
Max. rope speed hoist 145 m/min (476 ft/min)
Drive motor DaimlerChrysler OM 904 LA,
130 kW (175 HP)
675 Nm (498 lbf−ft)
The dimensions in the opposite figure are reference values.
You will find further technical data on possible optional

equipment in part 5 of this manual.
The load capacity tables in the leaflet are only for your
information.
Only the load capacity tables delivered with the crane may
be used for crane operation.
140−1020−103a_en 3/45
2
7 3
6 4
Z 54 011
4/45 140−1020−103a_en
2.2 Overview
(Z 54 011, principal drawing)
(1) − Main boom
(2) − Luffing cylinder
(3) Hoist gear 1
(4) Crane operator’s cab
(5) Crane chassis

(see part 2, chassis)
(6) Counterweight
(7) Hook block and / or hook suspension gear
140−1020−103a_en 5/45
2
1 2 3
4 5
10 9 8 7 6
Z 54 012
6/45 140−1020−103a_en
2.3 Superstructure
(Z 54 012).
Superstructure side, right:
(1)− Diesel engine
(2) − Hydraulic pumps
(3)− Hydraulic oil tank
Superstructure side, left:
(4)− Main electrical unit, cab
(5)− Superstructure frame
(6)− Hydraulic control block
(7)− Diesel tank, filling capacity 234 l (61.8 US gal)

(with autom. tank filling, buffer tank 200 l / 52.8 US gal)
(8)− Batteries
(9)− Slew gear
(10)− Roller bearing slewing rim
The listed elements are for the most part only visible and
accessible after opening/removing the corresponding cover.
140−1020−103a_en 7/45
2
3
4
1d
2a
2b
1a
Z 54 013
1c
”X”
1b
1a Z 54 014
8/45 140−1020−103a_en
2.4 Safety−relevant Components

2.4.1 Ladders and safety harnesses/guards
(Z 54 013, Z 54 014)
In addition to suitable and safe accessories provided, only

the ladders described may be used to access the super-
structure. There are sufficient gripping points to hold onto.
The catwalks are designed to be slip−free (sanding,
checker plating, etc.).
(1a) − Ladder, hinged

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

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

2a/b − Platforms on crane operator’s cab
To allow the platform (2b) to be used across its full width, the
door of the crane operator’s cab must be closed.
3 − Grab rail
4 − Rail (in transport position)
Handling of the rail is described on the following page.
140−1020−103a_en 9/45
2
1a
1a 1b
Z 54 015
4 12
”A”
1.
2.
11 12
”B”
Z 53 422
10/45 140−1020−103a_en
Transport position of the mobile ladders

(Z 54 015).
When they are not being used or are to be transported, the

hinged ladders (1a) and the hanging ladders (1b) must be placed
in the transport position, i.e. they must be laid on the crane
chassis and secured as shown in figure (Z 54 015).
Risk of accidents! Risk of damage !

If these ladders remain folded down in position and are
hanging or if they are not secured when in the transport
position, it can cause unchecked changes to the positions
with the corresponding risks.
Using the rail on the superstructure frame

(Z 53 422)
When climbing in the area closed in by the rail (4), after leaving
the corresponding ladder, the rail must immediately be folded
from the transport position (”A”) into position (”B”).
If this doesn’t happen, there is a risk of falling when walking

in this area due to the insufficient height of the rail!
To fold up, remove the locking bolt (11) and fold the hinged upper
section of the rail through 180° so that the guide pins (12) first
slide forwards (1st stage) and then downwards (2nd stage) up
to the stop.
The upper section of the rail folded into the vertical position then
remains safely in this position ”B” due to its own dead weight.
Immediately before leaving the area, fold down the upper part of
the rail again and secure. Otherwise the crane height of 4 m is
exceeded.
Proceed in the same way as when folding up the rail, only in the
reverse order.
When folding down the rail there is a risk of crushing be-

tween the hinged and fixed part of the rail!
Proceed with appropriate caution!
140−1020−103a_en 11/45
2
12/45 140−1020−103a_en
2.4.2 Spotlights
Depending on the design, there are spotlights fitted to the

superstructure:
− on the basic case of the main boom, can be adjusted
electrically from the cab,
− on the front of the cab,
− on the back of the cab,
− in the engine compartment, automatically actuated by the
door contact switch.
− on the hydraulic crossbar on the main boom
2.4.3 Emergency Exit
The front window of the superstructure can be opened wide to the

front. It is therefore suitable as an emergency exit.
140−1020−103a_en 13/45
2
Z 50 657d
14/45 140−1020−103a_en
2.5 Signs and Symbols
Obtain all signs specified in the following and make sure

they are legible!
2.5.1 Signs in the Crane Operator’s Cab

(Z 50 657)
(1) − Warning sign: Slewing, telescoping and luffing prohibited

without extended outriggers
(2) − Plate: Driver instructions
(3) − Warning sign: Dolly preparation (optional)
140−1020−103a_en 15/45
2
Z 54 016
16/45 140−1020−103a_en
Only for Germany

(Z 54 016).
(4) − Plate: Operating regulations for cranes in accordance

with the accident prevention regulation ”Cranes” (BGV
D6)
140−1020−103a_en 17/45
2
2 3
Z 54 017e
18/45 140−1020−103a_en
2.5.2 Signs and Symbols on the Superstructure

(Z 54 017).
(1) − Warning sign: Danger zone

(2) − Plate: Hydraulic oil (on the hydraulic oil tank)
(3) − Plate: Diesel (on the fuel tank)
(4) − Plate: Quick releases
(5) − Warning sign: Caution during welding work
(6) − Warning sign on the slew gear: Dolly preparation
(optional)
140−1020−103a_en 19/45
2
X Y
X Y 7
Y X
X Y
Z 50 675
20/45 140−1020−103a_en
(Z 50 675)
(7) − Warning sign for stowing / assembly of main boom

extension
140−1020−103a_en 21/45
2
1 4 3 9 7 6 5
10
11 7 1 5 6 7 8 1
2 4 3 1
1 7 1 7
Z 54 018
22/45 140−1020−103a_en
2.5.3 Safety Signs

(Z 54 018).
(1) − Warning: Crushing / collision

(2) − Warning: Snagging / dragging
(3) − Warning: Risk of falling
(4) − Prohibited: Access prohibited
(5) − Warning: Risk of fire
(6) − Prohibited: Naked flame
Plates (5) and (6) are fixed on the diesel tank of the
superstructure and crane chassis.
(7) − Prohibited: Access for unauthorised persons

(8) − Warning: Crushing
(9) − Warning: Swinging load
(10) − Sign: Fire extinguisher
The fire extinguisher supplied is located in the cab of the crane

chassis.
(11) − Sign: First aid
First aid box − and other accessories in accordance with German

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

fully legible.
140−1020−103a_en 23/45
2
178 722 12 178 716 12 178 722 12
Z 55 125 Z 55 126
178 722 12
178 722 12
Z 55 127 Z 55 128
24/45 140−1020−103a_en
2.5.4 Safety signs ( US only )
Follow the depictions on the next page which show some

examples (Terex−Demag AC 160) of where the safety signs
should be fixed.
Each individual sign can be clearly identified thanks to the item

number on each sign.
All safety instructions on the crane must be complete and

fully legible.
Figure Location of fixture Item no. Type of risk

no.
Z 55 125 Superstructure cab door, 178 722 12 Risk: electricity
exterior
Superstructure cab door, 178 716 12 Hand symbols USA
exterior
Z 55 126 Rear, left 178 722 12 Risk: electricity
Z 55 127 Crane chassis, left,
3rd axle
Z 55 128 Crane chassis, right,
3rd axle
140−1020−103a_en 25/45
2
178 713 12 178 713 12
Z 55 129 Z 55 130
178 713 12
Z 55 131
26/45 140−1020−103a_en

no.
Z 55 129 Superstructure, top tank 178 713 12 Risk of fire
inlet
without Superstructure hydrau-
figure lics, right
Z 55 130 Superstructure, main
boom foot bearing, left
Z 55 131 Crane chassis, hydraulic
oil reservoir
140−1020−103a_en 27/45
2
179 564 12
178 720 12 178 728 12
Z 55 132 Z 55 136
178 728 12 178 707 12
Z 55 137 Z 55 138
28/45 140−1020−103a_en

no.
without Luffing cylinder near low- 179 564 12 Risk: oil jet
figure ering brake valve
Z 55 132 Superstructure hydrau-
lics, right
without Lift cylinder, left and right
figure
without Sheave head main
figure boom, left and right
Z 55 132 Filter superstructure 178 720 12 Risk: pressure
without Superstructure, flap, ex-
figure terior
Z 55 136 Superstructure cab next 178 728 12 Welding prohibited
to steps
Z 55 137 Crane chassis, cab, exte-
rior under side glass
Z 55 138 all 4 outrigger cylinders 178 707 12 Risk due to outriggers
140−1020−103a_en 29/45
2
178 721 12
178 721 12
Z 55 133 Z 55 134
178 721 12 178 712 12 178 711 12
Z 55 135 Z 55 140
30/45 140−1020−103a_en

no.
Z 55 133 Battery superstructure 178 721 12 Risk: battery
Z 55 134 Battery box superstruc-
ture
Z 55 135 Battery box crane chas-
sis
Z 55 140 Main boom sheave head, 178 711 12 Risk of bodies getting
front crushed
140−1020−103a_en 31/45
2
178 712 12 178 711 12
178 712 12
Z 55 139 Z 55 140
178 712 12
Z 55 141
32/45 140−1020−103a_en

no.
Z 55 139 Top piece of the main 178 712 12 Risk: winding up
boom extension, both
sides
Z 55 140 Main boom sheave head,
front
Z 55 141 Sheave of the main
boom extension
140−1020−103a_en 33/45
2
178 710 12 178 710 12
Z 55 142 Z 55 143
178 710 12
178 710 12
Z 55 144 Z 55 145
34/45 140−1020−103a_en

no.
Z 55 142 Step behind superstruc- 178 710 12 Risk of falling
ture cab
Z 55 143 Step at superstructure
hydraulics tank
Z 55 144 Ladder to superstructure
cab
Z 55 145 Ladder superstructure,
right
140−1020−103a_en 35/45
2
178 706 12
178 706 12
Z 55 146 Z 55 147
178 706 12 178 706 12
Z 55 148 Z 55 149
36/45 140−1020−103a_en

no.
Z 55 146 Foot bearing main boom, 178 706 12 Risk of hands getting
left crushed
Z 55 147 Luffing cylinder, left
Z 55 148 Luffing cylinder, right
Z 55 149 Rail of the main boom
extension
140−1020−103a_en 37/45
2
178 706 12
178 706 12
Z 55 150 Z 55 151
178 729 12 178 706 12 178 706 12
Z 55 152 Z 55 153
38/45 140−1020−103a_en

no.
Z 55 150 Superstructure slew gear 178 706 12 Risk of hands getting
mechanism crushed
Z 55 151 Main boom sheave head,
left and right
Z 55 152 Foot of the main boom
extension, left and right
Z 55 153 Crane chassis, all 4
struts
Z 55 152 Foot of the main boom 178 729 12 Risk: installation work
extension, left and right
140−1020−103a_en 39/45
2
178 705 12 178 705 12
Z 55 154 Z 55 155
511 685 98 511 686 98

178 719 12
Z 55 156 Z 55 159
40/45 140−1020−103a_en

no.
Z 55 154 Superstructure rear, right 178 705 12 Risk due to machines
and left
Z 55 155 Superstructure, on the
side on the flap
Z 55 156 Crane chassis passenger 511 685 98 Fire extinguisher
door 511 686 98 First aid box
Z 55 159 Superstructure engine 178 719 12 Warning: fan rotor
140−1020−103a_en 41/45
2
178 718 12 178 718 12
Z 55 157 Z 55 158
178 727 12 178 715 12
Z 55 160
42/45 140−1020−103a_en

no.
Z 55 157 Crane chassis, exhaust 178 718 12 Risk of combustion
cover
Z 55 158 Superstructure frame
next to exhaust
Z 55 160 Crane chassis, cab, next 178 727 12 Risk passenger
to pressure gauge 178 715 12 Risk of tipping
140−1020−103a_en 43/45
2
178 708 12
178 702 12
178 709 12
178 715 12
178 714 12
Z 55 161
44/45 140−1020−103a_en

no.
Z 55 161 Superstructure cab 178 702 12 Risk: electricity
178 708 12 Warning before using the
crane
178 709 12 Warning: lifting people
178 714 12 Crane operation
178 715 12 Risk of tipping
140−1020−103a_en 45/45
Crane Operator’s Cab 4
140−1040−003b_en 1/35
4
1 2 3 4 5 7 8 9 10 11
1 2 3
0 4
14
30 15
31 16
32
26
34 25
35 24
36
28
23 17
ÁÁ
ÁÁ
22
18 21
20
19
Z 55 370
2/35 140−1040−003b_en
4 Crane operator’s cab
4.1 Controls and Displays

(Z 55 370)
No. Element Designation Function

1 P 1212 Fuel gauge Revolution counter
2 P 1367 Fuel gauge Engine oil pressure
3 P 1351 Fuel gauge Engine temperature
4 P 3251 Fuel gauge Hydraulic oil temperature
5 P 0460 Fuel gauge Level fuel tank
7 A 5155 Timer Control of the engine−indepen-
dent heating
8 S 5152 Rotary switch Fan
9 R 5170 Rotary switch Thermostat
10 S 5183 Luminous switch Air circulation on / off
11 S 5176 Luminous switch Air conditioning equipment on /
off
14 Self−return rocker Precision control (%) for luffing
switch gear and hoist 1
15 Hoist rotation indi- Display: Hoist 1 rotating
cator
16 Control lever Hoist 1 / luffing gear (mode 1, for
control lever assignments, see
section 10)
17 Switch box Main electrical unit cab
18 Lever Release cab door
19 S 9333 Self−return rocker Extend/retract platform (no. 22)
switch
RISK OF ACCIDENTS!
The symbol shown for the assignment of the control lever
(16) / (24) represents the standard assignment. This (or the
assignment selected by the customer) is shown on the
sticker on the right−hand cab window.
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the cur-
rent function of the lever is before he commences a crane
movement.
Otherwise, there is a risk of accidents if accidental crane
movements are initiated.
140−1040−003b_en 3/35
4
1 2 3 4 5 7 8 9 10 11
1 2 3
0 4
14
30 15
31 16
32
26
34 25
35 24
36
28
23 17
ÁÁ
ÁÁ
22
18 21
20
19
Z 55 370
4/35 140−1040−003b_en
(Z 55 370)

20 B 1251 Pedal Speed adjustment of the engine
21 B 8806 Pedal Slew gear brake
22 Step Cab entry / exit
23 S 7111 Foot switch Horn
24 Control lever Telescopic sections / slew gear
(mode 1, for control lever assign-
ments, see section 10)
25 Hoist rotation in- Display: Hoist 2 (*) rotating
dicator
26 Self−return rocker Precision control (%) for the slew
switch gear and hoist 2 (*)
28 Operating panel Radio / CD
30 Push button High speed
31 Push button Precision control (%) for the luf-
fing gear and hoist 1 (together
with item 14)
32 Button Dead man’s handle
34 Push button w/o function
35 Push button Precision control (%) for slew
gear and hoist 2 (*), (together
with item 26)
36 Button Dead man’s handle
RISK OF ACCIDENTS!
The symbol shown for the assignment of the control lever
(16) / (24) represents the standard assignment. This (or the
assignment selected by the customer) is shown on the
sticker on the right−hand cab window.
As several variants can be selected for assignment of the
lever using the IC−1 (see section 10), it is the responsibility
of the crane operator to make sure he knows what the cur-
rent function of the lever is before he commences a crane
movement.
(*) = Optional
140−1040−003b_en 5/35
4
24V
42 43
41 44
47
45 48
46
51
49 52
50
Z 56 989
6/35 140−1040−003b_en
(Z 56 989)

41 S 6540 Luminous switch Aircraft warning light
42 S 6421 Luminous switch Rotaflare light
43 S 1262 Luminous switch Dash board illumination
44 S 6130 Luminous switch Lighting equipment operating
range; front and rear of the cab
45 S 6211 Luminous switch Lighting equipment outrigger

area;
integrated on the crane chassis in
the covers
46 S 6140 Luminous switch Lighting equipment operating
range, can be adjusted electri-
cally;
fitted on the basic boom section,
left−hand side
47 S 6145 Luminous push- Adjustment of spotlight (item 46)
button
48 S 6120 Luminous switch Lighting equipment superstruc-
ture;
left−hand side to the rear (*)
49 S 5251 Luminous switch Roof window wiper, 2−level (inter-

mittent / continuous)
50 S 5261 Luminous push- Windscreen washing assembly
button
51 S 5253 Luminous switch Wiper, front, 2−level (intermittent /
continuous)
52 S 9310 Self−return rocker Tilt cab
switch
(*) = Optional
140−1040−003b_en 7/35
4
24V
24V
61 62 63 64
65 66
67 68
Z 56 990
8/35 140−1040−003b_en
(Z 56 990)

61 S 1260 Luminous touch Quick stop of the engine
contact
62 S 300 Ignition lock Engine start / engine stop
63 Adjustment knob Tilt adjustment of the monitor
64 Monitor Intelligent Control System (IC−1)
65 X 5453 Service socket Cigarette lighter and power supply
24V DC
66 X 5452 Service socket Power supply 24V DC
67 Service socket USB connection for crane control
68 Service socket Ethernet RJ45 CAT 5 − connec-
tion for crane control
140−1040−003b_en 9/35
4
24V
71
74
75 76
78
Z 56 991
10/35 140−1040−003b_en
(Z 56 991)

71 S 9380 Luminous push- Raise / lower counterweight
button
red
74 S 0960 Luminous switch Unlock / lock superstructure lock-
red ing device
75 S 8805 Luminous switch Release / block the slew gear
red brake (slew gear parking brake)
76 S 8817 Luminous switch Switchover slew gear: open /
yellow closed circuit
78 S 1210 Luminous switch Engine chassis; START / STOP
green only when the ignition of the chas-
sis is in position ON
140−1040−003b_en 11/35
4
24V
81 82 83 84 85
89
1
86 90
87
88
Z 56 992
12/35 140−1040−003b_en
(Z 56 992)

81 H 0451 Indicator light Battery charge indicator
82 H 1363 Indicator light Monitor engine oil level
83 H 1377 Indicator light Engine stop
84 H 1260 Indicator light Engine quick stop
85 H 1375 Indicator light Engine fault: if indicator light is il-
luminated, switch off the engine
and check
86 H 1335 Indicator light Fault chassis engine:
− air filter clogged
− fault engine
− fault transmission
− filter hydraulic oil
chassis clogged
87 H 1372 Indicator light Air filter check
88 H 0420 Indicator light Monitoring of the fuel level, warn-
ing on “reserve”
89 H 3350 Indicator light Hydraulic oil filter control
90 H 3351 Indicator light Hydraulic oil temperature control
140−1040−003b_en 13/35
4
24V
101 102
100
108 103
107 104
106 105
Z 56 993
14/35 140−1040−003b_en
(Z 56 993)

100 S 4331 Double key Outriggers complete,
retract / extend vertically
101 S 4316 Double key Outrigger front left,
retract / extend horizontally
102 S 4315 Double key Outrigger front right,
103 S 4319 Double key Front right jack,
retract/extend vertically
104 S 4321 Double key Outrigger rear right,
105 S 4317 Double key Outrigger rear right,
106 S 4318 Double key Outrigger rear left,
107 S 4322 Double key Outrigger rear left,
108 S 4320 Double key Outrigger front left,
140−1040−003b_en 15/35
4
24V
111
112
113
114
115
117
116
Z 56 994
16/35 140−1040−003b_en
(Z 56 994)

111 H 7924 Indicator light Load limit device bridged
112 S 7924 Key−operated Bridging load limit device
pushbutton
113 H 7270 Indicator light Hoist limit switch bridged
114 S 7270 Key−operated Bridging of the hoist limit switch
pushbutton
115 H 7925 Indicator light Load−moment−reducing move-
ment “raise luffing gear” bridged
116 S 7925 Key−operated Bridging of the load−moment−re-
pushbutton ducing movement “raise luffing
gear”
117 S 0460 Luminous push- Refueling pump (*)
button “tank fill−up from the chassis to
the superstructure”
(*) = Optional
140−1040−003b_en 17/35
4
121
Z 59 318
122
Z 59 321
18/35 140−1040−003b_en
Warning light with buzzer signal

(national regulation or optional)
(Z 59 318)
In some countries a warning light / buzzer signal (121) is stipu-

lated by law. Its function is to indicate the dangerous states listed
in the following also outside of the crane operator’s cab:
− overload
− bridging: load limit device
− bridging: hoist limit switch
− bridging: movement “raise luffing gear”.
There is a switch on the housing of the warning light / buzzer sig-

nal (121) with which the warning signal can be interrupted.
Warning light
(national regulation and optional)
(Z 59 321)
Warning light’s (122) function is to indicate the load of the max.

permitted load moment also outside of the crane operator’s cab:
− green: load moment in the permitted range (0% − 90%)
− yellow: load moment in the prewarning range (90% − 100%)
− red: overload (over 100%); load limit device switches off.
140−1040−003b_en 19/35
4
”A”
41
”B” 42
22
43
32
Z 52 909
32 31
18
52
19
Z 52 910 Z 52 967
20/35 140−1040−003b_en
4.2 Entering / Exiting the Cab

(Z 52 909, Z 52 910, Z 52 967)
Depending on the position of the cab relative to the crane chas-

sis, access is via ladder assembly (43) or integrated steps in the
frame of the crane chassis.
To open the cab door from the outside use the lockable door
catch (41). The door lock is unlocked and the cab door can be
opened (or closed) using handle (42).
To enter / leave the cab, platform (22) should be completely ex-

tended. To retract and extend the platform, use rocker switch
(19).
In order to drive the crane the platform (22) must be com-

pletely retracted (transport position).
The opened cab door is locked in place when it reaches its end
position, to avoid it closing accidentally.
To close the cab door first press lever (18) lightly outwards. A
spring then releases the lock on the cab door. The door can then
be slid closed using handle (31).
Risk of crushing!
When closing the door, there is a risk of crushing between
the door and the cab frame. Therefore use the handles pro-
vided to avoid placing your hands in dangerous areas!
Also make sure that your hand is not trapped between the
handle (31) and grip (52) of the front window.
To open the cab door from the inside press lever (32) lightly
backwards. The cab door opens and can be pushed open using
handle (31).
Platform (32) at the front of the crane operator’s cab is foldable.

It should, where possible, be kept in the lowered position (”B”)
where it can be used as a step.
140−1040−003b_en 21/35
4
52
Z 52 911
22/35 140−1040−003b_en
4.3 Tilting the Cab

(Z 52 911)
To enable work with the crane to be followed more easily, the cab
can be tilted backwards using hydraulic cylinders (max. 18°).
Press self−return rocker switch (52) up − tilt cab forwards.

Press self−return rocker switch (52) down (on the symbol) − tilt
cab backwards.
There is a risk of crushing when tilting the cab!

Persons must stay clear of the hazardous area!
140−1040−003b_en 23/35
4
9
8
7 4
6
Z 52 912
24/35 140−1040−003b_en
4.4 Workplace Ergonomics
4.4.1 Adjusting the Crane Operator’s Seat

(Z 52 912)
The crane operator is protected against mechanical vibrations by

means of a hydraulically dampened seat. In addition, the seat
can be adjusted individually to the weight of the individual crane
operator.
The seat offers infinite adjustment options for the seat height and
tilt, backrests and armrests. This enables the seat to be set to the
optimum operating position for every operator.
The seat can be adjusted infinitely variably using the following

equipment:
(1) − Control knob for angle adjustment of the arm rests
Risk of crushing!
The arm rests can be folded away. When folding down from
the upright into the horizontal position, there is a risk of
crushing between the armrest and the side console.
(2) − Control knob for setting the lumbar support

(3) − Control element for adjusting the backrest
(4) − Bar for horizontal adjustment of the seat (without con-
sole)
(5) − Control knob for weight adjustment
(6) − Bar for horizontal adjustment of the seat (with console)
(7) − Luminous switch seat heating on / off
After it is switched on, the seat heating is thermostat controlled,

i.e. it switches off and on automatically to maintain a certain tem-
perature, as long as the switch is switched to position “On”. The
integrated indicator light lights up.
(8) − Control element for adjusting the angle of the seat sur-
face
(9) − Control element for vertical adjustment of the seat.
140−1040−003b_en 25/35
4
21
22
23
Z 52 960
31
Z 52 961
26/35 140−1040−003b_en
4.4.2 Sun Shield

(Z 52 960, Z 52 961)
The crane operator’s cab is fitted with roll−down sun visors on the
roof window, rear window and side window. These can be low-
ered down to the desired level as required to avoid being dazzled
by the sun or the cab becoming too warm.
The window shade on the roof window can be moved backwards

and forwards as required on the corresponding flap (21).
The vertical window shades can be pulled down to the desired

position on the corresponding flap (23). Once the shade has
been pulled down to the required level, it stays in that position.
To roll the shade back up, pull it down slightly first using the lever
on the cord (22). The window shade is then rolled up fully.
The sun visor (31, Z 52 961) on the front window can be pivoted
around into different positions as required.
140−1040−003b_en 27/35
4
41 42
Z 52 962
43
44
Z 52 963
28/35 140−1040−003b_en
4.4.3 Lighting Equipment

(Z 52 962, Z 52 963)
The interior cab light (41) is located to the rear of the roof of the
cab and is actuated using switch (42).
Switch (42) has three possible positions:
− upper position (as shown in “Z 52 962”): Light OFF
− middle position: Light OFF
− bottom position: Light ON.
In addition there is a reading light in the right−hand corner of the

instrument panel (44, Z 52 963). It is fitted on a flexible arm (swan
neck) and can therefore be pivoted into any position within its ex-
tension radius.
It is switched on and off on the light itself using switch (43).
140−1040−003b_en 29/35
4
46
47.1
47
47.2
Z 52 964
30/35 140−1040−003b_en
4.4.4 Open / Close Window
4.4.4.1 Side Window, Rear Window

(Z 52 964)
The side window (Z 52 964) which forms the upper part of the cab
door and the window in the rear wall of the cab are sliding win-
dows.
When closed, the catch (47) on the window element and the fixed
counterpiece (46) on the cab frame support are locked together.
To open the individual window press the catch on the gripping

piece together (47.2) as shown in figure (Z 52 964). The locking
nose (47.1) is lifted and the window element can be closed/
opened.
Risk of crushing!
When closing, there is risk of crushing between the window
element and the door / cab frame support. Only use the han-
dles provided to ensure that your hand doesn’t get caught!
140−1040−003b_en 31/35
4
51
”A”
52.1
52.2
”B”
52
Z 52 965
32/35 140−1040−003b_en
4.4.4.2 Front Window

(Z 52 965)
The front of the cab is fitted with a large front window.
When closed, the two handles (52) are in position (”A”). The cor-
responding locking nose (52.2) is then in the transverse position
behind the fixed locking plate (52.1) on the cab frame.
To open the front window turn both handles inward by 90°. They
are then in position (”B”). Press the window element outwards
lightly with your hand. The window is then opened completely by
means of the two gas−operated positioners (51).
To close the window, the retaining pressure of the gas springs

must be overcome and handles (52) returned to position (”A”).
Risk of crushing!
When closing the window there is a risk of crushing be-
tween the window element and the cab frame. Use the han-
dles provided to ensure that your hands are not caught in
the hazardous areas!
In case of emergency, the wide−opening front window can be

used as an emergency exit.
140−1040−003b_en 33/35
4
61
62a
63
62b
Z 53 493
34/35 140−1040−003b_en
4.4.5 Storage
(Z 53 493).
There are a number of storage areas in the cab where things can
be put down:
− on top of the instrument panel
− behind the seat of the crane operator (e.g. for storing the op-
erating instructions)
− plastic elements (63) in the footwell, right−hand side
− ashtray (61) on the right−hand side panel and further ones in
the consoles of the control levers.
− fold−out cup holders (62a) and (62b) on the consoles be-
neath the control levers.
These cup holders must be folded out to hold drinks contain-

ers. This is shown for cup holder (62a) in the drawing.
When the cup holders are not needed, they should be folded
back in. This is shown for cup holder (62b) in the drawing op-
posite.
140−1040−003b_en 35/35
Engine 5
5 Engine
The engine OM 904 LA is a six−cylinder engine with direct injec-

tion, exhaust turbocharger and charge air cooling. It has particu-
larly low pollutant emissions and has an electronic control system
(control devices and sensors).
Safety measures for engines with electronic control devices
The following safety measures must be observed, in order

to avoid injury to persons and damage to the engine, com-
ponents or cables.
− Only start the engine when the batteries are properly con-
nected. Never disconnect the batteries when the engine is
running.
− Only start the engine with the revolution pick−up fitted.
− Do not use a high−speed charger to start the engine.
Jump starting only permitted with separate batteries.
− For high−speed charging of the batteries, the battery clamps
must be removed. Follow the operating instructions for the
high−speed charger.
− In case of electric welding work, the batteries must be discon-
nected and the two cables “+” and “−” connected firmly to-
gether.
− The connections of the control devices may only be fitted and
removed when the electrical system is switched off.
− Reversal of the polarity for the supply voltage of the control
devices (e.g. reversal of the battery poles) can lead to the
control devices being destroyed.
− Tighten the connections on the injection system with the pre-
scribed tightening torque.
− With forecast temperatures of over 80° C / 176°F (e.g. dry fur-
naces) the control devices must be removed.
− For measurements on plug connections, use only suitable
test lines (connecting set of the engine manufacturer).
− Telephones and radios that are not connected to an outside
antenna can lead to malfunctions on the vehicle electronics
and can thus endanger the operational reliability of the en-
gine.
140−1050b_en 1/29
5
Cable channel 60X25X40.5 (30)
A0303
F1 25 A F8 25 A F15 10A F22 10 A F29
F2 10 A F9 15A F16 10 A F23 10A F30 10 A
F3 10 A F10 10A F17 10 A F24 10A F31 10 A
F4 10 A F11 10 A F18 10 A F25 10 A F32 10A
X1
X2
X3
X4
X5
X6
F5 10 A F12 10 A F19 10 A F26 10 A F33 ›2‹a
F6 10 A F13 10 A F20 F27 10 A F34 15A
(31)
F7 25 A F14 10A F21 10 A F28 25A F35 25A
A0513
Cable channel 60X25X31

V11 V22 K5 K10 K5 K10 25A
R16 R15
V10 V21 15A
R13 R14
V9 XV2 V20 X2 X2 10A
R11 R12
V8 V19 K4 K9 K4 K9 10A
R9 R10
V7 V18
10A
A0591
A0583
5a
A0561
A0564
X1 K3 K8 K3 K8
5a
17
V6 V17
R7 R8 5a
V5 V16
R5 R6
V4 V15 K2 K7 K2 K7
R3 R4 XV1 X1 X1
V3 V14
R1 R2
V2 V13
V1 V12 K1 K6 K1 K6
Cable channel 60X40X37 (29)
A0562 A0563
K3
X2
K6 K3
X2
K6
15 18 12 21
17a
(28)
K2 K5 K2 K5
A1157
ADM
Cable channel 73X49X23.5

X1 X1
K1 K4 K1 K4
17b
X0859
X0701 X0858
K8000
X0703 X0705
VOLTAGE CONVERTER
K0552 K0551
A0154
B5252 B5253
Z 54 700
85
Z 54 701
2/29 140−1050b_en
Engine 5
5.1 Engine control/monitoring

(Z 54 700, Z 54 701)
Detailed information on this subject as well as fault codes

can be found in the operating instructions of the engine
manufacturer (see part 5 of these documents).
These must be observed in addition to the basic information
given below.
The engine is equipped with a fully electronic control system incl.

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

Network) line, via which all necessary data / information can be
exchanged.
If the engine monitoring system recognises a fault, this is dis-

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

nected to the socket “17b”). Please contact our customer service
department in this regard.
The gravity of the fault can only be determined using the

diagnosis unit.
Thus: as soon as the indicator light (85, Z 54 701) lights up
indicating a motor fault, the motor must be shut down imme-
diately and the cause of the fault must be determined (to
avoid damage to the motor).
Operation of the crane is only permitted again once the fault
has been rectified.
Risk of accidents!
If this is not possible due to an existing hazardous situa-
tion, different engine running characteristics (emergency
running program) or possible engine damage are to be ex-
pected. Proceed with appropriate caution.
140−1050b_en 3/29
5
Z 53 438
4/29 140−1050b_en
Engine 5
5.2 Starting
5.2.1 Before starting

(Z 53 438)
Before operating the engine for the first time, the operating
instructions of the engine manufacturer for the diesel engine
OM 904 LA must be observed. These can be found in section
5 of these documents.
The following information is limited to the factors that di-
rectly affect the crane.
1. Check before starting:

− the hydraulic oil level
− the engine oil level
− the coolant level.
To proceed, observe the corresponding sections of the mainte-

nance and lubrication instructions of the superstructure.
− the fuel level on the fuel gauge (5).
The indicating instrument (5) displays correctly when the

ignition is switched on.
140−1050b_en 5/29
5
81
62 62a
Z 54 702
23
20
Z 53 440
6/29 140−1050b_en
Engine 5
5.2.2 Starting procedure

(Z 54 702, Z 53 440)
Before starting, check that all control levers are in the off
position.
1. Insert the ignition key in the “0” position in the ignition lock
(62) and turn clockwise up to the second notch.
After about 1 s, only the charge control lamp (81) is lit up.
The key−operated switch (62a) of the ignition lock is a four−

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

ments the crane operator must actuate the horn using foot
switch (23), in order to warn persons who are in the vicinity
of the crane.
2. Place the setpoint sensor, i.e. pedal (20) in the idle position.
The engine speed can alternatively be adjusted using the

IC−1 control. This is described on the next page.
140−1050b_en 7/29
5
800
0.0
Z 54 703
81
Z 54 704
8/29 140−1050b_en
Engine 5
(Z 54 703, Z 54 704)
To adjust the engine speed via the IC−1 control press the key
in the displayed “Quick Menu” mask (Z 54 703, left−hand
side). The “engine display” mask appears.
Here the engine speed can be regulated between maximum and

minimum by using the arrows or moving the slide control (1).
The current speed is displayed directly beneath the slide control
switch and additionally behind the corresponding symbol.
3. Turn the ignition key further up to the stop and hold in this
position until the engine starts. If required, stop the starting
procedure after max. 20 s and repeat again after approx.
60 s.
When the engine is running, the charge control light (81) must
go out.
Release the ignition key as soon as the engine starts. On no

account should the starter be operated with the engine run-
ning.
If the indicator light (81) does not go out, there is a fault in
the power supply.
The corresponding instructions in the operating instruc-
tions of the engine manufacturer must be observed.
140−1050b_en 9/29
5
Z 53 456
85
87
Z 54 705
10/29 140−1050b_en
Engine 5
5.2.3 To be observed after starting

(Z 53 456, Z 54 705)
− Directly after starting, check the oil pressure on pressure

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

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

of the fault (to avoid damage to the engine).
has been rectified.
Risk of accidents!
If this is not possible due to an existing hazardous situa-
tion, different engine running characteristics (emergency
running program) or possible engine damage are to be ex-
pected. Proceed with appropriate caution.
− If the indicator light (87) lights up, service the air filter (see
maintenance and lubrication instructions of the superstruc-
ture).
140−1050b_en 11/29
5
3 4
Z 53 457
82 85
89 90
Z 54 706
12/29 140−1050b_en
Engine 5
(Z 53 457, Z 54 706)
− If indicator light (90) lights up, the hydraulic oil temperature

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

ture.
At lower temperatures, it is possible that this lamp does not go out
for a short period, even though no fault is present.
− Observe the coolant temperature on round instrument (3).

The coolant temperature is also displayed via the mask “en-
gine display” of the IC−1. To call up this mask, observe the de-
scription on page 9.
If the maximum permitted temperature is exceeded, indicator
(85) lights up.
As soon as indicator light (85, Z 54 706) lights up and dis-

plays an engine fault, the engine must be switched off imme-
diately and the cause of the fault determined (to prevent
damage to the engine).
has been rectified.
− If the indicator light (82) lights up, check the engine oil level
(see operating instructions of the engine manufacturer).
The engine oil amount (%) is also displayed via the mask “en-
gine display” of the IC−1. To call up this mask, observe the de-
scription on page 9.
This display of the motor oil level (%) is only meant as addi-
tional information. The monitoring of the oil level may only
be done using the oil−level stick.
Depending on the version, it is possible that this display
function is not possible for technical reasons. The respec-
tive display at the IC−1 will then always be 0%.
If this is the case, the indicator light (82) is not displayed ei-
ther.
140−1050b_en 13/29
5
88
Z 54 707 Z 53 453
31
117
Z 54 708
14/29 140−1050b_en
Engine 5
(Z 54 707, Z 53 453, Z 54 708)
− If the indicator light (88) lights up, fuel must be topped up; the
fuel level in the tank is down to reserve.
For the fuel level observe the fuel gauge (5).
Indicating instrument (5) displays the fuel level superstructure

tank. The indicating instrument (5) displays correctly when the
ignition is switched on.
Refuelling is normally carried out using the filling nozzle (31), ac-
cessible by using the ladder behind the cab.
Optionally, one can also fit the device with a fuel tank filling sys-
tem for filling the superstructure tank through the tank of the
crane chassis. The fuel tank filling system is operated using a lu-
minous pushbutton (117).
Information about filling the tank of the crane chassis can be

found in the operating instructions or in the crane chassis lubrica-
tion und maintenance instructions, part 4 of these operating in-
structions.
140−1050b_en 15/29
5
23
20
Z 53 440
16/29 140−1050b_en
Engine 5
(Z 53 440)
− At extreme minus temperatures do not place the cold engine

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

− the oil pressure falls or fluctuates violently.
− the output and speed falls without the position of pedal
(20) being changed.
− the exhaust is smoking heavily.
− the coolant and oil temperature climbs abnormally.
− abnormal noises suddenly occur in the engine or turbo-
charger.
140−1050b_en 17/29
5
2000000
1000000
500000
300000
200000
100000
Viskosität−Temperatur−Blatt
70000
50000 nach Prof. Ubbelohde
30000
20000 Temperaturachse: log(abs. Temperatur)
10000 Viskositätsachse: log(log(kin. Viskosität + 0,8))
7000
5000
4000
3000
2000
1500
1000
500
kinematische Viskosität [mm**2/s]
400
300
200
150
100
90
80
70
60
1
50 2
40
30
25 Tellus TX 46
20
18
16
14
12
10
9
8
7
5
4.5
4
Shell Tellus TX 32
3.5 V40: 32; V100: 6,5
Shell Tellus TX 46
3
V40: 46; V100: 8,4
Shell Tellus TX 68
2.5 V40: 68; V100: 11,4
2
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Öltemperatur [°C]
Z 59 740
18/29 140−1050b_en
Engine 5
5.2.4 Warming up the hydraulic system

Warming up the hydraulic system is only required when:
− in relation to the ambient temperature the oil viscosity is bet-
ween 1000 and 1600 cSt (that means, with a standard hy-
draulic oil filling between −13°C and −18°C / +8.6°F and
−0.4°F, see Table)
and
− the hydraulic oil has cooled down to ambient temperature fol-
lowing a longer standstill (approximately 8 to 10 hours).
5.2.4.1 Hydraulic oil

(Z 59 740)
Make sure that, in relation to the oil temperature and visco-

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

Oil tempe-
Oil viscosity Diesel engine
Shell Tellus TX 46 rature
(cSt) speed (rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idle speed)
min −13 / +8.6 1000
Operation (2) max
max +92 / +198 10
The conditions that are listed in the table must be observed.

Otherwise safe operation of the crane cannot be guaranteed
and hydraulic components could be damaged.
When using comparable oils, make sure that these corres-

pond to the recommended oils, especially with regard to the
listed characteristics.
140−1050b_en 19/29
5
2000000
1000000
500000
300000
200000
100000
Viskosität−Temperatur−Blatt
70000
50000 nach Prof. Ubbelohde
30000
20000 Temperaturachse: log(abs. Temperatur)
10000 Viskositätsachse: log(log(kin. Viskosität + 0,8))
7000
5000
4000
3000
2000
1500
1000
500
kinematische Viskosität [mm**2/s]
400
300
200
150
100
90
80
70
60
1
50 2
40
30
25 Tellus TX 46
20
18
16
14
12
10
9
8
7
5
4.5
4
Shell Tellus TX 32
3.5 V40: 32; V100: 6,5
Shell Tellus TX 46
3
V40: 46; V100: 8,4
Shell Tellus TX 68
2.5 V40: 68; V100: 11,4
2
−40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Öltemperatur [°C]
Z 59 740
20/29 140−1050b_en
Engine 5
5.2.4.2 Warming up procedure

(Z 59 740)
1. Make sure, using the following table, that a correct hydraulic

oil is added in relation to the prevailing temperatures. The vi-
scosity of the oil must be below 1600 cSt.
2. Start the diesel engine.
The correspondingly permitted engine speeds are specified in

the following table.
Standard hydraulic oil fill for average temperatures

Oil tempe-
Oil viscosity Diesel engine
Shell Tellus TX 46 rature
(cSt) speed (rpm)
(°C/°F)
If started without load below 1000
−18 / −0.4 1600
(1) (idle speed)
min −13 / +8.6 1000
Operation (2) max
max +92 / +198 10
As soon as the diesel engine is running − first in idle −, the hydrau-

lic pumps are automatically started. In this way the hydraulic oil
circulates without pressure and heats up.
The hydraulic system must run itself warm until the viscosity of
the oil is below 1000 cSt.
With a running time of 30 minutes and approximately 1000 rpm

the hydraulic oil is warmed by 4° to 5°C (7° bis 9°F).
3. After this carry out all movements again after approximately

10 to 15 minutes without load. The warming up procedure is
then completed.
140−1050b_en 21/29
5
800
0.0
23
0
20
Z 53 440 Z 54 709
62 62a
Z 54 710
22/29 140−1050b_en
Engine 5
5.2.5 Switching off

(Z 53 440, Z 54 709, Z 54 710)
1. Place the pedal for speed adjustment (20) in the ”idle” posi-
tion or set the corresponding speed on the ”engine display”
mask of the IC−1.
To call up this mask, observe the description on page 9.
After operating with full engine output or high coolant tem-

perature, leave the engine running without load for 1 − 2 min-
utes at idle speed.
2. Turn ignition key (62a, Z 54 710) anti−clockwise (to posi-

tion ”0”) and remove the ignition key.
When leaving the crane, remove the ignition key and lock the
cab.
140−1050b_en 23/29
5
61
84
Z 54 711
“X”
“B”
“A”
Z 54 092
24/29 140−1050b_en
Engine 5
5.2.5.1 Motor Quick Stop (Emergency stop)

(Z 54 711)
The crane is equipped with a motor quick stop device. The motor
quick stop button (61) is built into the control panel in the super-
structure cab as standard.
Use the quick stop button (61) to switch off the engine only
in an emergency.
In this case, press the ”quick stop” button. It latches in
places in the activated position. Indicator light (84) lights up.
The previously pressed ”quick stop button” must first be re-
leased again before starting up the motor again. To this end,
turn the button slightly.
5.2.5.1.1 Motor Quick Stop (Optional)

(Z 54 092)
The crane can optionally be equipped with two motor quick stop
buttons. These are then to be found on the crane chassis on the
left and right in the outrigger controls area (“X”).
The functioning of both these motor quick stop buttons is assured

only when the parking brake is activated in the carrier cab and the
gear box is in “neutral”.
If the crane is equipped with an optional motor quick stop device,

“all motors” are switched off upon pressing one motor quick stop
button. The indicator light (84) lights up.
The flaps in the air intake channels of the motor are closed and
must be manually opened again before restarting the motor (le-
ver at the air intake channel).
Before restarting, the flap in the air inlet channel to the su-
perstructure engine must be opened manually by pulling the
chain.
If the air shut−off valve is closed, the engine must not be
started and can’t be started. Even one attempt at starting the
engine will lead to damage to the engine.
− “A” = flap open
− “B” = flap closed
140−1050b_en 25/29
5
›2‹a
− ›1‹a
+
›2‹b
›1‹b
+ −
3
Z 54 712
26/29 140−1050b_en
Engine 5
5.3 Jump starting

(Z 54 712)
Observe the operating instructions for the crane chassis. Sec-

tion 5 “Engine”, sub−point “Jump starting with external batteries”.
140−1050b_en 27/29
5
Z 54 713
28/29 140−1050b_en
Engine 5
5.4 Operating hour display (engine)

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

(Z 54 713)
With “automatic driving” the engine speed is automatically ad-

justed as the control lever is moved. This ensures comfortable
working processes as the engine speed does not need to be ad-
ditionally activated by the crane operator.
To activate “automatic driving” press key in the displayed

“Quick Menu” mask (Z 54 713, left−hand side). The “engine dis-
play” mask appears. Press button here. It is highlighted in
green.
To switch off “automatic driving” press key again. In the de-

activated state, the button is grey in colour.
5.6 Coolant preheating
Please see section 16 “Heating”.
140−1050b_en 29/29
Supporting the Crane on Outriggers from the Superstructure Cab 7
7 Supporting the Crane on Outriggers from the Super-

structure Cab
Before supporting the crane on outriggers from the super-

structure cab, all procedural and health and safety instruc-
tions as outlined in section 12 “Outriggers”, part 2 must be
observed.
As a general rule, the outriggers should be set using the con-

trols in the outrigger control panels on the crane chassis.
(see section 12, part 2)
For subsequent levelling, however, it is possible to adjust
the outriggers from the superstructure cab.
This should only be done in exceptional cases and only when the
crane operator has a clear and unobstructed view of all outrigger
jacks.
(If necessary, a banksman should be used)
140−1070_en 1/3
7
101 102
100
74
108 103
75
107 104
106 105
Z 54 019
2/3 140−1070_en
Supporting the Crane on Outriggers from the Superstructure Cab 7
(Z 54 019)
For additional (subsequent) levelling, proceed as follows:

− Slew the superstructure to the rear (see section 8 “Slewing the superstruc-
ture”) and, using button (74, S0960), lock the superstructure.
− Actuate the slew gear parking brake using button (75, S8805).
The outriggers are controlled using the following buttons:
Ite Element Designation Function

m
100 S 4331 Dual button All outriggers,
101 S 4316 Dual button Front left jack,
retract/extend horizontally
102 S 4315 Dual button Front right jack,
103 S 4319 Dual button Front right jack,
104 S 4321 Dual button Rear right jack,
105 S 4317 Dual button Rear right jack,
106 S 4318 Dual button Rear left jack,
107 S 4322 Dual button Rear left jack,
108 S 4320 Dual button Front left jack,
Risk of crushing between the wheels and road surface when the crane
is lowered onto its wheels by retracting the outriggers.
Before lowering, make sure that this area is completely free of people.
The equipment may only be operated in areas where the crane operator
can see the outrigger jacks directly or via the mirrors. Check all mirror
positions before operating the outriggers.
140−1070_en 3/3
Slewing the Superstructure 8
140−1080 1/23
8
74
75 76
Z 53 461
180°
Z 54 004
2/23 140−1080
8 Slewing the Superstructure
8.1 General
(Z 53 461, Z 54 004)
Depending on the preferred method of operation, the slew gear

can be operated optionally in the closed or in the open circuit.
− Luminous switch (76, Z 53 461) not activated (indicator light
in the switch does not light up) − closed circuit.
In a closed circuit, the speed of the slewing movement de-

pends directly on the movement of the corresponding control
lever. Therefore, it is possible
− to specifically decrease the slewing speed by taking the
control lever back or even
− to directly stop the slewing movement by taking the control
lever back into the neutral position.
− Luminous switch (76) activated (indicator light in the switch
lights up) − open circuit.
In addition, symbol appears next to symbol on
IC−1 display (Z 54 004).
In the open circuit, the torque of the slewing movement is not

stopped abruptly if the corresponding control lever has been
brought back into the neutral position. The movement slowly
runs its course and comes to a stop during freewheeling.
It is also possible to place the boom head in a vertical posi-
tion over the load without any problems.
140−1080 3/23
8
180
90 270
180° 0
360
Z 54 055
4/23 140−1080
(Z 54 055)
180° Before initiating a slewing movement, always take into consider-

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

lowing meanings:
− left−hand half of arrow − slew to the left
− right−hand half of arrow − slew to the right. .
140−1080 5/23
8
180
90 270
180° 0
360
Z 54 055
6/23 140−1080
(Z 54 055)
These directions relate to the movement which the crane opera-

tor carries out with the cab.
The colour of each arrow half indicates which slewing direction

the crane operator can even steer (slewing release):
− both arrow halves green: crane operator decides
left−hand arrow half green,
− only slewing to the left
right−hand arrow half red:
left−hand arrow half red,
− only slewing to the right
right−hand arrow half green:
− both arrow halves red: slewing not permitted
Risk of accidents!
It is prohibited to slew the superstructure if the counter-
weight has not been raised to its final position.
In this case, crane controls stops the slewing movement.

However, if crane control is bridged after a malfunction,
there risk still exists.
Determine cause of the fault immediately and rectify it.
Check regularly that the raised counterweight has not be-

come lowered (for example, in the case of extreme temper-
ature variations after the equipment has been idle for a lon-
ger period or because of leaks). If this has happened, raise
the counterweight completely.
140−1080 7/23
8
Z 53 468 Z 53 459
8/23 140−1080
Danger of tipping over!

(Z 53 468)
The superstructure can only be slewed if the crane is sup-
ported on outriggers in accordance with regulations.
(Z 53 459)
After the crane has been supported on outriggers and the
counterweight has been fitted, the existing outrigger sup-
port area must be inspected BEFORE the superstructure
may be slewed.
Take the details in the load capacity tables into consider-

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

of reach for which load capacity values are still indicated
in the tables.
It is generally prohibited to slew the superstructure in the

overload range (load limit device has switched off).
Risk of accidents!
When slewing the superstructure, the following dangers
are present:
Risk of crushing in the area of the disconnecting point be-
tween the superstructure and the chassis.
Risk of crushing between the back end of the superstruc-
ture (counterweight) and obstacles in the vicinity.
Therefore persons must stay clear of the slewing range at
all times.
Do not slew over people. Do not jump in front of slewing

crane.
Risk of accidents!
If your crane is prepared for driving with a dolly (optional),
you must observe section 8.5 as well as the corresponding
passages in the operating instructions of the crane chas-
sis, part 2 − section 6 “Driving”.
140−1080 9/23
8
180°
Z 54 005
10/23 140−1080
8.2 Initiating a Slewing Movement

(Z 54 005)
In order to initiate a slewing movement, proceed as follows:
1. Support crane on outriggers in accordance with regulations

and align (see part 2, operating instructions of the crane
chassis, section 12 “Outriggers”).
2. Start the superstructure engine.
3. Check which mode has been selected for the assignment of

the control levers. The current mode (here: 1) is shown by the
display of the corresponding symbol in the top line of
the IC−1 display.
You will find detailed information on the selection and range of the
different modes in section 10 “Safety devices”.
Risk of accidents!
It is the crane operator’s responsibility to check the current
control lever assignment before initiating a crane move-
ment.
4. Raise main boom so that it cannot get caught by other crane

components (see section 13 “Luffing”).
140−1080 11/23
8
64
66
74
75 76
Z 53 461 Z 53 462
180°
21
Z 53 464 Z 54 005
12/23 140−1080
(Z 53 461, Z 53 462, Z 53 464, Z 54 005)
5. Release the mechanical superstructure locking device by

pressing luminous switch (74). The indicator light in the
switch lights up. The locking pin (64) is extended outwards
from the locking strip (66) into the position shown. In the top
line of the IC−1 display symbol must appear.
Each state of the superstructure locking device is displayed
using the following symbols:
Superstructure unpinned
Superstructure pinned
Red, fault in the superstructure pinning.
Slewing is only authorised if the locking pin is driven upwards in

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

the luminous switch (75). The indicator light in the switch
lights up.
Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewheel-
ing. This can cause accidental slewing movements or inde-
pendent afterrunning of the superstructure due to wind or
oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (21).
140−1080 13/23
8
30 16
31
32
24
34
35
36
Z 54 006
14/23 140−1080
(Z 54 006)
7. Initiate slewing movement by pressing one of the buttons

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

Control lever (16/24) to the left − slew to the left.
You must take the current assignment of the control levers

into consideration.
In order to prevent accidental initiation of crane movements, both

control levers are equipped with an additional button (dead man’s
handle). A crane movement may only be carried out as long as
one of these buttons is pressed.
You may only activate (press as well as release) a dead man’s
switch if the corresponding control lever is in the “neutral position”
and/or the initiated working movement has been completed.
Risk of accidents!
Pressing / releasing one of these dead man’s switches
when the control lever is fully steered causes abrupt initia-
tion / braking of the corresponding movement.
Risk of accidents!
Only by adapting the acceleration or speeds of all crane
movements can you avoid that the load or the hook block
swings out, causing risk of crushing or crashing when
each movement is switched off.
Control levers (16/24) may not be switched to the opposite

slewing direction, but must first remain in the neutral posi-
tion. Slew the superstructure in the opposite direction only
when the superstructure has come to a standstill.
RISK OF DAMAGE!
Never initiate a slewing movement using the control lever
without first having unpinned the superstructure or released
the slew gear brake.
140−1080 15/23
8
74
75 76
21
Z 53 461 Z 53 464
30 16
31
32
24
34
35
36
Z 54 006
16/23 140−1080
8.3 Braking the Slewing Movement

(Z 53 461, Z 53 464, Z 54 006)
The slew gear has two braking systems:

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

gear parking brake.
If luminous switch (75) has not been activated (indicator light in
the switch does not light up), the slew gear parking brake is
locked. Slewing is not possible.
If luminous switch (75) is activated (indicator light in the switch
lights up), the slew gear parking brake is not locked. Slewing is
possible by moving the control lever (16/24) if the dynamic brake
is not activated using pedal (21).
Risk of accidents!
If the slew gear parking brake is not locked in the open cir-
cuit during slew gear operation, the slew gear is freewheel-
ing. This can cause accidental slewing movements or inde-
pendent afterrunning of the superstructure due to wind or
oblique positioning of the crane.
In this case, the superstructure must be braked / stopped
carefully using the dynamic brake with pedal (21).
140−1080 17/23
8
30 16
31
32
24
34
35
36
21
Z 54 006 Z 53 464
74
75 76
Z 53 461
18/23 140−1080
(Z 53 461, Z 53 464, Z 54 006)
In order to brake slewing movements, bring control lever (16/24)

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

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

can swing of its own accord if the crane is at an angle or un-
der the influence of wind forces. Maintain a safe distance
from buildings. If the crane is not supported on outriggers,
the slew gear brake must be locked.
Before leaving the crane operator’s cab, e.g. during work

breaks or at the end of work, the slew gear brake must be
locked. Press switch (75). The indicator light in the switch
must not light up.
140−1080 19/23
8
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
180°
Z 54 008
20/23 140−1080
8.4 Regulating the Slewing Speed

(Z 54 007, Z 54 008)
The slew gear is electrically pre−controlled. The slewing speed

depends on the engine speed and the movement of the corre-
In addition, it is possible to fine tune the slewing speed. To do so,

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

self−return rocker switch is pressed to the left or right.
If there is no adjustment of the percentages, the mask disappears

again after 5 seconds.
Look out for low slewing speeds (lower scale region):− for
operation with loads > 30% of the load capacity
− with a long boom
− with a fitted main boom extension.
140−1080 21/23
8
64
65
65
65
62
63
Z 54 009
22/23 140−1080
8.5 Preparation for Dolly (Option)

(Z 54 009)
If your crane has been prepared for driving with a dolly, you must
follow the instructions in section 6 of the operating instructions of
the crane chassis (part 2 of these operation manual) under point
“Driving with Dolly”. This section describes how and when the set-
tings listed in the following should be made.
Risk of accidents!
The following conditions must be fulfilled for CRANE OP-
ERATION and for DRIVING WITHOUT DOLLY.
The shift rod (62) must be extended as far as possible, as

shown. The “B” position must be secured using padlock
(63).
The shift rod (62) in the inserted “A” position would mean
that multiple−disk brake of the slewing gear transmission
is blocked in an opened condition.
This could cause unchecked slewing of the superstructure
and to the crane tilting.
The locking pin (64) of the mechanical superstructure lock-

ing device may not be secured mechanically against ex-
tending with the use of fore lock (65). The fore lock must be
in the transport position as shown.
If these conditions are not fulfilled, operation of the crane is not

permitted.
Also observe the corresponding warning signs on the slew

gear and in both cabs (see also section 2.5 “Signs”).
Make sure that these signs are complete and are easily read-
able.
140−1080 23/23
Counterweight 9
9 Counterweight
9.1 General
When planning a load case, the required counterweight

combination is determined using the load capacity tables. This
counterweight combination represents an important part of the
crane configuration, especially for safe operation of the crane.
The crane operator is responsible for making sure that the

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

slew ring to the rear edge of the counterweight is 4.10 m (13.5 ft)
for all counterweight combinations.
Only counterweight combinations listed in this section

may be fitted. There is risk of damage and accidents if other
counterweight combinations are used!
In order to ensure exact fitting, only counterweight ele-
ments may be fitted which are marked with the construc-
tion number of the crane.
140−1090−103b 1/105
9
2/105 140−1090−103b
Counterweight 9
9.2 Important Assembly Instructions
Risk of crushing!
When fitting and removing individual counterweight ele-
ments, there is a risk of crushing between the individual
counterweight elements, between the counterweight and
the superstructure frame as well as between the counter-
weight and the undercarriage (counterweight support)!
To avoid these risks, the safety instructions in section 1,
sub−point ”When Assembling and Dismantling Crane
Components” must be observed.
In particular, maintain a sufficient safety clearance!
The counterweight elements are set down on the crane
chassis with the help of an additionally trained person,
who, as an exception, is on the crane with the crane opera-
tor during this procedure. This person must leave the
crane and the area at risk immediately after the setting
down procedure has been completed.
The crane operator must be in constant visual contact with
this person and must make sure that there is no−one in the
hazardous area. Before the superstructure is slewed, the
crane operator must have made sure that this person has
left the crane and/or the endangered area.
When turning, there is a risk of crushing between the coun-
terweight and obstacles in the vicinity.
Persons must not stand or walk beneath suspended loads
or in areas where loads/equipment could fall.
RISK OF TIPPING!
If the outrigger support areas are reduced, the maximum
counterweight that may be fitted is the largest one as-
signed to the configuration as indicated in the table.
To do so, follow the corresponding details in the load ca-
pacity tables.
If a larger counterweight is fitted, there is a risk of tipping
backward during slewing.
140−1090−103b 3/105
9
min. 2o
Z 55 421
10
Z 55 422
4/105 140−1090−103b
Counterweight 9
Risk of collision!
During the configuration of all counterweight combina-
tions and when turning the superstructure, there is a ”dan-
ger of collision” of the rear main boom drum with the coun-
terweight elements (Z 55 421), if the main boom was low-
ered to 0 beforehand.
Therefore, turning the superstructure is only permissible if
the main boom is lifted up at least 2 ” when the counter-
weight elements have been placed on the counterweight
platform of the crane chassis.
Otherwise the cable reel will be damaged.
ACCIDENTS MAY OCCUR.

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

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

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

the crane must be supported on outriggers. Observe the
instructions in section 12 of the operating instructions of the
crane chassis.
Crane operation is only permitted when all required ele-

ments of the counterweight combination which corre-
spond to the details in the load capacity tables are fitted!
If this is not observed, the risk of accidents is increased!
140−1090−103b 5/105
9
10
Z 55 422
10
10 6
R L
6R
6L
1a
1a
Z 54 020 Z 54 021
6/105 140−1090−103b
Counterweight 9
9.4 Counterweight Combination 0 t / 0 lbs
For the 0 t / 0 lbs counterweight combination, no counterweight

elements and no hoist 2 is required.
All pins needed for fastening the counterweight elements to the

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

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

(Z 54 020, Z 54 021)
In the following you will see the depictions of the individual

counterweight combinations from the viewpoint of the crane
operator in the superstructure cab when setting down the
counterweights (here: Z 54 020) and when completed and fitted
on the superstructure frame (here: Z 54 021).
9.5.1 Components
(Z 54 020, Z 54 021)
The 6.3 t counterweight combination (13 900 lbs) consists of the

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(6) − Counterweight section L/R 2.6 t (5 830 lbs)
(10) − Single−hand locking pins (6x)
140−1090−103b 7/105
9
10
10
6L
6R
1a
5
”X”
1a
Z 54 034
8/105 140−1090−103b
Counterweight 9
9.5.2 Fitting the Counterweight Combination 6.3 t

(13 900 lbs) to the Superstructure
(Z 54 034).
Fitting with your own crane
1. Set down the counterweight base plate (1a) on the

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

section 9.17 “Counterweight Combination 39 t (86 000 lbs)”
from page 55 .
The counterweight sections 6L + 6R can remain pinned after the

first fitting to the superstructure frame.
When fitting further counterweight combinations as described in
the following, this step can be dropped in the fitting sequence.
140−1090−103b 9/105
9
10
10 6
R L
6R
6L
1b 1b
1a
1a
Z 54 022 Z 54 023
10/105 140−1090−103b
Counterweight 9
9.6.1 Components
(Z 54 022, Z 54 023)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(1b) − Cover plate 1.99 t (4 390 lbs)
140−1090−103b 11/105
9
10
10
6L
6R
1b
1a
5 ”X”
1b
1a
Z 54 035
12/105 140−1090−103b
Counterweight 9

(Z 54 035).

2. Fit cover plate (1b) to the counterweight base plate (1a).
The base plate and the cover plate are both manufactured
from the same basic component. Make sure that you only
use 2 components marked with the same 5−digit serial
number (xxxxx−A + xxxxx−B).

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

from page 55 .
140−1090−103b 13/105
9
10
10 6
6R
R L
5 9
5
6L
1b
1b 1a
1a
Z 54 024 Z 54 025
14/105 140−1090−103b
Counterweight 9
9.7.1 Components
(Z 54 024, Z 54 025)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(5) − Counterweight section 2.59 t (5 700 lbs)
(9) − Pins with clip pins (2x)
140−1090−103b 15/105
9
10
10
6L 6R
5
9
1b
1a
5 ”X”
1b
1a
Z 54 036
16/105 140−1090−103b
Counterweight 9

(Z 54 036).

The base plate and the cover plate are manufactured from
the same basic component. Make sure that you only use 2
components marked with the same 5−digit serial number
(xxxxx−A + xxxxx−B).
3. Fit counterweight section (5) to the supporting surface (”X”)

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

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

from page 55 .
140−1090−103b 17/105
9
10
10 6
9
R L 6R
5
4 10 5
4
6L
1b
1b 1a
1a
Z 55 380 Z 55 381
18/105 140−1090−103b
Counterweight 9

“US−Variant / 1”
9.8.1 Components
(Z 55 380, Z 55 381)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 19/105
9
10
10
6R
9 5
4
6L 10
1b
1a
6
5
4
”X”
1b
1a
Z 55 382
20/105 140−1090−103b
Counterweight 9
9.8.2 Fitting the Counterweight Combination 13.5 t (29 800

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

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

required, place strips of timber underneath.
4. Fit counterweight section (5) to section (4). Pin using
single−hand locking pins (10) (3x).
5. Fit both counterweight sections (4 + 5), which are now one
unit, to the supporting surface (”X”) on the jack.

The fitting and removal sequences are described in detail

from page 55.
140−1090−103b 21/105
9
1b 2
1a 1b
1a
Z 55 383 Z 55 384
22/105 140−1090−103b
Counterweight 9

“US−Variant / 2”
9.9.1 Components
(Z 55 383, Z 55 384)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 23/105
9
2
1b
1a
1b
1a
Z 55 385
24/105 140−1090−103b
Counterweight 9

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

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


from page 55.
140−1090−103b 25/105
9
10
10 6
6R
R L
5 9
5
6L
2
2
1b
1b 1a
1a
Z 54 026 Z 54 027
26/105 140−1090−103b
Counterweight 9
9.10.1 Components
(Z 54 026, Z 54 027)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 27/105
9
10
10
6R
6L
5
9
2
1b
1a
5 ”X”
2
1b
1a
Z 54 037
28/105 140−1090−103b
Counterweight 9

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

components with the same 5−digit serial number
3. Set down the counterweight section (2) on the cover plate

(1b).


from page 55 .
140−1090−103b 29/105
9
10
10 6
6R
9
R L
5 5
4 10 4
6L
2 2
1b
1b 1a
1a
Z 54 028 Z 54 029
30/105 140−1090−103b
Counterweight 9
9.11.1 Components
(Z 54 028, Z 54 029)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 31/105
9
10
10
6R
9 5
4
6L 10
2
1b
1a
6
5
4
”X”
2
1b
1a
Z 54 038
32/105 140−1090−103b
Counterweight 9

(Z 54 038).


4. Set counterweight section (4) down safely on the ground. If
required, place strips of timber underneath.
5. Fit counterweight section (5) to the section (4). Pin using
6. Fit both counterweight sections (4 + 5), which are now one
unit, to the supporting surface (”X”) on the jack.


from page 55.
140−1090−103b 33/105
9
3
2
3
2
1b
1b
1a 1a
Z 55 386 Z 55 387
34/105 140−1090−103b
Counterweight 9

“US−Variant”
9.12.1 Components
(Z 55 386, Z 55 387)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 35/105
9
3
2
1b
1a
3
2
1b
1a
Z 55 388
36/105 140−1090−103b
Counterweight 9

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


4. Fit counterweight section (3) to section (2).

from page 55.
140−1090−103b 37/105
9
10
10
6
L 6R
R
6L 3
3
2 2
1b
1b 1a
1a
Z 55 389 Z 55 390
38/105 140−1090−103b
Counterweight 9

“US−Variant”
9.13.1 Components
(Z 55 389, Z 55 390)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 39/105
9
10
10
9 6R
3
6L 2
1b
1a
2
1b
1a
Z 55 391
40/105 140−1090−103b
Counterweight 9

(Z 55 391).



from page 55.
140−1090−103b 41/105
9
5 5
4 10
4
3 3
2 2
1b
1b 1a
1a
Z 55 392 Z 55 393
42/105 140−1090−103b
Counterweight 9

“US−Variant”
9.14.1 Components
(Z 55 392, Z 55 393)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 43/105
9
4
10
3
2
1b
1a
5
4
3
1b
1a
Z 55 394
44/105 140−1090−103b
Counterweight 9

(Z 55 394).




from page 55.
140−1090−103b 45/105
9
10
10 6
6R
9
R L
5
5
4 10
6L 4
3 3
2 2
1b
1a
1b
1a
Z 54 030 Z 54 031
46/105 140−1090−103b
Counterweight 9
9.15.1 Components
(Z 54 030, Z 54 031)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
140−1090−103b 47/105
9
10
10
6R
9
5
4
6L
3 10
2
1b
1a
6
5
4
3
2
1b
1a
Z 54 039
48/105 140−1090−103b
Counterweight 9

(Z 54 039).
1. Set down counterweight base plate (1a) on the

The base plate and the cover plate are manufactured form
the same basic component. Make sure that you use 2
components with the same 5−digit serial number
3. Fit counterweight section (2) to thecover plate (1b).

7. Both counterweight sections (4 + 5) are now one unit.


from page 55 .
140−1090−103b 49/105
9
7L
7R
3
2
1b
1a
Z 55 395
7R
7L
3 2 1b
1a
Z 55 396
50/105 140−1090−103b
Counterweight 9

“US−Variant”
9.16.1 Components
(Z 55 395, Z 55 396)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(7) − Counterweight saddle L/R 4.01 t (8 845 lbs)
140−1090−103b 51/105
9
7R
7L
3 2 1b
1a
3
2
1b 7
1a
Z 55 397
52/105 140−1090−103b
Counterweight 9

(Z 55 397).


5. Hang saddle weight (7 L + 7 R) into the counterweight
section (3) on the left− and right−hand side with both hooks
in the corresponding cast−iron pins.
140−1090−103b 53/105
9
10
10
9
6L
6R
5
4
10
7L
7R
3
2
1b
1a
Z 54 032
6R
7R
6L
7L 1b
5 4 3 2 1a
Z 54 033
54/105 140−1090−103b
Counterweight 9
9.17.1 Components
(Z 54 032, Z 54 033)

following elements:
(1a) − Base plate 3.66 t (8 060 lbs)
(7) − Counterweight saddle L/R 4.01 t (8 845 lbs)
140−1090−103b 55/105
9
10
10
6R
9
7R
6L
10
7L
1b
3 2 1a
5 4
6
5
4
3
2
1b 7
1a
Z 54 040
56/105 140−1090−103b
Counterweight 9

(Z 54 040).
1. Set down counterweight base plate (1a) on the


7. Both counterweight sections (4 + 5) are now one unit.
8. Hang saddle weight (7 L + 7 R) into the counterweight
section (3) on the left− and right−hand side with both hooks
in the corresponding cast−iron pins.

140−1090−103b 57/105
9
Z 54 041
58/105 140−1090−103b
Counterweight 9
9.17.3 Fitting and Removal of the Counterweight

Combination
39.0 t (86 000 lbs)
The fitting procedure consists of two processes which follow

each other:
− setting down the counterweight combination on the crane
chassis (see section 9.17.3.1 from page 61).
− fitting and removal of the counterweight combination onto
and from the superstructure frame (see section 9.17.3.2,
from page 73).
All counterweight sections and saddle weights are always

marked (Z 54 041) with:
− Item no.
− Counterweight weight in kg / lbs
− Manufacturer ’s details
− Crane construction number
140−1090−103b 59/105
9
0.0
7.50
15
Z 54 042
60/105 140−1090−103b
Counterweight 9
9.17.3.1 Setting Down the Counterweight Combination on the

Crane Chassis
(Z 54 042).
1. Support the crane on outriggers and align. Select the

outrigger support area in accordance with the subsequent
crane operation.
RISK OF TIPPING!
If outrigger support areas are reduced, the maximum coun-
terweight that may be fitted is the largest one in the table
which corresponds to the configuration.
To do so, follow the corresponding details in the load ca-
pacity tables.
If a larger counterweight is fitted, there is a risk of tipping
backward during slewing.
2. Drive up counterweight element (s) on the low−loader up to

the crane.
3. Set the load limit device to the current load case. In order to
fit the counterweight elements the 0 t / 0 lbs tables must be
used.
You will find a detailed description on how to set the load limit
device to the current crane configuration via the mask for
operating mode preselection (Z 54 042) in section 10 “Safety
Devices”.
You will find a short description in this section from page 91.
140−1090−103b 61/105
9
17
18
1a 19
Z 54 043 Z 54 044
Z 54 045
62/105 140−1090−103b
Counterweight 9
(Z 54 043, Z 54 044, Z 54 045)

4. Using your own crane, attach counterweight base plate
3.66 t / 8 060 lbs (1a, Z 54 043) with 4 falls at the relevant
attachment points and position over the counterweight
support of the crane chassis (Z 54 044).
In this position (Z 54 045, principle depiction), the area of the
counterweight support is directly in front of the
superstructure cab on the crane chassis.
140−1090−103b 63/105
9
11
22
22 1b
1a
Z 54 046 Z 54 047
33
33 3
44
34 44 4
34
Z 54 048 Z 54 049
64/105 140−1090−103b
Counterweight 9
(Z 54 046, Z 54 047, Z 54 048, Z 54 049)
RISK OF ACCIDENTS!
You must take the safety instructions listed in the following
into consideration when attaching the counterweight ele-
ments!
All counterweight elements must be attached in the prescribed

attachment points. The attachment points are designed for the
individual max. dead weight of the counterweight elements. The
attachment points may not be loaded more than this. They are as
follows:
− Hanging hook (11) on the base plate (1a, Z 54 046).
− Hanging hook (22) on the cover plate (1b, Z 54 047).
− Pins (33) which are cast into cast−iron components, e.g. in
the counterweight section (3, Z 54 048).
− Bollards (34) which are cast into cast−iron components,
e.g. in the counterweight section (3, Z 54 048).
− Hanging eyelets (44) which are cast into cast−iron compo-
nents (44), e.g. in the counterweight section (4, Z 54 049).
Only use load handling attachments which are suitable for

the counterweight elements to be raised and are sufficiently
dimensioned.
It is especially important that only flat lifting slings made of
plastic are used for hanging for the cast bollards.
Make sure that the attached counterweight element is not

crooked and does not swing out.
The attachment points are designed for the dead weight of

the counterweight elements. Only individual elements may
be attached.
The exceptions are the counterweight base plate and the
cover plate as one unit and the counterweight sections
(4 + 5), which form a unit when pinned together (see sec-
tion 9.11.2., page 33).
If this is not adhered to, risk of accidents is increased!
140−1090−103b 65/105
9
17
18
19
Z 54 044 Z 54 050
18
1a
19
Z 54 051
66/105 140−1090−103b
Counterweight 9
(Z 54 044, Z 54 050, Z 54 051)
A trained assembly assistant must get on the crane chas-

sis in order to align and remove the counterweight ele-
ments (Z 54 050). He should get on by climbing up one of
the hinged ladders on the left− or right−hand side of the
chassis.
There is risk of crushing between the counterweight sec-
tion and the crane chassis and between the individual
counterweight elements! Proceed with appropriate cau-
tion! Maintain a sufficient safety clearance. Stay in the area
between the set down counterweight and the cab of the
crane chassis.
Persons must not stand or walk beneath suspended loads
If these instructions are not followed, the risk of accidents
is increased!
5. Position the base plate (1a) over the counterweight support

so that both spigots (18) are flush with the corresponding
central holes on the bottom of the base plate.
Then lower the base plate so that it is level on the
counterweight support. Spigots (18) determine the correct
position of the base plate (Z 54 044, Z 54 050).
A spigot (19) are needed for removing the combination base

plate (1a) with cover plate (1b). It helps to centre things when the
unit is removed.
The rear holders (17) protect bordering components from
damage when the counterweight sections are set down.
140−1090−103b 67/105
9
6R 6L
7L
4
7R
3
2
1b
1a
13
Z 54 052
68/105 140−1090−103b
Counterweight 9
6. As the base plate (1a) 3.66 t / 8 060 lbs is now fitted to the
crane chassis, all other counterweight sections are fitted to
this one or hung onto the side saddle weights one by one.
To do so, proceed as follows: (Z 54 052).
Risk of accidents! Risk of crushing!

There is risk of crushing between the counterweight sec-
tion and the crane chassis and between the individual
counterweight elements! Proceed with appropriate cau-
tion.
Take special care to follow all safety instructions listed pre-
viously in this section for attaching / removing the counter-
weight elements!
6.1 Using your own crane, attach cover plate (1b) 1.66 t /
4 390 lbs with 4 falls and position over the already
removed base plate (1a).
Lower cover plate (1a). Make sure that the draw bars
(13) are within the grooves of the cover plate (1b).
6.2 Using your own crane, attach counterweight section

(2) 7.92 t / 17 455 lbs with 4 falls and position over the
already removed cover plate (1b).
Lower section (2). Make sure that the draw bars (13)
are within the grooves of the section (2).

already removed section (2).
Lower section (3). Make sure that the draw bars (13)
are within the grooves of the section (3).

(4) 2.63 t / 5 800 lbs lbs with 4 falls and position over
the already removed section (3).
Lower section (4). Make sure that the spigots of the

section (3) dip into the centre holes on the bottom of
the section (4).
140−1090−103b 69/105
9
6R 6L
7L
4
7R
3
2
1b
1a
13
”X”
Z 54 053
70/105 140−1090−103b
Counterweight 9
(Z 54 053).

already removed section (4).
Lower section (5). Make sure that the spigots of the
the section (5).
Using single−hand locking pins (3x), pin the section (5)
to section (4).
6.6 Using your own crane, attach one of the two

counterweight sections (6L / 6R) 1.295 t / 2 855 lbs
with 2 falls and position over the section (5) which has
already been set down.
Lower section (6L / 6R). Make sure that the spigots of
the section (6L / 6R).
Proceed as previously described in order to fit the
second section.
6.7 Using your own crane, attach one of the two saddle
weights (7L / 7R) 4.01 t / 8 845 lbs with 3 falls and
position at the side of the counterweight section (3).
Hang saddle weight (7L / 7R) with both hooks in the
corresponding pins onto section (3).
Make sure that the hooks lie securely on the pins.
Proceed as previously described to hang the second
saddle weight.
If these two exterior saddle weights have been hung, the

procedure of setting down the desired counterweight
combination 39.0 t (86 000 lbs) onto the counterweight support
(see detail “X”) has been completed.
Make sure that all counterweight elements are correctly

fitted or attached.

After the desired counterweight stack has been set down
onto the counterweight support of the crane chassis, the
assembly assistant must leave the crane and the endan-
gered area. He should leave by using one of the hinged lad-
ders on the left−hand or right−hand side of the chassis.
Only then can the fitting procedure be continued as de-
scribed on the following pages.
140−1090−103b 71/105
9
180°
Z 54 054
min. 2o
Z 55 421
72/105 140−1090−103b
Counterweight 9
9.17.3.2 Fitting and Removing the Counterweight

Combination on the
Superstructure Frame
Requirements
− desired counterweight combination must be set down as

described in section 9.17.3.1 “Setting down the
Counterweight Combination on the Crane Chassis”, from
page 61.
− the crane operator has made sure that no−one is on the
superstructure or in the endangered area.

If these instructions are not followed, there is risk of crush-
ing as soon as a slewing movement is introduced.
Proceed as follows if these requirements are fulfilled:
(Z 54 054).
1. Call up mask (Z 54 054) on the monitor of the IC−1. It
appears after the ignition has been switched on and
confirmation of enquiry for the current configuration
(operating mode selection) has been called up automatically
or by corresponding navigation.
For detailed information see section 10 “Safety Devices”.
The relevant keys or display areas are marked in the individual

figures.
Risk of collision!
During the configuration of all counterweight combina-
tions and when turning the superstructure, there is a ”dan-
ger of collision” of the rear main boom drum with the coun-
terweight elements (Z 55 421), if the main boom was low-
ered to beforehand.
Therefore, turning the superstructure is only permissible if
the main boom is lifted up at least 2 ” when the counter-
weight elements have been placed on the counterweight
platform of the crane chassis.
Otherwise the cable reel will be damaged.
140−1090−103b 73/105
9
180
90 270
180° 0
360
Z 54 055
180
90 270
10°
0
360
Z 54 056
74/105 140−1090−103b
Counterweight 9
(Z 54 055, Z 54 056)
In the following, the movement ”Slewing” is to be driven.

Before introducing slewing for the first time, check how the
assignment of the control levers has been selected and
whether the slew gear has been switched in open or closed
circuit (see section 8 “Slewing”).
180° Before introducing the slewing movement, take the symbol with
the details of the corresponding slewing angle into consideration.
Starting point is 180° (Z 54 055), i.e. the superstructure is flush
with the crane chassis (situation after the counterweight
elements have been set down on the crane chassis). The crane
operator in the superstructure cab faces the direction of the cab
of the crane chassis.
Subsequently, it is to be slewed to the left.
The symbol consists of two arrows shaped as semi−circles

with the following meaning:
− left−hand half of the arrow − slew to the left
− right−hand half of the arrow − slew to the right .
These directions pertain to the movement that the crane operator

carries out using the cab (and not to the movement of the
superstructure frame in the back with the counterweight lift
cylinders).
The colour of each individual arrow halves determine which
slewing direction the crane operator can select:
both arrow halves are
− the crane operator decides
green:
left arrow half is green,
− only slew to the left
right arrow half is red:
left arrow half is red,
− only slew to the right
right arrow half is green:
− both arrow halves are red: slewing is not permitted.
2. Slew superstructure until a position of 0° / 360° ±10° has

been achieved (Z 54 056). The value of the slewing angle
which is to be driven is then:
− when slewing to the right: 350°
− when slewing to the left: 510≥
IN the following example, we will assume a slewing
movement to the left is being undertaken.
140−1090−103b 75/105
9
10°
Z 54 057
10°
Z 54 058
76/105 140−1090−103b
Counterweight 9
(Z 54 057, Z 54 058)
3. In mask “Quick Menu” (Z 54 057), press key
The mask “Configure counterweight” appears (Z 54 058).
The mask “Configure counterweight” contains all information

which is required in the following for fitting the counterweight.
The slewing angle symbol is identical with the same
symbol on the left−hand side of the monitor; however, it does
not indicate the current slewing angle in (°).
The slewing angle is only displayed in the mask “Configure

counterweight” for the range 0°/360° ± 5.0 ° in the bar display
under the slewing angle symbol .
Further fitting can be undertaken either automatically or

manually .
In order to improve comprehension of the connections, first
manual fitting is described in detail.
Automatic fitting is described in section 9.17.3.2.3. from page 97.
9.17.3.2.1 Manual Fitting

(Z 54 058).
If, as described above, the mask “Configure counterweight” is

opened after the quick menu has been selected, the
superstructure frame with the fitted counterweight is displayed in
the top left−hand corner. The counterweight configuration is
shown which was determined in the mask for operating mode
selection (here: 0t / 0 lbs).
Press button has a grey background and is not crossed

through and symbolises the operating mode “manual”. This
means that for the desired manual fitting procedure the correct
selection is already determined.
The status display is under this key (here: S:0). As this is only
relevant for internal control processes, it has not been taken into
consideration in the following description.
140−1090−103b 77/105
9
4.0°
Z 54 059
Z 54 060
78/105 140−1090−103b
Counterweight 9
(Z 54 059, Z 54 060)
1. Continue to slew the superstructure to the left until a slewing
angle of approx. 4.0 ° has been achieved. The slewing speed
is automatically reduced.
The mask “Configure counterweight” on the right−hand side
of the monitor is changed (Z 54 059).
As the value of the slewing angle is now also displayed in this

area, only the right−hand side of the monitor is shown in the
further description, i.e. the mask “Configure counterweight”
(Z 54 060).
The set counterweight configuration is no longer displayed

in the top left−hand corner, instead only the superstructure
frame with the counterweight lift cylinders and the
counterweight base plate with the draw bars are shown. The
following processes can be illustrated very well using these
components.
This depiction does not depend on the actual counterweight
combination to be fitted.
The current value of the slewing angle is indicated in the

slewing angle display under the slewing angle symbol
by using a horizontal bar (here: °
The slewing angle symbol itself indicates whether

slewing is permitted and in which direction.
The depicted symbol represents the luminous pushbutton in

the superstructure cab for lowering ( ) / raising ( ) the
counterweight hoist cylinders. Both arrows indicate with their
colour which movement is possible or permitted:
− arrow green: movement possible / permitted
− arrow red: movement not possible / permitted.
140−1090−103b 79/105
9
13 38 13 3
71
−1,0
+1,0
4 + 1,0
Z 54 061 Z 52 979
10% 10%
Z 54 062
80/105 140−1090−103b
Counterweight 9
For all counterweight combinations for the described fitting

procedure the counterweight lift cylinders may only be
lowered in exactly this position 4 1.0. This range in the
slewing angle display has a green background.
Only this can ensure that the counterweight lift cylinders are
extended down through the kidney−shaped grooves (38) of
the counterweight sections (here: 3, Z 54 061) into the
counterweight stack and that they cannot collide with the
brackets (13) of the base plate.
This is monitored by the control system − also in the manual

operating mode. It will only be permitted to extend the
counterweight lift cylinders (symbolised by “ ”), if a
position has been achieved in the area permitted therefore.
(Z 52 979, Z 54 062)
2. Extend counterweight lift cylinders. To do so, press luminous
pushbutton (71) in the bottom half and hold in this position.
This is symbolised on the monitor by the a grey background
behind the corresponding symbol.
At the status display of the counterweight lift cylinders, the

10 % 10 % top horizontal line (as display for counterweight lift cylinders
completely retracted) is is replaced by (as display for
extending counterweight lift cylinders). The percentage
(here: 10%) is changed successively from 0% (completely
retracted) up to approx. 98% −100% (completely extended).
140−1090−103b 81/105
9
Z 54 063
Z 54 064
82/105 140−1090−103b
Counterweight 9
(Z 54 063).
If the counterweight lift cylinders are completely extended, the

display changes accordingly. The mushroom−shaped ends of
the piston rods of the counterweight lift cylinder are on the side
next to the accordingly shaped receptacles of the draw bar of the
counterweight base plate.
The percentage display (here: 98%) does not change any more.
The arrow between both cylinder symbols has disappeared and
instead the bottom horizontal line is shown which symbolises that
the counterweight lift cylinders are completely extended.
If the counterweight combination does not just consist of the base

and cover plate, the counterweight lift cylinders are within the
counterweight stack. This is symbolised by .
Subsequently, slewing takes place within the counterweight
stack.
(Z 54 064).
3. Slew superstructure from the current position 4.0° ±1.0° in
the direction 0°/360°, in this example to the left. The slewing
speed is automatically reduced.
Observe the angle indicator. As soon as position 0°/360° has
been achieved, stop slewing movement. The angle indicator
indicates 0°.
The depiction changes. The mushroom−shaped ends of the

piston rods of the counterweight lift cylinder retract into the
accordingly shaped receptacles of the draw bars of the
counterweight base plate.
Only in this 0°/360° ±0.1° position is it permitted to raise the

counterweight combination. The arrow pointing upwards
( ) at the corresponding symbol must be green.
140−1090−103b 83/105
9
71
Z 52 979
85 % 85 %
35 bar
Z 54 065
84/105 140−1090−103b
Counterweight 9
(Z 52 979, Z 54 065)
4. Retract counterweight lift cylinders in order to raise the
counterweight combination. To do so, press the top half of
luminous pushbutton (71) and hold in this position. This is
symbolised on the monitor by the a grey background behind
the corresponding symbol.
At the status display of the counterweight lift cylinders, the

85 % 85 % top horizontal line (as display for counterweight lift cylinders
completely extended) is is replaced by (as display for
retracting counterweight lift cylinders). The percentage
(here: 85%) is reduced successively.
p= 35 bar The pressure display indicates the pressure in the

counterweight lift cylinders and changes depending on the
mass of the attached counterweight combination (here:
35 bar / 508 psi).
140−1090−103b 85/105
9
71
Z 52 979
57 % 57 %
153 bar
Z 54 066
86/105 140−1090−103b
Counterweight 9
(Z 52 979, Z 54 066)
5. Press luminous pushbutton (71) until raising is switched
off. Engine speed is reduced.
Authorisation for slewing is given as soon as the

counterweight combination is raised to a sufficient height
over the crane chassis, but before the top end position has
been reached. However, raising must be completed as
described above.
The depiction changes. At the superstructure symbol, the

counterweight combination is shown which was determined
in the mask for operating mode selection (here: 0t / 0 lbs).
At the status display the counterweight lift cylinder is (as

display for retracting counterweight lift cylinders) replaced by
a horizontal line at the top (as display for counterweight lift
cylinders retracted in the highest possible position). The
percentages (here: 57%) do not change any longer.
The percentages cannot go back to 0% as the retraction

movement of the counterweight lift cylinders is limited due to the
driving of the upper rim of the draw bars (or the highest
counterweight section) against the bottom rim of the
superstructure frame.
140−1090−103b 87/105
9
10
10
10
10
3 9 6R
9 10
6L 5 4
Z 54 067
10
6R
13
10
14
6L
1a
Z 54 068
88/105 140−1090−103b
Counterweight 9
(Z 54 067, Z 54 068)
This completes the actual manual fitting / raising of the counterweight

combination (here 39 t / 86 000 lbs) to the superstructure frame.
However, before a slewing movement can be carried out, the crane
operator must pin the top counterweight sections and with a visual
inspection make sure that the following conditions have been met.
Conditions: Counterweight combination completely raised and

pinned
5.1 Both of the top counterweight sections (6L + 6R) must be fitted
evenly to the supporting consoles of the superstructure frame in the
pinning position (see arrows in figure “Z 54 067”). Each section
must be pinned with 3 single−hand locking pins (10).
5.2 The counterweight section (5) must be pinned to the superstructure
frame with 2 pins (9) and each pin must be secured with a clip pin.
5.3 The counterweight section (4) must be pinned to the section (5) with
3 single−hand locking pins (10).
5.4 The counterweight section (3) must lie flat on the section (4). The
2 centring pins of the section (3) are dipped into the centre holes
of the section (4).
5.5 For counterweight combinations (here 6.3 / 13 900 lbs) which are
smaller than the one described in the fitting procedure above, the
draw bars (13) of the base plate (1a) must be fitted to the
superstructure frame (see arrows in figure “Z 54 068”).
The top counterweight sections are pinned as previously
described.
The mushroom−shaped ends (14) of the piston rods of the
counterweight lift cylinders must lie in the centre in the
corresponding receptacles of the draw bars (13).
RISK OF ACCIDENTS!
No crane movement may be initiated if not ALL of the previously
listed conditions are fulfilled! If necessary, the fitting / raising pro-
cedure must be repeated!
Check regularly to ensure that the raised counterweight has not

lowered itself on its own (for example, due to extreme temperature
shifts after the machine has stood still for a longer period of time
or due to leaks). In such a case, completely raise the counterweight
again.
140−1090−103b 89/105
9
57 % 57 %
0° 153 bar 0°
Z 54 069 Z 54 070
0.0
7.50
15
Z 54 071 Z 52 988
90/105 140−1090−103b
Counterweight 9
After the actual fitting of a counterweight combination, the load

limit device must be set immediately in accordance with the
modified configuration.
RISK OF ACCIDENTS!
If the load limit device is not adapted to the actual crane
configuration, no crane movement is permitted!
(Z 54 069, Z 54 070)
1. Press button and then key . You will enter the
mask for operating mode preselection (Z 54 071).
(Z 54 071).
2. Once you have entered the mask for operating mode
preselection, select the actually fitted counterweight.
To do so, open the counterweight in the corresponding field
using the pull−down−menu and select actual fitted
counterweight (here: 39.0 t / 86 000 lbs).
(Z 54 071, Z 52 988)
3. In order to confirm the modification, quit the mask via .
While the preparation procedure is proceeding, mask
(Z 52 998) is displayed.
If your selection does not become active, press key .
140−1090−103b 91/105
9
0°
Z 54 072
57 % 57 %
0° 153 bar
Z 54 073
92/105 140−1090−103b
Counterweight 9
(Z 54 072, Z 54 073)
4. After preparations have been completed, mask (Z 54 072)
appears. If key is pressed in this mask, the mask
“Erect counterweight” is displayed in the modified
configuration (Z 54 073).
The counterweight combination, here: 39.0 t (86 000 lbs), is
depicted and it is permitted to slew in both directions.
Press key you return to the starting mask (Z 54 072).
5. Check crane levelling, if necessary, repeat procedure(see

section 12, Outriggers, in the operating instructions of the
crane chassis).
RISK OF ACCIDENTS!
Before the superstructure may be slewed or a load may be
attached, the load limit device must be set to the current
crane configuration and the crane must be levelled cor-
rectly.
Bridging control
Even in manual operation only movements (slewing, lower / raise

counterweight lift cylinder) are permitted which have been
authorised by control.
You must bridge in order to cancel surveillance by control.
This may be done − but only in exceptional cases − for
example, if there is a fault.
Risk of damage !
When bridged, control does not monitor anymore. Only the
crane operator decides which movements are safe and
therefore can be carried out.
This is why only the crane operator may bridge if he is ac-
quainted with the counterweight assembly in accordance
with the operating instructions and he is aware of the exist-
ing dangers.
If, as an exception, assistants must get back on the crane
for trouble shooting, there is RISK OF CRUSHING!
140−1090−103b 93/105
9
10°
Z 54 074 Z 52 990
0% 0%
10° 0 bar
Z 54 075
94/105 140−1090−103b
Counterweight 9
(Z 54 074, Z 52 990, Z 54 075)
1. In order to bridge control press the depicted key in mask

(Z 54 074). Mask (Z 52 990) is displayed which expressly
warns the crane operator of existing dangers.
If you then do not want to bridge, you can cancel by pressing

key “Return”. The starting mask (Z 54 074) then appears
again unchanged.
If existing dangers are consciously risked, press key

“Continue”. Only then will bridging actually be activated.
The bridged state is shown in two places. On the right−hand

side of the monitor, the originally pressed key changes to a
warning symbol with a red frame (Z 54 075).
In addition, the displayed warning symbol appears on the

left−hand side of the monitor (Z 54 075).
This ensures that the bridged state is always displayed, even
when the mask “Erect counterweight” is quit (the state
“bridged” remains).
2. Press the displayed key again in order to cancel bridging.
The symbol changes back to the state “not bridged”.
The warning symbol on the left−hand side of the monitor
disappears (Z 54 074).
9.17.3.2.2 Manual removal
As with the fitting procedure, the following basic requirements

must be satisfied:
− Support the crane on outriggers / align
− Set the load limit device (0 t / 0 lbs tables).
The equipment is removed as it is fitted, in the reverse order.
140−1090−103b 95/105
9
10°
Z 54 076
96/105 140−1090−103b
Counterweight 9
9.17.3.2.3 Automatic fitting
In the case of automatic fitting, the crane operator is only

minimally involved in the procedures. For this reason, the
following description is not in great detail.
You will find details which will improve understanding of the
procedures in section 9.17.3.2.1“ Manual Fitting”, from page 77.
For the numerous additional general rules and regulations that

are also relevant to automatic fitting, reading of this chapter is
required. Such points include:
− Allocation of the control levers
− Slewing directions
− Navigating on the IC−1
− Explanation of the symbols in the mask “configuring the
counterweight” (Z 50 076).
The starting condition is as described from page 73 to page 77.
(Z 50 076).
1. In the mask “configure counterweight” press . The
symbol changes to and is highlighted in green.
The automatic operating mode is then selected.
Automatic mode can only be selected when the counterweight lift

cylinders are retracted as far as possible.
140−1090−103b 97/105
9
98/105 140−1090−103b
Counterweight 9
2. Actuate the corresponding control levers so that the

superstructure turns out of the 10°/350° position further in
the direction 0°/360°. Hold the control lever in the extended
position.
For the position of 10° taken in the example, this means:
Slew to the left.
This determining of the slewing direction by corresponding

movement of the control lever and holding the control lever
in this position, are the only movements that need to be
actively carried out by the crane operator. The remaining
procedure is then carried out automatically and can be
observed on the screen.
The automatic process can be interrupted at any time by

releasing the control lever and can be reinstated by
actuating the controls again.
After the control lever is actuated for slewing, the control system
checks by means of sensors to see if the counterweight is fitted
or not and then carries out the corresponding procedure (here:
fitting).
In automatic operation the slew gear works in closed circuit (see

section 8). This setting cannot be changed.
To ensure sufficient sensitivity, the engine speed is regulated by
the control system.
140−1090−103b 99/105
9
10°
Z 54 076
100/105 140−1090−103b
Counterweight 9
When the control lever is actuated the following steps are carried
out automatically:
− Slew to 4.0 1.0°±°.
− Extend the counterweight lift cylinders into the counterweight
stack.
− Slew to 0° with the lowered counterweight lift cylinders within
the counterweight stack.
− Raising the counterweight stack into the end position.
(Z 54 076).
3. When the movement is switched off and the engine speed
has been reduced, release the control lever, i.e. place in the
neutral position.
The symbol for automatic operation changes back to
the symbol “manual” .
The actual automatic fitting procedure is concluded.
As with the manual fitting procedure, certain additional tasks

must still be carried out:
− Check that the counterweight combination has been
completely raised.
− Check that the counterweight combination is located central
to the superstructure frame.
− The top counterweight sections must be pinned, see the
detailed description under point 5.1 to point 5.5, page 89.
− Set the load limit device to the changed crane configuration.
− Check the crane levelling.
Observe the corresponding description from page 89 to page 93.
RISK OF ACCIDENTS!
Crane movements may only be carried out once all tasks
have been completed.
Bridging of the control with automatic fitting is identical to bridging

in manual operation. If required, follow the corresponding
description on page 95.
140−1090−103b 101/105
9
−1,0
+1,0
4 + 1,0
Z 54 077
102/105 140−1090−103b
Counterweight 9
Special case
(Z 54 077).
If the automatic system is not activated in the superstructure

position of approx. 10 / 350 − as specified in point 2., page 75
− a differentiation must be made between two different cases:
− 1stcase: Position 4/356 1.0
This is the range in which lowering of the counterweight lift

cylinders into the counterweight stack is permitted.
A differentiation must then be made with regard to the
selected slewing direction:
∗ Selected slewing direction 0°/360° (e.g. for starting
position 4°: slew to the left);
after actuating the control lever the automatic fitting
procedure is carried out as previously described; only the
first step “slew to 4 1.0°±°” is omitted, as this position has
already been reached.
∗ Selected slewing direction opposite the direction 0°/360°
(e.g. for starting position 4°: slew to the right);
after actuating the control lever, the counterweight lift
cylinders also move into the counterweight stack; however
further slewing in this direction is then no longer
possible/permitted within the counterweight stack − this
would lead to a collision between the counterweight lift
cylinders and the counterweight stack. The fitting
procedure is not continued.
For this reason, the control lever must be moved in the
opposite direction. Only then is the remaining procedure
carried out automatically.
− 2nd case: Position 0 3.0
After actuating the control lever, the superstructure first

moves in the selected direction until a position of 4/356 1.0
°°±°is reached; the counterweight lift cylinders then move into
the counterweight stack.
Within the counterweight stack, the equipment can then no
longer be turned in this direction. The fitting procedure is not
continued.
For this reason, the control lever must be moved in the
opposite direction. Only then is the remaining procedure
carried out automatically.
140−1090−103b 103/105
9
104/105 140−1090−103b
Counterweight 9
9.17.3.2.4 Automatic removal
Automatic removal is the same as automatic fitting, only in the

reverse order.
The following requirements must be satisfied:
− Crane supported on outriggers and correctly aligned.
− The load limit device must be set correctly (0 t / 0 lbs table).
− Position 10°/350° selected.
If the automatic system is then activated and the control lever

actuated for slewing, the control system checks by means of
sensors whether the counterweight is fitted or removed and then
carries out the required procedure (here: removal).
The following steps are then carried out automatically:

− Moving to the 0° position.
− Lowering the fitted counterweight combination onto the
counterweight support.
− Turning within the counterweight stack to 4/360 1.0°°±°.
− Complete raising of the unladen counterweight lift cylinder.
After releasing the control lever the automatic removal procedure

is ended.
9.17.3.3 Removing the Counterweight Combination from the

Crane Chassis.
The counterweight combination is removed from the crane

chassis is the same way as it is set down, just in the opposite
sequence (see section 9.17.3.1, from page 61).
In any case the following requirements must be satisfied:
− Crane supported on outriggers and correctly aligned.
− The load limit device must be set correctly (0 t / 0 lbs table).
140−1090−103b 105/105
Safety Equipment 10
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Z 56 930
2/161 140−1100−181_en
Safety Equipment 10
10 Safety Equipment
(Z 56 930)
10.1 IC−1 crane control
The crane control IC−1 (Intelligent Control System) combines se-

veral devices which provide the crane driver with essential infor-
mation for operating the crane within the parameters specified by
the manufacturer:
− Overload cut−off device (load limit device LLD)

− Telescoping Information System
− Display of numerous crane functions, for example, support
pressure, tilt, crane configuration, lifting capacities etc.
− Warning (optical and acoustic) in case of prohibited condi-
tions.
This crane control (incl. load limit device) is an operating aid. It

provides the crane operator with essential information concer-
ning crane data such as length and angle of the boom, sheave
head height, nominal lifting capacity, the total load suspended
from the boom, etc. and gives warning when an overload condi-
tion is being approached or when the hook block gets too close
to the boom head.
This safety device is no substitute for the judgement and ex-

perience of the crane operator and use of recognised safe
operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility for
safe operation of the crane.
140−1100−181_en 3/161
10
0,0°
LMB
Z 54 751
4/161 140−1100−181_en
Safety Equipment 10
10.1.1 Load limit device (LLD)
10.1.1.1 Function
(Z 54 751)
If, when raising a load or increasing the working radius with load,
the permissible load moment/the permissible load is exceeded,
both the movements which increase the load moment and the
movement which decreases the load moment ”Raise luffing gear”
and ”Raise load on hook” are disabled. ”Lower load on hook” is
permitted.
A continuous tone sounds and the Stop symbol appears.
The warning message LLD appears (red). In addition, the colour
of the bar display (C) changes from yellow to red. Lifting of loads
is not permitted!
After a shutdown by the load limit device, only movements which
decrease the load moment may now be initiated.
RISK OF ACCIDENTS!
It is absolutely forbidden to override the load limit device
to overload the crane above its load bearing capacity!
Lifting a load with the load limit device overridden is prohi-
bited!
The load limit device should only be activated in an emer-

gency situation. Under no circumstances may it be used as
a standard operating tool!
This means that the crane operator must be satisfied, before
hoisting the load, that the load bearing capacity of the crane
is not exceeded by the load to be lifted. Loads that are too
heavy and exceed the load bearing capacity of the crane
must not be accepted, even if there is a load limit device in-
stalled!
Even without a load, the boom may only be moved in those

ranges where load bearing capacities are specified.
Before a load is raised, its weight must be known. The safety de-
vice may not be used to determine the weight.
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10
6/161 140−1100−181_en
Safety Equipment 10
To ensure that the load limit device functions properly, it must:

− be set by the crane operator in accordance with the crane
configuration before work is commenced (as soon as the
configuration is achieved) after the ignition/engine is swit-
ched on.
− reset by the crane operator in accordance with the new ope-
rating mode once the crane configuration has been changed.
This is set by selecting the operating mode (detailed des-

cription as of p.).51
Only when the load limit device has been correctly set by the
crane operator in accordance with the current operating
mode/crane configuration, can it operate automatically.
The crane operator is responsible for the correct setting by
acknowledging the crane configuration.
Danger of accident − limits of the load limit device!

Despite a functional load limit device that is correctly set in
accordance with the crane configuration, the load limit de-
vice can become ineffective in particular cases/operating
errors:
− insufficient load bearing capacity on the ground used for
the set−up site of the crane
− support errors
− not switching on the prescribed telescoping sequences
− influence of the wind
− diagonal pull
− dynamic influences, e.g. by crane movements that are
too fast and end with an abrupt stop
− dismounting work, if loads are unscrewed/burnt off after
slinging, then hang loosely from the crane and prove to
be too heavy
− lifting overloads with the luffing gear
− co−operation of several cranes.
The crane operator must observe these system limits
when setting up and operating the crane!
140−1100−181_en 7/161
10
8/161 140−1100−181_en
Safety Equipment 10
The load may only be taken up by the hoist in hook opera-

tion.
If the load is still in contact with the ground and raising of
the hoist has been switched off, the load is too heavy. In this
case, activating the ”Lift main boom” movement is not per-
mitted!
This movement is not to be used to lift the load under any
circumstances!
It is essential for the operating safety of the crane that the

IC−1 crane control functions in its original condition.
Necessary updates can be obtained from the after−sales
service department of the crane manufacturer.
Danger of crushing!
The swinging−out of the load during switch−off cannot al-

ways be avoided, even with the use of automatic safety de-
vices!
It can be avoided only by all crane movements being car-
ried out at appropriate speeds.
Also take note of the continuous display of the load mo-
ment with preliminary warning at 90% of the permissible
load moment prior to switch−off.
Risk of crane control system being influenced!

The risk of the load limit device being influenced by high−
frequency radiation is minimised by the latest technology
(shielding). It cannot, however, be completely excluded − in
particular under extreme conditions, for example near po-
werful transmitters.
See in particular the instruction ”High−frequency radia-
tion” in Section 1.4.3 ”Special safety instructions”.
140−1100−181_en 9/161
10
115
116
Z 54 599
LMI
0,0°
Z 54 752
10/161 140−1100−181_en
Safety Equipment 10
10.1.1.2 Bridging load limit device
10.1.1.2.1 Bridging shutdown of movement which decreases

the load moment ”Raise luffing gear”
(Z 54 599, Z 54 752)
If a prohibited overload condition has occurred, the load−mo-

ment−reducing movement ”Raise luffing gear” is also shut down
by the load limit device. Only lowering of the load on the hook is
permitted.
Once an overload condition has been switched off by the load li-
mit device, load moment reducing movements can be carried out
to move a freely suspended load out of the overload range
again, back into the normal operating range. In this case the key−
operated pushbutton (116) must be pressed. Indicator light (115)
lights up.
The status display ”LLD” (or LMI) changes from red to black on
the IC−1 display.
The override can only be initiated if the control levers are in

the neutral position and/or the initiated crane movement is
finished.
RISK OF ACCIDENTS!
This load moment reducing movement may only be ena-
bled if it does not present a hazard. Make sure that this is
the case before pressing the key−operated pushbutton.

the hoist has been switched off, the load is too heavy. In this
case, activating the ”Raise luffing gear” movement is not
permitted!
This movement is not to be used to lift the load under any

circumstances!
Danger of falling backwards!

In some cases, enabling the movements which reduce the
load moment is not permissible.
This is the case, for example, if ”Raise luffing gear” is swit-
ched off due to the permissible minimum radius being re-
ached.
In this instance, bridging is not allowed and the load−mo-
ment−reducing movement ”Raise luffing gear” cannot be
continued, because the crane could tip over backwards.
140−1100−181_en 11/161
10
111
112
Z 55 101
LMI
0,0°
Z 54 752
12/161 140−1100−181_en
Safety Equipment 10
10.1.1.2.2 Bridging the shutdown of all movements

(Z 54 752, Z 55 101)
The load limit device can be overridden using key−operated

pushbutton (112).

finished.
The button must be turned in the clockwise direction and held in

this position.
When overridden, indicator light (111) lights up.

The status display ”LLD” (or LMI) changes from red to black on
the IC−1 display.
The load limit device may only be overridden in exceptional

cases, for example in case of repairs, fitting a rope etc.
This can only be done by authorised personnel who are fa-
miliar with the operation of the crane!
The bridging of the load limit device may not be used to in-
crease the load moment under any circumstances.
Lifting a load with the load limit device overridden is prohi-
bited!
140−1100−181_en 13/161
10
64
64.1 64.11
64.2 64.12
64.3 64.13
64.4
64.14
64.15
64.6
64.7
64.8 64.16
63
64.19
Z 56 931
14/161 140−1100−181_en
Safety Equipment 10
10.1.2 Control and display elements

(Z 56 931)
(63) − Adjustment toggle for adjusting inclination of the display

(64) − IC−1 display
This display has a large colour monitor to enable the in-
formation shown to be read easier. The brightness ad-
justs itself automatically to the ambient conditions.
All keys are activated by tapping the symbol (touch
screen) directly with the finger.
An exact description can be found on the following page
under Section 10.1.3 ”Operating the IC−1”.
RISK OF DAMAGE!
Adhesive materials may not be affixed to the monitor! Moun-
ting stick−on labels would destroy the monitor (touch-
screen)!
You will get the best results when cleaning the monitor by using
a clean, damp, non−abrasive cloth and any commercially−availa-
ble window cleaning agent without ammonia. The window clea-
ning agent should be applied to the cloth first instead of directly
onto the surface of the monitor.
(64.1)− On/Off switch

For rebooting the IC−1 when necessary: switch off igni-
tion, wait at least 30 s, press switch for at least 3 s.
Switch ignition on again.
(64.2)− key: brightness ”+” (manual)
(64.3)− key: brightness ”−” (manual)
(64.4)− key not allocated
140−1100−181_en 15/161
10
64
64.1 64.11
64.2 64.12
64.3 64.13
64.4
64.14
64.15
64.6
64.7
64.8 64.16
63
64.19
Z 56 931
16/161 140−1100−181_en
Safety Equipment 10
(Z 56 931)
(64.6)− lamp: temperature warning
If the temperature in the computer is lower than 05 C (325 F), the

LED lights up red and the computer is heated internally. When the
temperature is more than 0 5 C (325 F), the computer starts auto-
matically. The heating procedure can take between one and eight
minutes, depending on the outside temperature.
The computer is ready for use as soon as the red LED (temp,
64.6) goes out and the green LED (power, 64.8) illuminates.
If the display cancels the operation (monitor goes black) and at
the same time the temperature warning light comes on, then the
ambient temperature may be too high. The cab will then need to
be cooled down with the air conditioner. As soon as the tempera-
ture has once again fallen to an acceptable level, the display will
attempt once again to dial into the CAN network.
(64.7) − lamp: hard drive access
(64.8) − lamp: operating condition
(64.11)− key: move the mouse cursor upwards
(64.12)− key: move the mouse cursor downwards
(64.13)− key: move the mouse cursor to the left
(64.14)− key: move the mouse cursor to the right
(64.15)− key: switch key/mouse operation on/off
(64.16)− key: trigger one mouse−click (touch pressure)
(64.19)− USB connections on the underside of the display. If

these are to be used, then the display should first be
taken out.
140−1100−181_en 17/161
10
Z 54 753
18/161 140−1100−181_en
Safety Equipment 10
10.1.3 Operating the IC−1

(Z 54 753)
For this system, all functions are operated by ”tapping” the keys
or buttons shown on the monitor (touchscreen).
By tapping a key/active button, a selection window is opened for

parameter selection (1), or the display changes to another selec-
tion window.
When opening a selection window, a list of selection options
(pull−down menu) appears in the selected area. A value must
then be selected from the selection list. If the set value is not to
be modified, then the previous value must be selected again from
the selection list.
The values selected are always dependent on the previously se-

lected settings. If, for example, crane mode is selected without
main boom extension, then no values are offered for setting the
parameter with main boom extension. These keys then only ap-
pear ”grey”. All parameters which can be set appear on a key in
a black frame.
In principle, the following applies:

”Save” symbol:
Diskette selected setting is saved, and the display is
changed
”Exit” symbol:
Door the display is left without saving the modi-
fied settings
The displayed value must be changed or, at
”Red” en- least, confirmed by tapping. Otherwise, the
tries settings for the crane mode can not be sa-
ved.
Operation at ambient temperatures in excess of 50C

(122F)
To avoid malfunctioning of the display, the air conditioner should

be used to cool the cabin both before and during crane opera-
tions when ambient temperatures are in excess of 50° C (122° F).
Direct sunlight should then be avoided on the display.
An appropriate cooling−down stage should be prescribed if ne-
cessary for the period before work begins.
140−1100−181_en 19/161
10
STOP STOP
Z 54 754 Z 54 755
39,0
7,50
Z 54 756
20/161 140−1100−181_en
Safety Equipment 10
10.1.4 System start/Switching the system off

(Z 54 754, Z 54 755, Z 54 756)
The IC−1 is automatically started when the ignition is switched

on. At the same time, a system check is made automatically. De-
pending on the temperature of the computer (monitor), the dis-
play of the previously set crane status with the ”CAN initialisation”
screen positioned above it appears after an appropriate warm−
up time.
Momentary ”error” displays appearing during the automatic

check serve to test the functional reliability of the system, and are
of no importance to you.
If the computer is recognised by the PLC within 30 s, the CAN in-

itialisation screen closes automatically. The CAN status in the up-
permost line changes to ”OK”.
The CAN status can have the following conditions:
STOP crane operation not permissible
a subscriber is missing, but not relevant
OK crane operation permissible
If CAN initialisation is not initialised within 30 s, the screen is not

closed automatically. The two keys and ”CAN reset” are acti-
vated and must be actuated manually:
1. Option: actuate ”CAN reset”: the initialisation is restarted. If

that doesn’t work:
2. Option: actuate: a screen appears (Z 54 756) for selec-

ting the operating mode in non−active status. That means that an
entry is not possible for the ”type” field, so crane operation is not
permissible.
The existing error must be located − for example, with the help
of diagnostics screens − and removed. It is only then that the in-
itialisation can be restarted.
”Operating mode selection” (Z 54 756) screen appears after the

CAN initialisation is completed.
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10
39,0
7,50
Z 54 756
0,0°
Z 54 757
22/161 140−1100−181_en
Safety Equipment 10
(Z 54 756, Z 54 757)
If the assembly or operating condition remains unchanged, the

screen can be exited via (54 756) .
If the assembly or operating condition has been changed, the

specifications in the screen must be adjusted accordingly
(Z 54 756). In order to be able to transfer the modifications to the
control system, the screen must be exited in this case via .
In both cases, the ”Crane operation” screen then appears

(Z 54 757).
A detailed description on selection of operating mode can be
found in Section 10.1.7.4.1, from page 51, and on ”Crane opera-
tion” in Section 10.1.5, from page 27.
As a starting point for using the IC−1 functions, the most impor-
tant screens are ”crane operation, (Z 54 757)” − and specifically
area ”e”, the screen ”Quick Menu” (see Section 10.1.5.5, from
p.35) − and the screen ”main menu (see Section 10.1.6, from
page 39).
Using these screens the desired functions can be selected by cal-

ling up the corresponding submenus (see Section 10.1.7, from
page 43).
140−1100−181_en 23/161
10
Z 54 537
24/161 140−1100−181_en
Safety Equipment 10
Power control
(Z 54 537)
When the electric power supply fails, or after switching off the
ignition, the display changes automatically to the ”Power control”
screen. The remaining time (starting at 15 min.) up to switching
off the computer is displayed here. If the ignition is switched on
again within this time, the display changes directly to the ”Opera-
ting mode selection” screen. IC−1 is immediately ready for use
again.
The ignition can be checked after three minutes. If the ignition is

switched on and then switched off directly after, it can take ap-
prox. three minutes until the ”Power control” screen is selected.
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10
B C
0,0°
Z 54 758
0,0°
1 2 3 4 5 6 7 8 9 10 11
12
Z 54 759
26/161 140−1100−181_en
Safety Equipment 10
10.1.5 ”Crane operation” screen

(Z 54 758, Z 54 759)
The ”Crane operation” screen appears automatically after actua-

ting the ”Operating mode selection” screen. It is the display for
normal work with the crane. All current and selected crane para-
meters are shown in it.
The ”Crane operation” screen is divided into five sections. At the

same time, the contents of the Sections ”A” to ”D” are fixed.
Section ”e”, on the other hand, can − as and when required − be
assigned with different contents/screens.
10.1.5.1 Section (A): display of current loading information
(1) − Designation of the type of operating mode:

HA − Main boom
HA−0 − Main boom − special case 0° (to the rear)
MBE − Main boom extension
MS − Runner (assembly top section)
HA−RSV − Configuring the front supports (optional)
(2) − counterweight
(3) − outrigger span
(4) − reeving number
(5) − longitudinal code no. LC
(6) − status of the superstructure lock (for detailed information,
see Section 8 ”Slewing”)
(7) − CAN bus status (for detailed information, see page)21
(8) − permissible slewing range
(9) − configuration of the control lever (for detailed information,
see page)69
(10) − warning buzzer
After the warning buzzer sounds, it can be acknowledged
by pressing the loudspeaker symbol, and is switched off
in doing so.
(11) − time
(12) − software version
RISK OF ACCIDENTS!
The displayed values must comply with the actual crane
status. If this is not the case, crane operation is not permis-
sible. The operating mode must be reset. This is described
in Section 10.1.7.4.1””, from page 51.
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10
B C
0,0°
1 2 3 4 C
Z 54 760
28/161 140−1100−181_en
Safety Equipment 10
10.1.5.2 Section (B): display of load and radius

(Z 54 760)
(1) − Net load

By pressing the ”Net” button, the current load is tared (see
Section 10.1.9 ”load monitoring device”, from p. 139).
(2) − Maximum load (for the set crane configuration)
For loading in the longitudinal code (LC 1), the loading
symbol appears instead of the maximum is dis-
played. It is then prohibited to raise loads (see Sec-
tion 10.1.8 ”Configuration mode”, p. 137).
(3) − Current total load (gross load)
This includes load, hook block, all lifting tackle and, if ap-
plicable, additional device attached.
(4) − Current radius
10.1.5.3 Section (C): loaded display

(Z 54 760)
Continuously changing display of the load moment as ”bar dis-

play” with superimposed display percentage/overload display.
For loading in longitudinal code (LC 1), the whole field (C) is
shown in red with 3 stars instead of the bar display .
Raising of loads is prohibited (see Section 10.1.8 ”Configuration
mode”, p. 137).
A warning buzzer sounds when the prewarning range

(90−100% of the max. permissible load moment) is reached, and
a warning symbol appears in Section ”D” (see following
page). In addition, the colour of the bar display changes from
green to yellow.
When the overload range is reached, the load limit device shuts
down movements which increase the load moment and ”Raise
luffing gear”. A continuous tone sounds and the Stop symbol
appears in Section ”D” (see following page). In addition,
the colour of the bar display changes from yellow to red. Lifting
of loads is not permitted!
In order to indicate the actual rating of the max. permitted load

moment additionally outside the crane cabin there is a warning
light (option). It is shown and described in Sect. 4 “Cabin”.
140−1100−181_en 29/161
10
0,0°
1 2 3 4 5 6 7
8
9
28
10
11
27
12
13
26
25 15
16
24
17
18
23
22 21 20 19
Z 54 761
30/161 140−1100−181_en
Safety Equipment 10
10.1.5.4 Section (D): display of status information on crane

condition
(Z 54 761)
(1) − ”Error” display: is superimposed when an error occurs

(2) − ”HES (red)”: lifting limit switch triggered, and not bypas-
sed
”HES (black)”: lifting limit switch bypassed, regardless
whether triggered or not
(3) − ”SES (red)”: lowering limit switch triggered, and not by-
passed
(4) − Emergency operation (optional) is active (see Section 36)
(5) − ”LLD (or LMI) (red)”: load limit device is switched off, and
is not bypassed
”LLD (or LMI) (black)”: , load limit device is bypassed, re-
gardless whether it is switched off or not;
simultaneously appears (also see item ”8”)
(6) − Reading below min. permissible outrigger pressure
(< 1 t)
(7) − Current wind speed
(8) − Fade−in of different symbols:
: Prewarning range; 90%−99% of the permissible
crane load reached

: − Load limit device is switched off
− Load limit device is bypassed
: Load capacity table being loaded; only appears
for a few seconds; crane operation is not
permissible during this time
(9) − Counterweight control overridden (see Section 9 ”Coun-
terweight”)
(10) − Current tilt (see Section 10.1.7.20, from p. 127)
(11) − Working range limit (see Section 10.1.7.11, from p. 91)
active; can be deactivated by tapping
(12) − Length main boom
140−1100−181_en 31/161
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0,0°
1 2 3 4 5 6 7
8
9
28
10
11
27
12
13
26
25 15
16
24
17
18
23
22 21 20 19
Z 54 761
32/161 140−1100−181_en
Safety Equipment 10
(Z 54 761)
(13) − Max. main boom length reached

(15) − High speed
(16) − Configuration mode: raising of loads prohibited (see Sec-
tion 10.1.8 ”Configuration mode”, p. 137).
(17) − Current slewing angle (see Section 8 ”Slewing”)
(18) − Slewing operation in open circuit (see Section 8 ”Sle-
wing”)
(19) − Key for calling up the ”Quick menu” screen; is used espe-
cially if the free Section ”e” (see next page) is assigned
with a submenu which otherwise provides no option to
exit.
(20) − Current radius
(21) − LLD relevant LC and radius step
(22) − (red): min./max. radius reached,
LLD switches off
(black)”: min./max. radius reached
LLD shutdown bypassed

(23) − Angle of the main boom to horizontal (foot angle)
(24) − (red): min./max. main boom angle
reached, LLD switches off
(black)”: min./max. main boom angle
reached, LLD shutdown bypassed
(25) − Telescoping is only possible with bridging of the load limit
device due to telescoping error (see Section 12 ”Telesco-
ping”)
(26) − Head height
(27) − Radio remote control (optional) active (see Section 34);
operation no longer possible on the IC−1 display
(28) − Angle of the main boom to horizontal (head angle)
More displays, for example in connection with additional devices,

are described in the corresponding sections.
140−1100−181_en 33/161
10
0,0°
2 5 6 7
9 10 11 12
17 18 19 20
21 22 23
Z 54 762
34/161 140−1100−181_en
Safety Equipment 10
10.1.5.5 Section (e): assignment with different screens is pos-

sible (here: Quick menu)
(Z 54 762)
Call up the screen ”main menu” (see Section 10.1.6,

(1)
from p.39)
Call up the screen ”system” (see Section 10.1.7.1,

(2)
p. 43)
Call up the screen ”TableViewer” (see Section 10.1.7.4,

(5)
from p. 49)
Call up the screen ”parameter” (see Section 10.1.7.8,

(6)
from p. 75)
Call up the screen ”control lever assignment” (see Sec-

(7)
tion 10.1.7.6, from p. 69)
Call up the screen ”operating range limit” (see Sec-

(8)
tion 10.1.7.11, from p. 91)
Call up the diagnostics screen ”joystick” (see Sec-

(9)
tion 10.1.7.12, p. 103)
Call up the diagnostics screen ”I/O” (see Sec-

(10)
tion 10.1.7.13, p. 103)
Call up the diagnostics screen ”CAN” (see Sec-

(11)
tion 10.1.7.14, p. 105)
Call up the diagnostics screen ”LS” (see Sec-

(12)
tion 10.1.7.15, p. 117)
140−1100−181_en 35/161
10
0,0°
2 5 6 7
9 10 11 12
17 18 19 20
21 22 23
Z 54 762
36/161 140−1100−181_en
Safety Equipment 10
(Z 54 762)
Call up the screen ”telescoping information system”

(17)
(see Section 12 ”Telescoping”)
Call up the screen ”support pressure/tilt display” (see

(18)
Section 10.1.7.20, from p. 127)
Select/display ”operating mode of the hydraulic pumps”

(19)
(see Section 10.1.7.21, from page 131)
Display ”operating mode of the hydraulic pumps” (see

(20)
Section 10.1.7.21, from page 131)
Call up the screen ”active operating range limits” (see

(21)
Section 10.1.7.11, from p. 91)
Call up the screen ”engine display” (see Section 5 ”en-

(22)
gine”)
Call up the screen ”configure counterweight” (see Sec-

(23)
tion 9 ”counterweight”)
140−1100−181_en 37/161
10
0,0°
7 8 9 10 11
1 2
13 14 15 16
19 20 21 22 23 24
Z 54 763
38/161 140−1100−181_en
Safety Equipment 10
10.1.6 ”Main menu” screen

(Z 54 763)
The ”Main menu” screen can be called up by pressing the key

on the ”Quick menu” screen.
The name, time, and version number of the software are dis-
played in the top section of the screen.
Call up the screen ”system” (see Section 10.1.7.1,

(1)
p. 43)
Switch off the background lighting (see Sec-

(2)
tion 10.1.7.2, p. 47)
Call up the screen ”crane operation” (see Sec-

(7)
tion 10.1.5, from p. 27)
Call up the screen ”TableViewer” (see Section 10.1.7.4,

(8)
from p. 49)
Call up the screen ”fault messages” (see Sec-

(9)
tion 10.1.7.5, p. 67)
Call up the screen ”control lever assignment” (see Sec-

(10)
tion 10.1.7.6, from p. 69)
Call up the screen ”hour meter” (see Section 10.1.7.7,

(11)
p. 73)
140−1100−181_en 39/161
10
0,0°
7 8 9 10 11
1 2
13 14 15 16
19 20 21 22 23 24
Z 54 763
40/161 140−1100−181_en
Safety Equipment 10
(Z 54 763)
Call up the screen ”parameter” (see Section 10.1.7.8,

(13)
from p. 75)
(14) Call up the screen ”info” (see Section 10.1.7.9, p. 89)
Activate/deactivate the ”emergency control” (optional),

(15)
(see Section 36 ”emergency control”)
Call up the screen ”operating range limit” (see Sec-

(16)
tion 10.1.7.11, from p. 91)
Call up the diagnostics screen ”joystick” (see Sec-

(19)
tion 10.1.7.12, p. 103)
Call up the diagnostics screen ”I/O” (see Sec-

(20)
tion 10.1.7.13, p. 103)
Call up the diagnostics screen ”CAN” (see Sec-

(21)
tion 10.1.7.14, p. 105)
Call up the diagnostics screen ”LS” (see Sec-

(22)
tion 10.1.7.15, p. 117)
Call up the ”Datalogger” screen (optional), (see Sec-

(23)
tion 10.1.7.16, from p. 119)
Call up the screen ”function diagnosis” (see Sec-

(24)
tion 10.1.7.17, p. 123)
Functions which are not enabled although available as an option

are displayed in grey.
140−1100−181_en 41/161
10
Z 54 764
Z 60 020
42/161 140−1100−181_en
Safety Equipment 10
10.1.7 Submenus
(Z 54 764)
Submenus which can be called up from the ”Main menu” or the

”Quick menu” are described below:
The sequence is based at first on the arrangement of the symbols
in the ”Main menu” screen (Z 54 764, left side, from the top left
to the bottom right).
If the function can be called up from the ”Main menu” as well as
from the ”Quick menu”, the position of the corresponding key is
also shown in the ”Quick menu” (Z 54 764, right side).
Finally (from Section 10.1.7.18, p. 125) the buttons that only occur
in the ”Quick Menu” are described.
10.1.7.1 ”System”screen
(Z 54 764, Z 60 020)
Press button the ”System” (Z 60 020) screen is called up.

The parameters displayed on the screen are fixed display values
and changeable (*) values.
By pressing the corresponding button, the display is activated
and the current set value can be changed.
Language: * selection of the language setting

Unit: * selection of the unit display.
You can select between ”Metric” and ”Feet”.
Date: * setting option for the date
Time: * setting option for the time
Audio: * not assigned (optional)
APP: Display of the version number of the crane
software
OS−IPC: Display of the version number of the opera-
ting system
140−1100−181_en 43/161
10
Z 60 020
44/161 140−1100−181_en
Safety Equipment 10
(Z 60 020)
Continued screen ”system”:

CPU−FAN− Display of the current ventilating fan speed.
RPM: Not possible with all devices. If the fan does
not have a speed indicator, rectangles are
superimposed.
CPU: Display of the current CPU temperature
Software: A screen is opened by pressing the key.
The version numbers of all configuration or
parameter files are listed on this screen.
Demag Pin: * for customer serviceonly
Calibration:* the crane application is ended by pressing
the key. After this, different items have to be
pressed on the display as prompted. After
the calibration has ended, the crane appli-
cation is automatically started.
Server: for customer serviceonly
Save: If modifications in language, unit, date, time, or

audio have been carried out, they must be sa-
ved by pressing this key.
Exit via key without saving .
140−1100−181_en 45/161
10
Z 54 765
0,0°
Z 54 766
46/161 140−1100−181_en
Safety Equipment 10
10.1.7.2 Background illumination

(Z 54 765)
Press button to switch off the background lighting. The

background illumination is switched on by pressing on the screen
centre.
10.1.7.3 ”Crane operation” screen

(Z 54 766)
Press button to call up the ”crane operation” screen

(right−hand side with ”quick menu” screen).
With regards to this, please observe Section 10.1.5 ”Crane ope-
ration screen”, from page 27.
140−1100−181_en 47/161
10
Z 54 767
1 2
39,0
7,50
Z 54 768
48/161 140−1100−181_en
Safety Equipment 10
10.1.7.4 ”TableViewer”screen
(Z 54 767, Z 54 768)
Press button to call up the ”TableViewer” (Z 54 768)

screen.
This comprises of 4 secondary screens which are allocated to the
corresponding register symbols (1) as follows:
− ”Selection of operating mode” screen (see from

page 51)
This secondary screen always appears first when calling up the

”TableViewer” screen.
− ”View table” screen (see from page 59)
− ”Search configuration for load case” screen (see from

page 63)
LC − ”Length code LC” screen (see p. 65)
The display of the load bearing capacity dependent on the set

reeving number is superimposed in the position indicated (2,
Z 54 768) in all secondary screens for the ”TableViewer” screen.
140−1100−181_en 49/161
10
G
39,0
7,50
Z 54 769
50/161 140−1100−181_en
Safety Equipment 10
10.1.7.4.1 ”Selection of operating mode” screen

(Z 54 769)
This screen appears:

− after every restart, as soon as the IC−1 has run through the
starting procedure
− as input screen if the ”TableViewer” screen is called up
(49see page)
− if the register symbol is actuated within the ”TableVie-

wer” screen.
The single parameters which are relevant to the operating mode/

crane configuration are listed on this screen.
RISK OF ACCIDENTS!
All parameters must be selected by the crane operator in
such a way that they correspond to the actual status of the
crane. This responsibility lies with the crane operator
alone. It is only when this entry has been correctly carried
out that the load limit device can reliably monitor the crane
operation.
If the specifications shown in the heading (F) or in selection area

”G” are consistent with the actual crane status when the screen
appears, the screen can be exited by pressing the key.
The previously shown screen then appears, or, if it is the first time
that this screen has been exited after a restart, the ”Crane opera-
tion” screen.
Exiting this screen via key can also be used to gain informa-
tion on or locate the details on certain configurations.
One can, for example, select ”MS” type to check under outrigger
span which outrigger spans can be used, or to call up the lifting
capacity tables for this equipment.
When this screen is exited via key , the settings which have
just been carried out are rejected, and the original configuration
remains set.
140−1100−181_en 51/161
10
Z 54 770
52/161 140−1100−181_en
Safety Equipment 10
(Z 54 770)
If the specifications shown are not consistent with the crane sta-
tus, the operating mode must be reset. Proceed as follows to
set/change the parameters:
Beginning in the first field open ”Type” via the matching pull−
down menu and select according to the required equipment (e.g.
”HA” for working with the main boom).
The corresponding abbreviations (such as ”HA”) can be found in

all lifting capacity tables. The meanings of all abbreviations can
be found on page 27.
The special case HA−0 can only be selected in a slewing range
of 05 + 25.
Depending on the amount of corresponding selection elements,

these pull−down menus are opened with or without scroll bars.
An element in the list must then always be selected in the pull−
down menu so that the pull−down menu can be closed.
This has to happen if one decides, after opening the pull−down
menu, to keep the original selection.
The selection for the ”Type” field determines the content of all the
other fields. Proceed in the same way for all other parameters
that have to be changed. The field lengths and angles are only
relevant when working with additional equipment.
Selection elements which only contain one parameter can not be

changed. Its text is shown in grey.
If, when changing a parameter, another parameter is also
changed automatically by the system, (here, for example, a
fictitious outrigger span of 5.14 m / 16.9 ft), this is then
shown in red lettering. Values in ”red” must be confirmed by
the user; this means the key must be actuated again.
If the key then appears with a red background and black let-
tering (here fictitious equipment MBE), this configuration can
not be set due to the current crane status.
140−1100−181_en 53/161
10
G
39,0
7,50
Z 54 771
Z 54 550 Z 54 551
54/161 140−1100−181_en
Safety Equipment 10
(Z 54 771, Z 54 550, Z 54 551)
If all the fields in selection area ”G” are filled in correctly in accor-
dance with the actual configuration of the crane, exit the screen
to transfer the reset values by pressing the key .
If a parameter was highlighted red on the screen, an error mes-

sage appears ”Selection incorrect!” (Z 54 550, top). Return via
key and execute the selection correctly, as described on the
previous page.
After actuating the key , a check is made as to whether the

current extending sequence of the telescopic sections exists as
longitudinal codes (LC) for the selected crane configuration.
If this is not the case, error message (Z 54 550, bottom) appears.
Return via key to the ”Selection of operating mode” screen,
and after actuating the register symbol LC , check which per-
missible longitudinal codes there are for the selected configura-
tion. Re−telescope main boom to one of the permissible lengths.
If authorisation is given once the length code (LC) has been chek-
ked, the set configuration is transferred to the control system. The
screen (Z 54 551) is displayed during the transfer.
140−1100−181_en 55/161
10
0,0°
Z 54 772
56/161 140−1100−181_en
Safety Equipment 10
(Z 54 772)
After the transfer has ended, the screen from which the ”Selec-
tion of operating mode” was selected, appears again. After a re-
start, this is always the ”Crane operation” (Z 54 772) screen. The
parameter values just selected appear there in the left−hand area
of the top line.
RISK OF ACCIDENTS!
If these values are not consistent with the actual crane sta-
tus, crane operation is not permissible!
140−1100−181_en 57/161
10
2
10 1 3 4 5 6 2 8 9
3
16 15 12 9 8 14 12 9
8
22156512
7
6 5 Z 54 773
58/161 140−1100−181_en
Safety Equipment 10
10.1.7.4.2 ”View table” screen

(Z 54 773)
In the ”TableViewer” screen (10), all stored lifting capacity tables

for the set crane configuration can be called up by pres-
sing key (9).
The following details can be found in these lifting capacity tables
stored in the system:
(1) − pinned lifting capacities

Risk of overturning! RISK OF BREAKAGE!
The lifting capacities outlined in the lifting capacity tables
represent 100% of the permitted maximum load for each
crane configuration. If these limit values are exceeded,
there is a risk of the crane overturning and/or crane compo-
nents and auxiliary equipment breaking.
(2) −
no. of the longitudinal codes (LC)
(3) −
main boom length
(4) −
scroll bar
(5) −
ID No. of the lifting capacity table
(6) −
button for calling up information on a special load
(7) −
key for calling up the unpinned load bearing capacities.
For this, please observe Section ”Lifting capacities in un-
pinned condition” in Section 12 ”Telescoping”.
(8) − minimum reeving
(9) − radius
(10) − with luffing boom extensions, the current angle step
(e.g. 10°) is also displayed here. By pressing this key, the
other angle steps can be called up one after the other.
Please refer to the lifting capacity tables, which you will receive
with the crane − either on paper or as a CD−ROM − for more de-
tails on lifting capacities.
Please observe the following page.
140−1100−181_en 59/161
10
B C
A
D
E
F
G
H
P
Z 54 774
60/161 140−1100−181_en
Safety Equipment 10
Lifting capacity table (on paper or CD)

(Z 54 774)
The following example shows where you can find which details
in the lifting capacity table.
The following lifting capacity table is only a specimen. Only

the load capacity tables which are supplied with the crane
may be used for operation of the crane.
(A) − crane type and construction no. of the crane

(B) − lifting capacities on the main boom, all telescopic sec-
tions pinned
(C) − abbreviation of operating mode (here: HA for working
with the main boom)
The meaning of all abbreviations is described on page 27.
(D) −
permissible slewing range: 0° − 360°
(e) −
outrigger length (here: 8.23 m / 27 ft)
(F) −
outrigger width (here: 7.5 m / 24.6 ft)
(G) −
counterweight (here: 39.0 t / 86000 lbs)
(H) −
main boom length (here: 16.8 m / 55.1 ft)
(I) −
radius (here: 7 m / 23 ft)
(K) −
lifting capacity (pinned), (here: 57.8 t / 127.4 kip)
(L) −
minimum reeve count of hoist cable (here: 12−rope)
(M) −
longitudinal code no. (LC) of extension sequence (here:
4)
(N) − extension length of telescopic sections:
Tele 1 − 0%
Tele 2 − 0%
Tele 3 − 45%
Tele 4 − 0%
Tele 5 − 0%
(O) − restrictions/health and safety issues,

make sure these are stringently observed (here:
none)
(P) − ID No. of the lifting capacity table
140−1100−181_en 61/161
10
7,50
Z 54 775
7,50
Z 54 776
62/161 140−1100−181_en
Safety Equipment 10
10.1.7.4.3 ”Search configuration for load case” screen

(Z 54 775, Z 54 776)
Within the ”TableViewer” screen (Z 54 775), press button

to call up the screen ” search configuration for load case”
(Z 54 776).
On this screen, the possible configuration modes for the current
load and radius can be viewed. Proceed as follows:
4. tap entry field below ”Load (t/kip)”. A numerical pad appears

where the required list can be entered − within the limits spe-
cified in the head of the numerical pad. If the entry is outside
the permissible range, it will be shown in red.
By pressing , the previously entered character can be
deleted.
5. Either by pressing the key reject entry or by pressing the

key accept entry and return to start screen.
6. Select radius. Proceed in the same way as described for the

load.
7. If both fields for load and radius are filled with the required
entries, search by pressing key start.
All configurations found are entered into the corresponding field

(Z 54 776, marked range). By pressing on , the whole selec-
tion is opened.
140−1100−181_en 63/161
10
7,50
Z 54 777
Z 54 778
64/161 140−1100−181_en
Safety Equipment 10
(Z 54 777)
An entry such as HA (0.0/0.0) 15.0 7.5 means:

− Main boom operation
− the specifications in brackets (length/angle) are only relevant
for working with additional equipment
− Counterweight combination: 15.0 t / 33.1 kip
− Outrigger span: 7.5 m / 24.6 ft
The required configuration can be selected by tapping key, and

is then transferred to the screen for selecting the operating mode.
10.1.7.4.4 ”Extension conditions of main boom” screen

(Z 54 778)
Within the ”TableViewer” screen, the ”Extension conditions”

screen can be called up by pressing the register symbol ”LC”.
Listed here are − depending on the currently set configuration −
the possible extension states of the main boom with specification
of longitudinal code (LC), main boom length, extension condition
of the single telescopic sections, and possible lifting capacities.
140−1100−181_en 65/161
10
Z 54 779
Z 54 563
66/161 140−1100−181_en
Safety Equipment 10
10.1.7.5 ”Error messages” screen

(Z 54 779, Z 54 563)
Press button / to call up the list of the existing PLC

errors (Z 54 563).
In any case, all error messages are retained until they have been
viewed. This is especially useful for identifying errors which only
occur for a short time, and then disappear automatically.
The corresponding symbol can − with the exception of the ”Main

menu” screen − also appear in various other screens as soon as
an error occurs or is cancelled.
− the list of error messages is either empty or all error

messages have already been displayed once
− new (not yet displayed) errors have arisen, or existing

errors are cancelled − or both at the same time
RISK OF ACCIDENTS!
As soon as an error is displayed, shut off operations and
immediately have the error identified and eliminated!
Only qualified personnel (e.g. Customer Service) may eli-
minate errors.
If non−qualified personnel attempt to eliminate errors, they
could be fatally injured and/or cause serious damage!
Providing the update key is white in the ”Error messages”

(Z 54 563) screen , the list shows the current status for the
error messages.
Currently red, must be updated by tapping the key. This
may be necessary again should the symbol stay red.
If − when the ”Error messages” screen is open − new errors occur,

or are cancelled, or both at the same time, the update key
is red. It must then be tapped, if necessary, repeatedly − until it
is white again.
Only after this is the list of displayed errors complete, and the
screen can be exited via .
140−1100−181_en 67/161
10
Z 54 780
Z 54 565
68/161 140−1100−181_en
Safety Equipment 10
10.1.7.6 ”Control lever configuration” screen

(Z 54 780, Z 54 565)
Press button to call up the ”Control lever configuration”

(Z 54 565) screen.
It is here that the current configuration of the control lever is dis-
played.
This is where the various options for configuration of the control

lever can be selected (mode 1 − 6). By tapping one of the corres-
ponding fields (e.g. mode 1), the corresponding configuration of
the control lever can be selected. It is then displayed on the con-
trol lever symbols.
RISK OF ACCIDENTS!
control lever configuration before initiating a crane move-
ment.
Otherwise there is risk of accidents if accidental crane mo-
vements are triggered!
The configuration of the control lever is also linked to the assign-

ment of the rocker switch and pushbutton in the head of the con-
trol lever. These are adjusted to the new configuration.
More detailed information on this theme can be found in the cor-
responding sections which describe the crane movements (for
example, Section 8 ”Slewing”).
140−1100−181_en 69/161
10
Z 54 565
0,0°
Z 54 781
70/161 140−1100−181_en
Safety Equipment 10
(Z 54 565, Z 54 781)
The following table contains the control lever assignments for the
different modes:
Mode 1: SLH = slew gear SRH = luffing gear
SLV = tele SRV = Hoist 1
Mode 2: SLH = slew gear SRH = luffing gear
SLV = Hoist 2 SRV = Hoist 1
Mode 3: SLH = slew gear SRH = Hoist 2
Mode 4: SLH = luffing gear SRH = slew gear

Mode 5: SLH = luffing gear SRH = slew gear
SLV = Hoist 2 SRV = Hoist 1
Mode 6: SLH = slew gear SRH = tele
SLV = luffing gear SRV = Hoist 1
(S = control lever, R = right, L = left, H = horizontal, V = vertical)
The mode no. of the current control lever setting is shown in the
top line of the IC−1 display (Z 54 781).
Set−up − This button only appears when the screen is started

from the main menu. Additional possible programming
can only be carried out with the help of our service de-
partment.
− Exit the screen without changing the lever setting
− Exit the screen with a change to the lever setting
140−1100−181_en 71/161
10
Z 54 782
Z 54 567
72/161 140−1100−181_en
Safety Equipment 10
10.1.7.7 ”Hour meter” screen

(Z 54 782, Z 54 567)
Press button to call up the screen ”hour meter”

(Z 54 567).
This is where the operating hours for the crane drives slew gear,
hoists, luffing gear and tele unit are displayed. The operating
hours are displayed in the format ”hours : minutes”.
In the bottom left−hand corner of the display, press to select

the corresponding crane operation from a pull−down menu.
In the case of the hoist unit (e.g. H1−L, H1−S) a differentiation is

made between the load and rope load.
140−1100−181_en 73/161
10
Z 54 783
2
1
3
9 8 7 6
Z 54 569
74/161 140−1100−181_en
Safety Equipment 10
10.1.7.8 ”Parameter” screen

(Z 54 783, Z 54 569)
Press button to call up the ”Parameter” (Z 54 569) screen.

This is where the solenoid valve data for the individually crane
functions are displayed and set in relation to the movement of the
corresponding control lever.
The detailed list of the individual parameters from field (1) can be
found from the following page.
As crane movements can also be carried out when setting the pa-
rameters for test purposes, the load utilisation display (2) of the
load limit device is also displayed in this screen.
The crane operator is therefore continually informed of the cur-
rent load range of the crane.
140−1100−181_en 75/161
10
Z 54 596
Z 54 597
76/161 140−1100−181_en
Safety Equipment 10
(Z 54 596, Z 54 597)
In field (1) the following parameters are displayed and can be set:
The current set values of the parameters are displayed graphi-

cally in field (4). Use button (5) to select between the display of
the current ramp (Z 54 596, y−axis [mA]) or the time ramp
(Z 54 597, y−axis [s]).
For the parameters ”Start1” to ”stop limit” it is best to choose the
time ramp display, for the remaining parameters, the current
ramp.
− Start1 [s] (here: 0.5):

The time that passes when the control lever is fully activated
for the control lever movement from zero up to the defined
start limit (point P1, see graphic).
− Start2 [s] (here: 0.5):
The time that passes when the control lever is fully activated
for the control lever movement from the defined start limit
(point P1, see graphic) up to the end point (P2, see graphic).
− Start limit [%] (here: 30%):
Specification of the control lever movement for point (P1, see
graphic).
− Stop1 [s] (here: 0.5):
The time that passes when the control lever is suddenly retur-
ned to neutral for the control lever movement from the end
point (P2, see graphic) to the defined stop limit (point P1, see
graphic).
− Stop2 [s] (here: 0.5):
The time that passes when the control lever is suddenly retur-
ned to neutral for the control lever movement from the defined
stop limit (point P1, see graphic) to zero.
− Stop limit [%] (here: 70%):
Specification of the control lever movement for point (P1, see
graphic).
140−1100−181_en 77/161
10
Z 54 596
Z 54 597
78/161 140−1100−181_en
Safety Equipment 10
(Z 54 596, Z 54 597)
− Y1 [mA] (here: 250):

Current slightly beneath the current for movement start Y2,
which serves to ensure a smooth commencement of the mo-
vement when Y2 is reached.
− Y2 [mA] (here: 270):
Current at which the selected movement starts.
The values Y1 and Y2 have been optimised ex works and should,

as a rule, remain unchanged.
− X 3 [%] (here: 70):

Value for the movement of the control lever for a defined cur-
rent Y3 (between the current for the start of the movement Y2
and the final current Y4).
− Y3 [mA] (here: 340):
Current between the current for the start of the movement Y2
and max. current Y4.
If Y3 is defined as such that − as in the example shown − the

straight line between Y2 and Y3 is very flat, the corresponding
crane movement can be influenced very precisely in this move-
ment range of the control lever. In the steep range of the straight
line between Y3 and Y4 movements of the control lever are ap-
plied more directly.
− Y4 [mA] (here: 800):

Max. current to the solenoid valve.
140−1100−181_en 79/161
10
8 7 6
Z 54 598
80/161 140−1100−181_en
Safety Equipment 10
(Z 54 598)
When changing to the ”Parameter” screen, the data set ”slew

gear left” of the PLC is always displayed. The remaining crane
functions can then be selected − after opening a pull−down menu
with button − in field (3). The PLC then sends its data directly
to the display.
If the menu points pump 1 or pump 2 are called up, only parame-
ter Y2 is assigned.
If the menu points ”luffing gear” or ”tele” are called up, the pump
symbol appears as well (pumps activated).
By tapping on this pump symbol the two pumps of the hydraulic
circuits 1 and 2 can be blocked. The symbol changes to .
It is then possible to carry out the setting for pump 3 in isolation.
Once the setting has been made, the pumps can be reactivated
by tapping on the pump symbol again .
Status display
(6) − to no. (7) corresponding output current to the solenoid

valves
(7) − movement of the control lever in increments (0 − 500)
(8) − Data set that is currently saved in the PLC ( 1, 2, 3, D ).

When the data set of the PLC does not align with any sto-
red on the computer, PLC appears in the symbol. Other-
wise, the number of the corresponding data set is dis-
played.
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10
Z 54 572
Z 54 570
82/161 140−1100−181_en
Safety Equipment 10
Entering/changing a parameter
(Z 54 570, Z 54 572)
Tap the entry field that belongs to the desired parameter (here:
to Stop1).
A numerical pad appears on which the desired value − within the

limits specified at the top of the block − can be entered. If the entry
is outside the permissible range, it will be shown in red.
By pressing , the previously entered character can be de-
leted.
Either by pressing the key reject entry or by pressing the key
save the entry and transfer directly to the PLC.
140−1100−181_en 83/161
10
9
Z 55 108
9.1
9.2
9.3
9.4
9.5
9.6
9.7
Z 54 571
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Safety Equipment 10
Selecting a stored data set

(Z 55 108, Z 54 571)
Press key (9) ”Menu” to open the selection window (Z 54 571).

(9.1) − Load setting 1
(9.4) − Load Demag default setting
(9.5) − Load current setting of the PLC
(9.6) − Save settings
(9.7) − Exit ”Parameter” menu
This is where different settings can be loaded or saved. Using

the ”Parameter” menu is ended and exited.
If a new setting is loaded from the computer, key this key. The
setting is then transferred to the PLC.
The default setting cannot be modified. For the functions ”tele in

and out” and ”slew gear brake” only the default setting can be se-
lected, i.e. the crane operator cannot make a personal setting. In
the case of the slew gear setting, the values for Y1 and Y2 cannot
be changed.
140−1100−181_en 85/161
10
9 8
Z 55 121
9.1
9.2
9.3
9.4
9.5
9.6
9.7
Z 54 571
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Safety Equipment 10
Copying a data set

(Z 55 121, Z 54 571)
If, for example, you want to assign the default setting to setting
1, proceed as follows:
1. Press key (9, Z 55 121) to open the ”Menu” selection window

(Z 54 571) and then press key to load the Demag de-
fault setting. Selection window (Z 54 571) closes.
2. Press the ”Menu” key again and in the selection window

(Z 54 571) press to save. Selection window (Z 54 571)
closes.
3. Press the ”Menu” key again and in the selection window

(Z 54 571) press key . Selection window (Z 54 571)
closes.
4. Press the ”Menu” key again and in selection window

(Z 54 571) press key to load the current PLC setting
in the data set ”setting 1”. Item (8, Z 55 121) changes to
. Selection window (Z 54 571) closes.
5. Press the ”Menu” button again and in the selection window

(Z 54 571) press save to complete the selection. Selec-
tion window (Z 54 571) closes.
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10
Z 54 784
AC140
14101
Z 56 932
88/161 140−1100−181_en
Safety Equipment 10
10.1.7.9 ”Info” screen

(Z 54 784, Z 56 932)
Press button to call up the ”INFO” (Z 56 932) screen.
It contains the specifications concerning:

− crane type
− Construction No.
− Software Versions No.
10.1.7.10 ”Emergency operation” screen (optional)

(Z 54 784)
Press the key or to switch the emergency opera-

tion on/off.
All information on this option can be found in Section 36 ”Emer-

gency operation”.
140−1100−181_en 89/161
10
Z 54 785
C
E
Z 54 577
90/161 140−1100−181_en
Safety Equipment 10
10.1.7.11 ”Operating area limit” screen

(Z 54 785, Z 54 577)
Press button to call up the ”operating area limit”

(Z 54 577) screen. This is where operating area limits can be ob-
served, defined and activated/deactivated.
The operating area which is defined by active operating area li-

mits is displayed in field ”A” as a green area. The black square
(1) shows the current position of the main boom head.
Field ”B” contains the current values for the load, radius and load
utilisation.
Field ”C” contains a bar diagram for the values for the actual and
max. permitted height of the boom head.
Field ”e” shows the current values for the slewing angle and main
boom angle on the symbols.
To exit the screen press key .
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10
H
F
G Z 55 109
92/161 140−1100−181_en
Safety Equipment 10
(Z 55 109)
To ensure that the crane and/or boom stays clear of existing ha-
zardous areas − for example in the vicinity of power cables − the
crane operator can define the following limits for the operating
range:
− Slewing angle limit (field ”H”)
− Radius limit (field ”G”)
− Height limit (field ”D”)
− Operating area limit by means of a virtual wall (field ”F”)
This safety device is no substitute for the judgement and

experience of the crane operator and use of recognised
safe operating procedures for the use of cranes.
The crane operator still carries the ultimate responsibility
for safe operation of the crane.
Make sure that you deactivate the activated limits as soon as

work in a limited operating range has been completed.
Otherwise, when the crane is next operated in an open area,
crane movements may suddenly and abruptly be stopped,
causing the hook block/load to swing outwards.
140−1100−181_en 93/161
10
Z 54 578
0,0°
Z 54 786
94/161 140−1100−181_en
Safety Equipment 10
10.1.7.11.1 Slewing angle limit (field ”H”)

(Z 54 578, Z 54 786)
− Activate/deactivate the slewing angle limit
− Teaching the left−hand slewing angle

Move to the left−hand limit point and press this key; the
angle setting above the button is overwritten by the cur-
rent slewing angle.
Active: key is green; not active: key is grey.
− Teaching the right−hand slewing angle:

Move to the right−hand limit point and press this button;
the angle setting above the button is overwritten by the
current slewing angle.
Active: key is green; not active: key is grey.
Follow the instructions in Section 8 ”Slewing”.

In particular, make sure that the selected angle limit (= shu-
toff point) actually guarantees sufficient safety clearance to
the hazardous area in extreme situations (e.g. if the hook
block swings out once the crane movement has been shut
off)!
All crane movements should be carried out at a suitable
speed!
After setting the angle limits, carry out a test run to check
that the crane movements are shut down at the intended
points.
Press key . If one of the limits is still active (e.g. slewing angle
limit), the crane operation screen (Z 54 786) displays the symbol
.
Press this key in the ”crane operation” screen to switch off all ac-
tive operating range limits in one go.
140−1100−181_en 95/161
10
G
Z 54 579
Z 55 110
96/161 140−1100−181_en
Safety Equipment 10
10.1.7.11.2 Radius limit (field ”G”)

(Z 54 579)
− Activate/deactivate the max. radius limit
− Teach the max. radius
− Activate/deactivate the min. radius limit
− Teach the min. radius
With regard to changes in the colour, the teaching procedu-

res, exiting the screen and warning instructions, see the
description of the slewing angle limit (p. 95).
10.1.7.11.3 Height limit (field ”D”)

(Z 55 110)
− Activate/deactivate the height limit
− Teaching the max. height
With regard to changes in the colour, the teaching procedu-

res, exiting the screen and warning instructions, see the
description of the slewing angle limit (p. 95).
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10
P1
Y+
X− X+
Y−
P2
Z 55 112
98/161 140−1100−181_en
Safety Equipment 10
10.1.7.11.4 Limitation by a virtual wall(field ”F”)

(Z 55 112)
− Activate/deactivate the limit by means of a virtual wall
− Teaching the first wall point (P1)

Approach the desired wall point with the hook block
and confirm this with this key. On the display (field
”A”) a red dot appears (P1).
The co−ordinates for this dot (in this case: ”0” as a va-
lue on the x−axis, +31,92 as a value on the y−axis)
are displayed.
− Teaching the second wall point (P2)

Approach the desired wall point with the hook block
and confirm this with this key. On the display (field
”A”) a blue dot appears (P2).
The co−ordinates for this dot (in this case: ”−18,62”
as a value for the x−axis, ”−25,92” as a value for the
y−axis) are displayed.
The second wall point must be at least 8 m (26.3 ft)
from the first wall point. Otherwise the range is high-
lighted in red with the co−ordinate information.
If, after teaching the two wall points, the limits are activated with
key , the two points are automatically linked with a line.
The resulting permitted operating range is displayed as a green
area.
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10
Z 54 580
100/161 140−1100−181_en
Safety Equipment 10
(Z 54 580)
− Switching over the permitted operating range

If the other side of the wall is to be defined as the per-
mitted operating range, press this key; its appea-
rance changes from to , i.e. it is high-
lighted in green.
In particular, make sure that the selected limit

(= shutoff point) guarantees sufficient safety clearance from
the hazardous area in extreme situations (e.g. if the hook
block swings out when a crane movement is shut down)!
All crane movements should be carried out at a suitable
speed!
After setting the angle limits, carry out a test run to check
that the crane movements are shut down at the intended
points.
140−1100−181_en 101/161
10
Z 54 787
Z 54 581 Z 54 582
102/161 140−1100−181_en
Safety Equipment 10
10.1.7.12 ”Joystick”screen
(Z 54 787, Z 54 581)
Press button to call up the ”joystick” (Z 54 581) screen in

order to diagnose the control lever.
The function can be checked by moving the control lever.
10.1.7.13 ”I/O”screen
(Z 54 787, Z 54 582)
Press button to call up the ”I/O” screen (Z 54 582) for dia-

gnosing the individual in− and outputs for the control unit.
By pressing to open a pull−down menu and make the required

selection.
If the selected element is a CPU, the version no. is also displayed.
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10
Z 54 787
Z 56 933
104/161 140−1100−181_en
Safety Equipment 10
10.1.7.14 ”CAN”screen
(Z 54 787, Z 56 933)
Press button to call up the ”CAN” screen (Z 56 933) to dia-

gnose the CAN bus.
This screen can be used to check the status of each individual

CAN participant. The status of a participant is OK when the Bits
B1 and B2 are set at ”1”.
In addition, the possibility exists of using the CANLogger to view

bus error lists (Emergency) or logs of guarding errors. This infor-
mation is important for our service department in case of a fault.
Configuration of the CAN participants is also possible in special
cases.
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10
1 2 3 4
Z 56 934
106/161 140−1100−181_en
Safety Equipment 10
10.1.7.14.1 CAN Diagnostics
1. CAN screen (Z 56 934)
1 Bus participants table

2 Key data
3 Bus status
4 Button, call up of CANLogger
(call−up possible only ”by customer service techni-
cians” using a PIN Code)
1.1 Bus participants table (1, Z 56 934)
B1 B2 Description
0 0 Node not available:
Participant is not on the ”bus”
0 1 Node preoperational:
Participant was set to Preoperational by the Ma-
ster.
1 0 Stopped:
Participant was set to stopped by the Master.
1 1 Operational:
Participant is on the bus and is behaving cor-
rectly, meaning that it is participating in guarding
(normal operative state)
All bus participants are listed in the Table. The state of the bus
participants is described by two status bits, the meaning of which
can be obtained from the Table. Under normal operating condi-
tions, B1 and B2 are set to 1.
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10
1 2 3 4
Z 56 934
3A
“a”
“b”
Z 56 935
108/161 140−1100−181_en
Safety Equipment 10
1.2 Key data (2, Z 56 934)
3 key data are shown in the display (2) of the CAN screen
(Z 56 934), which can also provide indication of any possible er-
rors.
The three numerical values mean the following, in the sequence
shown:
− Overruns (OR): number of messages lost at the time of recep-
tion (PDO)
− Java State (JS): shows in the form of numerical values the
status that the Java application has assumed.
There are three possible statuses: Preoperational = 127,
Operational = 5, Stopped = 4.
− Task State (TS): shows which status the CAN Demon (CAN
Task) has assumed.
Here, too, there are three possible statuses: Preoperational
= 127, Operational = 5, Stopped = 4.
Communications between CAN Task and application are disrup-

ted when there are different values in ((JS) and (TS).
− Display in error−free normal operation:
”CAN−OR−JS−TS: 0−5−5”
1.3 Bus status (3, Z 56 934)
The current bus status is shown in the display (3) of the CAN
screen (Z 56 934).
− The green bar (”a”, Z 56 935) means that the DloG is recei-
ving data from the CAN bus.
− If a red bar is visible that is interrupted by a lightning symbol
(”b”, Z 56 935), then the computer is receiving no data from
the CAN bus.
Press button Communications between the application

and the CAN Task can be tested by pressing the button
(3A, Z 56 935).
If the connection is OD, then the monitor screen of the symbol
(3A) needs to be changing back and forth between blue and
green.
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10
1 2 3 4
Z 56 934
1 2 3
6 5 4
Z 56 936
110/161 140−1100−181_en
Safety Equipment 10
1.4 CANLogger button (4, Z 56 934/Z 56 936)
Press button One can switch to the CANLogger by pres-

sing the button (4) in the CAN screen (Z 56 934/Z 56 936).
This call−up for this mask cannot be enabled except by means

of the PIN code being entered by trained customer service techni-
cians.
1.5 Appearance of an error
(Z 56 936)
Two additional buttons are displayed in the event of a CAN error:

− The monitor is completely restarted when key (6) ”Reboot
IPC” is actuated.
− The ”Reset CAN” pushbutton (5) causes a restart of the pro-
gram parts that are responsible for communications with the
CAN card.
140−1100−181_en 111/161
10
1 2 3 7 8
6 5 4 13 10
Z 56 936 Z 56 937
7 8 9
13 10 12 11 10
Z 56 938 Z 56 939
112/161 140−1100−181_en
Safety Equipment 10
2. CANLogger
(Z 56 936, Z 56 937, Z 56 938)
Press button One can switch to the CANLogger by pres-

sing the button (4) in the CAN screen (Z 56 936).
This call−up for this mask cannot be enabled except by means

of the PIN code being entered by trained customer service techni-
cians.
The number of messages is shown in the display (7) of the CAN-

Logger screen (Z 56 937),
if the number of messages (MSG) > 0, then the CAN lists can be
transmitted from the PLC to the DloG computer by pressing key
(13) ”PLC”. Depending on the quantity, the data transfer may
take several seconds.
The ”Data transfer” pop−up shown in the illustration (Z 56 938)
will be displayed during the transfer.
A switchover to the ”CANEmergency screen” fault display is ef-

fected by actuation of key (10) ”Emergency”.
2.1 Status of the CAN bus participant (9, Z 56 939)
The current status of the CAN bus participant is shown in the dis-
play of the CANLogger screen (Z 56 939)
(also see in this connection Point 1.2 ”Key data”, Page 109).
0= Not available
1= Configured, but without message
4= Stopped
5= Operational
127 = Preoperational
Actuating the ”Save” key (11) causes the data on the PLC to be
saved on the DloG computer.
Actuating the ”Reset” key (12) causes the data on the PLC to
be deleted.
A switchover to the ”CANEmergency screen” fault list display,

page 115 is effected by actuation of key (10) ”Emergency”.
140−1100−181_en 113/161
10
12 11 10 13 10B
Z 56 939 Z 56 940
10B
Z 56 941
114/161 140−1100−181_en
Safety Equipment 10
2.2 Error list display (CANEmergency)
(Z 56 939, Z 56 940)
The ”CANEmergency screen” (Z 56 940) fault display is shown

by actuating the ”Emergency” key (10, Z 56 939).
If the number of messages (MSG) is > 0, then the CAN emergen-

cies can be transmitted from the PLC to the DloG computer by
pressing the ”PLC” key (13).
Illustration (Z 56 941) shows the error lists displaywith the errors

that were transmitted.
One can switch back to the CANLogger view (Z 56 939) by actua-

ting the ”State” key (10B, Z 56 941).
2.3 General fault messages

(independent of the screen that is currently present)
If the master PLC (A0624) fails, then the E102 error message is
reported: ”Display gets no data from A0621.”
The DloG and its connection to the CAN bus are running in or-
derly fashion in such cases.
If the computer is receiving no signals from the CAN bus, then er-
ror E101 is reported: ”Monitor is receiving no CAN data”.
140−1100−181_en 115/161
10
Z 54 787
1 2
Z 54 789
116/161 140−1100−181_en
Safety Equipment 10
10.1.7.15 ”LS” screen

(Z 54 787, Z 54 789)
Press button to call up the ”LS” screen (Z 54 789) to dia-

gnose the electric ”Load Sensing” system.
On this screen the status of the pumps, ”coupled” or ”separate”,

is displayed. At the same time the pump pressure and the electric
control of each pump can be read off. (Pump mode 3 only with
Hoist 2, optional)
Depending on the mode selection the screen display changes

(Z 54 789). The left−hand mode key can be pres-
sed. The selected mode is displayed top left in the left−hand key
area.
As an example for all pump modes:
Mode 1 = deactivated (left−hand display, Z 54 789)
Mode 2 = activated (right−hand display, Z 54 789)
LS operation is deactivated by pressing key . The bridging

key is displayed in red . In addition, the warning symbol
is displayed.
140−1100−181_en 117/161
10
Z 54 790
Z 54 585
118/161 140−1100−181_en
Safety Equipment 10
10.1.7.16 ”Datalogger” screen (optional)

(Z 54 790, Z 54 585)
Press button to call up the ”Datalogger” (Z 54 585)

screen.
The Datalogger saves every set configuration of the crane.
The current configuration is displayed in grey (1).
The date and time show when these configurations were set.
No: The number of data sets currently stored

Current:The currently visible data sets
LLD: 0= Enabled
1= Not enabled
CAN: 0= CAN bus OK

1= CAN bus error
U−LMI 0= Bridging switch load limit device not actua-

ted
1= Bridging switch load limit device actuated
U−HES: 0= Bridging switch HES (hoist limit switch) not

actuated
1= Bridging switch HES (hoist limit switch) ac-
tuated
U_AUF 0= Bridging switch UP (luff up) not actuated

1= Bridging switch UP (luff up) actuated
TELE_M: 0 = Tele automatic active

1= Tele manual active
LC: Selected length code
LK−RV: The relevant length code for the load cal-

culation
140−1100−181_en 119/161
10
Z 54 585
120/161 140−1100−181_en
Safety Equipment 10
(Z 54 585)
EIN: Hoist rope reeving
AUSL: Current crane load
MAX: Maximum load
Last/ Current load

load:
RAD: Current radius
RAD−RV Radius relevant to load calculation
HA−W: Current boom angle
HA−KW: Current main boom head angle
HA−L: Current main boom length
DREHW: Current superstructure slewing angle
140−1100−181_en 121/161
10
Z 60 257
Z 54 587
122/161 140−1100−181_en
Safety Equipment 10
10.1.7.17 ”Function diagnosis” screen

(Z 60 257, Z 54 587)
Press button to call up the ”function diagnosis” (Z 54 587)

screen.
By pressing to open a pull−down menu and make the required

selection.
For the selected function, the setpoint and actual values can be
compared to diagnose an existing malfunction.
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10
Z 54 792
Z 54 793
124/161 140−1100−181_en
Safety Equipment 10
The following provides a description of the keys that can only be

pressed on the ”Quick Menu” screen.
10.1.7.18 ”Main menu” screen

(Z 54 792)
Press button to change to the main menu.
10.1.7.19 ”Telescoping information system” screen

(Z 54 793)
Press button to change to the ”telescoping information sy-

stem”.
Detailed information on this subject can be found in Section 12
”Telescoping”.
140−1100−181_en 125/161
10
Z 54 794
75,0 75,0
95,0 95,0
Z 54 795
126/161 140−1100−181_en
Safety Equipment 10
10.1.7.20 ”Support pressure/tilt display” screen

(Z 54 794, Z 54 795)
Press button to call up the ”support pressure−/tilt display”

(Z 54 795) screen.
This screen displays:

− the current support pressure (upper range)
− current crane tilt (lower range)
Support pressure gauge
The current support forces are recorded by pressure contacts in

the vertical outrigger cylinders.
RISK OF ACCIDENTS!
For the supporting procedure refer to Chapter 12 ”Sup-
porting on outriggers”.
If the vertical outrigger cylinders − contrary to the pre-
scribed procedure − are extended fully up to the stop, the
support forces displayed will be inaccurate.
For correct crane operation in accordance with the specifications

in the load capacity tables, the maximum (permitted) support for-
ces are:
front − max. 75 t (165 kip)
rear − max. 95 t (209 kip).
If the permitted limit values are exceeded there is a risk

of accidents!
Depending on the load−bearing capacity of the ground
where the crane is parked, it may well be that the permit-
ted support forces are much lower.
Observe the permitted limit values when supporting the
crane on outriggers and when operating the crane.
140−1100−181_en 127/161
10
0,0°
STB
Z 54 795 Z 54 797
128/161 140−1100−181_en
Safety Equipment 10
(Z 54 795, Z 54 797)
On the ”support pressure” screen (Z 54 795) the current and the

max. permitted/occurring support pressure are displayed for
each of the 4 supports.
For support pressures in the limit range, i.e. < 5% or > 95%, the
display bars are shown in red.
If the support pressure falls below 1 t (2.2 kip), the warning buz-
zer sounds and the ”crane operation” screen (Z 54 797) displays
the warning ”STB” (red).
If the crane is equipped with support area monitoring (optional),

the recorded outrigger support area is displayed on the struts.
Inclination display
Before commencing crane operations, the crane must be sup-

ported on outriggers and aligned horizontally. Observe the cor-
responding information in the operating manual of the crane
chassis, Section 12 ”outriggers”.
In the display of the ”support pressure/tilt display” screen

(Z 54 795) one line represents 1°.
The current tilt is permanently displayed on the ”crane operation”

screen (Z 54 797) by means of the symbol .
Risk of overturning!
Operation of the crane is only permitted when the crane
is aligned horizontally.
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10
Z 54 798
Z 54 799
130/161 140−1100−181_en
Safety Equipment 10
10.1.7.21 Keys for ”Operating mode of the hydraulic pumps”

(Z 54 798, Z 54 799)
Preferred hydraulic circuits can be assigned to the crane move-

ments ”luffing” and ”telescoping”.
The hydraulic pumps can be assigned so that they combine to
supply all hydraulic functions.
To achieve improved operation/activation, the pumps can be se-
parated.
Select the operating mode of the hydraulic pumps.

Press the left−hand key (Z 54 798). The selected
operating mode is displayed in the top left−hand corner of the
left−hand key pad. In both keys the movements of
the assigned pumps are now displayed.
By repeatedly pressing the left−hand button additional operating
modes can be selected.
The key displays change in accordance with the selected opera-

ting mode.
When ”operating mode 4” is selected, telescoping is not

possible.
When attempting to telescope, an information message is
shown on the display (Z 54 799). To enable telescoping, an-
other operating mode must now be selected.
Press key to call up the assigned screen ”LS” to diagnose

the operating mode selection. See Section 10.1.7.15 ”LS
screen”, page117.
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10
Z 55 350
0°
Z 55 351
132/161 140−1100−181_en
Safety Equipment 10
10.1.7.22 ”Active operating range limits” screen

(Z 55 350, Z 55 351)
Press button to call up the screen ”Active operating range

limits” (Z 55 351) on the right−hand half of the screen.
In status line (1) the corresponding active limits are displayed

using the corresponding symbols (here: height limit, max. radius
and virtual wall).
The graphic display shows the permitted operating range as a

green area.
The current position of the main boom head is displayed as a
black square.
On the bar display (2) the blue bar shows the actual height of the
main boom head in relation to the max. permitted head height
(green).
Press button (Z 55 351) to switch off all active operating

range limits in one go.
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10
Z 55 352
Z 55 353
134/161 140−1100−181_en
Safety Equipment 10
10.1.7.23 ”Engine display” screen

(Z 55 352)
Press button to call up the ”engine display” screen.

”engine”.
10.1.7.24 ”Configure counterweight” screen

(Z 55 353)
Press button to call up the screen ”configure counter-

weight”.

”Counterweight”.
140−1100−181_en 135/161
10
Z 55 354
136/161 140−1100−181_en
Safety Equipment 10
10.1.8 Configuration
(Z 55 354)
If, when configuring with the length code (LC 1) − i.e. the main
boom is completely retracted − there are no table readings for the
current crane configuration, the opposite symbols are displayed
and the load utilisation display of the load limit device is
displayed in red (with 3 stars) .
In configuration operation no lifting capacities are enabled!

The raising of loads is not permitted!
The crane may only be configured in an erected state (ou-
triggers, counterweight etc.) for which there are load capa-
city tables.
During configuration, the crane cannot be monitored by the
load limit device.
140−1100−181_en 137/161
10
B1
B2
0,0°
Z 55 355
138/161 140−1100−181_en
Safety Equipment 10
10.1.9 Load Monitoring Assembly

(Z 55 355)
With the help of the computer of the load limit device it is possible
to check the weight of the raised load (net load).
The load monitoring assembly may not be used to calculate

the load, but is used to check the weights of loads that have
been previously calculated in order to calculate better the
load hoist and to avoid potentially hazardous situations.
Before raising the load, the maximum load corresponding to the

driving operation must be determined. It is displayed in relation
to the selected operating mode on the screen in the MAX (t / kip)
display (B2).
Load monitoring
1. With the hook block hanging free (without load, with load−
handling device) press the button of the net display NET
(t / kip) (B1). The lifting tackle is tared and set at 0.0 t
(0.0 kip) net load.
2. Raise the load with the hoist.

The net display now shows the net load (actual load on the
hook without load−handling device).
The gross load contains − in addition to the load weight − the

weight percentage of the main boom extension in the transport
position, the weight of the hook block and all load−handling
equipment. The net load is the actual load on the hook block wi-
thout the load handling devices. Display errors are possible be-
cause of outside factors, e.g. wind, which have an effect on both
the crane and the load.
The load may only be raised with the hoist. Raising the load
by extending the telescopic sections or luffing cylinders is
prohibited.
140−1100−181_en 139/161
10
30 16
31
32
24
34
35
36
Z 54 006
140/161 140−1100−181_en
Safety Equipment 10
10.1.10 Dead man’s handle

(Z 54 006)
To prevent unintentional activation of crane movements, both

control levers are fitted with an additional button (32/36, dead
man’s handle). A crane movement can only be carried out as long
as one of these buttons is pressed.
For example, a movement can be carried out with the left−hand
control lever while the dead man’s handle is pressed in the right−
hand control lever.
The dead man’s handle may only be actuated (pressed and re-
leased) when the corresponding control lever is in the ”neutral po-
sition” and/or the operating movement has been completed.
RISK OF ACCIDENTS!
If one of these dead man’s switches is pressed or released
when a control lever is fully actuated, the corresponding
movement will be started/braked abruptly.
RISK OF ACCIDENTS!
All crane movements should be started and carried out at
suitable speeds to avoid the load or hook block swinging
out when the corresponding movement is switched off and
the subsequent risk of crushing or collision.
The control levers (16/24) may not be switched directly in the

opposite direction before first being returned to the neutral
position. Only when the superstructure is at a standstill may
the opposite movement be carried out.
140−1100−181_en 141/161
10
B C
0,0°
Z 55 378
Z 55 379
142/161 140−1100−181_en
Safety Equipment 10
10.1.11 Malfunction procedure
10.1.11.1 Malfunction−free operation

(Z 55 378, Z 55 379)
When crane operation is free of malfunctions, the menus and

screens currently configured are shown on the IC−D display
(DLOG). Crane movements can be executed with the aid of the
control lever.
The individual areas ’A’ to ’e’ are arranged on the display In the
”Crane operation” mask (Z 55 378). For fault−free operation the
spaces between the individual fields are separated with a grey
background colour.
In the main menu and in other submenus, the top line is displayed
in blue for fault−free operation (Z 55 379).
In the case of fault, the colour of the top line changes to red.
140−1100−181_en 143/161
10
64.1 64.11
64.2 64.12
64.3 64.13
64.4 64.14
64.15
64.6
64.7
64.8 64.16
63
64.19
Z 58 745
67
Z 56 192
144/161 140−1100−181_en
Safety Equipment 10
10.1.11.2 Failure of the display ”touchscreen” feature

(Z 58 745, Z 56 192)
If no more entries can be made on the display (DLOG) by tou-

ching the monitor screen surface (touch screen), even though no
other malfunctions are present, then the functioning of the load
limit device is ensured. The monitor view is shown the same as
with ”Malfunction−free operation” (see p. 143).
One possible cause for the failure of the ”touchscreen” could be

the operation of the display when ambient temperatures are too
high. The crane cab will then need to be cooled down with the air
conditioner. Direct sunlight on the display must be avoided.
In order to continue directly with crane operation, the keys (64.11)

− (64.16) on the right−hand side of the screen can be used:
(64.11)− key: move the mouse cursor upwards
(64.12)− key: move the mouse cursor downwards
(64.13)− key: move the mouse cursor to the left
(64.14)− key: move the mouse cursor to the right
(64.15)− key: switch key/mouse operation on/off
(64.16)− key: trigger one mouse−click (touch pressure).
If these keys are not present, then a commercially available com-

puter input device with USB connection (e.g. USB mouse, USB
trackball or similar) can be connected in order to be able to under-
take entries at the screen.
A USB connection (67, optional) can be located for this purpose

on the cabin instrument panel.
If this kind of USB connection is not present in the instrument pa-
nel, then the display (Z 58 745) must be removed. Two USB con-
nections (64.19) are located on its underside.
140−1100−181_en 145/161
10
B C
0,0°
Z 55 378
Z 55 379
146/161 140−1100−181_en
Safety Equipment 10
10.1.11.3 Display screen failure

(Z 55 378, Z 55 379)
If only the display (DLOG) fails, then the functioning of the load
limit device is ensured.
The display can fail in two ways:
1. Option:
The background colour switches to red and/or the header is

shown in red.
The configured menus/masks continue to be displayed, but now
they are no longer being updated, either to a partial extent or ent-
irely.
RISK OF ACCIDENTS!
Please note that the load and radius display is not updated!
2nd option:
Monitor failure − the monitor turns black.
What is to be done?
Proceed with both types of monitor malfunction as follows:
1. Place load down.
2. Look for the source of the error.
3. Rectify the error.
RISK OF ACCIDENTS!
No crane operation is permissible when the display fails!
The error must be eliminated before crane operation is per-
mitted to resume!
140−1100−181_en 147/161
10
39,0
7,50
Z 54 756
64.6
Z 58 747
148/161 140−1100−181_en
Safety Equipment 10
(Z 54 756)
The display of the crane control (DLOG) attempts to register au-

tomatically with the crane network. Once registration has been
completed, the screen ”Operating mode selection” will appear.
All crane movements are stopped for as long as the ”Operating

mode selection” screen is displayed. The crane control reacts as
with a new start.
Once the operating mode has been selected, you can proceed
further, as described in detail starting on page 51.
If automatic registration with the crane network fails, the CAN

mask can be selected to search for the fault. Here checks can be
carried out to see which components are in the network.
Depending on which faults exist the load can still be set

down using the hoist.
The main boom can be telescoped in by means of actuation
of the corresponding control lever in the telescoping−in de-
vice (dependent on the control lever function configura-
tion). If telescoping retraction is not possible, then the
crane and/or the load must be put down with an auxiliary
crane as an emergency measure.
It must be observed that the load and radius display are not
updated.
In this event, please contact our customer service depart-
ment.
Monitor failure due to ambient temperatures being too high

(Z 58 747)
If there is monitor failure (”black screen”) at the same time that the
”Temp” warning lamp (64.6) is illuminated, then the ambient tem-
perature is too high. The crane cab will then need to be cooled
down with the air conditioner. Direct sunlight on the crane con-
trols display must be avoided.
As soon as the ambient temperature has been reduced to a per-
mitted value, the display (DLOG) will once again report to the
crane network on its own.
140−1100−181_en 149/161
10
150/161 140−1100−181_en
Safety Equipment 10
10.1.11.4 Failure of the crane control (CAN stop)
In the event of crane control failure all crane movements are stop-
ped within one second.
No further crane movements can then be driven using the control
lever. Only such inputs as affect diagnostics can be carried out
via the display (DLOG).
Before continuing operation of the crane, the fault must first

be rectified.
RISK OF ACCIDENTS!
If necessary, the crane and load must be emergency lowe-
red using an auxiliary crane.
In this event, please contact our customer service depart-
ment.
140−1100−181_en 151/161
10
Hoist limit switch
0,0°
Z 55 356
152/161 140−1100−181_en
Safety Equipment 10
10.2 Limit switch
10.2.1 Hoist limit switch
10.2.1.1 Function
(Z 55 356)
Hoist limit switches are safety devices that limit the upwards mo-
vement of hoist ropes and hook blocks.
This avoids collisions between the hook block and boom head
and therefore possible damage to these parts and/or the hoist
rope, which could cause the load to fall.
For this reason, the crane may only be operated with fully func-
tional hoist limit switches that have not been triggered.
RISK OF ACCIDENT!
Approach the hoist limit switch daily and check that it func-
tions properly!
If a hoist limit switch is triggered (and not overridden), HES (red)

appears on the IC−1 display and the warning buzzer sounds. The
following crane movements are shut down:
− Raise hoists
− Extend telescopic sections
− Lower luffing gear and raise luffing gear.
Then either lower the hoist or telescope in in order to end this pro-
hibited condition.
140−1100−181_en 153/161
10
113
114
Z 55 102
0,0°
Z 55 357
154/161 140−1100−181_en
Safety Equipment 10
10.2.1.2 Bridging the Hoist Limit Switch

(Z 55 102, Z 55 357)
Key−operated pushbutton (114) is used to bridge the hoist limit

switches ”raise hoists”.
When the limit switches are overridden, the indicator light (113)
lights up.
On the IC−1 display HES appears (black). This means that the
hoist limit switches are overridden, regardless of whether they
are triggered or not.

finished.
The limit switches may only be overridden in exceptional ca-

ses, e.g. when configuring the crane (fitting or changing
equipment components, fitting ropes etc.).
Operation of the crane with the limit switches overridden

is prohibited. RISK OF ACCIDENTS!
140−1100−181_en 155/161
10
0,0°
Z 55 358
156/161 140−1100−181_en
Safety Equipment 10
10.2.2 Lower limit switches
10.2.2.1 Function
(Z 55 358)
Lower limit switches are safety devices which shut down the un-
reeling function of the hoist rope when it is down to 3 remaining
turns on the drum. This prevents the rope being wound back on
in the opposite direction.
If a lower limit switch has been triggered (and not overridden), the
IC−1 Display shows SES (red) and the warning buzzer sounds.
”Lower hoist” is switched off. Only ”raise hoist” is possible.
10.2.2.2 Bridging the Lower Limit Switch
A lower limit switch must be overridden directly at the correspon-

ding proximity switch.
The lower limit switches may only be overridden in exceptio-

nal cases (e.g. to change or fit ropes).
Operation of the crane with the limit switches overridden

is prohibited. RISK OF ACCIDENTS!
140−1100−181_en 157/161
10
”X0550”
2
3 5
4
6
Option Option Option

X0560
X0561 X0550
X6540
X7811
X7272
X7811
X6540
X7272
H6263
X6540
X7271 H6262
B7513
+341−X7811 X7811 X7811
HES
HES HES
Z 56 945
”Y”
”X”
7
Z 56 946
158/161 140−1100−181_en
Safety Equipment 10
10.3 Electric safety chain

(Z 56 945, Z 56 946)
On distribution box ”X0550” on the main boom head the electric safety
chain for operation of the crane is connected.
10.3.1 Main boom operation
For main boom operation the sockets on the distribution box ”X0550”
must be assigned on the main boom head as follows:
Socket (3)
− either with the plug of the wind speed rotor (2)

− or with the connection plug for the main boom extension
− or with bridging plug “17−poles” (6).
Socket (3) must in any case be fitted with one of the named plugs.
Socket (4)
− with the plug for the aircraft warning light (1) (as shown)
− or protection cap.
The aircraft warning light is secured− as shown − with two wing nuts on
the main boom head.
Cable (5) of the hoist limit switch (7)
− Hoist limit switch (7) is screw−connected to switch box ”X0550” via

cable (5).
iThe plug−in connection of the hoist limit switch is to be found on the

opposite side of the main boom head (Z 56 946).
To guarantee the function of the hoist limit switch (7) on the main
boom head, the shift weight must hang freely and the hoist limit
switch may not be bridged.
Make sure that the hoist limit switch retainer (red flag) is inserted
in the storage position (Z 56 946, “X”).
Hoist limit switch ”bridged” is shown in (Z 56 946, “Y”).
140−1100−181_en 159/161
10
”B”
”A”
4 1
7 2
1
Z 56 947
”B”
”A”
Z 56 948
160/161 140−1100−181_en
Safety Equipment 10
Removing and storing the hoist limit switch retainer.
To change the retainer from the locking position to the storage

position, proceed as follows (Z 56 947, Z 56 948):
1. Pull hoist limit switch cable downwards 1 , then bend back-

wards parallel to the boom and hold in this position 2
(Z 56 947).
2. Move the retainer down 3 , and then to the 4 left. Release

the hoist limit switch cable (Z 56 947).
3. To store, push the retainer from the left over the hoist limit
switch (7) 5 until the two clips “A“ lock in the hole “B” of the
hoist limit switch (Z 56 948).
10.3.2 Operation “Main Boom Extension”
Information on connecting the safety chain for crane operation on

the main boom extension can be found in section 18.3 of these
operating instructions.
For crane operation open hoist limit switch connections at

components of the main boom extension have to be bridged
via plug (2 poles).
Only then it is guaranteed, that the signal of the hoist limit
switch may be looped through the components.
140−1100−181_en 161/161
Working Instructions 11
140−1110c_en 1/25
11
2
3
Z 54 714
180°
Z 54 715
2/25 140−1110c_en
11 Working Instructions
11.1 Wind Speeds

(Z 54 714, Z 54 715)
It is essential that you observe the permitted maximum wind

speeds. To check the wind speed, the crane is equipped with an
air speed indicator (anemometer).
This comprises two elements:
(Z 54 714)
1. the rotor (1), which must be fitted to the head of the main
boom or main boom extension at the prescribed bracket (2).
To do so, insert the rotor into the bracket, screw the lock nut
(3) onto the thread of the bottom rotor component and
tighten.
With an attached rotor, the transport height of 4 m (13.1 ft) is

exceeded.
(Z 54 715)
2. the display on the IC−1 screen with the corresponding sym-
bol.
The rotational movement of the rotor caused by the wind is
converted into an electrical signal which is displayed on the
IC−1 display in the crane operator’s cab. The crane operator
can read off the wind speed here in m/s (mph).
Before commencing work or erecting the equipment it must

be ensured that the anemometer is fully functional. This is
the case if the displayed value changes when the rotor is ro-
tated.
If there is no wind, this must be simulated by manual rotation
of the rotor.
140−1110c_en 3/25
11
4/25 140−1110c_en
The wind speeds specified below are maximum values.

In any case, pay attention to the information in the lifting ca-
pacity tables, as there can, under certain circumstances,
be reductions in the permitted wind speeds.
National regulations must also be observed.
Wind speed What you have to do....

up to 9.8 m/s (21.9 mph) operation of the crane is per-
mitted without any restrictions
over 9.8 m/s (21.9 mph) stop operation of the crane
above 15 m/s (33.6 mph) telescope main boom in,
main boom extension can re-
main in the operating posi-
tion.
If possible, place the boom
system into the wind.
above 20 m/s (44.7 mph) bring the boom system into
the transport position.
Before the crane is operated, the local weather authority

should be contacted for information on expected wind con-
ditions during the entire operation of the crane.
For the wind speeds listed in the load capacity tables, a load sur-
face area exposed to the wind of 1.0 m2/t (4.88 ft2/kip) − at least
2 m2 (21.5 ft2) − and a wind resistance value cw of 1.2 has been
calculated.
Also take the detailed information in “Instructions on opera-

tion of the crane” into consideration, which were supplied
with the load capacity tables.
For loads with a larger surface area exposed to the wind,
please contact the crane manufacturer.
140−1110c_en 5/25
11
6/25 140−1110c_en
If the crane is to be left unattended for a longer period of

time, e.g. overnight, the main boom must be telescoped in
and any additional equipment which is fitted set down on
the ground.
If wind speeds exceeding 20 m/s (44.7 mph) are to be ex-
pected, set the boom system in transport position.
At the work site make sure that sufficient space is left in the
vicinity of the crane so that the main boom can be tele-
scoped in and the additional equipment placed on the
ground, if a (strong) wind suddenly occurs.
If site conditions do not allow the boom system to be low-

ered to the ground, a weather forecast must be obtained for
the whole of the work period.
A suitable and safe contingency plan must be put in place
to lower the boom system in the event of (strong) winds.
For all crane configurations the boom system may only be

erected (raised from the ground) if the expected wind speeds
(weather forecast) are also permitted for operation of the crane.
140−1110c_en 7/25
11
8/25 140−1110c_en
11.2 Crane Operation
Before starting the engine or starting crane movements the

crane operator must sound the horn to warn persons who
are in the vicinity of the crane.
The crane may only be placed in operation when:

∗ the engine of the crane chassis is switched off.
∗ the cab of the crane chassis is closed.
∗ the control panels of the outriggers are closed.
To increase the operating speed, four movements can be carried
out at the same time and independently of each other.
Before each load case, the corresponding limit switches must be

checked to make sure that they are functioning correctly.
When operating the main boom, observe section 10.4 of these

operating instructions for information on how to connect the elec-
trical lines (closing the safety chain).
The procedures for operating the crane with additional equip-

ment are contained in the individual sections (e.g. main boom ex-
tension).
Simultaneous raising of a load on the main boom extension and

on the main boom is not permitted.
Danger of tipping over!

Two−hook operation is not secured by the load limit de-
vice and can lead to overloads and tilting of the crane.
It is not permitted to raise a load on the main boom with the main
boom extension in operating position (loaded or unloaded).
If the main boom is extended and pinned in its final operating

length, the locking and pinning unit must be completely retracted.
140−1110c_en 9/25
11
80 o
1 1 4
70 o
Z 54 090 Z 54 091
10/25 140−1110c_en
There are load capacity tables for which a permitted minimum

radius must be observed. The corresponding crane movements
are then shut down.
This minimum radius must not be exceeded.

Risk of falling backwards!
There is one load capacity table that only allows operation of the
crane with the superstructure in the 0 ° position, i.e. the super-
structure to the rear. In this case:
∗ Slew superstructure to a position of 0° +/− 2°.

∗ Select “HA−0” operating mode(refer to sect. 10 of these oper-
ating instructions).
Failure to observe this can lead to a RISK OF TIPPING.
If not otherwise instructed in the load capacity tables, the number

of the reevings may not be smaller than 2−falls.
However, if a 1−fall reeving is required, the load capacities listed
in the table must be reduced by 20%. This also applies if the lifting
capacity lies beneath the maximum permitted cable tension of
8.1 t (17.9 kip) per rope fall.
(Z 54 090)
RISK OF DAMAGE!
If the main boom is in the high position (80−82) and is com-
pletely telescoped in, the crane movements must be carried
out with appropriate care and at slow speeds. By doing this
you prevent swinging movements of the hook block (1),
which could cause collisions with the luffing cylinder (2).
(Z 54 091)
RISK OF DAMAGE!
If the main boom basic case is fitted with dolly supports (op-
tion “dolly operation”), the main boom angle must not ex-
ceed 70 towards horizontal when telescoping from basic
length (LK 1).
If the angle exceeds 70, there is a danger of collisions be-
tween hook block (1) / hoist limit switch (3) and dolly sup-
ports (4).
140−1110c_en 11/25
11
12/25 140−1110c_en
The weight of the hook blocks and lifting tackle must be taken off
the values in the load capacity tables.
When raising a load on the main boom with the main boom exten-
sion locked in the transport position, the load capacities specified
in the load capacity tables are reduced. You also calculate mini-
mum loads.
With regard to “hook block weights” and “minimum loads”

observe the “Instructions on Operating the Crane”, which
are supplied with the load capacity tables.
Operation of the crane is only permitted when supported on out-

riggers and horizontally aligned. Only values which are listed in
the load capacity tables are valid as a support base area.
If no specifications are present in the load capacity table concern-

ing the outrigger span, work with the crane should be carried out
on outriggers and with fully extended supports (outrigger span:
7.5 m (24.6 ft), extend as far as the mark).
For the reduced outrigger support area, the maximum counter-

weight that can be fitted is the one listed in the corresponding
load capacity table.
If, in contrast with these specifications, larger counter-

weights are fitted, the superstructure may not be rotated.
RISK OF TIPPING!
If the crane is equipped with a follower axle (option), the maxi-

mum counterweight mounted must not exceed the counterweight
stated in the corresponding load chart.
For this especially refer to Section 9 ”Counterweight” , subitems
” Configuring the counterweight on the crane chassis support at
the front or rear”.
If, in contrast with these specifications, larger counter-

weights are fitted, the superstructure may not be rotated.
RISK OF TIPPING!
140−1110c_en 13/25
11
14/25 140−1110c_en
Handle the slew gear and slew brake carefully. Select a low slew-
ing speed. Brake carefully.
This applies especially to operation with the main boom exten-
sion or fly jib or special site conditions.
Risk of crushing!
In spite of the use of state of the art automatic safety equip-

ment, the load cannot always be prevented from swinging
out when a movement is switched off.
This can only be prevented by braking and accelerating all
crane movements carefully and appropriately.
To allow for immediate reaction if the crane is subjected to chang-

ing environmental conditions, it is prohibited to switch off the drive
of the crane when a load is attached and / or to leave the crane
cab.
An exception is only permitted in emergency situations. To

avoid dangerous situations, as a last option the power
source (diesel engine) can be switched off using the quick
off switch in the crane operator’s cab. First, where pos-
sible, any movements which have been started should be
completed using the control lever.
The erected crane without load may only be left without the su-
pervision of a trained crane operator if certain conditions are met
(see part 2, operating instructions for the crane chassis, Sect. 14
”Parking”).
140−1110c_en 15/25
11
Z 53 498
16/25 140−1110c_en
To prevent the unintentional activation of crane movements, both

control levers are fitted with an additional button (dead man’s
switch).
A crane movement may only be carried out as long as one of
these buttons is pressed.
The dead man’s switch in the control levers may only be actuated
(pressed and released) and the limit switches may only be
bridged on the instrument panel when the corresponding lever is
in the neutral position and/or the working movement has been
completed.
Risk of accidents!
If one of these buttons is actuated when the lever is fully de-
flected, the current movement is stopped suddenly and
abruptly.
(Z 53 498)
During operation of the crane observe display (4). The tempera-
ture of the hydraulic oil must not exceed 85° C (185° F).
This applies to the oil filled ex works. For oils with a different vis-
cosity, observe the corresponding characteristic curves or get in
touch with the crane manufacturer.
If this value is exceeded, operation of the crane should be

stopped temporarily. Leave the diesel engine running at low revs
so that the hydraulic oil can be cooled down via the oil cooler.
140−1110c_en 17/25
11
18/25 140−1110c_en
11.3 Operation Planning / Monitoring Safety Measures
Before commencing work, i.e. before taking up a load, the condi-

tions described below must be fulfilled.
11.3.1 General
For every crane operation that is planned, the crane operator /

operation planner must place ready a suitable crane with suffi-
cient lifting capacity, hoist height and working radius.
The weight of the load must be known.
Move the load as low above the ground as possible.
Avoid excessive operating speeds which could cause the load to

swing. Large loads must be guided from the ground with ropes.
11.3.2 Condition of the Crane
− correctly supported on outriggers and horizontally aligned.

− all four outriggers extended to the support base area speci-
fied in the corresponding load capacity table.
− all four outriggers safeguarded with pins to prevent them
shifting.
− all four vertical outrigger cylinders extended so that all axles
are relieved of load i.e. so that no tyres are in contact with the
ground.
− support plates locked.
− suspension system of the crane chassis switched to “raise
axles” or “hold axles”.
140−1110c_en 19/25
11
20/25 140−1110c_en
11.3.3 Condition of the Environment
Load−bearing capacity of the ground
The ground must have sufficient load−bearing capacity to take

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

ring as well as further important information concerning safe out-
rigging can be found in sect. 12 ”Outrigging” of the crane chassis
operating instructions (Part 2 of these operating instructions).
140−1110c_en 21/25
11
22/25 140−1110c_en
11.4 Conversion of units
Instructions:
Multiply the known value by the conversion factor to obtain the

result in the desired units.
Example: 2 kg in lbs (US) as follows:

2 x 2.2046 = 4.4092 lbs (US)
Converting from in Multiply by

kg lbs 2.2046
lbs kg 0.45359
lbs kip 0.001
kip lbs 1000
kg kip 0.002205
kip kg 453.6
t (SI) ton (US) 1.103
ton (US) t (SI) 0.907
kip ton (US) 0.5
ton (US) kip 2.0
mm inch 0.039
in mm 25.4
cm inch 2.54
inch cm 0.394
m ft 3.281
ft m 0.3048
km mile 0.621
mile km 1.6093
cm2 inch2 0.155
inch2 cm2 6.4516
ft2 m2 9.2903 x 10−2
m2 ft2 10.746
140−1110c_en 23/25
11
24/25 140−1110c_en
Continuation of conversion of units
Converting from in Multiply by

m/s ft/sec 3.281
ft/sec m/s 0.3048
m/s ft/min 196.86
ft/min m/s 0.00508
m/s mph 2.236
mph m/s 0.447
km/h mph 0.621
mph km/h 1.6093
bar psi 14.513
psi bar 0.0689
psf lbs/ft2 1.0
lbs/ft2 psf 1.0
ltr gal (US) 0.264
gal (US) ltr 3.7854
ltr barrel 0.0063
barrel ltr 158.99
oC oF toF= 1.8 (toC) + 32
oF oC toC= (toF−32) / 1.8
140−1110c_en 25/25
Telescoping 12
140−1120−101a 1/77
12
Z 54 716
3 3
5 Z 54 717
2/77 140−1120−101a
Telescoping 12
12 Telescoping
12.1 General
(Z 54 716, Z 54 717)
”Telescoping“ means retracting or extending the main boom.
The main boom consists of a basic case and five telescopic sec-
tions.
When fully retracted, the main boom is 12.5 m (41 ft) long, when
fully extended it is 60 m (196.9 ft). All telescopic sections must al-
ways be pinned at these and all other working lengths.
This means that each boom section is locked to the next largest
boom section by a spring−loaded pin or bolt (3) on the left−hand
and right−hand side at the rear.
There are also load capacities in the unpinned condition. Refer

to section 12.4.1 ”Lifting Capacity at Intermediate Conditions”,
starting at page 67.
All five telescopic sections are retracted and extended using the
following elements:
− − a telescoping cylinder (1), which is fastened to the back of
the basic case.
− a safety and locking unit “LPU” (5) attached to the cylinder
pipe.
It is connected with the top of the piston rod of the telescoping
cylinder via a pulling frame (6) and is therefore moved as
soon as the telescoping cylinder is moved.
− − the LPU is activated via two hydraulic cylinders.
When retracting and extending, there is a risk of crushing

at the bearing points of the telescopic sections.
Persons must therefore remain clear of the danger zone.
140−1120−101a 3/77
12
4/77 140−1120−101a
Telescoping 12
All necessary steps are shown to the crane driver by the telesco-
ping information system.
To extend the boom, the telescopic sections to be extended must

be extended one after the other.
When extending, begin with the smallest telescopic section (the
one nearest the centre).
During telescoping, the telescopic section is locked at the LPU
(locking and pinning unit).
To telescope out the next telescopic section, the telescoping cy-
linder with fitted LPU must first be moved back in empty an empty
state.
Before each telescoping procedure, all telescopic sections must

be pinned and unlocked. The corresponding telescopic section
is then locked and unpinned.
After each telescoping procedure, the individual telescopic sec-
tion is pinned and unlocked before the next telescopic section is
extended.
All telescopic sections can be pinned at 0% / 45% / 90% and

100%. Length codes exist for all extension states used in load ca-
pacity tables.
If the main boom has been extended or retracted to its final

operating length and pinned, the LPU must be completely re-
tracted.
Lifting capacities are valid only after the LPU has been com-
pletely retracted.
Telescoping of the main boom without the load on the hook and
without the auxiliary equipment fitted is described below.
For telescoping when a load is present, refer to Sect. 12.4.2 “Te-

lescoping with Loads”, page 73.
Telescoping of the main boom when additional equipment fitted
is described in the section where the corresponding additional
equipment is outlined, e.g., Sect.18 ”Main Boom Extension
(MBE)”.
140−1120−101a 5/77
12
Z 54 716
6/77 140−1120−101a
Telescoping 12
12.2 Locking and Pinning Unit (LPU)
12.2.1 Functional Characteristics

(Z 54 716)
The LPU (5) is attached to the pipe of the telescopic cylinder (1).
It is connected with the top of the piston rod of the telescoping cy-
linder via a pulling frame (6) and is therefore moved as soon as
the telescoping cylinder is moved.
Each procedure runs automatically at the LPU and consists of

two interlinked processes:
− Locking and unpinning
− Pinning and unlocking.
The locking and pinning unit is designed in such a way that

once the corresponding procedure has been activated, the
telescopic sections are always locked (or pinned) before the
following action of unpinning (or unlocking) can be carried
out mechanically.
This ensures that the system is never in an unsafe condition
(unpinned and unlocked at the same time).
140−1120−101a 7/77
12
1
2
2
A A
4 4
3 B B 3
1
2
2
D D
4 4
3 C C 3
Z 200 036
8/77 140−1120−101a
Telescoping 12
(Z 200 036)
Locking / unpinning
Two pins (2) on both sides of the LPU are used for mechanical
locking between the locking and pinning unit and the corres-
ponding boom section. This is described as “locking” (A).
“Unpinning” (B) follows immediately after the locking proce-

dure. In this case, the grippers (4) draw the pins (3) in the lateral
walls inwards to loosen the lock between the one boom section
and the next largest section.
In this state, telescoping can be carried out. The LPU is moved

at the same time.
Pinning / unlocking
Is carried out in the same way as locking / unpinning. First the

grippers (4) of the spring−loaded pins (3) re−establish the lock
between the two respective telescopic sections (”Lock, C”), then
the two horizontal locking pins (2) are retracted (”Unlock, D”) so
that there is no connection between the LPU and the telescopic
section.
140−1120−101a 9/77
12
A B
45%
90%
100%
90%
45%
10° 28%
Z 54 718
23.9 m
10°
Z 60 350
10/77 140−1120−101a
Telescoping 12
12.2.2 Supply of the LPU with hydraulic oil

(Z 54 718, Z 60 350)
Supply of the LPU with hydraulic oil is done through the telesco-
ping cylinder with an internal oil conduit. A hydraulic accumulator
is needed to do this. This accumulator should always be within
a pressure range of 65 − 85 bar (943 − 1233 psi).
The pressure display is shown at (3) in the display “TeleManual”

(Z 60 350). This can be activated in the following way:
On the screen ”Quick Menu” (Z 54 718, ”A”) press the key

. The input screen of the telescoping information system,
the ”telescoping display” (Z 54 178, ”B”), appears instead of the
”Quick Menu”. Press the button there.
If the pressure in the accumulator falls below 76 bar (1100 psi),

normally the loading procedure is started automatically.
The loading procedure is not carried out if:
1. the pressure in the accumulator is >86 bar

(1247 psi)
2. the telescopic cylinder is retracted
3. the LPU is in the state ”locked / unpinned” and the
telescopic cylinder is not telescoped (unpinned
loads)
4. the LPU is in the state ”unlocked / pinned”, the
telescopic cylinder is not telescoped and the entire
telescoping drive is telescoped out less than 1.5 m
(4.9 ft)
5. the LPU is in the approach position, fine position or
follow−up position during the locking and pinning
procedure
140−1120−101a 11/77
12
23.9 m
10°
Z 60 350
12/77 140−1120−101a
Telescoping 12
(Z 60 350)
If the pressure sensor malfunctions, the fault symbol ap-

pears on the left side of the IC−1 display. When the fault message
is called up, the fault code no. “E:325” appears.
Then the accumulator pressure has to be manually brought into

the normal range of 65 − 85 bar (943 − 1233 psi). The button
next to the accumulator symbol has to be pushed to do this.
The button is left green when the pressure is within the normal
range and is left red when the pressure is NOT within the normal
range.
During the loading procedure − a maximum of 15 s − the button
is yellow.
140−1120−101a 13/77
12
14/77 140−1120−101a
Telescoping 12
12.3 Telescoping
12.3.1 General
There are two possible operating modes for telescoping the main
boom:
− Automatic telescoping (see section 12.3.5, from page 37);
As long as there is no fault, telescoping must always be car-
ried out in automatic operation.
Automatic telescoping is carried out with the help of the tele-
scoping information system.
The telescoping information system is an aid to operation.
It is not a replacement in any way for the judgement and ex-

perience of the crane operator as well as recognised safe
operating procedures for the operation of cranes.
When using the operating aid, the crane operator still re-
mains fully responsible for the safe operation of the crane.
He must ensure that he fully understands and follows the no-
tes and instructions in their entirety. The system can only be
guaranteed to work correctly if it is checked daily and used
in accordance with the operating instructions.
− Manual telescoping see section 12.3.6, from page 41);

Manual telescoping is done without monitoring by the load li-
mit device, which is why it is only permitted in exceptional
cases :
− when the automatic telescoping system is not working
(e.g., fault with a sensor)
− to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).
140−1120−101a 15/77
12
39.0
7.50
1
0°
Z 54 720 Z 54 721
180°
Z 54 722
16/77 140−1120−101a
Telescoping 12
12.3.2 Telescoping Procedure

(Z 54 720, Z 54 721, Z 54 722)
Proceed in the following manner when telescoping:
1. Support and align the crane on outriggers in accordance with

the regulations (see operating instructions of the crane chas-
sis, section 12 “Outriggers”).
(Z 52 986, Z 54 104)
3. Enter the operating mode. Press the button there.
The screen for preselecting the operating mode (Z 54 104)
appears. Make a selection of all relevant fields in accordance
with the actual state of the crane (e.g. “type” here: main
boom) and exit the screen via .
For more detailed information, refer to Section 10 “Safety
Equipment”.
(Z 53 470)
4. Check which mode has been selected for the assignment of
the control levers. The current mode (here: 1) is displayed by
the corresponding symbol in the top line of the IC−1
display.
Detailed information on the selection and limits of the different

modes can be found in Section 10 “Safety Equipment”.
RISK OF ACCIDENTS
control lever assignment before initiating a crane move-
ment.
Otherwise there is risk of accidents if accidental crane mo-
vements are triggered.
140−1120−101a 17/77
12
180°
Z 54 723
18/77 140−1120−101a
Telescoping 12
(Z 54 723)
5. Select the operating mode of the hydraulic pumps.
The hydraulic pumps can be connected so that they supply

all hydraulic functions together.
The pumps can be separated for improved control.
To do so, press the left−hand key. The selected
mode “1 − 4” is displayed in the top left−hand corner in the
key field. Then the movements of the assigned pumps are
displayed in the two keys.
The key displays change according to the mode selection.

Follow the instructions under point ”Operating mode of the hy-
draulic pumps” in these operating instructions in section 10 “Sa-
fety equipment”.
140−1120−101a 19/77
12
30 16
31
32
24
34
35
36
Z 54 006
20/77 140−1120−101a
Telescoping 12
(Z 54 006)
6. Start telescoping by pressing one of the buttons (32/36)

“dead man’s control” and carefully moving the corresponding
control lever (16/24):
Automatic Manual tele-

telescoping scoping
Activate control after entering the LK Telescoping
lever (16/24) for- (length code) of the out
wards / to the preselected process (see from
right (see from page 37) page 41)
Control lever Activate LK 1 (length Telescoping
(16/24) back- code 1) and activate in
wards / to the left complete telescoping in (see from
of the main boom (see page 41)
from page 37)
You must take the current position of the control levers into
consideration.
In order to prevent accidental initiation of crane movements, both

control levers are equipped with an additional key (dead man’s
control). Only when one of the buttons is pressed is it possible to
carry out a crane movement.
You may only activate (press or release) a dead man’s switch if
the corresponding control lever is in the neutral position and/or
the initiated working movement has been completed.
RISK OF ACCIDENTS
Pressing/releasing one of these dead man’s switches
when the control lever is fully engaged causes abrupt in-
itiation/braking of the corresponding movement.
RISK OF ACCIDENTS
140−1120−101a 21/77
12
30 16
31
32
24
34
35
36
Z 54 006
22/77 140−1120−101a
Telescoping 12
(Z 54 006)
Control levers (16/24) may not be switched directly to the op-

posite direction, but must first remain in the neutral position.
Only initiate the opposite movement once the movement has
come to a standstill.
The control lever automatically returns to the zero position once

released. The current crane movement is stopped.
If the hook is raised, and if the hoist limit switch has triggered, the
main boom can no longer be extended. First the hoist (the hook)
must be lowered (see section 14).
140−1120−101a 23/77
12
10°
Z 54 724
1 2 3
45%
90%
100%
90%
9
45%
28%
7 6 5 4
Z 54 725
24/77 140−1120−101a
Telescoping 12
12.3.3 Telescoping display

(Z 54 724, Z 54 725 principle depiction)
On the screen ”Quick Menu” (Z 54 724) press the key .

The input screen of the telescoping information system, the ”tele-
scoping display” (Z 54 725), appears instead of the ”Quick
Menu”.
This is where submenus can be selected and information on the
status of the telescoping system can be found:
(1) Entering the length Refer to Section 12.3.4.1 ”Selection

code of the length code”, starting at
page 31
Grey: The selected length code has not
been achieved.
Green: The selected length code has been
achieved.
(2) Final length of the main boom
(3) Actual length of the main boom
140−1120−101a 25/77
12
1 2 3
45%
90%
100%
9 90%
45%
28%
7 6 5 4
Z 54 725
A B C
Z 54 726
26/77 140−1120−101a
Telescoping 12
(4) Changes to the display of the tele aid (Z 54 726)

Electrical limit switches are fitted on the LPU and on the drive
unit of the LPU:
B 9160 − B 9163 used to recognise the telescopic
section (Z 54 726, ”D”). The corres-
ponding digit after the designation
“tele” indicates which boom section
is being dealt with.
Example: 1st boom section; des-
cription “Tele 1”:
As shown, both lamps are illumina-
ted, which symbolise the limit swit-
ches B 9160 and B 9161.
B 9164 − B 9165 show the position of the LPU to the
telescopic section (Z 54 726). When
both light up, the LPU can lock the
affected telescopic section, i.e.,
create the connection to the tele-
scopic section.
B 9156, B 9157, B 9158, show the status of the LPU.
B 9168, B 9169
Z 54 726 “A”: pinned / unlocked
Z 54 726 “B”: pinned / locked
Z 54 726 “C”: unpinned / locked
(5) Display of the current condition of the telescopic cylinder

and/or of the LPU
/ forwards / backwards with reduced
speed
/ forwards / backwards with high
speed
/ Telescopic section pinned / unpin-
ned
/ LPU locked / unlocked
Point black: telescoping system
stop
Point red: fault in the telescoping
system (see section 10).
140−1120−101a 27/77
12
1 2 3
45%
90%
100%
9 90%
45%
28%
7 6 5 4
Z 54 725
28/77 140−1120−101a
Telescoping 12
(Z 54 725)
(6) Telescoping speed display of main boom / telescoping cy-

linder
Just before the pinning position is reached, the telescoping
speed is reduced, so that the telescopic sections can be pin-
ned.
(7) Switches to the “TeleManual” screen (see sect. 12.3.6, as
from page 41)
(8) LPU position display
(9) Extension length for a telescopic section in per cent
telescopic section blue: these telescopic sections are al-
ready extended to the selected
length code
telescopic section grey: these telescopic sections are retrac-
ted and yet to be extended
telescopic section black: in combination with grey back-
ground: this telescopic section must
be retracted for the new LK (length
code), and extended again later
in combination with white back-

ground: this telescopic section must
be retracted for the new LK(length
code)
telescopic section yellow: this telescopic section extends or
retracts with the LPU
telescopic section white: these telescopic sections are retrac-
ted
telescopic section this telescopic section’s position is
orange: teached (see sect. 12.3.7, as from
p. 59).
140−1120−101a 29/77
12
45%
90%
100%
23.9 m
90%
45%
10° 28%
Z 54 727
3 4 5 6 7
1 8
12 10 11 10 9
Z 54 728
30/77 140−1120−101a
Telescoping 12
12.3.4 Length code
12.3.4.1 Selection of length code

In order to select the length code (LK) for the desired main boom
length, press ”LK” button (Z 54 727). The “Tele operation mode”
screen appears (Z 54 728).
Here, all length codes are displayed that can be selected and that
are compatible with the selected operating mode, including main
boom length, extension configuration for the individual telesco-
pes and possible max. lifting capacities.
Press to select the desired length code (entire line 1, Z 54 728,

is touch−sensitive). By pressing the button, the length code
is saved and you exit the screen. Now the “Telescoping display”
screen appears (Z 54 727).
The “LK” button with the newly selected length code now has a
grey background. <This means that the corresponding length
has not yet been reached. This LK code is also displayed in black
in the topmost line of the IC−1 display.
As soon as the following telescoping procedure has been com-
pleted and thus the appropriate target length reached, both dis-
plays change their colour to green.
140−1120−101a 31/77
12
3 4 5 6 7
8
2
1 9
14 13 12 11 10
Z 54 728
32/77 140−1120−101a
Telescoping 12
“Tele operating mode” screen

(Z 54 728 principle depiction)
(1) − Length code number (LK No.)

(2) − Main boom length
(3) − Extension configuration of telescopes 1 to 5 (from left to
right)
0 % extended 90 % extended
(4) − Max. lifting capacity in high position

(5) − Radius in high position
(6) − Max. lifting capacity in low position
(7) − Radius in low position
(8) − Activation of the mask for selection of the length code for
lubrication of the main boom (only for operating mode
HA)
(9) − Scrollbar for browsing through the length codes, line by
line
(10) − Exit the mask with save; the settings are assumed
(11) − Leafing through the length code, page by page:
> one page down;
(12) − Length code selection for the LPU position for moving the
crane (only for operation mode HA)
(13) − Leafing through the length code, page by page:
< one page up
(14) − Exit the mask without save; the settings are not assumed
140−1120−101a 33/77
12
Z 54 746
17 18 19
31,5 21,4 7.5
31,5 21,4 7.5
31,5 21,4 7.5
31,2 21,4 7.5
−−− −−− −−− −−−
Z 55 399
34/77 140−1120−101a
Telescoping 12
12.3.4.2 Selection of the Length Code for Lubrication of the

Main Boom
(Z 54 746 principle depiction, Z 55 399)
In order to select the length code (LK) for lubrication of the main
boom, the crane must be switched to operating mode ’HA’ (’main
boom operation’).
In the mask ’Tele operating mode’ (Z 54 746), the ’lubrication
symbol’ is displayed at the marked place.
By selecting the lubrication symbol mask (Z 55 399) is dis-
played with the selection list of the corresponding length code.
Instead of displayed the details on load capacities and radius, the
values for counterweight combination and outrigger support area
are indicated, which must be fulfilled at the very least:
(17) − minimum counterweight
(18) − minimum outrigger support area
(19) − key: back to the mask “Tele operating mode”
Risk of tipping!
Only when the actual crane configuration fulfils the mini-
mum requirements for counterweight combination and ou-
trigger support area is it ensured that lubrication of the
main boom is risk−free.
You will find the actual lubrication procedure in the mainte-
nance and lubrication instructions of the superstructure,
section 10 “Main boom”.
After activating the corresponding length code for lubrication of

the main boom, you can exit the mask with ’Save’.
If the configuration of the crane currently reserved in control does

not fulfil the indicated minimum requirements for counterweight
and outrigger support area, the relevant value will be displayed
in red. The mask then cannot be exited with ’Save’.
140−1120−101a 35/77
12
16
24
Z 54 101 Z 54 119
45%
90%
100%
23.9 m
90%
45%
10° 28%
Z 54 729
36/77 140−1120−101a
Telescoping 12
12.3.5 Automatic telescoping

(Z 54 101, Z 54 119, Z 54 729)
The IC−1 enables automatic telescoping, after selecting the re-

quired final length (by entering the corresponding length code
“LK”), by operating the corresponding control lever (Z 54 101).
This means that if the boom is to be extracted to a new length,
the corresponding control lever must be moved explicitly in ex-
tending direction and held (when selecting an operating mode
with which telescoping is possible).
This is also the case, if the new main boom length is less than the
current length.
If the control lever is moved to retracting direction, then LK 1 (all
telescopes 0%) is activated and the automatic system begins to
retract the main boom entirely.
The telescoping speed varies throughout the procedure.
Just before the pinning position is reached, the telescoping

speed is reduced, so that the telescopic sections can be pinned.
The telescoping procedure can be observed at the telescope dis-

play on the right side of the IC−1 display (Z 54 729). As soon as
the desired final length is reached, the colour of the ”LK” button
switches from grey to green.
During the telescoping procedure, the current total length of the

main boom as well as other geometric data are displayed at the
crane symbol to the left of the IC−1 display (Z 54 729).
Also, the configuration of sensors and pins for the LPU can be
monitored during the telescoping procedure. To do so operate “?”
button. The screen (Z 54 119) appears.
The displayed configuration is unlocked and pinned.
140−1120−101a 37/77
12
45%
90%
100%
90%
45%
28%
Z 54 730 Z 54 119
45%
90%
100%
23.9 m
90%
45%
10° 28%
Z 54 731
38/77 140−1120−101a
Telescoping 12
(Z 54 119, Z 54 730, Z 54 731)
The system uses the Is−values, provided by the length transmit-

ter, to calculate the most advantageous run sequence, by making
comparisons with the stored operating programs and other fac-
tors. The sequence is displayed using different coloured telesco-
pic sections in illustration (Z 54 730). Each step required is dis-
played until the telescoping procedure is completed.
The display of the movement of the individual telescope levels as

well as the locking and pinning unit (LPU) and the configuration
of the locking and pinning elements is continuously adapted to
correspond to the changes made (Z 54 119).
If work has to be stopped, the system automatically saves the va-

lues last displayed, so that work can be resumed accordingly.
Error routines monitor the correct locking / pinning of the main

boom. System errors are displayed by a red mark (see illustration
“Z 54 730”). At the same time a symbol appears to the left
of the IC−1 display (Z 54 731). The error must then be identified
and eliminated.
For more detailed information on calling up error messages see

section 10 “Safety devices”.
After eliminating the error, work can only be continued, once the
error message has been acknowledged.
140−1120−101a 39/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
40/77 140−1120−101a
Telescoping 12
12.3.6 Manual telescoping

(Z 54 133)
Manual telescoping is carried out without the supervision of the

load limit device and is therefore only permitted in exceptional
cases:
− if the automatic telesystem fails (e.g. malfunction of a sen-
sor).
− to achieve lengths for which there is no length code (e.g.,
when greasing the main boom).
In manual operation, it is not possible to monitor of the

crane via the LMI! Maximum risk of accidents!
The crane operator is responsible for any damage or acci-
dents that might be caused in this situation!
Under certain circumstances (no monitoring of the crane

control during manual telescoping) the telescopic drive can
be extended so much that it slides off the inner guide rails.
For this reason there is a table with the LPU’s approximate
locking and pinning positions under subpoint 12.3.8
“Locking and pinning positions of the telescopic drive” on
page 63.
The table values correspond with the LPU position (1) in the
’TeleManuell’ mask.
The corresponding locking and pinning positions may be
exceeded by approx. 0.05 m (approx. 0.164 ft) at the most.
If the corresponding locking and pinning position is not
found, probably several electronic sensors are defective at
once. In this case or when the telescopic drive has come off
the inner sliding rails please contact our customer services
department.
If the telescopic drive has come off the inner guiding slides,
telescoping is no longer possible. Locking and pinning (or
unpinning) the telescopic sections of the main boom is then no
longer possible either. The telescopic drive can be extended but
will always stick at the same place when being retracted.
140−1120−101a 41/77
12
A B
45%
90%
100%
90%
45%
10° 28%
Z 54 718
Z 54 110
42/77 140−1120−101a
Telescoping 12
(Z 54 110, Z 54 718)
You will find the required information − specially on position and

configuration of the LPU − in the ”TeleManual” screen (Z 54 110).
In order to call up the “TeleManual” screen, press the button in the

“Quick Menu” screen (Z 54 718, ”A”) . The “Telescoping
display” (Z 54 718, ”B”) appears in place of the ”Quick menu”.
Press the button button − the “TeleManual” screen ap-
pears (Z 54 110).
When the “TeleManual” screen opens, the hand symbol is cros-

sed out . This means that the automatic mode is still ac-
tive. One can then take a look at information e.g. on the configu-
ration of the initiators and then return to the original screen.
The procedure for manual telescoping is described in

sect. 12.3.6.2, as from page 49.
140−1120−101a 43/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
44/77 140−1120−101a
Telescoping 12
12.3.6.1 “TeleManual” screen

(Z 54 133)
(1) − LPU position

(2) − LPU speed
(3) − Hydraulic supply for LPU (see sect. 12.2.2, from p. 11)
(4) − Number of the telescopic section, which is connected to
the LPU; the depicted no. “0” means that the LPU is not
connected to any telescopic section and can be driven
”empty” in the basic case.
(5) − Secure preselection
(6) − Status display telescoping system (see sect. 12.3.3 “Te-
lescoping display”, point 5, p. 27)
(7) − Pinning
(8) − Unpinning
(9) − Locking
(10) − Unlocking
(11) − Back to the telescoping display; is locked after hand ope-
ration
(12) − Teaching (setting and saving) telescope position
(13) − Switching between automatic (hand symbol crossed out)
and manual telescoping operation (hand symbol not
crossed out)
140−1120−101a 45/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
46/77 140−1120−101a
Telescoping 12
(Z 54 133)
(14) − Initiators for the configuration of the LPU (connected in-

itiators are highlighted in red)
The following states are indicated by letters in German and by a

number in brackets in all other languages:
ES / VB (1) Unlocked / Pinned

? / VB (12) Intermediate position
GS / VB (2) Locked / Pinned
GS / ? (23) Intermediate position
GS / EB (3) Locked / Unpinned
(15) − Initiators for the identification of the telescopes. The te-
lescope currently identified by the LPU is specified at
pos. 4 (switched initiators on a red background)
(16) − Initiators for initial and subsequent position for locking
(switched initiators on a red background)
(17) − Initiators for initial and subsequent position for pinning
(switched initiators on a red background)
140−1120−101a 47/77
12
Z 54 135
111
112
10°
Z 54 111 Z 54 732
48/77 140−1120−101a
Telescoping 12
12.3.6.2 Manual telescoping procedure

(Z 54 111, Z 54 135, Z 54 732)
Please make sure you observe the instructions on the permissi-

ble employment of manual telescoping and on calling up the “Te-
leManual” screen (Z 54 135) in Sect. 12.3.6, from page 41.
To activate manual telescoping in the “TeleManual” screen, press
the key . It turns into .
High risk of accidents!

In manual operation mode it is not possible to monitor the
crane with the load limit device. The load limit device must
be bypassed.
It is only permitted to bypass the load limit device in excep-
tions! Bypassing must be reversed immediately after ma-
nual telescoping!
Crane operation with bypassed load limit device is FOR-
BIDDEN!
To bypass the load limit device, operate the key−operated button

(112). The corresponding indicator light (111) goes on.
The telesystem must be informed about the extension status of

the main boom after manually telescoping the main boom. This
procedure is called ”teaching” (refer to Sect. 12.3.7, beginning on
page 59). The ”TeleManual” screen cannot be exited without
”teaching”.
After the manual telescoping or “teaching” procedure the load li-

mit device can only be operated again and hence be reactivated
after passing or reaching a valid length code.
If the telesystem is activated without bypassing the LMI before re-
aching a valid length code (key (Z 54 135),
(Z 54 732) appears in the crane display symbol.
On principle, the smallest (furthest inward) telescopic section to

be telescoped must be started with whenever the main boom is
to be extended.
The largest (furthest outward) telescopic section to be telesco-
ped must be started with whenever the main boom is to be retrac-
ted.
140−1120−101a 49/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
50/77 140−1120−101a
Telescoping 12
Example of manual telescoping (Z 54 133):
The 1st boom section must be driven out of the 100% pinning
hole into the 0% pinning hole.
1. Check the “TeleManual” screen, (14, right field), to see whe-

ther the LPU is unlocked and pinned ( or digit “1”).
The LPU can be operated in this state using the respective
control lever without moving any telescopic section.
This can be seen in the mask “TeleManual” at (2): a speed
value > 0 mm/s (ft/min) must then be displayed without the
main boom moving.
2. Since the LPU has been fully retracted (1, LPU position
0.000 m / ft), it must be “extended” in order to be locked (as
desired) to the fully extended first telescopic section.
Steer the respective control lever in order to extend the LPU.
The LPU is driven to the 1st boom section.
As soon as the 1st boom section has been reached, the dis-
play (4) changes from “IK 0” to “IK 1”.
Then the telescopic drive is telescoped out approx. 9,595 m

(31.48 ft) (1st boom section, 100% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.3.8 “Locking and pinning positions of the telescopic drive”
on page 63).
During the following procedure, telescoping can be interrupted or

resumed with the appropriate control lever, depending on which
action step is specified.
140−1120−101a 51/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
52/77 140−1120−101a
Telescoping 12
(Z 54 133)
3. Interrupt telescoping, then actuate the Preselection key,

(5, )press the lock key (9, ) and slowly continue
telescoping.
The keys are displayed on a red background after actuation.

They automatically turn grey again as soon as the selected pro-
cedure is over.
You must make sure that you follow the correct sequence:
first preselection, then locking! The locking process is now
automatically actuated when the fine position is approa-
ched. In the “Lock” fine position, the two initiators VPS and
NPS (16) are active, i. e. on a green background.
The locking process is over as soon as the locked and pinned

state is indicated for the LPU by the symbol or digit ’2’ at
(14, at the end of the line).
4. The telescopic section must be locked manually if it is unable

to be locked automatically. Operate the key (9, ).
This key may only be operated in the “Lock” fine position

(VPS and NPS “16” active, i. e. on a green background).
After locking the telescopic section the pinning fine position must
be reached, i.e. both initiators NPV and VPV (17) must be on a
green background. Only then may the unpinning process begin.
5. To unpin, actuate key (8, ).

cedure is over.
140−1120−101a 53/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
54/77 140−1120−101a
Telescoping 12
(Z 54 133)
6. Extend the LPU about 1 to 2 cm (0.5 − 1 in) by steering the

respective control lever. The unpinning process is then car-
ried out.
The unpinning procedure is over as soon as the locked and un-

pinned state is indicated for the LPU by the symbol or di-
git ’3’ at (14, at the end of the line).
In this state, the telescopic section is attached to the LPU and can
be retracted in the following.
(Z 54 133)
7. Retract the first telescopic section from the 100% locking

hole to the 0% locking hole locked to the LPU by steering the
control lever accordingly.
The 90% and 45% pinning hole positions are crossed during the
retraction process. The initiators for pinning then indicate whe-
ther any potential pinning positions have been crossed. In this
case the two initiators “VPV” and “NPV” (17) are on a green back-
ground.
The unpinning procedure may only be actuated once the two in-
itiators “VPV” and “NPV” (17) are on a green background after re-
aching the 0% pinning position.
Then the telescopic drive is telescoped out approx. 0,035 m

(0.115 ft) (1st boom section, 0% pinning hole: for further
extension lengths of the telescopic drive, see table in section
12.3.8 “Locking and pinning positions of the telescopic drive” on
page 63).
8. As soon as the two initiators “VPV” and “NPV” (17) for the 0%
pinning hole of telescopic section 1 are on a green back-
ground, actuate key (7, ). It is displayed on a red back-
ground.
The pinning procedure is accomplished as soon as the locked

and pinned state is indicated for the LPU by the symbol
or digit ’2’ at (14, at the end of the line).
140−1120−101a 55/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
56/77 140−1120−101a
Telescoping 12
(Z 54 133)
9. In this state, actuate the key (7, ) again in order to

complete the pinning procedure. It turns grey again.
The respective valve remains in a switched position and the key

remains on a red background if the key (7) is not actuated again.
10. To unlock the LPU, press first the Preselect key , (5, )
then the Unlock key (10, ) and slowly continue tele-
scoping.
The unlocking procedure is then actuated automatically
when the fine position (VPS and NPS “16” initiators active,
i. e. on green background) is approached.

cedure is over.
(Z 54 133)
If the unlocking procedure can not be started automatically, it can

be started manually by pressing the unlock button. (10).
In this case the Preselection key (5, ) may not be actuated.
The unlocking procedure is over as soon as the locked and pin-

ned state is indicated for the LPU by the symbol or digit ’1’
at (14, at the end of the line).
As a result, the sample manual telescoping procedure is in effect

over.
In order to now switch to the automatic telescoping, the posi-

tions of all individual telescopic sections ”must be taught” (defi-
ned and saved) (refer to Sect. 12.3.7 on the following pages).
140−1120−101a 57/77
12
Z 54 733
Z 54 734
58/77 140−1120−101a
Telescoping 12
12.3.7 Teaching the extension status of the telescopes

(Z 54 733, Z 54 734)
The telescoping system must be informed about the extension

status of each telescope after manually telescoping the main
boom. This procedure is referred to as ”teaching”.
Proceed as follows:
(Z 54 733)
1. Push button on the “TeleManual” screen (Z 54 733,

left side). The “TeleTeach” screen (Z 54 733, right side) ap-
pears.
All of the keys assigned to individual telescopes T1 − T5 are at

first only filled in with a star. Subsequently, the current extension
statuses for all telescopes must be selected manually. There are
the following possibilities for selection:
“0”, “45”, “90” and “100” for the pinned state and “LPU” when the
telescopic section is unpinned and locked to the LPU.
(Z 54 734)
2. Press key next to T1 until the value appears which corres-
ponds to the actual extension state of T1 (here: 0, i.e. tele-
scopic section 1 is 0% extended).
3. Repeat the procedure specified for telescope 1 accordingly

for the remaining telescopes T2 − T5.
4. Make sure the defined status corresponds to the actual ex-

tension status for all telescopes. If so, actuate the “Teach”
key. The initial screen “TeleManuell” appears.
The saved values are adopted by the control system in preci-
sely the same way. Incorrect values are unable to be identi-
fied as such.
RISK OF ACCIDENTS
During the “teaching” process only those values may be
transferred to the control system which correspond to
the actual state. The crane operator is solely responsible
for this!
140−1120−101a 59/77
12
Z 54 735
60/77 140−1120−101a
Telescoping 12
(Z 54 735)
If the extension state of the telescopic sections correspond with

a length code, the selection can be made faster than described:
press key “LK” and select the line of the length code which corres-
ponds to the actual extension state of the telescopic sections.
Use button to exit the screen.
The screen ”TeleManual” appears again and all field concerning
the individual telescopes are then filled out together.
140−1120−101a 61/77
12
2
17
3
16
4
15
14
5
13 6
12 7
11 8
10 9
Z 54 133
62/77 140−1120−101a
Telescoping 12
12.3.8 Locking and Pinning Positions of the

Telescopic Drive
(Z 54 133)
The locking and pinning positions are required during manual

telescoping.
Observe the entry (1, LPU position) of the following table in order
to tell beyond doubt at which pinning hole the LPU is located for
the respective telescopic section (indication of the telescopic
section at “4”):
The indicated extension lengths may be exceeded by

approx. 0.05 m (approx. 0.164 ft) at the most during manual
telescoping so that the telescopic drive does not come off
the inner guide rails.
Telesco- Pinning LPU−Position Telesco- Pinning LPU Position

pic hole (%) pic hole (%)
section [m] [ft] section [m] [ft]
0 0,035 0.115 0 0,575 1.886
45 4,585 15.043 45 4,875 15.994
1 4
90 8,635 28.329 90 9,175 30.102
100 9,595 31.479 100 10,075 33.054
0 0,215 0.705 0 0,755 2.477
45 4,515 14.813 45 5,055 16.585
2 5
90 8,815 28.921 90 9,355 30.692
100 9,765 32.037 100 10,055 32.988
0 0,395 1.296
45 4,695 15.404
3
90 8,995 29.511
100 9,945 32.628
140−1120−101a 63/77
12
Z 54 736
1 3 4 5 6 2 8 9
16 15 12 9 8 14 12 9
22156512
Z 54 737
64/77 140−1120−101a
Telescoping 12
12.4 Lifting Capacities in the Unpinned Condition

(Z 54 736, Z 54 737)
The lifting capacities that are specified in the load capacity tables
in relation to the radius (see marked area in the display) only ap-
ply when all telescopic sections are pinned.
The lifting capacities can either be read from the load capacity ta-
bles which come with the machinery (Excerpt from a sample ta-
ble, Z 54 736) or else be taken from the IC−1 display for the parti-
cular actual configuration (Z 54 737).
The following load table is only a specimen. Only the load ta-
bles supplied with the crane may be used for operating the
crane.
There are also load capacities for the case that one telescope is
not pinned:
− Unpinned lifting capacities for which the main boom length re-
mains unchanged, so−called “lifting capacities in interme-
diate positions”. Refer to Section 12.4.1.
− Unpinned load capacities, for which the main boom length is
changed under load, so−called “telescoping load capaci-
ties“. Refer to Section 12.4.2.
140−1120−101a 65/77
12
A
1 3 4 5 6 2 8 9
B C
16 15 12 9 8 14 12 9
22156512
Z 54 738
A
3 4 5 6 2 8 9 10
B D
5 5 6 6 5 5 5 6
22142012
Z 54 739
66/77 140−1120−101a
Telescoping 12
12.4.1 Lifting Capacities in Intermediate Positions

(Z 54 738, Z 54 739)
The lifting capacities that are specified in the load capacity tables
in relation to the radius only apply when all telescopic sections
are pinned.
At a main boom length (A) of 16.8 / 55.1 ft m (with LK 5) and a

radius (B) of 8 m (26.2 ft), the corresponding pinned lifting capa-
city (C) is then 40.7 t (89.7 ft) (Z 54 738).
There are also lifting capacities for the unpinned state of a tele-
scopic element (only for main boom operation). These allow lif-
ting when working with unpinned lengths because of particular
space constraints. The bottom extended telescopic section is
then connected to the telescoping cylinder via the LPU.
When attaching loads in unpinned intermediate positions, the at-

tachable loads are limited additionally by the load capacity of the
telescoping cylinder and the bend of the main boom.
These effects are dealt with in “Unpinned Loading Capacities”

(Z 54 739).
This would mean with regard to the example above:

if the main boom length (A) is 16.8 m / 55.1 ft (with LK 5) and the
radius (B) is 8 m (26.2 ft), the corresponding unpinned load ca-
pacity (D) would then be 36.6 t (80.7 kip).
The unpinned lifting capacities quoted are only maximum

values and are not valid in all cases.
This ”unpinned” maximum value is adjusted to the ”pinned”
value using the load limit device − corresponding to the ra-
dius in question.
If the ”pinned” value of 40.7 t / 89.7 kip (C) is greater than the
”unpinned” value of 36.6 t/ 80.7 kip (D) − as is the case here
− the permitted lifting capacity is then reduced to 36.6 t
(80.7 kip).
If the unpinned value were smaller than the unpinned value,
then the permitted lifting capacity would be reduced to the
pinned value.
140−1120−101a 67/77
12
A B
39.0
10°
Z 54 740
1 3 4 5 6 2 8 9 3 4 5 6 2 8 9 10
16 15 12 9 8 14 12 9 5 5 6 6 5 5 5 6
22156512 22142012
Z 54 741 Z 54 742
68/77 140−1120−101a
Telescoping 12
(Z 54 740, Z 54 741, Z 54 742)
The load limit device automatically carries out this comparison

between the pinned and unpinned lifting capacities. The value is
then displayed in the mask “Operation of the crane” (Z 54 740)
(here: MAX (t) 13.0 / 28.7 kip), which is a result of the comparison
of both values as the max. permitted one.
The unpinned/pinned lifting capacities can then be read from the

IC−1 Display as follows:
1. In the Quick menu (Z 54 740, ”A”), press the there.

The “Operating Mode Preselection” screen then appears
(Z 54 740, ”B”).
2. In this screen, press the there. The “Table View”

screen then appears (Z 54 741).
The pinned lifting capacities (marked region) for the opera-
ting mode selected appear there.
Differently to the display of unpinned lifting capacities, the boom

symbol in the bottom left corner does not have a double arrow.
The appearance of the displays is otherwise very similar.
3. Push button there. The unpinned lifting capacities

(marked region) for the operating mode selected appear
(Z 54 742).
The boom symbol in the bottom left−hand corner is marked with

a double arrow.
140−1120−101a 69/77
12
A
1 3 4 5 6 2 8 9
B C
16 15 12 9 8 14 12 9
22156512
Z 54 738
A
3 4 5 6 2 8 9 10
B D
5 5 6 6 5 5 5 6
22142012
Z 54 739
70/77 140−1120−101a
Telescoping 12
Example
(Z 54 738, Z 54 739)
Operational planning has determined that, due to restricted

space, a main boom length of approx. 15 m (49.2 ft) is required
for a radius of 8 m (26.2 ft). The weight of the load to be raised
equals 38 t (83.7 kip).
Proceed then as follows:

− Select the locked main boom length above the one actually
required (here: 16.8 m / 55.1 ft).
− Select the length combination which offers the best values for
the desired radius (here: LK 5, 0/0/0/45/0).
− Enter corresponding length code (here: LK 5) and telescope
the main boom out unloaded in accordance with the speci-
fications of the telescoping information system until telesco-
pic section 4 is locked in the state and is telescoped out while
unpinned up to the required entire main boom length of ap-
prox. 15 m (49.2 ft).
At this point interrupt the telescoping, despite the specifica-
tions from the telescoping information system.
The permitted unpinned load capacity corresponds with the va-

lue from the depiction “unpinned” (Z 54 739, here: 36.6 t /
80.7 kip), as it is lower than the value “pinned” (here: 40.7 t /
89.7 kip).
So the load of 38 t (83.7 kip) in an unpinned state for telescopic

section 4 cannot be lifted.
140−1120−101a 71/77
12
72/77 140−1120−101a
Telescoping 12
12.4.2 Lifting capacities that can be telescoped

The lifting capacities in intermediate positions described in the
sect. 12.4.1 will also be released during a telescoping procedure.
However, the lifting capacities that are actually achievable du-

ring telescoping under load are only given as approximate values
due to the large number of variable external influences.
The load capacities which can be telescoped (on request) are

achieved under the following conditions:
− Sliding surfaces well lubricated
− Normal ambient temperature
− The systematic of the tele control system when carrying out
the extension sequences are predetermined and do not need
to be determined by the crane operator.
− During telescoping, the main boom angle may not be chan-
ged using the luffing cylinder.
140−1120−101a 73/77
12
39.0
7.50
Z 54 721 Z 54 743
A B
45%
90%
100%
90%
45%
10° 28%
Z 54 744
74/77 140−1120−101a
Telescoping 12
12.5 Main boom state to move the crane in

transport position
(Z 54 721, Z 54 743, Z 54 744)
To move the crane in transport position, all telescopic sections

have to be completely retracted and pinned and the LPU has to
be secured for transport configuration in the prescribed position
(5th telescopic section).
Otherwise there is a risk of the locking and pinning unit mo-

ving/sliding by itself in an uncontrolled manner. If the LPU is
secured in the wrong place the indicated axle loads are in-
correct.
Staring situation:
main boom telescoped in and set down on the crane chassis in
transport position; current LK = 1.
Proceed then as follows:
1. Switch on the ignition on the superstructure and start the en-

gine. The IC−1 will start and the and the “Operation mode
preselection” (Z 54 721) will then appear.
2. Select “HA” operating mode and save by actuating the

button.
The input screen “Quick Menu” appears on the right side of
the IC−1 display (Z 54 744, ”A”).
3. Push button there. The mask “Telescoping display”

(Z 54 744, “B”) appears.
4. Push the “LK” button. The “Tele operating mode” screen ap-
pears (Z 54 743).
140−1120−101a 75/77
12
Z 54 745
76/77 140−1120−101a
Telescoping 12
(Z 54 745)
5. Press push button and steer the corresponding con-

trol lever in the direction “Telescoping out” − the LPU is driven
accordingly and locked onto the 5th boom section.
The control lever has to be actuated long enough that crane re-
presented on the screen appears (Z 54 745, right side).
Only then is the main boom (including the LPU) in transport posi-
tion for moving the crane.
After moving, a length code can be selected again for the main
boom working range using the “LK” button.
140−1120−101a 77/77
Luffing 13
140−1130a_en 1/13
13
Z 54 748
180°
Z 54 722
2/13 140−1130a_en
Luffing 13
13 Luffing
13.1 Luffing Operation

(Z 54 748, Z 54 722)
The main boom is raised and lowered (luffed) by extending and

retracting the luffing cylinder (Z 54 748).
It is prohibited to raise the load from the ground using the

luffing gear! This should only be done using the hoist!
Proceed as follows to luff the main boom:
1. Support the crane on outriggers in accordance with the regu-

lations and align (see the operating instructions of the crane
chassis, section 12 “Outriggers”).
3. Make sure you are aware which mode has been selected for
the control lever settings. The current mode (in this case: 1)
is indicated by the corresponding symbol in the upper
line of the IC−1 display.
Detailed information on the selection and scope of the different

modes can be found in section 10 “Safety equipment”.
Risk of accidents!
It is the responsibility of the crane operator to make sure
which mode is currently selected for the control lever set-
tings before commencing any crane movements.
Otherwise accidents could occur as a result of unintended
crane movements!
140−1130a_en 3/13
13
180°
Z 54 723
H1
Z 54 749
4/13 140−1130a_en
Luffing 13
(Z 54 723)
4. Select the operating mode for the hydraulic pumps.
The hydraulic pumps can be set so that they combine to sup-

ply all hydraulic functions.
To achieve better activation, the pumps can be separated.
To do this press the left−hand button. The se-
lected mode “1 − 4” is displayed top left in the button field. In
both buttons the movements of the assigned
pumps are then displayed.
The button displays change depending on the selected mode.

Please follow the instructions in this manual, in section 10 “safety
equipment”, under the point “operating mode of the hydraulic
pumps”.
(Z 54 749)
5. If your crane is equipped for driving with a dolly (optional), the
ball cock (H1) must be in the position “not blocked” (as shown
in figure “Z 54 749”).
If this ball cock is in the locked position, the luffing cylinder
cannot be actuated.
140−1130a_en 5/13
13
30 16
31
32
24
34
35
36
Z 54 006
6/13 140−1130a_en
Luffing 13
(Z 54 006)
6. Start the luffing movement by pressing one of the buttons

Control lever (16/24) to the right − Lower main boom

/ to the front (luff down)
Control lever (16/24) to the left / − Raise main boom
to the rear (luff up)
The current setting for the control lever must be observed!
To avoid unintentional crane movements being activated, both

handle). The crane movement can only be carried out as long as
The dead man’s handle may only be actuated (pressed or re-
leased) when the corresponding control lever is in the neutral
position and/or the operating movement has been completed.
Risk of accidents!
Pressing or releasing one of these dead man’s handles
with the control lever fully actuated causes the corre-
sponding movement to be started or stopped very abruptly.
Risk of accidents!
Control levers (16/24) may not be switched directly to the op-

posite direction without first being placed in neutral. Do not
switch to the opposite direction until the main boom has
come to a halt.
140−1130a_en 7/13
13
115
116
Z 53 475
8/13 140−1130a_en
Luffing 13
The control lever automatically returns to the neutral position

when it is released. The crane movement which has been started
is stopped.
If the hook is fully raised, and if the hoist limit switch has triggered,
the main boom can no longer be lowered. First the hoist (the
hook) must be lowered (see section 14).
(Z 53 475)
If a prohibited overload condition has occurred, the load−
moment−reducing movement ”raise main boom” is also
shut down by the load limit device. This movement can be
carried out after actuating and holding key−operated push-
button (116) in order to move a free−hanging load back out
of the overload range into the normal range. Indicator light
(115) lights up to display the bridged condition.
This load−moment−reducing movement may only be car-

ried out if it is safe to do so. Make sure that it is safe before
actuating the key button.
the hoist has been shut down, the load is too heavy. The
movement ”raise main boom” may not be enabled!
The movement ”raise main boom” may not be used under

any circumstances to raise the load!
Risk of falling backwards!
In some cases it is not possible to enable load−moment−re-

ducing movements.
Example: the permitted minimum radius is 3 m (9.8 ft) and
”luffing up” is switched off.
The system cannot then be bridged and the load−moment−
reducing movement “luff up” be continued, as the crane
could tip backwards − with a large counterweight.
140−1130a_en 9/13
13
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
180°
Z 54 750
10/13 140−1130a_en
Luffing 13
13.2 Regulating the luffing speed

(Z 54 007, Z 54 750)
The luffing gear is electrically pre−controlled. The luffing speed

is determined by the engine speed and the movement of the cor-
responding control lever (16/24).
High speed “raise main boom”
To raise the main boom (luff up) the high speed can be activated.
To this end, press push button (30) on control lever (16). The
high−speed remains activated as long as this button is pressed.
The activated high speed is shown using the symbol in the
IC−1 display.
In the following cases, high−speed may not be activated:

− when working with loads > 30% of the load capacity
− with a main boom extension fitted
− when raising and lowering the fully or partially retracted
main boom from the low position

− with a long main boom.
Activating the luffing gear at high speed for main boom op-
eration without load is only permitted up to a point well be-
fore the load limit device shuts down the movement (maxi-
mum up to the advanced warning).
Risk of crane tipping as a result of the ensuing crane dynam-
ics!
140−1130a_en 11/13
13
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
180°
Z 54 008
12/13 140−1130a_en
Luffing 13
Precision control “lower main boom”

(Z 54 007, Z 54 008)
In addition, to lower the main boom (luff down) the speed can be
precision controlled. To this end, first press push button (31/35),
i.e. the left−hand button on the corresponding control lever,
briefly. On the right−hand side of the IC−1 display the ”percent-
age display” mask appears (Z 54 008).
As long as this mask is displayed, the displayed percentage value
and the speed can be changed as follows:
− using self−return rocker switch (14/26) on the corresponding
control lever, when the movement is activated by horizontal
(left / right) movement of the control lever.
− using self−return rocker switch (14/26) and at the same time
by pressing push button (31/35) on the corresponding control
lever when the movement is activated by vertical (front / rear)
movement of the control lever.
Depending on whether the self−return rocker switch is actuated

on the left or right, the value is either reduced or increased.
If the percentage values have not been adjusted, the mask disap-
pears again after 5 s.
140−1130a_en 13/13
Hoist 1 14
140−1140 1/11
14
48
71
Z 54 078 Z 54 079
180°
Z 54 722
2/11 140−1140
Hoist 1 14
14 Hoist 1
14.1 Hoist Operation

(Z 54 078, Z 54 079, Z 54 722)
Loads are raised and lowered by reeling the hoist rope on and off
the rope drum of the hoist.
Risk of accidents!
The load may only be raised using the hoist!
Set the mirror (71) in the cab so that you can observe the reeling
of the hoist using the additional mirror located next to the hoist.
Switch on the hoist lighting (optional) if required using luminous
switch (48).
Proceed as follows to actuate the hoist:
1. Support the crane on outriggers in accordance with the regu-

lations (see operating instructions of the crane chassis, sec-
tion 12 “Outriggers”).
3. Make sure of which mode has been selected for the control
levers. The current mode (in this case: 1) is displayed by
means of the corresponding symbol in the upper line
of the IC−1 display.
Detailed information of the selection and scope of the different

modes can be found in section 10 “Safety equipment”.
Risk of accidents!
It is the responsibility of the crane operator to check the
current lever assignment before commencing work.
Otherwise there is a risk of unintentional crane movements
being activated!
140−1140 3/11
14
30 16
31
32
24
34
35
36
Z 54 006
4/11 140−1140
Hoist 1 14
(Z 54 006)
4. Start the hoist movement by pressing one of the buttons

Control lever (16/24) − Load / hook

forwards / to the right lower
Control lever (16/24) − Load / hook
to the rear / to the left raise
Beware of the current lever assignment!
To prevent the unintentional activation of crane movements, both

handle). The crane movement can only be carried out as long as
The dead man’s handle may only be actuated (pressed and re-
leased) when the corresponding control lever is in the neutral
position and/or the operating movement that has been started
has been completed.
Risk of accidents!
Pressing or releasing the dead man’s handle when the con-
trol lever is fully actuated leads to the corresponding move-
ment being started or stopped abruptly.
Risk of accidents!
movements can you avoid the load or hook block swinging
out, causing risk of crushing or crashing when each move-
ment is switched off.
The control levers (16/24) may not be switched directly in the

opposite hoist direction, but must first be placed in the neu-
tral position. Only start the contrary movement when the
hoist movement is at a standstill.
140−1140 5/11
14
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
6/11 140−1140
Hoist 1 14
(Z 54 007)
The control lever automatically returns to the zero position when

released. The crane movement which has been started is
stopped.
When using control lever (16/24), touch hoist rotation indicator

(15). You will feel definite vibration there as soon as the hoist ro-
tates,.
The movement ”raise load” is automatically switched off when the

:
* load limit device has tripped.
* the hook block in the hoist limit switch is activated.
Lowering of the load is possible.
The movement ”lower load” is automatically shut down, when the

lower limit switch for hoist 1 has tripped.
Raising of the load is possible.
140−1140 7/11
14
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
180°
Z 54 750
8/11 140−1140
Hoist 1 14
14.2 Regulating the hoist speed

(Z 54 007, Z 54 750)
The hoist is pilot controlled electrically. The hoist speed changes

in accordance with the engine speed and the movement of the
corresponding control lever (16/24).
High speed
High speed can be activated for the hoist. To this end, press push
button (30) on control lever (16). The high−speed function re-
mains activated as long as this button is pressed. The activated
high speed is displayed with the symbol in the IC−1 dis-
play.
In the following cases, high−speed may not be activated:

− when working with loads > 30% of the load capacity
− with single−rope operation of the main boom−
extension.
140−1140 9/11
14
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
180°
Z 54 750
10/11 140−1140
Hoist 1 14
Precision control
(Z 54 007, Z 54 750)
In addition, the speed can be precision−controlled for the hoist.

First press push button (31/35) briefly, i.e. the left−hand button on
the corresponding control lever. On the right−hand side of the
IC−1 display the mask “percentage display” (Z 54 750) appears.
As long as the mask is displayed, the displayed percentage value

and the speed can be changed as follows:
− using self−return rocker switch (14/26) on the corresponding
control lever, when the movement is controlled by means of
horizontal (left / right) movement of the control lever.
− using self−return rocker switch (14/26) and at the same time
pressing push button (31/35) on the corresponding control le-
ver, when the movement is controlled by vertical (forward /
backward) movement of the control lever.
Depending on whether the self−return rocker switch is actuated

to the left or right, the value is either reduced or increased corre-
spondingly.
If there is no adjustment of the percentage values, the mask dis-

appears again after 5 seconds.
140−1140 11/11
Hoist 2 15
140−1150−001a 1/21
15
1a
1b
Z 55 371
2/21 140−1150−001a
Hoist 2 15
15 Hoist 2 (optional)
You have the opportunity of using the second hoist when working
with the main boom extension and when utilising to auxiliary head
sheave and/or a runner.
15.1 Fitting and removing Hoist 2
(Z 55 371)
Equipment may only be fitted and removed by trained

and qualified personnel!
The attachment of Hoist 2 (1a) can be performed with to auxiliary

crane or with your own crane together with the assembly aid (1b)
in combination with the additional block (2) as a place of deposit.
In transport configuration, the actual Hoist 2 (1a) is mounted to-
gether with the assembly aid (1b).
Z 55 371 shows the transport configuration, mounted on the addi-
tional block (2) on the crane chassis.
The Hoist 2 needs to be secured against falling when
transported separately.
The weight of Hoist 2, including hoist rope and assembly aid is

approximately 1650 kg (3638 lbs).
The weight of the additional block is approximately 100 kg
(221 lbs).
A risk of crushing exists during attachment of Hoist 2 be-

tween the hoist housing and the superstructure frame
and the counterweight that has been set down.
The outrigger span needs to be selected in accordance
with subsequent crane operation.
140−1150−001a 3/21
15
A A
1a
5
3
4 3a
1b
3b
Z 55 372
Z 55 373
4/21 140−1150−001a
Hoist 2 15
15.1.1 when fitting and removing Hoist 2with the auxiliary

crane
15.1.1.1 Fitting
(Z 55 372, Z 55 373)
5. stabilise crane and make it level.
6. Hitch the entirety of Hoist 2 to the slinging points (A) provided

on the auxiliary crane and raise slightly (Z 55 372).
The weight of Hoist 2 including the hoist rope is approx. 1500 kg

(3307 lbs).
Persons must not stand or walk beneath suspended

loads or in areas where loads/equipment could fall.
The auxiliary crane must be able to hold the load until
the bolting at all locking points has been completed.
7. Separate Hoist 2 (1a) from the assembly aid (1b):

release pins (3) and (4) for this purpose.
The rod of the hydraulic cylinder (5) can not be locked with
the pins (3) at point (3b) until after connection with thesuper-
structure hydraulic system.
8. Hoist 2 Using the upper securing forks, place Hoist 2 on the

guide rail on thesuperstructure frame and push towards the
superstructure. Pin and secure Hoist 2 with the 4 biconical
pins (6/7) (Z 55 373).
Risk of crushing!
Risk of crushing exists between Hoist 2 and the respec-
tive fastening points on the superstructure frame.
9. Release the auxiliary crane.
10. Set up hydraulics and electrical connections between

Hoist 2 and the superstructure frame.
The hydraulic lines and connections are equipped with signs
which indicate which belongs where.
All hydraulic couplings are fitted with protective caps which

mustbe removed before fitting.
140−1150−001a 5/21
15
9B 9
5 9A
3
F1 3a
Z 55 374
Z 170 939
6/21 140−1150−001a
Hoist 2 15
(Z 55 374 , Z 170 939), principle illustration
10.1 Plug in the hydraulic couplings (raising and lowering

Hoist 2) (G1 to G2).
10.2 Also plug in the hydraulic couplings (leakage oil (H1 to

H2), control pressure (K1 to K2) ) for Hoist 2.
10.3 Attach the hydraulic system connections of the erec-

tion cylinders (F1 to F2).
Always make sure that the hydraulic lines are connected

properly, i.e. that the couplings open correctly.
The setting up and detachment of hydraulic connections is
not permissible except in the depressurised state, i.e.the su-
perstructure engine may not be running during these opera-
tions.
Connect the mobile control panel (9) to the connection (Q,

“X0029”).
11. Retract the erection cylinders (5) using the key (9B) on the
mobile control panel to such an extent that the rods can be
pegged and secured with the pins (3) at point (3a).
12. The attachment of Hoist 2 is thus completed. Make a test run

and check all hydraulics connections against leaks.
13. Reeve the hoist rope of Hoist 2 as needed.
15.1.1.2 Removal
Proceed in reverse sequence when dismounting Hoist 2 with the

aid of an auxiliary crane.
No personnel are permitted in areas where loads/equip-

ment could fall while the biconical pins are being re-
leased.
140−1150−001a 7/21
15
9B 9
9A
5
3
F1 3a
”1” ”2” ”3”

A ”AA” 6
6c 6b 6a A
1a 7
5 7a
3
3
3a
4
1b
8 3b
Z 55 375
8/21 140−1150−001a
Hoist 2 15
15.2 when fitting and removing Hoist 2with your own

crane
15.2.1 Fitting
(Z 55 375)
Fitting and removing of Hoist 2 with your own crane is carried out
using the assembly aid (1b).
The weight of Hoist 2 including the hoist rope and assembly aid
is approximately 1650 kg.
A risk of crushing exists when fitting and removing Hoist

2 between the individual elements and the superstruc-
ture frame and the crane chassis!
To avoid dangerous situations, pay particular attention to
the safety instructions in Chap. 1.4.8 ”When Assembling
and Dismantling Crane Components”.
In particular, make sure that you allow sufficient safety
clearance.

The auxiliary crane must be able to hold the load until
the bolting at all locking points has been completed.
1. stabilise crane and make it level.
2. Adjust crane controls in accordance with the rigging situa-

tion.
3. Place additional block (2), on the crane chassis and fasten

it if it has not yet been mounted.
4. suspend Hoist 2 (1a) to the 4 suspension points (A) provided

using the attached assembly aid (1b) , place on additional
block (2) and pin and secure with 4 pins (8) to the additional
block.
Select lifting gear in such a way that Hoist 2 is suspended
horizontally from the auxiliary crane. Lengthen the suspen-
sion chain on the ”AA” bracketing side somewhat as needed
by suspending with a shackle.
Failure to observe this will lead to inclined positioning, re-
sulting in problems when lifting and/or placing down on the
additional block and/or the assembly aid.
5. Release lifting tackle.
140−1150−001a 9/21
15
9B 9
9A
5
3
F1 3a
”1” ”2” ”3”

A ”AA” 6
6c 6b 6a A
1a 7
5 7a
3
3
3a
4
1b
8 3b
Z 55 375
10/21 140−1150−001a
Hoist 2 15
(Z 55 375)
6. Rotate superstructure to the rear and pin (superstructure) to

the undercarriage.
7. Set up hydraulic and electrical connections between hoist

and superstructure frame (see for this Chap. 15.1.1.1, start-
ing from page 5).
All hydraulic couplings are fitted with protective caps which

mustbe removed before fitting.
Always make sure that the hydraulic lines are connected

properly, i.e. that the couplings open correctly.
The setting up and detachment of hydraulic connections is
not permissible except in the depressurised state, i.e.the su-
perstructure engine may not be running during these opera-
tions.
Connect the mobile control panel (9) to the connection (Q,

“X0029”).
8. Extend the erection cylinders (5) using the key (9A) on the
mobile control panel (9).
Hoist 2 performs a movement thereby by which the upper se-
curing forks (6a) are guided along the guide rails (6b) of the
superstructure frame. Continue the adjustment movement of
the erection cylinders (5) until the biconical pins (6) in point
(6c) can be pegged (”1”).
9. Pin and secure Hoist 2 with the biconical pins (6) in point (6c)
(2 x) (”2”).
10. Remove pins (4) (”2”).
11. Retract the erection cylinders (5) using the key (9B) on the
mobile control panel until the pins (7) in point (7a) can be
mounted (”3”).
12. Pin and secure Hoist 2 with the biconical pins (7) in point (7a)
(2 x) (”3”).
13. Retract erection cylinders (5) using the key (9B) on the mo-
bile control panel until the rod eye can be pinned with the pin
(3) in point (3b) − secure pins (2 x) (”3”).
140−1150−001a 11/21
15
B B
1b
8
9B 9
9A
2
Z 55 376
12/21 140−1150−001a
Hoist 2 15
(Z 55 376)
14. Remove the mobile control panel (9).
15. Lift the assembly aid (1b) down from the additional block (2)
using your own crane apparatus.
For this, hitch the suspension chain in four strands to the lift-
ing eyes (B), lift slightly and remove the pins (8).
The weight of the assembly aid is approximately 145 kg (320 lbs).
The assembly aid must be lifted off Hoist 2 after assembly,

otherwise there is a danger of collision with the superstruc-
ture when rotating.
Danger of injury!
As soon as a load is lifted, no one is permitted beneath it
16. Reeve the hoist rope of Hoist 2 as needed.
15.2.2 Removal
Proceed in reverse sequence when dismounting Hoist 2.
Risk of injury!
Wind the hoist rope onto the drum completely prior to
dismantling the hoist and fasten the rope end to the
frame of Hoist 2.
No personnel are permitted in areas where loads/equip-
ment could fall while the biconical pins are being re-
leased.
140−1150−001a 13/21
15
11
12
2
4 3 1
5
13
14
Z 55 377
14/21 140−1150−001a
Hoist 2 15
15.3 Fitting and removing the additional top rollers

(Z 55 377)
In order to prevent the hoist ropes from rubbing against one

another, they need to be separated by
additional top rollers.
The additional top rollers must be removed in order to main-

tain the vehicle height of 4,0 m / 13.1 ft (transport state).
Risk of load being torn off!
You must use the supplied folding / sliding ladder or

another suitable aid, e.g. operating hoist stage, in order
to carry out the work described in the following.
The additional top rollers (1 to 4) each needs to be fastened with

screws (5) (4 x).
The additional top rollers are removed in the same way in the op-
posite sequence.
140−1150−001a 15/21
15
11
12
2
4 3 1
5
13
14
Z 55 377
16/21 140−1150−001a
Hoist 2 15
15.4 Rope guide

(Z 55 377)
When the two hoists are reeved together, the hoist rope (11) of
Hoist 1 is guided between the rope guides of the standard top roll-
ers and the additional top rollers (1 to 4) and are placed on the
main boom head over the rope pulley (14).
The hoist rope (12) of Hoist 2 is to be placed over the upper addi-
tional top rollers (1 to 4) and on the main boom head over the rope
pulley (13) (centreline main boom head).
Now the hoist limit switches must be fitted in accordance with the
equipment used.
140−1150−001a 17/21
15
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
0,0°
Z 55 363
18/21 140−1150−001a
Hoist 2 15
15.5 Hook Operation with Hoist 2
15.5.1 Pilot control assignment

(Z 54 007)
Depending on the crane equipment, different control lever as-

signments can be selected.
See section 10 (Safety equipment) ”Pilot Control Assignment”.
To prevent the unintended activation of crane movements, both

control levers are fitted with an additional button (32/36) (dead
man’s switch).
All crane movements can be performed if one of the keys is
pressed.
In order to avoid unplanned movements, take each selection

of pilot control assignment into consideration. Risk of dan-
ger!
The movement ”Raise load” is automatically switched off if:

* the LMI has been switched off.
Load capacity of 100 % is reached (bar display D, Z 55 363)
* The hook block is driven in hoist limit switch.

Lowering load is possible.
The movement ”Lower load” is automatically switched off if the

lower limit switch for Hoist 2 has been activated.
Raising of the load is possible.
140−1150−001a 19/21
15
14
30 15
31 16
32
26
34 25
35 24
36
Z 54 007
A
B
C
D
180°
Z 55 364
20/21 140−1150−001a
Hoist 2 15
(Z 54 007, Z 55 364)
When activating control lever (16 / 24), touch the cone of the hoist
rotation indicator (15/25).
As soon as the hoist rotates, you will feel a definite vibration there.
15.5.2 Hoist speeds

(Z 54 007)
The hoist is pilot controlled electrically. The hoist speed is in-

fluenced by the engine speed, steering of the control lever as well
as the number of movements carried out at the same time.
Fine tuning:
The speed of the crane movement ”Hoist 2” can be additionally

fine tuned. The movements carried out via the X−axle (horizontal
steering of the control lever) of each control lever can be adjusted
via the corresponding self−return rocker switch (14 / 26) (key
moved to the right − fast; key moved to the left − slow). Move-
ments performed along the Y axis of the control lever (vertical
movement of control lever), can be adjusted by activating the cor-
responding rocker switch (14/26) and at the same time pressing
the button (31/35); on front side of control lever, always on left
side in relation to direction of travel.
As long as the speed is adjusted via key (14 / 26), the correspond-
ing percentage appears in the display of the LLD (D, Z 55 364)
(see also section 10).
High range :
The high range for Hoist 2 is activated by pressing key (30 / 34)
and control lever (5 /10) at the same time.
To ensure progressive acceleration of the crane move-

ments, the crane movement must already be initiated before
switching to high−speed mode.
High−speed mode may only be used for up to a maximum of
30% of the corresponding load capacity.
High speed may not be used for one−rope crane operation
with main boom extension.
140−1150−001a 21/21
Heating and Ventilation 16
140−1160−003a 1/21
16
7 8 9 10
2
1 3
0 4
11
Z 54 530
12a 12b
zum Motor
zum Wärmetauscher
Heizung
Motor
Zulauf
vom Wärmetauscher
12c 12d 12e
Z 55 361
2/21 140−1160−003a
16 Heating and Ventilation

(Z 54 530, Z 55 361)
16.1 Engine−Dependent Heating
This heating is dependent on the coolant temperature of the

engine. The heating temperature in the cab is regulated using
rotary switch (9).
The fan can be switched to 4 different settings using rotary switch

(8) or switched off (setting “0”). The air exchange in the can be
accelerated accordingly by using the fan.
Using luminous switch (10), you can select between fresh air and
surround air operation:
− Luminous switch (10) not activated; the indicator light in the
switch does not light up: fresh air operation.
− Luminous switch (10) activated; the indicator light in the
switch lights up: surround air operation.
There are several air nozzles (12) in the cab. The air nozzles
(12b−e) can be opened or closed individually as required.
In order for the defroster nozzles (12a) to have as great an effect
as possible, the other air nozzles (12b−e) should be closed.
140−1160−003a 3/21
16
7 8 9 10
2
1 3
0 4
11
Z 54 530
4/21 140−1160−003a
16.2 Engine−Independent Heating with Coolant Preheating

System
In addition, observe the operating instructions of the

manufacturer in part 5 of this documentation.
They are in much greater detail and include additional areas
(such as fitting, safety devices and others).
16.2.1 General
(Z 54 530)
The mobile crane is equipped with an engine−independent

coolant preheating system for the superstructure engine. When
external temperatures are low, down to −20°C ( −4 °F), it makes
the engine start−up easier.
You must preheat the coolant under −20°C ( −4 °F). There is a
timer (7) in the crane cab for operation of the system.
Coolant preheating without preheating the cab: set the rotary
switch (9) to minimum.
Coolant preheating with preheating the cab: set rotary switch (9)
to maximum. The fan automatically starts up after a certain
coolant temperature which has been set that switch (8).
The heating system may only be used for the purposes

indicated by the manufacturer and while following the
supplied operating instructions.
Operation is not permitted:
− where flammable fumes or dust can be produced (i.e. near
fuel, coal dust, wood dust, wheat depots, or similar
places)
− in closed rooms (e.g. garages) due to risk of poisoning
− when refuelling.
When carrying out electric welding work on the vehicle, the

positive terminal must be disconnected from the battery to
protect the control unit and connected to ground.
140−1160−003a 5/21
16
8 9 10
MO ºC
7
3 20:30 11
1 2 3 4 5
Z 36 772
6/21 140−1160−003a
If the coolant has been replaced or if larger quantities of

coolant have been topped up, the operating temperature of
the engine must be brought to approx. 80 C (176 F)
( = opening point coolant thermostat) before the
engine−independent heating is switched on. The coolant
circuit and the circuit for the engine−independent heating
can then be ventilated automatically.
16.2.2 Operating Elements

(Z 36 772)
(1) − Time
(2) − Preselection
(3) − Heater
(4) − Backwards
(5) − Forwards
Display of the timer
(6) − Memory
(7) − Symbol for radio remote control
(8) − Week day / selected day
(9) − Current time / selected time
(10) − Temperature
(11) − Service indicator light
The heater should be switched on briefly (approx. 10 s)

outside of the normal heating periods at least once a month.
Thisprevents the water pump and the burner motor from
seizing up.
You must carry out a test run with the heater before the
heating period. If there is a development of thick smoke
which remains a longer period of time or if there are unusual
burner noises or a definite stench of burning, the heating
must be switched off and put out of operation by removing
the fuse. The equipment should only be restarted once it has
been tested by an authorised service outlet.
140−1160−003a 7/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
8/21 140−1160−003a
16.2.3 Settings
(Z 36 739)
After the power supply has been connected, all signals flash on
the display − all setting of the timer must be set. In this condition,
the heater assembly cannot be switched on.
16.2.3.1 Setting Time and Weekday for the First Time
Press briefly; time display flashes 12:00.

Set the current time.
Note: If two keys are shown next to each other, one or the
other must be pressed.
As soon as this stops flashing, it is saved. Then the weekday
flashes.
Set the current week day.
As soon as this stops flashing, it is saved.
If ignition is switched “On”, the display remains, if ignition is
switched “Off”, it goes out after 10 seconds.
16.2.3.2 Resetting Time and Weekday
Press longer until the time flashes. Then proceed as de-

scribed above in section 16.2.3.1.
If you press 2 x after the time has been reset, you can skip
the resetting function for weekdays.
If you press after the weekday has been reset, the flashing
of the weekday can be decreased.
With the ignition switched on the time and week day are
constantly displayed. With the ignition switched off, the
display goes out after 15 s.
Power failures are bridged by the heating timer.
All signals flash in the display after power failures. The
system must be completely reset!
140−1160−003a 9/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
10/21 140−1160−003a
16.2.4 Heating Operation without Preselection

(Z 36 739)
Before switching the heating on for the first time, bring the
engine temperature of the superstructure engine to approx.
80° C (176 F) before every heating period so that the heating
system is ventilated 100 %.
16.2.4.1 ... for Ignition “OFF”
Switch on the heater

Heating symbol = observe the service indicator light.
Press briefly.
Display: Operation, heating time.
The heating time is set at a default of 120 minutes. It can be

modified once or permanently.
Modifying the heating period once

Switch on the heating.
Press − shorten (min. 1 minutes) or lengthen (max. 120 min-
utes) heating time
Modifying the heating period permanently

Do not switch on the heating
Keep pressed for approx. 3 seconds until the display ap-
pears and flashes. Release briefly.
Press − shorten (min. 10 minutes) or lengthen (max. 120
minutes) heating time
When the display goes out, the new heating time is saved.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
140−1160−003a 11/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
12/21 140−1160−003a
16.2.4.2 ... for Ignition “ON”

(Z 36 739)
Switch on the heater

Press briefly.
Display: Operation, time, day of week.
The heater remains in operation as long as the ignition is

switched on. After ignition has been switched off, there are 15
minutes remaining heating time.
Changing the residual heating time

Switch on the heating.
Press − shorten (min. 1 minute) or lengthen (max. 120 min-
utes) residual heating time.
Switch off heating

Press briefly.
Operating display goes out.
Automatic run−on for cooling down.
16.2.5 Heating Operation with Preselection

(Z 36 739)
Starting point: Neutral position, as long as the display is visible.

No memory activated.
Three switch−on times within the next 24 hours or one switch−on

time up to seven days beforehand can be preselected.
Only one switch−on time can be activated.
Before switching on the heating for the first time, bring the
engine temperature of the superstructure engine to approx.
80° C (176 F) so that the heating system is ventilated 100 %.
140−1160−003a 13/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
14/21 140−1160−003a
16.2.5.1 Heating Start Within 24 Hours
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The preselected time is displayed

flashing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Press to select a memory again.
Set the preselected day

The preselected day is set automatically. It is therefore not
necessary to set it.
Preselected time and day are saved as soon as the time dis-
play goes out or it switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The preselected time of the displayed memory is shown for
approx. 5 seconds. It then goes out or the time is displayed
(with the ignition ON).
Press once to call up the preselected time with preselected
day (for 5 seconds).
140−1160−003a 15/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
16/21 140−1160−003a
16.2.5.2 Heating Start Later than 24 Hours (Max. 7 Days)

(Z 36 739)
Set the preselected time

Press until the desired memory display (1, 2, 3) is shown
flashing (here: memory 1) or goes out again. The basic set-
ting is 12 00.
and is displayed as follows.
Press briefly and release. The preselected time is displayed

flashing.
Press to set the preselected time. This is only possible as
long as the preselected time is displayed flashing.
Set the preselected day

The preselected day is shown flashing approx. 5 seconds
after the preselected time has been set.
Press to set the preselected day for the heater.
Preselected time and day are saved as soon as the time dis-
play goes out or switches to time display.
The memory display shows the activated memory.
Flashes and shows additionally an activated memory.
Check the activated memory

The preselected time of the displayed memory is displayed
for approx. 5 seconds. It then goes out or the time is dis-
played (with the ignition ON).
Press once to call up the preselected time with preselected
day(for 5 seconds).
140−1160−003a 17/21
16
MO ºC
6
3 20:30
P
1 2 3 4 5
Z 36 739
18/21 140−1160−003a
16.2.6 Rectifying Faults

In case of faults or damage to the heater, an authorised service
outlet must be contacted to repair the damage using original
spare parts.
Repairs in house are therefore not permitted.
Proceed as follows:
− switch off and on (not more than twice)
− check main fuses
− check that the air flow is not blocked
− go to a workshop.
If there is a fault when the heating is switched on and the

diagnosis lead is connected, the service indicator light will flash
and the fault code no. is displayed (go to a workshop).
140−1160−003a 19/21
16
7 8 9 10
2
1 3
0 4
11
Z 54 530
20/21 140−1160−003a
16.3 Air Conditioning Unit

(Z 54 530)
The air conditioning unit only works when the engine is running
and the fan is switched on. Proceed as follows in order to operate
the air conditioning unit:
1. Set switch (8) to the desired fan setting.
2. Press luminous switch (11); the indicator light in the switch

lights up.
The air conditioning unit works permanently with maximum

performance. The actual cooling performance is determined by
the selection of the fan setting.
In order achieve maximum cooling in the cab:

− Set fan to highest setting using switch (8).
− Turn switch (9) fully to the left (anti−clockwise) up to the stop.
− Fully open the ventilation nozzles.
− Activate luminous switch (10) for surround operation.
− Close windows and doors of the cab.
Instructions on operating the air conditioning unit
If the cooling performance of the air conditioning unit decreases

noticeably even though the switch settings have not been
changed, it is possible that the vaporiser has become iced up.
In this case, switch the air conditioning unit off for approx.
3 minutes with the vaporiser fan still running. The ice on the
vaporiser will melt.
On damp days the air conditioning unit can dehumidify the cab
air. Cooling is compensated by the heating. This then achieves
a pleasant cab climate and prevents windows fogging up.
Cold air coming out of the ventilation nozzles must not be allowed
to flow directly over unprotected skin.
The air conditioning unit must be switched on at least once

a month for a short period of time (compressor lubrication).
140−1160−003a 21/21
Reeving 17
140−1170b_en 1/35
17
Z 53 401
2/35 140−1170b_en
Reeving 17
17 Reeving
17.1 General
(Z 53 401, similar depiction)
The safety of the crane is endangered by incorrect reeving.
Every configuration is assigned a corresponding reeving

number that is shown in the load capacity tables supplied.
Work only in accordance with the reeving numbers listed!
The corresponding reeving number must be set on the load
limit device (IC−1).
Unless otherwise specified in the load capacity tables, the

number of reevings must not be lower than 2 rope lines.
If, however, single−line reeving is required, the lifting capac-
ities specified in the table must be reduced by 20%. This also
applies when the lifting capacity is less than the maximum
permitted cable tension per strand of 8,1 t (17.9 kip).
When fitting a new hoist rope, which has never been placed
under load, twisting problems can occur. For this reason we
would recommend you use a spin stabilizer (1, Z 53 401, sim-
ilar depiction) in this case.
140−1170b_en 3/35
17
Z 53 401
“a” “b”
ca. 1250
ca. 1500
Z 55 732
4/35 140−1170b_en
Reeving 17
(Z 53 401, Z 55 732)
If a spin stabilizer (1) is fitted on the rope attachment point

of the main boom head, the length of the shift weight chain
for the hoist limit switch (up to the bottom edge of the hoist
limit switch) must be AT LEAST approx. 1500 mm / 59.1 in
(see ”a” in Fig. Z 55 732). Only then is it guaranteed that the
”raise hoist” function is shut off by the hoist limit switch at
a sufficient distance from the lowest point of the main boom
head. Otherwise there is a risk of damage!
If the chain is not long enough, the additional chain that is
supplied with the spin stabilizer must be fitted as an exten-
sion.
If there is no spin stabilizer fitted on the main boom head, the

length of the shift weight chain for the hoist limit switch (up
to the bottom edge of the hoist limit switch) must be AT
LEAST approx. 1250 mm / 49.2 in (see ”b” in Fig. Z 55 732).
In order to achieve maximum hoist heights, a chain that is
possibly too long can be shortened accordingly. The di-
stance of approx. 1250 mm (49.2 in) must, however, be main-
tained under all circumstances. Otherwise there is a risk of
damage!
140−1170b_en 5/35
17
3
2
Z 52 210
6/35 140−1170b_en
Reeving 17
17.2 Load Lifting Equipment

(Z 52 210)
If a load is to be raised with the crane, so−called ›‹load lifting de-

vices are required to raise the said load. These are:
− Carrying Equipment
Carrying equipment is permanently connected to the crane.
This includes:
− hoist ropes (1, see section 17.2.1)
− hook blocks (3, see section 17.2.2).
− Load−handling devices
Load−handling devices are equipment, for example lifting
beams, that are not part of the crane. They are connected to
the carrying equipment and take up the load.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
− Lifting tackle
Lifting tackle is equipment, e.g. sling ropes, which does not
belong to the crane. They connect the carrying equipment
and load or carrying equipment and lifting devices.
Their selection and subsequent safe operation of the crane
are the responsibility of the crane operator.
To ensure that the load−handling equipment is used cor-

rectly the individual national regulations, for example the ac-
cident prevention regulations “Load handling equipment in
hoist operations” (VBG 9a / BGV D6)” must be observed.
140−1170b_en 7/35
17
Z 55 368 Z 55 369
8/35 140−1170b_en
Reeving 17
17.2.1 Hoist Ropes
17.2.1.1 General
Information on how to handle ropes safely and correctly is con-

tained in section 11 of the lubrication and maintenance instruc-
tions for the chassis.
When reeving there is a risk of becoming caught and en-

tangled in the head− and deflection rollers as well as in the
hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
Risk of overloading and accidents!

If a rope has to be replaced, the new rope must satisfy the
technical parameters of the original rope, for example with
regard to rope diameter, nominal tensile strength, calcu-
lated breakage force, minimum breakage force, type of lay
etc. in accordance with the rope certificate in the crane log-
book.
If this is not the case, the operational reliability of the crane
in the normally permitted lifting capacity range is no longer
guaranteed!
The length of the ropes of hoist 1 and hoist 2 is 305 m (approx.

1000 ft) each.
17.2.1.2 Rope Connections
(Z 55 368, Z 55 369, similar depiction)
The rope ends of the hoist ropes are fitted with different rope
sockets:
− Rope socket “with press fitting”: Z 55 368
− Rope socket “without press fitting”: Z 55 369
The drawings of the rope socket and rope clamp are only ex-
amples and do not correspond exactly with the components
supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.
140−1170b_en 9/35
17
2
4
Z 41 375
1 1
4
2
3 3
Z 41 383 Z 41 384
10/35 140−1170b_en
Reeving 17
Rope end connection “with press fitting”
(Z 41 375, Z 41 383, Z 41 384, similar depiction)
The rope end connector of the rope “hoist 1” comprises the fol-
lowing components (Z 41 375):
− the rope socket (1)
− the flap (2) with mushroom grip (4)
− the rope sleeve (3)
The rope sleeve (3) is a component of the hoist rope and is firmly
fitted to it.
− To secure the rope end, it is inserted in the rope socket (1)

with the help of the fitted rope sleeve (3) and secured with flap
(2).
− Before fitting the rope sleeve (3), fold up flap (2) with the help
of mushroom grip (4) (Z 41 383).
− After fitting the rope sleeve (3), fold flap (2) into the “lock”
position and insert the locking pin using the mushroom grip
(4) (Z 41 384).
Before reeving the rope “hoist 1” on the main boom, on the

fly jib and on the main boom extension, all rope protection
arrangements such as rollers or bolts on the reeved deflec-
tion and rope idlers must be removed or opened. If this is not
done, the hoist rope with the attached rope sleeve cannot be
drawn through, when reeving the hoist rope using the auxil-
iary reeving winch there is a risk of damage for the winch, the
sheaves and the hoist and auxiliary reeving rope.
140−1170b_en 11/35
17
1
2
Z 41 377
1
1
5
›4‹a ›4‹b
›4‹a
Z 200 177 Z 41 379
12/35 140−1170b_en
Reeving 17
Rope end connection “without press fitting”
(Z 41 377, Z 200 177, Z 41 379, similar depiction)
The illustrations of the rope socket (1) and the cable clip (3)
are principle drawings and do not correspond exactly with
the components supplied by the crane manufacturer.
Use only original parts supplied by the crane manufacturer.
In order to fit the rope socket (1), first the free rope end is pulled
through the conical rope pocket, laid in a loop and then pulled out
of the rope pocket again. The rope key (2) is laid into the rope loop
and the hoist rope is pulled through the rope socket (1), so that
the free end juts out by approx. 8 times the width of the rope diam-
eter. The free end must be secured against pulling using a cable
clip (3) of the correct size.
Danger of the load and / or the hook block falling down!
140−1170b_en 13/35
17
Z 200 342 Z 200 343
1
1
5
›4‹a ›4‹b
›4‹a
Z 200 177 Z 41 379
14/35 140−1170b_en
Reeving 17
Using a rope clamp (3), the ”unloaded” rope end (4a; Z 200 177)
is now secured with a gap of approx. 3−fold rope diameter where
it exits the rope lock, in order to prevent the hoist rope being
pulled through.
The free end is connected with Litz wire (5) ø1.5 mm (0.06 in)
from the rope clamp to prevent the hoist rope from being pulled
through.
(Z 41 379)
Risk of damage to the rope!
The cable clip may not be attached in such a way that it con-
nects the „loaded“ (4b) and „unloaded“ ropes (4a) with each
other.
(Z 200 342)
When fitting the rope socket you must make sure that the
„loaded“ rope (4b) runs through the rope socket in such a way that
the tension force’s line of action runs exactly through the fasten-
ing pin without bending the cable when the end connection is
loaded.
(Z 200 343)
When fitted incorrectly, the end connection will align itself
whenever loaded so that the tension force’s line of action
runs through the fastening pin, bending the highly loaded
„loaded“ rope of the cable at the rope pocket exit every time.
On one hand, this reduces the maximum transmittable ten-
sion force of the end connection, on the other hand the pres-
sure coupled with the frequent bending within a very small
radius creates a premature wear of the rope cables in this
area, so that the end connection can fail prematurely even
when there are only small tension forces.
140−1170b_en 15/35
17
E1
11 3−TOP
12
13
K
Z 52 200 Z 53 402
16/35 140−1170b_en
Reeving 17
17.2.1.3 Reeving / unreeving the hoist rope

(Z 52 200) (Z 53 402, similar depiction)
Reeving
1. Position the hook block beneath the main boom head so that
it is stable.
RISK OF TIPPING!
Work may only be carried out on the hook block (reeving
and unreeving), if it is set down on stable ground.
2. Remove bolts for rope guard (11) from the hook block and
fold out the rope protection plate (12).
3. Remove the bolt for the rope guard (13) from the main boom
head.
4. Guide the hoist rope from the hoist via the main boom to the
guide sheave (E1) on the main boom head.
Guide sheave (E2) is optional.
While the crane operator is using the hoist, the hoist rope
must be guided by a helper to prevent slack rope from form-
ing.
If it is unavoidable for personnel to walk on the main boom

during this procedure, suitable safety measures must be
put in place.
There is a risk of accidents as a result of slipping /
stumbling on the main boom or if the hoist is incorrectly
operated.
140−1170b_en 17/35
17
E1
11 3−TOP
12
13
K
Z 52 200 Z 53 402
18/35 140−1170b_en
Reeving 17
(Z 52 200) (Z 53 402, similar depiction)
5. Guide the hoist rope via guide sheave (E1) to the sheaves
(K) in the main boom head and reeve in accordance with the
corresponding reeving diagram (see section 17.3).
6. Fit the bolt for rope guard (11) on the hook block and (13)
reattach on the main boom head and secure. To this end the
rope protection plate (12) must be folded in again on the
hook block.
7. Fit rope end into rope socket (if this has not already been
done). Follow the instructions in section 17.2.1.2 “Rope End
Connections”.
140−1170b_en 19/35
17
”A”
FKR
F Kl
Z 53 409
2 1
Fu
3
2
2a 2b
Z 52 214 Z 52 209
20/35 140−1170b_en
Reeving 17
(Z 53 409, Z 52 214, Z 52 209)
8. Bolt the rope socket or rope pocket to the corresponding fix-

ing point:
− with uneven number of rope strands fixing point on the
hook block (FU, Z 52 209)
− with even number of rope strands fixing point on the main
boom head, here: right−hand side (Z 53 409).
9. Release the shift weight of the hoist limit switch from the
transport position (”A”, Z 53 409), remove both clip pins and
pull the two halves (2a) and (2b) of the shift weight apart.
10. Guide the separated halves of the shift weight around the
hoist rope and secure again with clip pins.
The condition shown in picture (Z 52 209) must be shown.
The shift weight should be fitted on the “resting” rope. This

avoids wearing of the hoist rope and shift weight.
The “resting” rope is the rope line that goes to the fixing
point:
Make sure that the shift weight is hanging free. Only then is
it guaranteed to function properly.
Risk of damage !
If the shift weight of the hoist limit switch is not − as de-
scribed − fitted on the hoist rope, the hoist stroke limitation
does not work.
There is a risk of damage to the rope, sheave and shift
weight.
140−1170b_en 21/35
17
22/35 140−1170b_en
Reeving 17
Unreeving
In principle, unreeving is carried out in the same as reeving, only

in the reverse order.
In particular pay attention to the following points:
− Tipping over of the stationary hook block
RISK OF TIPPING!
Work may only be carried out on the hook block (reeving
and unreeving), if it is set down on stable ground.
− Sudden release of the hoist rope end from the hook block
RISK OF ACCIDENTS!
When unreeving, the hoist must be operated carefully and
the hoist rope wound slowly.
The area around the hook block must be kept clear at all
times.
− Watch the winding pattern of the hoist rope when reeling in

the rope. There must be no slack rope.
140−1170b_en 23/35
17
Z 50 696
24/35 140−1170b_en
Reeving 17
17.2.2 Hook blocks

(Z 50 696)
17.2.2.1 Definition
In DIN 15002 the hook block is defined as the “multiple line sus-
pension of carrying equipment with a hook“.
A single−line suspension would be referred to as a hook suspen-

sion gear. As this differentiation is not relevant for the following
general contexts, only the description “hook block” is used.
Only hook blocks may be used which have been obtained

from the crane manufacturer.
The use of other hook blocks is only permitted following
consultation with the crane manufacturer.
17.2.2.2 Markings
The following details must be permanently and legibly marked on

hook blocks:
− Warning marking
− Manufacturer or supplier
− Year of construction
− Type, if type designation applies
− Factory or serial number
− Permitted load
− Rope diameter
− Drive group
− Dead weight.
140−1170b_en 25/35
17
Z 42 980
26/35 140−1170b_en
Reeving 17
17.2.2.3 Operation
(Z 42 980)
When reevingthere is a risk of persons becoming caught

and dragged into equipment and crushing near rotating
and moving components on the hook blocks !
Proceed with appropriate caution and make sure that the
safety guards and intake guards are fitted.
In particular the following points must be observed:

− The personnel (person attaching/detaching the load) must be
qualified and conversant with the handling of hook blocks and
must be wearing suitable protective clothing.
When attaching and disconnecting the load, particular care

should be taken as a result of swinging loads or hook
blocks.
Once the load has been attached or released, the fitter must
leave the slewing or hazardous area immediately.
The fitter must be easily recognisable to the crane operator.

The fitter must wear one or more means of identification
e.g. jacket, helmet, special collars, armbands, signalling
discs.
These items of recognition must be of a distinctive colour
and preferably all in the same design and must be worn/car-
ried exclusively by the person connecting up the load.
Before starting movements of the winches (raising or low-

ering) all persons must leave the danger zone in the prox-
imity of the rope drums and sheaves.
The crane operator must have visual contact with the oper-
ating personnel and must give a warning signal before
starting the crane movements.
140−1170b_en 27/35
17
Z 42 975
Z 50 697 Z 42 976
28/35 140−1170b_en
Reeving 17
(Z 50 697, Z 42 975, Z 42 976)
− Touch the hook block only using the handrails provided. The
hands must be ›‹KEPT CLEAR of the following areas:
∗ between the sheaves, side plates and covers.
∗ in the area of the fixing points (sometimes of a folding de-
sign), the hook, the hook nut, the lifting beam or the pro-
tecting cages.
− Make sure that items of clothing do not get caught in rotating
parts.
− Work on the hook block may only be carried out (ie reeving),
when it is set down in a stable position on firm ground.
RISK OF TIPPING!
Be aware that the hook block could still tip over however!
− Only use the hook block for lifting in the vertical direction. Pull-
ing sideways is not permitted.
− Place the hook block under load slowly and evenly.
No sudden loads! No one−sided loads!
− Always fit the load / load−handling device in the middle of the
hook (hook jaw), never at the tip.
− Never load only one side of the twin hook.
Welding on the hook block is prohibited.
140−1170b_en 29/35
17
30/35
1−fach 2−fach 3−fach 3−fach 4−fach 5−fach 6−fach
2 6
4
2 2 4 4 2
3 2 5 2
3 3 5 3
1 1 1 3 1
1 1 1
7−fach 7−fach 8−fach 9−fach 10−fach 11−fach
9 10
6 4 8 8 6 10
8 6 11 8 6
2 6 4
2
6 4 4 2
7 5 7 5 7 5 2 7 5 9 7 4 2 9 7 4 2
3 1 3 1 3 1 3 1 5 3 5 3
1 1
12−fach 13−fach 14−fach 15−fach 16−fach

HW2 HW2 HW2 HW2
HW1 HW1 HW1 HW1
14 15 16
12 12 12 14 12 14 12
10 8 6 10 8 10 8 10 8 10 8
4 2
2 4 2 4 2 4 2 4
11 9 6 6 6
7 5 13 11 13 11 13 15 13
3 1 9 7 9 7 11 9 11 9
1 1 7 7
3 5 3 5 1 3 5 1 3 5
Z 55 366
140−1170b_en
Reeving 17
The safety of the crane is impaired by incorrect reeving!

This is why you must follow the reeving examples in figure
Z 55 366.
(Z 55 366)
Other reeving configurations would disrupt the function of the

load limit device.
The following hook blocks can be used:
Type 200−9/21−D 9−sheaves, Double hook,

weight 1750 kg (3858 lbs)
with mutual HD attachment
or with one−sided HD attachment (max.
16 falls)
Type 100−7/21−D 7−sheaves, max. 13 falls, Double hook,
Typ 80−5/21−E 5−sheaves, max. 11 falls, Single hook,
Type 63−3/21−E 3−sheaves, max. 7 falls, Single hook,
Type 32−1/21−E 1−sheaves, max. 3 falls, Single hook,
Type 8−0/21−E Hook suspension gear,
140−1170b_en 31/35
17
5
2
1
3b
3a
Z 55 367
32/35 140−1170b_en
Reeving 17
The weights of the hook blocks, hook suspension gear, lifting de-
vices, etc. must be deducted from the working loads in the tables.
Use only original hook blocks which are intended for this
crane.If you wish to use other hook blocks, you must first
contact our customer service departments.

with Auxiliary Sheaves (HD attachment, optional)
RISK OF ACCIDENTS!
Only the original HD attachment of the crane manufacturer
for this crane type may be used!
For the use of other additional equipment the crane opera-
tor carries sole responsibility.
17.4.1 Fitting and Removal of “One−Sided” Fitted HD At-

tachment
In the standard design there are 5 sheaves on the axle (2) of the
main boom.
For reevings above 10−strands, it is possible to attach additional
sheaves (3, HD attachment).
The HD attachment weighs approx. 100 kg (approx. 221 lbs).
Stand the main boom axis (2) on its end, push on HD attachment
(3) and secure with bolt (1) as shown.
Secure the bolts (1) on both sides with locking pins (5).
To reeve the hoist rope on the HD attachment (3) the three rope
locking pins (4) can be removed.
Immediately after fitting the hoist rope all 3 rope locking pins (4)
must be fitted again and locked.
The HD attachment is removed in the same way, in the reverse

order.
When using the heavy duty device, you must move the hoist limit
switch from the head and hang it onto the heavy duty equipment.
The existing forelock must be used for locking.
140−1170b_en 33/35
17
5
2
1
3b
3a
Z 55 367
34/35 140−1170b_en
Reeving 17
Only the heavy duty equipment supplied by the crane

manufacturer may be used.
The crane manufacturer is not responsible for possible ac-
cidents or damage caused by using incorrect optional
equipment.
17.4.2 Fitting and Removal of “Mutual” Fitted HD attachment

In the standard design there are 5 sheaves on the axle of the

main boom.
For the heavy duty equipment mounted at both sides, there are
additional sheaves mounted to the left and right side of the main
boom head. The hook block is reeved with the hoist rope of the
hoist 1 and the hoist rope of the hoist 2. This means that 16−fold
reeving is possible with the hook block “Type 200”.
Only the heavy duty equipment supplied by the crane

manufacturer may be used.
The crane manufacturer is not responsible for possible ac-
cidents or damage caused by using incorrect optional
equipment.
140−1170b_en 35/35
Main Boom Extension 18
18 Main Boom Extension (Option)
18.1 General
The bugles of the main boom extension must be inspected at least

once a year by a specialist (in accordance with the local accident
prevention regulations for load−handling equipment).
They should also be checked by a specialist in the meantime
depending on the applications of use and the operating
conditions. The inspection intervals generally depend on the
operating conditions and the applications for which the
equipment is used. This means that if the equipment is used more
often, the inspection intervals should be shortened accordingly.
The performance of these inspections must be recorded (e.g. in

the crane log book).
The following inspections should be performed:
* Inspection for cracks

* Inspection of length
* Inspection for wear
* Inspection of paint work
* Inspection for vivid deformation
You will find how the inspection must be carried out in the
”Maintenance and lubrication instructions of the superstructure”,
part 3, section 24).
You must also make sure that there is no damage to the tubes
in the lattice mast components. If damaged tubing is discov-
ered during visual inspections, further operation of the main
boom extension is prohibited.
There are the following combination lengths for the main boom
extension (MBE):
− 9.1 m / 29.9 ft
− 17 m / 55.8 ft
− 25 m / 82.0 ft
− 33 m / 108.3 ft
When an anemometer is mounted onto the main boom exten-

sion, the anemometer previously removed from the crane
must be used.
Failure to observe this can cause damage to the anemometer.
140−1180−181_en 1/51
18
”A”
Z 54 080
2/51 140−1180−181_en
When slewing the main boom extension from the transport

to the operating position or vice versa or when operating
with a folded main boom extension on the main boom, the
ladder (1) on the hydraulic oil reservoir must always be
folded against the oil reservoir. (Z 170 841).
RISK OF ACCIDENTS!
When carrying out installation work on the main boom
extension, use the supplied folding−sliding−ladder. It is
prohibited to walk on the main boom extension or on the
top of the main boom!
Always position the ladder so that is standing securely
and so that the resting point cannot slide away (i.e. after
loosening a pin).
RISK OF ACCIDENTS!
Only biconical pins which are cylindrical at one end may
be used for fitting the main boom extension (A, Z 54 080).
Each pin must be secured with 2 functioning locking

springs.
18.2 Fitting the Main Boom Extension 9.1 / 17 m

(29.9 / 55.8 ft)
When in the transport position or as long as the main boom

extension is not required, it can be carried along on the main
boom. The main boom extension is then folded alongside the
main boom and locked in place (Z 155 151). The permissible axle
loads must be observed.
For crane operation with the main boom extension locked in

the transport position, the loads specified in the load table
are reduced, i.e. the proportional weight of the main boom
extension in the transport position must be added to the load
that is to be lifted (see Notes on Crane Operation).
The following is a description of how you can get the main boom
extension from the transport position into the operating position.
18.3 Folding the Main Boom Extension 9.1 / 17 m

(29.9 / 55.8 ft)
Before folding the main boom out, it must be fully retracted

(catches must be flush, Z 170 608).
140−1180−181_en 3/51
18
4/51 140−1180−181_en
18.3.1 Folding the Lattice Mast 9.1m (29.9 ft) from the
Transport into the Operating Position
The conditions listed in the following must be observed for folding

out of the transport into the operating position and vice versa.
∗ Crane supported on outriggers and horizontally aligned.
∗ Counterweight fitted in accordance with the planned
configuration of the crane. To do so, follow the corresponding
details in the load capacity tables.
∗ Superstructure turned to the rear while supported on
outriggers and main boom set down (Z 170 610).
∗ Slew gear brake applied.
∗ Main boom in transport position (fully telescoped in and
pinned).
Safety and locking unit secured on the last (fifth) telescopic
section (see section 12 ”Telescoping”).
∗ The catches must (right and left on the main boom) be flush
(Z 170 608, page 2).
Operating position 0
1. Pull out pins (2) at point (C) using remote control (3)
(Z 170 609) and remove locking pin (7) (Z 170 611).
2. Slew main boom extension around the side center of motion

(E) (Z 155 154).
To avoid damage, a guide rope should be secured at the head

of the lattice mast.
The main boom extension can be pulled and braked with the
aid of the rope.
140−1180−181_en 5/51
18
Z 54 089
6/51 140−1180−181_en
3. Pin main boom extension at the boom head axles in fixing

points (F) and (G) using pins (3) and secure with locking
spring (4). (Z 54 089).
The pins (3) and locking springs (4) can be found at point (Q). (Z
54 089)
The double cones must be well greased before each pinning

and unpinning procedure.
The telescopic sections must be completely telescoped in to

fold the main boom extension into the working position.
In order for slewing round to function without any problems, the

main boom must be fully retracted. The stops between the
telescopic sections must be flush. Some of the stops have been
fitted so that they are covered. This is why you cannot tell if the
stops are flush just by looking.
If required, extend the main boom somewhat and recreate the

transport condition (Display) using the telescoping information
system (see in section 12: LPU in the position ”Transporting by
road”) again or manually retract the telepinion secured to the last
telescopic section (see section12 telescroping information
system ”Manual telescoping”).
140−1180−181_en 7/51
18
(3 + 4)
8/51 140−1180−181_en
4. Remove both pins from the side center of motion:

− pull out the pin (5) using abellcrank (Z 170 899)
− knock out the pin (6) (Z 170 899)
First remove the pin (5) from the centre of motion marked
with coloured decals, if pinning and locking has taken
place at the points (F) and (G) which are also marked
with colours.
5. Slew the main boom extension round to the front.

Here it must be ensured that the stop pin (8) slots into place
on the cross axle the left−hand (Z 170 613).
6. Pin in points (H) and (I) using pins (3) and secure with locking
spring (4) (Z 155 157) and (Z 54 089, page 6).
The pins (3) shall be inserted on the top and at the bottom.
Both pins shall be beaten far in alternately until the locking
springs can be mounted to secure the pins.
7. Attach the hoist limit switch and shift weight to the position
intended for this purpose on the main boom extension. (Z
155 200)
Check that all pins and locking elements are seated cor-
rectly.
8. Remove anemometer and aircraft warning light from the main

boom head and install them on the intended places on the
main boom extension.
140−1180−181_en 9/51
18
”X0550”
3
”X0560”
4
3 X0560 9,1m
Option
8,0m
Option
8,0m
X0550
X6540
X7272
X7811
H6263
X6540
5 H6262
X7271
B7513
+341−X7811 X7811 X7811
7
”X” HES HES
Z 60 250
10/51 140−1180−181_en
(Z 60 250).
9. Insert the plug of the cable (”X7811”) of the main boom

extension in the socket (3) at the distributor box (“X0550”) on
the main boom head.
10. Insert the plug of the anemometer in socket (3) on the

distributor box (“X0560”) of the main boom extension
(detail “X”).
11. Insert the plug of the aircraft warning light in socket (4) on the
(detail “X”).
12. Insert the plug of the hoist limit switch in socket (5) on the
(detail “X”).
First, the 2−pin bridging plug (7) may have to be removed
from socket (5).
RISK OF ACCIDENTS!
Open hoist limit switch connections on components of the
main boom extension must be ”2−pin” bridged in crane op-
eration at the appropriate distributor box/plug connection
(5) by means of bridging plug (7).
That is the only way to ensure that the safety chain is
closed and the hoist limit switch signal can be looped over
the components.
13. Reeve hook block. (see section 17).
14. For erecting the main boom with fitted main boom extension,
see from section 18.5, page 29.
Conversion to the travel position is the reverse of the above

procedure.
The pins in the coloured points (F) and (G) may only be
removed if the
main boom extension has been slewed back and has
been pinned and locked in the coloured point (E) again
(Z 155 147, page 12).
140−1180−181_en 11/51
18
14
12
12/51 140−1180−181_en
18.3.2 Folding the main boom extension 17.0 m (55.8 ft)

from transport position into working position
(Z 155 147).
Slew the superstructure to the back while supported on

outriggers and set down the main boom (take min. counterweight
into consideration).
During operation with the 17.0 m (55.8 ft) main boom extension
(lattice mast and tip section), ensure the following:
− the tip section must be pinned and locked to the lattice mast
at the rear end using pins (9) and (10). (Z 155 161, Z
155 147)
− the tip section must be locked to the lattice mast at the front
using the locking bolt (8) at point (R). (Z 170 613, Z 155 147)
− pin (12) must be pulled out at point (R) using the
bellcrank (Z 170 612, Z 155 147).
For details on folding the 9.1 m (29.9 ft) lattice mast with folded
tip section from the transport to the operating position, see
section 18.3.1, page 5.
1. Pull out pin (2) point (C) using remote control (3) (Z 170 609).
2. Unlock the locking bolt (7) at the runway (B) (Z 170 611).
3. Fold main boom extension (lattice mast 9.1 m / 29.9 ft with

folded tip section) from the transport into the operating
position.
For details on folding the 9.1 m (29.9 ft) lattice mast with folded
tip section from the transport to the operating position, see
section 18.3.1, page 5.
4. Loosen locking bolt (14) at point (R) (Z 155 147).
140−1180−181_en 13/51
18
14/51 140−1180−181_en
(Z 155 167, Z 155 169, Z 170 134)
5. Slew tip section round pins (9) and (10).

Here it must be ensured that stop pin (8) slots into place
afterwards (Z 155 169).
To avoid damage, a guide rope should be secured at the head
of the lattice mast.
The main boom extension can be pulled and braked with the
aid of the rope.
6. Pin and secure tip section in points (K) and (L) using pins (13
and 14) (Z 155 167).
The pins (13) and (14) shall be inserted on the top and at the
bottom. Both pins shall be beaten far in alternately until the
locking springs can be mounted to secure the pins.
7. Attach the hoist limit switch and shift weight to the top box
piece at the position intended for this purpose (Z 170 134).
rectly.
8. Remove anemometer and aircraft warning light from the main

boom head and install them on the intended places on the
box top piece.
140−1180−181_en 15/51
18
”X0550”
3
”X0560” 6
4 4
3 4
5
7
”X”
”X0561”
3 4
”Y” 5

X0560 9,1m 8,0m 8,0m
X0561 X0550
X6540
X7272
X7811
X7811
X6540
X7272
H6263
X6540
H6262
X7271
B7513
+341−X7811 X7811 X7811
HES
HES HES
Z 60 251
16/51 140−1180−181_en
(Z 60 251).

extension in the socket (3) at the distributor box (“X0550”) on
the main boom head.
10. Insert the plug of the cable (”X7811”) of the box top piece in
the socket (3) at the distributor box (“X0560”) on the main
boom extension (detail ”X”).

(detail “Y”).
(detail “Y”).
(detail “Y”).
from socket (5).
RISK OF ACCIDENTS!
the components.
Conversion to the travel position is the reverse of the above

procedure. The biconical pins (9 + 10, Z 155 169, page 14) in the
points (F) und (G) may not be removed until the box top piece has
been swivelled back and bolted and secured in point (E)
(Z 155 147, page 12).
140−1180−181_en 17/51
18
”A”
Z 54 080
18/51 140−1180−181_en
18.4 Fitting the Main Boom Extension 25 m / 33 m

(82 / 108.3 ft)
Slew the superstructure to the rear while supported on outriggers
luff the main boom down horizontally (0°). Create the minimum
counterweight as well as the minimum support base area. To do
so, follow the corresponding details in the load capacity tables.
RISK OF ACCIDENTS!
Only biconical pins which are cylindrical at one end may
be used for fitting the main boom extension (A, Z 54 080).
Each pin must be secured with 2 functioning locking

springs.
Use the folding−sliding ladder that was delivered with the

crane for pinning and locking the main boom extension.
Make sure that the climbing aid is on firm / secure ground.

The auxiliary crane must hold the load until pin locking is
completed at all pin lock points.
The single components of the main boom extension may

only be fitted individually.
18.4.1 Installation of main boom extension 25 m (82 ft)

(Z 170 954).
Proceed as follows in order to fit the main boom extension 25 m

(82 ft):
Before fitting the main boom must be completely retracted

and pinned.
Only use the attachment points designed for lifting which are on
the individual components of the main boom extension, see
detail X, (Z 170 954).
1. Raise the first intermediate section (8 m / 26.3 ft; with

deflection roller (Y)), using an auxiliary crane, in front of the
main boom head (main boom and intermediate section
compose a line) and pin lock and secure at the fixing points.
2. Using an auxiliary crane, raise the lattice mast 9.1 m (29.9 ft)
in front of the intermediate section and pin and lock in the
fixing points.
140−1180−181_en 19/51
18
20/51 140−1180−181_en
(Z 170 134, Z 170 955)
3. Lift the box top piece with an auxiliary crane in front of the
intermediate section and pin lock and secure at the fixing
points(Z 170 955).
4. Attach the hoist limit switch and shift weight to the top box
piece at the position intended for this purpose (Z 170 134).
5. Attach the anemometer and aircraft warning light to the top

box piece at the position intended for this purpose.
140−1180−181_en 21/51
18
”X0550”
3
”X0560” 6
4 4
3 4
5
7
”X”
”X0561”
3 4
”Y” 5

X0560 9,1m 8,0m 8,0m
X0561 X0550
X6540
X7272
X7811
X7811
X6540
X7272
H6263
X6540
H6262
X7271
B7513
+341−X7811 X7811 X7811
HES
HES HES
Z 60 251
22/51 140−1180−181_en
(Z 60 251).
6. Connect the plug of the cable (”X7811”) of the main boom

extension 9.1 m (29.9 ft) to the socket of the cable (”X7811”)
of the main boom extension 8.0 m.

extension 8 m / 26.3 ft in the socket (3) at the distributor box
(“X0550”) on the main boom head.
8. Insert the plug of the cable (”X7811”) of the box top piece in
the socket (3) at the distributor box (“X0560”) on the main
boom extension (detail ”X”).

(detail “Y”).
(detail “Y”).
(detail “Y”).
from socket (5).
RISK OF ACCIDENTS!
the components.
rectly.

Dismantling is carried out in the same manner, but in the opposite

order.
No persons may be in the area where there is a risk of

falling items when loosening the biconical bolts.
140−1180−181_en 23/51
18
24/51 140−1180−181_en
18.4.2 Installation of main boom extension 33 m (108.3 ft)

(Z 170 955).
Proceed as follows in order to fit the main boom extension 33 m

(108.3 ft):
Before fitting the main boom must be completely retracted

and pinned.
1. Raise the first intermediate section (8 m / 26.3 ft; without

deflection roller), using an auxiliary crane, in front of the main
boom head (main boom and intermediate section compose
a line) and pin lock and secure at the fixing points.
2. Raise the second intermediate section (8 m / 26.3 ft; with

deflection roller (Y)) with an auxiliary crane in front of the first
points.
fixing points.
4. Lift the box top piece with an auxiliary crane in front of the
points.
For the further procedure, see section 18.4.1 from point 4., page
21.
For bending the main boom extension from 05 to operating

position 205 or 405, see section 18.5.3, page 37.
140−1180−181_en 25/51
18
26/51 140−1180−181_en
(Z 170 955).
1. Raise the first intermediate section (8 m / 26.3 ft; without

deflection roller), using an auxiliary crane, in front of the main
boom head (main boom and intermediate section compose
a line) and pin lock and secure at the fixing points.
2. Raise the second intermediate section (8 m / 26.3 ft; with

deflection roller (Y)) with an auxiliary crane in front of the first
points.
fixing points.
4. Using an auxiliary crane, raise the box top piece 7.4 m

(24.3 ft) in front of the intermediate section and pin and lock
in the fixing points.
For the further procedure, see section 18.4.1 from point 4., page
21.
For bending the main boom extension from 05 to operating

position 205 or 405, see section 18.5.3, page 37.
140−1180−181_en 27/51
18
(82 / 108.2 ft)

25m / 33m = 45 % 0/0/0/0 %
(29.9 / 55.8 ft)
9.1m / 17m = 100 % 0/0/0/0 %
Z 54 082
28/51 140−1180−181_en
18.5 Configuration and Fitting Program for Erecting or

Bending the Main Boom Extension
In order to configure the main boom extension using a frame (0°,

20°, 40°), a special configuration program is required.
The selection of the configuration program is described in section
18.5.1, page 31 and in section 18.5.2, page 33.
(Z 54 082).
Main boom extension 9.1 / 17.0 m (29.9 / 71.5 ft):

− maximum permitted main boom erection length 21.8 m
(71.5 ft)
(extension sequence 0/0/0/0/100%; LK code 12).
Main boom extension 25 / 33 m (82 / 108.3 ft):

− maximum permitted main boom erection length 16.8 m
(55.1 ft)
(extension sequence 0/0/0/0/45%; LK code 6)
Requirements for configuration:
− the superstructure must be slewed to the rear (0°) and pinned

− the main boom angle is between −2° and +0° to the horizontal
− counterweight is in accordance with the load capacity tables
− the outrigger support area corresponds to the load capacity
tables
Additional loads must not be attached once the erection and

assembly programme has been set.
140−1180−181_en 29/51
18
10°
Z 60 253
1 2 3
45 %
90 %
100 %
90 %
4 45 %
28 %
Z 60 254
30/51 140−1180−181_en
18.5.1 Telescoping Display

(Z 60 253, Z 60 254)
In mask “Quick Menu” (Z 60 253), press key . Instead of

the “Quick Menu”, the entry mask of the telescoping information
system will appear, the “Telescoping Display” (Z 60 253).
You can select submenus here as well as information on the state
of the telescoping system.
(Z 60 254).
(1) Length code selection see section 18.5.2 ”Selection of the

longitudinal code”, from page 33
grey: the selected length code has not
been achieved.
green: the selected length code has been
achieved.
(2) End length of the main boom
(3) Actual length of the main boom
(4) Extension length of one telescopic section in percentage
140−1180−181_en 31/51
18
45 %
90 %
100 %
23.9 M
90 %
45 %
10° 28 %
Z 54 727
3 4 5 6 7
8
2
1 9
14 13 12 11 10
Z 54 728
32/51 140−1180−181_en
18.5.2 Selection of the Length Code

(Z 54 727, Z 54 728)
In order to select the length code (LK) for the desired main boom
length, press key ”LK” (Z 54 727). The mask “Tele operation
mode” will appear (Z 54 728).
All length codes are displayed here, including the corresponding
main boom length, extension state of the individual telescopic
sections and possible max. lifting capacities which are permitted
and can be selected for the chosen operating mode.
Call up the desired length code line using arrow keys (8 or 10).
You activate the desired length code by pressing it (the entire line
1, Z 54 728, is sensitive to touch). You exit the mask by pressing
key , the length code is saved and the mask “Telescoping
display” appears again (Z 54 727).
The key “LK” with its newly selected length code now has a grey
background. This means that the corresponding length must yet
be activated. This LK code is also displayed in black in the top line
of the IC−1 display.
As soon as the following telescoping procedure has been
completed, meaning that the corresponding aimed length has
been achieved, both displays change their colour to green.
140−1180−181_en 33/51
18
3 4 5 6 7
8
2
1 9
14 13 12 11 10
Z 54 728
34/51 140−1180−181_en
Mask “Tele operation mode”

(Z 54 728)
(1) − Number of the length code (LK no.)

(2) − Length of the main boom
(3) − Extension state of the telescopic sections 1 to 5 (from left
to right)
(4) − Max. lifting capacity in high position

(5) − Radius in high position
(6) − Max. lifting capacity in low position
(7) − Radius in low position
(8) − Scrollbar for flicking thorough the length codes, line by
line
(9) − Exiting the mask with save; the settings are saved
(10) − Flicking through the length codes, page by page:
> one page down; < one page up
(11) − Length code selection for the position of the LPU for
driving the crane (only for operating mode HA)
(12) − Exiting the mask without save; the settings are not saved.
140−1180−181_en 35/51
18
36/51 140−1180−181_en
18.5.3 For bending the main boom extension from 0 degrees

to operating position 20 degrees or 40 degrees
1. For requirements see 18.5, from page 29.
2. Main boom extension installed in 0° working position (see

18.3, from page 3 or 18.4, from page 19)
3. Configuration and Fitting Program for the Main Boom

Extension:
− at 9.1 / 17 m (29.9 / 55.8 ft), select LK code 12,
Display 090030
− at 25 / 33 m (82 / 108.3 ft), select LK code 6,
Display 090033
4. Pull out pin (18) at point (M), unfold roller strut and pin and
lock diagonal movable tube in point (N) with pin (18)
(Z 155 148).
140−1180−181_en 37/51
18
(82 / 108.2 ft)

25m / 33m = 45 % 0/0/0/0 %
(29.9 / 55.8 ft)
9.1m / 17m = 100 % 0/0/0/0 %
Z 54 082
Z 54 084
38/51 140−1180−181_en
− Lay down hook block on the ground

− Slew superstructure slightly to the side
5. Extend main boom in accordance with the configuration

program and luff it downwards until the roller strut is sitting on
the ground (Z 54 082) and the biconical pins (3) are relieved
of load in the points (F) and (H) (Z 54 084).
6. Remove biconical bolts (3) and store in the prepared bearing

plates (Q) in the main boom extension and secure with
locking spring (4). (Z 54 084).
140−1180−181_en 39/51
18
21 21
20 19
20
Z 54 085 Z 54 086
20o 40 o
20 20
19 19
0o
20
19
20 19 20
”O” 19
”P”
Z 54 087
40/51 140−1180−181_en
(Z 54 085, Z 54 086, Z 54 087)
7. Pull out pin (20) and slide tension bars (21) into the fitting
position (Z 54 085, Z 54 086); pin lock using pin (20), and
guard (Z 155 567).
Depending on the desired operating position, pin and lock the
shackles in the fitting position (for 20°−position at point “O”)
or (for 40°−position at point “P”) on the main boom extension
using pins (19) (Z 54 087).
8. Raise the roller struts so that they come off the ground. To do
so:
8.1 for 9.1 m (29.9 ft) extension:

Luff the main boom upwards until the roller strut lifts off
the ground.
8.2 for 17.0 m / 25 m / 33 m (55.8 ft / 82 ft / 108.3 ft)

extension:
Luff the main boom forward until the main boom
extension is lying on the plastic roller of the tip section
and roller strut is lifted off the ground.
140−1180−181_en 41/51
18
42/51 140−1180−181_en
9. Remove pins (18) of the roller struts between the frame and
the movable tube (point N).
10. Fold diagonal movable tube and frame of the roller strut
upwards.
11. Pin and lock the frame of the roller struts on the lattice mast
in point (M) using pins (18). (Z 155 177).
12. The conversion of 20°/40° to 0° operating position is carried

out in a similar manner, in the opposite sequence.
Risk of tilting when bending the main boom extension.
Adhere to max. extension length and extension se-
quence in % (see section 18.5, page 29)
18.5.4 Telescoping the Main Boom with Fitted MBE in the

Load Raising Position
Before raising or telescoping, check that all required

pins are fitted and that there are no objects that are not
tied down (e.g. hammers) on the main boom or the MBE.
1. Raise the main boom with fitted main boom extension off the
ground and place in a steep position (approx. 82°).
2. Telescope main boom in fully, while pulling in the hoist rope.
3. Set the load limit device to the desired operating length (to
select LK code, see section 18.5.1, page 31 and section
18.5.2, page 33, or section 12 “Telescoping” of these
operating instructions).
Make sure that the details of each individually valid load
capacity table correspond to the current crane configuration
(e.g. main boom length, fitted counterweight, etc.).
When the main boom extension 9.1 / 17 m (29.9 / 55.8 ft) is

folded up, the load values in the tables are reduced.
4. Telescope main boom out to the planned final length.
5. Telescoping in is done in a similar manner, in the opposite

sequence.
140−1180−181_en 43/51
18
12
Z 54 088
44/51 140−1180−181_en
18.6 Fitting the main boom extension with auxiliary crane

9.1 / 17 m (29.9 / 55.8 ft)
18.6.1 Fitting the 9.1 m main boom extension (29.9 ft)

1. Using the auxiliary crane, attach the basic boom MBE at the
prescribed attachment points and hang in front of the main
boom head (Z 54 088).
2. Knock in the fixing pins in points (F, G, H, I) and secure.
3. Fit the hoist limit switch, set the operating angle, reeve in
hook block.
4. Establish electric safety chain, see section 18.10, from page

49.
18.6.2 Fitting the main boom extension 17 m (55.8 ft)
Fitting individually
Place basic boom MBE and tip section individually in the

corresponding fitting positions, similar to 18.6.1, pin and lock.
18.7 Fixing the Tip Section to the Main Boom
If the crane is equipped with a 17.0 m (55.8 ft) main boom

extension, but work is only to be done with a lattice mast 9.6 m
(31.4 ft):
1. Pin pins (2) in point (C) using remote control (3), (Z 170 609).
2. Pin pins (12) to the main boom in point (S) using the bellcrank
(Z 155 202), (Z 170 612).
3. Remove connecting pins (9 and 10) in points (K and L) and

hang onto the lattice mast in the support plates (Q1) and
secure. (Z 155 202).
4. Further procedure as described in 18.3.1, from page 5.
5. Establish electric safety chain, see section 18.10, from page

49.
140−1180−181_en 45/51
18
46/51 140−1180−181_en
18.8 Operation with Main Boom Extension
1. Fit the main boom extension in the desired operating position

(load rasing position) and reeve in hoist rope 2−fold.
Depending on the starting point, consult the corresponding

subpoint.
2. Setting the crane configuration in the operating mode

preselection mask (section 10. Safety devices)
Type: MBE
other settings in accordance with set−up state
When selecting the operating mode MBE when already

telescoped out, you must remember
that the selected and currently relevant length code
(LK) must also exist as the extension sequence with MBE.
Otherwise it is not possible to change the operating mode.
The loads of the load tables are valid for 2−fold hoist
rope reeving.
If the hoist rope is reeved in only once:
− You must set simple reeving in the operating mode
preselection mask.
− The table values valid for 2−fold reeving are reduced by
20%. Then the already reduced value is displayed.
− It is prohibited to use high speed.
18.9 Emergency Removal in the Case of Telescoping

Problems
If telescoping the main boom in is not possible due to a fault, the

main boom must be removed as an emergency measure.
Depending on the state of assembly (outriggers, counterweight),
the
main boom can be removed directly. Otherwise you must use an
auxiliary crane. You can receive corresponding details on
request.
140−1180−181_en 47/51
18
1 5
”X0550”
2
3 5
4
6

X0560
X0561 X0550
X6540
X7811
X7272
X7811
X6540
X7272
H6263
X6540 H6262
X7271
B7513
+341−X7811 X7811 X7811
HES
HES HES
Z 60 255
”X0561” ”X0560”
8 4
3 4 3
5
5
7
8
Z 60 256
48/51 140−1180−181_en
18.10 Electric safety chain

(Z 60 255, Z 60 256)
The electric safety chain for operation of the crane is connected

at the distributor boxes ”X0550”, ”X0560” and ”X0561”.
− ”X0550” Main Boom Head
− ”X0560” Basic boom main boom extension
− ”X0561” Box top piece
Caption to (Z 60 255, Z 60 256)
1. Aircraft warning light
2. Anemometer
3. Socket:
− Anemometer
− Connecting cable for main boom extension
− Bridging plug “17 pin” (6)
4. Socket: Aircraft warning light (1)
5. Cable / socket: Hoist limit switch

− Bridging plug “2 pin” (7)
6. Bridging plug “17 pin”
7. Bridging plug “2 pin”
8. Connection cable / plug “X7811”

(connection to the distributor boxes)
RISK OF ACCIDENTS!
When several components of the main boom extension are

in operation, it must be ensured that the anemometer (2),
the plug of cable connection (8) or the bridging plug (6) “17
pin” is attached at the appropriate distributor box connec-
tion (3).
Open hoist limit switch connections must be ”2−pin”

bridged in crane operation at the appropriate distributor
box/plug connection (5) by means of bridging plug (7).

the components.
140−1180−181_en 49/51
18
”B”
”A”
4 1
7 2
1
Z 56 947
”B”
”A”
Z 56 948
50/51 140−1180−181_en

(Z 56 947, Z 56 948)
To switch the restraint from the locking position into the storage
position proceed as follows (Z 56 947, Z 56 948):
1. Pull hoist limit switch cable downwards 1 , then bend

backwards parallel to the boom and hold in this position 2
(Z 56 947).

switch (7) 5 until the two clips ”A” lock in the hole ”B” of the
hoist limit switch (Z 56 948).
RISK OF ACCIDENTS!


the components.
140−1180−181_en 51/51
Head roller 21
140−1210a_en 1/13
21
E2 E1
Z 200 183
2/13 140−1210a_en
Head roller 21
21 Head roller (option)

(Z 200 183)
21.1 General
The head roller (1) is used for lifting smaller loads (max. 8,1 t
(17,8 kip), single−strand), whereby the hook block on the main
boom head can stay reeved.
The head roller can be folded, and can be folded laterally onto the
main boom for transport.
The head roller consists of the frame and a bolted−on collapsible

rocker.
The head roller is marked with the factory number of the

crane. The head roller may only be assembled on the crane
with this factory number.
Exceptions are only permissible if this is explicitly noted in
the vehicle documents for the crane (e.g. crane pass).
140−1210a_en 3/13
21
”A”
9
1
1a
1b
”B”
8
”C”
Z 200 184
4/13 140−1210a_en
Head roller 21
There is a danger of crushing when assembling or dis-

mantling the head roller between the main boom head
and the head roller.
Please pay particular attention to the inctructions on
dangers in chap. 1.4.8 “Assembly and dismantling of
crane components“ and the subsequent procedures des-
cribed.
Several types of assembly work are to be carried out
using suitable aid(ladders, lifting platforms, scaffolding,
auxiliary crane). Stepping onto the boom is strictly for-
bidden !
21.2 Assembly and dismantlement of head roller during

separate transport
(Z 200 184)
4. Move head roller against auxiliary crane.

The head roller must not be leaning or swinging during lifting.
The head roller is in transport position, i.e. the collapsible rocker

( 1b) is connected in point ( C) with bolts ( 8), and secured with
a forelock.
The weight of the head roller is approx. 160 kg (approx. 353 lbs).
5. Bring the head roller (1) into assembly position using auxi-
liary crane on the main boom head. For this purpose, the re-
spective bore holes for the fastening shackles of the head
roller must be in alignment with those for the corresponding
fastening shackles on the left (point “A”) and right (point “B“)
main boom head.
Rig both points with bolts (9), and secure these using fore-
locks.
As long as the head roller is only pushed against or not

completely bolted onto the auxiliary crane, no person
may be allowed in the crash range !
140−1210a_en 5/13
21
”C”
B
”D”
1b
”C”
”D”
Z 200 185
6/13 140−1210a_en
Head roller 21
The head roller is now fastened on the main boom head.

To reach the actual working position, it must still be fol-
ded downwards!
Please make sure, therefore, you observe the following
points!
(Z 200 185, A)
1. Lift the collapsible rocker (1b) slightly to relieve bolts (8) and
to remove the bolts (8) from position (C).
Gas−operated positioner holds the rocker in the horizontal
position.
Danger of crushing!
There is a danger of crushing between the rocker and
frame of the head roller as soon as the rocker moves or
is moved.
Please take the appropriate measures to ensure safety!
(Z 200 185, B)
2. Manually press the rocker (1b) downwards against the pres-

sure of the gas−operated positioner until the matching hole
for the rocker is in alignment with the hole on the frame of the
head roller.
Then rig bolts (8) in position (D), and secure.
Only after this has happened is the head roller in working posi-
tion.
Danger of accident!
The head roller may not, in any case, be operated in the
folded up position (transport position)!
3. Insert the plug of the hoist limit switch for the head roller into
the free socket on the main boom head.
140−1210a_en 7/13
21
8/13 140−1210a_en
Head roller 21
4. To avoid endangering persons or causing damage to the

equipment, hang up the shift weight of the hoist limit switch
on the head of the main boom in transport position (dis-
mantle if necessary).
If the hoist limit switch for the main boom is dismounted, then
the bridge plug must be mounted instead of the HES plug.
If the main boom is also equipped with a hoist rope when opera-
ting auxiliary devices such as a head roller, then the shift weight
of the hoist limit switch on the main boom must hang freely, and
the hoist limit switch must not be bypassed.
The head roller is dismantled in the reverse sequence accordin-

gly.
21.3 Folding in transport position
If the head roller is not required, then it can be folded laterally onto
the main boom head.
When folding the head roller, there is a danger of crus-

hing between the main boom head and the head roller.
During the folding process, no person is permitted in the
crash range !
1. Unload the hoist rope and wind up on rope drum.
2. Disconnect the electrical connection between the hoist limit

switch for the head roller and socket for the main boom head.
3. Rig the shift weight of the hoist limit switch in transport posi-
tion, and secure using locking spring.
140−1210a_en 9/13
21
A B
”C” 9
”A” 9
8
8 ”B”
”D” ”C”
”D”
1b
”A” 9
C D
9 10
”B” ”E” ”F” ”B”
”E”,”F”
11
Z 200 186
10/13 140−1210a_en
Head roller 21
Fold the head roller upwards in transport position.
(Z 200 186, A)
1. Lift the collapsible rocker (1b) slightly to relieve bolts (8) and
to remove the bolts (8) from position (D).
Danger of crushing!
There is a danger of crushing between the rocker and
frame of the head roller as soon as the rocker moves or
is moved.
(Z 200 186, B)
2. Manually press the rocker (1b) upwards using the support of
the gas−operated positioneruntil the matching hole for the
rocker is in alignment with the hole on the frame of the head
roller.
Then rig bolts (8) in position (C), and secure.
Danger of accident!
The head roller may not, in any case, be operated in the
folded up position (transport position)!
(Z 200 186, C)
3. Remove the bolts on the right−hand side (9) from point (A).
(Z 200 186, D)
4. Turn head roller around point (B) until the bore hole (F) mat-
ches up on the main boom head.
5. Rig bolts (10) at the congruent bore holes (E, F).
(Z 200 186, E)
6. Remove bolts (9) at position (B).
7. Turn head roller around point (E, F) until bolts (11) can be rig-
ged on the welding holder of the head.
Rig bolts (11), and secure.
The head roller can be swivelled aroung from transport position

to working position in the reverse sequence accordingly.
140−1210a_en 11/13
21
E2 E1
Z 200 183
12/13 140−1210a_en
Head roller 21
21.4 Operation
(Z 200 183)
1. Assemble head roller in working position
2. Release shift weight (3) of hoist limit switch from transport

position.
3. Reeve hoist rope single−strand. In doing so, make absolu-

tely sure the hoist rope is guided through the shift weight (3).
The rope guide for the hoist rope (2) must ensue via the upper
run−in roller (E2) on the head of the main boom to the rope
sheave in the head roller (1).
When reeving, there is a danger of coiling and being pul-

led in at the head− and deflection roller.
4. Bolt on hook suspension gear, type 12.5 (4).
5. Set the IC−1 in accordance with the crane configuration.

(Chap. 10 “Safety device“).
Type HA
Reeving 1
Other settings in accordance with construction state
140−1210a_en 13/13
Dismantling and Assembly of the Main Boom (optional) 31
31 Dismantling and Assembly of the main boom (optio-

nal)
In the course of assembling and dismantling the main

boom there is the danger of being crushed:
− between the main boom foot and the bearings.
− between the main boom and the superstructure frame.
This is why no person is permitted in the danger zone!
Pay special attention to the notes on dangers in section
1.4.8 In the course of assembling and dismantling
crane components as well as the procedure described
in the following.
All assembly work is to be carried out using suitable
equipment (ladders, lifting platforms, frames, auxiliary
crane).
Should it not be possible to carry out work either using
such equipment or from the ground, then the assembling
personnel must protect themselves with suitable means
(e.g. safety belt) against the RISK OF FALLING!
In particular, it is prohibited to stay in the areas beneath
the suspended load where loads & equipment might fall
during the assembly or dismantling process (main
boom)!
Always keep safe distance!
Main boom assembly and dismantling must be carried

out by a well coordinated team. When doing this, each
assembling or dismantling step has to be planned care-
fully. All individual components have to be supported sa-
fely or secured by auxiliary cranes.
Moreover, the crane manufacturer recommends pre−trai-

ning at a secure location so that the course of action −
taking into account all safety measures for the assembly
personnel − can be practised BEFORE the first use.
The responsibility for installation or dismounting the

crane and leading the activities are part of the overall re-
sponsibility of the crane operator.
140−1310−102a_en 1/25
31
11
Z 55 400
Z 55 401
2/25 140−1310−102a_en
31.1 General
In various countries, the regulations on crane and traffic appro-
vals demand modified axle loads.
If necessary, the main boom must be removed from the super-

structure in order to achieve country−specific axle loads or to
carry out repairs. Therefore two auxiliary cranes are necessary.
The transport condition without a main boom is described in the
crane chassis operating instructions, part 2, sect. 6 “driving”.
The assembly and dismantling procedures described in this sec-

tion only apply if your crane is equipped with these devices (op-
tional).
(Z 55 400, Z 55 401)
Upon completion of the work, the railing (4) tilted up in order to

mount/dismount the crane must be tilted down and secured in its
standard transport position during road travel.
If the railing remains in a tilted−up position, the crane height of
4 m (13.1 ft) will be exceeded.
During road travel, the railing must always be tilted and se-
cured in its transport position (Z 55 400).
Especially the operations listed in the following that are

necessary to draw out the main boom foot pin must be
carried out with special care and in accordance with all
necessary safety measures because there is a repeated
risk of stumbling and falling.
During these operations the railing (4) must absolutely

be in tilted−up position. Otherwise there is danger of fal-
ling!
Upon completion of these operations the support bracket (1,

Z 55 401) attached to the superstructure frame for mounting/dis-
mounting the main boom foot pin must always be removed.
140−1310−102a_en 3/25
31
Z 42 980
”A”
Z 55 402
4/25 140−1310−102a_en
31.2 Before dismantling
1. Put the crane on outriggers and adjust it horizontally. Use the

big outrigger span.
When assembling or dismantling the main boom, the crane

must always be on outriggers.
2. Please ensure that:

− The telescopic sections are retracted and pinned.
− There is no main boom extension attached (please refer
to sect. 18 of this operating instruction).
− There is no laterally tiltable head sheave available (please
refer to sect. 21 of this operating instruction).
− There are no counterweights attached any more (please
refer to sect. 9 of this operating instruction).
− Hoist 2 is removed (please refer to sect. 15 of this opera-
ting instruction).
3. Unreeve the bottom hook block or the hook suspension gear

and wind the hoist rope onto the rope drum.
While unreeving, there is risk of winding and retracting at

the head and deflection sheaves as well as at the bottom
hook blocks!
Please act carefully.
Please touch the bottom hook block with the available
hand grips (Z 42 980). Your hands are explicitly not allo-
wed to come into the following areas:
* between rope pulleys, side panels, and coverings.
* into the area of the locating points (sometimes with
tiltable design), the hook, the hook nut, the cross head
or the hoop guards.
You’re only allowed to work at the bottom hook block
(reeved) if it is parked solidly on firm ground.
4. In transport position peg and secure the switching weight of

the hoist limit switch at the main boom head (Z 55 402, ma-
gnifying glass “A”).
140−1310−102a_en 5/25
31
31
Z 55 403
74
Z 55 404
6/25 140−1310−102a_en
31.3 Dismantling
1. Using the luffing gear, lift the main boom to approx. 45° and
rotate the superstructure approx. 15° to the side.
This will ensure that the assembly personnel does not need
to stay beneath the lifted main boom during the subsequent
attachment of the luffing cylinder support (31).
Danger of accident!
Staying beneath the lifted main boom is forbidden!
Proceed accordingly when assembling the luffing cylin-
der support.
(Z 55 403)
2. Assemble the luffing cylinder support (31) in the designated
area at the end of the chassis frame between stopper plate
and the load−securing plate.
The load−securing strap to fasten the removed luffing cylin-
der will be located on these plates later on.
Use theluffing cylinder support solely to place the luffing cy-

linder. Otherwise it has to be removed.
(Z 55 404)
3. Rotate the superstructure in a way that the main boom points
to the rear and insert the mechanical superstructure locking
device. Therefore, operate the light switch (74). The pin (1)
must retract into the stop device (2) The indicator light inside
the switch must go out.
140−1310−102a_en 7/25
31
31
Z 55 405
8/25 140−1310−102a_en
(Z 55 405)
4. Lower the main boom by using the luffing gear until the luffing
cylinder is situated directly (3−5 mm / 0.1−0.2 in) above the
luffing cylinder support (31).
Risk of damage!
The luffing cylinder support is designed only to bear the
weight of the luffing cylinder. Therefore, the weight of the
main boom shall not be transmitted to the luffing cylinder
support by the luffing cylinder.
140−1310−102a_en 9/25
31
”B”
12500
5896
”A”
Z 55 406
10/25 140−1310−102a_en
(Z 55 406)
5. Sling the main boom with a 2−string suspension gear re-
spectively to two auxiliary cranes:
− Slinging points at the main boom foot: please see magni-
fying glass “A”
− Slinging points at the main boom head: please see magni-
fying glass “B”.
Position the auxiliary cranes such as to bring the boom head

exactly into a vertical position above the corresponding slin-
ging points.
The main boom weight amounts to approx. 15.6 t (34 392 lbs).
The resulting vertical loads for hauling amount to:
− at the main boom foot (”A”): approx. 8.25 t (18 188 lbs)
− at the main boom head (”B”): approx. 7.35 t (16 204 lbs).
The main boom centre of gravity is located 5896 mm away from

the main boom foot bearing in direction of the sheave head.
Danger of accident!
Select the auxiliary cranes and the lifting tackle accor-
dingly to the prescribed main boom weight (or the loads
for hauling).
The necessary lifting capacities including adequate sa-
fety factors − especially in respect of the simultaneous
operation of two cranes − are to be defined according to
the regulations of the country of operation.
6. Tighten the lifting gear with auxiliary cranes. The auxiliary

cranes must take over the main boom load.
140−1310−102a_en 11/25
31
Z 55 407
800
Z 55 408
12/25 140−1310−102a_en
(Z 55 407, Z 55 408)
7. Make sure that the luffing cylinder is depressurised.
For this purpose, call the ”I/O” mask on the IC−1 display in
the superstructure cab for the diagnosis of inlets and outlets.
In this mask, by pushing ” Select ”Open pull−down menu
and “ A0701” for the control unit.
Then, scroll through the display until you find the last entry
“pressure absorber luffing cylinder”. The displayed value
must be included in the range “800”. This is the only way to
guarantee that the luffing cylinder is depressurised.
A display of 800 “increments” corresponds to a pressure

of bar / psi.
If the displayed value exceeds “800” you have to do the following

in order to depressurise the luffing cylinder:
− Make sure that both auxiliary cranes have taken over the
main boom load completely.
− Rock the luffing cylinder slightly by manipulating the corres-
ponding control lever until a value of approx. “800” is obtai-
ned.
As long as the luffing cylinder is not depressurised, the dra-

wing of the luffing cylinder pin described in the following is
not possible.
140−1310−102a_en 13/25
31
”B”
4
H1
5
61
”A”
H1
64
64
3
Z 55 409
14/25 140−1310−102a_en
(Z 55 409)
8. Turn off the superstructure engine.
9. Release the hydraulic connections. Therefore:

Release the quick−release closures of the hydraulic cou-
plings to the telescopic cylinder (1, “ST”), (2, “B1”), (3, “B2”),
(4, “P”) and (5, “T”) on the hydraulic console, in the area left
of the boom foot section and lock them using the correspon-
ding protecting caps.
The hydraulic hoses arrangement makes sure that no mistake

occurs while reestablishing the hydraulics connections.
The identification number in the facing diagram (Z 55 409) is for
informational purposes only.
10. Lock the ground hydraulic connection of the luffing cylinder

using the ball tap (H1) on the luffing cylinder “A”.
The loosening and establishing of hydraulic connections is

only permissible in depressurised condition, i.e. the super-
structure engine has to be turned off.
11. Disconnect electrical connections. For this purpose:

Detach the three plugs (61) on the angle sheet and the plug
connection (64) of the violet bus cable.
Lock all disconnected joints with protective caps.
140−1310−102a_en 15/25
31
A
K1
Z 55 410
31
Z 55 411
16/25 140−1310−102a_en
31.3.1 Dismantling luffing cylinder headpin

(Z 55 410, Z 55 411)
1. Unscrew the safety device (K1) on the luffing cylinder head-

pin (Z 55 410).
2. Pull out the luffing cylinder headpin by means of the extrac-

tion device (A).
Risk of overturning:
Shortly before the luffing cylinder headpin is pulled out
completely there is risk of overturning for the extraction
device with the suspended pin.
Weight:
pin approx. 19.2 kg (42.33 lbs)
extraction device approx. 19.2 kg (42.33 lbs)
After the main boom was removed, push the pin into the luffing
cylinder head bedding in order to park and secure it.
3. Tie down the luffing cylinder to the luffing cylinder support

(31) using the load−securing strap (Z 55 411).
140−1310−102a_en 17/25
31
A
K2
1
2
”2”
”1”
Z 55 412
18/25 140−1310−102a_en
31.3.2 Dismantling boom foot pin

(Z 55 412)
1. Tightening of the lifting gear on the main boom by means of

auxiliary cranes. The auxiliary cranes have to take over the
main boom load, i.e. the boom foot pin must be free.
2. Remove safety device (K2) on the boom foot pin.
3. Pull out the boom foot pin as far as possible using the extrac-
tion device (A).
4. Secure the provided pin support (1) to the superstructure

frame by means of two pins (2).
5. Pull out the main boom foot pin to the end of the pin support
or drive it out with a mandrel (e.g. a brass mandrel).
Risk of overturning:
Shortly before the boom foot pin has been completely
retracted, there is a risk that the pin will overturn.
Weight: pin approx. 120 kg (264.55 lbs)
6. Slowly drive out the main boom by means of auxiliary cranes

horizontally for the moment from the superstructure frame
foot bearing (“1”).
In this working step it is necessary to take special care on

free passage between luffing cylinder and main boom basic
case.
Make sure that tilting of the main boom on the bearing points
is avoided.
7. When the main boom foot bearing as well as the bearing of

the luffing cylinder at the basic case are free, lift the main
boom vertically out of the superstructure frame (“2”).
DANGER OF ACCIDENT!
While lifting the main boom, take care that it does not begin
to swing!
No persons are allowed to approach the suspended main

boom!
Risk of being crushed!

While lifting the main boom, there is risk of being crushed
between main boom and superstructure frame.
140−1310−102a_en 19/25
31
Z 55 413
Z 55 414
20/25 140−1310−102a_en
(Z 55 413, Z 55 414)
8. Placing the main boom on the transport vehicle, packing it

accordingly and lashing it (Z 55 413).
Risk of crushing!
While putting down the main boom, there is a danger of be-
coming trapped between main boom and the support on the
ground or the support on the transport vehicle.
9. Loosen the lifting tackle from the main boom and remove it.
10. For transport purposes, push the main boom foot pin into the
superstructure frame far enough so that can be secured with
both locking pins (3) in the support (1) (Z 55 414).
11. Retracting the crane stabilisers.
Pay special attention to the corresponding specifications in

the crane chassis operating instruction, section 6, when dri-
ving the crane in this configuration.
140−1310−102a_en 21/25
31
31
Z 55 405
K1
7
8
K2
7
Z 55 415
22/25 140−1310−102a_en
31.4 Main boomassembly

(Z 55 405, Z 55 415)
Assembly of the main boom occurs in reverse order to dismant-

ling.
Pay attention that:

− The crane is supported and adjusted by big outrigger span,
− The load securing strap at the luffing cylinder is released,
− The main boom foot and the luffing cylinder head correctly re-
tract into their bearings.
− The retracting of the luffing cylinder into the corresponding
bearing at the main boom is explicitly described on page
25 in sect. 31.4.1.
− The electrical and hydraulic connections are restored cor-
rectly.
− Plugs and plug−in connections have the same marking
and the hydraulic couplings must open correctly.
After reattaching of the main boom foot pin and the connec-
ting pin main boom/luffing cylinder these pins must be secu-
red unconditionally. Therefore, fasten with screws the re-
spective axis holders (K1) by the luffing cylinder headpin
and (K2) by the main boom foot pin. The screws to use to that
purpose (7), M 24 must be tightened with a tightening torque
of approx. 880 Nm (649 lbf−ft) and the screws (8), M 20 with
a tightening torque of approx. 510 Nm (376 lbf−ft).
As long as these two axis holders are not attached correctly,
crane operation is not permissible.
The battering of the pins as well as the attaching of the axis hol-
ders can be carried out best as long as the auxiliary cranes still
take over the load of the main boom.
Once the main boom is reattached and the luffing cylinder is

pinned with the main boom the unloaded luffing cylinder
support (31) must be removed and transported separately.
After assembly of the boom foot pin and before crane opera-
tion the foot pin support (1) must be removed.
140−1310−102a_en 23/25
31
”A” ”B”
H1
Z 55 416
24/25 140−1310−102a_en
31.4.1 Assembly luffing cylinder headpin
Procedure of retracting the luffing cylinder into the bearing

on the main boom.
(Z 55 416)
Before retracting the luffing cylinder into the bearing on the main
boom it first has to be retracted “actively”.
Therefore, please proceed as described in the following.
− Start superstructure engine.
− Retract the luffing cylinder by operating the corresponding
control lever in the crane cab (downluffing).
Once the luffing cylinder is retracted completely put the con-
trol lever into neutral position. The luffing cylinder piston rod
begins to come out of the cylinder pipe step by step (or must
be drawn out step by step by operating the control lever tem-
porarily).
Once the piston rod mounting eyelet of the luffing cylinder is
in alignment with the corresponding bearing on the main
boom the luffing cylinder pin can be pushed in.
Before pushing in, look out for the centering of the pin axles
so that the receiving bushes will not be damaged.
As a rule, only a soft iron (e. g. a brass mandrel) may be used
to hammer directly on the pins in order to drive the pins in
or out.
To push in the pins a pin extractor may be used as well.
Before starting the engine make absolutely sure that the ball
tap (H1) on the luffing cylinder is closed “A” because other-
wise the luffing cylinder will drive out some centimetres
(problems with pin assembling).
Once the luffing cylinder pin is embedded completely and

secured with the axis holder it is essential to restore the
shut off valve (H 1) into its initial position (open “B”).
Any failure to carry out this step may result in serious da-
mage to the hydraulic system.
140−1310−102a_en 25/25
Emergency Operation 36
140−1360 1/11
36
6
5 P
T
L UW
T UW 4
P
UW
Z 200 171
2/11 140−1360
36 Emergency Operation (Optional)
Follow all safety instructions which are also valid for nor-
mal operation!
The emergency operation procedures described in the following

are only for when the superstructure engine or a pump fail so that
small loads (load pressures < 210 bar / 3046 psi) can be recove-
red safely.
Emergency operation is not equipped or suitable for maintaining
normal crane operation.
36.1 General
The required connections (hydraulic interfaces) are standardi-

sed.
The required auxiliary power unit is a hydraulic transformer,
which basically consists of a pump and an engine.
Such a transformer can be ordered from the crane manufacturer.
(Z 200 171)
The transformer has the following connections:
TUW − Tank connection crane chassis
LUW − Leakage oil connection crane chassis
PUW − Pressure connection crane chassis
T − Tank connection superstructure
P − Pressure connection superstructure
The shut−off lever (6, Z 200 171) of the hydraulic transformer is

set to open throughfeed and is only closed when a movement is
to be driven immediately afterwards.
The engine of the transformer (4) is driven by an external hydrau-
lic system (e.g. from the crane chassis, a second crane or a spe-
cial unit) and it then drives the transformer pump (5), which sup-
plies the superstructure hydraulic system.
The following movements can then be driven by activating the
control lever in the superstructure:
− Luffing
− Raising / lowering hoists
− Rotating (in connection with a stop valve on the super-
structure)
The required hydraulic transformer and all required hoses must
be supplied by the customer or can be delivered as optional
equipment.
140−1360 3/11
36
6
5 P
T
L UW
T UW 4
P
UW
Z 200 171
4/11 140−1360
36.2 Connecting the Transformer

(Z 200 171)
Initial situation:
− Crane in relevant operating configuration (outrigger support

area, counterweight and similar) with hanging small load.
− Superstructure:
∗ Failure of diesel engine or pump
∗ Hydraulics and electrics functioning
∗ Engine and ignition off
− Crane chassis:
∗ Hydraulic external supply from the crane chassis or exter-
nal machine with connections for driving the transformer
∗ Engine and ignition off
− Use of a standard transformer In the following, an example
of the transformer (Z 200 171) supplied by the crane manu-
facturer is described.
12. Unfold protection caps on the relevant couplings of the trans-

former and unscrew hydraulic hoses.
140−1360 5/11
36
6
5 P
T
L UW
T UW 4
PUW
Z 200 171
Á 2.1 1.1 P
Á
S
Á
7
T
D
H
TUW
4
5 6
m P
PUW
LUW LUW
PUW
TUW
Z 60 208
6/11 140−1360
(Z 200 171, Z 60 208)
13. Connect transformer engine (4) to the corresponding hy-

draulic couplings on the crane chassis using hoses.
These hydraulic couplings (x 3) are on the left−hand side of the

chassis between the wheels of axles 2 and 3 on the bottom of the
covering (Z 60 208). There are protection caps on the hydraulic
couplings which must be removed.
The coupling sleeves and plugs which belong together can

be marked with plates as follows:
TUW − Tank connection crane chassis
LUW − Leak oil crane chassis
PUW − Pressure connection crane chassis
There is no risk of them being confused as the connections of the

different hoses have different sizes.
In transformers without a leak oil connection the coupling ”LUW”

on the crane chassis remains free.
The shut−off lever (6, Z 200 171) of the hydraulic transformer is

set to ”open throughfeed”. Figure (Z 200 171) shows the stop
valve (6) in the closed position.
14. Connect pump (5) of the transformer to the corresponding

hydraulic couplings of the superstructure using hoses.
To do so, unscrew each protection cap and screw on the hy-
draulic hose.
The coupling sleeves and plugs which belong together can
be marked with plates as follows:
P − Pressure connection superstructure
T − Tank connection superstructure
There is no risk of them being confused as the connections of the

different hoses have different sizes.
Stop valve (7) must be opened once tank connection ”T” has
been set up (Z 60 208).
15. Connect bridging hose ”S” on the superstructure between

the connections 1.1 and 2.1 (rotate for function Superstruc-
ture).
140−1360 7/11
36
25
203.3
A
Z 200 173
103
Z 200 174
8/11 140−1360
36.3 Recovering a Small Load

(Z 200 173, Z 200 174)
1. Connect the transformer in accordance with section 36.2.
2. Switch on the ignition of the superstructure.
3. Activate the function Emergency lowering (optional) (203.3,

Z 200 173) in the service line in the main menu of the crane
control system.
The function surface then displays “ON”.
When the crane operating mask is switched on, a red cross
with “ON“ written on it is displayed at (25, Z 200 173) in the
crane display (A, Z 200 173).
4. Open stop valve (6) of the hydraulic transformer (= pres-

sure−free circuit from pump side), if this has not already been
done!
The stop valve is only closed shortly before a movement is execu-

ted.
5. Start up the engine of the crane chassis.
6. Press switch (103, S 2430) (Z 200 174) in the chassis cab.

To do so, the hand brake must be applied and the transmis-
sion must be in “neutral position“.
The engine of the hydraulic transformer is supplied with oil.
7. Close stop valve (6) of the hydraulic transformer: The super-

structure hydraulic system is supplied with oil.
The further procedure depends on the movement to be carried:
Hoist and luffing
8. The crane movements “Hoist and luffing“ can be carried out

as before using the joystick.
140−1360 9/11
36
Á
Á
S 2.1 1.1 P
Á 7
T
D
H
TUW
4
5 6
M P
PUW
LUW LUW
PUW
TUW
Z 60 209
103
Z 200 174
10/11 140−1360
(Z 60 209, Z 200 174)
Rotating the superstructure
9. In order to rotate the superstructure, the position of the stop valve (H)
must be modified:
During normal crane operation, the stop valve (H) is in the middle posi-
tion. In order to rotate the superstructure clockwise, the lever of the
stop valve must be pressed inwards. In order to rotate the super-
structure anti−clockwise the lever of the stop valve must be pulled
outward.
The lever of the stop valve is moved in the final position each time (locks
in place!)
The speed of the slewing movement is set using the knob of the throttle (D).
You will have a slewing speed that is easily manageable when you turn the
rotating knob half a turn from the completely screwed−in position (clo-
sed).Further opening of the throttle results in an increase of the slewing
speed.
The actual slewing movement is introduced by pressing the corresponding
joystick to the right or the left.
(Steering direction immaterial!)
Risk of crushing and pushing!

The slewing direction of the superstructure is determined
by the position of the hand stop valve (H) and not by
steering the joystick.
10. Open stop valve (6) of the hydraulic transformer after the movement has
been carried out (= pressure−free circuit from pump side).
Only operate the transformer as long as is required for recovering the

load and do not let it run at idle speeds for longer periods of time.
The oil can overheat if the transformer is operated for a longer period
of time.
11. After the load has been recovered, switch off the ignition in the super-
structure and with there was a slewing movement previously: return
hand stop valve (H) to the middle position (locks in place).
12. Switch off switch (103, S 2430) in the crane chassis and turn off the engi-
ne.
13. Remove all connections to the transformer again and cover couplings
with protection caps.
Stop valve (7) must be closed before tank connection ”T” is

disconnected (Z 60 209).
140−1360 11/11
Runner 41
140−1410−181 1/25
41
”A”
Z 60 210
2/25 140−1410−181
Runner 41
41 Runner (optional)
(Z 60 210)
41.1 General
The runner (1) is for lifting small loads (see the ”MS” load capacity
table); during this procedure the hook block can remain reeved
on the main boom head.
Figure (Z 60 210) shows the runner with the reeved hook block
in working position.
The runner can be folded and can be folded into parking position
at the side on the main boom (detail ”A”), in line with the permitted
axle loads for transportation or for main boom operation without
runner.
Operating the main boom with the runner attached will lead
to the lifting capacity of the crane being reduced.
In this case, pay particular attention to the ”MS” load ca-
pacity table supplied with the crane.
Non−compliance leads to greater risk of accidents!
The Runner is marked with the construction number of the

crane. It may only be fitted to the crane with this construction
number.
Exceptions are only permitted if this is expressly stated in
the crane papers (e.g. crane log book).
Risk of accidents !
When fitting or removing the runner, there is risk of crush-
ing between the main boom head and the runner.
You must take special care to follow the instructions on
risks in Section 1.4.8 ”When fitting and removing crane
components” and the procedure described in the follow-
ing.
All assembly work is to be carried out with the help of suit-
able equipment (ladders, hoist platforms, scaffolding, aux-
iliary crane).
It is prohibited to walk on the boom.
140−1410−181 3/25
41
22
1c
1b
1a
1
E
”B”
Z 60 211
4/25 140−1410−181
Runner 41
41.2 Fitting and Removal

(Z 60 211)
Before attaching, the runner (1) is on the ground on the fork ends
and the standing tubes of the runner frame (1a).
It is ”folded”, e. g., the runner frame (1a) is pulled on to the runner
adapter (1b) using an auxiliary winch (22) and on the bracing rods
using locking bolts (1c) pegged on both sides.
The weight of the runners is about 500 kg / 1102.3 lbs.

Sling the runner on to the auxiliary crane in such a way that it
neither off centre nor swings when raised.
1. Attach runner (1) to the auxiliary crane at the 4 attachment

points (E) with suitable lifting tackle and bring the main boom
head into the fitting position.
To do so, each drilled hole in the fork ends of the runner
adapter (1b) must be flush with the ones on the right− and
left−hand head axle, top and bottom.
RISK OF ACCIDENTS!
No one may be in the area at risk of falling equipment, etc.
as long as the runner is attached to the auxiliary crane or
has not yet been completely pinned!
2. Knock 4 biconical bolts at the pinning points and secure each

one with 2 locking springs.
The ”folded” fitting position which has then been achieved

(representation ”B”) is only for driving on a construction site
(technical drivability − take axle loads into consideration; see
section 6 “Driving” in the operating instructions of the crane
chassis).
RISK OF ACCIDENTS!
This “folded” fitting position may NEVER be used for rais-
ing loads. To do so, the runner must first be brought in the
operating position. To do this, refer to section41.3 ”Fold-
ing”, from page 7.
The runner must also be removed in the ”folded” position. To do

so, proceed in the same manner just in the opposite sequence.
140−1410−181 5/25
41
21 22
24 24
1b
1c
1a 23
25
30
31
31
Z 60 212
6/25 140−1410−181
Runner 41
41.3 Folding
(Z 60 212)
Proceed as follows to fold the runner from the transport position

to the working position:
1. Lower runner frame (1a). To do so:
1.1 Remove the locking bolts (1c) at the bracing rods (24)
on both sides and peg them in the parking position.
1.2 Fit the crank (25) onto the hanging eyelet (23) of the
auxiliary winch (22) and unreel rope (21) of the
auxiliary winch until the bracing rods (24) are straight
on both sides.
1.3 While in the operating position of the runner (bracing

rods straight), loosen rope by unreeling it slightly so
that it is never loaded during runner operation.
2. For even reevings, loosen carabiner hook (30) from the

fastening chain of the rope attachment point: rope
attachment point (31) swings down.
3. Feed hoist rope from the hoist drum to the intake sheaves on
the main boom head.
Observe for this the detailed specifications contained in
Chap. 17 ”Reeving” in the Subpoint ”Reeving the hoist rope
in and out”.
140−1410−181 7/25
41
R2
E2
R1
E1
Z 60 213
”A” 4 3 2
E2 E2 E2
E1 E1 E1
R2 R2 R1 R2
FR R1 R1
fR fR
FU
3 2 2
3 4
1 2 1 1
U3 U2 fU U3 U2 U3 U2
U1 U1 U1
Z 60 214
8/25 140−1410−181
Runner 41
(Z 60 213)
4. Feed hoist rope to the sheave (R1) of the runner via intake
sheave (E2).
The rope may not be fed via intake sheave (E1) as this would
make the deviation angle of the hoist rope too large. Risk of
damage to the rope.
Risk of accidents!
During reeving, there is a risk that all involved sheaves be-
come wrapped and wound up. Proceed with appropriate
caution!
(Z 60 214)
5. Reeve the hoist rope to the hook block (4−ropes, 3−ropes or
2−ropes).
The safety of the crane is impaired by incorrect reeving!

Therefore observe the following reeving examples.
Example: Hook block type 63, 3−sheave
The weight of the 3−sheave hook block is 700 kg (1543.22 lbs).
”A” − Reeving plan direction of sight

E − Intake sheaves on the main boom head
R − Sheaves on the runner
U − Hook block pulleys
FR − Fixing point on the runner
FU − Fixing point on the hook block
The hoist rope may only be reeved in accordance with the

following table. Other reeving configurations would disrupt
the function of the load limit device.
Num-
ber of Guidance of rope over the sheaves
strands
4 E2−R1−U1−R2−U3−FR
3 E2−R1−U2−R2−FU
2 E2−R1−U2−FR
140−1410−181 9/25
41
27
27
26
Z 60 263
10/25 140−1410−181
Runner 41
(Z 60 263)
1. Attach hoist limit switch (27) with associated switching
weight to the runner. For this, peg the hoist limit switch to the
respective mandrel at the top section of the runner on the
left−hand side − as shown − and secure with a linchpin.
This hoist limit switch and und associated shift weight can be
used on all additional equipment (main boom extension, box top
piece, etc.). That is the reason that there is only one of them for
all additional equipment. It may therefore be required that they be
dismantled from a different auxiliary device in order to be able to
be used on the runner.
2. Fit the shift weight (26) of the hoist limit switch to the hoist
rope of the runner.
The shift weight should be attached to the ”resting” rope.

This avoids wearing of the hoist rope and shift weight.
The “resting” rope is the rope line that goes to the fixing
point:
Make sure that the shift weight is hanging free. Its
functioning is only guaranteed when this is the case.
140−1410−181 11/25
41
”B”
7 ”A”
27
3
26
4 1
2
1
Z 60 264
”B”
”A”
Z 56 948
12/25 140−1410−181
Runner 41
(Z 60 264, Z 56 948)
To switch the restraint from the locking position into the storage
position proceed as follows (Z 60 264, Z 56 948):
1. Pull hoist limit switch cable downwards 1 , then bend

backwards parallel to the boom and hold in this position 2
(Z 60 264).

switch 5 until the two clips ”A” lock in the hole ”B” of the hoist
limit switch (Z 56 948).
Open hoist limit switch connections must be bridged with

2−pin plugs in crane operation.
That is the only way to ensure that the hoist limit switch can
be looped over the components.
140−1410−181 13/25
41
”X0560.2”
27 3
”X0550”
3 5
Z 60 265
”X0550”
2
3 5
4
6
Option
X0560.2
X0550
X0560.2
H6263
X6540
X7274
H6262
X7271
B7513
X7811
HES HES
HES HES
Z 60 266
14/25 140−1410−181
Runner 41
41.3.2 Electric safety chain

(Z 60 265, Z 60 266)
The electric safety chain for operation of the crane is connected at the
distributor boxes ”X0550” and ”X0560.2”.
− ”X0550” Main boom head
− ”X0560.2” Runner
Close safety chain, i.e. the sockets on the distributor boxes are to be
allocated as follows:
1. Insert the plug of the hoist limit switch (27) in socket (5) on the distributor
box (“X0560.2”) (Z 60 265).
First remove the protective cap on the socket.
Securely lay the connection cable.
If there is no hoist limit switch installed on the main boom head, then the open
hoist limit switch plug connection must be bridged using a “2−pin bridging
plug” (right side of main boom head).
2. Remove plug (3) of the anemometer (2) on the distributor box “X0550”
main boom head (Z 60 266).
Insert plug (3) on the distributor box “X0560.2” runner in socket (3)
(Z 60 265).
The anemometer (2) remains installed on the main boom head.
3. Guide the plug from the connection cable distributor box “X0560.2” to the
distributor box “X0550” and plug it in socket (3). If the 17−pin bridging
plug (6) is plugged in, remove it. Securely lay the connection cable.
4. If the aircraft warning light (1) is not attached, attach it to the main boom
head on the left side of the head (Z 60 266).
Plug in the plug to socket (4) on distributor box “X 550” on the main boom
head.
When working with a runner, make sure the safety chain is closed, as
described above.
That is the only way to ensure that the hoist limit switch can be looped
over the components.
Unfolding from the working position into transport position is done a similar
manner in the opposite order.
140−1410−181 15/25
41
A B
4
Z 60 217
16/25 140−1410−181
Runner 41
41.4 Flaps
41.4.1 General
(Z 60 217)
If the runner is not needed, then this can be folded into the folded
position (detail ”A”) at the main boom head (left side) (detail “B”).
Preconditions for the procedure:

− The runner is in folded position at the main boom head (detail
“A”); for more, see section 41.3 ”Folding”, from page 7.
− The main boom head is equipped on the left side with holder
bearings (4 and 5) (detail “C”).
Before folding on the main boom side, the runner has to be

folded out of the working position into the transport position
(detail ”A”) !
Risk of accidents!
When folding the runner, there is risk of crushing be-
tween the main boom head and the runner. Proceed with
appropriate caution!
During the folding process, no person may be in the area
at risk from falling equipment!
If the runner is fitted to the left−hand side of the head in the

transport position, the main boom extension can not be
attached in working position (see section 18) and the head
roller (see section 21) can not be attached in working
position or in transport position.
For actually folding out of the working position into the transport
position and back again, one needs a pulling and guiding rope.
The main boom extension’s pulling and guiding rope can be used
for this.
140−1410−181 17/25
41
A B
4.1 4
5.2 5.1 5
C 3−”F(G)”
3−”H(J)” E
3−”H(J)” 3
4/5 5
4.1/5.1 5.2
Z 60 218
18/25 140−1410−181
Runner 41
41.4.2 Folding in transport position

(Z 60 218)
Fold the runner as described in the following working steps into

the transport position. To do so:
1. Attach the pulling and guiding rope to the attachment eyelet

on the runner frame.
RISK OF ACCIDENTS! Risk of falling!

For the following unblocking: Do not lean the ladder on
the runner.
2. Remove the biconical pin (3) from points (F / G, detail ”C”).

Hold the runner in position while doing this with the pulling
and guiding rope.
In case the runner is NOT kept in position, this can be folded

away to the side when the pins are unpinned (3, F / G).
3. Fold the runner around using the pulling and guiding rope
until it is in the holder bearings’ storage brackets (4 and 5,
detail ”D”).
− Before folding, remove the lock pins (4.1 / 5.1) as well as
the locking bolts (5.2) at the storage bracket (detail ”A”).
4. Peg the runner using lock pins (4.1 / 5.1) in the holder
bearings (4 und 5) and secure them on both sides
(detail ”D”).
5. If the runner is secured at the holder bearings (4/5), remove

the biconical pin (3) at points (H / J, detail ”D”).
Hold the runner in position while doing this with the pulling
and guiding rope.
6. Use the pulling and guiding rope to further fold the runner
until it is in die second bearing on the holder bearing (5) with
the lower storage bracket (detail ”E”).
7. Peg and secure the runner using locking bolts (5.2) in the
holder bearing (5) (detail ”E”).
140−1410−181 19/25
41
A B
4.1 4
5.2 5.1 5
C 3−”F(G)”
3−”H(J)” E
3−”H(J)” 3
4/5 5
4.1/5.1 5.2
Z 60 219
20/25 140−1410−181
Runner 41
(Z 60 219)
8. Peg the biconical pins (3) on the fork heads on the runner in
park position and secure them on both sides with locking
springs (detail ”E”).
The aircraft warning light (optional) can stay attached or can be

attached to the attachment apparatus on the main boom head,
on the left side.
41.4.3 Folding in working position

(Z 60 219)
Fold the runner towards the front as described in the following

working steps into the working position. To do so:
1. Attach the pulling and guiding rope to the attachment eyelet

on the runner frame.
2. Remove the biconical pins (3) on the four fork heads on the
runner (detail “E”).
3. Remove the locking bolts (5.2) in the holder bearing (5)

(detail “E”).
4. Use the pulling and guiding rope to position the runner at the
attachment points (H / J, detail ”D”) in pinning position.
To do this, the fork−head bore holes of the runner adapter
have to be flush above and below with the bore holes of the
left head axle.
5. At the upper and lower locking points (H / J, detail ”D”),

knock in one biconical pin (3) each and secure each one with
two locking springs.
Risk of accidents !
As long as the runner is not completely pinned at the lock-
ing points (H / J), then the lock pins (4.1 / 5.1) at the points
(4 / 5) may not be removed and no one may be in the area
where equipment could fall.
140−1410−181 21/25
41
A B
4.1 4
5.2 5.1 5
C 3−”F(G)”
3−”H(J)” E
3−”H(J)” 3
4/5 5
4.1/5.1 5.2
Z 60 219
22/25 140−1410−181
Runner 41
(Z 60 219)
6. If the runner is secured at the locking points (H / J), remove

lock pins (4.1 / 5.1) in the holder bearings (4 / 5) (detail ”D”).
7. Use the pulling and guiding rope to position the runner at the
attachment points (F / G, detail ”C”) in pinning position.
To do this, the fork−head bore holes of the runner adapter
have to be flush above and below with the bore holes of the
right head axle.
8. At the upper and lower locking points (F / G, detail ”C”),

knock in one biconical pin (3) each and secure each one with
two locking springs.
Risk of accidents! Risk of falling

For pinning: Do not lean the ladder on the runner.
9. Peg the lock pins (4.1 / 5.1) as well as the locking bolts (5.2)
at the storage bracket (detail ”A”) in park position and secure
with locking springs.
10. Remove pulling and guiding rope an the runner frame.
11. Fold down the runner into working position (see section 41.3,
from page 7).
The runner has to be folded downwards before reeving the

hoist rope into working position.
140−1410−181 23/25
41
HA
HA 1.
2.
Z 60 220
HA
HA
Z 60 221
24/25 140−1410−181
Runner 41
41.5 Operation
(Z 60 220, Z 60 221)
After all the mechanical prerequisites for the operation of the

runner have been met (runner attached, put in working position
folded down, and the hoist rope has been reeved as in the
specifications), the operating mode for runner operation has to
be selected. To do so:
1. Select the ”MS” variant in the ”Type” field in the ”Operating

mode selection” screen (Z 60 220) (see section 10.1.7.4.ff,
”Selection of the operating mode”).
2. Select all the other parameters (counterweight and reeving)

according to the actual crane configuration − which have to
correspond to the respective ”MS” load capacity table
(Z 60 221).
If correct values appear in red, they must first be confirmed
by pressing on them lightly.
3. Save the operating mode selection by pressing the key

and leave the screen with the key.
You can find detailed information about operating mode selection

in section 10 ”Safety devices” at section 10.1.7.4.ff in the
”TableViewer” screen.
140−1410−181 25/25
Central lubricating system 46
140−1460−148a_en 1/17
46
2/17
A
B 4.1
1.0
”Y”
3.1
2.2 2.1
C
5.0 ”X”
6.0
Z 55 935
140−1460−148a_en
46 Central lubricating system (optional)

(Z 55 935)
The central lubricating system (comprising a central lubrication

pump with an integrated control circuit board, a progressive main
distributor (B) and a progressive subdistribution (C) makes pos-
sible the automatic lubrication of all safety−relevant lubrication
points during crane operation.
Legend ”A − D” for (Z 55 935):

(A) Pump element with control circuit board and safety valve
(B) Progressive main distributor
(C) Progressive subdistributor
(D) Distributor, ball bearing slewing
(”X”) Quick coupling connection, hoist 2
(”Y”) Disconnectable tube connection 3x
(option for dismounting the main boom)
If hoist 2 is not fitted, the lubrication line (1) from the subdis-
tributor (C) must be connected with the lube pump return line
(R) using the quick coupling connection (”X”).
Legend ”1.0 − 6.0” to (Z 55 935):

(1.0) Ball bearing slewing
(2.1 / 2.2) Main boom foot section bearing
(3.1) Luffing cylinder foot section bearing
(4.1) Luffing cylinder head bearing
(5.0) Winch, hoist 1
(6.0) Winch, hoist 2 (option)
140−1460−148a_en 3/17
46
6
Z 55 936
P I
8
9
15 M
7 10
T
11
Z 55 937
4/17 140−1460−148a_en
46.1 Components
(Z 55 936, Z 55 937)
(1) Grease container (2 l. / 0.53 US gal)

(2) Pump element (K6, ca. 2.8 cm3/min / 0.17 in3/min)
(3) Safety valve
(4) Filling nipple, installation (emergency lubrication possible)
(5) Filling nipple, pump (for filling grease container)
(6) Sealing cap, control circuit board<HR>
After the sealing cap (6) has been removed, the control board
with the following details becomes visible (Z 55 937):
(7) LED on the left ”Battery voltage applied”

(8) Rotary switch blue ”Pause time”
(9) Rotary switch red ”Operating time”
(10 LED on the right ”Display lubrication procedure”
(11) Button for additional lubrication impulse
140−1460−148a_en 5/17
46
6
Z 55 936
P I
8
9
15 M
7 10
T
11
Z 55 937
6/17 140−1460−148a_en
46.2 Function
(Z 55 936, Z 55 937)
The central lubrication pump automatically supplies the con-

nected lubrication points with grease via the main distributor and
the local subdistributor.
The control circuit board of the central lubrication pump controls
the preset cycles of pause and operating times.
The sequence of pause and operating times is activated when
the ignition unit in the superstructure is switched on.
The pause time
− determines the time period in which no lubrication cycle takes
place
(an exception is possible via auxiliary lubrication impulse to
be carried out manually by pressing the pushbutton (11).
The operating time
− determines the time period in which the lubrication cycle oc-
curs.
A precise description of ”Setting the pause and operating time”

can be found in Chap. 46.3, page 9.
The pressure limitation valve (safety valve −3−)

− limits the build−up of pressure in the lubrication system.
− opens in the presence of unauthorised overpressure.
If lubricant emerges at the pressure limitation valve (safety
valve −3−), this indicates a malfunction in the lubrication system.
A precise description of how to react to malfunctions can be

found in Chap. 46.7 ”Malfunctions/Elimination of malfunctions”,
starting from page 13.
Function test
A test run is possible for the purpose of testing the functioning of
the lubrication system. To do so:
1. Switch on ignition unit, the integrated LED (7) must light up.
2. Hold down the auxiliary lubrication impulse pushbutton (11)
for as long as it takes (>2 seconds) for the right−hand LED
(10) to light up.
The pause time proceeds in abbreviated fashion thereby. A
normal lubrication sequence follows afterwards.
Additional manual lubrication procedures are possible at any
time.
140−1460−148a_en 7/17
46
P I
8
9
15 M
7 10
T
11
Z 55 937
8/17 140−1460−148a_en
46.3 Setting the interval and operating times

(Z 55 937)
46.3.1 General
The pause and operating times are controlled electronically via
the control circuit board.
The pause time begins its sequence as soon as the ignition unit
in the superstructure is switched on.
When the interval time has expired, the operating time starts,
which is the actual lubrication cycle.
46.3.2 Time setting
The length of a lubrication cycle depends on the lubrication re-
quirements of the safety−relevant lubrication points.
The pause and operating times are determined at the factory and
are set as follows:
− Pause time: 2 hours
− Switch position, rotary switch blue (8) = 2
− Operating time: 4 minutes
− Switch position, rotary switch red (9) = 2
The pause and operating times are set at the factory .

In order to ensure sufficient lubrication at the safety−rele-
vant lubrication points, it is not permitted to modify the times
that have been configured.
Pause time
If the preset time of 2 hours is interrupted by shutting off the igni-
tion unit, i.e. after 30 min., then the time which has passed prior
to this point will be stored in the memory. Once the ignition unit
is switched back on, the time period resumes its sequence at the
point that it was switched off.
Operating time
If the preset time of 4 minutes is interrupted by shutting off the
ignition unit, i.e. after 30 sec., then the time which has passed
prior to this point will be stored in the memory. Once the ignition
unit is switched back on, the time period resumes its sequence
at the point that it was switched off.
Storing time in the memory
The amounts of time which has elapsed remains stored in the
memory for an indefinite period when the ignition unit is switched
off.
Once the ignition unit is switched back on, the control system re-
sumes its sequence at the point that it was switched off.
140−1460−148a_en 9/17
46
6
Z 55 936
P I
8
9
15 M
7 10
T
11
Z 55 937
10/17 140−1460−148a_en
(Z 55 936, Z 55 937)
46.4 Auxiliary lubrication impulse
When you are not within an automatic lubrication cycle, it is pos-

sible to end the interval time prematurely and to introduce addi-
tional lubrication procedures. To do so:
1. Switch on ignition unit, the integrated LED (7) must light up.
2. Hold down the auxiliary lubrication impulse pushbutton (11)
for as long as it takes (>2 seconds) for the right−hand LED
(10) to light up.
The pause time proceeds in abbreviated fashion thereby. A
normal lubrication sequence follows afterwards.
Additional manual lubrication procedures are possible at any
time.
After the additional lubrication procedure has completed its se-

quence, it is followed automatically by a normal electronically
controlled lubrication cycle.
46.5 Manual lubrication in the case of an emergency
If the lube pump fails, the lubricating pointscan also be lubricated

manually using grease.
To do so, grease is fed into the system via the lubricating nipple
(4) using a grease gun.
46.6 Filling the grease container
The grease container (1) is filled via the filling nipple (5) up to the
”Max.” marking, capacity = 2 l. (0.53 US gal)
The filling takes place in an appropriate manner with a standard
commercial grease pump or a hand lever press.
The pump must be put into operation during the filling procedure
(through advance activation of the auxiliary lubrication impulse).
After complete drainage, the pump can require up to 10 minutes

running time to reach maximum delivery rate.
The grease that is filled in must be free of any contamination

and must not lose its consistency with time.
Follow the instructions for prescribed lubricants in “Maintenance

and lubrication instructions for the superstructure” (Part 3)!
140−1460−148a_en 11/17
46
12/17 140−1460−148a_en
46.7 Malfunctions/Elimination of malfunctions
The function of the pump can be recognised from the outside by the rotation of the agitator
blade (e.g. by initiating an additional lubrication cycle) or at the LEDs of the control circuit
board.
Fault: The engine of the pump is not running

Cause Remedy
Electricity supply interrupted. Check electricity supply/(safety) fuses. Rectify
malfunction/if required replace (safety) fuses.
Inspect the line to the plug of the pump/to the
control circuit board.
Fault: Pump is not delivering

Cause Remedy
Container is empty. Fill up container with clean grease, allow
pumpto run (triggering additional lubrication),
untillubricant emerges at all lubricating points.
Note: Depending on the ambient temperature

and/or the lubricant, the pump elements can
require up to 10 minutes in order to achieve
the full pumping capacity.
Air trapped in the lubricant. Activate additional lubrication impulse. Re-
move exhaust screw from the safety valve.
The lubricant must emerge without any
bubbles.
Unsuitable lubricant used. Renew lubricant, see lubrication table
(“Maintenance and lubrication instructions of
the superstructure”, Part 3).
Suction bore hole of the pump element Remove pump element and examine intake
blocked. bore for foreign bodies and remove if neces-
sary.
Pump piston worn. Replace pump element.
Non−return valve in the pump element defec- Replace pump element.
tive or blocked.
Fault: different quantities of lubricant at the lubrication points

Cause Remedy
Corresponding valve body was fitted without a Remove valve body and check if there is a
clamping ring. clamping ring. If not, fit a clamping ring.
140−1460−148a_en 13/17
46
4.1
3.1
”X”
B
A
C
”Y”
2.1
5.0
6.0
D
1.0
2.2
Z 55 935
14/17 140−1460−148a_en
Malfunctions/Elimination of malfunctions, continued
Fault: Blockage in the progressive system that is connected in series,

see in this connection the lubrication chart (Z 55 935)
Cause Remedy
Bearing, lines or distributor Find and remove cause of blockage − as described in the
blocked. following example.
The malfunction can beidentified 1. Allow the pump to keep running

by the followingcharacteristics: (initiate auxiliary lubrication impulse, see in this connec-
tion Chap. 46.4, page 11).
a) Grease leaking from the 2. At the main distributor (B), remove all main lines (G) to
safety valve (A). the subdistributors one after the other. If, for example,
b) The check bolts (if present) grease emerges from outlet (1/3/5/7) of the main distribu-
fitted to the distributor piston tor (B), under pressure, the cause of the blockage is in
are not moving. the lubricating circuit of the subdistributor (C).
Note:
If there is a blockage in the progressive installation con-
nected in series, the lubrication lines will be under pres-
sure. The plug−in connection parts of the lubrication lines
will be almost impossible to disconnect in such cases.
Pressure on the installation is to be relieved by removing
the filling nipple on the safety valve (A).
Caution:
The installation is under pressure. Carefully loosen/
remove the lubrication lines and/or filling nipple.
3. Let the pump continue to run.
4. Remove all lubricating point lines of the subdistributor (D)
one after the other. If, for example, grease escapes at the
exhaust (1/2) of the distributor (C) when pressure is ap-
plied, the blockage is to be looked for in the exhaust line
(1/2) or in the connected bearing.
5. Pump through blocked line/bearing with a hand pump.
Note:
To check the individual outlets, leave each outlet loose for
a longer period of time, as only one piston stroke is car-
ried out for each rotation of the pump. However, several
strokes are required for a complete run of all distributors.
6. Check the safety valve (A), replacing it if necessary.
140−1460−148a_en 15/17
46
16/17 140−1460−148a_en
Malfunctions/Elimination of malfunctions, continued
Fault: Blockage in the progressive installation connected in series
Cause Remedy
c) Distributor blocked, Exchange distributor or clean as described in the following:
(when a distributor is blocked,
no lubricant emerges at any 1. Remove all pipe connection screws.
exit point). 2. Unscrew piston sealing screws.
3. Push pistons out, if possible using a small mandrel
( smaller than 6 mm/0.24 in. ).
Important note:
The pistons are fitted flush in the distributor bores. After
they have been removed, mark the fitting position and di-
rection of the pistons for refitting. They must not be con-
fused during fitting.
4. Clean distributor bodies thoroughly in a fat−dissolving
cleaner and blow out using compressed air.
5. Using a pin, press the sloped channels (ø 1.5 mm/0.059
in) through at the thread ends of the piston bore holes.
6. Clean and blow out distributors again.
7. Assemble distributors. Replace copper washers.
8. If possible, pump oil through the distributor several times
using a hand pump before screwing the hose connecting
screws in place. The pressure in the distributor must not
exceed 25 bar ( 362.6 psi).
9. If a pressure build−up in excess of 25 bar ( 362.6 psi) oc-
curs in the distributor, then it should be replaced.
140−1460−148a_en 17/17

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140−0000 1/1

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

4 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7 Supporting the Crane on Outriggers from the

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

9.15 Counterweight Combination 31.0 t (68 300 lbs) . . . . . . . . . . . . . . . 47

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

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

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

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

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

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

The operating, lubricating and maintenance instructions included

Crane classification Mobile crane

Crane type AC 140

Construction number _______________

Maximum capacity 140 t / 308.6 kip

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

The complete manual comprises 5 parts:

Please note that the information contained in this manual corres-

In such cases we make every effort to bring your documentation

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

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

Should you discover any mistakes when reading this manual or

Terex − Demag GmbH & Co. KG

Handover of the crane

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

The protective coating can be removed using:

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

”Instructions on using the catalogue”

Please contact the service department if you have any questions

From within Germany:

From outside Germany:

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

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-

WHAT do I want to know ?

WHERE do I find the information required above ?

The complete manual comprises 5 parts:

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

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

HOW do I find the page in Section 11 ?

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

Please note that this option of fast and accurate access to

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

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

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

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

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

This section ”Safety Instructions” provides a compact and

The safety instructions for lubrication, maintenance and service

1.2 Intended Use

The crane is designed for lifting loads.

It is prohibited to transport people with personnel carrying

The crane is designed exclusively for assembly operation.

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

1.3 Operating Conditions and Computed Design of the

The term ”operating instructions” refers to the operating

1.3.2 Classification of the Crane

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

All important components of the crane are designed and

Operating conditions or types of use other than assembly